Csp-Hmi-2 I00 r51 tr18-002 PDF

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

(CSP−HMI−2)
SERVICING AND MAINTENANCE
MD Helicopters, Inc.
4555 East McDowell Road
Mesa, Arizona 85215−9734
Copyright E 1999-2018 by MD Helicopters, Inc. Issued: 31 October 1990

All rights reserved under the copyright laws.
Revision 51: 31 May 2018
PROPRIETARY RIGHTS NOTICE
The technical data and information contained in this publication

is the property of and proprietary to MD Helicopters, Inc. and is
not to be disclosed or reproduced in whole or in part without the
written consent of MD Helicopters, Inc.
Mesa, Arizona 85215−9734
369/500/600 Series
CSP-HMI-2 Revision
Manual: CSP−HMI−2, Handbook of Maintenance Instructions
Models: 369D/369E/369FF/500N/600N Helicopters
Issue: 31 October 1990
FILING INSTRUCTIONS:
Do not put this revision in the manual, if this manual does not have all the
CAUTION revisions from before.
1. Before you put this revision in the manual, make sure this manual has all the revisions from before. Look at
the List of Effective Pages for the last revision.
2. This revision includes all the Temporary Revisions since the last revision. It is permitted to put this revision in
the manual even if the Temporary Revisions were not put in.
3. To include this revision in the manual, remove the old pages and put in the new pages as shown:
Remove Pages Insert Pages Remove Pages Insert Pages

Cover/Title 20−20−00
Cover/Title . . . . . . . . . . . . . . . . . . . . . . . . Cover/Title 201 and 202 . . . . . . . . . . . . . . . . . . . . . . 201 and 202
Temporary Revision Chapter 28
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 and 2 Table of Contents
List of Effective Pages i thru viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i thru viii
A thru L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A thru L 28−00−00
Chapter 01 417 thru 420 . . . . . . . . . . . . . . . . . . . . . . 417 thru 420
Table of Contents
501 thru 510 . . . . . . . . . . . . . . . . . . . . . . 501 thru 516
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i and ii 28−00−60
503 and 504 . . . . . . . . . . . . . . . . . . . . . . 503 and 504
01−00−00
1 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 thru 6 Chapter 53
9 thru 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 thru 12 Table of Contents
15 and 16 . . . . . . . . . . . . . . . . . . . . . . . . . . 15 and 16 i thru viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i thru viii
19 thru 20 . . . . . . . . . . . . . . . . . . . . . . . . . . 19 thru 22 Chapter 62
Chapter 05 Table of Contents
Table of Contents i thru viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i thru viii
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i and ii 62−20−60
05−20−00 805 thru 814 . . . . . . . . . . . . . . . . . . . . . . 805 thru 814
1 thru 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 thru 12 Chapter 63
05−20−15 Table of Contents
3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 and 4 i thru x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i thru x
05−20−20 63−20−00
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 and 2 201 thru 208 . . . . . . . . . . . . . . . . . . . . . . 201 thru 212
05−50−00 63−20−25
9 thru 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 thru 14 201 thru 212 . . . . . . . . . . . . . . . . . . . . . . 201 thru 212
Chapter 18 Chapter 67
Table of Contents
18−10−00
i thru xii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i thru xii
507 and 508 . . . . . . . . . . . . . . . . . . . . . . 507 and 508
67−10−00
Chapter 20
1 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 thru 6
Table of Contents 401 thru 424 . . . . . . . . . . . . . . . . . . . . . . 401 thru 432
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i thru iv 501 thru 530 . . . . . . . . . . . . . . . . . . . . . . 501 thru 540
20−00−00 601 thru 611/612 . . . . . . . . . . . . . . . . . . 601 thru 610
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 and 2 803 thru 816 . . . . . . . . . . . . . . . . . . . . . . 803 thru 818
Page i
369/500/600 Series
CSP-HMI-2 Revision
Remove Pages Insert Pages Remove Pages Insert Pages
Table of Contents Table of Contents
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i thru vi i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i and ii
76−20−00 78−20−00
201 thru 214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . None 201 thru 212 . . . . . . . . . . . . . . . . . . . . . . 201 thru 212
None . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401 thru 414
None . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501 thru 526 Chapter 91
None . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 and 602 91−00−00
None . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801 and 802 21 and 22 . . . . . . . . . . . . . . . . . . . . . . . . . . 21 and 22
Page ii
369/500/600 Series
HMI Revision
Manual: CSP- HMI- 2 Handbook of Maintenance Instructions — Servicing and Maintenance
Models: 369D / 369E / 369FF / 500N / 600N Helicopters
Revision 51: 31 October 2018
TR18- 001: 27 August 2018
Do not put this temporary revision in the manual, if the manual does not
CAUTION have all the revisions and temporary revisions from before.
1. Before you put this temporary revision in the manual, make sure this manual has all the revisions and
temporary revisions from before. Look at the List of Effective Pages for the last revision and the Record of
Temporary Revisions for the last temporary revision.
2. Record this temporary revision in the Record of Temporary Revisions.
3. To include this temporary revision in the manual, remove the old pages and put in the new pages as shown:
Temporary Revision / Date Section Page Page Revision
TR18- 001 / 27 August 2018 01- 00- 00 1 thru 5 TR18- 001
6 Revision 51
21 Revision 51
22 TR18- 001
28- 00- 00 501 thru 512 TR18- 001
28- 00- 10 Cover / Blank --
501 thru 504 TR18- 001
28- 00- 60 503 and 504 TR18- 001
67- 00- 00 101 TR18- 001
102 Revision 21
105 thru 111 TR18- 001
112 Revision 43
67- 10- 00 501 thru 520 TR18- 001
531 Revision 51
532 TR18- 001
76- 10- 00 217 TR18- 001
218 Revision 45
219 TR18- 001
220 Revision 22
369/500/600 Series
HMI Revision
Manual: CSP- HMI- 2, Handbook of Maintenance Instructions — Maintenance & Servicing

Models: 369D / 369E / 369FF / 500N / 600N Helicopters
TR18- 002: 30 October 2018
Do not put this temporary revision in the manual, if the manual does not
CAUTION have all the revisions and temporary revisions from before.
1. Before you put this temporary revision in the manual, make sure this manual has all the revisions and
temporary revisions from before. Look at the List of Effective Pages for the last revision and the Record of
Temporary Revisions for the last temporary revision.
2. Record this temporary revision in the Record of Temporary Revisions.
3. To include this temporary revision in the manual, remove the old pages and put in the new pages as shown:
Temporary Revision / Date Section Pages Page Revision
TR18- 002 / 30 October 2018 62- 20- 60 807 and 808 TR18- 002
809 Revision 51
810 thru 816 TR18- 002
63- 22- 00 403 thru 414 TR18- 002
71- 00- 30 401 TR18- 002
402 Revision 22
403 thru 414 TR18- 002
76- 47- 00 205 thru 207 TR18- 002
208 Revision 44
MD HELICOPTER, INC.
TECHNICAL MANUAL RECOMMENDED CHANGE REPORT
This manual has been prepared and distributed by the Technical Publications Department and is intended
for use by personnel responsible for the maintenance of MDHI Helicopters. Periodic revision of this manual
will be made to incorporate the latest information. If, in the opinion of the reader, any information has been
omitted or requires clarification, please direct your comments to this office via this form (or a duplicate). An
endeavor will be made to include such information in future revisions.
Bldg 615 M/S G048
Mesa, AZ 85215−9734
Telephone: Technical Publications: (480) 346−6465 / (800) 310−8539, Option 3
Technical Publications Online Orders:
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Date:
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MD Helicopters, Inc. CSP-HMI-2
MAINTENANCE MANUAL
RECORD OF TEMPORARY REVISIONS
Rev. Date Date Rev. Date Date

No. Inserted By Removed By No. Inserted By Removed By
91−001 Removed by 95−003 Removed by

Revision 3 Revision 13
















Page 1
TR Revision 48
CSP-HMI-2 MD Helicopters, Inc.
MAINTENANCE MANUAL
Rev. Date Date Rev. Date Date

No. Inserted By Removed By No. Inserted By Removed By









10−001 Removed by 18-001 AUG 28, 2018 ATP/

Revision 44 RLL
10−002 Removed by 18-002 OCT 25, 2018 ATP/

Revision 44 RLL
10−003 Removed by
Revision 44
11−001 Removed by
Revision 44
12−001 Removed by
Revision 45
12−002 Removed by
Revision 45
12−003 Removed by
Revision 45
13−001 Removed by
Revision 45
13−002 Removed by
Revision 45
Page 2
Revision 51 TR
MD Helicopters, Inc. CSP- HMI- 2
MAINTENANCE MANUAL
LIST OF EFFECTIVE PAGES
INSERT LATEST CHANGE PAGES, DESTROY SUPERSEDED PAGES

The highest revision number indicates pages changed, added or removed by the current change.
Date of original and revision pages are:
Original . . . . . . . . . . . . . . . . . . . . 31 October 1990 Revision 26 . . . . . . . . . . . . . . . . . 17 August 2000
Revision 1 . . . . . . . . . . . . . . . . . . . . 29 March 1991 Revision 27 . . . . . . . . . . . . . . . . 09 October 2000
Revision 2 . . . . . . . . . . . . . . . . . . . . . 10 May 1991 Revision 28 . . . . . . . . . . . . . . 30 November 2000
Revision 3 . . . . . . . . . . . . . . . 09 September 1991 Revision 29 . . . . . . . . . . . . . . . . . . . . 11 May 2001
Revision 4 . . . . . . . . . . . . . . . . . . 20 January 1992 Revision 30 . . . . . . . . . . . . . . . . . . . . 11 July 2001
Revision 5 . . . . . . . . . . . . . . . . . . . 24 August 1992 Revision 31 . . . . . . . . . . . . . . 05 November 2001
Revision 6 . . . . . . . . . . . . . . . . 21 December 1992 Revision 32 . . . . . . . . . . . . . . . . . . 18 March 2002
Revision 7 . . . . . . . . . . . . . . . . . . . . . 01 June 1993 Revision 33 . . . . . . . . . . . . . . . . . . . 24 June 2002
Revision 8 . . . . . . . . . . . . . . . . . . . . . . 23 July 1993 Revision 34 . . . . . . . . . . . . . . . . . 21 August 2003
Revision 9 . . . . . . . . . . . . . . . . . . . . . 22 April 1994 Revision 35 . . . . . . . . . . . . . . . . . . . 20 May 2004
Revision 10 . . . . . . . . . . . . . 26 September 1994 Revision 36 . . . . . . . . . . . . . . 11 November 2004
Revision 11 . . . . . . . . . . . . . . . . . 18 January 1995 Revision 37 . . . . . . . . . . . . . . 13 December 2005
Revision 12 . . . . . . . . . . . . . . . . 06 October 1995 Revision 38 . . . . . . . . . . . . . . . . . . . 25 May 2006
Revision 13 . . . . . . . . . . . . . . . . . . . 31 May 1996 Revision 39 . . . . . . . . . . . . . . . . . . . 10 April 2007
Revision 14 . . . . . . . . . . . . . 13 September 1996 Revision 40 . . . . . . . . . . . . . . 10 November 2007
Revision 15 . . . . . . . . . . . . . . 15 November 1996 Revision 41 . . . . . . . . . . . . . . . . . . 03 March 2008
Revision 16 . . . . . . . . . . . . . . . . 06 January 1997 Revision 42 . . . . . . . . . . . . . . . . . . . 01 June 2009
Revision 17 . . . . . . . . . . . . . . . 24 February 1997 Revision 43 . . . . . . . . . . . . . . 23 December 2009
Revision 18 . . . . . . . . . . . . . . . . 17 October 1997 Revision 44 . . . . . . . . . . . . . . . . . . . . 05 July 2011
Revision 19 . . . . . . . . . . . . . . 16 December 1997 Revision 45 . . . . . . . . . . . . . . . . . . 07 March 2014
Revision 20 . . . . . . . . . . . . . . . . . . . 01 June 1998 Revision 46 . . . . . . . . . . . . . 19 September 2014
Revision 21 . . . . . . . . . . . . . . . . . 24 August 1998 Revision 47 . . . . . . . . . . . . . . . . 15 October 2016
Revision 22 . . . . . . . . . . . . . . . . . . 10 March 1998 Revision 48 . . . . . . . . . . . . . . 30 December 2016
Revision 23 . . . . . . . . . . . . . . . . . . . 01 June 1999 Revision 49 . . . . . . . . . . . . . . . . . . . . 15 July 2017
Revision 24 . . . . . . . . . . . . . . 07 December 1999 Revision 50 . . . . . . . . . . . . . 15 September 2017
Revision 25 . . . . . . . . . . . . . . . . . . . 28 April 2000 Revision 51 . . . . . . . . . . . . . . . . . . . 31 May 2018
Cover/Title Chapter 01
Cover/Title . . . . . . . . . . . . . . . . . . . . . . Revision 51 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
Change Request
CRi and CRii . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A 01- 00- 00
Temporary Revision 1 thru 5 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 48
6 thru 8 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 50
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
List of Effective Pages 9 thru 12 . . . . . . . . . . . . . . . . . . . . . . . Revision 51
A thru L . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51 13 and 14 . . . . . . . . . . . . . . . . . . . . . . Revision 50
Table of Contents 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 49
v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 50 16 thru 18 . . . . . . . . . . . . . . . . . . . . . . Revision 50
vi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 49 19 thru 22 . . . . . . . . . . . . . . . . . . . . . . Revision 51
Page A
LOEP Revision 51
CSP- HMI- 2 MD Helicopters, Inc.
MAINTENANCE MANUAL
Chapter 04 2 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45

i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 38
04- 00- 00 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
1 thru 3 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42 05- 50- 00
4 ............................... Revision 47 1 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
5 ............................... Revision 45
7 ............................... Revision 49
6 and 7 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42
8 and 9 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
8 ............................... Revision 46
10 thru 14 . . . . . . . . . . . . . . . . . . . . . . . Revision 51
9 ............................... Revision 45
10 and 11 . . . . . . . . . . . . . . . . . . . . . . . Revision 46 Chapter 06
12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 46 06- 00- 00
14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45
201 thru 203 . . . . . . . . . . . . . . . . . . . . . Revision 23
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45
205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
04- 00- 01
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39
1 ............................... Revision 26
207 thru 210 . . . . . . . . . . . . . . . . . . . . . Revision 23
2 ............................... Revision 43
211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
Chapter 05
212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
05- 00- 00 Chapter 07
1 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 38 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
05- 10- 00 07- 00- 00
1 ............................... Revision 44 201 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 23
2 ............................... Revision 45 Chapter 08
3 ............................... Revision 37 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
4 ............................... Revision 45
08- 00- 00
05- 20- 00
2 ............................... Revision 49 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
3 ............................... Revision 51 08- 10- 00
5 ............................... Revision 45 202 and 203 . . . . . . . . . . . . . . . . . . . . . Revision 27
6 thru 12 . . . . . . . . . . . . . . . . . . . . . . . . Revision 51 204 thru 210 . . . . . . . . . . . . . . . . . . . . . Revision 23
05- 20- 10 211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
1 ............................... Revision 47 212 and 214 . . . . . . . . . . . . . . . . . . . . . Revision 47
4 ............................... Revision 47
217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
05- 20- 15 218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
1 ............................... Revision 45
2 ............................... Revision 47 Chapter 09
3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
05- 20- 20 09- 00- 00
Page B
Revision 51 LOEP
MAINTENANCE MANUAL
Chapter 10 18- 10- 60

i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
10- 10- 00 202 and 203 . . . . . . . . . . . . . . . . . . . . . Revision 31
201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 23 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
10- 20- 00 401 and 402 . . . . . . . . . . . . . . . . . . . . . Revision 44
201 thru 203 . . . . . . . . . . . . . . . . . . . . . Revision 45 403 and 404 . . . . . . . . . . . . . . . . . . . . . Revision 23
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
10- 30- 00
503 and 504 . . . . . . . . . . . . . . . . . . . . . Revision 23
201 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 23
505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45
Chapter 11 506 thru 509 . . . . . . . . . . . . . . . . . . . . . Revision 23
11- 00- 00 511 and 512 . . . . . . . . . . . . . . . . . . . . . Revision 23
201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 23 18- 20- 00
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47 202 and 203 . . . . . . . . . . . . . . . . . . . . . Revision 47
11- 40- 00 206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
201 thru 203 . . . . . . . . . . . . . . . . . . . . . Revision 23 18- 20- 30
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45 201 thru 205 . . . . . . . . . . . . . . . . . . . . . Revision 23
212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
Chapter 20
Chapter 12 i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
20- 00- 00
12- 00- 00 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
301 thru 308 . . . . . . . . . . . . . . . . . . . . . Revision 45
20- 10- 00
309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 38
310 and 311 . . . . . . . . . . . . . . . . . . . . . Revision 45
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
204 thru 212 . . . . . . . . . . . . . . . . . . . . . Revision 48
Chapter 18
20- 20- 00
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
18- 10- 00 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
20- 30- 00
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 31
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45
203 and 204 . . . . . . . . . . . . . . . . . . . . . Revision 37
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 50
401 thru 403 . . . . . . . . . . . . . . . . . . . . . Revision 44
203 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 34
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23 20- 40- 00
503 and 504 . . . . . . . . . . . . . . . . . . . . . Revision 23 20- 50- 00
505 thru 507 . . . . . . . . . . . . . . . . . . . . . Revision 45 201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 49
508 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51 20- 90- 00
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Chapter 21 25- 50- 00

21- 10- 00 102 and 103 . . . . . . . . . . . . . . . . . . . . . Revision 47
104 thru 106 . . . . . . . . . . . . . . . . . . . . . Revision 23
201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 23
401 thru 408 . . . . . . . . . . . . . . . . . . . . . Revision 23
21- 40- 00 601 and 602 . . . . . . . . . . . . . . . . . . . . . Revision 23
209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44 25- 60- 00
901 thru 911 . . . . . . . . . . . . . . . . . . . . . Revision 23 25- 63- 00
i thru viii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47 Chapter 26
25- 00- 00 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23 26- 10- 00
201 thru 203 . . . . . . . . . . . . . . . . . . . . . Revision 23
25- 10- 00
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
26- 20- 00
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 50
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 23
203 thru 205 . . . . . . . . . . . . . . . . . . . . . Revision 23
Chapter 28
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24
i thru viii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
207 and 208 . . . . . . . . . . . . . . . . . . . . . Revision 23
28- 00- 00
25- 15- 00 1 ............................... Revision 46
201 thru 203 . . . . . . . . . . . . . . . . . . . . . Revision 23 2 ............................... Revision 47
901 and 902 . . . . . . . . . . . . . . . . . . . . . Revision 23 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
25- 20- 00 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
401 and 402 . . . . . . . . . . . . . . . . . . . . . Revision 19
207 thru 211 . . . . . . . . . . . . . . . . . . . . . Revision 23
403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
25- 21- 00 405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
25- 30- 00 410 and 411 . . . . . . . . . . . . . . . . . . . . . Revision 45
414 and 415 . . . . . . . . . . . . . . . . . . . . . Revision 44
210 thru 214 . . . . . . . . . . . . . . . . . . . . . Revision 23
416 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
25- 40- 00 417 thru 420 . . . . . . . . . . . . . . . . . . . . . Revision 51
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801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 46 Chapter 32

802 thru 805 . . . . . . . . . . . . . . . . . . . . . Revision 50 i thru vi . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 50
806 and 807 . . . . . . . . . . . . . . . . . . . . . Revision 19 32- 10- 00
808 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44 1 ............................... Revision 19
28- 00- 60 2 ............................... Revision 44
2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19 401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45
602 thru 606 . . . . . . . . . . . . . . . . . . . . . Revision 50
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39
801 thru 804 . . . . . . . . . . . . . . . . . . . . . Revision 19
401 thru 405 . . . . . . . . . . . . . . . . . . . . . Revision 19
805 and 806 . . . . . . . . . . . . . . . . . . . . . Revision 47
406 and 407 . . . . . . . . . . . . . . . . . . . . . Revision 34
807 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
408 thru 413 . . . . . . . . . . . . . . . . . . . . . Revision 19
808 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
901 thru 908 . . . . . . . . . . . . . . . . . . . . . Revision 19
415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45
32- 10- 60
416 thru 422 . . . . . . . . . . . . . . . . . . . . . Revision 19
1 ............................... Revision 19
501 and 502 . . . . . . . . . . . . . . . . . . . . . Revision 22
2 ............................... Revision 44
503 and 504 . . . . . . . . . . . . . . . . . . . . . Revision 51
301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
302 and 303 . . . . . . . . . . . . . . . . . . . . . Revision 19
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 31
304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
28- 25- 00 407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44 32- 40- 00
601 and 602 . . . . . . . . . . . . . . . . . . . . . Revision 20 201 thru 205 . . . . . . . . . . . . . . . . . . . . . Revision 19
604 and 605 . . . . . . . . . . . . . . . . . . . . . Revision 19 32- 40- 60
901 and 902 . . . . . . . . . . . . . . . . . . . . . Revision 20 32- 81- 00
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32- 82- 00 206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44

408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44 53- 30- 30
Chapter 52 202 and 203 . . . . . . . . . . . . . . . . . . . . . Revision 34
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
52- 10- 00
205 and 206 . . . . . . . . . . . . . . . . . . . . . Revision 34
207 and 208 . . . . . . . . . . . . . . . . . . . . . Revision 45
201 thru 212 . . . . . . . . . . . . . . . . . . . . . Revision 25
209 and 210 . . . . . . . . . . . . . . . . . . . . . Revision 34
213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 50 53- 40- 00
217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25 53- 40- 30
52- 40- 00 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
52- 50- 00 205 and 206 . . . . . . . . . . . . . . . . . . . . . Revision 39
208 thru 210 . . . . . . . . . . . . . . . . . . . . . Revision 18
210 and 211 . . . . . . . . . . . . . . . . . . . . . Revision 46
i thru viii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
801 and 802 . . . . . . . . . . . . . . . . . . . . . Revision 44
53- 00- 00 53- 50- 10
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
201 thru 208 . . . . . . . . . . . . . . . . . . . . . Revision 47
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 37
53- 50- 30
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 42
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
203 and 204 . . . . . . . . . . . . . . . . . . . . . Revision 33
53- 10- 00 205 thru 208 . . . . . . . . . . . . . . . . . . . . . Revision 40
53- 15- 00 Chapter 62
401 thru 410 . . . . . . . . . . . . . . . . . . . . . Revision 49 i thru vi . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
601 and 602 . . . . . . . . . . . . . . . . . . . . . Revision 49 62- 00- 00
53- 20- 00 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 31
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44 62- 10- 00
202 and 203 . . . . . . . . . . . . . . . . . . . . . Revision 19 401 and 402 . . . . . . . . . . . . . . . . . . . . . Revision 45
53- 30- 00 404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
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801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 33 62- 30- 00
601 and 602 . . . . . . . . . . . . . . . . . . . . . Revision 32
62- 20- 00
801 and 802 . . . . . . . . . . . . . . . . . . . . . Revision 46
403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20 62- 30- 60
806 thru 808 . . . . . . . . . . . . . . . . . . . . . Revision 20 i thru x . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
809 and 810 . . . . . . . . . . . . . . . . . . . . . Revision 50 63- 00- 00
817 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 46 63- 10- 00
62- 20- 60
407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45
409 thru 412 . . . . . . . . . . . . . . . . . . . . . Revision 46
402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 46
413 and 414 . . . . . . . . . . . . . . . . . . . . . Revision 32
801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 46 63- 15- 10
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606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44 63- 25- 10
63- 15- 30 63- 25- 30
63- 20- 00 63- 30- 00
63- 20- 25 203 and 204 . . . . . . . . . . . . . . . . . . . . . Revision 36
63- 21- 00
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 46
401 and 402 . . . . . . . . . . . . . . . . . . . . . Revision 20 Chapter 64
403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28 i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20 64- 00- 00
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36 64- 00- 05
803 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 50 64- 10- 00
63- 22- 00 209 and 210 . . . . . . . . . . . . . . . . . . . . . Revision 46
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42 64- 20- 00
408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20 64- 25- 30
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602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39 67- 20- 30
64- 30- 00 402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
Chapter 67 408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45
i thru xii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51 409 thru 412 . . . . . . . . . . . . . . . . . . . . . Revision 33
413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
67- 00- 00
414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 30
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 30
415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 49
102 and 103 . . . . . . . . . . . . . . . . . . . . . Revision 21
416 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 48
104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29
501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 33
105 and 106 . . . . . . . . . . . . . . . . . . . . . Revision 42
502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18
107 thru 111 . . . . . . . . . . . . . . . . . . . . . Revision 30
503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18
67- 10- 00 505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 30
1 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51 506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18
67- 10- 20 517 and 518 . . . . . . . . . . . . . . . . . . . . . Revision 45
67- 20- 10 606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21 801 thru 803 . . . . . . . . . . . . . . . . . . . . . Revision 18
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26 i thru x . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
405 and 406 . . . . . . . . . . . . . . . . . . . . . Revision 21 71- 00- 00
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71- 00- 30 901 thru 923 . . . . . . . . . . . . . . . . . . . . . Revision 22
2 ............................... Revision 44 71- 10- 60
71- 00- 47 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
402 thru 404 . . . . . . . . . . . . . . . . . . . . . Revision 29
3 ............................... Revision 45
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29
4 ............................... Revision 44
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 33
401 thru 405 . . . . . . . . . . . . . . . . . . . . . Revision 22
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 45 71- 20- 00
408 and 409 . . . . . . . . . . . . . . . . . . . . . Revision 45 2 ............................... Revision 44
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
71- 10- 00
405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
201 thru 203 . . . . . . . . . . . . . . . . . . . . . Revision 22
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 50
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
205 and 206 . . . . . . . . . . . . . . . . . . . . . Revision 22
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
71- 10- 05 801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44 71- 30- 00
71- 10- 10 2 ............................... Revision 22
3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22 401 thru 410 . . . . . . . . . . . . . . . . . . . . . Revision 22
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71- 60- 00 76- 47- 00

204 thru 212 . . . . . . . . . . . . . . . . . . . . . Revision 44
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
75- 10- 00 78- 20- 00
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
203 and 204 . . . . . . . . . . . . . . . . . . . . . Revision 45
204 thru 212 . . . . . . . . . . . . . . . . . . . . . Revision 51
78- 30- 00
205 and 206 . . . . . . . . . . . . . . . . . . . . . Revision 22
Chapter 76 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 38
i thru vi . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51 202 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 35
Chapter 79
76- 00- 00
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
1 ............................... Revision 45
79- 00- 00
76- 10- 00 209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
201 thru 209 . . . . . . . . . . . . . . . . . . . . . Revision 22
211 and 212 . . . . . . . . . . . . . . . . . . . . . Revision 45
79- 10- 10
210 thru 212 . . . . . . . . . . . . . . . . . . . . . Revision 44
220 and 221 . . . . . . . . . . . . . . . . . . . . . Revision 22 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 35 91- 00- 00
1 ............................... Revision 48
223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 47
2 ............................... Revision 50
76- 20- 00 4 ............................... Revision 50
401 thru 414 ..................... Revision 51 5 thru 13 . . . . . . . . . . . . . . . . . . . . . . . . Revision 48
14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 50
501 thru 526 ..................... Revision 51
15 thru 21 . . . . . . . . . . . . . . . . . . . . . . . Revision 48
601 and 602 ..................... Revision 51 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 51
801 and 802 ..................... Revision 51 23 and 24 . . . . . . . . . . . . . . . . . . . . . . . Revision 48
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TABLE OF CONTENTS
CSP−HMI−2
Cover / Title Page
Technical Manual Recommended Change Report
Record of Temporary Revisions
List of Effective Pages
01 Introduction
04 Airworthiness Limitations
05 Continued Airworthiness Checks / Inspections
06 Dimensions and Areas
07 Lifting and Jacking
08 Leveling / Weight and Balances
09 Towing
10 Parking and Mooring
11 Placards and Markings
12 Servicing
18 Vibration and Noise Analysis
20 Standard Practices
21 Environmental Control System
25 Equipment / Furnishings
26 Fire Protection
28 Fuel System
32 Landing Gear
52 Doors
53 Fuselage
62 Main Rotor
63 Transmission and Drive System
64 Anti−Torque Assembly
67 Flight Controls
71 Power Plant
75 Engine Anti−Ice System
76 Engine Power Controls
78 Engine Exhaust System
79 Engine Oil Supply System
91 Charts
Page i
Contents Revision 49
MAINTENANCE MANUAL
CSP−HMI−3
95 Instruments
96 Electrical Power
97 Avionics
98 Wiring Diagrams
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Revision 49 Contents
MAINTENANCE MANUAL
NOTE: These sections are applicable to the helicopter models denoted to the right of the section.
Section Title 369D 369E 369FF 500N 600N
01 INTRODUCTION
01−00−00 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
04 AIRWORTHINESS LIMITATIONS
04−00−00 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
04−00−01 Airworthiness Limitations Supplements . . . . . . . . . . . . . . . . . . . . . . X
05 CONTINUED AIRWORTHINESS
05−00−00 Checks/Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
05−10−00 Component Overhaul/Recommended Replacement . . . . . . . . . . X X X X X
05−20−00 100−Hour or Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
05−20−10 300−Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
05−20−15 Yearly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
05−20−20 Special Inspections Hourly and Calendar . . . . . . . . . . . . . . . . . . . . X X X X X
05−50−00 Conditional Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
06 DIMENSIONS AND AREAS

06−00−00 Dimensions and Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
07 LIFTING AND JACKING

07−00−00 Lifting and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
08 LEVELING / WEIGHT AND BALANCE

08−00−00 Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
08−10−00 Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
09 TOWING
09−00−00 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
10 PARKING AND MOORING

10−10−00 Parking and Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
10−20−00 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
10−30−00 Blade Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
11 PLACARDS AND MARKINGS

11−00−00 Placards and Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
11−40−00 Placards and Markings (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
12 SERVICING
12−00−00 Helicopter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
18 VIBRATION AND NOISE ANALYSIS

18−10−00 Main Rotor Track and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
18−10−60 Main Rotor Track and Balance (600N) . . . . . . . . . . . . . . . . . . . . . . X
18−20−00 Tail Rotor Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
18−20−30 NOTARr Anti−Torque System Fan Balance . . . . . . . . . . . . . . . . . . X X
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MAINTENANCE MANUAL
20 STANDARD PRACTICES
20−00−00 Standard Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
20−10−00 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
20−20−00 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
20−30−00 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
20−40−00 Corrosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
20−90−00 Nondestructive Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
21 ENVIRONMENTAL CONTROL SYSTEM

21−10−00 Ventilation Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
21−40−00 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
25 EQUIPMENT / FURNISHINGS
25−00−00 Equipment/Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
25−10−00 Upholstered Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
25−15−00 Mesh Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
25−20−00 Seat Belts/Inertia Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
25−21−00 Seating/Belts (Four on the Floor) . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
25−30−00 Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
25−40−00 Miscellaneous Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
25−50−00 Cargo Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
25−60−00 Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
25−63−00 Hoist Passenger/Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
26 FIRE PROTECTION
26−10−00 Engine Fire Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
26−20−00 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
28 FUEL SYSTEM
28−00−00 Fuel System (369D/E/FF − 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
28−00−60 Fuel System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
28−25−00 Anti−Ice / Airframe Fuel Filter (369D/E − 500/600N) . . . . . . . . . . X X X X
32 LANDING GEAR
32−10−00 Landing Gear System (369D/E/FF − 500N) . . . . . . . . . . . . . . . . . . X X X X
32−10−60 Landing Gear System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
32−40−00 Ground Handling Wheels (369D/E/FF − 500N) . . . . . . . . . . . . . . . X X X X
32−40−60 Ground Handling Wheels (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . X
32−81−00 Utility Float System (369D/E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X
32−82−00 Emergency Float System (369D/E/FF − 500N) . . . . . . . . . . . . . . . X X X X
52 DOORS
52−10−00 Crew, Passenger, Cargo Doors and Windows . . . . . . . . . . . . . . . . X X X X X
52−40−00 Engine Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
52−50−00 Miscellaneous Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
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MAINTENANCE MANUAL

53 FUSELAGE
53−00−00 Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
53−10−00 Windshields and Aft Section Windows . . . . . . . . . . . . . . . . . . . . . . X X X X X
53−15−00 Forward Lower Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
53−20−00 Lower Center Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
53−30−00 Upper Aft Section Fuselage (369D/E/FF) . . . . . . . . . . . . . . . . . . . . X X X
53−30−30 Upper Aft Section Fuselage (500/600N) . . . . . . . . . . . . . . . . . . . . . X X
53−40−00 Tailboom (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
53−40−30 Tailboom (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X
53−50−10 Stabilizer (T−Tail) (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
53−50−30 Stabilizer (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X
62 MAIN ROTOR
62−00−00 Main Rotor (369D/E/FF − 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
62−10−00 Main Rotor Blade (369D/E/FF − 500/600N) . . . . . . . . . . . . . . . . . . X X X X X
62−20−00 Main Rotor Hub (369D/E/FF − 500N) . . . . . . . . . . . . . . . . . . . . . . . X X X X
62−20−60 Main Rotor Hub (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
62−30−00 Swashplate and Mixer (369D/E/FF − 500N) . . . . . . . . . . . . . . . . . . X X X X
62−30−60 Swashplate and Mixer (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
63 TRANSMISSION AND DRIVE SYSTEM
63−00−00 Transmission and Drive System (369D/E/FF − 500/600N) . . . . . X X X X X
63−10−00 Drive Shafts / Clutches / Couplings (369D/E/FF − 500/600N) . . X X X X X
63−15−10 Tail Rotor Drive Shaft (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . X X X
63−15−30 NOTARr Anti−Torque System Drive Shafts (500/600N) . . . . . . . X X
63−20−00 369D25100 Main Transmission (369D/E/FF − 500N) . . . . . . . . . . X X X X
63−20−25 369F5100 Main Transmission (369D/E/FF − 500/600N) . . . . . . . X X X X X
63−21−00 Main Transmission Lubrication and Cooling System
(369D/E/FF − 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
63−22−00 Rotor Brake (369D/E/FF − 500/600N) . . . . . . . . . . . . . . . . . . . . . . . X X X X X
63−25−10 Tail Rotor Transmission (Two and Four Blade) (369D/E/FF) . . . . X X X
63−25−30 NOTARr Anti−Torque Fan Transmission (500/600N) . . . . . . . . . . X X
63−30−00 Main Rotor Static Mast (369D/E/FF − 500/600N) . . . . . . . . . . . . . X X X X X
64 ANTI-TORQUE ASSEMBLY
64−00−00 Anti−Torque Assembly (369D/E/FF − 500/600N) . . . . . . . . . . . . . . X X X X X
64−00−05 Four−Bladed Tail Rotor Assembly Initial Installation (369D/E) . . X X
64−10−00 Tail Rotor Blades (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
64−20−00 Tail Rotor Hub and Fork (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . X X X
64−25−30 Anti−Torque Fan (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X
64−30−00 Tail Rotor Pitch Control Assembly (369D/E/FF) . . . . . . . . . . . . . . . X X X
67 FLIGHT CONTROLS
67−00−00 Flight Controls (369D/E/FF − 500/600N) . . . . . . . . . . . . . . . . . . . . . X X X X X
67−10−00 Main Rotor Flight Controls (369D/E/FF − 500/600N) . . . . . . . . . . X X X X X
67−10−20 Collective and Cyclic Stick Grips (369D/E/FF − 500/600N) . . . . . X X X X X
67−20−10 Anti−Torque Flight Controls (Two and Four Blade)
(369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
67−20−30 NOTARr Anti−Torque System Flight Controls (500/600N) . . . . . X X
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MAINTENANCE MANUAL
71 POWER PLANT
71−00−00 Power Plant (250−C20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X
71−00−30 Power Plant (250−C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
71−00−47 Power Plant (250−C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
71−10−00 Engine Air Intake System (369D/E/FF − 500/600N) . . . . . . . . . . . X X X X X
71−10−05 Engine Compressor Water Wash Kit (369D/E/FF −
500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
71−10−10 Engine Air Particle Separator (369D/E/FF − 500N) . . . . . . . . . . . . X X X X
71−10−60 Engine Air Particle Separator (600N) . . . . . . . . . . . . . . . . . . . . . . . X
71−20−00 Engine Mounts (250−C20B, 250−C20R/2, 250−C30
and 250−C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
71−30−00 Engine Ignition Control System (250−C20B, 250−C20R/2
and 250−C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
71−60−00 Engine Cooling System (250−C20B, 250−C20R/2, 250−C30
and 250−C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
75 ENGINE ANTI-ICE SYSTEM

75−10−00 Engine Anti−Icing System (250−C20B, 250−C20R/2,
250−C30 and 250−C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
76 ENGINE POWER CONTROLS

76−00−00 Engine Power Controls (250−C20B, 250−C20R/2
and 250−C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
76−10−00 Power Turbine Governor Controls (250−C20B, 250−C20R/2
and 250−C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
76−20−00 Gas Producer Controls (250−C20B, 250−C20R/2 and
250−C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
76−47−00 Engine Power Controls (250−C47) . . . . . . . . . . . . . . . . . . . . . . . . . X
78 ENGINE EXHAUST SYSTEM

78−20−00 Engine Exhaust System (250−C20B and 250−C20R/2) . . . . . . . . X X X
78−30−00 Engine Exhaust System (250−C30 and 250−C47) . . . . . . . . . . . . X X
79 ENGINE OIL SUPPLY SYSTEM

79−00−00 Engine Oil Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
79−10−10 Engine Scavenge Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X
91 CHARTS
91−00−00 Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X X X X
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MAINTENANCE MANUAL
Chapter
01
Introduction
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table Title Page
01-00-00 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1. Optional Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. Tailboom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 1. Helicopter – Major Components (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . 6
D. Main Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
E. Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A. ATA Numbering System and Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
B. Division of Subject Matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 2. ATA Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
C. Page Number Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
D. Figure and Table Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. Associated MDHI Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
B. Rotorcraft (or Pilot's) Flight Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
C. Illustrated Parts Catalog (IPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
D. Component Overhaul Manual (COM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
E. Structural Repair Manual (SRM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F. Engine Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
G. Vendor Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table 2. Reference and Vendor Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. MDHI Publications, Revisions, and Reissues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
A. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
B. Temporary Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
C. Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
D. Reissue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Page i
01 Contents Revision 51
MAINTENANCE MANUAL
TABLE OF CONTENTS (Cont.)

5. Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
A. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
B. Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
C. Technical Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
D. Service Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6. Application of Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
A. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
B. Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7. Service and Operations Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
A. Maintenance Information Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Page ii
Revision 51 01 Contents
MAINTENANCE MANUAL
Section
01−00−00
Introduction
MAINTENANCE MANUAL
INTRODUCTION
DESCRIPTION AND OPERATION
1. Introduction Owners and operators can print hard copies of
this manual. Make a copy of this page to
All helicopters described in this manual are
satisfy copyright permissions with your local
manufactured by MDHI. The design features
and performance characteristics of all helicop copy center. Up to three copies of each manual
ters are essentially the same. The main can be made.
differences between helicopters are the type
and arrangement of interior furnishings and
equipment, the position of the pilot flight NOTE: Throughout this manual, references to
controls, engine power, anti-torque system, the 369FF model helicopters also include
and other optional equipment (Ref. Figure 1, the 369F model helicopters, unless other
Table 1). wise stated.
Table 1. Optional Equipment List

ATA Chapter and Nomenclature Part Number 369D 369E 369FF 500N 600N
10 − PARKING AND MOORING
Main rotor blade stowage rack 369D299913 X X X
21 − ENVIRONMENTAL CONTROL SYSTEM
Heating system 369H90020 X X X X X
Heating system 369H900020 X X X
25 − EQUIPMENT / FURNISHINGS
Cargo hook 369H90072 X X X X X
First aid kit 369H90090 X X X X X
Forward equipment tray 369D292200 X X X
Hoist 369H90070 X X X X
Litter kit 369D290170 X X
Litter kit TA−HH−0001 X X X
Litter kit (bubble doors and flat glass) 369H90011−519 X X
Litter kit (w/out doors) 369H90011−521 X X
Seat and belts (four on the floor) 369H90035 X X X X
Seat (mesh) 369H90040 X X X X
Rain Gutter Kit 369D220019 X
Seat assembly, passenger compartment 369D290037 X
Seat belt assembly (pilot, co−pilot) 369H6541 X
Shoulder harness and seat belt inertia reel 421−099 X X X
26 − FIRE PROTECTION
Fire extinguisher 369H90001 X X X X X
28 − FUEL SYSTEM
Anti−ice fuel filter 369H90022 X X X
Airframe fuel filter 600N98110 X
Page 1
01-00-00 TR18-001
MAINTENANCE MANUAL
Table 1. Optional Equipment List (Cont.)

Drain, auxiliary engine fuel filter 369H92255 X
Fuel tank, self−sealing 369H90029 X X X X
Crashworthy fuel system cutout modification, 369D298002 X
cabin floor
32 − LANDING GEAR
High−capacity gear 369D26116 X
Emergency floats 369D290121 X X X X
High capacity gear 369D26116 X
Extended landing gear 369D290007 X X X X
Extended landing gear 600N6000 X
Float lamp assembly 369D292032 X X X X
Ground handling wheels (compact) 369H90126 X X X X
Ground handling wheels (pneumatic) 369H90045 X X X X
Metal landing gear fairings SA4344 X
Step assembly, extended landing gear 600N6501 X
Carbide skid shoes 369D290029 X X X X X
Landing gear kit, mid−temp 369D290012 X X X X
Landing gear kit, winterized 369D290010 X X X X
Utility floats 369D290086 X X
52 − DOORS
Door (litter) 369H90085 X
Door opener (Paravion) 369D290038 X X X X X
53 − FUSELAGE
Clear windshield kit 369H90026 X
Comfort window 369D290026 X X X
Magnesium−to−aluminum conversion kit M30251−501 X X X X
Side window (fwd extended canopy) 369D292491 X X
Upper and lower windshield (Heliplex) SH7443SW X X X
Window, crew (Heliplex) SH7404SW X X X
Window, passenger (Heliplex) SH7405SW X X X
Windshield assembly, LH 369D22417−109 X
63 − TRANSMISSION AND DRIVE SYSTEM
Main rotor transmission oil cooler drain 369D290120 X
Rotor brake 369H90123 X X X X X
64 − ANTI−TORQUE ASSEMBLY
Four−bladed tail rotor drive system 369D292500 X X
Page 2
TR18-001 01-00-00
MAINTENANCE MANUAL

67 − FLIGHT CONTROLS
Cyclic stick grip kit 369H90129 X X X X
Dual controls, LH command 369H90033 X X X X X
Right−hand command kit 369D297001 X X X X X
Yaw Stability Augmentation System 600N97300 X
71 − POWER PLANT
C30 maintenance fuel pump kit 369D298100 X X
Engine compressor water wash kit 369H92537 X X X X X
Engine air inlet deflector kit 369D292044 X X
Foreign particle diverter kit 369D292045 X X
Mist eliminator 369D290125 X
Mist eliminator access panel 369D290270 X X X
Particle separator 369H90148 X X X X
Particle separation 500N70148 X
Particle separator filter 600N90148 X
Particle separator 600N90125 X
Particle separator fairing 600N90128 X
Starter−generator cooling system A1400−185 SH907GL X
250−C20R/2 conversion kit 369D298000 X X
95 − INSTRUMENTS
AIM attitude gyro (510−1BL) 600N96501 X
AIM 200 directional gyro (200DCL) 600N96502 X
AIM 205 directional gyro (205−1BL) 600N96503 X
AIM turn/bank indicator (TS400−1AL) 600N96504 X
Altimeter indicator (millibar scale) 369H90124 X X X
Attitude gyro indicator 369H90038 X X X X
Auto direction finder (Collins ADF−650A) 369D24165 X X
Auto direction finder (KR−85) 369H90067 X
Auto direction finder (KR−87) 600N96508 X
Compass system (KCS−55A) 600N96528 X
Digital/Analog TOT indicator 369D294509 X X X
Directional gyro indicator 369H90039 X X X X
Encoding altimeter (United 5035) 600N96522 X
Heated pitot tube 369H90034 X X X X
Heated pitot tube 600N90034 X
Instantaneous vertical speed indicator 369H90044 X X X
Instantaneous vertical speed indicator 600N96524 X
Page 3
01-00-00 TR18-001
MAINTENANCE MANUAL

IVSI 369D294508 X X X
Radar altimeter 600N96506 X
Vertical speed indicator 600N96523 X
96 − ELECTRICAL POWER
Dual Starting Kit 369D297807 X X X
Lead−acid Battery M30306 X
Forward battery 369D22505 X
13 amp−hour Ni−Cad battery 369D24296 X
17 amp−hour Ni−Cad battery 369D290011 X X X X
17ah−high rate, Lead Acid, 28 volts, 17 ampere, 369D290011−513 X
battery
97 − AVIONICS
ADF (Collins RCR−650) 369H90008 X
ADF (Collins 60A) 369D24333 X
ADF (King KR−87) 369D24161 X X
Audio control panel (KMA24−H) 600N96514 X
Collective Hobbs 600N96525 X
Communications receiver (Bendix/King KY−196) 369D24167 X X
Communications receiver (KY196A−30) 600N96513 X
Copilot foot switch 600N96526 X
GPS International (KLN 90B) 600N96507 X
Harness assembly (VHF−22B) 369D24321 X
Headset microphone H10−56 X X X X
Headset microphone assembly 369H92042 X X X X
ICS system 369H90068 X
ICS system 369D24118 X X X X
Instrument and electrical (RH command) 369D24175 X X X
Transponder (Collins TDR−950) 369D24166 X X
Transponder (Collins TDR−950) 369H90009 X
Transponder (King KT−76A) 369D24163 X X
Transponder (KT−76A) 369H90073 X
Transponder, Mode A/C (KT−76A) 600N96511 X
Transponder, Mode S (KT−70) 600N96509 X
Middle seat wire harness 600N96515 X
NAT AA82/AA83 stereo ICS 600N96505 X
NAV/COM (Collins) 369H90007 X
NAV/COM (Collins VHF−251 and VIR−351) 369D24164 X X
Page 4
TR18-001 01-00-00
MAINTENANCE MANUAL

NAV/COM transceiver (KX155) 369D24147 X X
NAV/COM transceiver (KX155) 600N96512 X
NAV/COM transceiver (KX−170A) 369H90071 X
NAV/COM transceiver (King KX−1756) 369D24162 X X
Radio (ASB/125/60) 369H90144 X
Rear seat transmit switch 600N96527 X
Stereo audio control 600N96529 X
Switch and jack assembly, intercom 369H92492 X X X X
Transceiver (VHF−22B) 369D24322 X
A. General command configuration helicopter. The cargo

compartment is behind the crew compartment
The Model 369D/E/FF - 500/600N helicopters and contains provisions for bench-type or
are turbine-powered, rotary-wing aircraft folding passenger seats. Passenger seats can
constructed primarily of aluminum alloy. The be folded out of the way or completely removed
main rotor system for the 369D/E/FF - 500N to accommodate cargo. The aft section houses
helicopter is five-bladed and fully-articulated. the engine and includes structure for tailboom
The main rotor system for the 600N helicopter attachment and in the case of the 500/600N,
is six-bladed and fully-articulated. The the fan assembly and fan transmission for the
anti-torque system can be two bladed, an NOTARR anti-torque system. The lower
optional four-bladed installation or a NOTARR section is divided by a center beam and
anti-torque system. Engine output is delivered provides two bays containing two fuel cells
to the main and anti-torque system by drive that make up the fuel tank.
shafts and two transmissions. A one-way
overrunning clutch between the engine and C. Tailboom
main transmission permits the main rotor to
freewheel for autorotational descent. The 369D/E/FF tailboom is a monocoque
structure of aluminum alloy frames and skin.
B. Fuselage The tailboom is the supporting structure for
the vertical and horizontal stabilizers, tail
The fuselage is a semi-monocoque construc rotor transmission and tail rotor. The tailboom
tion divided into three sections. The structure also houses the tail rotor transmission drive
consists of a central framework, a mast shaft and tail rotor blade-angle control rod.
support structure, two bulkheads and a center
beam. The forward section includes the crew The 500/600N tailboom assembly is a fully
and cargo or passenger compartment. The monocoque construction of carbon fiber
crew compartment is equipped with seats for composites. The tailboom is the supporting
the pilot and either one or two passengers. The structure for the stator assembly, horizontal
crew compartment left seat is the pilot seat stabilizer, two thruster assemblies and control
(LH command position) except in a RH cable assembly.
Page 5
01-00-00 TR18-001
MAINTENANCE MANUAL
HORIZONTAL STABILIZER
MAIN ROTOR INSTALLATION
VERTICAL STABILIZER
TAIL ROTOR
TRANSMISSION
TAILBOOM
AFT SECTION
INSTALLATION
TAIL ROTOR
FLIGHT CONTROL ASSEMBLY
INSTALLATION
ENGINE
INSTALLATION
MAIN TRANSMISSION AND
POWER TRAIN
FORWARD SECTION
INSTALLATION
ENGINE ACCESS DOOR ASSEMBLY
CARGO DOOR ASSEMBLY
LOWER SECTION INSTALLATION
PILOT DOOR
ASSEMBLY
LANDING GEAR
369D/E/FF HELICOPTER
G01−0001A
Figure 1. Helicopter – Major Components (Sheet 1 of 3)
Page 6
Revision 50 01-00-00
MAINTENANCE MANUAL
VERTICAL STABILIZER ASSEMBLY
MAIN ROTOR INSTALLATION
SAS CONTROL ACTUATOR
STATOR
AFT SECTION TAILBOOM

INSTALLATION ASSEMBLY
FAN
GEARBOX
FLIGHT CONTROLS
INSTALLATION
FORWARD SECTION MAIN

INSTALLATION TRANSMISSION
ENGINE
INSTALLATION
ENGINE ACCESS
DOOR ASSEMBLY
CARGO DOOR ASSEMBLY
LOWER SECTION INSTALLATION
PILOT DOOR
ASSEMBLY
LANDING GEAR
500N HELICOPTER
G01−0003
Page 7
01-00-00 Revision 50
MAINTENANCE MANUAL
6-BLADED MAIN ROTOR

INSTALLATION
FAN FAN
GEARBOX
MAIN
TRANSMISSION
FLIGHT CONTROLS HORIZONTAL

INSTALLATION STABILIZER
MID DOOR
ASSEMBLY
STATOR
AFT DOOR
ASSEMBLY
TAILBOOM
ASSEMBLY
VERTICAL STABILIZER
ENGINE ASSEMBLY
INSTALLATION
AFT SECTION
INSTALLATION
ENGINE ACCESS
DOOR ASSEMBLY
LANDING GEAR
FORWARD SECTION
INSTALLATION
PILOT DOOR
ASSEMBLY
LOWER SECTION
INSTALLATION
600N HELICOPTER
6G01−001A
Page 8
MAINTENANCE MANUAL
D. Main Rotor D Model 369FF (MD530F Plus)
The main rotor group consists of five or six D Model 500N (MD520N)
main rotor blades, a fully-articulated main
rotor hub with offset flapping hinges, a D Model 600N (MD600N)
scissors assembly, and a swashplate and Study the manual contents to understand the
associated mixer control mechanisms. The arrangement and use of this and associated
main rotor blades are secured to the rotor hub manuals (ref. Unit 3. and Table 2) before
with standard hardware and quick-release helicopter maintenance and inspection tasks
pins. are done.
E. Landing Gear A. ATA Numbering System and Format
The fixed skid landing gear is attached to the (Ref. Figure 2)
fuselage at 12 points. Fairings cover the struts
from the fuselage to the skids. Nitrogen- This MDHI maintenance manual and related
charged dampers between the struts and manuals are prepared in general compliance
structure cushion landing loads. with Air Transport Association Specification
for Manufacturers Technical Data (ATA-100).
2. Scope The uniform number system established by
ATA-100 is used. This system divides material
MDHI maintenance manuals are used for into chapters, sections, subjects, and page
system descriptions, servicing and mainte blocks. The number has three elements, each
nance procedures, periodic and special of two digits. The chapter and section/sub-as
inspections, overhaul schedules, limited life sembly elements are given by ATA-100. The
component replacement schedules, and weight subject/unit element numbers are from MDHI.
and balance calculations. B. Division of Subject Matter
This manual is an integral part of a publica The maintenance manual has two volumes:
tions library for the helicopters. The mainte
nance and inspection procedures are to be used D CSP-HMI-2 is for general mechanical
for these helicopters only: maintenance data.
D Model 369D (MD500D) D CSP-HMI-3 is for maintenance data on

instruments, electrical systems, and
D Model 369E (MD500E) avionics.
2ND ELEMENT
1ST ELEMENT
3RD ELEMENT
32 10 10
SUBJECT / UNIT
CHAPTER / SYS1TEM LANDING GEAR
LANDING GEAR SYSTEM
SECTION / SUB-ASSEMBLY
LANDING GEAR
G01−0004
Figure 2. ATA Numbering System
Page 9
MAINTENANCE MANUAL
C. Page Number Blocks 3. Associated MDHI Manuals

Page number blocks are used in each section in A. Introduction
the maintenance manual to arrange the Information beyond the scope of the mainte
maintenance practices: nance manual can be found in these related
Description and Operation . . . . . . . . . . . . . . . . 1 manuals which must always be kept and used
with the CSP-HMI-2 and CSP-HMI-3:
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . 101 D The applicable rotorcraft flight manuals
Maintenance Practices . . . . . . . . . . . . . . . . . 201 (RFMs) and supplements (RFMSs)
D CSP-IPC-4, Illustrated Parts Catalog
NOTE: Maintenance Practices are either a
brief subtopic or a combination of these D CSP-COM-5, Component Overhaul Manual
subtopics: Servicing, Removal/Installation,
Adjustment/Test, Inspection/Check, Clean D CSP-COM-5-1, Component Overhaul
ing/Painting and Repairs. Two methods are Manual, Transmission 369D25100
used to number the maintenance practices D CSP-COM-5-2, Component Overhaul
page blocks: Manual, Transmission 369F5100
(1) If a single subtopic or all subtopics are
D CSP-SRM-6, Structural Repair Manual
short, they are combined into one topic
(Maintenance Practices) and included in D Applicable vendor manuals (Ref. Table 2)
page block 201 thru 299.
B. Rotorcraft (or Pilot’s) Flight Manual
(2) If individual subtopics become so lengthy
that a combination would require numer Each model has its own RFM to give the pilot
ous pages, each topic is broken out in all the necessary information to operate the
their applicable page block. helicopter in a safe and efficient manner:
D CSP-D-1, Model 369D (MD500D)
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
D CSP-E-1, Model 369E (MD500E)
Removal/Installation . . . . . . . . . . . . . . . . . . . 401
D CSP-FF-1, Model 369FF (MD530F Plus)
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . 501 D CSP-520N-1, Model 500N (MD520N)
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . 601 D CSP-600RFM-1, Model 600N (MD600N)
Cleaning/Painting . . . . . . . . . . . . . . . . . . . . . 701 Maintenance checks for helicopter operation
must be done in accordance with requirements
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801 and limitations shown in the applicable MDHI
RFM and all the applicable optional equip
Initial Installation . . . . . . . . . . . . . . . . . . . . . 901 ment supplements.
Each page has an effective revision level: C. Illustrated Parts Catalog (IPC)
either original from the initial issue of the
These parts catalogs give text and illustrations
manual or the last revision of that page.
to completely define all the parts and spare
D. Figure and Table Numbers items available for these helicopter models:
D CSP-IPC-4, Illustrated Parts Catalog for
Illustrations and tables use the same numbers Models 369D/E/FF - 500/600N
as the page block in which they are part of. For
example, Figure 202 is the second figure in the D CSP-D-7, Illustrated Structures Catalog for
Maintenance Practices page block. When a Model 369D
figure or table within the same page block is D CSP-ISC-7, Illustrated Structures Catalog
referred to, it is shown as: (Ref. Figure 202). for Models 369E/FF - 500N
When a figure or table that is in another
chapter/section/subject is referred to, it is Use the IPC only for the purpose of parts
shown as: (Ref. Section 91-00-00, Table 1). procurement.
Page 10
MAINTENANCE MANUAL
D. Component Overhaul Manual (COM) tional and Maintenance Manual and the
Illustrated Parts Catalog supplied with the
The CSP-COM-5 has overhaul instructions engine for maintenance information.
for these major components:
G. Vendor Publications
D Fan Transmission
(Ref. Table 2)
D Landing Gear Dampers
D Lubrication Pump It is the responsibility of the
CAUTION maintainer, operator, and owner
D Main Rotor Swashplate to have the applicable up-to-date technical
data from the original equipment manufac
D One-Way Lock turer (OEM) for their helicopter configura
D Overrunning Clutch tion. Make sure the technical manuals have
all temporary revisions, revisions, and reis
D Pitch Control Assembly sues, and that the service and technical bul
letins, and service letters are up-to-date.
D Scavenge Pump
D Tail Rotor Transmission Publications, directives, vendor manuals,
catalogs, handbooks, and other published
D Tail Rotor Assembly documents that form part of the information
library for helicopter component maintenance
When components are removed from service are in Table 2 by vendor, title, and manual.
for overhaul, refer to the COM and/or speak to These documents are the primary source of
the appropriate manufacturer or their field service, maintenance, and repair information
service representative for necessary publica for vendor-supplied helicopter components.
tion (Ref. Table 2).
References to other equipment manufacturer-
E. Structural Repair Manual (SRM) provided documentation selected from the
helicopter options list (ref. Table 2) or as
The CSP-SRM-6 has illustrated helicopter
defined by commercial or government con
structural maintenance and repair informa
tracts, which include STC documentation,
tion.
Instructions for Continued Airworthiness
F. Engine Manuals (ICAs), and operators manual are usually
referenced by:
(Ref. Table 2)
D See the manufacturer instructions for ICA
The Model 250 Series gas turbine engines are and operating procedures (ref. Vendor
manufactured by Rolls-Royce Corporation. Manual, Title, Vendor manual Part Number)
Refer to the applicable Rolls-Royce Opera - if available.
Table 2. Reference and Vendor Manuals
Component and Publication or
Manufacturer, or Source Publication Title Directive
General Information
Superintendent of Documents Acceptable Methods, Techniques and FAA AC No. 43.13−1A (1)
U.S. Government Printing Office Practices − Aircraft Inspection and
Division of Public Documents Repair (GPO Catalog No. TD
Washington, DC 20402 4−28/2:972)
Advisory Circular − Corrosion Control for FAA AC No. 43−4 (1)
Aircraft
IHS Aviation & Aerospace Nondestructive Testing Personnel NAS−410
15 Inverness Way East Qualification and Certification
Englewood, CO 80112
Page 11
MAINTENANCE MANUAL
Table 2. Reference and Vendor Manuals (Cont)

Nondestructive Testing Personnel ASNT−SNT−TC−1A
Qualification and Certification
Standard Terminology for ASTM E 1316
Non−destructive Examinations
Aerospace Industries Association of National Aerospace Standard NAS No. as applicable
America, Inc. (Title as applicable)
1725 De Sales Street, Northwest
Washington, DC
MDHI Publications
MD Helicopters, Inc. 369D Rotorcraft Flight Manual (with CSP−D−1 (1)
4555 East McDowell Road applicable Equipment Supplements)
Mesa, AZ 85215
369E Rotorcraft Flight Manual (with CSP−E−1 (1)
CAGE Code: 1KVX4
applicable Equipment Supplements)
369FF Rotorcraft Flight Manual (with CSP−FF−1 (1)
500N Rotorcraft Flight Manual (with CSP−520N−1 (1)
600N Rotorcraft Flight Manual (with CSP−600NRFM−1 (1)
600N Rotorcraft Flight Manual (with CSP−600NRFM−2 (1)
Illustrated Parts Catalog (IPC), Model CSP−IPC−4 (1)
369D/E/F − 500/600N
Basic Handbook of Maintenance CSP−HMI−2 (1)
Instructions (HMI−2) Servicing and
Maintenance, Model 369D/E/F −
500/600N
Basic Handbook of Maintenance CSP−HMI−3 (1)
Instructions (HMI−3) Instruments−Elec-
trical−Avionics, Model 369D/E/F −
500/600N
Component Overhaul Manual (COM), CSP−COM−5 (1)
Model 369D/E/F − 500/600N CSP−COM−5−1
CSP−COM−5−2
Structural Repair Manual (SRM), Model CSP−SRM−6 (1)
369D/E/F − 500N
Illustrated Structures Catalog (ISC), CSP−D−7 (1)
Model 369D
Illustrated Structures Catalog (ISC), CSP−ICS−7 (1)
Model 369D/E/FF − 500N
Corrosion Control Manual CSP−A−4
Page 12
MAINTENANCE MANUAL

Avionics Equipment
VHF/COMM Transceiver AVC−110 VHF Communications IB8029004
RCA Aviation Equipment Dept. Transceiver Instruction Manual
11819 W. Olympic Blvd.
Los Angeles, CA 90064
VHF/NAV Receiver AVN−210 Series Integrated Navigation IB96460

RCA Aviation Equipment Dept. Systems
University Sound of LTV Ling Altec, Inc. Operators Manual, SA−250 and SA−500
Oklahoma City, OK High Power Sound and Siren Systems
Operators Manual, Model 500 Super
High Power Solid−State Amplifier and
Model RMC−1 Remote Control
Automatic Direction Finder KR 85 Automatic Direction Finder 006−0043−00
King Radio Corp. Installation Manual (has repair/overhaul
400 North Rogers Road information)
Olathe, KS
KR 86 Automatic Direction Finder 006−5084−00
Maintenance/Overhaul Manual
KR 87 Automatic Direction Finder 006−5184−00
NAV/COMM Receiver KX 155 NAV COMM Receiver 006−5179−00
King Radio Corp. Maintenance/Overhaul Manual
NAV/COMM Transceiver and COMM KX 170A/B − KX 175B NAV/COMM 006−5053−00

Transceiver Transceiver and KY 195B
King Radio Corp. Communications Transceiver
COMM Transceiver KY 196 VHF COMM Transceiver 006−5169−00

King Radio Corp. Maintenance/Overhaul Manual
Transponder KT 76A Transponder Maintenance/Ov- 006−5143−00

King Radio Corp. erhaul Manual
VOR Indicator KI 201C VOR Indicator Maintenance/ 006−5052−00

King Radio Corp. Overhaul Manual
KI 208 VOR Indicator Maintenance/Ov- 006−5137−00
erhaul Manual
Audio Control Panel KMA 24H−70/71 Audio Selector Panel 006−5586−00
King Radio Corp. and Interphone System Maintenance/
Overhaul Manual
Page 13
MAINTENANCE MANUAL

Automatic Direction Finder System ADF−60 Automatic Direction Finder 523−0766184−00611A
Collins General Aviation Division System Instruction Book
Avionics Group
CTL−X2 Controls and CAD−62 Control 523−0772494−00111A
Rockwell International Corp.
Adaptor Instruction Book
Cedar Rapids, Iowa 52498
Collins Pro Line II Com/Nav/Pulse 523−0772719−00211A
System Instruction Book
ALT−55 Radio Altimeter System ALT−55 Radio Altimeter System 523−0766793

Instruction Book (Repair Manual)
Rockwell Collins Flight Services, Inc.
400 Collins Road Northeast
Phone: 319−263−3031
CAGE Code: 6B4R0
Automatic Direction Finder System ADF−650/650A Automatic Direction 523−0766207−00411A

Collins General Aviation Division Finder System − RCR−650/650A
Receiver, ANT−650 Antenna,
IND−650/650A Indicator and ADA−650
ADF to RMI Adaptor Instruction Book
COMM Transceiver VHF−22B VHF COMM Transceiver 523−0771854−00311A

Collins General Aviation Division Instruction Book
VHF−251 Communications Transceiver 523−0766029−00511A
and PWC−150 Power Convertor
Instruction Book
NAV Receiver VIR−351 Navigation Receiver, IND−350 523−0766030−00511A

Collins General Aviation Division Indicator, and PWC−150 Power
Convertor Instruction Book
Transponder TDR−950 Transponder Instruction Book 523−0766464−00311A

Collins General Aviation Division
VHF AM/FM AN/ARC−186(V) Collins VHF−186 Transceiver Instruction 523−0770251−00111A

Collins Government Avionics Division Book
Avionics & Missiles Group
Rockwell International
ICS Control Panel (C−6533/ARC) A301−1 Communication Control C46−5020 027

Andrea Radio Corp. Technical Manual − Installation,
11−40 45 Road Operation and Maintenance
Long Island City, NY 11101
COMM Transceiver ASB−125, ASB−60 SSB 99655

Sunair Electronics, Inc. Communications Equipment
3101 Southwest 3rd Avenue Maintenance Manual
Fort Lauderdale, FL 33315
Page 14
MAINTENANCE MANUAL

Garmin International, Inc. GDU 620 Installation Manual 190−00601−04
1200 East 151st Street G500/G600 TXi Part 23 AML STC
Olathe, KS 66062 Maintenance Manual 190−01714−B1
Phone: 913−397−8200
CAGE Code: 0TRC3
Spilsbury & Tindall, Ltd. Instruction Manual, ‘‘Stringer’’ Model 65−018

120 East Cordova Street AC−21 Mobile Antenna System
Vancouver 4, BC Canada
Battery
Marathon Battery Co. Marathon Battery Instruction Manual BA−89
Cold Spring, NY 10516 (REV 2−71)
Phone: (817) 776−0650
Engine
Rolls−Royce Corp. Operation and Maintenance Manual, 10W2 (1)
2001 South Tibbs Avenue Turboshaft Engine Model 250−C20,
Indianapolis, IN 46206 −C20B
Phone: 317−230−3744
Overhaul Manual, Turboshaft Engine 10W3 (1)
CAGE Code: 63005
Model 250−C20, −C20B
Illustrated Parts Catalog, Turboshaft 10W4 (1)
Engine Model 250−C20, −C20B
Installation Bulletin, Three Cubic Inch 1005 (1)
Accumulator for 250−C20 Bendix Fuel
System
Operation and Maintenance Manual, GTP−5232−2 (1)
Turboshaft Engine Model 250−C20R/2
Overhaul Manual, Turboshaft Engine GTP−5232−3 (1)
Model 250−C20R/2
Illustrated Parts Catalog, Turboshaft GTP−5232−4 (1)
Engine Model 250−C20R/2
Operation and Maintenance Manual, 14W2 (1)
Turboshaft Engine Model 250−C30
Overhaul Manual, Turboshaft Engine 14W3 (1)
Model 250−C30
Illustrated Parts Catalog, Turboshaft 14W4 (1)
Engine Model 250−C30
Operation and Maintenance Manual, CSP 21004 (1)
Turboshaft Engine Model 250−C47M
Overhaul Manual, Turboshaft Engine CSP 22004 (1)
Model 250−C47M
Illustrated Parts Catalog, Turboshaft CSP 23001 (1)
Engine Model 250−C47M
Page 15
MAINTENANCE MANUAL

Engine Intake Air Particle Separator
Pall Land Marine Corp. (PLM) Vortex Tube Repair PLM−TM−80−1

7070 Moon Lake Road
New Port Richey, FL 33552
Phone: (813) 849−9999
Engine Oil Cooler
General Motors Corp. Service Overhaul Manual, Harrison HES−66 77

Harrison Radiator Division Aluminum Plate Type Liquid−to−Air
200 Upper Mountain Road Coolers
Lockport, NY 14094
Phone: 716−439−3328
CAGE Code: 27462
Stewart Warner Southwind Corp.

Suite F, 2495 Directors Row
Indianapolis, IN 46221
Phone: 317−486−2600
CAGE Code: 78285
Fuel Cells
Department of the (US) Navy Military Standard Inspection & MIL−STD−801

Naval Forms Online Acceptance Standards For Propulsion
Fluid Cells & Fittings
Meggitt (Rockmart), Inc. Maintenance and Repair Manual, AP 368

669 Goodyear Street VITHANE\R Fuel Tanks,
Rockmart, GA 30153 July 1988, ATA 28−10−13
Phone: 770−684−7855
Quick Cure Repair for Engineered AP 472
CAGE Code: 56221
Fabrics Corp. Fuel Tanks of VITHANE\R
Construction,
March 1988, ATA 28−10−15
Repair & Maintenance Manual, Bladder, AP 430
Self Sealing, & Non−Self−Sealing
Tanks, ARM Type Constructions,
April 1987, ATA 28−10−16
Repair & Maintenance Manual, Bladder AP 258−4
Fuel Tanks,
Nitrile Type Constructions,
June 1988, ATA 28−10−1
Uniroyal, Inc. Recommended Handling, Storage and FC−1473−73

Engineered Systems Department Repair Procedures For Non−Self−Seal-
Mishawaka, Indiana 46544 ing Flexible Fuel, Oil And Water Alcohol
Phone: (219) 255−2181 Cells
Repair Procedure For Self−Sealing Fuel RK−10−34
Cells
Page 16
MAINTENANCE MANUAL

Fuel Filter Pressure Switch
Jensen Raymond West Industries Pressure Switch Repairs
215 Arena Street
El Segundo, CA 90245
Phone: 213−322−5549
CAGE Code: 17816
Hoist Equipment
Hoist Winch Assembly BL−16600−12 Series 300 Pound HB−136
Capacity Hoist Operating Instructions
Transtechnology Corporation
Breeze−Eastern Division BL−16600−40 Series Hoist Operating
700 Liberty Avenue Instructions
Union, NJ 07083
Phone: 908−686−4012 Use and Maintenance of Aircraft Hoist
CAGE Code: 08484 Cable
Landing Gear Equipment
Helicopter Float Assemblies Overhaul Manual with Illustrated Parts
Garrett−Air Cruiser Company List, Helicopter Float Assemblies,
P.O. Box 180 Utility Floats 21D24368−1/−2,
Belmar, NJ Emergency Floats D24484−5/−6
Maintenance and Test Equipment
Model 177M−6 Balancer Honeywell Operation and Service Call or write
Model 8350 Balancer Instruction Handbooks are normally
Model 192A Balancer supplied with the equipment.
Model 8500 Balancer
Model 135M−11 Strobex Blade Tracker
Model 135M−12 Strobex Blade Tracker −
must be used with Model 8500 Balancer
Honeywell International Inc.

23500 W 105th St
Olathe, KS, 66061
Phone: (913) 712−0400
CAGE Code: 99866
Main Rotor Blades
Helicopter Technology Company (HTC) Main Rotor Blades (Installation and HTCM−001
12902 South Broadway Maintenance)
Phone: 310−523−2750
Scavenge Oil Filter
Facet Kit No. 1741050−01 Installation and Service Manual for E−947 (1)
Scavenge Lube Oil Filter System for
Purolator Facet, Inc. McDonnell Douglas 500 Series Models:
8439 Triad Drive 369HS, 369HM, 369HE, 369D
Greensboro, NC 27409
Phone: 336−668−4444
CAGE Code: 90005
Page 17
MAINTENANCE MANUAL

Searchlight
Alexair SX Nightsun Searchlight STC No. SH2288NM
25320 Bellanca Way (Spectrolab)
Torrance, CA 90505
Phone: (213) 326−5222
Starter−Generator
Skurka Engineering Co. Brush Seating − APC Brushes in High SB150SG105
4600 Calle Bolero Speed Starter Generators: MDHI Part
Camarillo, CA 93012 Nos. 369A4550 and 369D28550
Phone: 805−484−8884
CAGE Code: 95270 Overhaul Manual With Illustrated Parts TM 101
Breakdown
Kelsey−Hayes Company Inc Overhaul Instructions with Parts Call or write

Customer Support Breakdown, Models 23032−010,
30 Van Nostrand Avenue 23032−011, 23032−020, 23032−022,
Englewood, NJ 07631 23032−028, 23081−001
Phone: 201−567−6400
CAGE Code: 19527
Fargo Manufacturing Co., Inc. Starter/Generator Cooling System STC No. SH907GL
130 Salt Point Road Supplemental Type Certificate
Poughkeepsie, NY 12603
CAGE Code: 91046
Tail Rotor Blades
Helicopter Technology Company (HTC) Tail Rotor Blades (Installation and HTCM−002
12902 South Broadway Maintenance)
Phone: 310−523−2750
Transmissions
Threaded Inserts Keenserts Catalog D
Newton Insert Co.
6500 Avalon Blvd.
Trim Actuators
CEF Industries, Inc., Trim Actuator Overhaul
Calco Division
320 South Church Street
Addison, IL 60101
Phone: 630−628−2594
CAGE Code: 00268
NOTES:
(1) This publication must be maintained as part of the primary information library for the helicopters.
Page 18
MAINTENANCE MANUAL
4. MDHI Publications, Revisions, and deletion of pages, figure, or items will not
Reissues have a revision bar, but the revision level of
the page will change to the new revision
A. Introduction level.
The HMI is periodically updated by one of D All changed pages in the same revision will
three methods: have the same revision number and the
D Temporary Revision same date. The dates and revision number
on unchanged backup pages will stay at
D Revision their old revision level.
D Reissue D. Reissue
Each method will have a Transmittal Page to A reissue is a completely new manual that
show the manual, model, the issue number, replaces the previous issue and all its related
the revision level, date, and filing instructions. revisions and TRs. A reissue will begin as an
initial issue without revision bars.
B. Temporary Revision
5. Service Information
Temporary Revisions (TRs) are issued when
important information must be quickly put A. Introduction
into the manual. TRs are included in the next
revision of the manual and thus are removed Service information is to be thought of as part
by the next revision. of the maintenance manuals. Service informa
tion is sent to owners and operators as:
C. Revision
D Service Bulletins
Revisions are replacement pages to be added
or deleted, and inserted or removed at the D Technical Bulletins
locations shown on the Filing Instructions D Service Letters
page. Revisions are issued on a periodic basis.
For information about active and cancelled
D A new Title Page and LOEP are part of each bulletins and letters, go online to MD Heli
HMI revision. The tables of contents (TOCs) copters, Support at: https://www.mdhelicopter
and Index are revised when necessary. s.com/contact.html, or call the MDHI team at
D Text that is changed in a revision will be 480-346-6300.
identified by a black revision bar in the left B. Service Bulletins
or right margin.
Service bulletins have technical procedures
D Figures that have a major change in a and critical parts that must be corrected
revision will be identified by black revision because it can have an effect on helicopter
bar in the left or right margin. Figures that safety. Service bulletins must be done immedi
have a minor change will have the change ately (within the time compliance as shown in
pointed to by a hand in the graphic . the bulletin) and have mandatory compliance
D Spelling corrections, punctuation changes with a record or accomplishment. Service
and/or corrections, will not have a revision bulletins can have tasks that have multiple
bar, if this is the only change(s) in a scheduled occurrences (by flight-time or
sentence, paragraph, or page. However, the calendar) or have a one-time-only compliance.
revision level of the page will change to the Service bulletins are issued:
new revision level. D To give special instructions and checks that
D TRs that have been issued, but not put into are necessary to keep the helicopter and/or
a revision, will be included in the next its components in a safe operational
revision. condition (for example: special inspections to
find a flaw by a one-time or continuous
D Page rolls, figure number rolls, and item inspection until corrective action can be
number rolls caused by the addition or done).
Page 19
MAINTENANCE MANUAL
D When there is a reduction in the life-limit of D To tell owners and operators of an available
a component. or future modification.
D To give instructions and the authority for D For a change in material finishes, protective
the inspection, modification, repair, and/or coatings, consumable materials, or special
rework of the helicopter and/or its compo tools.
nents.
6. Application of Warnings, Cautions and
D To give instructions and the authority to do Notes
a retrofit of the helicopter or its components
by the modification of old components and/or
A. Introduction
the inclusion of new components.
Service bulletins replace the old red border Throughout this manual Warnings, Cautions,
notice. and Notes are used to emphasize instructions
or information considered to be critical or
unusual:
C. Technical Bulletins
Technical bulletins have technical procedures D A WARNING or WARNING Symbol (ref.

and parts that are not safety related or critical, Subunit 6.B.) always will be before the
or are optional equipment, and usually do not instructions or information which the
have a compliance requirement (but can be WARNING applies to.
done at the option of the owner/operator).
Technical bulletins are issued: D A CAUTION will always follow a WARN
ING, but will be before a NOTE or the
D To give instructions and the authority to do instruction or information which the
modifications, inspections, repairs, or CAUTION applies to.
rework of the helicopter or its components.
D A NOTE can be before or follow the instruc
D To give instructions and the authority to do tion or information, dependent upon the
a retrofit of the helicopter or its components significance of the content, which the NOTE
by the modification of old components and/or applies to.
the inclusion of new components.
Warnings, Cautions, and Notes are used for
Technical bulletins replace the old blue border these conditions:
notice.
Procedures and practices
D. Service Letters WARNING which, if not obeyed, can
cause injury to or kill personnel.
Service letters are informational and do not
have a compliance requirement. Service letters Procedures and practices which,
CAUTION if not obeyed, can cause damage
are issued:
to or destruction of equipment.
D To discuss field problems and to highlight
information already in or to be added to the NOTE: A condition, description, or explanation
maintenance manuals. that is essential to highlight.
D To tell owners and operators of interchange B. Warning Symbols

able or future spare parts which will have
no effect on helicopter safety, performance, Symbols are used as a method to show danger
maintainability, and reliability. to maintenance personnel by graphic informa
tion. These symbols are easily understood
D To give preliminary information of a future graphic keys to technical descriptions of a
service bulletin or technical bulletin. hazard.
Page 20
MAINTENANCE MANUAL
B = Burns/Irritate Chemical EX = Explosion

This quickly expanding sym
The symbol of a liquid drop WARNING bol shows that the material
WARNING from a vial that falls on a can explode because of high tempera
hand shows that the material will ture, sources of ignition, or high pres
cause burns or irritation to human sure.
skin or tissue.
FO = Falling Object
BA = Bacteria/Biological The symbol of a person be
WARNING ing struck by a falling object
The abstract bug symbol shows a danger to life and health.
WARNING shows that a material can
contain bacteria or viruses that are a
danger to life and health.
F = Flammable
The symbol of a flame shows
WARNING that a material can burn.
ËË
C = Cold
The symbol of a hand above

WARNING an icy area shows that the ËË
H = Hot/Burn
material is very cold and can injure hu
man skin or tissue. The symbol of a hand above
WARNING a fiery area shows that the
material is very hot and can injure hu
man skin or tissue.
E = Eye Injury
The symbol of a person with I = Bodily Strike Injury

WARNING goggles on shows that the
The symbol of a person be
material can injure your eyes. WARNING ing struck by an object
shows a danger to life and health.
EL = Electrical/Shock
P = Poison
The symbol of a hand with The symbol of a skull and
WARNING an electrical wire with an WARNING crossbones shows that the
arc or bolt of electricity shows a danger material is poisonous and is a danger
to life and health. to life and health.
Page 21
MAINTENANCE MANUAL
To report service and operational problems with

the helicopter, fill out a Service and Operations
Report (SOR) at:
R = Radiation https://www.mymd.aero/dashboard (select the
The symbol of three circular SUPPORT dropdown menu, select New SOR, ,
WARNING wedges shows that a materi select the Purpose of SOR submittal drop
al gives off radioactive energy and can down menu, and then select Next to fill out a
injure human tissue or organs. new SOR).
Use of SOR is recommended so that MDHI can

give owners and operators better service. The
SOR is used as a detailed record of service
problems, solutions, and actions.
S = Electrostatic Discharge
A. Maintenance Information Requests
The abstract circle segments
WARNING and arrows symbol show All questions about 369D / 369E / 369FF /
damage by electrostatic discharge, or 500N / 600N helicopter maintenance go to
injury, or death. MDHI Field Service Engineering. Tell or email
your MDHI Field Service Engineer (FSE)
about your issue or question.
If there is no FSE in your area, contact the

V = Vapor MDHI team at:
The symbol of a human fig D https://www.mymd.aero/dashboard
WARNING ure in a cloud shows that
material gases are danger to life and D https://www.mdhelicopters.com/contact.html
health.
D Phone number: 480-346-6300
7. Service and Operations Reports
B. Technical Manual Recommended Change
If the item in question is vendor supplied (for Report
example: the engine, engine fuel control and
governor, starter-generator, fuel cells) go In addition to the Contact form, the Technical
directly to the manufacturer to get definitive Manual Recommended Change Report can be
answers to your questions (ref. Table 2, which filled out and faxed, scanned, and emailed, or
has component manufacturers, suppliers, and mailed to your MDHI Field Service Representa
their addresses and contact information). tive.
Page 22
TR18-001 01-00-00
MAINTENANCE MANUAL
Chapter
04
Airworthiness
Limitations
MD Helicopters, Inc. CSP−HMI−2
MAINTENANCE MANUAL
TABLE OF CONTENTS
04-00-00 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Component Mandatory Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Component Mandatory Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Retirement Index Number (RIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Torque Event (TE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. External Lift and Torque Event (TE) Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 1. Airworthiness Limitations Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
04-00-01 Airworthiness Limitations Supplements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. UK CAA Airworthiness Limitations Section Supplement . . . . . . . . . . . . . . . . . . . . . . . . 1
Page i
CSP−HMI−2 MD Helicopters, Inc.
MAINTENANCE MANUAL

Page ii
MAINTENANCE MANUAL
Section
04−00−00
Airworthiness
Limitations
MAINTENANCE MANUAL
AIRWORTHINESS LIMITATIONS
Type Certificate No. H3WE
FAA Approved Airworthiness Limitations for MD Helicopters, Inc., Models 369D/E/F/FF and
500/600N.
1. General
The Airworthiness Limitations section is FAA approved and specifies maintenance required under
Code of Federal Regulations (CFR), Title 14, Federal Aviation Regulation (FAR), Part 43.16 and
91.403 unless an alternative program has been FAA approved.
REVISION: DATE FAA SIGNATURE AND DATE

Original Issue: October 31, 1990 Not FAA approved
Revision 1: March 29, 1991 Not FAA approved this revision
Revision 2: May 10, 1991
TR 91−001 August 12, 1991
Revision 3: September 9, 1991
TR 91−002 November 5, 1991
Revision 4: January 20, 1992
TR 92−004 May 20, 1992
Revision 5: August 24, 1992
TR 92−005 November 20, 1992
Revision 6: December 21, 1992
Revision 7: June 1, 1993 Section 04−00−00 Not Affected This Revision
TR 93−002 May 27, 1993
Revision 8: July 23, 1993
TR 94−001 January 21, 1994
Revision 9: April 22, 1994
Revision 10: September 26, 1994 Section 04−00−00 Not Affected This Revision
TR 94−002 October 24, 1994
Page 1
FAA APPROVED 04-00-00 Revision 42
MAINTENANCE MANUAL
Revision 11: January 18, 1995
Revision 12: October 6, 1995 Section 04−00−00 Not Affected This Revision
TR 96−002: April 24, 1996
Revision 13: May 31, 1996
Revision 14: September 13, 1996
Revision 15: November 15, 1996 Section 04−00−00 Not Affected This Revision
Revision 16: January 6, 1997 Section 04−00−00 Not Affected This Revision
Revision 17: February 24, 1997
TR 97−001: July 2, 1997
TR 97−002: August 19, 1997
Section 04−00−00 Not Affected This Revision

Revision 18: October 17, 1997
T/R 97−001 and 97−002 Previously Signed
Revision 19: December 16, 1997
TR 98−001: March 25, 1998

Revision 20: June 1, 1998
T/R 98−001 Previously Signed
TR 98−002: June 22, 1998
TR 98−003: 3 August 1998

Revision 21: 24 August 1998
Revision 22: 10 March 1999 Section 04−00−00 Not Affected This Revision
Revision 23: 1 June 1999 Section 04−00−00 Not Affected This Revision
Revision 24: 7 December 1999
Revision 25: 28 April 2000 Section 04−00−00 Not Affected This Revision
Revision 27: 9 October 2000 Section 04−00−00 Not Affected This Revision
Revision 28: 30 November 2000 Section 04−00−00 Not Affected This Revision
Page 2
Revision 42 04-00-00 FAA APPROVED
MAINTENANCE MANUAL
Revision 30: 11 July 2001 Section 04−00−00 Not Affected This Revision
TR 01−001: 10 August 2001

Revision 31: 5 November 2001
TR 02−002: 30 January 2002
Revision 32: 18 March 2002
Revision 33: 24 June 2002
TR 03−001: 18 June 2003
TR 03−002: 25 June 2003

TR 03−003: 30 September 2003
TR 03−004: 17 December 2003

TR 04−001: 28 May 2004
Revision 36: 11 November 2004
Revision 37: 13 December 2005 Section 04−00−00 Not Affected This Revision
TR 05−002: 16 December 2005

Revision 38: 25 April 2006
Page 3
MAINTENANCE MANUAL
TR06−001: 05 July 2006
Revision 39: 10 April 2007 Section 04−00−00 Not Affected This Revision
TR07−001: 11 April 2007 Section 04−00−00 Not Affected This Revision
Revision 41: 03 March 2008
TR08−001 14 March 2008
TR08−002 07 November 2008

Revision 42:
TR08−001 and TR08−002 Previously Signed
TR12−002 04 June 2012
TR12−003 31 December 2012
TR13−001 20 March 2013
TR13−002 13 December 2013
Revision 45: 07 March 2014 Section 04−00−00 Not Affected This Revision
TR14−001 14 May 2014 Section 04−00−00 Not Affected This Revision
TR14−002 25 June 2014

Revision 46: 19 September 2014
TR14−002 Previously Signed
TR15−001 20 March 2015 Section 04−00−00 Not Affected This Revision
TR15−002 30 June 2016
TR15−003 30 October 2015 Section 04−00−00 Not Affected This Revision

TR15−004 09 December 2015 Section 04−00−00 Not Affected This Revision
Revision 47: 30 September 2016 TR15−002 Previously Signed
Page 4
MAINTENANCE MANUAL
AIRWORTHINESS LIMITATIONS
2. Component Mandatory Replacement helicopter hours are recorded in the Log
Book and component log for the
The Airworthiness Limitation Replacement helicopter. Whether the life-limited
Schedule specifies the mandatory replacement part is new or used, the remaining
time, structural inspection interval and related number of useful life hours and pre
structural inspection procedures approved per vious inspection time, if applicable, for
the certificate basis of the Type Certificate the part is added to the existing
Data Sheet No. H3WE and CAR 6 (6.250, helicopter time. The total helicopter
6.251) and CFR 27.571 for models 500/600N hours obtained then denotes the
unique components only. At the listed finite- subsequent time at which the part
life, components or assemblies must be must be removed from the helicopter or
removed from the helicopter and permanently inspected.
retired from service. At the listed inspection
interval, the components or assemblies must (4). If a life-limited part, is part of an
be inspected in accordance with the Handbook assembly, the assembly must be
of Maintenance Instructions (HMI). The title removed from the helicopter when the
of the task and section of the HMI are referred time expires. The assembly may be
to which provide the inspection procedures and overhauled and restored to maximum
criteria. number of hours of useful life by
installing new life-limited parts plus all
NOTE: Refer to CFR Part 43.10 for latest re other parts specified in the overhaul
quirements for the removal, installation, instructions (Refer to Component
storage and disposition of life-limited parts. Overhaul Manual).
(1). A ``life-limited'' part is a physical (5). If interchanged between different
component of the helicopter to which a model helicopters (for instance, Model
maximum number of allowable operat 369D to 369FF or vice versa), any
ing hours or cycles are assigned. component having a limited life or
Certain assemblies and components on overhaul schedule must be restricted to
the helicopter have a limited life the lowest service life or TBO schedule
established by MDHI and approved by indicated for the helicopter models and
FAA Engineering. For example, a part serial numbers affected.
with an assigned limit of 1000 hours,
may accumulate 1000 hours of opera (6). Refer to the appropriate Rolls-Royce
tion in service. Upon completion of the Operation and Maintenance Manual for
1000 hours of operation, useful life of engine component replacement require
the part is ended. The finite-life ments. (Ref. Section (01-00-00, Table
assigned to different parts varies 3, Reference and Vendor Manuals)
according to engineering fatigue tests,
part experience, etc. The parts listed in 3. Component Mandatory Inspections
this section must be removed from the
Some components with mandatory inspection
helicopter at the finite-life indicated
intervals require inspections to be completed
and identified as to it's expired life (Ref,
in accordance with procedures detailed in
Table 1, Note (1)).
other sections of this maintenance manual.
(2). All parts not having an assigned life or The appropriate inspection procedures are
stated to be of unlimited life, have a life referenced in the Notes flagged to each
of not less than 20,000 hours. component to be inspected. All maintenance
manual procedures which are referenced in the
(3). When a life-limited part or an assem FAA Approved Airworthiness Limitations
bly that incorporates a life-limited part Component Mandatory Replacement Schedule
is installed on a new or used helicopter, are FAA approved procedures which cannot be
the nomenclature, part number, serial changed without FAA review and approval of
number, component time and current the proposed changes.
Page 5
MAINTENANCE MANUAL
4. Retirement Index Number (RIN) For external lift operators, an external

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

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

Finite Life Mandatory
Component Part Number
Model Hours Inspection
(1) (2)
(1) Hours
Main Rotor System
Blade assembly, main rotor 369D/E(5)(6) 369D21100 3530 (37) 25 (11)(20)
369D21100−516 3530 (37) 100 (20)
369D21100−517 2500 (31) 25 (22)
369D21100−517 3530 (37) 100 (20)
369D21100−523 4000 (37) 100 (20)
369D21120−501 3530 (37) 100 (20)
369D21120−503 3530 (37) 100 (20)
369D21120−505 3530 (37) 100 (20)
369F/FF (6) 369D21102 3430 (37) 25 (11)(20)
369D21102−503 3430 (37) 100 (20)
369D21102−517 2500 (31) 25 (22)
369D21102−517 3430 (37) 100 (20)
369D21102−523 4000 (37) 100 (20)
369D21121−501 3430 (37) 100 (20)
369D21121−503 3430 (37) 100 (20)
369D21121−505 3430 (37) 100 (20)
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MAINTENANCE MANUAL
Table 1. Airworthiness Limitations Schedule (Cont.)

Component Part Number Finite Life Mandatory
(1) (2)
(1) Hours
Blade assembly, main rotor 500N (6) 369D21102−503 3430 (37) 100 (20)
369D21102−517 2500 (31) 25 (22)
369D21102−517 3430 (37) 100 (20)
369D21102−523 4000 (37) 100 (20)
369D21121−501 3430 (37) 100 (20)
369D21121−503 3430 (37) 100 (20)
369D21121−505 3430 (37) 100 (20)
600N (6) 369D21102−517 (21) 1900 (32)(37) 100 (20)
369D21102−523 3200 (33)(37) 100 (20)
369D21121−501 3200 (33)(37) 100 (20)
369D21121−503 3200 (33)(37) 100 (20)
369D21121−505 3200 (33)(37) 100 (20)
Folding pin, main rotor blade attach 369D/E/F/FF 369A1004 2850
369A1004−3 2850
369A1004−5 7600
500/600N 369A1004−5 7600
Hub subassembly, main rotor 369D/E/F/FF 369D21201 8900
500N
Pitch housing assembly, main rotor hub 369D 369D21300 9100
369D21300−501 9100
369E/F/FF 369D21300−501 9100
500N
Retention strap assembly, main rotor hub 369D 369D21210 2770 100 (4)
369D21210−501 2770 100 (4)
369E/F/FF 369D21210−501 2770 100 (4)
500/600N 369D21210−501 2770 100 (4)
Bolt − lead−lag hub, main rotor 369D 369A1220 6120
369D/E/F/FF 369D21220 6120
500N
600N 369D21220 5400 (34)
Page 7
MAINTENANCE MANUAL

(1) (2)
(1) Hours
Link assembly − lead lag hub, main rotor 369D/E 369H1203−BSC (39) 5762 25 (23)
369H1203−21 (39) 5762 25 (23)
369H1203−31 (39) 5762 25 (11)
369H1203−51 (39) 11080
369H1203−53 (40) 11080
369H1203−61 (39) 11080
369F/FF 369H1203−21 (39) 5762 25 (23)
369H1203−31 (39) 5762 25 (11)
369H1203−51 (39) 11080
369H1203−53 (40) 11080
369H1203−61 (39) 11080
500N 369H1203−51 (39) 11080
369H1203−53 (40) 11080
369H1203−61 (39) 11080
600N 369H1203−51 (39) 11080
369H1203−53 (40) 11080
Lead lag damper − main rotor 369D 369D21400−501 6060
M50452 On Cond. (16)
369D/E/F/FF 369D21400−503 On Cond. (16)
500/600N
Drive shaft, main rotor 369D/E 369D25510 5020 300 (8)
369F/FF 369D25510 3410 300 (8)
500N 369D25510−21 3260 300 (15)
369D/E 369F5510 (42)
369F/FF 369F5510 (42)
500N 369F5510 (42)
600N 600N5510 14000 (35)
Mast assembly, main rotor 369D/E/F/FF 369D22014 10450
500N
600N 369D22014 3500
Page 8
MAINTENANCE MANUAL

(1) (2)
(1) Hours
Drive Shafts, Couplings and Clutches
Drive shaft, main rotor transmission 369D/E/F 369A5510 3790
Coupling, main transmission drive shaft 369D/E/F/FF 369H5660 4300
500N 369H5660 3200
Overrunning clutch assembly 369D/E/F/FF 369F5450−501 On Cond. 100 (24)
500/600N
Sprag assembly, overrunning clutch 369D/E/F/FF 369A5364 (3) 300 (10)
369D25351
500N 369D25351 (3) 300 (10)
369D/E/F/FF 369F5456 (3) 300 (17)
500/600N
Drive shaft, fan 500N 500N5200 2620
600N 500N5200 1200 (36)
Drive shaft, tail rotor 369D/E 369D25518 13900
369F/FF 369DSK152−11 13900
369D25518−503 14610
Coupling − tail rotor drive shaft (Bendix) 369D/E/F 369A5501 4980
(NOTE: Not certified on 369FF Model) (9) 369H92564 (7) 4980
Anti−Torque System
Gearshaft assembly, tail rotor input 369D/E 369D25434 12000
369D25434−3 12000
Gearshaft assembly, tail rotor input 369F/FF 369D25434 3365
369D25434−3 3365
Gearshaft, tail rotor output pinion 369D/E/F/FF 369D25430 7290
369D25430−5 7290
Blade assembly, tail rotor 369D/E 369D21613 5200
369D21613−11 5140
369D21613−31 5140
369D21613−41 5140
369D21613−51 5140
369D21613−61 5140
369D21613−71 5140
369D21640−501 (38) 400 (46)
369D21640−503 (38) 400 (46)
369D21640−505 (38) 5140
369D21640−507 (38) 5140
369F/FF 369D21606 5140
369D21642−501 (38) 400 (46)
369D21642−503 (38) 400 (46)
369D21642−505 (38) 5140
369D21642−507 (38) 5140
Page 9
MAINTENANCE MANUAL

(1) (2)
(1) Hours
Blade assembly, tail rotor 369D/E 369D21615 10000
(optional 4−blade) 369D21641−501 (38) 400 (46)
369D21641−503 (38) 400 (46)
369D21641−505 (38) 10000
369D21641−507 (38) 10000
Hub, tail rotor 369D/E/F/FF 369A1725 3450
Retention strap assembly, tail rotor 369D/E/F 369A1706 5100
369FF 369A1706−507 5100
369A1706−509 5100
Blade assembly, NOTARR fan 500N 500N5310−15 7500
500N5310−19 7500
500N5310−23 7500
Blade assembly, NOTARR fan 600N 500N5310−19 12500
500N5310−23 12500
Hub, fan 500N 500N5352−7 7500
500N5352−9 7500
600N 500N5352−9 7500
Tension−Torsion Strap, NOTARR 500N 500N5311−5 (43)(44)
600N
Shaft, NOTARR fan support 600N 500N5357−13 4000
Pitch plate assembly 500/600N 500N5363−7 7500
Tube assembly, fan pitch 500N 500N7113−3 600 (18)
Rotating cone assembly 500N 500N3740−1 10000
500N3740−41 10000
500N3740−81 10000
600N 500N3740−61 10000
500N3740−71 10000
Tailboom
Bolts, tailboom attach 369D/E/F/FF MS21250−06014 21950
Tailboom assembly 369D/E 369D23500 10300
369F/FF 369D23500−507 10300
369D23500−513 10300
Page 10
MAINTENANCE MANUAL

(1) (2)
(1) Hours
Tailboom assembly 500N 500N3500−19 10204 100 (14)
500N3500−29 10204
500N3500−501 10204
500N3600−501 10204 100 (14)
600N 600N3500−503 2500 (25)
600N3500−505 5900
600N3500−507 1000
600N3500−509 6000 (19)
600N3500−511 6000 (19)
600N3500−513 2500 (25)
600N3500−515 5900
600N3500−517 1000
Empennage fittings 600N 500N3530−7/8 On Cond. 100 (26)
500N3530−9/10 On Cond. 100 (26)
Vertical stabilizer assembly 369D/E 369D23600 12700
369F/FF 369D23600−505 3388
Torque tube, horizontal stabilizer 500N 500N3950−5 5000
600N 500N3950−7 3000 (45)
500N3950−9 3000 (45)
600N3950−1 400
600N3950−3 1000
Horizontal stabilizer assembly 369D (12) 369D23601 7700
369E (12) 421−087−505 7700
421−087−905 (13) 7700
369F/FF (12) 421−087−503 7700
421−087−903 (13) 7700
600N 500N3910−25 10000 (19)
500N3910−27 10000 (19)
Controls
Longitudinal idler bellcrank assembly 369D/E/F/FF 369A7301−501 6500
500N 369A7301−501 2870
Idler assembly, longitudinal pitch mixer 369D/E/F/FF 369A7603 13600
500N 369A7603 6050
Longitudinal control rod 500N 369A7011−13 7740
369A7011−15 7740
Socket, cyclic stick 600N 369A7141 1000 8 (27)
Cyclic tube assembly 600N 369D27132−503 1200 8 (27)
Housing, collective stick 600N 369A7347 450
Tube, collective pitch control 600N 369A7348 400
Tube assembly, collective pitch (pilot) 600N 369H7354−3 600
Socket, cyclic stick 600N 369A7802 1000 8 (27)
Page 11
MAINTENANCE MANUAL

(1) (2)
(1) Hours
Tube, collective pitch (co−pilot) 600N 369A7809 1800
Housing, collective stick 600N 369A7820 450
Housing, collective stick 600N 369H7837 450
Tube assembly, collective pitch (co−pilot) 600N 369H7838−3 1000
Fuselage Sta. 75 controls support bracket 600N 369N2608−11 6000 (41)
600N2608−9 Unlimited
Link assembly, collective / longitudinal 600N 600N7617−1 15,000 (47)
600N7617−5 Unlimited
Airframe
Landing gear brace 600N 600N6010−17/19 5900 (28)
Landing gear strut 600N 600N6022−7 696 (29)
600N6022−8 696 (29)
600N6022−9 696 (29)
600N6022−10 696 (29)
600N6022−11 696 (29)
600N6022−12 696 (29)
600N6022−13 696 (29)
600N6022−14 696 (29)
Landing gear foot 600N 600N6043−3 3900 (30)
Floats
Squib cartridge, used on Emergency float 369D/E/F/FF 12552−1 5 years
kit 369D292473−5, −6, −9, −10, −11, −12 500N (Holex, Inc.)
NOTE: Life is based from original date of 281993 5 years
manufacture. (Walter Kidde)
12754−1 5 years
(Holex, Inc.)
5003527 5 years
(Tavco)
Stabilizer support, utility float 369D/E 369D292036 3190
369DSK66 3190
NOTES:
(1) Life−limited components interchanged between models or configurations must be restricted to the lowest
service life indicated for the models or configurations affected. Life−limited components removed at
retirement are to be mutilated/destroyed or conspicuously marked to prevent inadvertent return to service.
Parts are applicable only on models under which a service life is listed.
Life−limited components cannot be altered or permanently marked in any manner without compromising
the part integrity. Part tagging or other record keeping system is required.
Related component records must be updated each time component is removed from service.
(2) Service life shown for the basic (no dash number) part numbers apply to all dash numbered versions
unless otherwise indicated.
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MAINTENANCE MANUAL
(3) With no cargo hook attached: − No retirement life assigned (Ref. Sec. 05−10−00, Component Overhaul or
Recommended Replacement Schedule).
With cargo hook attached and no separate log: − 1800 hours.
With cargo hook attached and with separate log: − 1800 hours of external load operating time when logged
separately.
(For 369D/E/F/FF helicopters with 369A5364 or 369D25351 sprag assembly, Refer to AD 90−19−02.)
(4) Inspect in accordance with Main Rotor Strap Pack Lamination Inspection at 100−hour intervals, or 25−hour
intervals if 2 laminates (369D/E/F/FF − 500N) or 1 laminate (600N) have failed in any one leg or tongue
area of any strap assembly. A single cracked laminate between the shoes at the outboard end of a strap
pack is cause for rejection of the hub assembly
369D/E/F/FF − 500N: (Ref. Sec. 62−20−00, Main Rotor Strap Pack Lamination Inspection).
600N: (Ref. Sec. 62−20−60, Main Rotor Strap Pack Lamination Inspection).
(For 369D/E/F/FF helicopters, refer to AD 89−02−01.)
(5) The 369D21100−513, −515, 516, 517 and −523 main rotor blades are not interchangeable with any earlier
configuration blades (Basic, −505 or −509); however, the −505 and −509 blades are interchangeable and
the −513 and −515 blades are interchangeable. The −505 and −509 configuration blades may be modified
to the −513M configuration, which is fully compatible with the −513 blade. (For information concerning
modification, contact MDHI Customer Service Department.)
(6) For the 369D/E helicopters, the 369D21120−501, −503 main rotor blade has all the same inspections and
interchangeability as the 369D21100−517 main rotor blade.
For the 369F/FF − 500N helicopters, the 369D21121−501, −503 main rotor blade has all the same
inspections and interchangeability as the 369D21102−517 main rotor blade.
For the 600N helicopters, the 369D21121−501, −503 main rotor blade has all the same inspections and
interchangeability as the 369D21102−523 main rotor blade.
(7) Used with 369H90123 Rotor Brake Kit.
(8) Inspect main rotor drive shaft every 300 hours (Ref. Sec. 63−10−00, Main Rotor Drive Shaft Inspection
(300 Hour)) (Reference AD 81−26−01 R1).
(9) Failsafe device, P/N 369D25530 bolt and 369D25531 socket, must be used at both ends of tail rotor
driveshaft in accordance with Tail Rotor Drive Shaft Installation with Bendix Couplings (Reference AD
86−20−07).
(10) For helicopters equipped with a cargo hook, inspect overrunning clutch sprag assembly P/N 369D25351,
clutch inner race P/N 369A5353 and outer race 369A5352 every 300 hours (Ref. C.O.M., Sec. 63−10−10,
Overrunning Clutch Sprag Inspection (300 Hour)). To establish time in service, either clutch total time with
hook attached or a separate and permanent log of external load operating time per CFR 91.417, may be
used.
(For 369D/E/F/FF helicopters with 369A5364 or 369D25351 sprag assembly, Refer to AD 90−19−02.)
(11) Inspect main rotor blade root fittings and main rotor lead−lag link assemblies every 25 hours in accordance
with Main Rotor Blade Upper and Lower Root Fitting Attach Lug and Lead−Lag Link Attach Lug Inspection
(25 Hour) and every 100 hours in accordance with Main Rotor Blade Upper and Lower Root, Fitting Attach
Lug and Lead−Lag Link Attach Lug Inspection (100 Hour) (Ref. Sec. 62−10−00) (Reference AD
95−03−13).
(12) Tip plates, tip weights (where applicable) and attaching hardware have no retirement life and may be
reused on replacement horizontal stabilizers.
(13) 421−087−903 and −905 require the addition of tip plates, tip weights and attaching hardware before
installation.
(14) Inspect the three upper slot bridges for cracks (Ref. Sec. 05−20−00).
(15) Inspect main rotor drive shaft every 300 hours (Ref. Sec. 63−10−00, Main Rotor Drive Shaft Inspection
(300 Hour)).
(16) Inspect for deterioration every 600 hours up to a total time of 4200 hours and every 300 hours thereafter
until deterioration is sufficient to retire assembly
369D/E/FF − 500N: (Ref. Sec. 62−20−00, Main Rotor Damper and Attachments Inspection)
600N: (Ref. Sec. 62−20−60, Main Rotor Damper and Attachments Inspection).
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MAINTENANCE MANUAL
(17) For helicopters equipped with a cargo hook, inspect overrunning clutch sprag assembly P/N 369F5456,
clutch inner race P/N 369F5455 and outer race 369F5453 every 300 hours. To establish time in service,
either clutch total time with hook attached or a separate and permanent log of external load operating time
may be used.
(18) 500N7113−11 tube assembly, fan pitch is an On−Condition part and replaces the 500N7113−3 tube
assembly.
(19) Interim hours: life extension testing in progress.
(20) Inspect upper and lower blade root fittings every 100 hours in accordance with Main Rotor Blade Upper
and Lower Root, Fitting Attach Lug and Lead−Lag Link Attach Lug Inspection (100 Hour) (Ref. Sec.
62−10−00)
(For 369D/E/F/FF — 500N helicopters, Reference AD 96−10−09).
(21) Main rotor blades, P/N 369D21102−517 with S/N 1976 thru 2100, 2106 thru 2115 are not to be installed on
600N helicopter (Reference Service Bulletin SB600N−007R2) (Reference AD 98−15−26).
(22) Inspect main rotor blades with 600 or more hours of operation every 25 hours of helicopter operation with a
10X magnifying glass for cracking of the lower surface of the blade emanating from the root fitting and
doubler at the inboard end of the blade and to detect debonding between the blade root end fitting and
doubler if missing or cracked adhesive or paint is observed. (Reference Service Bulletins SB369D−195R3,
SB369E−088R3, SB369F−075R3, SB500N−015R3) (Reference AD 98−15−26).
(23) Perform Main Rotor Blade Upper and Lower Root, Fitting Attach Lug and Lead−Lag Link Attach Lug
Inspection (25 Hour) up to a total time of 500 hours and every 15 hours thereafter and every 100 hours in
accordance with Main Rotor Blade Upper and Lower Root Fitting, Attach Lug and Lead−Lag Link Attach
Lug Inspection (100 Hour) (Ref. Sec. 62−10−00) until retirement of 369H1203−BSC and −21 Lead−Lag
Link Assembly. (Reference AD 95−03−13).
(24) Inspect clutch retainer and bearing carrier for evidence of spinning and/or wear (Ref. Sec. 05−20−20).
(25) The 600N3500−503 tailboom may be reworked to a 600N3500−505 tailboom, and the 600N3500−513
tailboom may be reworked to a 600N3500−515 tailboom by modifying the attachment fittings to all−steel
fittings.
(26) (Ref. Sec. 05−20−00) Using a flashlight and 10X magnifying glass, inspect horizontal stabilizer mounting
brackets for cracks (pay particular attention to the forward inboard legs) (Ref. Tailboom Inspection).
(27) Sockets must be inspected for cracks every eight hours after the initial 100 hour inspection.
(28) Log all landings: Brace life is limited to 35400 logged landings or 5900 hours flight time if landing are not
logged (assumed six landings per one hour of flight time).
(29) Log all landings: Strut life is limited to 4170 logged landings or 696 hours flight time if landing are not
(30) Log all landings: Foot life is limited to 23780 logged landings or 3900 hours flight time if landing are not
(31) The following main rotor blades have a finite life of 2,500 hours or 15,000 torque events*, whichever occurs
first;
P/N 369D21100−517 with S/N H664, H665, H667, H669, H671, H672, H674, H676, H679, H680, H683
thru H724, H726 thru H999 and J000 thru J039, J041 thru J055 and
P/N 369D21102−517 with S/N 1976 thru 2100, 2106 thru 2115.
* TORQUE EVENT (TE) — A TE is recorded for every transition from forward flight to a hover (Reference
Service Bulletins SB369D−195R3, SB369E−088R3, SB369F−075R3, SB500N−015R3). (Reference AD
95−03−13).
(32) RIN = (200 x Hrs.) + (52 x TE).
(33) RIN = (160 x Hrs.) + (24 x TE).
(34) RIN = (153 x Hrs.) + (3 x TE).
(35) RIN = (50 x Hrs.) + (3 x TE).
(36) RIN = (768 x Hrs.) + (11 x TE).
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MAINTENANCE MANUAL
(37) After accumulation of 750 flight hours and 13,720 TE, perform Main Rotor Blade Torque Event Inspection
(Ref. Sec. 62−10−00) every 35 flight hours or 200 TE’s (whichever occurs first).
(38) The 369D21640−501, −503, −505, −507 tail rotor blades are two−way interchangeable with the 369D21613
tail rotor blades in sets of two only.
The 369D21641−501, −503, −505, −507 tail rotor blades are two−way interchangeable with the 369D21615
tail rotor blades in sets of two only (installed on the same inboard or outboard hub).
The 369D21642−501, −503, −505, −507 tail rotor blades are two−way interchangeable with the 369D21606
tail rotor blades in sets of two only.
(39) The 369H1203−BSC, −11, −21, −31, −51 and −61 lead lag link assemblies can only be installed using the
369H1235−BSC bearing.
(40) The 369H1203−53 lead lag link assembly can only be installed using the 369H1235−1 bearing.
(41) The 369N2608−11 Control Support Bracket must be removed from 600N helicopters equipped with YSAS
(Ref. SB600N−040).
(42) RIN = (29 x Hrs.) + (1 x TE).
(43) The tension−torsion straps have a 5−year calendar life that starts the day the package is opened (Ref.
Sect 64−25−30). If the date the package was opened is unknown, the 5−year calendar life is based on the
manufacturing cure date.
For straps installed before 06 March 2008 on Model 500N helicopters serial numbers LN−001 thru LN−105
and Model 600N helicopters serial numbers RN003 thru RN074, the initial calendar replacement is based
on the cure date on the strap. Refer to Table 2 to find the expiration date.
(44) 500N5311−5 straps previously installed on MD900 helicopters are life limited to 2,500 hours when installed
on 500N and 600N series helicopters.
(45) Use only on 600N helicopters without a yaw stability augmentation system (YSAS) (Pre−TB600N−006R1).
(46) Life−limited hours changed from 4500 to 400 (Reference AD 2013−19−24).
(47) Life−limited hours is only for helicopters with a yaw stability augmentation system (YSAS).
Table 2. Tension−Torsion Strap Expiration Date

Manufacturers Cure Date Expiration Date
Before 03/1999 09/2008
03/1999 thru 02/2001 03/2009
03/2001 thru 02/2005 03/2010
03/2005 thru 02/2008 Cure Date Plus 5 Years
Page 15
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Page 16
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Section
04−00−01
Airworthiness
Limitations
Supplements
MAINTENANCE MANUAL
UK CAA ALS SUPPLEMENT

1. UK CAA Airworthiness Limitations
Section Supplement
NOTE:
D The following components are further
limited when helicopters are operating
under UK CAA TC.
D Refer to 04-00-00 for all other Compo
nent Mandatory Replacement Times and
Component Mandatory Inspections.
Airworthiness Limitations
Component Mandatory Replacement Schedule
(1) (2) Hours (RIN) Inspection
(1) Hours
Main Rotor System
Drive shaft, main rotor 600N5510 14000 (1,000,000) (3)
Tailboom
Tailboom assembly 600N3500−503 800 (4)
NOTES:
(1) Life−limited components interchanged between models or configurations must be restricted to the lowest
service life indicated for the models or configurations affected. Life−limited components removed at
retirement are to be destroyed or conspicuously marked to prevent inadvertent return to service. Parts are
applicable only on models under which a service life is listed.
(2) Service life shown for the basic (no dash number) part numbers apply to all dash numbered versions
unless otherwise indicated.
(3) RIN = (50xHrs.) + (3xTE)
(4) The 600N3500−503 tailboom can be reworked to a 600N3500−505 tailboom by modifying the attachment
fittings to all steel fittings.
REVISION: DATE FAA SIGNATURE AND DATE *
Initial Issue: 24 May 2000
* FAA approval in behalf of UK CAA per letter, Winnert to Wang, Ref. 9/33/0649/A26479, Dated 2 May 2000.
Page 1
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Chapter
05
Continued
Airworthiness
MAINTENANCE MANUAL
TABLE OF CONTENTS
05-00-00 Continued Airworthiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Checks/Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General Description of Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Continued Airworthiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Records of Aircraft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Additional Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Visual Inspection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. General Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Component Overhaul/Recommended Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Component Overhaul or Recommended Replacement Schedule . . . . . . . . . . . . . . . . 1
Table 1. Component Overhaul Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 2. Component Recommended Replacement Schedule . . . . . . . . . . . . . . . . . 3
Table 3. Kamatics Component Overhaul Schedule . . . . . . . . . . . . . . . . . . . . . . . . . 4
100-Hour or Annual Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. 100-Hour or Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1. 100-Hour or Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Retirement Index Numbers Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table 2. Permanent Record of Retirement Index Numbers/Torque Events . . . . . 11
300-Hour Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. 300-Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1. 300-Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Yearly Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Yearly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1. Yearly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Special Inspection Hourly and Calendar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1. Special Inspections Hourly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 2. Special Inspections Calendar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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MAINTENANCE MANUAL


Conditional Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Conditional Inspection Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1. Conditional Inspections After a Hard Landing . . . . . . . . . . . . . . . . . . . . . 2
4. Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Overtorque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6. Sudden Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 2. Conditional Inspections — Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 3. Conditional Inspections – Overtorque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 4. Conditional Inspections – Sudden Stoppage . . . . . . . . . . . . . . . . . . . . . . . 6
7. Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8. Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table 5. Conditional Inspections After a Lightning Strike . . . . . . . . . . . . . . . . . . . 10
Table 6. Special Conditional Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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MAINTENANCE MANUAL
Section
05−00−00
Continued
Airworthiness
MAINTENANCE MANUAL
CONTINUED AIRWORTHINESS
CHECKS/INSPECTIONS
1. General Description of Inspections (1). COMPONENT OVERHAUL/RE
COMMENDED REPLACEMENT
The following Continued Airworthiness (Ref. Section 05-10-00) is a schedule
Sections specify inspections and other mainte for the overhaul and recommended
nance required under the Federal Aviation replacement of components and/or
Regulations unless an alternative program has assemblies and scheduled maintenance
been FAA approved. checks.
NOTE: Because this manual pertains to MDHI (2). 100-HOUR OR ANNUAL INSPEC
model 369D, 369E, 369FF, 500N and 600N TION CHECKLIST (Ref. Section
helicopters (including the basic 500MD con 05-20-00) is a schedule of inspections
figuration), it can contain inspection re that must be accomplished every 100
quirements applicable to specific equipment hours of helicopter operation or on a
not installed on individual helicopters. 12-month (annual) basis. An Annual
When this situation is encountered, require Inspection is required on this helicopter
ments that are not applicable should be dis for continued airworthiness and can be
regarded. accomplished in combination with a
100-hour inspection.
The inspection intervals designated herein are
the maximum allowable and should not be NOTE:
exceeded. When unusual local conditions, such
D To comply with the requirements of ser
as environmental conditions, utilization, etc.
vice bulletins which have been incorpo
dictate, it is the prerogative and responsibility
rated into the appropriate maintenance
of the operator to increase the scope and
and inspection manuals, the latest
frequency of the inspections as necessary to
100-Hour or Annual Inspection must be
ensure safe operation. Each item shall conform
used.
with the FAA Requirements, A.D.'s and
Manufacturer Bulletins and Letters. Over D Refer to applicable Rolls-Royce Engine
flying the inspection interval, or any change Operation and Maintenance Manual (Ref.
desired to the requirements of this chapter, Section 01-00-00, Table 201) for detailed
can be requested through the local aviation requirements on inspection of the engine.
regulatory authority.
(3). 300-HOUR INSPECTION CHECK
A. Airworthiness Limitations LIST (Ref. Section 05-20-10) is a
schedule of inspections that must be
Refer to section 04-00-00 for mandatory accomplished every 300 hours of
inspections and component mandatory helicopter operation.
retirement schedule.
(4). YEARLY INSPECTION CHECK
B. Continued Airworthiness LIST (Ref. Section 05-20-15) is a
schedule of inspections that must be
This section contains the requirements for accomplished on a yearly basis.
Component Overhaul/Recommended Replace
ment, 100-Hour or Annual Inspection Check (5). SPECIAL INSPECTIONS (Ref.
list, 300-Hour Inspection Checklist, Special Section 05-20-20) consist of inspections
Inspection Schedule and Conditional Inspec that are contingent upon elapsed flight
tions. time or calendar time.
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MAINTENANCE MANUAL
(a). Special Inspections Hourly should include a visual examination of the area,
be referred to for additional inspec component, detail, assembly, or installation
tion requirements that must be and its surrounding environment, as well as
performed at specified periodic any associated equipment within the immedi
hourly intervals. ate vicinity, using any inspection aids consid
ered necessary.
(b). Special Inspections Calendar
should be referred to for additional A. General Visual Inspection
inspection requirements that must be
A visual inspection that will detect obvious
performed at specified periodic
unsatisfactory conditions/discrepancies. This
calendar intervals.
type of inspection can require cleaning,
(6). CONDITIONAL INSPECTIONS (Ref. removal of fillets, fairings, access panels/doors,
Section 05-50-00) includes inspection etc.
requirements for unusual or other (1). Metal parts (all metal parts, bodies, or
specific conditions or circumstances casings of units in systems and in
that might occur. electrical, instrument, and radio
installations, ducting, tubing, rods, and
2. Documentation
bellcranks). Inspect for the following:
A. Records of Aircraft Inspection (a). Cleanliness, external signs of dam
(1). Aviation regulatory agencies require age, leaks, overheating, discharge, or
pilots, mechanics, owners and operators fluid contamination.
to be familiar with, and to maintain (b). Obstruction of drainage or vent holes.
records of aircraft maintenance,
inspections and repairs. This includes, (c). Correct seating and sealing of
but is not limited to, Airworthiness fairings and serviceability of fasten
Directives, Manufacturers Notices, ers.
Scheduled Inspections and Time/Cycle
(d). Security of attachment, fasteners,
limited-life components.
and connections.
B. Additional Documentation (e). Distortion, dents, scores, chafing,
(1). Additional documentation is required to pulled or missing fasteners, rivets,
be available, or inside the aircraft, bolts, or screws.
during operation. This documentation (f). Signs of cracks or wear.
includes: Airworthiness and Registra
tion Certificates, Rotorcraft Flight (g). Separation of bond.
Manual, Weight and Balance informa
(h). Failure of welds or spot welds.
tion and Radio Permits. It is important
that all required documentation be (i). Deterioration of protective treatment
reviewed and revised as necessary and corrosion.
during regular inspections, mainte
nance and operation of the helicopter. (2). Composite, rubber, fabric, fiberglass,
and plastic parts (coverings, ducting,
3. Visual Inspection Criteria flexible hoses, flexible mountings, seals,
insulation of electrical cables, windows,
Any time an area of the helicopter is visible etc.). Inspect for the following:
during an inspection or maintenance action,
the following ”Visual Inspection Criteria” shall (a). Cleanliness, cracks, cuts, chafing,
be accomplished without requiring disassem kinking, twisting, crushing, or
bly or removal of adjacent equipment unless contraction -(sufficient free length).
otherwise specified. It will normally apply to (b). Damage, delamination, or deteriora
those areas, surfaces, or items which become tion.
visible by the removal or opening of access
doors, panels, fairings, or cowlings. It shall (c). Crazing.
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MAINTENANCE MANUAL
(d). Loss of flexibility (other than fabric (b). If protective covers are required to be
covered component). removed, check for cleanliness,
scoring, pitting or burning of con
(e). Overheating. tacts, brushes for condition, and
security of exposed contacts.
(f). Fluid saturation.
(c). Overheating.
(3). Control System Components. Inspect (d). Fluid contamination.
for the following:
NOTE: For detailed Wiring Inspection criteria,
(a). Correct alignment, no binding. refer to CSP-HMI-3, Section 96-00-00.
(5). Wire harness. Inspect for the following:
(b). Distortion, signs of bowing, scoring,
chafing, fraying, kinking, signs of (a). Routing, contact with structure,
wear, flattening, cracks, or loose proper support and protection.
fasteners.
(b). Strain at termination points, free
movement of shock-mounted or
(c). Deterioration of protective treatment hinged equipment and proper slack
or corrosion. for equipment installation and
maintenance.
(d). Electrical bonding correctly posi
tioned, undamaged, and secure. (6). Inside fuel cell areas. Inspect for the
following:
(e). Attachments, end connections, and
(a). Leaks, cleanliness, foreign objects,
locking devices secure.
cracks.
(4). Electrical components (circuit protec (b). Components for security and general
tion devices, wiring, connectors, plugs, condition.
motors, generators, actuators, relays,
solenoids, and contacts). Inspect for the (c). Plumbing, and wiring for security,
following: and general condition.
(7). Markings, labels, and placards. Inspect
(a). Cleanliness, obvious damage, corro for the following:
sion, security of attachments and
connections. (a). Legibility and security of attachment.
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MAINTENANCE MANUAL
Page 4
MAINTENANCE MANUAL
Section
05−10−00
Continued
Airworthiness
MAINTENANCE MANUAL
COMPONENT OVERHAUL/RECOMMENDED REPLACEMENT
1. Component Overhaul or Recommended overhaul/exchange. Any shaft or coupling
Replacement Schedule removed for After Main Rotor Drive System
Sudden Stoppage - Level 2, conditional
Table 1 is the Overhaul Schedule. The listed inspection requirements (Ref. Section
components or assemblies should be removed 05-50-00, Table 1) is not eligible for overhaul
from the helicopter and overhauled at inter or exchange.
vals specified.
Table 2 is the Recommended Replacement Neither the assignment of an airworthiness
Schedule. The listed components should be life to a component nor failure to assign an
removed from the helicopter and scrapped at airworthiness life constitutes a warranty of
intervals specified. any kind. The only warranty applicable to the
helicopter and any components is that
Table 3 is the Kamatics Component Overhaul warranty included in the Purchase Agreement
Schedule. The listed shafts and couplings for the helicopter or the component.
should be removed from the rotorcraft and
overhauled at the interval specified. To be NOTE: Hours for the 369F Model helicopters
eligible for the program, the shaft or coupling will be the same as the 369FF unless other
must be serviceable before return to MDHI for wise noted.
Table 1. Component Overhaul Schedule

Component (1) Model Part Number (2) Hours
Main rotor transmission assembly 369D/E/FF − 500N 369D25100 3000
369D25100 4000 (12)
369D/E/FF − 500N 369F5100 5000
600N 369F5100 3000
Main rotor swashplate assembly 369D/E/FF − 500N 369D27609 2770 (3)(9)
600N 600N7630−3 2700 (4)(9)
Main rotor hub assembly 369D/E/FF − 500N 369D21200 2770 (7)(9)
600N 600N1200 2700 (7)(9)
Landing gear damper 369D/E/FF − 500N 369D26300 On Cond. (6)
369D26301 On Cond. (6)
600N 600N6300 On Cond. (6)
Overrunning clutch assembly 369D/E/FF − 500N 369A5350−603 1800 (5)
369A5350−605 1800 (5)
369D/E/FF − 500/600N 369F5450 1800 (10)(11)
Tail rotor transmission 369D/E 369D25400 4800
369FF 3365
369D/E 369D25300 4800
Starter/Generator (8) 369D/E − 500N 369A4550 1200
369FF − 600N 369D28550 1200
NOTES:
(1) Components interchanged between models or configurations must be restricted to the lowest service life
indicated for the models or configurations affected. Components removed at retirement are to be
destroyed or conspicuously marked to prevent inadvertent return to service. Parts are applicable only on
models under which a service life is listed.
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MAINTENANCE MANUAL
(2) Service life shown for basic part number applied to all dash−numbered versions unless otherwise
indicated.
(3) Bearing assembly must be relubricated every 2 years or 2770 hours, whichever occurs first (Ref.
CSP−COM−5, Section 62−30−10).
(4) Bearing assembly must be relubricated every 2 years or 2700 hours, whichever occurs first (Ref.
CSP−COM−5, Section 62−30−60).
(5) Under some operating conditions, overrunning clutch splines can need to be regreased more often than at
the 100−hour intervals and bearings can need to be regreased more often than at the 300−hour intervals.
With no cargo hook attached, inspect and regrease splines every 100 hours and bearing every 300 hours
(Ref. CSP−HMI−2 Section 63−10−00, Installation of Overrunning Clutch Subassembly and CSP−COM−5,
Ball Bearing Inspection and Grease Repack).
With cargo hook attached, inspect sprag assembly, inner race and outer race every 300 hours or 300
hours of actual hook time when logged separately as per FAR 91.417, regrease clutch splines every 100
hours and bearing every 300 hours (Ref. CSP−HMI−2 Section 63−10−00, Installation of Overrunning
Clutch Subassembly and CSP−COM−5, Ball Bearing Inspection and Grease Repack).
(6) When inspected per Landing Gear Damper Inspection (Ref. Section 32−10−00 for 369D/E/FF − 500N, or
Section 32−10−60 for 600N).
(7) Use only main rotor hubs overhauled by MDHI or approved MDHI Licensees.
(8) Refer to data plate to determine start/generator manufacturer.
(9) The shelf life of bearings preserved with grease is limited to 4 years.
(10) Regrease overrunning clutch bearings every 300 hours (Ref. CSP−COM−5, Section 63−10−15).
(11) Interim hours: life extension testing in progress.
(12) The 369D25100 main rotor transmission overhaul time can be extended from a mandatory 3000 hour
overhaul time to a mandatory 4000 hour overhaul time, provided, the transmission is operated with Mobil
AGL since last overhaul.
The transmission shall not exceed 3000 hours if cargo hook time has reached a quantity of 750 hours.
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MAINTENANCE MANUAL
Table 2. Component Recommended Replacement Schedule

Component (1) Model Part Number (2) Hours
Tail rotor swashplate (duplex) bearings 369D/E/FF 369D21832 On Cond. (3)(9)
Fan support bearing 500/600N 500N5364 2400 (8)(9)
Pitch plate bearing 500/600N 500N7120 2400 (8)(9)
Thrust bearing cup, upper 369D/E/FF − 500N 369D21255 On Cond. (3)(9)
Thrust bearing cone, upper 369D/E/FF − 500N 369D21254 On Cond. (3)(9)
Thrust bearing cup, upper 600N 369D21255 600 (5)(9)
Thrust bearing cone, upper 600N 369D21254 600 (5)(9)
Thrust bearing cup, lower 369D/E/FF − 500N 369D21257 On Cond. (3)(9)
Thrust bearing cone, lower 369D/E/FF − 500N 369D21256 On Cond. (3)(9)
Thrust bearing cup, lower 600N 369D21257 5400 (4)(9)
Thrust bearing cone, lower 600N 369D21256 5400 (4)(9)
Bearings, oil cooler blower 369D/E/FF − 500/600N 369H5655−3 1200
369D/E/FF − 500/600N 369H5655−5 1200
Belt, oil cooler blower 369D/E/FF − 500N 369D25623 1200
600N 93920219 1200
Cyclic stick trim switch (7) 369D/E/FF − 500N A218−100646−02 1000
NOTES:
(1) Limited−life or scheduled replacement components interchanged between models or configurations must
be restricted to the lowest service life indicated for the models or configurations affected. Limited−life or
scheduled replacement components removed at retirement are to be destroyed or conspicuously marked
to prevent inadvertent return to service. Parts are applicable only on models under which a service life is
listed.
(2) Service life shown for basic part number applied to all dash−numbered versions unless otherwise
indicated.
(3) Bearing assembly must be relubricated every 2 years or 2770 hours, whichever occurs first (Ref. Section
64−30−00, Tail Rotor Swashplate Bearing Regreasing).
62−20−60, Main Rotor Hub Tapered Bearing Grease Repack, Inspection and Replacement).
62−20−60, Main Rotor Hub Upper Bearing Grease Repack, Inspection and Replacement).
(6) Deleted
(7) Installed in 369D27133 grip assembly made by Guardian Electric Co., PN A218966714−00 (Ref. Section
67−10−20, Cyclic Stick Grip Switch Replacement (Standard Grip)).
64−25−30, Anti−Torque Fan Bearing Regreasing).
(9) The shelf life of bearings preserved with grease is limited to 4 years.
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MAINTENANCE MANUAL
Table 3. Kamatics Component Overhaul Schedule

Component Part Number Serial Number (3) Initial TBO Next Overhaul
Date
Interconnecting Shaft 369D25515 0001 thru 0535 2010 − 2011 2021 (1)
Interconnecting Shaft 369D25515 0536 thru 1070 2012 2022 (1)
Interconnect Shaft 500N5215 0001 thru 0516 2013 2023 (1)
Interconnect Shaft 500N5215 1776 thru 1824 (2) 2018 2028 (1)
Tail Rotor Driveshaft Coupling 369D25501−BSC N/A 2010 − 2011 2021 (1)
Tail Rotor Driveshaft Coupling 369D25501−3 0001 thru 0493 2010 − 2011 2021 (1)
Tail Rotor Driveshaft Coupling 369D25501−9 0001 thru 0505 2010 − 2011 2021 (1)
Tail Rotor Driveshaft Coupling 369D25501−3 0494 thru 1087 2012 2022 (1)
Tail Rotor Driveshaft Coupling 369D25501−9 5026 thru 5527 (2) 2021 2031 (1)
NOTES:
(1) Interconnect shafts and tail rotor driveshaft couplings will be overhauled at ten (10) year intervals after this
date.
(2) Subsequent serial number components, not installed as part of the initial OEM installation on new
rotorcraft, shall have the initial TBO date ten (10) years from the documented date of initial installation.
Documented date of initial installation to be recorded by installer in the Rotorcraft Log Book and on
component card.
(3) Serial number components listed in Table 3 with 0 hours (new condition) shall have the initial TBO date ten
(10) years from the documented date of initial installation. Documented date of initial installation to be
recorded by installer in the Rotorcraft Log Book and on component card.
Page 4
MAINTENANCE MANUAL
Section
05−20−00
Continued
Airworthiness
MAINTENANCE MANUAL
100−HOUR OR ANNUAL INSPECTION CHECKLIST
1. 100−Hour or Annual Inspection NOTE:

D The Chap/Sect column of Table 1 is for
This check sheet is designed to be used for the
reference, unless a specific inspection re
100-Hour Inspection or the Annual Inspection,
quirement is called out. If there are only
as defined by FAR, Part 43, Appendix D. This
two numbers in the column, it refers to
checklist, when completed, must be kept as a
the Chapter. If there are three numbers
permanent part of the helicopter records.
(six-digits), it refers to the Section or Sub
Adherence to Maintenance Manual informa
section where the inspection is found.
tion is required, and the manual must be
consulted when you use the checklist. D Refer to applicable Rolls-Royce engine in
spection check list for required engine
maintenance (ref. Section 01-00-00, Ta
ble 3, Reference and Vendor Manuals).
Table 1. 100−Hour or Annual Inspection

Registration No. Serial No.
Helicopter Hours Torque Events
Model Requirement Chap/Sect Initial
GENERAL
ALL Thoroughly clean the helicopter and engine before the start of the inspection. 20
ALL Remove the trim panels, covers, and access panels as necessary. 52−50−00
ALL Make sure all the placards and markings are installed. 11−00−00
ALL Make sure to obey the component mandatory retirement schedule. 04−00−00
ALL Calculate and record TEs or RINs, of all affected components in Table 2. 04−00−00
ALL Make sure compliance with component overhaul schedule. 05−10−00
ALL Make sure compliance with all applicable airworthiness directives, service N/A
bulletins, and special inspections.
ALL Review aircraft maintenance records for recorded discrepancies and correct N/A
discrepancies as applicable.
ALL Refer to applicable manufacturer publications for detailed requirements for 01−00−00
inspection of the engine, the starter/generator, battery, avionics, and all
installed STC equipment.
EXTERIOR
ALL * Air intake for cleanliness and foreign matter. 71
* Visible portion of engine compressor inlet for foreign object damage.
CAUTION: Make sure that the compressor cover is installed to prevent FOD.
ALL Engine air plenum chamber for: 71
* Damage and cleanliness. 53
* Wear and security of internal components.
* Particle separator mounting structure for cracks or damage.
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MAINTENANCE MANUAL
Table 1. 100−Hour or Annual Inspection (Cont.)

ALL Fuselage upper surfaces for: 52
* Damage and condition. 53
* Mast base drain holes clean and free of debris (blow air thru holes to
ensure no clogging).
* Engine air inlet fairing free from damage. No delamination noted.
* Engine air bypass door operationally checked. Seals free from damage.
Cable system checked for smooth operation. 71
* Engine access doors for proper operation of latches and closure,
distortion, damage, cracks and security.
52
ALL Fuselage for: 52
* Damage and condition. 53
* Compartment fresh air vents in doors and front of canopy for easy of
operation and security.
* Fuel cell vent fairings free of obstructions and obvious damage.
* Pilot’s and passenger/cargo compartment doors for condition of door
glass, vents and proper operation of latching and locking mechanisms.
* Door hinges and pins for play or wear. Ensure door pin locking tab is
engaged with slot in frame.
* No evidence of oil leakage around fuselage drain holes.
369D/E/FF Sta. 142.0 tail rotor control bellcrank support for cracking or damage, use 67−20−10
bright light and mirror (Ref. Upper Fuselage and Tailboom Control Linkage
Inspection).
500/600N Anti−torque fan inlet for: 53
* Screen for cleanliness and damage.
* Attaching hardware for security.
* Interior of fan inlet for cleanliness and damage.
* Driveshaft cover for damage.
ALL * Check for no gap between tailboom and fuselage at attach points. 53
* Check tailboom skin around stabilizer fittings for cracks.
* Tailboom attachment−to−fuselage for security, evidence of corrosion or
cracks, loose rivets or buckling.
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MAINTENANCE MANUAL

500/600N * Thruster cones and tip cap (500N only) for damage and security. Inspect 53−40−30
for wear between thruster cones and tailboom at points of contact. 53−50−30
* Using a flashlight and 10X magnifying glass, inspect horizontal stabilizer
mounting brackets for cracks (pay particular attention to the forward inboard
legs) (Ref. Tailboom Inspection).
* Using a bright flashlight, inspect fore and aft radii of the lower portion of
the three upper slot bridges for cracks, illuminate area under the flap. The
flap may be raised slightly, using finger pressure only, to aid in checking this
area (Ref. Tailboom Inspection).
* Using a bright light and 10X magnifying glass, inspect the four tailboom
attachment lugs for cracks and fiber damage. Pay particular attention to area
on top of the lug from the radius block to 2 inches aft (Ref. Tailboom
Inspection).
* Tailboom closeout fairings for security of attachment hardware. Inspect
for damage and chafing between closeout fairing and tailboom.
369D/E/FF Horizontal stabilizer for: 53−50−10
* Skin damage and loose rivets.
* Tip plates for damage. Check for secure attachments (Ref. Horizontal
Stabilizer and Tip Plates Inspection).
500/600N Horizontal stabilizer for: 53
* Skin damage and loose rivets.
* Mounting fittings for cracks and security.
* Stabilizer attach bolts for security.
369D/E/FF Vertical stabilizer for: 53−50−10
* Damage to leading and trailing edges and damaged stressed side panels
(no repair of side panels permitted).
* Mounting fittings for cracks and security.
* Tail skid for obvious damage and security (Ref. Vertical Stabilizer
Inspection).
* Anti−Collision light mount for cracks
500/600N Vertical stabilizers for: 53
* Damage to leading or trailing edges and damaged side panels.
* Cracks in skin, no cracks permitted (pay particular attention to areas
around mounting bolts).
* Stabilizer attach bolts for security.
* Stabilizer mount bushings for wear, security and correct installation.
* Excess play in control linkage, bearings and security of attaching
hardware.
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MAINTENANCE MANUAL

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

NOTE: With main rotor blades stationary, some friction drag is felt in the cyclic. The collective also has some drag,
plus resistance of the collective bungee spring. Heavy drag is an indication of droop stop deformation caused
by droop stop pounding.
ALL Engine N1 and N2 power controls (600N engine power controls)for: 76
* Free movement, full travel, security, obvious damage and proper rigging.
* Pilot’s and copilot’s throttle rigging checks at FULL, GROUND IDLE and
CUTOFF positions.
MAIN ROTOR
ALL Main rotor mixer control push−pull rods, links, scissors and bellcranks for 62
excessive bearing play, bent rods or links, worn bushings and cracked 67
bellcranks or brackets; all rodends centered.
ALL Main rotor pitch control rod assemblies, upper and lower rod end bearing for 62−30−00
evidence of axial play and for any extrusion, displacement or damage to the 62−30−60
bearing teflon liner. Check that all rodends are centered and security of
lockwire (Ref. Pitch Control Rod Inspection).
ALL Swashplate for evidence of galling or corrosion of spherical bearing, and 62
seals for deterioration and evidence of grease leakage. Upper and lower dust
boots free from damage and security. Swashplate interrupters and magnetic
pick−up secure.
ALL Main rotor hub retention strap assemblies for breaks or cracks in strap pack 62−20−00
laminations. Check visible portions of both lead and lag legs of pack in each 62−20−60
pitch housing (Ref. Main Rotor Strap Pack Lamination Inspection). Refer to
04−00−00 for strap pack lamination airworthiness requirements.
ALL Outboard ends of main rotor hub retention strap assemblies for gaps 62−20−00
between pack laminates (Ref. Main Rotor Strap Pack Lamination 62−20−60
Inspection).
ALL * Main rotor hub feathering bearings for excessive wear (Ref. Main Rotor 62−20−00
Hub Inspection). 62−20−60
* Main rotor droop stop ring for corrosion, dents and scratches.
* Main rotor droop stop striker plate rollers for play and excessive wear.
* Main rotor droop stop follower attachment pins for proper installation.
* Main rotor droop stop plunger for corrosion, dents and scratches.
ALL Main rotor blade damper assemblies for obvious damage, security and 62−20−00
excessive play in blade and pitch housing bearings, bonding of elastomeric 62−20−60
material and corrosion (Ref. Main Rotor Damper and Attachments
Inspection).
ALL Using bright light and 5X magnifying glass, inspect all main rotor hub 62−20−00
assembly lead−lag links for corrosion, discoloration, pitting, intergranular 62−20−60
cracks or stress corrosion cracks. Any discoloration or pitting is evidence of
more than superficial corrosion, and the main rotor hub must be removed for
replacement of lead−lag links (Ref. Main Rotor Hub Inspection).
Page 5
MAINTENANCE MANUAL

ALL Main rotor hub bearings for roughness by rotating main rotor assembly 62−20−00
several times by hand and listening for unusual noise (Ref. Main Rotor Hub 62−20−60
Inspection).
NOTE: Do not confuse with normal no−load transmission and overrunning clutch noise.
ALL Main rotor blade and damper attach pins tight and levers properly locked. 62
ALL Entire trailing edge and tabs for nicks, scratches and cracks generating from 62−10−00
trailing edge (Ref. Main Rotor Blade Inspection).
WARNING: Using a bright light and 5X to 10X magnifying glass, inspect root fitting,
attach lugs and doublers for cracks and security.
ALL Inspect main rotor blade root fittings, attach lug and lead−lag link attach lug 62−10−00
every 100 hours in accordance with Main Rotor Blade Upper and Lower Root
Fitting, Attach Lug and Lead−Lag Link Attach Lug Inspection (100 Hour). Pay
particular attention to the lower side of the root fitting.
ALL Using a bright light and 10X magnifying glass, inspect main rotor blade 62−10−00
abrasion strips for security of bonding on lower and upper surfaces, and by
tapping at bond lines. Any blisters, bubbling or lifting of abrasion strip
indicates a void (Ref. Main Rotor Blade Inspection).
ALL Tip area of main rotor blades for evidence of corrosion; pay particular 62−10−00
attention to mating area of blade skin−to−tip weight interface; verify integrity
of sealant coating (Ref. Main Rotor Blade Forward Tip Cap Inspection and
Corrosion Protection).
ALL Drain holes in main rotor blade aft tip cap and vent holes in lower skin for 62
clogging. Main rotor tip caps for security and evidence of corrosion.
369D/E/FF Main rotor hub fairing for cracks, damage and security. 62
500N
DRIVE TRAIN
ALL Main transmission lubrication and cooling system for: 63
* Main transmission case and cooling installation for evidence of leakage
and security of attachment.
* Oil cooler blower, mount, ducting and hardware for security and damage.
* Oil lines for chafing damage.
* Clamps attached to oil lines for evidence of cushion wear or deterioration
(If found, remove clamp and inspect tube under clamp for chafing damage).
* Pressure switch for security and deterioration; wiring for chafing.
* Temperature Sensor for security and damage
369D/E/FF Tach generator for security and deterioration; wiring for chafing. 63
500N
Page 6
MAINTENANCE MANUAL

ALL Rotor brake for: 63
* Pucks and disc for wear and general condition.
* Hydraulic lines for security and leaks.
* Master cylinder for leaks.
* Air in system (spongy feel at brake actuating handle when force is
applied).
ALL Overrunning clutch for: 63
* Evidence of oil leakage.
* Proper operation: turn rotor in forward direction by hand − engine must
decouple; turn rotor in reverse direction − engine must rotate (listen for
turbine noise during reverse rotation). Rotor brake disc should not drag.
NOTE: Normal seal drag may be sufficient to rotate engine at low rpm.
369D/E/FF For aircraft equipped with 369A5350 overrunning clutch, regrease clutch 63
500N splines.
ALL Engine−to−main transmission drive shaft couplings and shaft for condition 63−10−00
Bendix couplings only: inspect shaft coupling diaphragms for scratches,
nicks or cracks (Ref. Main Transmission Drive Shaft Inspection (Bendix)).
500/600N * Main transmission−to−fan transmission drive shaft for dents, bulkhead 63
chafing and obvious damage.
* Inter−Connect drive shaft for dents and obvious damage.
* Free movement of control rod thru interconnect drive shaft.
369D/E Bendix couplings only: Check tail rotor blade tip movement in excess of 0.75 63
inch, without main rotor blade movement, when tail rotor blades are rocked
back and forth in plane of rotation.
369D/E/FF Tail rotor drive shaft for: 63−15−10
* Evidence of buckling, dents, bulkhead chafing and obvious damage.
* Align aft coupling index stripe with corresponding tail rotor transmission
stripe and verify that bulkhead−to−drive shaft index stripes align (Ref. Tail
Rotor Drive Shaft Twist Inspection).
ANTI−TORQUE
Tail Rotor System
369D/E/FF Tail rotor transmission for: 63−25−10
* Corrosion, excessive oil leakage, cracks and other damage.
* Check torque of mounting nuts (also tailboom extension hardware on
369FF helicopters) (Ref. Tail Rotor Transmission Installation).
Page 7
MAINTENANCE MANUAL

369D/E/FF Tail rotor and pitch control assembly for: 64
* Binding and unusual sounds (teeter blades to check for binding).
* Control rod, pitch control links, hub and drive fork for play or damage.
* Boots for installation and deterioration.
* Retaining nut and lockwasher secure (no broken tangs noted and nut
has not rotated, visual inspection of torque stripe).
* Pitch control for evidence of seal rotation or loss of grease.
369D/E/FF Drive fork for; 64
* Elastomeric bearing elements for bond failure.
* Apply teetering force by hand (stop−to−stop) to rotor blades and inspect
elastomers for radial−molded ridges on each bearing face. Discontinuity in
molded ridges indicates bearing failure. There should by no apparent motion
between the cage and fork, observed motion indicates bond failure.
NOTE: Light swelling, pock marks and crumbs are surface conditions and do not indicate bearing failure.
369D/E If equipped with conical−type teetering bearings, torque check teeter bolt. 64
* Conical bearings for axial or radial play (no play allowed).
369D/E/FF Tail rotor blades for: 64−10−00
* Evidence of damage, including leading edges, trailing edges, skin.
* Open vent and drain holes.
* Loose or damaged tip caps.
* Rivets securing tip cap for installation and condition.
* Abrasion strips free of damage, no excessive erosion noted and no
separation in bond around edges or at tip end of blade (Ref. Tail Rotor Blade
Inspection).
* While holding hub stationary, check tail rotor blade pitch bearings for
lead−lag play in excess of 0.250 inch (6.35 mm) at blade tip. If excess play is
found, remove blades, replace pitch bearings and inspect hub−to−pitch
bearing contact surface of hub (Ref. COM).
369D/E/FF Perform Tail Rotor Balance. 18
NOTARR Anti−Torque System
500/600N * Rotate rotor system and check for unusual noises. 64
* Fan assembly for cleanliness and damage.
* Fan blades for excessive play.
* Fan seal for cleanliness, cracks, damage and corrosion.
* Check gap between fan blades and tip seal.
* Check gap between fan blades and hub.
NOTE: If any of these gaps for any blade exceeds the average gap of the other blades by more than 0.10 inch
(2.54 mm), remove and inspect the tension−torsion strap for that blade.
500/600N Perform Fan Blade Inspection (100−Hour). 64−25−30
Page 8
MAINTENANCE MANUAL

500/600N Fan Transmission for corrosion, excessive oil leakage, cracks, damage and 63
security on mounting frame. Drain line for cracks and security.
500/600N Remove rotating cone and tip cap (500N) and inspect: 67
* Cables, cable ends and pulleys for condition and security. Perform
Forward and Center Cable Assembly Inspection and Sector Assembly
and Control Cable Inspection.
* Aft cable ends and turnbuckles for condition and security. Evidence of
corrosion pitting requires replacement.
* Rotating cone control tubes and cables for freedom of movement and
unusual sounds.
Reinstall rotating cone and tip cap (500N).
ELECTRICAL
NOTE: When possible, use auxiliary power source, not battery, during POWER ON inspection.
ALL XMSN OIL TEMP, FUEL FILTER and CHIPS warning lights; electrical 95−00−00
circuits for continuity to lamps by connecting jumper wire from each sender
or chip detector terminal stud to an unpainted grounding surface; check each
light for illumination (ref. Caution/Warning System Operational Check).
ALL Push PRESS TO TEST switch: all caution and warning lights ON; depress 95
instrument light rheostat knob; verify CAUTION lights dim.
369D/E/FF Conduct operational check of automatic reignition system; igniter noise heard PFM
500N and reignition indicator light functions. Reset as required.
369D/E/FF Do a check of the TOT indicating system for correct calibration (Ref. TOT 95−30−00
500N Indicating System Calibration or Digital TOT Indicating System Inspection).
600N Do a check of the TOT indicating system for correct calibration (Ref. Digital 95−30−00
TOT Indicating System Inspection).
CAUTION: Do not leave landing light ON for more that one minute during next check; lamp will overheat and
lamp life will be shortened.
ALL Exterior lighting (landing, position and anti−collision lights) for proper 96
operation; all switches OFF after check.
WARNING: Do not leave pitot heater ON for more than one minute during next check; severe burns to
personnel may result.
ALL PITOT HTR switch ON for a few seconds. Heated pitot tube will feel warm to 95
the touch; turn switch to OFF after check.
600N Apply power to aircraft and disconnect CIT sensor (Ref. CIT (Compressor 76−00−00
Inlet Temperature) Sensor Replacement); Verify ECU FAIL light illuminates.
Re−connect CIT sensor.
Page 9
MAINTENANCE MANUAL

ALL Clean battery and inspect for: 96
* Connector pins for evidence of corrosion.
* Leakage (if battery is leaking (wet), remove and replace battery).
* Battery case for cracks in support flanges.
* Dc wiring for chafing caused by wiring rubbing against battery case.
* Deep cycle charge (recondition) battery every 100 hours or on
conditional basis at operator’s discretion.
ALL Functionally check and inspect all installed avionics, auxiliary or optional 97
systems and equipment. Do not actuate hoist guillotine or emergency floats.
ENGINE COMPARTMENT
ALL Do a fuel system vacuum leak check (Ref. Fuel System Vacuum Leak 28
Inspection) and the fuel air bleed procedures (Ref. the applicable
Rolls−Royce Operation and Maintenance Manual for special engine fuel
system air bleed information) after the fuel supply system has been opened.
ALL Entire engine for: 71
* Loose bolts; loose or broken connections. 75
76
* Accessories for security and broken or missing lockwire.
* Fuel and oil lines for chafing and kinking.
* Fuel drain line valve for leakage.
* Oil cooler and cooler deflector for security and obvious damage.
* Accessible areas for obvious damage; evidence of fuel and oil leaks.
* Engine mounts for cracks and play in mounting hardware at engine and
airframe (retorque any loose mounting bolts).
* Fuel control and compressor exterior for condition and security.
ALL Exhaust stack(s) and exhaust supports for cracks, defects, and improper 78
attachment.
Examine hanger saddle cushion assembly for wear, tear, and security. (Ref
Exhaust Hanger Saddle Cushion Assembly Repair) 78−20−00
ALL Engine compartment plumbing and electrical relay installation on left or right 96
side oleo (landing gear damper) support fitting for good condition and
security of mounting. Diodes for broken terminals and wires. Diode bracket
for security and corrosion.
369D/E/FF Anti−ice air tubes and compressor scroll for cracks or breaks at the anti−ice 75−10−00
500N air valve and bleed port. If cracks exist, check engine for possible vibration
causes (Ref. Engine Anti−icing System and applicable Rolls−Royce
Operation and Maintenance Manual).
369D/E/FF RPM governor lever control rod (replace if aluminum). 76−10−00
500N
369D/E/FF Clean and lubricate drive splines of starter−generator drive shaft, and female 96
500N splines in engine accessory gear case on dry spline installations.
Page 10
MAINTENANCE MANUAL

AFTER INSPECTION
ALL Make sure all fluid levels are correct; service as required. 12
ALL Touch−up all damaged paint and exterior markings, as necessary. 20
ALL Do an operational check of particle separator filter (Ref. Scavenge Air 71−10−10
Operational Check).
ALL Install or close all stressed panels, covers and trim panels removed or 52−50−00
opened for inspection. Check closure, fit and security. All loose equipment
for proper stowage.
CAUTION: Helicopter must not be flown unless controls access panel and fuel cell access panels in cargo
compartment are securely installed. These are stressed panels.
POST INSPECTION RUN UP
See applicable Pilot’s Flight Manual for cockpit check and engine starting procedures. For troubleshooting
procedures, refer to applicable section of this manual.
100−HOUR OR ANNUAL INSPECTION CERTIFICATION
It is certified that this helicopter has been thoroughly inspected as required by FAR, found to be airworthy, and
appropriate entries made in the helicopter log book. It is further certified that the helicopter conforms to FAA
specifications, that all FAA Airworthiness Directives and Manufacturer’s Service Notices and Maintenance
Manual data have been complied with, and the helicopter records are in proper order
Signature
Rating Type or Certificate No.
Date
Page 11
MAINTENANCE MANUAL
2. Retirement Index Numbers Attachment Refer to Section 04-00-00 for components

requiring calculation of RIN's/TE's and
Table 2 is to be used for calculating and information pertaining to calculation of
recording the Retirement Index Number (RIN) RIN's/TE's.
or Torque Events (TE) of components that are
affected by Torque Events (TE).
Component must be scrapped when it reaches
This record of RINs/TE's should be kept as a 1,000,000 RIN's or maximum TE's (Ref. Sec.
permanent record. 04-00-00).
Table 2. Permanent Record of Retirement Index Numbers/Torque Events

Component Part No. Serial No. Hours TE’s RIN’s Signature
Page 12
MAINTENANCE MANUAL
Section
05−20−10
Continued
Airworthiness
MAINTENANCE MANUAL
300−HOUR INSPECTION CHECKLIST
1. 300−Hour Inspection NOTE:
D The Chap/Sect column of the following
table is for reference unless a specific in
This check sheet is designed to be used when spection requirement is called out. If
performing scheduled inspections as defined there is only two numbers in the column,
under FAR Part 91. This checklist, when it refers to the Chapter. If there is three
completed, should be kept as a permanent part numbers, it refers to the Section the in
of the helicopter's records. Adherence to spection is found.
Maintenance Manual information is required, D Refer to applicable Rolls-Royce engine in
and the manual should be consulted when spection check list for required engine
using the checklist. maintenance.
Table 1. 300−Hour Inspection
Registration No. Serial No. Helicopter Hours
EXTERIOR
ALL Retorque tailboom attachment bolts. 53
500/600N Remove rotating cone and tip cap (500N) and inspect: 53
* Cone rollers for condition and security.
* Four fasteners that attach 500N3760−1 upper input shaft to the
stationary thruster for play (replace pins and collars if any play is found).
* Three fasteners that attach 500N3759 support shaft assembly for play (if
play is found in top bolt, retorque to 10—15 inch−pounds (1.13—1.69 Nm).
Replace pins and collars if any play is found in bottom fasteners).
Reinstall rotating cone and tip cap (500N).
369D/E/FF Remove engine inlet bypass door and inspect: 71−10−10
* Latches, hinges and hardware for condition, wear and security.
* Cables, cable ends and pulleys for condition, corrosion and wear.
* Remove and replace the latch retention cotter pin MS24665−103
(located inside the attach ”U” clamp) (Ref. Engine Air Inlet Bypass Door
300−Hour Inspection).
369D/E/FF Check horizontal and vertical stabilizer attach bolts for proper torque (Ref. 53−50−10
Horizontal Stabilizer Tip Plate Installation and Vertical Stabilizer Installation).
369D/E/FF Check lower surface of horizontal stabilizer for drain holes. Also check for 53−50−10
gaps between upper and lower doublers and stabilizer skin (Ref. Horizontal
Stabilizer and Tip Plates Inspection).
500/600N Control tubes and bellcranks in horizontal stabilizer for condition and 53
security.
Page 1
MAINTENANCE MANUAL
Table 1. 300−Hour Inspection (Cont.)

500/600N Inspect S.A.S. system for: 67
* Actuator for security and damage (no damage allowed).
* Wiring for condition and security (no wire chaffing, fraying or insulation
cracking allowed).
* Actuator mounting bracket for cracks, pay particular attention to area
around four rivet attach holes (no cracks allowed).
* Rate gyro and control box for security in mount and electrical connector
secure. Inspect mount for security and condition (no corrosion or cracks
allowed).
LANDING GEAR
ALL Perform Landing Gear Inspection. 32−10−00
ALL Perform Cabin Entry Step Inspection. 32−10−00
CABIN
ALL Remove instrument console base covers and inspect anti−torque pedal 67
crossover torque tube and bellcrank for cracks, damage and security.
ALL Push−pull rods for excessive bearing play, wear and security. 67
ALL Perform Tunnel−Routed Control Rod Inspection. 67−10−00
ALL Check oil tank for security and evidence of leakage and damage. 79
MAIN ROTOR
ALL Perform Swashplate Inspection. 62
ALL Perform Lead−Lag Bolt Inspection. 62
ALL Perform Main Rotor Hub Droop Angle Check. 62
ALL Perform Main Rotor Blade Inspection. 62
ALL Inspect main rotor mast, mast base and mast base support structure for 63−30−00
evidence of cracks. Check with bright light and 5X magnifying glass. Visually
check mast support bolts for security and condition. Inspect internal bore for
chipping, orange peeling or flaking paint (Ref. Main Rotor Static Mast
Inspection and Repair).
ALL Inspect hoisting eye−bolts for cracks or corrosion. 63
369D/E/FF 369D25510 drive shaft only, perform Main Rotor Drive Shaft Inspection 63−10−00
500N (300−Hour).
DRIVE TRAIN
ALL Remove, inspect and clean main transmission chip detectors. 63
369D/E/FF 369A5350 Overrunning Clutch: Perform Ball Bearing Inspection and Grease COM
500N Repack (300 Hour).
ALL 369F5450 Overrunning Clutch: Perform Ball Bearing Grease Repack (300 COM
Hour).
369D/E/FF Remove tail rotor drive shaft and check boom fairing and tailboom for 53
buckles, dents, bulkhead chafing and obvious damage.
Page 2
MAINTENANCE MANUAL

369D/E/FF Remove tailboom control rod and inspect for wear though hard anodized 67−20−10
surface (Ref. Tailboom Control Rod Replacement); inspect grommets for
wear and deterioration.
369D/E/FF Check shaft damper for proper friction drag. Inspect damper for damage and 63−15−10
security (Ref. Tail Rotor Drive Shaft Damper Inspection).
369D/E Check forward and aft coupling bolt and socket for indication of contact, 63−15−10
Bendix couplings only (Ref. Tail Rotor Drive Shaft Inspection).
ANTI−TORQUE
Tail Rotor System
369D/E/FF Remove, inspect and clean chip detector. 63
369D/E/FF Check for contact between tail rotor bellcrank and tail rotor transmission 67
housing at extreme right pedal travel.
369D/E/FF Tail rotor assembly: Elastomeric teeter bearings for wear; bond between 64−20−00
concentric metal cones and elastomer rings of bearing assembly (Ref.
Elastomeric Bearing Inspection).
369D/E/FF Remove blade stop for thorough inspection; in particular, check for cracks or 64−30−00
splits in stem area (Ref. Tail Rotor Blade Stop Inspection).
NOTARR Anti−Torque System
500/600N Check balance weights for security. If any balance weight stud is found to be 64
loose, perform Fan Balance Stud Replacement.
500/600N Remove, inspect and clean fan transmission chip detector. 63
500/600N Remove tailboom: 53
Perform visual inspection of fan assembly for: 64
* Cracks, nicks or corrosion.
* Blades for cracks, nicks or impact damage.
* Check pitch horn counterweights for security. If counterweight(s) are
found loose, perform Pitch Horn Counterweight Set Screw Replacement
(Ref. Sec. 64−25−30). NOTE: Access the forward counterweights through
the fan inlet (fan hub fairing must be removed).
* Gap between fan blade and tip seal and gap between fan blade and hub
(inboard end of the blade). If any of these gaps for any blade exceeds the
average gap of the other blades by more than 0.10 inch (2.54 mm)., remove
and inspect the tension−torsion strap for that blade.
* Fan liner for cracks, debonding or corrosion of liner material.
* P−seal for tears, deterioration and debonding.
Reinstall tailboom (on 600N only, install new tailboom mounting bolts).
ELECTRICAL
NOTE: When possible, use auxiliary power source during POWER ON inspection, not battery.
ALL Perform Battery Temperature Sensing Switches Testing. 96
369D/E/FF Deleted. Moved to Section 05−20−00, 100−Hour or Annual Inspection
500N Checklist, Table 1. 100−Hour or Annual Inspection, ELECTRICAL.
Page 3
MAINTENANCE MANUAL

ENGINE COMPARTMENT
ALL Do the Fuel Filter (Bypass) Caution Light Pressure Switch Test. 28−00−00
28−00−60
NOTE: Also, do this operational check whenever low pressure fuel pump filter element is replaced for any reason,
or if contaminated.
ALL Examine the starter/generator for: 96
* Condition of brushes, electrical connections and commutator.
* Screens for clogging.
* Condition of O−ring on drive spline.
* Damper backplate and clutch for condition.
Page 4
MAINTENANCE MANUAL
Section
05−20−15
Continued
Airworthiness
MAINTENANCE MANUAL
YEARLY INSPECTION CHECKLIST
1. Yearly Inspection NOTE:

This check sheet is designed to be used when
performing special inspections as defined
spection requirement is called out. If
under FAR Part 91. This checklist, when
there is only two numbers in the column,
completed, should be kept as a permanent part
it refers to the Chapter. If there is three
of the helicopter's records. Adherence to
numbers, it refers to the Section the in
Maintenance Manual information is required,
spection is found.
and the manual should be consulted when
using the checklist. D Refer to applicable Rolls-Royce engine in
maintenance. (Ref. Section 01-00-00, Ta
ble 2)
Table 1. Yearly Inspection

1 YEAR
EXTERIOR
ALL Perform Pitot Static System Inspection. 95−10−00
ALL Check outside air temperature probe for security and obvious damage. 95
ALL Particle separator for condition and servicing. 71
NOTE: If equipped with a Donaldson Particle Separator, ensure O−rings for rubber boot 71−10−10
are not deteriorated (Ref. Donaldson Particle Separator Inspection).
ALL Perform engine air inlet Air Pressure Sensing Switch Calibration Check. 71−10−10
71−10−60
LANDING GEAR
369D/E/FF Perform Landing Gear Strut Inspection. 32−10−00
500N
CABIN
ALL * First aid kit contents and security of attachment. 25
* Fire extinguisher for charge pressure and security of attachment. 26
ALL * Inspect seats, interior trim, panels and covers for damage and security. 25
* Inspect seat base structure for evidence of deformation.
ALL * Perform Tank Vent System Inspection. 28−00−00
28−00−60
369D/E/FF Inspect fuel vent system rollover valve for condition and operation (Ref. Tank 28−00−00
500N Vent System Inspection).
NOTE: The 369H8108−505, 369H8108M, 369H8108−501M,−503M and 369D28108−1 rollover valves do not re-
quire a yearly inspection.
Page 1
MAINTENANCE MANUAL
Table 1. Yearly Inspection (Cont.)

ALL * Actuate and visually inspect fuel shutoff valve for proper operation. 28−00−00
* Inspect fuel cell sending unit for electrical terminals and wiring for 28−00−60
security and condition.
* Inspect wiring harness between sending unit and instrument cluster.
* Check FUEL LEVEL LOW caution light for correct operation (ref. Fuel
Level Low Caution Light System Test).
600N Aircraft WITHOUT airframe fuel filter option: 28−00−60
* Do a Fuel Transfer System Functional Check.
ALL Inspect instrument plumbing and electrical wiring for chafing, damage and 95
security. 96
NOTE: In the following inspection, do not pull on torque or oil pressure lines.
369D/E/FF Inspect torque and oil pressure lines from the firewall forward to the 95
500N instruments for seepage, chafing, cracking, damage and security.
ANTI−TORQUE
500/600N Drain fan transmission. Flush with sufficient new oil to remove sludge 12
accumulation. Refill with new oil.
369D/E/FF Drain tail rotor transmission. Flush with sufficient new oil to remove sludge 12
accumulation. Refill with new oil.
369D/E/FF Inspect Tail Rotor Blade Assembly pitch horn area for corrosion. 64−30−00
FLIGHT CONTROLS
500/600N Inspect forward thruster cable at Sta. 123.30 for crack in relieved area 67
between threads and swage.
Inspect the conduit cap of the telescopic swivel end for crack, corrosion and
obvious damage to the cable swage area or evidence of ball separation.
500N Inspect center thruster cable at Sta. 264.00 for crack in relieved area 67
600N Inspect center thruster cable at Sta. 292.00 for crack in relieved area 67
ELECTRICAL
NOTE: When possible, use auxiliary power source, not battery, during POWER ON inspection.
ALL Check wiring from battery connector to warning lights for continuity, use an 96
ohmmeter.
Page 2
MAINTENANCE MANUAL
Table 1. Yearly Inspection

ENGINE COMPARTMENT
ALL Inspect firewall insulator panels for security and obvious damage. 53
ALL Inspect overrunning clutch firewall seal and engine compressor firewall 63
(plenum chamber) seal for proper sealing and good condition. 71
24 MONTHS
TRANSPONDER — Altimeter Checks
369F/FF Test according to 14 CFR §43 Appendix E. *Ref. Note
Do the pitot−static checkout procedure.
*Note: Refer to G500/G600 TXi Part 23 AML STC Maintenance Manual.
4 YEARS
NOTE: Shelf life of bearings preserved with grease is limited to 4 years. For this reason, it is of extreme
importance that bearings carry the date of last lubrication or preservation and inspection. After 2 years of shelf
life, it is advisable to relubricate bearings upon installation.
ALL Clean, inspect and relubricate (repack) main rotor swashplate bearings that COM
have been in storage.
500/600N Clean, inspect and relubricate (repack) fan support and pitch plate bearings 64
that have been in storage.
369D/E/FF Clean, inspect and relubricate (repack) tail rotor swashplate (duplex) 64
bearings that have been in storage.
AHRS Magnetic Field Model Update
5 YEARS
369FF The GSU 75, and GDU 700P Integrated ADAHRS use an Earth magnetic See Note
field model which is updated once every five years as part of the Aviation
Database maintained by the owner/operator. If the magnetic model is not up
to date, the unit will issue an alert upon startup indicating the model has
expired.
NOTE: For service bulletin that contains the updated magnetic field model and instructions for installation, refer
to the dealer resource center or speak with a Garmin Costumer Service Representative.
Electrical Bonding Check
2000 Flight Hours or 10 Years
369FF Check for Class R bond of the G500 TXi system LRUs See Note
NOTE: Refer to the G500/G600 TXi Part 23 AML STC Maintenance Manual.
Page 3
MAINTENANCE MANUAL
Table 1. Yearly Inspection (Cont.)

GDU 700P Cooling Fan
3000 Hours
369FF It is recommended that the cooling fan on the GDU 700 be replaced every See Note
3000 fan operating hours. The number of hours the fan has been operating
can be viewed using the following procedure:
S Power on the GDU 700 in configuration mode per the instructions
G500/G600 TXi Part 23 AML STC Maintenance Manual.
S Navigate to Diagnostics − Temp & Power Stats.
S The cooling fan operating hours can be found under Power Statistics as
”Fan OPER Hours”.
NOTE: Refer to the G500/G600 TXi Part 23 AML STC Maintenance Manual.
Page 4
MAINTENANCE MANUAL
Section
05−20−20
Continued
Airworthiness
MAINTENANCE MANUAL
SPECIAL INSPECTIONS
1. Special Inspection Hourly and Calendar NOTE:
This table is a schedule of time-phase inspec
tions that are contingent upon elapsed flight
spection requirement is called out. If
time or calendar time. These inspections
there is only two numbers in the column,
require a Log Book entry. Adherence to
it refers to the Chapter. If there is three
Maintenance Manual information is required,
numbers, it refers to the Section the in
and the manual should be consulted when
spection is found.
using this checklist.
D Refer to applicable Rolls-Royce engine in
maintenance. (Ref. Section 01-00-00, Ta
ble 2)
Table 1. Special Inspections Hourly

Model What to Inspect Chap/Sect
AFTER INSTALLATION OF NEW 369F5100 MAIN ROTOR TRANSMISSION
ALL Perform transmission break−in (Ref. Main Transmission Break−In Procedure) 63−20−25
2 − 10 HOURS AFTER INSTALLATION OF TAIL ROTOR TRANSMISSION
369D/E/FF Using drag torque previously recorded, apply a torque load of 75—95 inch−pounds 63−25−10
(8.47—10.73 Nm) plus the noted drag torque (noted for each individual nut) to
each mounting nut of the transmission (Ref. Tail Rotor Transmission Installation).
EVERY 10 HOURS or BEFORE FIRST FLIGHT OF EVERY DAY
600N Effectivity: RN003−RN059 (Ref. SB600N−039), Perform Tailboom Attach Fitting 53−30−30
Inspection (Ref. EAD 2001−24−51) (Not required if TB600N−007R1 has been
accomplished).
EVERY 15 HOURS
369D/E/FF Effectivity: 369H1203−BSC or 369H1203−21 lead−lag link assemblies with at least 62−10−00
500 hours, perform Main Rotor Blade Upper and Lower Root Fitting Attach Lug and
Lead−Lag Link Attach Lug Inspection (25 Hour) and every 100 hours in accordance
with Main Rotor Blade Upper and Lower Root Fitting Attach Lug and Lead−Lag Link
Attach Lug Inspection (100 Hour) until retirement of 369H1203−BSC or−21 Lead−Lag
Link Assembly. (Reference AD CSP−HMI−3, Section 95−03−13).
25 HOURS AFTER REPLACING TAIL ROTOR DRIVE FORK HINGE BOLT
369D/E/FF Check rotational torque of bolt by applying 125 inch−pounds (14.12 Nm) with torque 64−20−10
wrench. If 125 inch−pounds (14.12 Nm) torque does not rotate bolt, preload is correct 64−20−20
(Ref. CSP−COM−5, Hub and Fork Assembly).
25 HOURS AFTER INSTALLATION OF OIL COOLER BLOWER
ALL With two pounds of force applied, check belt tension for 0.17—0.20 inch (4.32—5.08 63−21−00
mm) deflection. Check pulley (Ref. Cooling Blower Belt Tension Check and
Adjustment). Check oil cooler blower driven pulley retaining nut for minimum torque of
160 inch−pounds (18.08 Nm). If loss of torque is noted, remove pulley nut and
inspect pulley shaft and splines for condition. Reinstall nut and torque to 160—190
inch−pounds (18.08—21.47 Nm) plus drag torque.
Page 1
MAINTENANCE MANUAL
Table 1. Special Inspections Hourly (Cont.)

EVERY 25 HOURS WITH 2 FAILED LAMINATES IN MAIN ROTOR STRAP ASSEMBLY
369D/E/FF Inspect in accordance with Main Rotor Strap Pack Lamination Inspection at 25−hour 62−20−00
500N intervals if 2 laminates have failed in any one leg or tongue area of any strap
assembly. A single cracked laminate between the shoes at the outboard end of a
strap pack is cause for rejection of the hub assembly (Ref. Main Rotor Strap Pack
Lamination Inspection).
EVERY 25 HOURS WITH 1 FAILED LAMINATES IN MAIN ROTOR STRAP ASSEMBLY
600N Inspect in accordance with Main Rotor Strap Pack Lamination Inspection at 25−hour 62−20−60
intervals if 1 laminate has failed in any one leg or tongue area of any strap assembly.
A single cracked laminate between the shoes at the outboard end of a strap pack is
cause for rejection of the hub assembly (Ref. Main Rotor Strap Pack Lamination
Inspection).
EVERY 25 HOURS
NOTE: This inspection does not apply to 369D21100−516, −517, −523 and 369D21102−503, −517, −523 main
rotor blades or the 369H1203−51 and −61 lead−lag links.
369D/E/FF Visually inspect exposed portion of all installed main rotor blade upper and lower root 62−10−00
fitting attach lugs and main rotor hub lead−lag link attach lugs for broken or cracked
lugs, corrosion or other damage to the lug areas (Ref. Main Rotor Blade Upper and
Lower Root Fitting Attach Lug and Lead−Lag Link Attach Lug Inspection (25−Hour)).
EVERY 50 HOURS
369D/E/FF Effectivity: On models equipped with Rotorcraft Litter Kit: visually inspect litter doors CSP−026
500N for condition and security of quick−release fasteners. Rubber gasket between window
glass and door for proper sealing.
EVERY 50 HOURS IF CRACKS ARE FOUND IN FAN LINER
NOTE: If cracks protrude into Felt Metal Seal, replace seal.
500/600N Inspect fan liner to ensure cracks do not protrude into Felt Metal Seal (Ref. 64−25−30
Anti−Torque Fan Liner (Felt Metal Seal) Inspection).
EVERY 50 HOURS
600N Effectivity: ECU P/N 23080491, 23088905, or 23089311 with ECU Overspeed RFM
Adapter (P/N M250−10684) installed, remove the overspeed adapter and perform the
overspeed shutdown test. Two overspeed shutdown tests must be performed one
after the other. Reinstall the overspeed adapter when test is complete. Refer to
applicable Rolls−Royce Operational and Maintenance Manual if engine fails the test
or any faults shown. (Ref. CEB−A−73−6059)
EVERY 100 HOURS
ALL If installed, floats and associated components for condition and security. 32
ALL Effectivity: With 369F5450−501 overrunning clutch installed, remove clutch assembly 63
and inspect clutch retainer, bearing carrier and housing at pin and shoulder for
evidence of spinning and/or wear. If spinning and/or wear is observed, replace clutch
assembly.
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MAINTENANCE MANUAL

EVERY 300 HOURS
600N Replace tailboom attach bolts with new bolts, scrap removed bolts 53−40−30
(Ref. Tailboom Installation).
Inspect radius blocks and tailboom attach points for corrosion and cracks
(Ref Tailboom Inspection).
EVERY 300 HOURS OR ONE YEAR (Whichever occurs first)
ALL Effectivity: For 369D25100 main transmission serviced with MIL−L−23699 oil, drain 12
main transmission oil system; Flush with sufficient new oil to remove sludge
accumulation. Replace filter and refill with new oil.
500/600N Effectivity: Forward and center cable couplings; Using a bright light and 10X 67−20−30
magnifying glass, inspect inner coupling male and female connectors for corrosion
pitting or cracks; none allowed.
EVERY 300 HOURS OR TWO YEARS (Whichever occurs first)
600N Main rotor upper thrust bearing assembly must be relubricated every 2 years or 300 62−20−60
hours, whichever occurs first (Ref. Main Rotor Hub Upper Bearing Grease Repack,
Inspection and Replacement).
EVERY 300 HOURS
ALL Effectivity: 369D21400−503 (369D/E/FF—500/600N) or M50452 (369D/E/FF—500N) 62−20−00
lead−lag dampers with at least 4200 hours, inspect for deterioration until deterioration 62−20−60
is sufficient to retire assembly (Ref. Main Rotor Damper and Attachments Inspection
and Main Rotor Damper Weight Loading and Extension Check).
NOTE: The following inspection does not apply to 369D25100−505 and −507 transmissions.
369D/E/FF Visually inspect upper surface of main transmission output shaft assembly (ring gear 63−20−00
carrier) for bulging or raised surfaces. Using 10X magnifying glass, inspect upper
surface of shaft for cracks. (Ref. CSP−COM−5, Output Drive Shaft Visual Inspection)
369D/E Replace anti−ice/airframe fuel filter element (if installed) (Ref. Anti−Ice Fuel Filter 28−25−00
500/600N Replacement).
ALL Mist eliminator and access door for proper installation (attaching hardware for 71
security).
ALL Hoist installation (if installed) for condition and security. 25
EVERY 600 HOURS OR ONE YEAR (Whichever occurs first)
ALL Effectivity: 369D25100 main transmission serviced with Mobil AGL oil and 369F5100 12
main transmission, drain main transmission oil system; Flush with sufficient new oil to
remove sludge accumulation. Replace filter and refill with new oil.
369D/E/FF Effectivity: 369F5510 Main Rotor Drive Shaft, perform 369F5510 Main Rotor Drive 63−10−00
500N Shaft Inspection (Ref. 600N5510 and 369F5510 Main Rotor Drive Shaft Inspection).
600N Effectivity: 600N5510 Main Rotor Drive Shaft, perform 600N5510 Main Rotor Drive 63−10−00
Shaft Inspection (Ref. 600N5510 and 369F5510 Main Rotor Drive Shaft Inspection).
EVERY 600 HOURS
ALL Cyclic control system for excessive slack or free play. Cyclic control stick, at grip, for 67−10−00
play in excess of 3/8 inch (9.53 mm) (Ref. Main Rotor Flight Control System
600−Hour Inspection).
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MAINTENANCE MANUAL

ALL Effectivity: 369D21400−503 (369D/E/FF—500/600N) or M50452 (369D/E/FF—500N) 62−20−00
lead−lag dampers with less than 4200 hours, inspect for deterioration until 62−20−60
deterioration is sufficient to retire assembly (Ref. Main Rotor Damper and
Attachments Inspection and Main Rotor Damper Weight Loading and Extension
Check).
500/600N Using a dial indicator, measure the rotation of the fan pitch control clevis mounted on 63−25−30
the fan pitch control tube. If clevis rotation is more than 0.025 inch (0.635 mm), 67−20−30
inspect splines on fan pitch control tube (Ref. Fan Pitch Control Tube Inspection) and
splines in tube support (Ref. Tube Support Inspection).
EVERY 1200 HOURS
ALL Test battery over temperature sensor unit for proper operation and accuracy (Ref. 96−05−00
Battery Temperature Sensing Equipment Operational Check).
500/600N Perform visual inspection, using a 10x magnifying glass, on horizontal stabilizer 53
mounting brackets (pay particular attention to the forward inboard legs).
500N Regrease YSAS actuator (Ref. YSAS Actuator Regrease Procedure). 67−20−30
600N Perform Upper Longeron Inspection (L153, R153). 53−30−30
EVERY 1200 HOURS OR 2 YEARS (WHICHEVER OCCURS FIRST)
500/600N Clean, inspect and relubricate (repack) fan support and pitch plate bearings (Ref. 64−25−30
Anti−Torque Fan Bearing Regreasing).
500/600N Perform Anti−Torque Fan Inspection. 64−25−30
500/600N Check pitch bearing retainer for cracks or damage. 64
600N Main rotor lower thrust bearing assembly must be relubricated every 2 years or 2700 62−20−60
hours, whichever occurs first.
600N Clean, inspect and relubricate (repack) main rotor swashplate bearings. 62−30−60
369D/E/FF Clean, inspect and relubricate (repack) main rotor swashplate bearings and main rotor 62−20−00
500N hub tapered bearings (Ref. Main Rotor Hub Tapered Bearing Replacement).
369D/E/FF Clean, inspect and relubricate (repack) tail rotor swashplate bearings (Ref. Tail Rotor 64−30−00
Swashplate Bearing Regreasing).
AT 6000 HOURS AND EVERY 100 HOURS THEREAFTER
600N Remove tunnel control boot. Inspect interface between 369H2564 tunnel beams and 53−30−30
369D22508−7 web for cracks (Ref. Control Tunnel (FS 78.50) Beam Inspection).
600N Effectivity: (RN003−RN077 with TB600N−007 completed, and RN078 and subs) 53−30−30
Perform Forward Upper Longeron Inspection (L137, R137).
AT 15,000 HOURS AND EVERY 1500 HOURS THEREAFTER
600N Effectivity: (RN003−RN077 with TB600N−007 completed, and RN078 and subs) 53−30−30
Perform Lower Longeron Inspection (L158, R158).
Page 4
MAINTENANCE MANUAL
Table 2. Special Inspections Calendar

Model What to Inspect Section
(DAILY) BEFORE FINAL SHUTDOWN IN CORROSIVE ENVIRONMENT
ALL It is recommended that before shutdown from the last flight of the day, for helicopters 20−40−00
operating in a corrosive environment, a Tri−Flow wash be preformed on the main
rotor hub and strap pack assembly (Ref. Main Rotor Hub Corrosion Prevention
(Tri−Flow Wash Procedure)).
(DAILY) AFTER FINAL SHUTDOWN IN CORROSIVE ENVIRONMENT
500N It is recommended that after shutdown from the last flight of the day, for helicopters 20
operating in a corrosive environment, the splitter bungee spring be sprayed with
Tri−Flow.
EVERY 6 MONTHS OR 5 INFLATIONS
ALL Inflate emergency floats to 4.5 psi (0.3164 kg/cm2) for one hour. Check for leaks and 32−82−00
condition. Continue inflation to 5.5 psi (0.3867 kg/cm2) and check that chamber
pressure relief valves operate. Pressure−test float compartments (Ref. Float
Compartments Pressure Test).
AFTER COMPRESSOR WATER WASH/RINSE WITH PARTICLE SEPARATOR INSTALLED
ALL During engine run after compressor water wash with particle separator installed, it is RFM
recommended that scavenge air switch be switched on to remove any moisture that
has accumulated in the solenoid air valve.
BEFORE OPERATION OF BREEZE HOIST SYSTEM
ALL Prior to daily hoisting operations: unreel and inspect entire length of hoist cable for 01
broken strands (cluster of 7 wires), excessive broken wires, corrosion, and security
of attachment to cable drums and swivel hook. Replace cable if broken strand or
excessive broken wires are noted. (Refer to hoist manufacturer’s handbook, Table
201.)
AFTER FIRST FLIGHT WITH NEW EXHAUST GASKET INSTALLED
369FF/600N Exhaust bolts should be retorqued after first flight. If bolts are found to be loose, 78−30−00
retorque after every flight until bolts retain torque.
Page 5
MAINTENANCE MANUAL
Page 6
MAINTENANCE MANUAL
Section
05−50−00
Continued
Airworthiness
MAINTENANCE MANUAL
CONDITIONAL INSPECTIONS
1. General NOTE: Ref. the applicable Rolls-Royce Engine
Operation and Maintenance Manual (Ref.
This section is for unscheduled or conditional Section 01-00-00, Table 201, therein) for
inspections. The specified inspections and the detailed requirements for engine inspec
procedures (Ref. Table 1) must be done to tions for specified or unique conditions com
make sure of the continued airworthiness of parable to those listed herein.
the helicopter. When a helicopter has been
involved in an accident, all its parts must be 2. Conditional Inspection Tables
inspected for damage. After an accident, parts The conditional inspections in these tables
may show damage, because of high force, (Ref. Table 1) are for the MDHI Model 369D,
extreme heat, and/or immersion. Assemblies, 369E, 369FF, 500N, and 600N helicopters
components, installations, and/or parts that only.
are involved in accidents or incidents that
involve high forces, extreme heat, and/or D The first column shows which model the
immersion can have a serious effect on the inspections or procedures are applicable to.
structural integrity and operation of a
D The second column is a short description of
helicopter.
the necessary inspections or procedures.
Helicopter and component records must be D The third column shows the chapter, section,
clear and complete and include the necessary or another manual that has the specified
details to show a complete parts history. inspections or procedures. The abbreviation
Without a complete parts history, the inspec COM is for the Component Repair Manual
tions given in this manual are not sufficient to CSP-COM-5. The abbreviation SRM is for
determine if the part is acceptable for installa Structures Repair Manual CSP-SRM-6.
tion. This is critical for life-limited components
(Ref. Chapter 04), flight-safety critical aircraft
WARNING
parts (FSCAPs), and primary load structures.
D Discard components that are replaced.
Damage from accidents and incidents can be The reuse of damaged assemblies and
very different between one event and another components is not allowed and can
event. The conditional inspections cannot fully cause loss of life and the helicopter.
cover the many possible accidents or incidents D Record in the Rotorcraft Log Book
that can occur and the damage that results. If (RLB) the reason for removal of an as
you are not sure what inspections, procedures, sembly, component, or detailed part for
or tests are necessary to make sure the overhaul, repair, or replacement.
helicopter and its parts are in a condition for
safe operation and conform to the type design: 3. Hard Landing
D Record all the information of the accident or A hard landing is an incident or accident
incident. where the helicopter hit the ground or landing
surface with sufficient force to cause:
D Speak to, or write, MDHI Field Service
(telephone: 800-388-3378, 480-346-6813, D The main rotor blade to hit the tailboom or
480-626-0075 (after hours) / email: upper fairings or cowlings.
serviceengineering@mdhelicopters.com) for
the necessary inspections, maintenance D The permanent deformation of the landing
procedures, and tests. gear more than the allowable limits.
D The lower fuselage, lower tailboom surface,
It is possible you will need to do more than one tail rotor, or thruster to touch the ground.
of the inspections or procedures shown in
Table 1 of this section. Do all inspections that Ref. Table 1 if there has been a hard landing
are applicable. or if you think there has been a hard landing.
Page 1
MAINTENANCE MANUAL
Table 1. Conditional Inspections After a Hard Landing

Model Requirement Chap/Sect
ALL Examine the main rotor blades for bending, cracks or wrinkles. 62
ALL Examine the main rotor blade droop stops for damage. 62
ALL Examine the main rotor hub assembly and strap pack assembly for evidence of 62
damage.
ALL Examine the accessible areas of the main rotor mast assembly and transmission 63
attachment area for damage.
ALL Do a Landing Gear Inspection. 32−10−00
Examine the forward and aft rub plates for condition.
ALL Do a Tailboom Inspection. 53−40−00
Torque the mount bolts. 53−40−30
ALL Do an inspection of the tailboom attachment area for damage. 53

500/600N Do an inspection of the stationary thruster attachment flange for damage. 53
Torque the mount bolts.
369D/E/FF Examine the tail rotor drive shaft and damper, tail rotor transmission and tail rotor for 63
distortion, loose mounting or attaching parts, buckling, breaks or other damage. 64
Examine the tail rotor drive shaft for contact with bulkheads.
500/600N Examine the main transmission−to−fan transmission drive shaft, fan transmission, fan 63
drive shaft, fan and fan control rod for distortion, loose mounting or attaching parts, 67
buckling, breaks or other damage.
Examine the drive shafts for contact with the bulkheads.
Examine the fan control rod for freedom of movement.
ALL Do the Engine Mounts and Fittings Inspection. 71
Examine the mounting pads and firewall for damage and distortion.
Do a inspection of all suspected parts by magnetic particle or dye−penetrant methods, SRM
as applicable (Ref. CSP−SRM−6).
ALL Examine all flight and engine control system push−pull tubes, links, bellcranks, and 67
bearings for bends, cracks, installation, and free movement.
ALL Examine the tunnel area A−frame for distortion, buckling, or other damage. 53
ALL Examine the fuselage fittings for bends and cracks. 53
ALL Examine the main transmission chip detectors for metal particles. 63
Examine the main transmission mounting flanges for cracks.
ALL Do the Main Transmission Drive Shaft Inspection. 63−10−00
ALL Examine all engine accessories for cracked flanges, loose bolts and nuts, 79
connections and general condition.
ALL Examine the engine accessory drive housing for cracks. 79
ALL Examine the engine chip detectors for metal particles. 79
ALL Examine the engine oil tank, supports, tubing and hoses for leaks, cracks and 79
security.
ALL Examine the fuel cells, supports, tubing and hoses for leaks, cracks, and installation. 28
ALL Examine the armor for installation, buckling, and distortion. CSP−014
ALL Examine the rotor brake for installation and disc alignment. 63
Page 2
Revision 47
05-50-00
MAINTENANCE MANUAL
WARNING WARNING
D Discard components that are re D Discard components that are re
placed. The reuse of damaged assem placed. The reuse of damaged assem
blies and components is not allowed blies and components is not allowed
and can cause loss of life and the he and can cause loss of life and the he
licopter. licopter.
D Record in the Rotorcraft Log Book
D Record in the Rotorcraft Log Book (RLB) the reason for removal of an
(RLB) the reason for removal of an assembly, component, or detailed
assembly, component, or detailed part for overhaul, repair, or replace
part for overhaul, repair, or replace ment.
ment.
An assembly, component, or de
CAUTION tailed part that is removed due
4. Overspeed to a Main Rotor Sudden Stoppage – Level 2
for overhaul must be identified as such after
removal. Failure to discard components that
Overspeed is an incident in which the rotor are replaced can result in damaged equip
speed (NR) is more than the limits of the ment.
applicable Rotorcraft Flight Manual (RFM) or
Supplement (RFMS). Go to Table 2 when an 6. Sudden Stoppage
overspeed incident has occurred.
Sudden stoppage is a rapid decrease in the
rotation/speed of the main rotor, rotor drive
system, tail rotor, or anti-torque fan. Sudden
WARNING
stoppage causes damage more than the
specified repair limits of the maintenance
D Discard components that are re
manual.
placed. The reuse of damaged assem
blies and components is not allowed D Sudden stoppage of the main rotor and rotor
and can cause loss of life and the he drive system occurs when one or more of the
licopter. main rotor blades hit the ground, water,
snow, thick vegetation, or an object of
D Record in the Rotorcraft Log Book sufficient mass to cause deceleration.
(RLB) the reason for removal of an
assembly, component, or detailed D Sudden stoppage of the main rotor and rotor
part for overhaul, repair, or replace drive system can occur at the same time
ment. during a hard landing if the blades hit the
upper fuselage structure or the tailboom.
5. Overtorque D Sudden stoppage of the tail rotor is caused
when the tail rotor blades hit the ground,
water, snow, thick vegetation, or an object of
Overtorque is an incident where the torque sufficient mass to cause deceleration.
loads of the main transmission are more than
the allowed limits. Go to Table 3 when an Go to Table 4 when a sudden stoppage has
overtorque incident has occurred. occurred.
Page 3
MAINTENANCE MANUAL
Table 2. Conditional Inspections — Overspeed

IF OVERSPEED IS BETWEEN 523 AND 549 RPM (369D/E), OR 508 AND 533 RPM (369FF, 500N),
OR 106 AND 112 PERCENT (600N):
ALL Examine the main rotor blades for visible damage and distortion. 62
Examine the installation of the main rotor blade tip caps.
Examine all bond lines for separation.
D Remove a main rotor blade with a visible bond−line separation.
Examine the installation of the root doublers and attachment fittings.
Examine the installation of the main rotor blade dampers.
369D/E/FF Examine the tail rotor blades and hub for visible damage, free movement, and 64
installation.
500/600N Examine the NOTARR fan blades and hub for visible damage, free movement, and 64
installation.
ALL Examine the main rotor hub and strap pack assembly for damage. 62
IF OVERSPEED IS MORE THAN 549 RPM (369D/E), OR 533 RPM (369FF, 500N),
OR 112 PERCENT (600N):
ALL Remove the main rotor hub assembly for an overhaul inspection. MDHI
ALL Remove, replace, and scrap the main rotor blades. 62
500/600N Do an inspection of the anti−torque fan assembly. 64
369D/E/FF Remove the tail−rotor hub assembly for an overhaul inspection. 64
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Revision 47
05-50-00
MAINTENANCE MANUAL
Table 3. Conditional Inspections – Overtorque

AFTER MAIN TRANSMISSION OVERTORQUE BEYOND TRANSIENT LIMITS
ALL Do a freedom of movement check of the main transmission. 63
ALL Do a check of the main transmission chip detectors for metal particles. 63
Do the chip detector check again after eight (8) hours of operation.
AFTER AIRSPEED 10% BEYOND VNE LIMIT
ALL Examine the main rotor blades for visible damage and distortion. 62
Examine the installation of the main rotor blade tip caps.
Examine all bond lines for separation.
D Remove a main rotor blade with a visible bond−line separation.
Examine the installation of the root doublers and attachment fittings.
Examine the main rotor hub assembly and strap pack assembly for damage.
Examine the installation of the main rotor blade dampers.
369D/E/FF Examine the tail−rotor blades and hub for visible damage, free movement, and 64
installation.
369D/E/FF Examine the horizontal stabilizer for skin damage and loose rivets. 53
Examine the tip plates and vertical stabilizer for damage to the leading and trailing
edges and damaged stressed side panels.
D Repair of a side panel is not allowed. Remove and replace a stressed/damaged
side panel.
Examine the mounting fittings for cracks and installation.
Torque the stabilizer attach bolts.
500/600N Examine the horizontal stabilizer for skin damage and loose rivets. 53
Examine the vertical stabilizers for damage to the leading and trailing edges and
damaged side panels.
Examine the mounting fittings for cracks and installation.
600N Examine the gurney flap for damage. 53
ALL Examine the tailboom for visible deformation, loose or missing rivets, cracks, and 53
installation.
Examine the attachment points to the fuselage for cracks and installation.
ALL Examine the canopy glass for installation and damage. 53
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MAINTENANCE MANUAL
Table 4. Conditional Inspections – Sudden Stoppage

AFTER MAIN ROTOR BLADE/DRIVE SYSTEM SUDDEN STOPPAGE
NOTE: Use the inspections of After Main Rotor Drive System Sudden Stoppage − Level 1 first if there has been
a sudden stoppage of the main rotor drive system. The additional Level 2 inspections must be done as neces-
sary when specified in the Level 1 inspections.
After Main Rotor Drive System Sudden Stoppage – Level 1
ALL Do an inspection of main rotor blades. Fully examine the upper and lower root fittings 62
and attach lug areas. If the inspection finds that one or more blades have a
separation of the trailing−edge bond due to leading edge impact, the blade is bent, or
there is evidence of a significant impact, and the damage occurred with the engine
running, do the additional inspections in After Main Rotor Drive System Sudden
Stoppage – Level 2.
ALL Do the inspection of the main rotor hub and lead−lag link attach lugs. If the lead−lag 62
lug is broken or the pitch housing striker strip shows evidence of contact with the
main rotor hub and damage occurred the the engine running, do the additional
inspections in After Main Rotor Drive System Sudden Stoppage – Level 2.
ALL Do the Main Rotor Strap Pack Lamination Inspection. 62−20−00
62−20−60
ALL Do the Main Rotor Blade and Damper Attach Pin Disassembly and Special 62−10−00
Inspection. If a pin is found cracked or bent and damage occurred with the engine
running, do the additional inspections in After Main Rotor Drive System Sudden
Stoppage – Level 2.
ALL Do the Main rotor Damper and Attachments Inspection. If damage to a damper is 62−20−00
suspected, do the Main Rotor Damper Weight Loading and Extension Check. 62−20−60
ALL Do a Main Rotor Drive Shaft Inspection. If main rotor drive shaft is rejected for broken 63−10−00
shaft splines, straightness or sheared shaft, do the additional inspections in After
Main Rotor Drive System Sudden Stoppage – Level 2.
ALL Do an inspection of the overrunning clutch sprag assembly (ref. Detailed Inspection COM
After Cleaning).
CAUTION: Kamatic couplings are a balanced unit and cannot be disassembled.
ALL Examine all power−train drive shafts and couplings for distortion, breaks, cracks, 63
contact with bulkheads, and other damage.
ALL Examine the oil cooler blower assembly. 63
ALL Do a check of the main rotor transmission for freedom of movement. 63
Examine the main rotor transmission mounting flanges for cracks.
Do an check of the main rotor transmission chip detectors for metal accumulation.
Do the chip detector check again after eight (8) flight hours.
ALL Examine the main rotor flight controls. 67
ALL Examine the anti−torque system. 64
ALL Examine the engine mounts for installation, cracks, or misalignment. 71
ALL Examine the engine control linkage for bends, breaks, and correct alignment. 76
ALL Do an engine inspection (Ref. the special inspection requirements in the applicable 01
Rolls−Royce Operation and Maintenance Manual).
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Table 4. Conditional Inspections – Sudden Stoppage (Cont.)

After Main Rotor Drive System Sudden Stoppage – Level 2
ALL Do an overhaul of the main rotor hub. 62
ALL Remove, replace, and scrap the main rotor drive shaft. 63
ALL Do an overhaul of the main transmission assembly (Ref. CSP−COM−5). 63
ALL Remove, replace, and scrap the engine−to−transmission drive shaft. 63
ALL Do an overhaul of the overrunning clutch assembly (Ref. CSP−COM−5). 63
AFTER TAIL ROTOR BLADE STRIKE
After a tail rotor blade strike, do these inspections:
369D/E/FF If equipped with Bendix couplings, remove, replace, and scrap the couplings. 63
369D/E/FF Examine the tail rotor blades for dents, nicks, scratches, or skin separation. 64
369D/E/FF Examine the tail rotor flapping hinge bolt for damage. 64
369D/E/FF Do an inspection of the tail−rotor transmission for radial play and run−out of the output 63
shaft, cracks in mounting flanges, and do a check of the chip detector for metal
particles.
Do an overhaul of the tail−rotor transmission if there is possible damage.
369D/E/FF If equipped with Kamatics couplings: HMI−2:
D Do the Tail Rotor Drive Shaft Twist Inspection. If there are misaligned or missing 63−15−10
stripes, remove, replace, and scrap the drive shaft and Kamatics couplings, and do 63−25−10
an overhaul inspection of the tail−rotor transmission. COM:
63−25−20
369D/E/FF Remove the tail−rotor drive shaft. 63
D Examine the couplings for distortion and cracks.
D Examine the damper, damper bracket, and bulkheads for damage.
NOTE: If the damage is more than the allowable limits because of a blade strike in the above areas, do these
inspections:
369D/E/FF Examine the tail−rotor drive fork, pitch links, swashplate, hub and pitch control 64
bearing housing for obvious damage.
369D/E/FF Examine the upper fuselage and boom tail rotor control linkage. 67
If the tail rotor control rod is damaged, make sure that all the rod bulkhead grommets
are in place.
369D/E/FF Examine the aft frame of the tailboom for cracks and the boom skin for loosened or 53
popped rivets.
369D/E/FF Do a check of the main transmission chip detectors and the transmission lube pump 63
oil filter for metal particles.
369D/E/FF Examine the main rotor hub assembly and strap pack assembly for damage. 62
AFTER TAILBOOM STRIKE
If one or more main rotor blades strike the tailboom during blade rotation, do these inspections:
ALL Do the Main Rotor Blade Inspection. 62−10−00
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MAINTENANCE MANUAL
Table 4. Conditional Inspections – Sudden Stoppage (Cont.)

ALL If there is so much damage that the main rotor blade(s) must be replaced, examine 62
the complete main rotor and scissors assembly, and the droop stop mechanism and
strap packs, for damage.
369D/E/FF Remove and examine the tail rotor drive shaft for impact damage, buckling. or 63
twisting.
Remove and examine the couplings for cracks and distortion.
Remove and examine the damper, damper bracket, and bulkheads for damage.
369D/E/FF If the damage is more than the allowable limit and the tail−rotor drive shaft must be 63
replaced, also replace the couplings and do the overhaul inspection of tail−rotor
transmission (Ref. CSP−COM−5).
CAUTION: All tailboom damage is significant (Ref. CSP−SRM−6).
ALL Do the Tailboom Inspection. 53−40−00

Do a dye−check or remove and scrap the tailboom attach bolts. 53−40−30
ALL Examine the structure forward of the tailboom attachment for evidence of sheet metal 53
yielding or buckling. Fully examine the right side forward of the tailboom attachment
for signs of buckling (Ref. CSP−SRM−6).
ALL Do the Upper Fuselage and Tailboom Control Linkage Inspection. 67
ALL Do the Horizontal Stabilizer Inspection. 53−50−10
Do the Vertical Stabilizer Inspection. 53−50−30
369D/E/FF Tail rotor assembly. 64
369D/E/FF Tail rotor transmission for radial play and run−out of output shaft; cracks in mounted 63
flanges and chip detector for metal particles.
ALL Main rotor brake, if installed, for condition and alignment of brake disc, calipers and 63
security of attachment.
If a tailboom strike occurred during the POWER ON condition, also do these inspections:
ALL Remove and inspect main rotor drive shaft, main transmission drive shaft and 63
couplings for distortion, breaks, cracks and other damage.
ALL Main transmission chip detectors and transmission lube system oil filter for metal 63
particles. Re−inspect chip detectors and oil filter after 8 hours of engine operation.
Examine transmission mounting flanges for cracks.
ALL Engine air inlet and plenum chamber for foreign objects; motor engine and check for 71
unusual noise. 76
Engine mounts for security, cracks, or distortion.
Engine control linkage for bends, breaks and proper operation.
500/600N Examine the stationary thruster attachment flange for damage. 53
ALL Examine the tailboom attachment area for damage. 53
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D There was an engine flame-out caused by

WARNING fuel exhaustion.
D Discard components that are re
D There was an engine shutdown with the
placed. The reuse of damaged assem
emergency fuel shutoff valve.
blies and components is not allowed
and can cause loss of life and the he D The main transmission has been removed
licopter. and replace because of an internal transmis
D Record in the Rotorcraft Log Book sion failure.
(RLB) the reason for removal of an
assembly, component, or detailed D The CAUTION light for the fuel filter came
part for overhaul, repair, or replace ON.
ment.
D There is a new or replacement main rotor
7. Lightning Strike hub installed.
If the helicopter has been struck by lightning, D There is a new battery to be installed (do
or you think the helicopter has been struck by the procedure before the battery is in
lightning, do the inspections in Table 5. stalled).
8. Special Inspections D The main rotor drive shaft has been
Complete the inspections in Table 6 if: removed.
D A chip detector light came ON. D The impending bypass indicator for the
369F5100 main transmission lubrication
D There has been an engine removal and pump “pops”.
replacement because of an internal engine
failure. D The engine has been removed.
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MAINTENANCE MANUAL
Table 5. Conditional Inspections After a Lightning Strike

IF A LIGHTNING STRIKE IS FOUND ON THE HELICOPTER EXTERIOR
ALL Examine the fuselage interior and exterior, landing gear, rotor systems, and ground 25
wire connection for burn marks, cracks, pitting, or other signs of high temperature 32
stress, to find the lightning entry and exit points. 53
ALL Follow the path of the lightning strike with a magnetometer, if possible.
ALL Do a check of the magnetic compass for accuracy (the degree of inaccuracy can be 95
an indicator of the severity of the strike).
ALL Examine all wiring. 96
ALL Examine the antenna(s) for burns and pitting. 97
ALL Examine all electrically operated components and lighting systems for damage. 96
ALL Examine the communications and navigation equipment for damage. 97
ALL If these inspections above show that major damage has occurred, do these tests: 96
D Do a bench test of all avionics, electrical systems, and components. 97
D Do a continuity check on all wiring and cables.
D Do a Voltage Standing Wave Ratio (VSWR) check on all antennas, antenna
cables, and connectors.
369FF Look for indications of a lightning strike of the GMU 44 magnetometer:
D Examine the GMU 44 magnetometer body and mount for scorching, soot, melting, * Ref Note
pitting, denting, or discoloration.
D Examine P441 and J441 for melting or pin damage.
D Examine the cable overbraid for pinching, melting or evidence of arcing.
D Examine the lug for evidence of arcing and verify the lug is still secured to the
overbraid.
D Examine electrical bonding between the GMU 44 overbraid and adjacent aircraft
structure. Make sure the resistance is less than 5 mW..
*NOTE: If one or more of the conditions show an indication of a lightning strike,
replace the overbraid assembly (Ref. G500 TXi Part 23 AML STC Installation
Manual).
ALL Do the specified inspections/replacements as necessary.
500/600N Do a check of the fan transmission and interconnecting drive shafts for magnetism 63
and/or burns.
500/600N If previous drive train items show magnetism, overhaul the fan transmission. COM
500/600N Examine the anti−torque fan and components for evidence of arcing and magnetism; 64
replace parts with evidence of arcing or magnetism.
500/600N Examine the bellcrank and control rod for indications of arcing. 67
Remove, replace, and discard parts with indications of arcing.
500/600N Examine the thruster cables, bellcranks, and control tubes for indications of arcing. 67
500/600N Examine thruster rollers for indications of arcing. 53
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MAINTENANCE MANUAL
Table 5. Conditional Inspections After a Lightning Strike (Cont.)

ALL Do a check of the oil cooler blower assembly and overrunning clutch for residual
magnetism.
Remove, replace, and discard parts with residual magnetism, as necessary.
ALL Examine the oil cooler assembly for damage.
Remove, replace, and discard parts with damage, as necessary.
ALL If previous drive train items show magnetism, overhaul the transmission.
ALL If the overrunning clutch assembly shows magnetism, remove the engine and the
overrunning clutch for an overhaul.
ALL Do a ground run operational check on the helicopter. 67
Do a functional check of the flight control system, and all avionics, electrical, lighting, 96
communication, and navigation systems 97
ALL Repair damage and replace damaged components as necessary.
IF A LIGHTNING STRIKE IS FOUND ON THE MAIN ROTOR SYSTEM
ALL Examine the blades for damage such as burns, pitting, skin separation, etc. 62
Remove, replace, and scrap the damaged blade(s).
ALL Remove hub assembly and return for overhaul. 62
ALL Do an inspection of all bearings in the fixed and rotating control system located on the 62
main rotor mast.
ALL Do an overhaul of the transmission assembly. 63
ALL Examine the main rotor mast and drive shaft for burns. 63
ALL Do a check of the drive shafts for residual magnetism. 63
D If a drive shaft is magnetized or damaged, remove, replace, and scrap it and 71
remove the engine for overhaul.
IF A LIGHTNING STRIKE IS FOUND ON THE TAIL ROTOR SYSTEM
369D/E/FF Examine the blades for damage such as burns, pitting, skin separation, etc. 64
D If there are indications of damage, remove, replace, and scrap the damaged
blade(s).
369D/E/FF Do an overhaul of the tail−rotor assembly. COM
369D/E/FF Scrap pitch change links and pitch change assembly. 64
369D/E/FF Do an inspection of the bellcrank and control rod for indications of arcing. 67
Remove, replace, and scrap parts with indications of arcing.
369D/E/FF Do an overhaul of the tail−rotor gearbox. COM
369D/E/FF Do an inspection of the tail−rotor drive shaft and the drive−shaft damper for 63
magnetism and/or burns.
369D/E/FF Do a check of the oil cooler blower assembly, overrunning clutch and tail rotor drive 63
shaft couplings for residual magnetism. Replace as necessary.
369D/E/FF Examine the oil cooler assembly for damage. Replace as necessary. 63
369D/E/FF If the old drive−train components have an indication of magnetism, do an overhaul of COM
the transmission.
369D/E/FF If the overrunning clutch assembly has an indication of magnetism, remove the 71
engine and overrunning clutch for overhaul. COM
369D/E/FF Examine the engine mounts and fittings for damage. Replace as necessary. 71
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MAINTENANCE MANUAL
Table 6. Special Conditional Inspections

AFTER CHIP DETECTOR LIGHT COMES ON
ALL Remove the chip detector leads, in turn, to find which chip detector caused the 63
indicator to light. 71
Remove and do an inspection of the applicable chip detector for metal accumulation.
ALL If an engine chip detector caused an indicator to light, refer to the applicable 01
Rolls−Royce Engine Operation and Maintenance Manual.
ALL If a main transmission chip detector caused an indicator to light, do a Main 63−21−00
Transmission Filter Replacement.
ALL If the metal chips measure no longer than 0.125 inch (3.18 mm), drain and refill main 12
transmission, tail rotor transmission or fan transmission as applicable with new oil.
Do a check again of the applicable chip detectors after four (4) flight hours.
AFTER ENGINE CHANGE BECAUSE OF INTERNAL ENGINE FAILURE
NOTE: Oil coolers are NOT cleanable and must be scrapped if an engine failure produces metal and NO scav-
enge oil filter is installed or if a scavenge oil filter is installed and indicates a by−pass has occurred.
ALL Remove, flush, and install the oil tank. 12
Flush all lines, fittings, and associated components. 79
Remove and reverse flush or replace the engine oil cooler.
CAUTION: Failure to bleed fuel system can result in unexpected engine flameout or power loss.
ALL Bleed the fuel system. 28

ALL Remove and install a new scavenge oil filter element (if installed). 79
AFTER ENGINE FLAMEOUT CAUSED BY FUEL EXHAUSTION
ALL Bleed the fuel system to remove entrapped air. 28
AFTER ENGINE SHUTDOWN WITH EMERGENCY FUEL SHUTOFF VALVE
ALL Bleed the fuel system to remove entrapped air. 28
AFTER MAIN TRANSMISSION CHANGE BECAUSE OF INTERNAL TRANSMISSION FAILURE
ALL Reverse flush or replace transmission oil cooler, all lines, fittings, and associated 63
components.
AFTER FUEL FILTER CAUTION LIGHT COMES ON
ALL Do a check of the FUEL FILTER caution light and circuit for discrepancies. 95
ALL Do a Fuel Filter (Bypass) Caution Light Pressure Switch Test. 28−00−00
ALL Remove and install a new engine−driven fuel pump filter. 01
Remove and clean the gas producer fuel control filter.
Clean and flush all lines and fittings.
Do a check of the bypass valve (Ref. the applicable Rolls−Royce Operation and
Maintenance Manual).
369D/E Examine the start pump inlet screen for contamination when large amounts of foreign 28
500N material are found in the engine driven fuel pump filter (or optional airframe fuel filter,
if installed).
ALL Do the Fuel Cell Inspection. 28−00−00
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Table 6. Special Conditional Inspections (Cont.)

AFTER NEW OR REPLACEMENT MAIN ROTOR HUB IS INSTALLED
ALL Do the Main Rotor Hub Droop Angle Check. 62−20−00
BEFORE INSTALLATION OF NEW BATTERY
ALL Do the Battery Charging – Deep Cycling Procedure. Repeat the deep−cycling 96−05−00
procedure one more time to make sure of the complete stabilization of battery.
AFTER MAIN TRANSMISSION DRIVE SHAFT IS REMOVED (ENGINE INSTALLED)
ALL Do a check of the overrunning clutch for the correct oil level. 12
AFTER COOLER BLOWER IS REMOVED
ALL Do the Cooling Blower Inspection (Disassembled). 63
Do a check of the belt tension and clearance after installation.
WHEN MAIN ROTOR DRIVE SHAFT IS REMOVED
ALL Do the Main Rotor Drive Shaft Inspection. 63−10−00
AFTER 369F5100 MAIN TRANSMISSION LUBRICATION PUMP IMPENDING BYPASS INDICATOR POPS
ALL Ref. Troubleshooting Power Train System 63−00−00
WHENEVER ENGINE IS REMOVED
ALL Remove the fire blanket above the engine and examine the airframe above the engine 53
for evidence of cracks.
WHENEVER FUEL CONTAMINATION IS FOUND
ALL This special condition inspection is for fuel lines with solid contamination (not water 28−00−00
contamination). Examine the connections and internal pathways of the fuel lines,
start pump or fuel pickup fitting, the fuel shutoff valve, drain valve, and the engine
filter inlet port.
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Chapter
06
Dimensions and
Areas
MAINTENANCE MANUAL
TABLE OF CONTENTS
06-00-00 Dimensions and Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Principal Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Airframe Stations Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Principal Dimensions - Model 369D . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Principal Dimensions- Models 369E . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 203. Principal Dimensions Model 369FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 204. Principal Dimensions - Model 500N . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 205. Principal Dimensions - Model 600N (Sheet 1 of 2) . . . . . . . . . . . . . . . 206
Figure 206. Station Diagram - Model 369D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 207. Station Diagram - Models 369E/FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 208. Station Diagram - Model 500N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 209. Fuselage Station Diagram - Model 600N . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 210. Aft Empenage Access Plugs - Model 600N . . . . . . . . . . . . . . . . . . . . . . 212
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Page ii
MAINTENANCE MANUAL
Section
06−00−00
Dimensions and
Areas
MAINTENANCE MANUAL
DIMENSIONS AND AREAS

MAINTENANCE PRACTICES
1. Principal Dimensions cm) forward of the fuselage nose for
Models 369E/FF. WL 0.00 is tangential
(Ref. Figure 201 for Model 369D, to bottom of fuselage at STA 90.61.
Figure 202 for Model 369E, Canted stations start at WL 0.00 unless
Figure 203 369FF, otherwise specified. The canted station
Figure 204 for 500N and is not the same distance from STA 0.00
Figure 205 for 600N) over its length, and should be referred
to in association with a waterline
2. Airframe Stations Locations reference.
(1). Reference is occasionally made to (3). For the 600 Series Helicopter, all
Fuselage Station (STA or FS), Fuselage dimensions are from three reference
Station Plug (P. STA or FSP) and points designated as STA 0.00, P. STA
Waterline (WL) throughout the manual. 0.00 and WL 0.00 for the fuselage/engi
P. STA or FSP refers to the stretched neering station references. STA 0.00 is
area or longer fuselage section of the 15.00 inches (38.1 cm) forward of the
600N as compared to the 500 Series fuselage nose. P. STA 0.00 is located at
Helicopter. Fuselage Station and the forward lower edge of the mid door
Waterline are the same as those (also designated as canted STA 78.50).
referred to in the other 500 Series All references outside of the designated
publications. To assist in locating P. STA areas are labeled STA or FS.
components being discussed, station Waterline 0.00 is tangential to bottom
diagrams are provided (Ref. Figure 206 of fuselage at fuselage station STA
for Model 369D, Figure 207 for Models 90.61. Canted stations start at water
369E/FF, Figure 208 for 500N and line 0.00 unless otherwise specified.
Figure 209 for 600N). Station and The canted station is not the same
Waterline references are also necessary distance from WL 0.00 over its length,
for weight and balance procedures (Ref. and should be referred to in association
Section. 08-10-00). with a waterline reference.
(2). For the 500 Series Helicopters, all (4). Measurements from a station repre
dimensions are from two reference sented by a rib, frame, or bulkhead that
points designated as STA 0.00 and WL is not accessible can be taken by noting
0.00. STA 0.00 is 28.00 inches (71.12 flange bend direction and compensating
cm) forward of the fuselage nose for on the correct side of visible external
Model 369D, and 15.00 inches (38.10 skin attachment rivet line.
Page 201
MAINTENANCE MANUAL
GENERAL NOTES:
1. HELICOPTER ON GROUND, MAX.
COMPRESSED DIMENSION: 6.8 IN.
(17.272 CM).
2. IF OPTIONAL EXTENDED LANDING
GEAR IS INSTALLED, ADD 0.63 FT.
(0.19 M) TO ALL VERTICAL DIMENSIONS.
8.2 FT. 7.2 FT.
(2.5 M) (2.2M)
0.76 FT.
(0.23 M)
26.41 FT. (8.06 M)
6.45 FT. 5.46 FT.

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

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

23.5 FT. (7.2 M)
G06−0000−201−1
Figure 201. Principal Dimensions − Model 369D
Page 202
MAINTENANCE MANUAL
GENERAL NOTES:
1. HELICOPTER ON GROUND WITH FULL
FUEL. TYPICAL ATTITUDE OF CARGO
DECK 4.7 DEGREES NOSE UP.
2. IF OPTIONAL EXTENDED LANDING GEAR
8.72 FT. IS INSTALLED, ADD 0.87 FT. (0.27 M) TO
(2.66 M) ALL VERTICAL DIMENSIONS.
7.65 FT.
(2.33 M)
1.27 FT.
(0.39 M)
30.81 FT. (9.40 M)

23.88 FT. (7.28 M)
6.43 FT.
(1.96 M)
8.15 FT.
(2.49 M) 8.4 FT.
(2.6 M)
6.77 FT.
(2.06 M) 4.58 FT.
(1.40 M) 2.0 FT.
(0.61 M)
22.42 FT. (6.84 M)

24.71 FT. (7.54 M)
G06-0000-202-1
Figure 202. Principal Dimensions− Models 369E
Page 203
MAINTENANCE MANUAL
GENERAL NOTES:
1. HELICOPTER ON GROUND WITH FULL FUEL.
TYPICAL ATTITUDE OF CARGO DECK 5.3
DEGREES NOSE UP.
2. IF OPTIONAL EXTENDED LANDING GEAR IS
INSTALLED, ADD 0.87 FT. (0.27 M) TO ALL
VERTICAL DIMENSIONS.
7.53 FT.
8.6 FT. (2.30 M)
(2.62 M)
1.15 FT.
(0.35 M)
4.57 FT. 5.43 FT.

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

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

25.46 FT. (7.77 M) 1.3 FT. (0.40 M)
G06−0000−203−1
Figure 203. Principal Dimensions Model 369FF
Page 204
MAINTENANCE MANUAL
GENERAL NOTES:
TYPICAL ATTITUDE OF CARGO DECK: 4.7 DEGREES
8.8 FT. NOSE UP.
(2.7 M) 2. IF EXTENDED LANDING GEAR IS INSTALLED, ADD
0.87 FT. (0.27 M) TO ALL VERTICAL DIMENSIONS.
7.7 FT.
(2.3 M)
27.35 FT.
(8.34 M)
6.3 FT.
(1.9 M)
4.6 FT. 6.5 FT.
(1.4 M) (2.0 M)
31.39 FT. (9.6 M)

24.9 FT. (7.6 M)
7.7 FT.
6.9 FT. (2.3 M)
(2.1 M)
1.4 FT.
(0.4 M)
G06−0000−204−1
Figure 204. Principal Dimensions − Model 500N
Page 205
MAINTENANCE MANUAL
27.5 FT
(8.4 M) DIA
6.6 FT
(2.0 M)
8.8 FT 4.6 FT
(2.7 M) (1.4 M)
36.9 FT
(11.3 M)
29.6 FT
(9.0 M)
9.7 FT
(2.9 M)
9.2 FT 7.8 FT 9.8 FT
(2.8 M) (2.4 M) (3.0 M)
2.4 FT
(0.7 M)
GENERAL NOTES:
TYPICAL ATTITUDE OF CARGO DECK 5.3 DEGREES NOSE UP.
2. HEIGHT ABOVE GROUND DIMENSIONS VARY WITH INSTALLED
EQUIPMENT, CENTER OF GRAVITY AND TERRAIN FEATURES.
3. ALL DIMENSIONS SHOWN DEPICT EXTENDED LANDING GEAR.
G06-0000-205-1
Figure 205. Principal Dimensions − Model 600N (Sheet 1 of 2)
Page 206
MAINTENANCE MANUAL
48 INCHES
(122 CM)
25 INCHES
(63 CM)
48 INCHES
(122 CM)
62 INCHES
(157 CM)
72 INCHES
(183 CM)
G06-0000-205-2
Figure 205. Principal Dimensions − Model 600N (Sheet 2 of 2)
Page 207
MAINTENANCE MANUAL
CANT STA STA STA STA

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

STA 44.65 56.85 84.79 96.42 108.04 119.67 137.50
0.00
STA STA CANT STA STA STA STA STA
50.50 64.37 78.50 90.61 102.23 113.85 124.00
WL
96.91
WL WL
55.34 54.17
CANT STA
209.78
CANT STA CANT STA CANT STA CANT STA
197.78 219.96 242.14 264.32
WL
26.67
CANT STA
273.00
CANT STA
281.12
FRAME BASE
NOTE:
WHEN MEASURING EXTERNALLY FROM RIVET LINES,
NOTE THE SIDE AT BULKHEAD OR FRAME INDICATED AS
THE STATION AND COMPENSATE FOR RIVET POSITION
IN THE ATTACHMENT FLANGE.
G06−0000−206−1
Figure 206. Station Diagram − Model 369D
Page 208
MAINTENANCE MANUAL
CANT STA
78.50
STA
108.50 STA STA
146.62 STA
164.87 185.89
CL CANT STA STA STA STA
124.00 137.50 155.75 174.00
MAST CANT STA
197.78
WL 76.70
WL 66.00
STA
15.00
WL
WL 45.36 49.37
CORNER
PILOT'S CL BEAM
SEAT
WL 21.50 WL 34.50
WL 32.00
WL 22.75 WL 11.98
WL 14.19 WL 13.10
JACKING POINT
STA 96.89, BL ±25.60
WL 0.00 WL 0.00
STA STA STA STA STA STA STA

STA
44.65 56.85 84.79 96.42 108.04 119.67 137.50
0.00 STA STA STA STA STA
50.50 64.37 90.61 102.23 124.00
CANT STA STA
78.50 113.85
WL 102.17
WL 96.91
STA 289.12 (369FF)
WL 55.34 WL 54.17
CANT STA
209.78 CANT STA 369FF ONLY
CANT STA CANT STA CANT STA 264.32
197.78 219.96 242.14
WL 26.67
CANT STA WL 25.46 (369E)
273.00 WL 22.36 (369FF)
CANT STA
281.12
NOTE: FRAME BASE
G06−0000−207−1
Figure 207. Station Diagram − Models 369E/FF
Page 209
MAINTENANCE MANUAL
STA
129.00
STA
132.90
STA
155.75
STA
124.75 STA STA
146.62 168.20
STA STA
137.50 CANT 174.00
CL
STA
MAST 159.97
WL 66.00
STA WL 60.00
15.00
WL 34.50
WL 22.75
WL 14.19 WL 13.10
JACKING POINT
STA 96.89, BL ±25.60
WL 0.00 WL 0.00
STA STA STA 96.42 STA STA STA

44.65 56.85 84.79 STA 108.04 119.67 137.50
STA
0.00 STA STA CANT STA STA 102.23 STA STA
50.50 64.37 78.50 90.61 STA 113.85 124.00
STA
AFT JACKING 315.00
POINT STA 275.40,
NOTE: BL 0.00, WL 41.00
G06−0000−208−1
Figure 208. Station Diagram − Model 500N
Page 210
MAINTENANCE MANUAL
NOTE 2 CL
NOTE 3
0 20 40 60 80 120 140 160 180 200 220 240 260 280 300 320 340
STA
100.00
STA
15.00
WL
83.00
WL
14.00
WL
0.00
MID
FORWARD JACK POINT AFT STA
JACK POINT JACK POINT 338.36
P.STA STA STA STA STA
18.76 96.90 124.00 168.66 303.30
30 IN.
STA
78.50
P.STA P.STA
STA 0.00 30.00
0.00
(NOTE 1)
NOTES:
1. STA. 0.00, 15 INCHES (381 MM) FORWARD OF NOSE OF AIRCRAFT.
2. THIS DIMENSION 15 INCHES (381 MM) AFT OF NOSE OF AIRCRAFT.
3. THESE DIMENSIONS IN INCHES.
G06-0000-209-1
Figure 209. Fuselage Station Diagram − Model 600N
Page 211
MAINTENANCE MANUAL
L137, R137
L153, R153
L167, R167
Î
Î
L166, R166
L158, R158
G06−0000−210−1
Item No. Name Permits Access To Qty. Type

L137 Plug Left forward upper longeron 1 Button Plug
R137 Plug Right forward upper longeron 1 Button Plug
L153 Plug Left upper longeron 1 Button Plug
R153 Plug Right upper longeron 1 Button Plug
L158 Plug Left lower longeron 1 Button Plug
R158 Plug Right lower longeron 1 Button Plug
L166 Plug Left lower attach fitting 1 Button Plug
R166 Plug Right lower attach fitting 1 Button Plug
L167 Plug Left upper attach fitting 1 Button Plug
R167 Plug Right upper attach fitting 1 Button Plug
Figure 210. Aft Empenage Access Plugs − Model 600N
Page 212
MAINTENANCE MANUAL
Chapter
07
Lifting and Jacking
MAINTENANCE MANUAL
TABLE OF CONTENTS
07-00-00 Lifting and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

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

Page ii
MAINTENANCE MANUAL
Section
07−00−00
Lifting and Jacking
MAINTENANCE MANUAL
LIFTING AND JACKING

1. Component Weights for Hoisting Table 203. Approximate Maximum Hoisting
Weights of Components − 500N
(Ref. Table 201 thru Table 204) The maximum
weights for large components that can require Wgt
hoisting are listed. Item Lb/kg
Tailboom (w/o empennage, thruster) 35/16
Use hoist with minimum 3500
CAUTION pound (1589 kg) capacity when Main rotor hub 92/42
hoisting complete helicopter. Use hoisting
Main transmission (wet) (369D25100) 105/48
equipment with minimum 20% overrate to
Main transmission (wet) (369F5100) 140/64
hoist heavier components of helicopter (Ref.
Table 201 thru Table 204 for approximate Engine (built−up) 207/94
weights).
Helicopter (less main rotor hub, 1314/597
Table 201. Approximate Maximum Hoisting swashplate, scissors and rotor blades)
Weights of Components − 369D/E
Helicopter (complete) 1542/700
Wgt
Item Lb/kg Table 204. Approximate Maximum Hoisting
Tailboom 18/8 Weights of Components − 600N
Main rotor hub 85/39 Wgt

Item Lb/kg
Main transmission (wet) (369D25100) 105/48
Main transmission (wet) (369F5100) 140/64 Tailboom (w/o empennage, thruster) 55/25
Engine (built−up) C20B 192/87 Main rotor hub (with dampers, pins) 107/49
Engine (built−up) C20R/2 207/94 Main transmission (wet) 140/64
Helicopter (less main rotor hub, 1153/523 Engine (built−up) C47 292/133
swashplate, scissors and rotor blades)
Helicopter (less main rotor hub, 1830/830
Helicopter (complete) 1361/618 swashplate, scissors and rotor blades)
Helicopter (complete) 2100/953
Table 202. Approximate Maximum Hoisting
Weights of Components − 369FF 2. Helicopter Hoisting
Wgt (Ref. Figure 201)
Item Lb/kg
Tailboom 23/10 Special Tools
(Ref. Section 91-00-00)
Main rotor hub 92/42 Item Nomenclature
Main transmission (wet) (369D25100) 105/48 ST201 Hoisting adapter
Main transmission (wet) (369F5100) 140/64 N/A Cable or Rope
Engine (built−up) 271/123

(1). Remove dome fairing (N/A 600N) from
Helicopter (less main rotor hub, 1369/622 main rotor hub and install hoisting
swashplate, scissors and rotor blades) adapter (ST201) on hub so that hoisting
eyebolts fit into slots on hoisting
Helicopter (complete) 1589/721 adapter.
Page 201
MAINTENANCE MANUAL
(2). Install quick release pins. (7). Secure tail rotor hub to Sta. 284
bellcrank with strap or rope (369D/E/
(3). Attach cable from overhead hoist to FF only).
adapter eye.
(8). Position one person to support tail of
(4). Secure a line to tailboom. Have assis helicopter.
tant hold line to keep helicopter from
swinging. (9). Position one person to accomplish
hookup to recovery helicopter.
(5). Hoist slowly and smoothly to maintain (10). Position one person in view of recovery
steady lifting force. helicopter to act as ground guide during
hookup.
3. Helicopter Sling Lifting
B. Helicopter Lifting
Follow below procedures for sling lifting the
helicopter. Tail of helicopter can come
WARNING down sharply if helicopter is
lifted abruptly.
Special Tools
(Ref. Section 91-00-00) Avoid dragging helicopter dur
Item Nomenclature
CAUTION ing lift before ground clearance
ST201 Hoisting adapter is obtained. Dragging helicopter can cause
extensive damage.
(1). Carefully lift helicopter. Ensure that
Sling-lift helicopter only when
CAUTION other means of recovery are not person at tail of helicopter is familiar
with above warning.
available. Ensure recovery helicopter has
adequate capabilities, performance and fuel (2). Transport recovery crew and removed
to accomplish sling-lift recovery. Ensure re equipment to landing site before
covery crew has experience level to assure recovery helicopter with lifted helicop
optimum performance at assigned positions. ter arrives.
Do not attempt lifting or lowering during
adverse wind or weather conditions. C. Helicopter Landing
A. Helicopter Preparations (1). Indicate wind direction with smoke

cannister.
Prepare helicopter to be lifted before attempt (2). Ground guide recovery helicopter to
ing lift to avoid damage or loss of equipment hover into wind before lowering begins.
during flight.
Do not attempt lowering if heli
(1). Remove dome fairing from main rotor CAUTION copter is spinning.
hub (N/A 600N).
(3). Lower helicopter.
(2). Remove main rotor blades (Ref. Section
62-10-00). (4). Restrain and support tail of helicopter
as it contacts ground.
(3). Replace and secure blade damper bolts
Ground guide must signal re
and attaching pins. CAUTION covery helicopter to move to one
(4). Tape elastomeric damper to pitch side before dropping sling or helicopter win
housing. dow damage can occur.
(5). Signal recovery helicopter to drop sling.
(5). Install hoisting adapter (ST201).
(6). Remove sling and hoist adapter.
(6). Attach lifting straps or swivel-equipped
cable slings that clear lead by 10 feet (7). Inspect recovered helicopter to deter
(3.048 M) to hoisting adapter. mine condition.
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MAINTENANCE MANUAL
(8). Inspect main rotor blades prior to (1). Install jack fittings (ST202) in fuselage
installation for damage caused during jacking points. Secure jack fittings with
removal and transportation (Ref. locking pins located in fuel cell access
Section 62-10-00). doors.
4. Helicopter Jacking
NOTE: When jacking the 600N helicopter, only
(Ref. Figure 201) Provisions for jacking use the forward and aft jacking points.
helicopter are provided by two (369D/E/FF -
500N) or four (600N) forward (side) jacking
point fittings and an aft jacking pad. The aft (2). Place suitable jacks (ST203 or ST204)
jack pad locations differ for the 369D/E/FF and under jack fittings and AFT jacking
the 500/600N helicopters. pad.
Special Tools
(Ref. Section 91-00-00) NOTE: If helicopter is jacked from one side
Item Nomenclature only, in next step, a cushioned saddle-type
support should be placed under tailboom at
ST202 Jack fittings
aft jacking pad location for extra stability.
ST203 Hydraulic jack: 1-5 ton (900-4500 kg)
ST204 Hydraulic jack: 80 inch (203 cm) leg
(3). Raise helicopter to desired height.
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MAINTENANCE MANUAL
HUB FAIRING
SUPPORT
HOISTING EYEBOLTS
(3 PLACES)
HOISTING QUICK RELEASE PINS

ADAPTER (3 PLACES)
HOISTING
NOTE: HUB SUPPORT

REMOVED FOR CLARITY.
Figure 201. Hoisting and Jacking Helicopter (Sheet 1 of 3)
Page 204
MAINTENANCE MANUAL
AFT JACKING PAD

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

(STA 275.4) (500N)
JACK FITTING
JACKING
G07-0001-2A
Page 205
MAINTENANCE MANUAL
NOTE
HOISTING
ADAPTER
NOTE
NOTE
HOISTING
RELEASE PIN
(3 PLACES)
LOCKPIN
HOISTING EYEBOLT
(3 PLACES)
JACK FITTING
HOISTING
VIEW ROTATED
AFT JACKING PAD

(STA 303.3) (600N)
JACKING
NOTE: USE APPROPRIATE JACKING POINT 6G07-005

ACCORDING TO C/G OF HELICOPTER.
Page 206
MAINTENANCE MANUAL
Chapter
08
Leveling/Weight and
Balance
MAINTENANCE MANUAL
TABLE OF CONTENTS
08-00-00 Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Helicopter Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Leveling Helicopter (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
08-10-00 Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. General Weight and Balance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Approved Center of Gravity Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Helicopter Weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Helicopter Weighing Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Preparation for Weighing - Electronic Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
C. Helicopter Weighing - Electronic Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
D. Preparation for Weighing - Mechanical Scales Method
(369D/E/FF - 500N Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
E. Weighing Procedures - Mechanical Scales Method
(369D/E/FF - 500N Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
F. Longitudinal CG Determination for Unadjusted Net Weight
(369D/E/FF - 500N Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
G. Lateral CG Determination for Unadjusted Net Weight . . . . . . . . . . . . . . . . . . . . . . 205
H. Basic Weight and CG Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 201. Balance Diagram - Model 369D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 202. Balance Diagram - Model 369E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 203. Balance Diagram - Model 369FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 204. Balance Diagram - Model 500N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 205. Balance Diagram - Model 600N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 206. Weight and Balance Report Form (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 212
Figure 207. Surplus and Missing Items Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Figure 208. Basic Weight and Balance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Figure 209. Example 1 (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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MAINTENANCE MANUAL

Page ii
MAINTENANCE MANUAL
Section
08−00−00
Leveling
MAINTENANCE MANUAL
LEVELING
1. Helicopter Leveling (1). Suspend plumb line from bracket on
right side of controls tunnel at Sta.
(Ref. Figure 201) Leveling is accomplished by 92.64, BL+ 6.20.
positioning helicopter to align a plumb bob (2). Adjust plumb line swing to leveling
with register marks on the target plate on target plate on floor of passenger/cargo
cargo compartment floor. compartment.
(3). With weight of helicopter supported by
Special Tools load cells of electronic weighing kit or
(Ref. Section 91-00-00) jacks (ST203), as applicable, adjust
Item Nomenclature appropriate jack until plumb line is
N/A Plumb bob (commercially available) centered (Ref. Section 07-00-00,
Helicopter Jacking).
N/A Twine
N/A Electronic weighing kit (a). Adjust side jacks to level helicopter
laterally.
ST202 Jack fittings
ST203 Hydraulic jack: 1-5 ton (900-4500 kg) (b). Adjust tailboom jack to level helicop
ter longitudinally.
(c). Recheck lateral and longitudinal
NOTE: Access to plumb line support bracket levels until plumb bob exactly aligns
and target plate on floor of passenger/cargo with marks on target plate.
compartment requires removal of trim on
right side of controls tunnel, and floor carpet (4). After leveling helicopter, remove plumb
in aft compartment (Ref. Section 25-30-00, bob, reinstall trim and carpet, and close
Carpeting). compartment door.
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MAINTENANCE MANUAL
AFT JACKING PAD

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

(STA 275.4) (500N)
RIGHT EDGE OF
PLUMB LINE CONTROL TUNNEL
SUPPORT CLIP
JACK FITTING
PLUMB LINE
JACKING
TARGET PLATE
LEVELING
G08-0001B
Figure 201. Leveling Helicopter (Sheet 1 of 2)
Page 202
MAINTENANCE MANUAL
PLUMB BOB SUPPORT
AFT JACKING POINT
JACKING
PLUMB LINE
TARGET
PLATE
LOCKPIN
LEVELING
JACK FITTING
JACKING
(FORE AND MID POINTS ARE TYPICAL)
6G08−041A
Figure 201. Leveling Helicopter (Sheet 2 of 2)
Page 203
MAINTENANCE MANUAL
Page 204
MAINTENANCE MANUAL
Section
08−10−00
Weight and Balance
MAINTENANCE MANUAL
WEIGHT AND BALANCE

1. General Weight and Balance Information NOTE: Weight and balance information for op
tional equipment is found in the Initial In
(1). Removal or addition of fuel or equip stallation section for the optional equip
ment results in changes to weight and ment.
balance of a helicopter, and the permis
sible useful load is affected accordingly. Wt
These changes must be investigated to Parameter lb/kg
eliminate possible adverse effects on
the helicopter's flight characteristics. Certified Gross Weight (369D/E) 3000/1362
Certified Gross Weight (369FF) 3100/1407
(2). Basic weight and corresponding center
Certified Gross Weight (500N) 3350/1521
of gravity is determined by weighing
the helicopter without crew and Certified Gross Weight (600N) 4100/1860
payload; however, basic weight does Cargo Deck Capacity 1300/590
include trapped and unusable fuel, full (369D/E/FF − 500N)
operating fluids, lubricants, etc., and
installed equipment. Cargo Deck Capacity (600N) 1350/613
Cargo Deck Capacity not to exceed 115 pounds per
(3). 369D/E/FF - 500N - The longitudinal square foot.
reference datum is located 100 inches
Certified Gross Weights are for weight−on−skids.
(254 cm) forward of the main rotor
centerline. The lateral reference datum
is located along the longitudinal A. Approved Center of Gravity Limits
centerline of the helicopter. The vertical
reference datum is located at a point (Ref. PFM)
100 inches (254 cm) below the center
of the main rotor blades. B. Terminology
Following are terms with definitions, used

(4). 600N - The Weight and Balance when determining helicopter weight and
longitudinal reference datum is located balance:
100 inches (254 cm) forward of the
main rotor centerline or 15 inches (38.1 (1). Arm: The distance in inches from the
cm) aft of the aircraft nose. The Weight longitudinal (longitudinal arm) and
and Balance (longitudinal) Reference lateral (lateral arm) reference datum of
Datum is different from the Fuselage/ a part to the center of gravity (CG) of
Engineering Reference Datum (Ref. the part.
Section 06-00-00). The lateral refer
ence datum is located along the longitu NOTE: When viewing helicopter from rear,
dinal centerline of the helicopter. The items to left of lateral reference datum (cen
vertical reference datum is located at a ter line of helicopter) will be expressed as
point 83 inches (210.8 cm) below the having negative (-) lateral arm, and those
center of the main rotor blades. items to right of reference datum, a positive
(+) lateral arm.
(5). Refer to the following for balance
diagrams (2). Center of gravity (CG): A point on a
Figure 201 for Model 369D part where the part will be perfectly
Figure 202 for Model 369E balanced. Center of gravity is measured
Figure 203 for Model 369FF in inches from a known reference. It
Figure 204 for Model 500N can be determined using the following
Figure 205 for Model 600N. formula:
Page 201
MAINTENANCE MANUAL
CG(in) =
Moment (in−lb) CAUTION
Weight (lb)
D The controls access panel (aft side of Sta.
78.5 bulkhead) and the fuel cell access
(3). Moment: Product of weight of a part panels must be installed before jacking
and its arm, either longitudinal or helicopter.
lateral, and is expressed in inch- D 369D/E/FF - 500N: There are two meth
pounds (in-lb). ods approved for weighing the helicopter.
Longitudinal moment = weight x The preferred method is by using elec
longitudinal arm; tronic weighing equipment. If equipment
Lateral moment = weight x lateral arm. for electronic weighing is unavailable, the
second approved method, mechanical
scales, can be used.
(4). Reaction point: A fixed point on helicop D 600N: There is one method approved for
ter where weight of helicopter counter weighing the helicopter. The method is by
acts on a weighing device. The main using electronic weighing equipment.
reaction points are;
A. Helicopter Weighing Preparation
(a). ALL: Long. Sta. 96.9. The following items are required and should be
readily available prior to preparing and
weighing the helicopter, using the electronic
(b). 369D/E/FF - 500N: Lat. Sta. ±25.6. weighing method.
Special Tools
(c). 600N: Lat. Sta. ±26.0. (Ref. Section 91-00-00)
Item Nomenclature
ST202 Jack fittings
(d). 369D/E/FF: Tail reaction point is at
Long. Sta. 197.2, Lat. Sta. 0.0.
NOTE:
D Weigh helicopter without fuel if possible.
(e). 500N: Tail reaction point is at Long.
Sta. 275.4, Lat. Sta. 0.0. D 369D/E/FF - 500N: If fuel is drained from
low point in cell, 1.4 pounds (0.64 kg) of
trapped fuel at 93.5 inch (237.5 cm) arm
(f). 600N: Tail reaction point is at Long. will remain. If fuel is pumped out using
Sta. 303.3, Lat. Sta. 0.0. start pump, 3.7 pounds (1.68 kg) of
trapped (unusable) fuel at 93.5 inch
(237.5 cm) arm will remain.
2. Helicopter Weighing D 600N: If fuel is drained from low point in
cell, 1.6 pounds (0.73 kg) of trapped (un
usable) fuel at 93.5 inch (237.5 cm) arm
will remain. If fuel is pumped out using
start pump, 9.5 pounds (4.31 kg) of
Forms
trapped (unusable) fuel at 93.5 inch
Form Figure (237.5 cm) arm will remain.
Nomenclature No. No.
(1). If defueling is not possible, ensure that
Weight and Balance Report 765B 206 fuel cell is full.
Surplus and Missing Items 1702 207 (a). Fluid weights at 70° ambient are:
Basic Weight and Balance 885 208 Fuel (Jet A)
Record 6.75 Lb (3.06 kg) per U.S. gallon
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MAINTENANCE MANUAL
Fuel (JP-4) B. Preparation for Weighing − Electronic

6.50 Lb (2.95 kg) per U.S. gallon Method
Fuel (JP-5)
Special Tools
6.80 Lb (3.09 kg) per U.S. gallon
Item Nomenclature
Fuel (JP-8)
6.75 Lb (3.06 kg) per U.S. gallon N/A Electronic weighing kit/Platform Scales
N/A Roll-away table (with weighing platform)
PRC Fuel (No 3) N/A Plumb Bob
6.75 Lb (3.06 kg) per U.S. gallon ST203 Hydraulic jack: 1-5 ton (900-4500 kg)
Lubricating Oil
7.70 Lb (3.50 kg) per U.S. gallon
(1). Position hydraulic jack (ST203) under
(2). De-fuel helicopter (Ref. Section each of main jacking points at Sta. 96.9,
12-00-00). left and right sides of helicopter.
(3). Select weighing area that is enclosed (2). Position third hydraulic jack (ST203 or
and draft-free, with hard-surfaced ST204), on roll-away table if needed,
floor. and attached load cell at aft jacking
point of helicopter.
(4). Ensure that helicopter and weighing
area is cleared of all tools and debris. (3). Attach electronic weighing kit load cell
to each jack, and to weighing kit control
(5). 369D/E/FF - 500N: Verify that five unit.
main rotor blades are uniformly spaced
(72 degrees apart). (4). Turn electronic weighing kit power ON
600N: Verify that six main rotor blades and allow warm up time as specified in
are uniformly spaced (60 degrees electronic weighing kit operation
apart). manual.
(6). Check lubricant level at engine oil tank, (5). Calibrate and zero-in each load cell
main rotor gear box and tail rotor or fan prior to applying aircraft load (Ref.
gearbox sight gages. Add lubricant as Electronic Weighing Kit operation
necessary where less than full indica manual).
tion is noted (Ref. Section 12-00-00).
On the 600N helicopter, never
CAUTION exceed aft (tailboom) jack load of
(7). Record weight, arm and moment of
500 Lbs (227 kg).
surplus equipment on board helicopter
at time of weighing, which will not be (6). Exercise load cells by jacking all three
part of basic helicopter weight (Ref. jacks simultaneously until load is
Figure 206). supported by load cells at all jack point
stations. Do not check helicopter level
(8). Record weight, arm and moment of at this time.
missing equipment, to be installed after
weighing and prior to flight, that will (7). Lower helicopter to floor so that no load
become part of basic helicopter weight is supported by load cells.
(Ref. Figure 206).
(8). Repeat above steps (exercise load cells
(9). Install two fuselage jack fittings and lower helicopter) twice.
(ST202) for main weighing points at
Longitudinal Sta. 96.9 and Lateral Sta. (9). Recheck calibration and zero of each
±25.6. Secure fittings with pip pins. load cell.
Page 203
MAINTENANCE MANUAL
C. Helicopter Weighing − Electronic Method (Ref. Figure 209, example 1(b)). This
reading represents calibration correc
When preparations have been made (Ref. tion for each load cell. Depending on
Helicopter Weighing Preparation and Prepara sign shown on control unit (+ or -),
tion for Weighing - Electronic Method), weigh reading will have to be added to or
helicopter as follows: subtracted from reading in step (3).
above to obtain corrected weight for
Special Tools each cell (Ref. Figure 209, example
(Ref. Section 91-00-00) 1(c)).
Item Nomenclature
(6). Add corrected readings for all three
N/A Spirit level cells to determine total unadjusted net
N/A Plumb Bob weight of helicopter (Ref. Figure 209,
ST203 Hydraulic jack: 1-5 ton (900-4500 kg) example 1(c).
D. Preparation for Weighing − Mechanical
ST205 Inclinometer Scales Method (369D/E/FF − 500N Only)
When preparing to weigh helicopter using
(1). Operate three hydraulic jacks (ST203 mechanical scales, complete preliminary
and/or ST204) simultaneously until procedure (Ref. Helicopter Weighing Prepara
entire load is supported by load cells. tion), then perform the following:
NOTE: If conditions permit, helicopter can be
leveled using plumb bob instead of spirit Special Tools
level (Ref. Section 08-00-00). (Ref. Section 91-00-00)
Item Nomenclature
(2). After landing gear skids are clear of
floor, level helicopter as follows: N/A Roll-away table (with weighing platform)
N/A Beam platform scales (two), 1000 lb. (450
(a). Remove main rotor hub fairing (Ref. kg) capacity with current calibration
Section 62-20-00) (N/A 600N). N/A Platform scale, 300 lb. (135 kg) capacity
(b). Check lateral level by placing spirit with current calibration
level on main rotor mast, with axis of ST202 Jack fittings
spirit level 90 degrees to longitudinal ST203 Hydraulic jack: 1-5 ton (900-4500 kg)
axis of helicopter. Adjust left or right ST204 Hydraulic jack: 80 inch (203 cm) leg
jack at main jack points, as required,
to center bubble in spirit level.
(1). Check 1,000 lb. (450 kg) capacity scales
(c). Place protractor or inclinometer for zero.
(ST205) on main rotor mast so that
its axis is parallel to longitudinal axis (2). Place 300 lb. (135 kg) capacity scale on
of helicopter. Adjust jack at aft roll-away table with weighing platform,
jacking point until protractor or and check zero on scale.
inclinometer shows 3 degrees forward (3). Hoist helicopter so that main landing
tilt. gear skids are sufficiently clear of floor
(d). Reinstall hub fairing (N/A 600N). to enable 1,000 lb. (450 kg) capacity
beam platform scales to be rolled under
(3). Record reading shown on weighing kit main skids on left and right sides.
control unit for each load cell (Ref.
Figure 209, example 1(a)). (4). Roll 1,000 lb. (450 kg) capacity beam
platform scales under main skids and
(4). Lower helicopter to floor by bleeding off position so main jack fittings (ST202) at
jacks, and clear load cells. Sta. 96.9 are on centerline of scale.
(5). Record reading on control unit for each (5). Place jack (ST203) on 300 lb. (135 kg)
load cell under NO LOAD condition capacity platform scale (67). Position
Page 204
MAINTENANCE MANUAL
roll-away table so that jack and 300 weight at each reaction point (Ref.
pound capacity scale are directly below Figure 209, example 1(b)).
AFT jacking point.
(9). Subtract total tare weight for the three
(6). Lower helicopter so its weight is reaction points obtained in step h above
supported by scales. from weight recorded in step c above to
obtain total unadjusted net weight of
(7). Place jack on each 1,000 lb. (450 kg) helicopter (Ref. Figure 209, example
capacity platform scale, inboard of main 1(c)).
skids and directly below main jacking
points at Sta. 96.9. F. Longitudinal CG Determination for
Unadjusted Net Weight (369D/E/FF − 500N
E. Weighing Procedures − Mechanical Only)
Scales Method (369D/E/FF − 500N Only)
(1). Multiply net weight obtained at each
Once preparations have been completed (Ref. jacking point by its longitudinal arm, to
Helicopter Weighing Preparation and Prepara obtain a moment (Ref. Figure 209,
tion for Weighing - Mechanical Scales Meth example 1(d)).
od), weigh helicopter as follows: (2). Add three moments determined in step
(1). Operate jacks (ST203 and/or ST204) (1). to calculate total moment (Ref.
simultaneously until helicopter is Figure 209, example 1(e)).
supported only by jacks at right and left (3). Divide total moment obtained in step
Sta. 96.9 and AFT reaction points. (2). by total unadjusted net weight, to
determine longitudinal CG (Ref.
NOTE: If conditions permit, helicopter can be Figure 209, example 1(f)).
leveled using plumb bob instead of spirit
level (Ref. Sec. 08-00-00). G. Lateral CG Determination for Unadjusted
Net Weight
(2). With main skids clear of 1,000 lb. (450
kg) capacity platform scales, level NOTE: Lateral CG is not critical with normal
helicopter (Ref. Helicopter Weighting - internal loading. Certain optional equip
Electronic Method). ment, such as an external cargo hook, can
induce lateral CG outside lateral CG limits,
(3). Record weight shown on scale at each if weight and CG control is not provided.
reaction point (Ref. Figure 209, exam However, the Initial Installation section for
ple 1(a)). each optional equipment installation pro
vides complete instructions on lateral CG
(4). Simultaneously bleed off hydraulic control, to ensure operation within ap
jacks until helicopter skids contact proved limits.
1,000 lb. (450 kg) platform scales, and
total weight of helicopter is supported (1). Multiply net weight for each jacking
by scales and AFT jack point. point by its lateral reaction point
(369D/E/FF - 500N: left main, -25.6;
(5). Remove jacks from 1,000 lb. (450 kg) right main, +25.6; and aft, zero)
capacity platform scales. (600N: left main, -26.0; right main,
+26.0; and aft, zero) to obtain moment
(6). Hoist helicopter until scales at right for each jacking point (Ref. Figure 209,
and left sides and jack at aft reaction example 1(g)).
point can be rolled clear of helicopter
(Ref. Section 07-00-00). (2). Add three moments determined in step
(1). above to calculate total moment
(7). Lower helicopter to floor. (Ref. Figure 209, example 1(h)).
(8). Weigh each jack on same scale jack (3). Divide total moment by total unad
occupied during helicopter weighing to justed net weight to determine lateral
get the tare weight. Record the tare CG (Ref. Figure 209, example 1(i)).
Page 205
MAINTENANCE MANUAL
H. Basic Weight and CG Determination moment of helicopter determined in

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

STA. 92.6
JIG POINT
3° AFT JACKING POINT
STA. 197.2 BL 0.00
STA. 174.0 STA.
BDH 284.0
ENGINE SECTION
REFERENCE FUEL CELL COMPARTMENT
BATTERY STA. STA.
DATUM
78.5 124.0
JIG POINT
MAIN JACKING POINT
STA. 96.9 BL ±25.6
G08-1001
Figure 201. Balance Diagram − Model 369D
Page 207
MAINTENANCE MANUAL
STA. STA.
78.5 ROTOR C 124.0
CG OF COPILOT/PASSENGER L
STA.
CARGO COMPARTMENT
100.0
STA.
15.00
STA.
174.0
+15.5
+12.2
0.0 REFERENCE DATUM
-12.2
-13.0
TWO-PLACE COCKPIT
(WITH DUAL CONTROLS)
CG OF PILOT
STA. STA.
73.3 105.0
STA. STA.
78.5 124.0
CG OF RIGHT SIDE ROTOR CL
FWD PASSENGER STA. CARGO COMPARTMENT
STA. 100.0
15.00
STA.
174.0
+15.5
+12.2
0.0 REFERENCE DATUM
-12.2
-13.0
THREE-PLACE COCKPIT
(WITH SINGLE CONTROLS)
CG OF FWD PASSENGER
CG OF AFT
CG OF PILOT PASSENGERS
STA. STA.
STA. 71.5 73.5 105.0
STA. STA. STA.
15.00 99.0 107.4
20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
LEVELING PLUMB
STA. 92.6
FIREWALL
3° JIG POINT
AFT JACKING POINT
STA. 197.2 BL 0.00
STA. 174.0 STA.
BDH 284.0
ENGINE SECTION
REFERENCE STA. STA. FUEL CELL JIG POINT
DATUM BATTERY 78.5 124.0 COMPARTMENT MAIN JACKING POINT
STA. 96.9 BL ±25.6
G08-1002
Figure 202. Balance Diagram − Model 369E
Page 208
MAINTENANCE MANUAL
STA. STA.
78.5 ROTOR CL 124.0
CG OF COPILOT/PASSENGER STA.
CARGO COMPARTMENT
100.0
STA.
15.00
STA.
174.0
+15.5
+12.2
0.0 REFERENCE DATUM
-12.2
-13.0
TWO-PLACE COCKPIT
(WITH DUAL CONTROLS)
CG OF PILOT
STA. STA.
73.3 105.0
STA. STA.
CG OF RIGHT SIDE 78.5 124.0
FWD PASSENGER ROTOR CL
STA. CARGO COMPARTMENT
100.0
STA.
15.00
STA.
174.0
+15.5
+12.2
0.0 REFERENCE DATUM

-12.2
-13.0 THREE-PLACE COCKPIT
(WITH SINGLE CONTROLS)
CG OF FWD PASSENGER CG OF AFT PASSENGERS

CG OF PILOT
STA. 71.5 STA. STA.
73.5 105.0
STA. STA. STA.
15.00 99.0 107.4
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
LEVELING PLUMB FIREWALL

STA. 92.6
3° JIG POINT
AFT JACKING POINT
STA. 197.2 BL 0.00
STA. 174.0 STA.
BDH 284.0
ENGINE SECTION
REFERENCE BATTERY STA. STA. FUEL CELL
DATUM 78.5 124.0 COMPARTMENT JIG POINT
MAIN JACKING POINT
STA. 96.9 BL ±25.6
G08-1003
Figure 203. Balance Diagram − Model 369FF
Page 209
MAINTENANCE MANUAL
ROTOR
STA CL STA
78.5 124.0
CARGO COMPARTMENT
CG OF COPILOT/ STA
PASSENGER 100.0
STA STA
15.0 168.8
+ 15.5 + 12.2
0.0 REFERENCE
DATUM
- 13.0 - 12.2
TWO-PLACE COCKPIT
CG OF PILOT WITH DUAL CONTROLS
STA STA
73.5 105.0
ROTOR
CL
STA STA
78.5 124.0
STA CARGO COMPARTMENT
CG OF COPILOT/ 100.0
PASSENGER
STA STA
15.0 168.8
+ 15.5 + 12.2
+ 0.8 REFERENCE
0.0 DATUM
CG OF CENTER
PASSENGER - 12.2
- 13.0
CG OF PILOT THREE-PLACE COCKPIT

STA WITH SINGLE CONTROLS
73.5 STA
STA STA 105.0
15.0 STA STA 71.5
28.0 100.0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
3°
LEVELING PLUMB OIL TANK - RH SIDE

STA 92.6
FIREWALL
REFERENCE DATUM
JIG POINT
ENGINE SECTION AFT JACKING POINT
STA 275.4
FUEL CELL
COMPARTMENT
STA STA
78.5 124.0
JIG POINT
FWD JACKING POINT
STA 96.9
G08-1007
Figure 204. Balance Diagram − Model 500N
Page 210
MAINTENANCE MANUAL
CG OF PILOT OR
COPILOT/PASSENGER 7‐PLACE SEATING,
TWO‐PLACE COCKPIT WITH DUAL CONTROLS,
AFT‐FACING MID‐CABIN SEAT
+ 15.0 + 12.2
MID SEAT
0.00 0.00 REFERENCE DATUM
- 13.0 - 12.2
- 15.0
STA
STA
70.4
41.50
8‐PLACE SEATING,
THREE‐PLACE COCKPIT WITH SINGLE CONTROLS,
MID SEAT FWD‐FACING MID‐CABIN SEAT
0.00 0.00 REFERENCE DATUM
STA STA STA

43.50 77.1 105.0
PASSENGER/CARGO
COMPARTMENT
THIS DIMENSION 15 INCHES

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

POINT STA 303.3
WEIGHT AND BALANCE
COMPARTMENT
REFERENCE DATUM
JIG POINT
MID JACKING POINT
STA 96.9
JIG POINT
FORWARD
JACKING POINT P.STA 18.76 OR
67.40 INCHES FROM DATUM 6G08-007B
Figure 205. Balance Diagram − Model 600N
Page 211
MAINTENANCE MANUAL
WEIGHT AND BALANCE REPORT

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

WEIGHING SCALE READING CALIBRATION WEIGHT ARM ARM MOMENT MOMENT
POINTS (LBS) CORRECTION (LBS) (INCHES) (INCHES) (INCH−LBS) (INCH−
(LBS) LBS)
Left Main 96.9 −26.0
Right Main 96.9 +26.0
Tail 303.3 0.0
TOTAL UNADJUSTED NET WEIGHT
Less: Weight of Surplus Equipment (See Table 1) −

Plus: Weight of Missing Require Equipment (See Table 1) +
TOTAL BASIC WEIGHT
FUEL/OIL ABOARD AT TIME OF WEIGHING:
EMPTY FULL
FUEL
OIL, ENGINE
OIL, MAIN GEARBOX
OIL, TAIL GEARBOX
FORM 765B (3/99) Page 1 of MD Helicopters Inc.
Figure 206. Weight and Balance Report Form (Sheet 1 of 2)
Page 212
MAINTENANCE MANUAL
MODEL SERIAL NO. REGISTRATION NO._____________________DATE
EXAMPLES OF FORWARD, AFT AND LATERAL LOADING

LONG. LONG.
EXAMPLE 1, FORWARD
WEIGHT
ARM MOMENT
(LBS)
(IN.) (IN. LB.)
BASIC WEIGHT
PILOT 43.5
COPILOT 43.5
FULL FUEL QUANTITY
GROSS WEIGHT (CRITICAL FUEL) − FWD C.G.
APPROVED FWD C.G. LIMIT FOR EXAMPLE 1 GROSS WEIGHT * INCHES.
LONG. LONG.
EXAMPLE 2, AFT
WEIGHT
ARM MOMENT
(LBS)
(IN.) (IN. LB.)
BASIC WEIGHT
PILOT
GROSS WEIGHT (ZERO FUEL) − AFT C.G.
APPROVED AFT C.G. LIMIT FOR EXAMPLE 2 GROSS WEIGHT * INCHES.
LATERAL LATERAL
EXAMPLE 3, LATERAL
WEIGHT
ARM MOMENT
(LBS)
(IN.) (IN. LB.)
BASIC WEIGHT
PILOT
GROSS WEIGHT (ZERO FUEL) − LATERAL C.G.
APPROVED LATERAL C.G. FOR EXAMPLE 3 GROSS WEIGHT * INCHES.
SEE FLIGHT MANUAL, SECTION 6, FOR C.G. LIMITS AT GROSS WEIGHT

Form 765X (3/99) Page _________ of __________ MD Helicopters, Inc.
Figure 206. Weight and Balance Report Form (Sheet 2 of 2)
Page 213
MAINTENANCE MANUAL
TABLE 1
SURPLUS AND MISSING EQUIPMENT
MODEL SERIAL NO. REGISTRATION NO. DATE
WEIGHT ARM − INCHES MOMENT − IN/LBS
EQUIPMENT − ITEM LBS LONG LATR LONG LATR
SURPLUS EQUIPMENT TOTAL: ( 1.3 ) ( 96.9 ) ( ) ( 126 ) ( )
JACK PADS (2) 1.3 96.9 126
MISSING EQUIPMENT TOTAL: ( 15.9 ) ( 97.4 ) ( ) ( 1549 ) ( )
ONE QT. ENGINE OIL 2.1 133.4 280

UNUSABLE FUEL 12.0 93.0 1116
FLIGHT MANUAL 1.8 85.0 153
FORM 1702 (3/99) Page of MD Helicopters Inc.
Figure 207. Surplus and Missing Items Report
Page 214
BASIC WEIGHT AND BALANCE RECORD
( CONTINUOUS HISTORY OF CHANGES IN STRUCTURE OR EQUIPMENT AFFECTING WEIGHT AND BALANCE )
AIRCRAFT MODEL SERIAL NUMBER REGISTRATION NUMBER
PAGE OF
WEIGHT CHANGE RUNNING TOTAL

ITEM NO. ADDED (+) REMOVED (−) BASIC AIRCRAFT
DATE DESCRIPTION OF ARTICLE OR MODIFICATION
LONG MOMENT1 LONG MOMENT1 LONG MOMENT
WEIGHT ARM WEIGHT WEIGHT
IN OUT IN .LB. ARM IN .LB. ARM IN .LB.
BASIC WEIGHT − DELIVERY 1510.0 109.0 164561
MAINTENANCE MANUAL
08-10-00
Figure 208. Basic Weight and Balance Record
1 ENTER CONSTANT USED BELOW LINE
FORM HOQ 014b ( REV 10/01 ) MD HELICOPTERS INC
G08−000−208−1
Revision 23
Page 215
CSP-HMI-2
MAINTENANCE MANUAL
Determining total unadjusted net weight and longitudinal CG - 369D/E/FF

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

(a) (b) (c) (d) (g)
Tare or
Scale Calibration Net Longitudinal Lateral Longitudinal Lateral
Weighing Reading Correction Weight Arm Arm Moment Moment
Points (lbs) (lbs) (lbs) (inches) (inches) (inch−lb) (inch−lb)
Left Main 1020.0 0.0 1020.0 96.9 − 25.6 98838 −26112
Right Main 939.0 0.0 939.0 96.9 + 25.6 90989 24038
Tail 128.0 0.0 128.0 197.2 0.0 25242 0
Total Unadjusted Net Weight 2087.0 103.1 − 1.0 215069 − 2074
(f) (i) (e) (h)
Determining total unadjusted net weight, longitudinal and lateral CG - 500N

(a) (b) (c) (d) (g)
Tare or
Points (lbs) (lbs) (lbs) (inches) (inches) (inch−lb) (inch−lb)
Left Main 759.0 0.0 759.0 96.9 −25.6 73547.1 −19430.4
Right Main 738.8 0.0 738.8 96.9 +25.6 71589.7 18913.2
Tail 136.8 0.0 136.8 275.4 0 3764.7 0
Total Unadjusted Net Weight 1634.6 111.8 −3.16 182811.5 −517.2
(f) (i) (e) (h)
Figure 209. Example 1 (Sheet 1 of 2)
Page 216
MAINTENANCE MANUAL
Determining total unadjusted net weight, longitudinal and lateral CG - 600N

(a) (b) (c) (d) (g)
Tare or
Points (lbs.) (lbs.) (lbs.) (inches) (inches) (inch−lbs.) (inch−lbs.)
Left Main 919.2 0.0 919.2 96.9 −26.0 89070 −23899
Right Main 885.4 0.0 885.4 96.9 +26.0 85795 23020
Tail 104.7 0.0 104.7 303.3 0 31756 0
Total Unadjusted Net Weight 1909.3 108.2 −.5 206621 −879
(f) (i) (e) (h)
Determining basic weight and the longitudinal and lateral CG - 500MD

Weighing Scale Tare or Net Weight Arm Moment
Points Reading Calibration (lbs) (in.) (in.−lb)
(lbs) Correction
(lbs)
Left Main 648.9 − 1.5 647.4 96.9 62733
Right Main 618.9 + 0.5 619.4 96.9 60020
Tail 195.9 0 195.9 197.2 38631
Total Unadjusted Net Weight 1462.7 110.3 161384
Total Weight of Missing Equipment (Ref. Figure 207) + 21.0 93.6 + 1966
Total Weight of Surplus Equipment (Ref. Figure 207) − 1.3 96.9 − 126
Total Basic Weight 1482.4 110.1 163224
Determining basic weight and the longitudinal and lateral CG - 600N

Tare or
Scale Calibration Longitudina Lateral Longitudinal Lateral
Weighing Reading Correction Net Weight l Arm Arm Moment Moment
Points (lbs.) (lbs.) (lbs.) (inches) (inches) (inch−lbs.) (inch−lbs.)
Left Main 919.2 0.0 919.2 96.9 −26.0 89070 −23899
Right Main 885.4 0.0 885.4 96.9 +26.0 85795 23020
Tail 104.7 0.0 104.7 303.3 0 31756 0
Total Unadjusted Net Weight 1909.3 108.2 −.5 206621 −879
Total Weight of Missing Equipment +15.9 97.4 0 1549 0
(Ref. Figure 207)
Total Weight of Surplus Equipment −1.3 96.9 0 −126 0
(Ref. Figure 207)
Total Basic Weight 1923.9 108.1 −.5 208044 −879
Figure 209. Example 1 (Sheet 2 of 2)
Page 217
MAINTENANCE MANUAL
Page 218
MAINTENANCE MANUAL
Chapter
09
Towing
MAINTENANCE MANUAL
TABLE OF CONTENTS
09-00-00 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Ground Handling Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Standard Ground Handling Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Special Ground Handling Wheels (Float-Equipped Helicopters,
369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Helicopter Towing and Manual Moving (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . 201
3. Helicopter Manual Moving (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Helicopter Towing (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Towing Helicopter (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Towing Helicopter (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page i
MAINTENANCE MANUAL

Page ii
MAINTENANCE MANUAL
Section
09−00−00
Towing
MAINTENANCE MANUAL
TOWING
1. Ground Handling Wheels Excessive lead-lag load applied
CAUTION to the main rotor blades during
ground handling can result in damage to the
NOTE: At regular intervals, check wheel tire elastomeric damper buns and failure of the
pressure and repack wheel bearings (Ref. damper assembly. Operators and mainte
Section 32-40-00/32-40-60). nance personnel should use extra caution to
avoid lead-lag loads in excess of 35 lb. (16
kg) at the tip of the main rotor blades.
A. Standard Ground Handling Wheels
(1). Attach ground handling wheels (ST101
or ST104) as shown (Ref. Figure 201),
(Ref. Figure 201) Standard ground handling and hold tail up while lowering the
wheels, available as a special tool for helicop wheels (raising helicopter) with
ters not equipped with floats, are used for detachable jack handle (ST102 or
moving helicopter by hand and for towing ST103).
helicopter. The wheels are manually lowered
with a detachable jack handle and are held in (2). Manually move helicopter on ground
the down position (helicopter raised on wheels) handling wheels by balancing at
by a mechanical lock. The wheels for the tailboom and pushing on rear fuselage
369D/E/FF - 500N helicopters are equipped portion of airframe.
with tow bar attach fitting.
Except under extreme emergen
CAUTION cy conditions, do not tow heli
B. Special Ground Handling Wheels copter at speeds over 5 mph (8 KmH). Do
(Float−Equipped Helicopters, 369D/E/FF − not allow front ends of skid tubes to drag on
500N) ground. Avoid sudden stops and starts, and
short turns which could cause helicopter to
turn over. Allow inside wheel to turn (not
Special ground handling wheels are available pivot) while helicopter is being turned. Safe
for towing helicopters equipped with utility or minimum turning radius is approximately
emergency floats (Ref. Section 32-40-00). 20 ft. (6 m).
NOTE: If tow bar is not equipped to keep front

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

wheels by attaching suitable tow bar to
Special Tools tow bar fittings.
Item Nomenclature 3. Helicopter Manual Moving (600N)
ST101 Ground handling wheels
(Ref. Figure 202)
ST102 Handle-jack assembly, ground handling
(straight)
Special Tools
ST103 Handle-jack assembly, ground handling (Ref. Section 91-00-00)
(offset) Item Nomenclature
ST104 Ground handling wheels (one side) ST101 Ground handling wheels
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MAINTENANCE MANUAL
Excessive lead-lag load applied ground handling wheel set, allowing the
CAUTION to the main rotor blades during helicopter to be moved by one person.
elastomeric damper buns and failure of the
Special Tools
damper assembly. Operators and mainte
nance personnel should use extra caution to
Item Nomenclature
avoid lead-lag loads in excess of 35 lb. (16
kg) at the tip of the main rotor blades. ST101 Ground handling wheels
ST105 Tow bar (600N)
(1). Ensure all stress panels are installed
on helicopter before jacking.
Excessive lead-lag load applied
NOTE: CAUTION to the main rotor blades during
D The ground handling wheel set can be at ground handling can result in damage to the
tached to the skids facing either direction elastomeric damper buns and failure of the
for ease of jacking. damper assembly. Operators and mainte
D Ensure all four ground handling attach nance personnel should use extra caution to
points are engaged in ground handling avoid lead-lag loads in excess of 35 lb. (16
wheel set. kg) at the tip of the main rotor blades.
(2). Attach ground handling wheels (ST101) (1). Ensure all stress panels are installed
and hold tail up while lowering the on helicopter before jacking.
wheels (raising helicopter).
(2). Raise helicopter with ground handling
(3). Manually move helicopter on ground wheel set (ST101).
handling wheels by balancing at
tailboom and pushing on rear fuselage (3). Position tow bar (ST105), with caster
portion of airframe. wheels, straddling front of skid tube
assembly.
CAUTION cy conditions, do not tow heli (4). Attach nylon straps under skid tube
copter at speeds over 5 mph (8 KmH). Do and ratchet skid tube into rubber cups
not allow front ends of skid tubes to drag on on tow bar.
ground. Avoid sudden stops and starts, and
short turns which could cause helicopter to CAUTION cy conditions, do not tow heli
turn over. Allow inside wheel to turn (not
copter at speeds over 5 mph (8 KmH). Do
pivot) while helicopter is being turned. Safe
not allow front ends of skid tubes to drag on
minimum turning radius is approximately
ground. Avoid sudden stops and starts, and
20 ft. (6 m).
short turns which could cause helicopter to
4. Helicopter Towing (600N) turn over. Allow inside wheel to turn (not
pivot) while helicopter is being turned. Safe
(Ref. Figure 202) The tow bar is equipped with minimum turning radius is approximately
caster wheels and is designed for use with the 20 ft. (6 m).
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MAINTENANCE MANUAL
WARNING:
BE SURE LOCK SNAPS INTO
POSITION SHOWN BEFORE
RELEASING JACK HANDLE
LOCK
TOW BAR FITTING
WHEELS LOWERED AND LOCKED

(HELICOPTER RAISED)
JACK HANDLE
HANDLE LOCK PIN
GROUND HANDLING WHEELS

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

LOWERED)
G09−0001
Figure 201. Towing Helicopter (369D/E/FF − 500N)
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MAINTENANCE MANUAL
TOW BAR
TOW BAR
SKID TUBE
ASSEMBLY
VIEW ROTATED
GROUND HANDLING
WHEEL SET
SKID TUBE
ASSEMBLY
GROUND HANDLING
ATTACH POINTS
VIEW ROTATED
6G09-040
Figure 202. Towing Helicopter (600N)
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MAINTENANCE MANUAL
Chapter
10
Parking and Mooring
MAINTENANCE MANUAL
TABLE OF CONTENTS
10-10-00 Parking and Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Helicopter Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Helicopter Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Parking and Mooring (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
10-20-00 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Preservation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Flyable Storage (No Time Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Inspection Before Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Storage Up to 45 Days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Inspection During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Storage Up to 6 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Inspection During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
10-30-00 Blade Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Blades Storage Rack Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Main Rotor Blades Storage Rack Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Main Rotor Blades Folding and Unfolding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Helicopter Location for Blade Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Main Rotor Blades Folddown Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Aft Main Rotor Blades Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. Forward Main Rotor Blades Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Folding and Stowing Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . 204
E. Main Rotor Blades Unfolding Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
F. Aft Main Rotor Blades Unfolding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
G. Forward Main Rotor Blades Unfolding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
H. Main Rotor Blades Storage Rack Removal and Storage . . . . . . . . . . . . . . . . . . . . . 206
4. Main Rotor Flight Controls Adjustment and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Page i
MAINTENANCE MANUAL

Page ii
MAINTENANCE MANUAL
Section
10−10−00
Parking and Mooring
MAINTENANCE MANUAL
PARKING AND MOORING

1. Helicopter Parking (c). Secure blade sock tiedown cord for
blade located above tailboom to
To park helicopter for short intervals, do tailboom. Secure other blade sock
following steps (1). thru (4). For longer tiedown cords to fuselage jack fittings
duration parking, also do steps (5). and (6). (ST202).
(4). Secure six-bladed main rotor blades as
Special Tools follows:
When securing blade sock tie
Item Nomenclature CAUTION down cords, take up slack but do
ST202 Jack fittings not apply bending loads on blades.
ST2002 Blade socks
(a). Position blades so that three blades
ST2004 Air inlet fairing cover are on each side of helicopter (Ref.
ST2005 Engine exhaust cover Figure 201).
(b). Install blade socks (ST2002) on all
To prevent rotor damage from blades.
CAUTION blade flapping (droop stop (c). Secure blade sock tiedown cords to
pounding) as a result of air turbulence from fuselage jack fittings or cabin steps.
other aircraft landing, taking off or taxiing,
or sudden wind gusts, rotor blades should be (5). Install air inlet fairing cover (ST2004)
secured whenever helicopter is parked. on air inlet front fairing (Ref.
Figure 201).
(1). Locate helicopter slightly more than
(6). Install engine exhaust cover (ST2005)
blade clearance from nearby objects on
on exhaust tailpipe (Ref. Figure 201).
most level ground available.
2. Helicopter Mooring
(2). Apply friction to lock cyclic and collec
tive sticks so that friction control knobs Whenever severe storm conditions or wind
are positioned as follows: neutral for velocities higher than 40 knots are forecast,
cyclic stick and full down for collective helicopter should be hangared or evacuated to
stick. a safer area. If these precautions are not
possible, moor helicopter as follows.
NOTE: If not already accomplished, apply
paint mark on edge of guide to locate neu Special Tools
tral position for future reference (Ref. Sec (Ref. Section 91-00-00)
tion 67-10-00). Item Nomenclature
N/A Stakes or ground anchors (two)
(3). Secure five-bladed main rotor blades as
follows: N/A Cable or rope
ST202 Jack fittings
When securing blade sock tie ST2001 Pitot tube cover
CAUTION down cords, take up slack but do ST2004 Air inlet fairing cover
not apply bending loads on blades. ST2005 Engine exhaust cover
(a). Turn blades until one blade is
directly above tailboom (Ref. (1). Park helicopter (Ref. Helicopter
Figure 201). Parking) or remove main rotor blades
(Ref. Section 62-10-00) and install air
(b). Install blade socks (ST2002) on all inlet fairing cover (ST2004) and engine
blades. exhaust (ST2005) covers.
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MAINTENANCE MANUAL
(2). Install pitot tube cover (ST2001). tive sticks (Ref. Helicopter Parking).
(5). Secure helicopter to ground by attach
(3). Fill fuel tank (if possible) (Ref. Section ing restraining lines (cable or rope)
12-00-00). between jack fittings (ST202) and
stakes or ground anchors (Ref.
(4). Apply friction to lock cyclic and collec Figure 201).
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MAINTENANCE MANUAL
BLADE SOCK
(5 PL)
TIEDOWN TETHER
CABLE OR
MANILA ROPE
MOORING ANCHOR
ENGINE EXHAUST (4 PL)
COVER
ZIPPER TIE CORD
AIR INLET
FAIRING COVER
PITOT TUBE
COVER
PITOT TUBE COVER

INSTALLATION
FUEL CELL
ACCESS DOOR
LOCKPIN
DOOR ACCESS
LATCH
JACK
JACK FITTING FITTING ENGINE AIR INLET FAIRING
INSTALLATION LOCKPIN STOWAGE
COVER INSTALLATION
(TYP 2 PL)
FUSELAGE STRUCTURE
JACKING FITTING
TO BLADE SOCK
TO MOORING ANCHOR TO BLADE SOCK
G10−1001
Figure 201. Parking and Mooring (Sheet 1 of 2)
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MAINTENANCE MANUAL
TIEDOWN TETHER
BLADE SOCK
(6 PL)
CABLE OR
MANILA ROPE
MOORING ANCHOR
(4 PL)
ENGINE EXHAUST
COVER
ZIPPER
AIR INLET
FAIRING COVER
DOOR ACCESS
PITOT TUBE LATCH
COVER
PITOT TUBE COVER

INSTALLATION
FUEL CELL TIE CORD
ACCESS DOOR
LOCKPIN
ENGINE AIR INLET FAIRING
JACK FITTING COVER INSTALLATION
LOCKPIN STOWAGE
TO BLADE SOCK
FUSELAGE STRUCTURE
JACKING FITTING
TO MOORING ANCHOR
TO BLADE SOCK
JACK FITTING INSTALLATION

(TYP 2 PL)
F60−039
Figure 201. Parking and Mooring (Sheet 2 of 2)
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MAINTENANCE MANUAL
Section
10−20−00
Storage
MAINTENANCE MANUAL
STORAGE
1. Preservation and Storage (e). Open movable air vents in each door
of cargo compartment. Position
A helicopter to be placed in storage or non-op opening in each air vent downward.
erational status must have adequate inspec Close all other vents.
tion, maintenance and preservation to avoid
unnecessary deterioration of airframe and (f). Install covers and equipment used to
components of equipment. Extent of preventive park and moor helicopter.
maintenance that is to be done depends on
(g). Install a static ground.
anticipated time in storage. Following para
graphs describe what should be done in C. Return to Service
helicopter: for flyable storage; for up to 45 days
in storage; and for up to 6 months in storage. (1). Remove covers and equipment used to
park and moor helicopter.
2. Flyable Storage (No Time Limit) (2). Do the Daily Pre-Flight Check (Ref.
A. Inspection Before Storage appropriate PFM or RFM).
(1). Do the Daily Pre-Flight Check (Ref. 3. Storage Up to 45 Days

appropriate PFM or RFM). A. Inspection During Storage
(2). Ensure that fuel cells are full (topped (1). Where local average humidity exceeds
off), and that oil in engine oil tank and 40 percent, carefully inspect helicopter
main, fan and tail rotor transmissions every 15 days for corrosion. Do corro
is at FULL level (Ref. Section sion control as necessary (Ref. Section
12-00-00). 20-40-00). When inspecting for
corrosion, pay particular attention to
B. Storage those areas where moisture deposits do
not evaporate rapidly.
To maintain a flyable storage condition, do the
following: (2). Where local average humidity is 40
percent or less, inspect for corrosion
(1). Do the Daily Pre-Flight Check (Ref. every 30 days.
appropriate PFM or RFM).
(3). If interior temperature of fuselage
(2). Do the ground runup at least once exceeds 1605F (715C), ventilate
every five days (Ref. applicable PFM or helicopter by opening all doors and
RFM, Section 01-00-00, Table 201, ). vents. If necessary, promote air circula
tion by use of fans or other forced air
(a). Start engine. After idle stabilizes, equipment.
accelerate engine to 100 percent N2,
collective full down. Operate until oil (4). Ensure that fuel cells are full (topped
temperature is in normal operating off) and that rotor transmissions are at
range and ammeter indicates battery FULL level.
is fully charged.
(5). Drain fuel cell sump daily. (Replenish
(b). Shut down engine. fuel as necessary).
(6). Check fuel and oil systems periodically
(c). Drain fuel cell sump (Ref. Section
for leakage. Replenish as necessary.
12-00-00). (Replenish fuel as neces
sary.) B. Storage
(d). Ensure that fuel shutoff valve is (1). Do the engine preservation according to
closed (Ref. Section 28-00-00). applicable Rolls-Royce Operation and
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MAINTENANCE MANUAL
Maintenance Manual (Ref. Section (8). Do the Daily Pre-Flight Check (Ref.
01-00-00, Table 201) and current appropriate PFM or RFM).
engine service letters.
4. Storage Up to 6 Months
(2). Remove battery (Ref. CSP-HMI-3,
Section 96-05-00) and store in cool, dry A. Inspection During Storage
area. (1). Do the same inspection as for 45 days of
(3). If necessary, clean battery compartment storage.
(Ref. Section 20-20-00). (2). Check main rotor, tail rotor and fan
blades for damage every 15 days (Ref.
(4). Ensure that fuel shutoff valve is closed Chapters 62 and 64).
(Ref. Section 28-00-00).
(3). Check areas around mooring attach
(5). Clean entire helicopter. ments for damage every 15 days.
(6). Inspect all drain holes (blades, fuselage, B. Storage
etc.) for obstructions and clear where
necessary.
Consumable Materials
(7). Open movable air vents in each door of (Ref. Section 91−00−00)
cargo compartment; position opening in Item Nomenclature
each air vent downward. Close all other CM201 Protective coating
air vents. CM210 Corrosive preventive
(8). Park and moor helicopter. CM729 Tape, masking, pressure sensitive
(9). Install a static ground. Special Tools

(10). Remove from area any objects that are Item Nomenclature
likely to strike helicopter during high
wind conditions. ST2001 Pitot tube cover
C. Return to Service
(1). Do the engine preservation according to
(1). Check that battery area is clean; then applicable Rolls-Royce Operation and
install and connect battery (Ref. Maintenance Manual (Ref. Section
CSP-HMI-3, Section 96-05-00). 01-00-00, Table 201, ) and current
applicable engine service letters.
(2). Check that fuel cells are full (Ref.
Section 12-00-00). (2). Drain engine oil system (Ref. Section
12-00-00) and fill engine oil tank with
(3). Remove covers and equipment used to corrosion preventive (CM210).
park and moor helicopter.
(3). Remove battery (Ref. CSP-HMI-3,
(4). Inspect areas around mooring attach Section 96-05-00) and store it in cool,
ments for damage. Repair damage as dry area.
necessary. (4). Clean battery compartment, if neces
(5). Clean helicopter, as necessary. sary.
(5). Ensure that fuel shutoff valve is closed
(6). Check that all drain holes in helicopter
are free of obstructions.
(6). Seal static source openings in engine
(7). Do the engine depreservation according inlet fairing with masking tape
to applicable Rolls-Royce Operation (CM729) and cover pitot tube with pitot
and Maintenance Manual (Ref. Section tube cover (ST2001).
01-00-00, Table 201) and current
applicable engine service letters. (7). Clean entire helicopter.
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MAINTENANCE MANUAL
(8). Inspect all drain holes (blades, fuselage, (2). Remove masking tape from all external
etc) for obstructions and clear them access doors.
where necessary.
(9). Spray or brush on the canopy and all Do not use steam or unautho
windows a 0.008 inch (0.203 mm) CAUTION rized cleaning compounds to
thickness of protective coating (CM201). clean helicopter as damage to equipment
Cover and overlap all edges. can result.
(10). Inspect all external access doors for
close fit. If doors are likely to admit (3). Drain corrosion preventive from oil
moisture, seal edges with masking tape tank and replenish with correct oil (Ref.
(CM729). Section 12-00-00).
(11). Park and moor helicopter.
(4). Do the same procedures as for return to
(12). Install a static ground. service after 45 days of storage.
(13). Remove any objects from area that are
likely to strike helicopter during high NOTE: Depreservation of engine fuel system
wind conditions. can usually be accomplished by making a
C. Return to Service normal start. (Ref. applicable Rolls-Royce
Operation and Maintenance Manual, Sec
(1). Carefully lift protective coating along tion 01-00-00, Table 201, and current appli
edges and peel it from canopy and cable engine service letters for engine de
windows. preservation procedures).
Page 203
MAINTENANCE MANUAL
Page 204
MAINTENANCE MANUAL
Section
10−30−00
Blade Folding
MAINTENANCE MANUAL
BLADE FOLDING
1. Main Rotor Blades Storage Rack (1). Verify that front and rear support
Description assemblies are complete and tight in all
details.
(Ref. Figure 201) (2). Visually inspect for missing nuts, bolts,
cushions, and shock cords.
(1). The main rotor blade storage rack
stows and secures the main rotor blades (3). Verify that no support tubing is bent.
on Model 369 helicopters during ground (4). Verify that plywood of rear support is
handling operations. The storage rack not split, cushions not torn, or nylon
consists of fore and aft units which, webbing harness not missing its buckle.
when installed, provide blade protection
for helicopters that cannot be placed in 3. Main Rotor Blades Folding and Unfolding
hangers or evacuated during adverse
weather conditions. The following paragraphs provide instruction
for operation of the main rotor blade storage
rack: For the unpinning of the main rotor
(2). The aft blade storage rack supports blades; for folding, unfolding, and repining of
three blades and consists of a plywood the blades. Adjustment and testing of main
blade rack which incorporates shock rotor flight controls, necessary after the blades
(bungee) cords and nylon-webbing have been re-pinned, is also covered here.
harness straps with buckles, pull tabs, (Ref. Section 20-40-00 for information about
and a grommet. The aft storage rack is adjustment and corrosion protection of main
installed on the tailboom at Sta. 197.78, rotor blade attaching pins.)
just above the jack fitting. A decal on
the aft side of the storage rack facili If main rotor blades are to re
tates proper fore and aft positioning on CAUTION main folded for a considerable
the tailboom. The harness grommet length of time, main rotor hub must be cov
engages the jack fitting and holds the ered with a suitable weather-resistant cov
storage rack in position when the er.
harness straps are tightened and
secured. Shock cords secure the blades. NOTE: A mechanic's assistant is needed for
blade folding and unfolding.
(3). The forward blade storage rack sup A. Helicopter Location for Blade Folding
ports two blades and consists of a
plywood blade rack which incorporates (1). Locate helicopter slightly more than
shock cords, blade clamp (top blade rotor span from other aircraft or
only), rack support tubes, and landing vehicles.
gear clamps. The storage rack is (2). Park helicopter on the most level
installed forward of the fuselage so that ground available so that the load is
the blade clamp support is positioned balanced as much as possible.
left of the helicopter centerline. The
rack support tubes are secured with B. Main Rotor Blades Folddown Preparation
clamps to the landing gear just aft of
the skid tip lights. Shock cords secure Special Tools
the blades. (Ref. Section 91-00-00)
Item Nomenclature
2. Main Rotor Blades Storage Rack ST2003 Main rotor blade storage rack
Inspection ST2004 Air inlet fairing cover
ST2005 Engine exhaust cover
(Ref. Figure 201)
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MAINTENANCE MANUAL
(1). Inspect rack (Ref. Main Rotor Blades (a). Position rear blade support assembly
Storage Rack Inspection). on tailboom at Sta. 197.78, with its
lower step on left side of helicopter.
(2). Position main rotor so that one blade is
directly above and parallel to helicopter (b). Attach and secure straps. Adjust
tailboom. strap pull tabs so that harness
grommet engages jack fitting on
(3). Lock cyclic control stick (by applying tailboom.
friction) in the following positions:
(2). Install trailing rotor blade to aft storage
rack.
(a). Set collective pitch to mid position.
(a). Into center cushioned support step of
(b). Set longitudinal cyclic to full aft rear blade support assembly, position
position. trailing rotor blade (blade that is
directly above and parallel to tail
(c). Set lateral cyclic to two thirds of total boom).
stick travel from full left toward full
right. Blade movement must be re
CAUTION strained in the following steps
During blade folding, continu to prevent damage since, with damper dis
CAUTION ally monitor stick positions to engaged, the blade is free to pivot on blade
make sure no change occurs. Serious blade attaching pin.
damage can result from improper stick
placement. (b). Remove bolt or (alternatively)
attaching pin from damper arm of
(4). Disconnect wires or antennas (as trailing rotor blade, and move
applicable) at tailboom attach fitting, damper away from blade; replace bolt
and coil them. (or attaching pin) in damper arm.
(5). Cover (ST2004 and ST2005) engine air

NOTE: It is not necessary to remove a blade at
taching pin in order to fold the first blade.
inlet and exhaust openings to prevent
entry of foreign objects during blade (c). Secure blade in support assembly
folding. with shock cord fastener.
During blade folding, use blade (3). Install remaining blades to aft storage
CAUTION support pole (ST2003). Prevent rack.
scratching of blade by attaching pins or
bolts. Avoid brushing of blades against one Blade movement must be re
another or against any other surface. Lift
blade near tip to remove load on blade at to prevent damage since, with damper dis
taching pins. engaged, the blade is free to pivot on blade
attaching pin.
C. Aft Main Rotor Blades Folding
NOTE: The right blade goes to the top hold
down position, and the left blade to the bot
(Ref. Figure 201)
tom holddown position.
Special Tools
(a). Remove bolt or (alternatively)
Item Nomenclature
rotor blade, and move damper away
from blade; replace bolt (or attaching
ST2003 Main rotor blade storage rack pin) in damper arm.
(b). Unlock (but do not remove) blade
(1). Install aft storage rack (ST2003) to attaching pin that secures leading
helicopter. edge of blade to main rotor hub.
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MAINTENANCE MANUAL
(c). Unlock and remove blade attaching (d). Attach upper ends of support tubes to
pin that secures trailing edge of blade double blade support. Adjust tube
to lead-lag link, and position cam length to proper height as required
handle vertically above pin. for extended or standard landing
gear. Secure with hardware provided.
(d). Instruct mechanic's assistant using
blade-support pole (ST2003) to guide (2). Install left forward blade to forward
rotor blade to its proper position on storage rack. Observe that one blade is
rear support assembly. directly above the left side of the front
(e). Secure blade in support assembly blade support assembly. Secure that
with shock cord fastener. blade in support with shock cord
fastener and hinged clamp fastener
(f). Reinstall blade attaching pin its support.
original position in lead-lag link of
main rotor hub. NOTE: It is not necessary to remove blade at
taching pins from the main rotor assembly
D. Forward Main Rotor Blades Folding or damper arm in order to secure this blade.
(Ref. Figure 201) (3). Install right forward blade to forward
storage rack.
Special Tools
(Ref. Section 91-00-00) Blade movement must be re
Item Nomenclature
ST2003 Main rotor blade storage rack to prevent damage since, with damper dis
engaged, the blade is free to pivot on blade
attaching pin.
(1). Install forward storage rack (ST2003)
to helicopter. (a). Remove bolt or (alternatively)
(a). Position blade storage rack so that right forward blade and move damp
top holddown position on rack is er away from rotor blade; replace bolt
approximately 15 degrees left of (or attaching pin) in damper arm.
helicopter centerline.
(b). Attach U-bolt clamp subassemblies (b). Unlock and remove blade attaching
to forward ends of each landing gear pin that secures trailing edge of blade
skid. Secure with hardware provided. to lead-lag link, and position cam
Ensure that each U-bolt is attached handle vertically above pin.
ahead of curved portion of skid (but
(c). Instruct mechanic's assistant using
aft of skid tip light) to assure ground
blade support pole to guide rotor
clearance.
blade to its proper position on right
NOTE: Top adjustment holes in support tubes side of double blade front support.
are for extended landing gear; bottom holes
are for standard landing gear. (d). Secure blade in support assembly
with shock cord fastener.
(c). Attach lower ends of support tubes to
U-bolt clamp brackets. Attach short (e). Reinstall blade attaching pin into its
tube to left skid. Secure with hard original position in lead-lag link of
ware provided. main rotor hub.
Page 203
MAINTENANCE MANUAL
CENTER LINE
NOTES:
1. BLADE ATTACHING PIN ON
SIDE OF BLADE FACING RACK.
IS RETAINED AS PIVOT.
2. FOR TAILBOOM JACK FITTING.
3. TOP POSITION ONLY.
15°
BLADE ATTACH PINS

(NOTE 1)
CUSHION
DAMPER ARM
BOLT OR ALTERNATE
ATTACHING PIN
SUPPORT POLE
BLADE PITCH HOUSING
RETAINER CLIP
SHOCK CORD
(TYP)
FORWARD BLADES
BLADE CLAMP AFT BLADES
(NOTE 3)
SUPPORT
ASSEMBLY
HARNESS STRAP
PULL TAB
HARNESS GROMMET
(NOTE 2)
RACK SUPPORT
TUBES
LANDING GEAR
AFT BLADE RACK
LANDING GEAR CLAMPS
FORWARD BLADE RACK
G10−3000
Figure 201. Folding and Stowing Main Rotor Blades
Page 204
MAINTENANCE MANUAL
E. Main Rotor Blades Unfolding Preparation (1). Begin with the trailing blade, the one
supported by the center support step of
the rear blade support assembly.
Special Tools
(Ref. Section 91-00-00) Blade movement must be re
Item Nomenclature
to prevent damage since, with damper dis
ST2003 Main rotor blade storage rack
ST2004 Air inlet fairing cover attaching pin.
ST2005 Engine exhaust cover (a). Remove damper arm bolt or (alterna
tively) attaching pin from damper
arm clevis. Extend and align damper
Before unfolding the main rotor blades, do the
arm with bolt hole in trailing edge of
following steps:
blade. Insert bolt or attaching pin,
(1). Lock cyclic control stick, by applying but: If pin is used, do not lock pin at
friction, in the following positions: this time; if bolt is used, tighten to
torque of 30—60 inch-pounds
(a). Set collective pitch to mid position. (3.39—6.78 Nm) and insert cotter
pin.
(b). Set longitudinal cyclic to full aft (b). Remove shock cord fastener and
position. release blade from support.
(c). Set lateral cyclic to two thirds of total NOTE: Only the damper arm attaching bolt (or
stick travel from full left toward full pin) was removed from this blade during
right. folding, not a lead-lag link attaching pin.
(2). For the remaining aft secured rotor
During blade unfolding, contin blades, proceed as follows:
CAUTION ually monitor stick positions to
Blade movement must be re
make sure no change occurs. Serious blade CAUTION strained in the following steps
damage can result from improper stick
placement. to prevent damage since, with damper dis
(2). Cover (ST2004 and ST2005) engine air attaching pin.
inlet and exhaust openings to prevent (a). Remove shock cord fastener and
entry of foreign objects during blade release blade from support.
folding.
(b). Instruct mechanic's assistant using
blade support pole (ST2003) to lift
During blade unfolding, use
CAUTION blade support pole (ST2003).
and rotate blade forward to align
trailing edge of blade and attachment
Prevent scratching of blade by attaching
hole in lead-lag link of main rotor
pins or bolts. Avoid brushing of blades
against one another or against any other hub (remove attaching pin from
surface. Lift blade near tip to remove load lead-lag link to allow hole align
ment). Re-insert attaching pin (but
on attaching pin.
do not lock at this time).
F. Aft Main Rotor Blades Unfolding (c). Remove damper arm bolt or (alterna
tively) attaching pin from damper
(Ref. Figure 201) arm clevis. Extend and align damper
blade. Insert bolt or attaching pin
Special Tools
but: If pin is used, do not lock pin at
this time; if bolt is used, tighten to
Item Nomenclature
torque of 30—60 inch-pounds
ST2003 Main rotor blade storage rack (3.39—6.78 Nm) and insert cotter
pin.
Page 205
MAINTENANCE MANUAL
G. Forward Main Rotor Blades Unfolding H. Main Rotor Blades Storage Rack Removal
and Storage
(Ref. Figure 201)
(Ref. Figure 201)
Special Tools
(Ref. Section 91-00-00) (1). Remove covers from engine exhaust
Item Nomenclature and air inlet fairing.
ST2003 Main rotor blade storage rack
(2). Unbuckle nylon webbing harness of
(1). Begin with the blade stowed on the left rear blade support assembly to disen
side of the double blade front support gage aft blade storage rack from
assembly. No attaching pins were tailboom. Further disassembly is not
removed from this blade for storage. required.
Release hinged clamp fastener support
and shock cord fastener. Alignment is (3). Loosen or remove wing nuts to disen
not necessary. gage U-bolt clamp subassemblies from
front end of landing gear skid assembly.
(2). For remaining forward rotor blade, Remove forward blade storage rack
proceed as follows: from helicopter.
Blade movement must be re
CAUTION strained in the following steps (4). Store blade storage racks.
to prevent damage since, with damper dis
engaged, the blade is free to pivot on blade (5). Reconnect any wires or antennas
attaching pin. disconnected for blade folding.
(a). Remove shock cord fastener and

release blade from support. 4. Main Rotor Flight Controls Adjustment
and Testing
(b). Instruct mechanic's assistant using
blade support pole (ST2003) to lift (Ref. Figure 201) Do the following steps after
and rotate blade aft to align trailing main rotor blades have been unfolded and
edge of blade and attachment hole in repined.
lead-lag link of main rotor hub
(remove attaching pin from lead-lag (1). Lock all attaching pins and check that
link to allow hole alignment). Re-in locking force required to close pin
sert attaching pin (but do not lock at handle is 25—35 pounds force
this time). (111.2—155.7 N) (Ref. Section
(c). Remove damper arm bolt or (alterna 62-10-00 Main Rotor Blade and
tively) attaching pin from damper Damper Attach Pin Installation and
arm clevis. Extend and align damper Adjustment, Section 62-10-00).
blade. Insert bolt or attaching pin, NOTE: Blade attaching pin handle is posi
but: If pin is used, do not lock pin at tioned behind retainer clip as shown.
this time; if bolt is used, tighten to
torque of 30—60 inch pounds (2). Loosen friction on cyclic and collective
(3.39—6.78 Nm) and insert cotter sticks and check movement of controls
pin. through complete range of travel.
Page 206
MAINTENANCE MANUAL
Chapter
11
Placards and
Markings
MAINTENANCE MANUAL
TABLE OF CONTENTS
11-00-00 Placards and Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Placards - Exterior (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Placards - Interior (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203. Placards - Instrument Panels (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . 212
Figure 204. Placards - Optional Equipment (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . 214
11-40-00 Placards and Markings (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Exterior Placards and Markings (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . 202
Figure 202. Interior Placards and Markings (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . 206
Figure 203. Instrument Panel Placards and Markings (Sheet 1 of 2) . . . . . . . . . 210
Page i
MAINTENANCE MANUAL

Page ii
MAINTENANCE MANUAL
Section
11−00−00
Placards and
Markings
MAINTENANCE MANUAL
PLACARDS AND MARKINGS

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

6 CRANK
HANDLE 12 CARGO
8 9
TO OUTER FLOOR
LOCK
HANDLE
TO
OPEN
CAUTION
11
7
5 10 JACK PAD
500E
EXT. LH DOOR SHOWN
RH OPPOSITE 15 OIL CAP
16 17 (REF)
18
3
13 14 1 N9011F
SHIP
FAIRING CL
19
16 AIR
DUCT 20
(REF)
HEATER 21
DUCT (NOTE 2)
(REF) FUEL CAP 12 11
NOTES: (REF)
1. EFFECTIVE ON S/N:
369D; 001 AND SUBS.
369E; 001 - 300
369FF; 001 - 054
2. EFFECTIVE ON S/N:
369E; 301 AND SUBS
369FF; 055 AND SUBS
500N; 001 AND SUBS
G11−0000−1B
Figure 201. Placards − Exterior (Sheet 1 of 5)
Page 202
MAINTENANCE MANUAL
22
23
24
25
27
26
G11-0000-2
Page 203
MAINTENANCE MANUAL
CAUTION
PUSH DISCONNECT ELECTRICAL WIRING
BEFORE REMOVING BOOM
1. PUSH 2. ELECTRICAL
DISCONNECT
3. 500D / 500E / 530F / 520N

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

TO
OPEN
6. OPEN AND LOCK, 7. LOCK BEFORE FLIGHT,
OUTER, LH & RH LH & RH
FULL
CAP. 0.4 U.S. PTS. JIG POINT
SEE FLT MANUAL
AND LOG BOOK CHECK LEVEL STA 92.64
FOR OIL USAGE
ADD
8. TAIL ROTOR 9. CHECK LEVEL 10. OIL LEVEL PLUG 11. JIG POINT
TRANSMISSION OIL
ATTACH JACK PAD THRU THRU
12. JACK PAD
THRU THRU
DANGER LEFT-HAND RIGHT-HAND

LETTERS AND NUMERALS LETTERS AND NUMERALS
13. DANGER
14. RADIO CALL G11−0000−3A
Page 204
MAINTENANCE MANUAL
STATIC LINE
DRAIN VALVE
PUSH BOTTOM UP
THRU
16. STATIC LINE
15. RADIO CALL
OIL
17. OIL 18. NON SELF-SEALING FUEL CELLS 18. SELF-SEALING FUEL CELLS
FUEL 62.1 GALLONS FUEL 60.0 GALLONS
STATIC PORT
KEEP HOLES AND MCDONNELL DOUGLAS
SURFACE CLEAN
HELICOPTER CO. MESA, AZ
MODEL NO. 369
SERIAL NO.
TYPE CERT NO. H3WE
PROD CERT NO. 410
19. STATIC PORT 20. GROUND SYMBOL 21. MODEL IDENTIFICATION
WARNING
CAP. 14.0 U.S. PTS.
SEE FLT MANUAL DO NOT SUPPORT
TORQUE SCREWS AND LOG BOOK
TO 20−25 IN−LB GEAR BOX WEIGHT FROM
FOR OIL USAGE DRIVE SHAFT COUPLING
22. HUB FAIRING 23. MAIN ROTOR 24. TAIL ROTOR

SCREW TORQUE TRANSMISSION OIL GEARBOX WARNING
ENGINE VENT
27. ENGINE VENT
25. FUEL DRAIN 26. OIL DRAIN
G11-0000-4
Page 205
MAINTENANCE MANUAL
28
30
30
2
29
31 1 32
33
28. CAUTION-CABLE 29. CAUTION-JACK LOAD 30. MODEL NUMBER
31. NO PUSH INFORMATION 32. LIGHT ACCESS 33. TRANSMISSION CHECK
G11-0000-5
Page 206
MAINTENANCE MANUAL
11
5
8
10
1 4
ROTATED
13
14
15
G11-0002-1
Figure 202. Placards − Interior (Sheet 1 of 5)
Page 207
MAINTENANCE MANUAL
18
17 16
20
18
20
19
16
17
17
17
G11-0002-2
Page 208
MAINTENANCE MANUAL
26
28
AFT BULKHEAD 21
ACCESS COVER
12
( NOTE 2 )
25
23
24
27
22
(NOTE 1)
ROTATED
NOTES:
1. NOT APPLICABLE TO 369D, SHIP
NO. 605 AND SUBSEQUENT,
2. NOT APPLICABLE TO 369E/FF - 500N.
ROTATED
G11-0002-3A
Page 209
MAINTENANCE MANUAL
G11−0000−202−4
Page 210
MAINTENANCE MANUAL
G11−0000−202−5
Page 211
MAINTENANCE MANUAL
G11−0000−203−1
Figure 203. Placards − Instrument Panels (Sheet 1 of 2)
Page 212
MAINTENANCE MANUAL
G11−0000−203−2
Figure 203. Placards − Instrument Panels (Sheet 2 of 2)
Page 213
MAINTENANCE MANUAL
ANTI-ICE
FUEL
FILTER
6
14
ENGINE OIL
SCAVENGE FILTER
PARTICLE SEPARATOR
8
HEATED
PITOT
TUBE
4
15
CARGO HOOK
CARGO HOOK
G11-0003-1
Figure 204. Placards − Optional Equipment (Sheet 1 of 4)
Page 214
MAINTENANCE MANUAL
FOUR BLADE TAIL ROTOR

AUTOMATIC ENGINE RE-IGNITION
G11-0003-2
Page 215
MAINTENANCE MANUAL
12
11
13
12
EMERGENCY FLOATS UTILITY FLOATS
10
10
SWITCH INSTALLATION
(SLIMLINE PANEL)
G11-0003-3
Page 216
MAINTENANCE MANUAL
G11−0000−204−4
Page 217
MAINTENANCE MANUAL
Page 218
MAINTENANCE MANUAL
Section
11−40−00
Placards and
Markings (600N)
MAINTENANCE MANUAL
PLACARDS AND MARKINGS

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

(LH SHOWN, RH OPP)
29
28 25
LOOKING INBOARD
(LH SHOWN, RH OPP)
6G11 010 1B
Figure 201. Exterior Placards and Markings (Sheet 1 of 4)
Page 202
MAINTENANCE MANUAL
19 17
TOP VIEW
18 (4 PLCS)
30
BOTTOM VIEW
6G11-010-2
Page 203
MAINTENANCE MANUAL
TO
LOCK
1. MCDONNELL DOUGLAS LOGO 2. 600N IDENTIFICATION

LOCKED
4. LOCKED
CAUTION WARNING
SAFELOCK TO
INNER HANDLE FAILURE TO PROPERLY INSTALL,ALIGN OPEN
IN POSITION
AND TORQUE,FUEL,OIL AND AIR TUBES
AND FITTINGS COULD RESULT IN AN
7. NO PUSH
SHOWN BEFORE ENGINE FAILURE.REFER TO THE APPLI
CABLE MANUAL FOR PROPER INSTAL4
3. DOOR
INSTRUCTIONS
PUSH
FLIGHT ATION AND TORQUE PROCEDURES
OIL
6. WARNING 8. PUSH
5. LOCK BEFORE FLIGHT
LEFT AND RIGHT HAND SIDES 9. OIL
DURING OPERATIONS IN TEMPERATURES OF 40 _F (4 _C)

OR COLDER, FUEL ADDED TO THE TANK MUST CONTAIN
EITHER ANTI-ICING ADDITIVE PFA-55MB OR ANTI-ICING
ADDITIVE PER MIL-I-27868 OR MIL-I-85470 WITH A
MINIMUM CONCENTRATION OF .06% BY VOLUME
AND A MAXIMUM CONCENTRATION OF .15% BY VOLUME.
JIG POINT
SEE FLIGHT MANUAL FOR MIXING PROCEDURES.
STA 92.64
11. DECAL, FUEL 12. DECAL, ANTI-ICE ADDITIVE

13. JIG POINT
10. REGISTRATION NUMBER
CAP. 12.0 U.S. PTS.

SEE FLT MANUAL
AND LOG BOOK FOR
ATTACH JACK PAD OIL USAGE
14. ATTACH JACK PAD
15. PLATE IDENTIFICATION 16. GROUND SYMBOL 17. MAIN ROTOR
TRANSMISSION OIL
SERVICED
WITH
MOBIL CAUTION
AGL
DISCONNECT ELECTRICAL WIRING
BEFORE REMOVING BOOM
19. OIL USAGE
18. FUEL DRAIN 20. ELECTRICAL DISCONNECT
CAUTION
21. CAUTION - CABLE
22. LIGHT ACCESS 23. TRANSMISSION CHECK 24. CAUTION-JACK LOAD
6G11-010-3B
Page 204
MAINTENANCE MANUAL
L O
O P
C E
K N
25. DECAL, ARROW 26. DECAL, ARROW 27. DECAL, LOCK 28. DECAL, OPEN
STATIC PORT
KEEP HOLES AND
SURFACE CLEAN
LOCKED ENGINE VENT

29. DECAL, LOCKED 30. DECAL, ENGINE VENT
31. DECAL, STATIC PORT
6G11-010-4A
Page 205
MAINTENANCE MANUAL
40 15 10
29 40 28 15
27
16 28
16
1
38 15
4
38
20 2
45 46 43 (4 PLCS)
44 (OPP)
7 (4 PLCS)
8 6
9 5
11
12
14
19
FS AFT 13
FS FORWARD
113.85 DAMPER DAMPER
119.67
VIEW ROTATED
LOOKING
17 OUTBOARD
17
LOOKING DOWN
PLAN VIEW OF CARGO FLOOR
18
4
16
LOOKING
CONVENIENCE OUTBOARD
INTERIOR PANEL
PANEL 18
VIEW LOOKING FORWARD

FROM CABIN INTERIOR
6G11-011-1B
Figure 202. Interior Placards and Markings (Sheet 1 of 4)
Page 206
MAINTENANCE MANUAL
36
21
25
22
23
24
37
VIEW LOOKING OUTBOARD

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

CANT STA 78.50
33 6G11-011-2A
Page 207
MAINTENANCE MANUAL
OFF CLOSE
IF MOISTURE VISIBLE CONTROLS ACCESS DOOR
BYP
DOOR
AND O.A.T. BELOW 5o C
USE ANTI-ICE
24 VOLT DC WARNING
3. 24 VOLT DC REPLACE DOOR BEFORE FLIGHT
CABIN 2. OUTSIDE AIR
HEAT
TEMPERATURE
OPEN 5. CONTROLS ACCESS DOOR
WARNING-REPLACE DOOR
BEFORE FLIGHT
ON
4. NO SMOKING/SEAT BELT
1. CABIN HEAT AND FUEL ACCESS DOOR

ENGINE ANTI-ICE
WARNING
REPLACE DOOR BEFORE FLIGHT
AND JACKING AIRCRAFT
LONG TRIM LAT TRIM
LEVEL HERE 7. FUEL ACCESS DOOR 8. LONGITUDINAL TRIM 8. LATERAL TRIM
6. LEVEL HERE
T
H
R
O
T
T
10. EXIT INSTRUCTIONS L
11. FORWARD DAMPER 12. AFT DAMPER E
WARNING WARNING
OPEN
CAUTION - TO ASSURE PROPER RESTRAINT. ADJUST SHOULDER
FRICTION HARNESS SLIDE SO HARNESS IS SNUG AGAINST TORSO
WHILE SEATED UPRIGHT. FULL BACK IN THE SEAT
13. THROTTLE TO
OPEN
TO
OPEN
OPEN
INCREASE 16. CAUTION SHOULDER HARNESS
14. FRICTION INCREASE
DANGER
WHEN EXITING, WALK AWAY FROM THE TANK COOLER TO TO
HELICOPTER, KEEP HANDS AND HEAD LOW, LOCK LOCK
DO NOT WALK TO THE REAR. ENGINE OIL DRAINS
15. EXIT
22. ENGINE OIL DRAINS
17. DOOR
INSTRUCTIONS
LONG RANGE TANK CONN
19. LONG RANGE TANK CONNECTION M/R OIL TANK OUTLET
XMSN
23. OIL TANK OUTLET
OIL
CAUTION WARNING COOLER
SAFELOCK
HANDLE IN FAILURE TO PROPERLY INSTALL,ALIGN
DRAIN OIL TANK VENT
AND TORQUE,FUEL,OIL AND AIR TUBES
POSITION AND FITTINGS COULD RESULT IN AN
24. OIL TANK VENT
SHOWN BEFORE ENGINE FAILURE.REFER TO THE APPLI
CABLE MANUAL FOR PROPER INSTAL4
FLIGHT ATION AND TORQUE PROCEDURES
21. MAIN ROTOR

OIL TANK INLET
20. WARNING TRANSMISSION OIL
18. LOCK BEFORE EXIT COOLER DRAIN 25. OIL TANK INLET
6G11-011-3
Page 208
MAINTENANCE MANUAL
FULL
ADD 1 PINT
27. ARROW 28. EXIT COCKPIT 29. OPEN FIRST
26. OIL LEVEL
AIRCRAFT LIMITATIONS
XXXXXXXXXXXXXXXXX
32. DECAL, E1 35. DECAL, E12 38. DECAL, AIRCRAFT LIMITATIONS 41. DECAL, TB-502
33. DECAL, E4 36. DECAL, E13 39. DECAL, TB-5 42. DECAL, TB-501
34. DECAL, E8 37. DECAL, K309
40. DECAL, EMERGENCY EXIT
O L
P O
E C
N K
43. DECAL ARROW 44. DECAL ARROW 45. OPEN DECAL 46. LOCK DECAL
AIRFRAME
FUEL FILTER
INSTL
20,000 FT MAX ALT
WHEN USING JET A,
JET A-1, JP-5,
OR JP-8
14,000 FT MAX ALT

WHEN USING JET B
OR JP-4
600N98113-1
47. AIRFRAME FUEL FILTER
6G11-011-4B
Page 209
MAINTENANCE MANUAL
VNE CARD HOLDER
OVSPD FAULT
TEST TEST
OFF OFF
2
1
1. RADIO CALL
2. CYCLIC FORCES
3. HELICOPTER LIMITATIONS
6G11-012-1
Figure 203. Instrument Panel Placards and Markings (Sheet 1 of 2)
Page 210
MAINTENANCE MANUAL
VNE CARD HOLDER
1. RADIO CALL
2. CYCLIC FORCES
3. HELICOPTER LIMITATIONS
6G11-012-2
Figure 203. Instrument Panel Placards and Markings (Sheet 2 of 2)
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MAINTENANCE MANUAL
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MAINTENANCE MANUAL
Chapter
12
Servicing
MAINTENANCE MANUAL
TABLE OF CONTENTS
12-00-00 Helicopter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

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

9. Overrunning Clutch Servicing and Oil Leak Analysis . . . . . . . . . . . . . . . . . . . . . . . . . 307
Figure 303. Checking Oil Level - Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . 309
10. Miscellaneous Component Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
A. Rotor Brake Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
B. Landing Gear Damper Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
C. Component Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
D. Tail Rotor Swashplate Dual Bearings Repack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
E. Main Rotor Swashplate Bearing Repack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
F. Main Rotor Hub Tapered Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
G. Ground Handling Wheels Bearing Repack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
11. Overrunning Clutch Subassembly Bearing Repack . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
12. Component Fluid Leak Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
A. Main Rotor Transmission or Anti-Torque Transmission Oil Leaks . . . . . . . . . . . 311
B. Engine Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
C. Landing Gear Damper Hydraulic Fluid Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
D. One-Way Lock Hydraulic Fluid Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Figure 304. Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
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MAINTENANCE MANUAL
Section
12−00−00
Helicopter Servicing
MAINTENANCE MANUAL
HELICOPTER SERVICING
SERVICING
1. Servicing (General) Fuel Cell Capacities 600N
Servicing of helicopter includes replenishment Total Fuel . . . . . . . . . . . . 116.2 U.S. Gal. (440 Liters)
of fuel, changing or replenishment of oil and Usable Fuel . . . . . . . . . . 114.6 U.S. Gal. (434 Liters)
other such maintenance functions.
A. Fuel System Servicing Precautions
For locations of servicing points of standard
Comply with following precautions when
equipment Refer to Figure 301. For optional
servicing fuel system.
equipment servicing points Refer to
Figure 302. For lubrication points Refer to Turn off electrical switches
Figure 304. WARNING and disconnect any external
power from helicopter. Electrically
NOTE: The servicing intervals designated ground helicopter prior to refueling or
herein are the maximum allowable and defueling. Static discharge spark in
should not be exceeded. When unusual local presence of fuel vapors can cause fire
conditions such as environmental condi or an explosion.
tions, utilization, etc., dictate, it is the pre
rogative and responsibility of the operator to (1). Refueling vehicle should be parked a
increase the scope and frequency of the in minimum of 20 ft. (6 m) from helicop
spections as necessary to ensure safe opera ter during fueling operation.
tion.
(2). Before starting fueling operation,
2. Servicing (Special) always ground fueling nozzle or fuel
truck to GROUND HERE receptacle or
Whenever helicopter operation has taken place to another bare metal location.
over or around salt water environments and
B. Approved Fuels
other environments found to be corrosive, the
following wash procedures must be done. Service the helicopter with one of the autho
rized fuels listed in the applicable Rolls-Royce
A. Main Rotor Hub Wash Procedure Operation and Maintenance Manual (Ref.
(Ref. Main Rotor Hub Corrosion Prevention Section 01-00-00, Table 201). For operation
Tri-Flow Wash Procedure, Section 20-40-00) under emergency conditions where authorized
fuel is not available, or for operation under
B. Main Rotor Blades Washing and Waxing cold weather conditions, refer to same manual.
(Ref. Main Rotor Blades Corrosion Arresting, C. Fuel System Filling

Section 20-40-00) The fuel system has two fuel cells that are
interconnected for simultaneous flow and
C. Engine Compressor Wash venting. Fuel system filler is on right side of
(Ref. Chap. 71 and applicable Rolls-Royce helicopter.
Operation and Maintenance Manual, Section (1). Refuel helicopter with correct fuel as
01-00-00, Table 201). soon after landing as possible to
prevent moisture condensation and to
3. Fuel System Servicing keep helicopter as heavy as possible in
Fuel Cell Capacities 369D/E/FF − 500N case of winds.
Nonself−Sealing . . . . . 64.0 U.S. Gal. (242 Liters) (2). Keep fueling nozzle free of all foreign
Usable Fuel . . . . . . 62.7 U.S. Gal. (237 Liters) matter.
Self−Sealing . . . . . . . . . 62.0 U.S. Gal. (234 Liters) (3). Check filler cap for security after
Usable Fuel . . . . . . 60.7 U.S. Gal. (229 Liters) fueling.
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MAINTENANCE MANUAL
D. Fuel System Draining NOTE: If the type of engine oil or the oil group
is changed, remove and inspect the oil filter
Fuel draining should be accomplished with each 25 hours of engine operation (Ref.
helicopter as level as possible. applicable Rolls-Royce Operation and
Maintenance Manual for further informa
(1). Fuel system can be defueled in either of tion).
two ways:
B. Engine Oil Changing
To avoid possible damage to fuel (Ref. Applicable Rolls-Royce Operation and
CAUTION pump, do not operate fuel pump Maintenance Manual, Section 01-00-00, Table
with fuel tanks drained. 201).
C. Engine Oil System Filling
(a). Defuel through filler port using a
pump. The engine oil tank filler is on the right side of
the helicopter. A liquid level sight gauge for
(b). Open system drain valves on fuselage checking oil level in tank is visible through a
underside and in engine compart transparent window near the filler.
ment. NOTE:
(2). Fuel supply line drain valves are spring D Before adding oil, the oil container must
loaded type and open by pushing valve be shaken to ensure proper mixture of the
and attached drain line. anti-foaming additive.
D If sight gauge does not permit positive de
(3). Fuel cells drain valve is spring-loaded termination, remove filler cap and visual
closed and is opened by pressing ly check the oil level.
internal plunger. (1). Check oil level within 15 minutes of
engine shutdown; replenish if low.
E. Fuel System Bleeding
(2). If engine oil level is low after helicopter
(Ref. Chap. 28 and applicable Rolls-Royce has set for more than 15 minutes;
Operation and Maintenance Manual, Section (a). Run engine for at least 1 minute at
01-00-00, Table 201) Purge entrapped air ground idle.
from the fuel system, if necessary.
Ensure engine oil pressure is at
CAUTION
F. Engine Fuel Filter Replacement tained when starting engine
(Ref. applicable Pilot's Flight Manual).
(Ref. Applicable Rolls-Royce Operation and (b). Shut down engine, check oil level,
Maintenance Manual, Section 01-00-00, Table replenish if low.
201).
NOTE:
4. Engine Oil System Servicing D Motoring engine can draw oil from the oil
tank to the gearbox, giving low oil level
Oil Tank Capacity . . . . 3.0 U.S. Qt. (2.84 Liter) indications.
D If engine oil level indicates a low condi
A. Approved Lubricants
tion after setting overnight, engine check
valve can be leaking oil from tank to en
Service the helicopter with one of the autho
gine gearcase.
rized oils listed.
(3). Ensure oil tank filler cap is securely
For operation under emergency conditions tightened immediately after servicing.
where different oils must be mixed, or for
D. Engine Oil System Draining (Helicopters
operation under cold weather conditions, use
With Sta. 137.50 Bulkhead Drain Ports
alternate lubricants (Ref. applicable Rolls-
Installed)
Royce Operation and Maintenance Manual,
Section 01-00-00, Table 201). (1). Open engine access doors.
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MAINTENANCE MANUAL
(2). Place suitable container under engine (1). Drain oil from engine, oil tank and oil
oil tank drain and remove engine oil cooler (Ref. Engine Oil System Drain
tank filler cap. ing).
(3). Remove engine oil tank drain cap. (2). Replace engine oil filter(s) (Ref. Appli
cable Rolls-Royce Operation and
(4). After draining oil from tank, reinstall Maintenance Manual).
engine oil tank drain cap and filler cap.
(3). Refill engine oil system (Ref. Engine Oil
(5). To drain residual oil from engine System Filling).
accessory gearbox drain, remove wire
(4). Operate engine for five minutes and
lead and lower chip detector. Use
repeat above procedures.
suitable container to catch oil. Check
that detector O-ring is serviceable 5. Main Rotor Transmission Servicing
(replace as required); reinstall detector;
torque to 50—60 inch-pounds Service the helicopter with one of the autho
(5.65—6.78 Nm); lockwire and recon rized oils listed (Ref. Section 91-00-00).
nect wire lead. NOTE: Mobil oil AGL can be formulated such
E. Engine Oil System Draining (Helicopters that it can have two different colors. The oil
with Drain Valve Installed) can still be mixed with no adverse affects.
Main Transmission Capacities
(1). Remove interior trim and aft bulkhead
right access cover. 369D25100 . . . . . . . . . . 12.0 U.S. Pt. (5.67 Liter)
369F5100 . . . . . . . . . . . 14.0 U.S. Pt. (6.62 Liter)
(2). Place a suitable container under
A. Main Rotor Transmission Filling
overboard oil drain line where it exits
fuselage underside at firewall. Transmission (gearbox) oil should be replaced
with new oil whenever it is drained. A liquid
(3). Remove cap from engine oil tank filler. level sight gauge for checking main rotor
Pull out knurled spring-loaded button transmission oil level is located on the
to open valve in engine oil drain line right-hand side and visible through the clear
just below engine oil cooler (Ref. panel of the main transmission interior cover.
Figure 301). Rotate button and valve
poppet so that locking pin rests on NOTE:
shoulders of pin slot. D Replacement of oil pump filter (Ref. Sec
tion 63-21-00) is required after oil is
(4). After draining oil from tank, reinstall
drained from main rotor transmission
filler cap and close oil drain valve;
and at intervals specified (Ref. Section
ensure that poppet pin is in stop slot.
05-20-20).
(5). Reinstall access cover and interior trim. D If oil was drained from transmission cool
er, ground-operate helicopter for 15 min
(6). To drain residual oil from engine utes after replenishing oil (Ref. applicable
accessory gearbox drain, remove wire PFM, Section 01-00-00, Table 201). Re
lead and lower chip detector (Ref. check oil level at liquid level sight gauge
Section 79-00-00). Use suitable and replenish as necessary. This purges
container to catch oil. Check that air from oil cooling system and ensures
detector O-ring is serviceable (replace that entire oil cooling system is full.
as required); reinstall detector, torque
to 50—60 inch-pounds (5.65—6.78 (1). Replenish with correct oil until oil level
Nm) and reconnect wire lead. is at FULL on sight gauge by lifting
breather-filler cap and inserting spout
F. Engine Oil System Flushing of oil can into opening.
The following procedure is for flushing oil that (2). Check that spring-loaded cap closes
has been contaminated or when changing the when oil can spout is removed. Replace
type of oil. trim cover.
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MAINTENANCE MANUAL
BATTERY ELECTROLYTE
WATER
MAIN XMSN FILLER

MIL-L-23699/MOBIL AGL
PF NOTE 1
EXTERNAL POWER
RECEPTACLE
ONE-WAY LOCK
RESERVOIR MIL-H-5606
FUEL FILTER 5 MICRON
FUEL CELL SUMP DRAIN
L/G DAMPERS, 4 PLACES FUEL SYSTEM FILLER

NITROGEN/MIL-H-5606 JP4/JP5 ENGINE OIL TANK FILLER
PF MIL-L-23699
PF NOTE 2
FAN XMSN FILLER PF NOTES 1, 2
FAN GEARBOX
PF NOTE 1 DRAIN (500/600N)
ENGINE OIL
TRANS. OIL COOLER DRAIN
COOLER DRAIN
ENGINE OIL
TANK DRAIN
OIL DRAINS FOR MAIN TRANSMISSION, ENGINE OIL COOLERS,

NOTES: ENGINE OIL TANK AND FAN GEARBOX
1. DO NOT MIX OILS.
2. REFER TO APPLICABLE ROLLS-ROYCE OPERATION MAINTENANCE
MANUAL FOR FREQUENCY OF OIL CHANGE, AUTHORIZED
FUELS AND OILS AND SERVICE CHECKS.
FAN TRANSMISSION
BREATHER FILLER FREQUENCY SYMBOL REQUIREMENTS

PF NOTE 1
DAILY . . . . . . . . . . . 1. INSPECT PRIOR TO FIRST FLIGHT OF THE DAY
PF PREFLIGHT . . . . . . . 1. INSPECT PRIOR TO EACH FLIGHT
100 HOURS . . . . . . . 1. REMOVE BATTERY AND SERVICE PER THE MANUFACTURER'S
MAINTENANCE MANUAL
2. INSPECT AND REPLENISH ONE-WAY LOCK RESERVOIR AS
APPLICABLE
YEARLY . . . . . . . . . . 1. DRAIN AND REFILL T/R GEARBOX, FAN TRANSMISSION
300 HRS / YEARLY . . 2. DRAIN AND REFILL 369D25100 M/R G/B SERVICED WITH MIL-L-23699;
REPLACE OIL FILTER ELEMENT
600HRS / YEARLY . . 3. DRAIN AND REFILL 369D25100 M/R G/B SERVICED WITH MOBIL AGL
OR 369F5100 M/R G/B; REPLACE OIL FILTER ELEMENT
3. REPLACE ENGINE FUEL FILTER (5 MICRON)
TAIL ROTOR ON CONDITION . . . . 1. ON CONDITION OR EVERY 9 MONTHS IF ON SHELF
TRANSMISSION
G12−0001D
Figure 301. Servicing Points − Standard Equipment
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ROTOR BRAKE RESERVOIR

MIL-H-5606
MIST ELIMINATOR
PARTICLE SEPARATOR
ANTI-ICE FILTER SCAVENGE OIL FILTER
NOTE
G12−0002C
Figure 302. Servicing Points − Optional Equipment
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MAINTENANCE MANUAL
B. Main Rotor Transmission Draining 6. Tail Rotor Transmission Servicing

Service the helicopter with one of the autho
Special Tools rized oils listed (Ref. Section 91-00-00, Table
(Ref. Section 91-00-00) 1).
Item Nomenclature NOTE: Mobil oil AGL can be formulated such
ST301 Main transmission drain hose that it can have two different colors. The oil
can still be mixed with no adverse affects.
Tail Rotor Transmission Capacity
(1). Remove main rotor transmission cooler 369D25300 . . . . . . . . . . 0.530 U.S. Pt. (0.250 Liter)
drain cap and drain oil into suitable
369D25400 . . . . . . . . . . 0.530 U.S. Pt. (0.250 Liter)
container.
A. Tail Rotor Transmission Filling
(2). Remove main rotor transmission drain Tail rotor transmission oil should be replaced
access covers, wire leads and chip with new oil whenever it is drained. A liquid
detectors. level sight gauge for checking oil level is
located on the transmission housing.
(3). Using main rotor transmission drain
hose (ST301), drain oil into suitable (1). Check oil level.
container. (2). Remove lockwire and unscrew brea
ther-filler cap.
(4). If damaged, replace O-rings used with
chip detectors and self-closing valves. (3). Fill with proper oil by pouring oil into
transmission until oil level shows
FULL on sight gauge.
(5). If removed, reinstall self-closing valve.
Torque valve to 50—60 inch-pounds (4). Check that filler O-ring is serviceable
(5.65—6.78 Nm) and chip detector to (replace if necessary). Reinstall brea
40—50 inch-pounds (4.52—5.65 ther-filler and torque to 45—55
Nm). Lockwire valve to gearbox and inch-pounds (5.08—6.21 Nm) with
detector to valve. Reconnect wire leads. breather hole aft (Ref. Section
63-25-10) at completion of torquing.
(6). Reinstall main rotor transmission Secure with lockwire.
access covers. B. Tail Rotor Transmission Draining
C. Main Rotor Transmission Oil System (1). Position suitable container under tail
Flushing rotor transmission drain.
(2). Remove wire lead, lockwire, chip
The following procedure is for flushing oil that detector and self-closing valve (Ref.
has been contaminated or when changing the Section 63-25-10).
type of oil.
(3). If damaged, replace O-rings used with
(1). Drain oil from transmission and oil chip detector and self-closing valve.
cooler (Ref. Main Rotor Transmission (4). After oil drains, install self-closing
Draining). valve. Torque valve to 50—60 inch-
pounds (5.65—6.78 Nm) and chip
(2). Replace transmission oil filter (Ref. detector to 40—50 inch-pounds
Section 63-21-00, Main Transmission (4.52—5.65 Nm). Lockwire valve to
Filter Replacement). gearbox and detector to valve; reconnect
wire leads.
(3). Refill transmission oil system (Ref.
Main Rotor Transmission Filling). C. Tail Rotor Transmission Flushing
The following procedure is for flushing oil that
(4). Operate aircraft for five minutes, shut has been contaminated or when changing the
down and repeat steps (1). thru (3). type of oil.
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MAINTENANCE MANUAL
(1). Drain oil from tail rotor transmission transmission drain and remove cap.
(Ref. Tail Rotor Transmission Drain (Ref. Figure 301).
ing).
(4). After draining oil from transmission,
(2). Refill tail rotor transmission (Ref. Tail reinstall drain cap.
Rotor Rotor Transmission Filling).
C. Anti−Torque Fan Transmission Flushing
(3). Operate aircraft for five minutes, shut The following procedure is for flushing oil that
down and repeat steps (1). and (2). has been contaminated or when changing the
type of oil.
7. Anti−Torque Fan Transmission Servicing
(1). Drain oil from fan transmission (Ref.
Service the helicopter with one of the autho Anti-Torque Fan Transmission Drain
rized oils listed (Ref. Section 91-00-00). ing).
NOTE: Mobil oil AGL can be formulated such (2). Refill fan transmission (Ref. Anti-
that it can have two different colors. The oil Torque Fan Transmission Filling).
(3). Operate aircraft for five minutes, shut
Fan Transmission Capacity . . . . 8 U.S. Oz. (236 cc) down and repeat steps (1). and (2).
A. Anti−Torque Fan Transmission Filling 8. One−Way Lock Control System Servicing
Anti-torque fan transmission oil should be Service the helicopter with one of the autho
replaced with new oil whenever it is drained. A rized hydraulic oils listed (Ref. Section
liquid level sight gage for checking oil level is 91-00-00).
located on the transmission housing.
One−Way Lock Capacity . . . . 0.67 U.S. Oz. (20 cc)
(1). Check oil level. (1). To check oil level, remove control access
cover.
(2). If servicing is required, remove fan
inlet screen and fan hub transmission NOTE: Reservoir should be 1/2 to 3/4 full.
fairing.
(2). If oil level in reservoir is low, lift filler
(3). Remove lockwire and remove filler cap and add oil as needed.
plug. (3). Reinstall pilot's seat cover.
(4). Fill by pouring oil into transmission NOTE: If oil level is consistently low, one-way
filler plug hole, until oil level shows lock should be repaired to stop oil leakage
FULL on sight gauge. (Ref. Component Overhaul Manual).
(5). Check that plug O-ring is serviceable 9. Overrunning Clutch Servicing and Oil
(replace as required). Reinstall filler Leak Analysis
plug and torque to 45—55 inch-
pounds (5.08—6.21 Nm). Secure with (Ref. Figure 303) When oil leakage or seepage
lockwire. is noticed at oil seals or assembly joint lines of
overrunning clutch, clutch requires further
B. Anti−Torque Fan Transmission Draining inspection and investigation as follows.
(1). Remove fan inlet screen and transmis NOTE: Mobil oil AGL can be formulated such
sion fairing. that it can have two different colors. The oil
(2). Cut lockwire and remove fan transmis
Overrunning Clutch Capacities
sion filler plug.
369A5350−11, −21, −31 . . . . . . 1.52 U.S. Oz. (45cc)
(3). Open engine access doors and place 369A5350−41, −51 . . . . . . . . . 1.01 U.S. Oz. (30 cc)
suitable container under the fan 369F5450 . . . . . . . . . . . . . . . . 3.64 U.S. Oz. (110 cc)
Page 307
MAINTENANCE MANUAL
(b). Read scale to determine oil level and

Consumable Materials servicing required. Full oil level is
(Ref. Section 91−00−00) indicated by oil level of 2 7/8 inches
Item Nomenclature (7.30 cm) on scale. Minimum allow
CM112 Anti-seize compound high temperature able quantity (13 cc) is 7/8 inch
(22.23 mm) on scale. Recheck reading
CM125 Oil a minimum of three times.
CM126 Oil, turbine
If oil quantity is less than 7/8
CAUTION inch (22.23 cm) on scale, the
CAUTION clutch subassembly must be removed and
inspected for evidence of overheating (Ref.
D Checking clutch oil level requires removal CSP-DEF-5).
of main rotor transmission drive shaft.
Use care not to stress drive shaft dia (6). For a 369F5450 clutch, there are two
phragms (early type) or flexible couplings methods for checking the oil level:
(current type) during removal and instal
lation. Deflection in these areas are lim
ited due to material hardness. (a). First Method: Full oil level is indi
cated by oil level of 3 1/8 inches (9.84
D The 369F5450 clutch is only to be serviced cm) on a 6 inch (15 cm) machinists
with Mobil AGL oil (CM125). scale, 1/2 inch (12.7 mm) width,
D The 369A5350 clutch is only to be ser inserted into clutch exactly 5 inches
viced with MIL-L-23699 oil (CM126). (12.7 cm). Minimum allowable
quantity (60 cc) is 5/8 inch (15.88
(1). Remove trim and blower access door. mm) on scale. Recheck reading a
minimum of three times.
(2). Remove main rotor transmission drive
shaft (Ref. Section 63-10-00). Carefully (b). Second Method: Full oil level is
slide shaft from drive couplings; do not indicated by oil level of 4 5/8 inches
strike shaft against any object. (11.77 cm) on a 12 inch (30 cm)
machinists scale, 1/2 inch (12.7 mm)
(3). Remove coupling bolt and O-ring from width, inserted to bottom of inner
end of clutch. race. Minimum allowable quantity
(60 cc) is 2 1/8 inch (5.40 cm) on
(4). Check that the three drain holes in scale. Recheck reading a minimum of
clutch housing are clean and free of three times.
obstruction. Oil leakage can indicate
engine power output seal leakage if If oil quantity is less than 5/8
clutch oil level is checked and within CAUTION inch (15.88 mm) on scale for the
limits. first method or 2 1/8 inches (5.40 cm) for the
second method, the clutch subassembly
(5). For a 369A5350 Clutch: must be removed and inspected for evidence
of overheating.
(a). Using a clean 6 inch (15 cm) machi
nists scale, 1/2 inch (12.7 mm) width,
slowly insert scale into center of (7). Service clutch with lubricating oil
clutch output shaft until scale (CM125 or CM126). If oil level readings
bottoms. Scale must be inserted 4 7/8 indicate less than full level. Do not
inches (12.38 cm). overfill. Recheck oil level as in previous
step.
NOTE: Trim edge of scale as required to reduce
width of scale and allow scale to bottom in NOTE: Always check oil level after installing
clutch. clutch in the helicopter.
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MAINTENANCE MANUAL
CLUTCH CENTERLINE CLUTCH OUTPUT SHAFT
SCALE CLUTCH
MINIMUM OIL LEVEL
FULL OIL LEVEL 7/8 IN. (22.23 MM)
2-7/8 IN. (7.30 CM)
ENGINE
4-7/8 IN. (12.38 CM)
SCALE BOTTOMED
COUPLING
DRAIN HOLES
O-RING
COUPLING 369A5350 CLUTCH OIL
MAIN TRANSMISSION LEVELS - SCALE INDICATIONS
DRIVE SHAFT
COUPLING BOLT
CLUTCH CENTERLINE
SCALE
ENGINE
3 1/8 IN. “FULL” OIL LEVEL
CLUTCH (9.84 CM) 110 CC
CENTERLINE
5/8 IN. MINIMUM OIL LEVEL
SCALE (15.88 MM) 60 CC
4 5/8 IN. “FULL” OIL LEVEL ENGINE

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

6 INCH (15 CM) SCALE METHOD
(5.40 CM) 60 CC
12 INCH (30 CM) SCALE METHOD
369F5450 CLUTCH
OIL LEVELS - SCALE INDICATIONS
G12−3001B
Figure 303. Checking Oil Level − Overrunning Clutch
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MAINTENANCE MANUAL
(8). If coupling shimming was disturbed, equipped with schrader valve, servicing with
shim coupling so that there is nitrogen if it does not meet the minimum
0.035—0.055 inch (0.889—1.397 mm) extension requirements (Ref. Section
O-ring gap. (Ref. Section 63-10-00 for 32-10-00).
clutch installation and shimming
requirement details.) C. Component Lubrication Chart
When installing clutch coupling (Ref. Figure 304 for required lubrication
CAUTION bolt in next step, installation points, and lubrication intervals.)
torque on the bolt must not be less than
250—300 inch-pounds (28.25—33.90 Use extreme care when apply
CAUTION ing any type of lubrication
Nm) plus drag torque for the 369A5350
clutch or 315—365 inch-pounds (grease, oil, dry-film, etc) in vicinity of te
(35.59—41.24 Nm) plus drag torque for flon bearings. Most lubricants allow a dirt-
the 369F5450 clutch. Torquing to lower val retaining film to form or have other detri
ue reduces clutch bearing clamp-up and can mental effects that can cause rapid
result in bearing race spinning. deterioration of bearing surface.
(9). Coat bolt threads with oil (CM112). D. Tail Rotor Swashplate Dual Bearings
Install coupling bolt and O-ring (Drag Repack
torque for bolt self-locking serviceabili
ty is 25 inch-pounds (2.82 Nm) Check ball bearing for excessive loss of grease
minimum, 200 inch-pounds (22.60 and serviceability and relubricate (repack)
Nm) maximum). Replace bolt if torque (Ref. Section 64-30-00).
values are exceeded.
E. Main Rotor Swashplate Bearing Repack
(a). For 369A5350 clutch, torque coupling
bolt to actual drag torque plus Check seals for evidence of deterioration and
250—300 inch-pounds grease leakage. Inspect bearing assembly for
(28.25—33.90 Nm). serviceability and repack (Ref. CSP-COM-5,
Section 62-30-10).
(b). For 36F5450 clutch, torque coupling
bolt to actual drag torque plus F. Main Rotor Hub Tapered Bearings
315—365 inch-pounds Clean, inspect, and relubricate (repack). (Ref.
(35.59—41.24 Nm). Section 62-20-00).
(10). Position main rotor transmission drive
G. Ground Handling Wheels Bearing Repack
shaft between drive couplings. Install
four bolts and washers each end of
drive shaft and torque bolts to 50—75 Consumable Materials
inch-pounds (5.65—8.47 Nm). (Ref. Section 91−00−00)
Item Nomenclature
(11). Reinstall blower access door and trim.
CM111 Grease, aircraft
10. Miscellaneous Component Servicing
A. Rotor Brake Servicing At regular intervals, repack wheel bearings
with grease (CM111).
(Ref. Section 63-22-00 for information on
adding hydraulic fluid to the rotor brake 11. Overrunning Clutch Subassembly Bearing
master cylinder and bleeding the hydraulic Repack
system.)
For 369A5350 overrunning clutch, repack
B. Landing Gear Damper Servicing bearing per CSP-COM-5, Section 63-10-10.
Servicing of the landing gear damper is done For 369F5450 overrunning clutch, repack
by overhauling the damper assembly, or if bearing per CSP-COM-5, Section 63-10-15.
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MAINTENANCE MANUAL
12. Component Fluid Leak Analysis Table 201) for definition of permissible engine
oil leakage.
A. Main Rotor Transmission or Anti−Torque
Transmission Oil Leaks C. Landing Gear Damper Hydraulic Fluid
Leak
Oil leakage, seepage, or capillary wetting at oil
seals or assembly joint lines of main or Hydraulic fluid leakage from any of landing
anti-torque transmissions are permissible if gear dampers is not permissible. If leakage is
leakage rate does not exceed 2 cc per hour (one present, damper assembly should be over
drop per minute). An acceptable alternate rate hauled (Ref. Component Overhaul Manual) as
of leakage from either transmission is, if oil required and a serviceable unit installed. If
loss is not more than from the full to the add leaking landing gear damper is not replaced
mark on the sight gauge within 25 flight hours when leakage is noticed, continuation of
(Repair leaks according to instructions in damper in service can result in unequal and/or
Component Overhaul Manual). unacceptable dampening and/or ground
NOTE: resonance.
D On gearbox oil seals with less than 2 NOTE: It is normal for a thin hydraulic oil film
hours of operation, some seepage or wet to remain on damper piston as a result of
ting of adjacent surfaces is normal until wiping contact with piston seal. Newly in
seal is wetted and worn-in (seated). If stalled dampers can also have slight oil
seepage continues at rate of one drop per seepage from oil trapped in end cap threads
minute or less, seal can be continued in during damper assembly. Neither of these
service. Check transmission oil level and should be considered damper leakage or
observe seepage rate after every 2 hours cause for damper replacement.
of operation. Shorter inspection periods
can be required if seal leakage appears to D. One−Way Lock Hydraulic Fluid Leak
be increasing.
Hydraulic fluid leakage from any part of
D If excessive gearbox oil seepage occurs, one-way lock is not permissible. When leakage
check breather filler for proper installa is observed, assembly should be overhauled
tion and operation (Ref. Component Over (Ref. Component Overhaul Manual) as
haul Manual for cleaning procedures). required and a serviceable unit installed. If
B. Engine Oil Leaks leaking one-way lock is not replaced when
leakage occurs, continuation in service can
(Ref. Applicable Rolls-Royce Operation and result in mechanical malfunction that could be
Maintenance Manual (Ref. Section 01-00-00, hazardous to flight safety.
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MAINTENANCE MANUAL
NOTE 2
NOTE 5
NOTE 3
NOTE 4
NOTE 3
NOTE 1
SYMBOL SPECIFICATION
300 HOURS
1200 HOURS
NOTES:
2770 HOURS OR 2 YEARS 1. T/R SWASHPLATE DUPLEX BEARINGS
2. M/R SWASHPLATE BEARING
HAND PACK 3. M/R HUB TAPERED BEARINGS
4. OVERRUNNING CLUTCH ASSEMBLY UPPER BEARINGS
SPECIAL TOOL RECOMMENDED 5. YSAS ACTUATOR G12-0003A
Figure 304. Lubrication Chart
Page 312
MAINTENANCE MANUAL
Chapter
18
Vibration and Noise
Analysis
MAINTENANCE MANUAL
TABLE OF CONTENTS
18-10-00 Main Rotor Track and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Main Rotor Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Main Rotor Hub Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Main Rotor System Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Balancing Equipment and Balance Spare Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Isolating Tracking Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Main Rotor System Tracking Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Interrupter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Magnetic Pickup Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
C. Tracking Tip Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
D. Main Rotor System Balancing Equipment Installation . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401. Blade Tracking Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Main Rotor Balancing Equipment Installation . . . . . . . . . . . . . . . . . . 404
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Blade Tracking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Figure 501. Typical Track Conditions and Adjustments . . . . . . . . . . . . . . . . . . . . . 501
A. Blade Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
B. Pitch Control Link Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
C. Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
D. Main Rotor Ground Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
E. Hover Track Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Figure 502. Main Rotor Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
F. Forward Flight Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
2. Main Rotor Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
3. Main Rotor System Balance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
4. Main Rotor Autorotation RPM Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
5. Main Rotor Hub Balancing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Table 501. Summary Procedure for Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . . 507
Table 502. Autorotation Rpm Chart (369D/E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Table 503. Autorotation Rpm Chart (369FF/500N) . . . . . . . . . . . . . . . . . . . . . . . . . 508
Figure 503. Main Rotor Hub Balancing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Figure 504. Main Rotor Hub Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
18-10-60 Main Rotor Track and Balance (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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MAINTENANCE MANUAL

2. Main Rotor System Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

3. Balancing Equipment and Balance Spare Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Isolating Tracking Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
1. Main Rotor System Tracking Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Interrupter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Magnetic Pickup Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Blade Tracking Equipment - Main Rotor Components
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
C. Tracking Tip Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
D. Main Rotor System Balancing Equipment Installation . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Main Rotor Balancing Equipment Installation . . . . . . . . . . . . . . . . . . 404
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Blade Tracking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Figure 501. Typical Track Conditions and Adjustments . . . . . . . . . . . . . . . . . . . . . 501
A. Blade Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
B. Pitch Control Link Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
C. Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Figure 502. Adjustment - Main Rotor Blade Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
D. Main Rotor Ground Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
E. Hover Track Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
F. Forward Flight Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
2. Main Rotor System Balance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
3. Main Rotor Autorotation Percentage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Table 501. Summary Procedure for Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . 506
Table 502. Autorotation Percentage Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Figure 503. Main Rotor System Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Figure 504. Main Rotor Track at Hover
(Pitch Change Link Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Figure 505. Main Rotor System Balance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Figure 506. Main Rotor Tracking at 100 - 130 KIAS
(Inner Tab Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
(Mid Tab Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
(Outer Tab Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
18-20-00 Tail Rotor Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Tail Rotor Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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MAINTENANCE MANUAL

A. Balance at Blade Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

B. Balance at Blade Pitch Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Short Method Balance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. Long Method Balance Check (Four-Bladed Tail Rotor) . . . . . . . . . . . . . . . . . . . . . . 202
2. Horizontal Stabilizer Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Tail Rotor Assembly Balancing (Two-Bladed Tail Rotor) . . . . . . . . . 204
Table 201. Tail Rotor Balance Weight - Value Chart . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 202. Short Method Tail Rotor Balancing (Four-Bladed Tail Rotor) . . . . . 205
Figure 203. Long Method Tail Rotor Balancing (Inboard Blade) . . . . . . . . . . . . . . 206
Figure 204. Long Method Tail Rotor Balancing (Outboard Blade) . . . . . . . . . . . . 206
18-20-30 NOTARr Anti-Torque System Fan Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Fan Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fan Balance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Preferred Hardware for Balancing Fan Assembly . . . . . . . . . . . . . . . . 202
Figure 201. Fan Balancing Stud Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Fan Balance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203. Fan Balancing Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . 205
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MAINTENANCE MANUAL

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MAINTENANCE MANUAL
Section
18−10−00
Main Rotor Track
and Balance
MAINTENANCE MANUAL
MAIN ROTOR TRACK AND BALANCE

1. Main Rotor Blade Tracking (f). Autorotation rpm adjustment (Ref.
Main Rotor Autorotation RPM
Main rotor blade track is observed by means of Check).
reflective tip caps temporarily installed on
each blade and a high-intensity strobe light. (2). No attempt should be made to verify or
Blade track is determined by observing the adjust blade track without first check
apparent tip cap pattern created by strobe ing and adjusting blade phasing, a
light pulses synchronized with the rotating function of main rotor damper adjust
blades. Strobe light electrical power is supplied ment (Ref. Section 62-20-00).
by the helicopter electrical system.
Understand the blade tracking
Immediately investigate the CAUTION sequence and related adjust
WARNING cause of a sudden onset of ments before attempting blade track proce
excessive or unusual main rotor vibra dures.
tion prior to continued flight. Under no
circumstance should main rotor track If main rotor hub balance is suspect, balance
ing be attempted to correct the prob rotor hub prior to doing blade track.
lem until a thorough inspection of the
main rotor blades, hub assembly and A. Main Rotor Hub Balancing
strap pack assembly has been done. Main rotor hub balancing is accomplished by
When working near engine air adding or removing weight (flat washers) as
CAUTION inlet, comply with all precau required at the lead-lag bolts (Ref. Main Rotor
tions to prevent entry of foreign material. Hub Balancing Procedure). Analysis of main
Carefully observe precautions in the Track rotor hub balance is accomplished using
ing and Balancing Manual relating to the instrumentation that measures and localizes
placement and security of equipment (espe vibrations due to main rotor hub imbalance.
cially cables) fastened to the exterior of the Data provided by the instrumentation is
helicopter. plotted on a chart designed to indicate how
much weight must be added or removed from
NOTE: Refer to Table 201 to isolate ground or the lead-lag bolt. No other means of balancing
in-flight blade tracking problems. is to be used.
(1). Tracking must be accomplished in the B. Main Rotor System Balancing

following sequence of six steps:
Main rotor system balancing is accomplished
(a). Verification of proper blade phasing by adjusting the turnbuckle on the elastomeric
(Ref. Main Rotor Blade Phasing damper. Analysis of main rotor system balance
Check and/or Adjustment, Section is accomplished using instrumentation that
62-20-00). measures and localizes vibrations due to main
rotor imbalance (Ref. Main Rotor System
(b). Ground tracking (Ref. Main Rotor Balance Procedure). Data provided by the
Ground Tracking). instrumentation is plotted on a chart designed
(c). Verification of proper rotor balance to indicate how much rotor blade shall be
(Ref. Main Rotor System Balance shifted in leading or lagging direction by
Procedure). adjusting turnbuckle. No other means of
balancing is to be used. Never add weight to,
(d). Hover verification (Ref. Hover Track subtract weight from or redistribute weight on
Verification). the main rotor blades. Do not attempt the
blade balancing procedure without first
(e). Forward flight tracking (Ref. For tracking the blades (Ref. Blade Tracking
ward Flight Tracking). Procedure).
Page 201
MAINTENANCE MANUAL
C. Balancing Equipment and Balance Spare

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

lower main rotor hub shoe.
Play between longitudinal pitch Re−bond collective pitch mixer

mixer bellcrank and collective pitch bearings and install shims between
mixer bellcrank. longitudinal pitch mixer bellcrank and
collective pitch mixer bellcrank
bearings (Ref. Sec. 62−30−00).
Helicopter has rough feeling with Tilted tracking images, no blade in Retrack blades.
some vibration while appearing to track.
be in track.
Pitch link control not coordinated Set pitch link to nominal 6.25 in.
with trim tab bend (intermixing (15.875 cm) and zero trim tabs.
control input), with climbing or
diving blades within acceptable
track limits.
Page 202
MAINTENANCE MANUAL
Table 201. Isolating Tracking Problems (Cont.)

Blades very erratic in response to Tab bent too much in wrong area. Correct by limiting bending.
tab bends.
Blade erosion, but within chordwise Track erratic blade to other blades.
limits.
Tab bent too many degrees in one Limit tab bending to smaller degree
area. over larger area.
Blades climb or dive excessively at Too much tab bending in outboard Remove outboard bending and
high speeds. tab areas. increase inboard bending.
Ground track off at low speed and Excessive tab bending and pitch Zero trim tabs and set pitch links to
stick shake at 103% N2. link control not coordinated with tab nominal 6.25 in. (15.875 cm)
bend (intermixing control input).
Helicopter in track but has stick Blade out of phase. Check phasing.
shake.
Feedback in collective control. Main rotor hub out of balance. Balance hub.
Loose or binding rotating scissors. Check and repair as required.
Heavy collective stick − climb and Overcenter adjustment set too low. Adjust.
cruise.
Trim tab bent down excessively. Adjust.
Light collective stick − climb and Overcenter adjustment set too Adjust.
cruise. high.
Trim tabs bent up excessively. Adjust.
Heavy collective lift-off − light flight. Bungee spring adjusted too short. Adjust to nominal.
Light collective lift-off − heavy flight. Bungee spring adjusted too long. Adjust to nominal.
Page 203
MAINTENANCE MANUAL
Page 204
MAINTENANCE MANUAL

REMOVAL/INSTALLATION
1. Main Rotor System Tracking Equipment located immediately inboard of each
Installation pitch control link attach clevis on the
rotating swashplate.
(Ref. Figure 401 and Figure 402) Equipment
needed to track main rotor blades consists of (2). The interrupter installation incorpo
the main rotor tracking and tail rotor vibration rates a double interrupter which can be
analyzer equipment, tracking and balancing used for both tracking and balancing.
equipment and the tip cap assembly. Instruc (3). Each interrupter insert is attached to
tions for equipment installation are contained the interrupter body at a different
in Chadwick-Helmuth Operation and Service position (left, center, or right). The
Instruction Handbook. interrupters create five equally spaced
When working near engine air horizontal reflective images, as viewed
CAUTION inlet, comply with precautions by the technician, when the main rotor
to prevent entry of foreign material. During blade tips are illuminated with the test
main rotor balancing the helicopter will be strobe light.
airborne. Carefully observe precautions in (4). Interrupter blade spacing separates the
the Tracking and Balancing Manual relat image of each main rotor blade tip cap
ing to the placement and security of equip by approximately 0.25 inch (6.35 mm).
ment (especially cables) fastened to the ex This staggered relationship allows the
terior of the helicopter. technician to view the stopped image of
NOTE: Main rotor tracking tip caps manufac each blade in order of rotation.
tured by the same firm that manufactures (5). The number one blade is seen on the
the tracking and balance equipment, are extreme left, number two blade is seen
components of the tracking and balancing second from left, and so on through
equipment and can be used instead of tip number five which is seen on the
cap assembly. In procedures that follow, use extreme right.
of tip cap assembly is presumed. If tip caps
from the balancing equipment are used, re (6). On current configuration helicopters,
fer to the Tracking and Balancing Manual the pulse of the double interrupter is so
for tip cap data. short that it appears as a single pulse
to the strobe light amplifier. The second
pulse created by the double interrupter
Special Tools is used during main rotor balancing.
Item Nomenclature (7). If counterweights are installed, coat the
ST901 Tip cap assembly
two interrupter bolts passing through
the swashplate counterweights with
ST903 Balancer/analyzer instrument kit grease (CM116) before installation.
Torque nuts to 30—60 inch-pounds
Consumable Materials (3.39—6.78 Nm).
(Ref. Section 91−00−00)
Item Nomenclature (8). Torque the three remaining interrupter
nuts to 15—20 inch-pounds
CM116 Grease, aircraft and instrument (1.69—2.26 Nm).
B. Magnetic Pickup Installation
A. Interrupter Installation
(Ref. Figure 401)
(Ref. Figure 401)
(1). The helicopter is originally equipped
(1). The helicopter is equipped with five with a magnetic pickup support bracket
main rotor blade tracking interrupters installed with shim washers to prevent
Page 401
MAINTENANCE MANUAL
distortion of the bracket when the nut C. Tracking Tip Cap Installation
on the bolt that secures the link bearing
is torqued to 30—60 inch-pounds (Ref. Figure 401)
(3.39—6.78 Nm).
(2). To preclude rocking movement of with five tip caps that must be removed
magnetic pickup support bracket when and replaced with five tracking tip caps
installed on stationary swashplate, (ST901).
check clearance between swashplate
and lower flange of bracket. If gap (2). When blade tracking has been accom
exists, tap bent tip of lower flange plished or verified, the tracking tip caps
(typical both sides of bracket) until bent must be removed and original tip caps
tip touches swashplate. installed.
(3). Reinstall by forcing bracket until (3). Torque the screw that secures the tip
elongated bracket holes align with hole cap to 15—20 inch-pounds
in stationary swashplate. (1.69—2.26 Nm).
(4). Install the magnetic pickup and cable NOTE: When installing tip cap targets, posi
as instructed in the Chadwick-Hel tion double interrupter over magnetic pick
muth Operation and Service Instruc up. The blade positioned forward is number
tion Handbook. 5. By rotating rotor head in operating direc
tion, the next blade pointing forward will be
(5). After final adjustment, torque the 4, then 3, 2 and 1.
adjustment nut to 15—20 inch-
pounds (1.69—2.26 Nm) and ensure D. Main Rotor System Balancing Equipment
the cable is routed and tied down in Installation
such a manner as not to be dislodged or
interfere with control components at (Ref. Figure 401 and Figure 402) and Chad
their extremes of travel. wick-Helmuth Operation and Service Instruc
tion Handbook to install that portion of the
(6). Ensure the interrupter passing closest balancing equipment (ST903) needed to
over either early or current configura balance the main rotor.
tion magnetic pickup, clears pickup by
not less than 0.030 inch (0.762 mm).
Page 402
MAINTENANCE MANUAL
1
ROTATION PLACE DOUBLE INTERRUPTER
OVER MAGNETIC PICKUP AND
2 THEN ATTACH TIP TARGET
NUMBERS EXACTLY AS SHOWN TAPE
TRACKING TARGET
(NOTE 1)
TIP CAP
TRACKING TIP CAP INSTALLATION INTERRUPTER

(NOTE 4) DOUBLE
(NOTE 5) ROTATION OF INTERRUPTER
HUB (NOTE 4)
SUPPORT NOTE 2 (NOTE 6)
SCISSORS
BRACKET LINK
ADJUSTMENT
JAMNUT
ROTATING
SWASHPLATE
PROTECTIVE CAP TEST EQUIPMENT

CABLE RECEPTACLE
PICKUP INSTALLATION (ROTATED)
INTERRUPTER SPACER
(NOTE 4) INTERRUPTER
(NOTE 5) (NOTE 4)
INTERRUPTER INTERRUPTER (NOTE 6)
(NOTE 3) (NOTE 4)
(NOTE 6)
STATIONARY NOTES:
SWASHPLATE 1. ALWAYS REMOVE TARGETS
AFTER TRACKING.
0.030-0.070 IN. 2. INSTALL WASHERS BETWEEN
(0.762-1.778 MM) BRACKET AND SWASHPLATE
GAP TYP. TO FILL GAP.
3. ADJUST AS REQUIRED FOR
GAP INDICATED.
4. REFER TO CSP-IPC-4 FOR
PART NO.
5. TORQUE NUT TO 30-60 IN. LBS
(3.39-6.78 NM).
INTERRUPTER-TO-MAGNETIC PICKUP GAP 6. TORQUE NUT TO 15-20 IN. LBS
MAGNETIC PICKUP (1.69-2.26 NM).
G18−1000C
Figure 401. Blade Tracking Equipment
Page 403
MAINTENANCE MANUAL
TAPE CABLE TO RIGHT HAND INBOARD MAGNETIC PICKUP CABLE AND

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

SECURING GAP AND
SAFETY WIRE
0.030-0.070 IN.
(0.762-1.778 MM)
ENGINE AIR INLET GAP (TYP)
MAGNETIC PICKUP
FAIRING (LEFT
HAND SIDE) VIEW LOOKING DOWN
MAGNETIC PICKUP INSTALLATION
TAPE
VELOMETER/ACCELEROMETER VIEW LOOKING INBOARD

BALANCING
ACCELEROMETER INSTALLATION
G18-2005
Figure 402. Main Rotor Balancing Equipment Installation
Page 404
MAINTENANCE MANUAL

ADJUSTMENT/TEST
1. Blade Tracking Procedure
Table 501 is a summary of the sequence of TIP PATH PLANE
required procedures for blade tracking.
1 2 3 4 5
(1). Install strobe light, blade tip cap
IMAGE A: ALL BLADES IN TRACK
reflectors and related equipment.
(2). Use 1/2 inch (12.7 mm) diameter
2
tracking tip cap reflector as a guide for 1 3 4 5
estimating track accuracy. For example: IMAGE B: ONE BLADE APPROX. 1/2 IN. (12.7 MM) HIGH
(a). A tip cap reflector image displace

ment of 1/2 diameter up, or down, 2
indicates blade tip is approximately 1 4 5
1/4 inch (6.35 mm) out of track. 3
IMAGE C: ONE BLADE APPROX. 1/2 IN. (12.7 MM) HIGH

(b). One full reflector diameter indicates ONE BLADE APPROX. 1 IN. (25.4 MM) LOW
1/2 inch (12.7 mm) out of track. G18−1001A
CORRECTIVE ACTION
NOTE: Rocking or stick shake caused by a cor
HIGH RPM AND
rectly tracking rotor indicates improper CONDITION GROUND IDLE RPM FWD FLIGHT
blade phasing. IMAGE A NONE REQUIRED NONE REQUIRED
IMAGE B SHORTEN PITCH CONTROL MOVE TAB DOWNWARD
(3). Accomplish blade phasing (Ref. Section ROD (2ND BLADE) (2ND BLADE) MOVE TAB
62-20-00) when installing new rotor UPWARD (3RD BLADE)
blades or if ground rock or stick shake IMAGE C SHORTEN PITCH CONTROL MOVE TAB DOWNWARD
is noted. This must be accomplished ROD (2ND BLADE): (2ND BLADE): MOVE TAB
prior to starting tracking procedure. LENGTHEN CONTROL ROD UPWARD (3RD BLADE)
(3RD BLADE)
NOTE: Final rotor system balance cannot be
accomplished until blades are in track. NOTE: Chordwise spacing of tracking images
are not an accurate indication of blade
(4). Ground tracking is basically track-ob phasing. Do not adjust blade phasing in an
servation and adjustment of idle and attempt to equalize spacing. Slight tilting of
flight rpm. Improper track at idle rpm magnetic interrupters or balance of the
is corrected by adjusting length of pitch main rotor system can move the image.
control links connecting rotating
Figure 501. Typical Track Conditions and
swashplate and blade pitch housing.
Adjustments
Ground track at flat pitch and flight
rpm is corrected by blade tab adjust (6). Forward flight track is corrected only
ment. by making blade tab adjustments.
Forward flight tracking requires track
(5). Hover track verification is essentially
observation during following airspeeds
an observation to check for track
and maneuvers: Flight at 0-100 knots.
variations between high rpm (flat pitch)
Forty-five degree banked turns at
ground track check and hovering.
80-100 knots. Flight at 100-155 knots.
NOTE: Track adjustments are not made on ba (7). Check for proper balance of rotor
sis of track observations during hovering. system prior to checking autorotation.
However, track variations should be noted
and recorded for use during check of track in (8). Obtaining correct autorotation rpm
forward flight. consists of checking main rotor rpm
Page 501
MAINTENANCE MANUAL
during stabilized autorotation flight

and adjusting rpm to specified limits as Special Tools
necessary. Autorotation rpm check (Ref. Section 91-00-00)
must be accomplished to ensure that Item Nomenclature
track adjustments do not alter rotor ST902 Main rotor blade fixture and tab bending
performance necessary for safe power- tool
off landings.
A. Blade Track Adjustment Minimize bending and restrict
CAUTION adjustments to very small incre
Although adjustment of pitch control links
ments so that bonded trailing edge joint be
affects blade track at all rotor speeds, they
tween upper and lower skins is not dam
should be adjusted only when necessary to
aged. Tabs must never be displaced more
establish acceptable track at ground idle
than five degrees above or below neutral po
speed; blade tabs are used for all other track
sition (parallel to chordline).
corrections.
(1). To lower blade tip that tends to climb
NOTE: Blade tab and/or track can make the during ground tracking at high rpm or
collective heavy or light. during forward flight, bend appropriate
B. Pitch Control Link Adjustment tab section slightly downward; to raise
tip of blade that tends to descend, bend
Repeat this adjustment procedure as necessary tab slightly upward. If only slight track
to establish ground idle track: correction is necessary, limit tab
bending to width of bending tool. If
(1). To lower a blade tip, shorten pitch more correction is necessary, bend a
control link assembly. To raise a blade slightly wider section of tab. Use small
tip, lengthen pitch control link assem adjustments to avoid excessive rebend
bly. One-sixth of a turn of link (one flat) ing of tabs.
raises or lowers blade tip approximately
1/4 inch (6.35 mm). NOTE: Tab zones on same blade can require
bending in opposite directions. For example,
Center each rod end or (fitting
CAUTION wear) results. Make sure there after bending tab zone A downward to get
good tracking at 60-90 knots, it might be
is no binding in full up travel position. come necessary to bend tab zone D or E up
(2). After adjusting pitch control link ward to correct track at redline airspeed. In
length, center each rod end in its fitting any case, do not use larger tab corrections
and hold while tightening jam nuts; than are actually necessary.
safety with lockwire. (2). Each time blade tabs are adjusted,
C. Blade Tab Adjustment recheck ground idle track and readjust
if necessary.
(Ref. Figure 502) Once ground idle track is
obtained, all remaining tracking correction is (3). After completion of forward flight
accomplished by very slight bending of various tracking, balance and check autorota
blade tab zones with tab bending tool (ST902). tion rpm.
Different zones of tabs are used to adjust blade D. Main Rotor Ground Tracking
track at different airspeeds. In general, tab
zone A is used for high rpm, flat pitch ground (Ref. Figure 502) For best results, tracking
tracking (369D/E - 103% N2, 369FF/500N - should be performed under calm air conditions.
100% N2) and zones C, D, and sometimes E, Wind velocity should not exceed six knots
are used for tracking at higher airspeeds. Zone during adjustments. Accurate adjustment of
B is used to supplement zone A track correc initial ground track is very important. In most
tion when maximum tab (5 degrees) has been instances, forward flight tracking problems
applied to zone A; if necessary, zone B can also can be avoided or greatly reduced by setting
be used for correction in 0-110 knot airspeed initial track as nearly perfect as possible.
range. Tolerances specified in following instructions
Page 502
MAINTENANCE MANUAL
should be considered maximum permissible blade tab zone A until high rpm ground
deviation rather than desired goal. track is within tolerance.
NOTE: If main rotor hub or a pitch control rod E. Hover Track Verification
end bearing has been replaced, adjust pitch
control link(s) before proceeding with (Ref. Figure 502)
ground tracking.
(1). Hover track verification must be
performed after ground tracking and
(1). Before tracking blades that are not new, before forward flight tracking. Verifica
check that normally straight (not to be tion is only a check of hover track. Do
used) tab areas are in neutral position
not adjust pitch control links or blade
(centered on chordline) and straight. tabs because of track images observed
during hovering. Tab adjustments often
NOTE: On new (untracked) blades, check that cause variation between ground track
all tab areas are straight and in neutral po and hovering track. A large track
sition (centered on chordline 0° ±0.5°). variation can indicate that one or more
blades is beyond its chordwise balance
tolerance, but this can only be deter
(2). Load helicopter to a gross weight of mined during forward flight tracking.
approximately 2350 pounds (1066 kg); Perform hover track verification as
then ground idle (approximately follows.
64-65% N1).
NOTE: Collective pitch stick can be ”heavy” af
(3). Observe tracking tip cap reflector image ter tracking reflectors are mounted on blade
by directing strobe light beam toward tips. This condition is not unusual and can
blade tip path and sweeping beam be disregarded.
slowly back and forth until reflector
images are clearly seen. Tracking image (2). Verify helicopter gross weight of
should appear directly in front of 2000—2500 pounds (908—1135 kg).
helicopter or slightly off helicopter
centerline. (3). With collective pitch stick full down,
increase N2 to 103% - 369D/E, 100% -
(4). If blades are in track, tip cap reflector 369FF/500N.
image pattern should resemble image A
(Ref. Figure 501), (no blade tip more (4). Observe tracking reflector images to
than 1/4 of one tracking reflector verify that ground track is within
diameter, 1/8 inch (3.175 mm) above or limits.
below adjacent reflectors). If blades are
in track, proceed with (5). below. If (5). With helicopter in a stable hover,
blades are out of track, adjust pitch observe reflector images. If one or more
control links and repeat step (3). above. blades are out of track, record condi
tion(s) for reference during forward
(5). With collective pitch stick full down, flight tracking.
increase engine speed to 103% N2 -
369D/E, 100% N2 - 369FF/500N and (6). Proceed with forward flight tracking.
observe tip cap reflector image to see if
blade track is changed from ground idle Use of the tracking strobe
track. When all five blades are in track WARNING light in night flight is not
within 1/4 of one reflector diameter, 1/8 recommended. Such use can result in
inch (3.175 mm), ground track is pilot disorientation or loss of vision
correct; proceed with hover verification. with resultant damage to the helicop
When a blade is out of track, adjust ter and personal injury.
Page 503
MAINTENANCE MANUAL
BLADE STATIONS 93 99 105 111 117 124 130 142 158

MAIN ROTOR BLADE
(TOP VIEW)
65 IN.
(165 CM) 59 IN.
(150 CM) 53 IN.
369D/E (135 CM) 47 IN.
(119 CM) 41 IN.
(104 CM) 34 IN.
(86 CM) 28 IN.
(71 CM) 16 IN.
(41 CM)
TAB ZONES E D A
NOT USED
(NOTE 1) C B TO END OF
NOTE 2 BLADE NOT USED
HIGH RPM GROUND (NOTE 1)
MEDIUM SPEED
TRACKING AND UP TO
FLIGHT TRACKING
110 KNOTS IN FLIGHT
130-145 KNOTS
(103 % N2)
HIGH SPEED 110-130 KNOTS
FLIGHT TRACKING IN FLIGHT
130-145 KNOTS (103 % N2)
(103 % N2)
MAIN ROTOR BLADE BLADE STATIONS 93 99 105 111 117 124 130 148 164
(TOP VIEW)
71 IN.
(180 CM) 65 IN.
(165 CM) 59 IN.
369FF/500N (150 CM) 53 IN.
(135 CM) 47 IN.
(119 CM) 40 IN.
(102 CM 34 IN.
(86 CM) 16 IN.
(41 CM)
TAB ZONES E D A
NOT USED
(NOTE 1) C B TO END OF
NOTE 2 BLADE NOT USED
HIGH RPM GROUND (NOTE 1)
MEDIUM SPEED TRACKING AND UP TO
FLIGHT TRACKING 110 KNOTS IN FLIGHT
130-145 KNOTS
SHOCK CORD (100% N2) 110-130 KNOTS
(OR EQUIVALENT) HIGH SPEED IN FLIGHT
FLIGHT TRACKING (100% N2)
145-152 KNOTS
(100% N2)
NOTES:
1. UNUSED TAB ZONES MUST BE MAINTAINED
STRAIGHT, NEUTRAL AND PARALLEL.
2. USE ONLY AS NECESSARY TO SUPPLEMENT
ZONE D TO AVOID EXCESSIVE TAB BENDING
POINTER IN ZONE D.
TAB BENDING TOOLS
BENDER
G18-1002C
Figure 502. Main Rotor Blade Tab Adjustment
Page 504
MAINTENANCE MANUAL
F. Forward Flight Tracking ferred, even though observed blade track

can be beyond specified tolerances.
(Ref. Figure 502) Forward flight tracking
should be performed whenever vertical flight (4). After flight tracking is completed,
vibrations indicate that blades can be out of perform a Main Rotor System Balance
track. Procedure and Main Rotor Autorotation
RPM Check.
(1). Verify helicopter gross weight of
2000—2500 pounds (907—1134 kg). 3. Main Rotor System Balance Procedure
(2). Perform flight tracking from hover up Balance the main rotor system according to
to 110 knots at 103% N2 - 369D/E, instructions in the Tracking and Balancing
100% N2 - 369FF/500N. If flight track Manual. Since vibration reduction is accom
varies from hover track more than 1/2 plished by slight adjustment in phasing, the
inch (12.7 mm), bend tab zone A (five instruction outline in the Tracking and
degrees maximum) to limit variation to Balancing Manual must be closely followed for
tab zone B (five degrees maximum). best results. Safety damper turnbuckle after
completing phasing balance adjustments.
2. Main Rotor Blade Tab Adjustment
(1). Check autorotation rpm; rpm must not 4. Main Rotor Autorotation RPM Check
be less than 480. (Ref. Table 502 for 369D/E and Table 503
Do not attempt to adjust chord 369FF and 500N). An autorotation rpm check
CAUTION wise balance of a blade found to is required after each blade tracking operation
be faulty when performing banked turns. and whenever rpm is outside limits listed.
Chordwise balance corrections must be ac Check rotor rpm and make adjustments as
complished by manufacturer (MDHI). follows.
(2). Perform a series of 45 degree banked CAUTION

turns at 100 knots and observe track
change from level flight. If any blade D Autorotation rpm is critical to a success
climbs or dives more than one inch out ful autorotation landing. When full main
of track with others, chordwise balance rotor rpm is not available, autorotation
(center of gravity) of that blade is function is decreased. At high gross
beyond its tolerance and blade must be weights and/or density altitudes, the
replaced. (Hover track variations of this main rotor rpm will try to overspeed. The
type that do not repeat during banked- pilot must increase collective pitch to
turn maneuver can be disregarded.) keep main rotor rpm within limits. At
lower gross weights and/or density alti
(3). Perform flight tracking at 110-155 tudes, the main rotor rpm will be under
knots and 103% N2 - 369D/E, 100% N2 speed. The pilot has less rotor energy
- 369FF/500N. If necessary, adjust tab available to do the autorotation landing.
zone B (five degrees maximum) to limit Set the autorotation rpm within the lim
track variation to 1/2 inch (12.7 mm) or its of the Autorotation Percentage Chart
less and to minimize excessive vertical to make sure sufficient autorotation rpm
(one-per revolution) vibration. If is available at the helicopter minimum
variation is excessive, bend tab zone C gross weight.
or D (five degrees maximum).
D All autorotation rpm adjustments shall
NOTE: When determining whether blade track be made at the main rotor pitch control
is acceptable, overall vibration level of heli links only. Do not re-adjust mixer control
copter should be determining factor. Some rods after rigging is accomplished. Fail
combinations of rotor blades might produce ure to observe this precaution can result
higher five-per-revolution vibration as in serious damage to rotor system and
blade tips are brought into close track; in controls. Do not adjust control rod end be
such cases, lowest vibration level is pre yond witness hole.
Page 505
MAINTENANCE MANUAL
D Tracking targets reduce blade to tailboom 5. Main Rotor Hub Balancing Procedure
clearance, performing autorotations to
the ground could result in boom strikes. Balance the main rotor hub according to the
following instructions.
NOTE: Change length of all five pitch control
links as necessary to adjust autorotation Consumable Materials
rpm. Be sure to lengthen or shorten all five (Ref. Section 91−00−00)
links exactly same amount or blade track is Item Nomenclature
changed. One flat (1/6 turn) of control link
CM420 Sealant
body causes approximately four rpm change
in autorotation rpm.
Special Tools
(1). Autorotation Rpm Check: Load 369D/E (Ref. Section 91-00-00)
helicopter to a gross weight of 2250 Item Nomenclature
pounds (1021 kg): 2350 pounds ST903 Balancer/analyzer instrument kit
(1066 kg) for 369FF and 500N. Per
form a practice autorotative descent
(Ref. PFM), taking care not to allow NOTE:
rpm to exceed rotor speed limitations. D If swashplate has weights removed,
During autorotation take careful note of there should be three AN970-3 washers
stabilized autorotation rpm at one of at the green pitch housing bolt.
gross weight/density altitude combina
D In some instances, main rotor hub bal
tions. After landing, compare observed
ance can not be achieved without addi
rpm with values (Ref. Tables 502 and
tion of swashplate weights (Ref. Section
503). If observed rpm is within limits in
62-30-00, Counterweight and
table, rpm setting is correct. If limits
Interrupter Installation)
were exceeded, make corrective adjust
ments according to (2). below, until rpm (1). Remove main rotor blades.
is within limits.
(2). Remove main rotor dampers.
NOTE: After autorotation rpm adjustments are
satisfactorily accomplished, remove track (3). Hook up Phazor. Refer to Chadwick-
ing equipment before returning helicopter Helmuth Operation and Service
to service. Be sure to correctly tighten and Instruction Handbook (ST903).
safety all bolts after they are reinstalled.
NOTE: Refer to applicable Rotorcraft Flight
Manual, Section 7, for blades-off operating
(2). Autorotation Rpm Adjustment: Change procedures.
length of all five pitch control links as
required to adjust autorotation rpm. (4). Run engine at 103% N2 - 369D/E,
Make certain all five links are short 100% N2 - 369FF/500N.
ened or lengthened exactly the same
amount or blade track will be altered. Observe N2 speed avoid range
CAUTION limits during this procedure and
exercise caution when increasing twistgrip
CAUTION to flight idle position to avoid N2 overshoots.
D Do not adjust (lengthen) pitch control link (5). Record IPS reading and direction on
rodend threads beyond witness holes in main rotor balance chart (Ref.
rods. Figure 503).
D Do not readjust mixer control rods after (6). Plot IPS reading and direction on main
rigging has once been accomplished. Fail rotor balance chart (Ref. Figure 503).
ure to observe this precaution can result
in serious damage to rotor system and (7). Analyze chart for weight location and
controls. amount requirements.
Page 506
MAINTENANCE MANUAL
The maximum allowable bal (3.39—6.78 Nm) as applicable. Coat

CAUTION ance weight per lead-lag bolt on screw threads, nuts and washers with
the main rotor hub assembly is 150 grams. sealant (CM420). (To prevent imbal
ance, do not use excessive amount of
(8). Install weights as follows: (Ref. sealant.)
Figure 504).
NOTE: Intermixing of P/N 369D21400-503 and
(a). Engage head of screw, inside lead-lag M50452 main rotor blade damper assem
bolt, with Phillips screwdriver, then blies in a shipset is not permitted. All damp
loosen locknut with 1/4 inch wrench. ers in shipset must be of same type and part
(b). Hold screw in place with screwdriver number.
while adding or removing flat wash (11). Reinstall main rotor blades (Ref.
ers as required, then reinstall Section 62-10-00).
locknut.
NOTE: If main rotor dampers require more
(9). Repeat steps (4). thru (8). until reading than four flats adjustment, re-phase main
is 0.15 IPS, or less. rotor dampers (Ref. Section 62-20-00, Main
(10). After balance has been established Rotor Damper Phasing Procedure).
satisfactorily, torque MS21042L08 (12). Perform main rotor system balance.
locknuts to 20—35 inch-pounds
(2.26—3.95 Nm) or MS21042L3 (13). Track main rotor blades (Ref. Blade
locknuts to 30—60 inch-pounds Tracking Procedure).
Table 501. Summary Procedure for Blade Tracking
Satisfactory Unsatisfactory
Step Result Result Corrective Action
(1) Observe ground track. Go to step (2). Ref. Corrective Adjust pitch control links and blade
Action. tabs as required. Repeat track
observation.
(2) Perform hover verification. Go to step (3). Ref. Corrective Record track verification and proceed
Action. with forward flight tracking.
(3) Perform forward flight tracking. Go to step (4). Ref. Corrective Adjust blade tabs and repeat forward
Action. flight tracking.
(4) Perform autorotation rpm Go to step (5). Ref. Corrective Adjust autorotation rpm and repeat
check. Action. rpm check.
(5) Remove tracking equipment
and return helicopter to service.
NOTE: Ground rock or stick shake with rotor blades in track during ground track indicates rotor blades are not
properly phased.
Page 507
MAINTENANCE MANUAL
Table 502. Autorotation Rpm Chart (369D/E)
Gross Wt Stabilized Autorotation Rpm at Density Chart

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

Gross Stabilized Autorotation Rpm/Percentage at Density Chart
Wt
lb (kg) Sea Level 1000 Ft 2000 Ft 3000 Ft 4000 Ft 5000 Ft
Analog Instrumentation (RPM)
2216
459—469 465—475 471—481 477—487 483—493 489—499
(1005)
2316
466—476 472—482 478—488 484—494 490—500 496—506
(1051)
2416
473—483 479—489 485—495 491—501 497—507 −−−
(1096)
2516
480—490 486—496 492—502 498—508 −−− −−−
(1189)
Digital Instrumentation (Percentage)
2216
96.23—98.32 97.48—98.58 98.74—100.84 100.00—102.10 101.26—103.35 102.52—104.61
(1005)
2316
97.69—99.79 98.95—101.05 100.21—102.31 101.47—103.56 102.73—104.82 103.98—106.08
(1051)
2416
99.16—102.26 100.42—102.52 101.68—103.35 102.94—105.03 104.19—106.29 −−−
(1096)
2516
100.63—102.73 101.89—103.98 103.14—105.24 104.40—106.50 −−− −−−
(1189)
NOTES:
(1) Chart values based upon 15°C (59°F) outside air temperature. At sea level, 8°C (14°F) temperature change is
equal to 1000 feet (305 M) of change in density altitude.
(2) Do the autorotation rpm/percentage checks at gross weight/density altitude combinations for which
rpm/percentage values are given. Blank spaces indicate that application of collective pitch may be necessary to
avoid rotor overspeed.
Page 508
MAINTENANCE MANUAL
60 GRAMS
BLUE
4 40
40 YEL
GRN 20
2 3
12
0
40 20 1 20
11
60 GRAMS 1.0
.9
.8
0 TGT
.7
2 WHITE
40 10 .6
20 5
YEL .5
3 .4
.3 40
20
.2
.1 .1 .2 .3 .4 .5 .6 .7 .8 .9 1.0
3 60 GRAMS
9 .1
0
.2
.3 40
.4
.5 BLUE
RED 20 20 4
1 .6
8 4
.7
.8 0
40 .9
1.0
7 5 20
20 0 RED
60 GRAMS 40 6 1
20 40
GRN
2 40
TGT
WHITE 60 GRAMS
HELICOPTER S/N HUB S/N 5
G18-1003A
CLOCK BALANCE WEIGHT AND LOCATION

RUN NO. IPS
ANGLE (1) RED (2) GREEN (3) YELLOW (4) BLUE (5) WHITE
Figure 503. Main Rotor Hub Balancing Chart
Page 509
MAINTENANCE MANUAL
MS21042L08 NUT A
369D29935 MAIN ROTOR NOTE 1 (NOTE 2)
HUB BALANCE WEIGHT AN960C8, AN960C8L WASHERS
SUPPORT WASHER AS REQUIRED TO BALANCE
(NOTE 5)
369D21220 LEAD-LAG BOLT
369D29934 WASHER
NAS602-64P, -72P OR -76P

SCREW
369D21300-501
LINK ASSY PITCH HOUSING
369A1219 NUT AND
MS24665-300 COTTER PIN
(NOTE 4)
A-A
SERIAL NO. 0260D AND SUBS
MS21042L3 LOCKNUT
(NOTE 3)
NOTE 1 AN960C10, AN960C10L WASHERS
AS REQUIRED TO BALANCE
(NOTE 5)
HS1555 WASHER AN970-3 WASHER
369A1220 LEAD-LAG BOLT
HS1554 WASHER
369A1219 NUT AND NAS603-56 OR -64

MS24665-300 COTTER PIN SCREW
(NOTE 4)
A-A
SERIAL NO. 003D THRU 0259D
NOTES:
1. COAT SCREW THREADS, NUTS AND WASHERS
WITH PR-1436-G, CLASS B-2 SEALANT.
2. TORQUE MS21042L08 NUT TO 20 - 35 INCH-POUNDS
(2.26 - 3.95 NM).
3. TORQUE MS21042L3 NUT TO 30 - 60 INCH-POUNDS
(3.39 - 6.78 NM).
4. DO NOT REMOVE OR DISTURB TORQUE ON 369A1219 NUT.
5. THE MAXIMUM ALLOWABLE BALANCE WEIGHT PER LEAD-LAG
G18-1004B
BOLT ON THE MAIN ROTOR HUB ASSEMBLY IS 150 GRAMS.
Figure 504. Main Rotor Hub Balancing
Page 510
MAINTENANCE MANUAL
Section
18−10−60
Main Rotor Track
and Balance (600N)
MAINTENANCE MANUAL
MAIN ROTOR TRACK AND BALANCE (600N)

1. Main Rotor Blade Tracking
CAUTION
Immediately investigate the
WARNING cause of a sudden onset of D Understand the blade tracking sequence
excessive or unusual main rotor vibra and related adjustments before attempt
tion prior to continued flight. Under no ing blade track procedures.
circumstance should main rotor track D If main rotor hub balance is suspect, bal
ing be attempted to correct the prob ance rotor hub prior to doing blade track.
lem until a thorough inspection of the
main rotor blades, hub assembly and 2. Main Rotor System Balancing
strap pack assembly has been done.
Main rotor hub balancing is accomplished by
NOTE: Ref. Table 201 to isolate ground or in- adding or removing weight (flat washers) as
flight blade tracking problems. required at the lead-lag bolts (Ref. Main Rotor
Main rotor blade track is observed by means of Hub Balancing Procedure). Analysis of main
reflective tip caps temporarily installed on rotor hub balance is accomplished using
each blade and a high-intensity strobe light. instrumentation that measures and localizes
Blade track is determined by observing the vibrations due to main rotor hub imbalance.
apparent tip cap pattern created by strobe Data provided by the instrumentation is
light pulses synchronized with the rotating plotted on a chart designed to indicate how
blades. Strobe light electrical power is supplied much weight must be added or removed from
by the helicopter electrical system. the lead-lag bolt. No other means of balancing
is to be used.
a. Tracking must be accomplished in the fol
lowing sequence of six steps: 3. Balancing Equipment and Balance Spare
1). Verification of proper blade phasing Kit
(Ref. Main Rotor System Balance Proce
dure).
Special Tools
2). Ground tracking (Ref. Section 91-00-00)
(Ref. Main Rotor Ground Tracking). Item Nomenclature
3). Verification of proper rotor balance
ST903 Balancer/analyzer instrument kit
(Ref. Main Rotor System Balance Proce
dure).
4). Hover verification The balancing equipment (ST903) contains all
(Ref. Hover Track Verification). equipment needed to analyze main rotor
5). Forward flight tracking balance.
(Ref. Forward Flight Tracking).
When working near engine air
6). Autorotation rpm adjustment CAUTION inlet, comply with all precau
(Ref. Main Rotor Autorotation RPM tions to prevent entry of foreign material.
Check). Carefully observe precautions in the Track
b. No attempt should be made to verify or ing and Balancing Manual relating to the
adjust blade track without first checking placement and security of equipment (espe
and adjusting blade phasing, a function of cially cables) fastened to the exterior of the
main rotor damper adjustment. helicopter.
Page 201
MAINTENANCE MANUAL
Table 201. Isolating Tracking Problems
GROUND TRACKING
Rotor does not follow adjustments. Turning P/C link wrong direction. Adjust correctly.
Pitch link bearing worn. Trim tab Replace bearing. Zero trim tabs.
bent excessively.
Excessive diving or climbing of Trim tab bent excessively. Zero trim tabs.
blade from low speed ground track
to high speed ground track. Pitch link control not coordinated Set pitch link to nominal 6.25 inches
with trim tab bend (Intermixing (15.88 cm) and zero trim tabs.
control input).
Damage to blade or tabs. Inspect for damage.
Excessive torque and erratic high Pitch change links too long or Set to nominal 6.25 inches (15.88
speed ground tracking. collective rigging too high. cm). Check collective rigging.
IN−FLIGHT TRACKING
Blade track changes with power Worn pitch bearing housing Replace bearings.
and control changes. bearings.
Missing pitch bearing liner. Replace bearing.
Broken or loose feathering studs. Repair or replace studs.
Binding rotating scissor crank at Repair or replace crank.

lower main rotor hub shoe.
Play between longitudinal pitch Re−bond collective pitch mixer

mixer bellcrank and collective pitch bearings and install shims between
mixer bellcrank. longitudinal pitch mixer bellcrank and
bearings (Ref. Sec. 62−30−60).
Helicopter has rough feeling with Tilted tracking images, no blade in Retrack blades.
some vibration while appearing to track.
be in track.
Pitch link control not coordinated Set pitch link to nominal 6.25 inches
with trim tab bend (intermixing (15.88 cm) and zero trim tabs.
control input), with climbing or
diving blades within acceptable
track limits.
Blades very erratic in response to Tab bent too much in wrong area. Correct by limiting bending.
tab bends.
Blade erosion, but within chordwise Track erratic blade to other blades.
limits.
Tab bent too many degrees in one Limit tab bending to smaller degree
area. over larger area.
Blades climb or dive excessively at Too much tab bending in outboard Remove outboard bending and
high speeds. tab areas. increase inboard bending.
Page 202
MAINTENANCE MANUAL
Table 201. Isolating Tracking Problems (Cont.)

Ground track off at low speed and Excessive tab bending and pitch Set pitch link to nominal 6.25 inches
stick shake at 100% N2. link control not coordinated with tab (15.88 cm) and zero trim tabs.
bend (intermixing control input).
Helicopter in track but has stick Blade out of phase. Check phasing.
shake.
Feedback in collective control. Main rotor system out of balance. Balance rotor system.
Loose or binding rotating scissors. Check and repair as required.
Heavy collective stick − climb and Overcenter adjustment set too low. Adjust.
cruise.
Trim tab bent down excessively. Adjust.
Light collective stick − climb and Overcenter adjustment set too Adjust.
cruise. high.
Trim tabs bent up excessively. Adjust.
Heavy collective lift-off − light flight. Bungee spring adjusted too short. Adjust to nominal.
Light collective lift-off − heavy flight. Bungee spring adjusted too long. Adjust to nominal.
Page 203
MAINTENANCE MANUAL
Page 204
MAINTENANCE MANUAL

1. Main Rotor System Tracking Equipment (4). The number one blade is seen on the
Installation extreme left, number two blade is seen
second from left, and so on thru number
(Ref. Figure 401 and Figure 402) Equipment six which is seen on the extreme right.
needed to track main rotor blades consists of
the tracking and balancing equipment (ST903) (5). Additional interrupters can be added to
and the tip cap assemblies (ST901). Instruc be compatible with the older balance/
tions for equipment installation are contained analyzer instrument kits.
in Chadwick-Helmuth Operation and Service
Instruction Handbook. (6). Torque the interrupter as shown in
Figure 401.
Special Tools
B. Magnetic Pickup Installation
Item Nomenclature
with a magnetic pickup support bracket
ST901 Tip cap assembly installed with shim washers to prevent
ST903 Balancer/analyzer instrument kit distortion of the bracket when the nut
on the bolt that secures the link bearing
is torqued to 30—60 inch-pounds
(3.39—6.78 Nm).
NOTE: Main rotor tracking tip caps manufac
tured by the same firm that manufactures (2). To preclude rocking movement of
the tracking and balance equipment, are magnetic pickup support bracket when
components of the tracking and balancing installed on stationary swashplate,
equipment and can be used instead of tip check clearance between swashplate
cap assembly (ST901). In procedures that and lower flange of bracket. If gap
follow, use of tip cap assembly is presumed. exists, tap bent tip of lower flange
If tip caps from the balancing equipment are (typical both sides of bracket) until bent
used, refer to the Tracking and Balancing tip touches swashplate.
Manual for tip cap data.
(3). Reinstall by forcing bracket until
A. Interrupter Installation elongated bracket holes align with hole
in stationary swashplate.
(1). The helicopter is equipped with a main
rotor blade tracking interrupter located (4). Install the magnetic pickup and cable
on the rotating swashplate. as instructed in the Chadwick-Hel
muth Operation and Service Instruc
tion Handbook.
(2). The interrupter creates six equally
spaced horizontal reflective images, as (5). After final adjustment, torque the
viewed by the technician, when the adjustment nut to 15—20 inch-
main rotor blade tips are illuminated pounds (1.69—2.26 Nm) and ensure
with the test strobe light. the cable is routed and tied down in
such a manner as not to be dislodged or
(3). The balance analyzer separates the interfere with control components at
image of each main rotor blade tip cap their extremes of travel.
by approximately 0.25 inch (6.35 mm).
This staggered relationship allows the (6). Ensure the interrupter passing closest
technician to view the stopped image of over magnetic pickup, clears pickup by
each blade in order of rotation. not less than 0.030 inch (0.76 mm).
Page 401
MAINTENANCE MANUAL
2
1
PLACE DOUBLE INTERRUPTER
ROTATION OVER MAGNETIC PICKUP AND
THEN ATTACH TIP TARGET
NUMBERS EXACTLY AS SHOWN.
TAPE
3 6
4
5
TRACKING TARGET
(NOTE 1)
SCISSORS
CRANK
TIP CAP
ROTATION
OF HUB
TRACKING TIP CAP
INSTALLATION INTERRUPTER
(NOTE 4)
SCISSORS LINK (NOTE 6)
INTERRUPTER
(NOTE 4)
(NOTE 5)
ROTATING
SWASHPLATE
STATIONARY
SWASHPLATE
NOTES:
1. ALWAYS REMOVE TARGETS AFTER TRACKING.
2. INSTALL WASHERS BETWEEN BRACKET AND
SWASHPLATE TO FILL GAP.
3. ADJUST AS REQUIRED FOR GAP INDICATED.
4. REFER TO IPC FOR PART NUMBER.
5. TORQUE NUT TO 15-20 IN. LBS (1.69-2.26 NM).
6. TORQUE NUT TO 50-60 IN. LBS ((3.39-6.78 NM). MAGNETIC PICKUP
6G18-014-1A
Figure 401. Blade Tracking Equipment − Main Rotor Components (Sheet 1 of 2)
Page 402
MAINTENANCE MANUAL
0.030-0.070 IN.
(0.762-1.778 MM)
INTERRUPTER GAP (TYP) SUPPORT NOTE 2
(NOTE 3) BRACKET
ADJUSTMENT
JAMNUT
TEST EQUIPMENT
PROTECTIVE CAP
CABLE RECEPTACLE
INTERRUPTER-TO-MAGNETIC PICKUP GAP PICKUP INSTALLATION
6G18-014-2
Figure 401. Blade Tracking Equipment − Main Rotor Components (Sheet 2 of 2)

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

SECURING GAP AND
VIEW LOOKING DOWN SAFETY WIRE
0.030-0.070 IN.
MAGNETIC (0.762-1.778 MM)
PICKUP GAP (TYP)
ENGINE AIR INLET FAIRING
(LEFT HAND SIDE)
MAGNETIC PICKUP INSTALLATION
ACCELEROMETER/VELOMETER
BALANCING VIEW LOOKING
INBOARD
TAPE
ACCELEROMETER INSTALLATION
6G18-015
Figure 402. Main Rotor Balancing Equipment Installation
Page 404
MAINTENANCE MANUAL

ADJUSTMENT/TEST
1. Blade Tracking Procedure
Table 501 is a summary of the sequence of TIP PATH PLANE
required procedures for blade tracking.
1 2 3 4 5
(1). Install strobe light, blade tip cap
IMAGE A: ALL BLADES IN TRACK
reflectors and related equipment.
(2). Use 1/2 inch (12.7 mm) diameter
2
tracking tip cap reflector as a guide for 1 3 4 5
estimating track accuracy. For example: IMAGE B: ONE BLADE APPROX. 1/2 IN. (12.7 MM) HIGH
(a). A tip cap reflector image displace

ment of 1/2 diameter up, or down, 2
indicates blade tip is approximately 1 4 5
1/4 inch (6.35 mm) out of track. 3
IMAGE C: ONE BLADE APPROX. 1/2 IN. (12.7 MM) HIGH

(b). One full reflector diameter indicates ONE BLADE APPROX. 1 IN. (25.4 MM) LOW
1/2 inch (12.7 mm) out of track. 6G18−016A
CORRECTIVE ACTION
NOTE: Rocking or stick shake caused by a cor
HIGH RPM AND
rectly tracking rotor indicates improper CONDITION GROUND IDLE RPM FWD FLIGHT
blade phasing.
IMAGE A NONE REQUIRED NONE REQUIRED
(3). Accomplish blade phasing (Ref. Section IMAGE B SHORTEN PITCH CONTROL MOVE TAB DOWNWARD
ROD (2ND BLADE) (2ND BLADE) MOVE TAB
62-20-60) when installing new rotor UPWARD (3RD BLADE)
blades or if ground rock or stick shake
IMAGE C SHORTEN PITCH CONTROL MOVE TAB DOWNWARD
is noted. This must be accomplished ROD (2ND BLADE): (2ND BLADE): MOVE TAB
prior to starting tracking procedure. LENGTHEN CONTROL ROD UPWARD (3RD BLADE)
(3RD BLADE)
NOTE: Final rotor system balance cannot be
accomplished until blades are in track. NOTE: Chordwise spacing of tracking images
are not an accurate indication of blade phas
(4). Ground tracking is basically track-ob ing. Do not adjust blade phasing in an at
servation and adjustment of idle and tempt to equalize spacing. Slight tilting of
flight rpm. Improper track at idle rpm magnetic interrupters or balance of the
is corrected by adjusting length of pitch main rotor system can move the image
control links connecting rotating
swashplate and blade pitch housing. Figure 501. Typical Track Conditions and
Ground track at flat pitch and flight Adjustments
rpm is corrected by blade tab adjust (6). Forward flight track is corrected only
ment. by making blade tab adjustments.
(5). Hover track verification is essentially Forward flight tracking requires track
an observation to check for track observation during following airspeeds
variations between high rpm (flat pitch) and maneuvers: Flight at 0-100 knots.
ground track check and hovering. Forty-five degree banked turns at
80-100 knots. Flight at 100-155 knots.
NOTE: Track adjustments are not made on ba (7). Check for proper balance of rotor
sis of track observations during hovering. system prior to checking autorotation.
However, track variations should be noted
and recorded for use during check of track in (8). Obtaining correct autorotation rpm
forward flight. consists of checking main rotor rpm
Page 501
MAINTENANCE MANUAL
during stabilized autorotation flight sometimes E, are used for tracking at higher
and adjusting rpm to specified limits as airspeeds. Zone B is used to supplement zone
necessary. Autorotation rpm check A track correction when maximum tab (5
must be accomplished to ensure that degrees) has been applied to zone A; if
track adjustments do not alter rotor necessary, zone B can also be used for correc
performance necessary for safe power- tion in 0-110 knot airspeed range.
off landings.
Special Tools
A. Blade Track Adjustment
Although adjustment of pitch control links Item Nomenclature
affects blade track at all rotor speeds, they ST902 Main rotor blade fixture and tab bending
should be adjusted only when necessary to tool
establish acceptable track at ground idle
speed; blade tabs are used for all other track Minimize bending and restrict
corrections. CAUTION adjustments to very small incre
ments so that bonded trailing edge joint be
NOTE: Blade tab and/or track can make the tween upper and lower skins is not dam
collective heavy or light.
aged. Tabs must never be displaced more
B. Pitch Control Link Adjustment than five degrees above or below neutral po
sition (parallel to chordline).
Repeat this adjustment procedure as necessary
to establish ground idle track: (1). To lower blade tip that tends to climb
during ground tracking at high rpm or
(1). To lower a blade tip, shorten pitch during forward flight, bend appropriate
control link assembly. To raise a blade tab section slightly downward; to raise
tip, lengthen pitch control link assem tip of blade that tends to descend, bend
bly. One-sixth of a turn of link (one flat) tab slightly upward. If only slight track
raises or lowers blade tip approximately correction is necessary, limit tab
1/4 inch (6.35 mm). bending to width of bending tool. If
more correction is necessary, bend a
Center each rod end or pitch slightly wider section of tab. Use small
CAUTION case and/or swashplate wear adjustments to avoid excessive rebend
will result. Ensure there is no binding in full ing of tabs.
up travel position.
NOTE: Tab zones on same blade can require
(2). After adjusting pitch control link bending in opposite directions. For example,
length, center each rod end in its fitting after bending tab zone A downward to get
and hold while tightening jam nuts; good tracking at 60-90 knots, it might be
safety with lockwire. come necessary to bend tab zone D or E (Ref.
Figure 502) upward to correct track at red
C. Blade Tab Adjustment line airspeed. In any case, do not use larger
(Ref. Figure 502) Once ground idle track is tab corrections than are actually necessary.
obtained, all remaining tracking correction is (2). Each time blade tabs are adjusted,
accomplished by very slight bending of various recheck ground idle track and readjust
blade tab zones with tab bending tool (ST902). if necessary.
Different zones of tabs are used to adjust blade
track at different airspeeds. In general, tab (3). After completion of forward flight
zone A is used for high-rpm, flat pitch ground tracking, balance and check autorota
tracking (100% N2) and zones C, D, and tion rpm.
Page 502
MAINTENANCE MANUAL
MAIN ROTOR BLADE BLADE STATIONS 93 99 105 111 117 124 130 148 164
(TOP VIEW)
71 IN.
(180 CM) 65 IN.
(165 CM) 59 IN.
(150 CM) 53 IN.
(135 CM) 47 IN.
(119 CM) 40 IN.
(102 CM 34 IN.
(86 CM) 16 IN.
(41 CM)
NOT USED
(NOTE 1) TAB ZONES E D A
NOTE 2 C B TO END OF
BLADE NOT USED
SHOCK CORD HIGH RPM GROUND (NOTE 1)
MEDIUM SPEED TRACKING AND UP TO
(OR EQUIVALENT)
FLIGHT TRACKING 110 KNOTS IN FLIGHT
130-145 KNOTS
(100% N2) 110-130 KNOTS
HIGH SPEED IN FLIGHT
FLIGHT TRACKING (100% N2)
145-152 KNOTS
(100% N2)
NOTES:
1. UNUSED TAB ZONES MUST BE MAINTAINED
STRAIGHT, NEUTRAL AND PARALLEL.
2. USE ONLY AS NECESSARY TO SUPPLEMENT
ZONE D TO AVOID EXCESSIVE TAB BENDING
POINTER IN ZONE D.
TAB BENDING TOOLS
BENDER
6G18-017A
Figure 502. Adjustment − Main Rotor Blade Tab

D. Main Rotor Ground Tracking NOTE: On new (untracked) blades, check that
all tab areas are straight and in neutral po
sition (centered on chordline 0.0° ±0.5°).
For best results, tracking should be performed
under calm air conditions. Wind velocity (2). Load helicopter to a gross weight of
should not exceed six knots during adjust approximately 2350 pounds (1066.9 kg);
ments. Accurate adjustment of initial ground then ground idle (approximately
track is very important. In most instances, 64-65% N1) with collective pitch stick
forward flight tracking problems can be full down.
avoided or greatly reduced by setting initial
track as nearly perfect as possible. Tolerances (3). Observe tracking tip cap reflector image
specified in following instructions should be by directing strobe light beam toward
considered maximum permissible deviation blade tip path and sweeping beam
rather than desired goal. slowly back and forth until reflector
images are clearly seen. Tracking image
should appear directly in front of
NOTE: If main rotor hub or a pitch control rod helicopter or slightly off helicopter
end bearing has been replaced, adjust pitch centerline.
control link(s) before proceeding with
ground tracking. (4). If blades are in track, tip cap reflector
image pattern should resemble image
A, (Ref. Figure 501) (no blade tip more
(1). Before tracking blades that are not new, than 1/4 of one tracking reflector
check that normally straight (not to be diameter, 1/8 inch (3.175 mm), above or
used) tab areas are in neutral position below adjacent reflectors). If blades are
(centered on chordline) and straight. in track, proceed with step (5). below. If
Page 503
MAINTENANCE MANUAL
blades are out of track, adjust pitch Use of the tracking strobe
control links and repeat step (3). above. WARNING light in night flight is not
recommended. Such use can result in
(5). With collective pitch stick full down, pilot disorientation or loss of vision
increase engine speed to 100% N2 and with resultant damage to the helicop
observe tip cap reflector image to see if ter and personal injury.
blade track is changed from ground idle
track. When all six blades are in track F. Forward Flight Tracking
within 1/4 of one reflector diameter, (Ref. Figure 502 and Figure 506 thru
ground track is correct; proceed with Figure 508) Forward flight tracking should be
hover verification. When a blade is out performed whenever vertical flight vibrations
of track, adjust blade tab zone A until indicate that blades can be out of track.
high rpm ground track is within
tolerance. (1). Verify helicopter gross weight of
2000—2500 pounds (908—1135 kg).
E. Hover Track Verification
NOTE: When bending trim tabs, do not bend
(Ref. Figure 504) more than 1.5° between six inch sections.
(1). Hover track verification must be (2). Perform flight tracking from hover up
performed after ground tracking and to 110 knots at 100% N2. If flight track
before forward flight tracking. Verifica varies from hover track more than 1/2
tion is only a check of hover track. Do inch (12.7 mm), bend tab zone A (five
not adjust pitch control links or blade degrees maximum) to limit variation to
tabs because of track images observed tab zone B (five degrees maximum).
during hovering. Tab adjustments often
cause variation between ground track (3). Check autorotation percentage; per
and hovering track. A large track centage must not be less than 480
variation can indicate that one or more (90%).
blades is beyond its chordwise balance Do not attempt to adjust chord
tolerance, but this can only be deter CAUTION wise balance of a blade found to
mined during forward flight tracking. be faulty when performing banked turns.
Perform hover track verification as Chordwise balance corrections must be ac
follows. complished by manufacturer (MDHI).
NOTE: Collective pitch stick can be ``heavy” af (4). Perform a series of 45 degree banked
ter tracking reflectors are mounted on blade turns at 100 knots and observe track
tips. This condition is not unusual and can change from level flight. If any blade
be disregarded. climbs or dives more than 1 inch (2.54
cm) out of track with others, chordwise
(2). Verify helicopter gross weight of balance (center of gravity) of that blade
2000—2500 pounds (908—1135 kg). is beyond its tolerance and blade must
(3). With collective pitch stick full down, be replaced or balanced by an MDHI
increase N2 to 100%. Field Representative. (Hover track
variations of this type that do not
(4). Observe tracking reflector images to repeat during banked-turn maneuver
verify that ground track is within can be disregarded.)
limits.
(5). Perform flight tracking at 100% N2. If
(5). With helicopter in a stable hover, necessary, adjust tab zone B (five
observe reflector images. If one or more degrees maximum) to limit track
blades are out of track, record condi variation to 1/2 inch (12.7 mm) or less
tion(s) for reference during forward and to minimize excessive vertical
flight tracking. (one-per revolution) vibration. If
variation is excessive, bend tab zone C
(6). Proceed with forward flight tracking. or D (five degrees maximum).
Page 504
MAINTENANCE MANUAL
NOTE: When determining whether blade track D All autorotation percentage adjustments
is acceptable, overall vibration level of heli shall be made at the main rotor pitch con
copter should be determining factor. Some trol links only. Do not re-adjust mixer
combinations of rotor blades might produce control rods after rigging is accomplished.
higher six-per-revolution vibration as Failure to observe this precaution can re
blade tips are brought into close track; in sult in serious damage to rotor system
such cases, lowest vibration level is pre and controls. Do not adjust control rod
ferred, even though observed blade track end beyond witness hole.
can be beyond specified tolerances.
D Tracking targets reduce blade to tailboom
(6). After flight tracking is completed, clearance, performing autorotations to
perform a Main Rotor System Balance the ground could result in boom strikes.
Procedure and Main Rotor Autorotation
RPM Check. NOTE: Change length of all six pitch control
links as necessary to adjust autorotation
percentage. Be sure to lengthen or shorten
2. Main Rotor System Balance Procedure
all six links exactly same amount or blade
track is changed. One flat (1/6-turn) of con
Balance the main rotor system according to trol link body causes approximately one per
instructions in the Chadwick-Helmuth cent change in autorotation percent.
Operation and Service Instruction Handbook.
The maximum allowable bal (1). Autorotation Percentage Check (Ref.

CAUTION ance weight per lead-lag bolt on Table 502) Load helicopter to a gross
the main rotor hub assembly is 143 grams. weight of 2775—2825 pounds
(1259—1281 kg). Perform a practice
autorotative descent (Ref. RFM), taking
3. Main Rotor Autorotation Percentage care not to allow percentage to exceed
Check rotor speed limitations. During autoro
tation, take careful note of stabilized
(Ref. Table 502) An autorotation percentage autorotation percentage at one of the
check is required after each blade tracking gross weight/density altitude combina
operation and whenever rpm is outside limits tions. After landing, compare observed
listed. Check rotor rpm and make adjustments percentage with values. If observed
as follows. percentage is within limits in table,
percentage setting is correct. If limits
were exceeded, make corrective adjust
CAUTION ments according to Autorotation
Percentage Adjustment, until percent
D Autorotation rpm is critical to a success age is within limits.
ful autorotation landing. When full main
rotor rpm is not available, autorotation
function is decreased. At high gross (2). Autorotation Percentage Adjustment:
weights and/or density altitudes, the Change length of all six pitch control
main rotor rpm will try to overspeed. The links as required to adjust autorotation
pilot must increase collective pitch to percentage. Make certain all six links
keep main rotor rpm within limits. At are shortened or lengthened exactly the
lower gross weights and/or density alti same amount or blade track will be
tudes, the main rotor rpm will be under altered.
speed. The pilot has less rotor energy
available to do the autorotation landing. NOTE: After autorotation percentage adjust
Set the autorotation rpm within the lim ments are satisfactorily accomplished, re
its of the Autorotation Percentage Chart move tracking equipment before returning
to make sure sufficient autorotation rpm helicopter to service. Be sure to correctly
is available at the helicopter minimum tighten and safety all bolts after they are re
gross weight. installed.
Page 505
MAINTENANCE MANUAL
Table 501. Summary Procedure for Blade Tracking

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

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

lb (kg) Sea Level (305 M) (610 M) (915 M) (1220 M) (1525 M)
2500 (1134) 93.8—95.8 94.6—96.6 95.4—97.4 96.3—98.3 97.1—99.1 98.0—100.0
2600 (1179) 95.6—97.6 96.4—98.4 97.3—99.3 98.1—100.1 99.0—101.0 99.9—101.9
2700 (1224) 97.4—99.4 98.2—100.2 99.1—101.1 100.0—102.0 100.9—102.9 101.8—103.8
2800 (1270) 99.2—101.2 100.0—102.0 100.9—102.9 101.8—103.8 102.7—104.7 103.6—105.6
2900 (1315) 101.0—103.0 101.8—103.8 102.7—104.7 103.6—105.6 104.6—106.4 ——
3000 (1361) 102.7—104.7 103.6—105.6 104.5—106.4 105.4—106.4 —— ——
NOTE: Do the autorotation percentage checks at gross weight/density altitude combinations for which percentage
values are given. Blank spaces indicate that application of collective pitch can be necessary to avoid rotor
overspeed.
Page 506
MAINTENANCE MANUAL
MAIN ROTOR
BALANCE WEIGHTS
(NOTE) MAIN ROTOR
LEAD-LAG BOLT
NOTE:
THE MAXIMUM ALLOWABLE BALANCE WEIGHT
PER LEAD-LAG BOLT ON THE MAIN ROTOR HUB
ASSEMBLY IS 143 GRAMS.
6G18-019A
Figure 503. Main Rotor System Balancing
Page 507
MAINTENANCE MANUAL
ROTATION
BLUE
MD600N HOVER PITCH LINK ADJUSTMENT
VELO.
WHITE 1. TAKE READINGS AT IGE HOVER USING VERTICAL

YELLOW
VELOCIMETER ON CONSOLE.
2. ADJUST PITCH CHANGE LINK IN FLATS. 1 FLAT=1/6 TURN
OF PITCH CHANGE BARREL.
3. BLADE SEQUENCE IS SHOWN WITH SINGLE INTERRUPTER
MAG P/U ATTACHED TO DRIVE LINK OF ROTATING SWASHPLATE.
4. TAKE READINGS FROM VERTICAL VELOCIMETER MOUNTED
RED ON INSTRUMENT PEDESTAL POINTING DOWN.
5. ADJUST PITCH CHANGE LINK BEFORE BALANCING AT HOVER.
GREEN
BLACK
ADJUSTMENT IN FLATS
OF PITCH LINKS
BLADE ORIENTATION WITH

DRIVE LINK INTERRUPTER MOVE MOVE
RED GREEN
UP UP 3 MOVE
AIRCRAFT VIEWED FROM ABOVE 3 3 BLACK
1 1/2
1 1/2 UP
MOVE 3 O 12:00
BLACK 11:00 1:00
1 1/2
UP MOVE
IPS 1 1/2 YELLOW
ADJUST .8 O
CLOCK 2:00 UP
10:00 .6 1 1/2
MOVE O .4 3
WHITE .2
1 1/2 .8
UP .6 .4 .2 3
3 9:00 3:00
MOVE
1 1/2 GREEN
UP
3 0
1 1/2 4:00
8:00
0
1 1/2
1 1/2 7:00 MOVE

5:00
BLUE
6:00 0 3
MOVE 1 1/2 UP
BLUE 3 1 1/2 3
UP MOVE
3 YELLOW
MOVE UP
WHITE
UP
NOTES:
1. ARROWS INDICATE DIRECTION POINT SHOULD GO WHEN
ADJUSTMENT TO NOTED BLADE IS MADE.
2. MOVE TO OPPOSITE BLADE IN OPPOSITE DIRECTION HAS
SAME EFFECT.
6G18-099
Figure 504. Main Rotor Track at Hover (Pitch Change Link Adjustment)
Page 508
MAINTENANCE MANUAL
ROTATION
BLUE
MD600N HOVER BALANCE CHART
WHITE YELLOW
1. TAKE READINGS AT IGE HOVER AFTER PCL TRACK.
2. USE WEIGHT, IN GRAMS, AT HUB LOCATION.
ATTACHED TO DRIVE LINK OF ROTATING SWASHPLATE.
4. LATERAL VELOCIMETER READINGS USING VELOCIMETER
AT LEADING SIDE OF CONTROLS COVER POINTING TO
LEFT OF AIRCRAFT.
GREEN
RED
BLACK
BLADE ORIENTATION WITH

DRIVE LINK INTERRUPTER
OVER MAGNETIC PICKUP
AIRCRAFT VIEWED FROM ABOVE
ADD TO ADD TO 200

BLACK YELLOW 200
200
200 100
100
ADD TO
0 12.00 100 GREEN
IPS ADD TO 11.00 1.00

ADJUST GREEN 100
CLOCK ADD TO
0 BLUE
10.00 2.00
100
0 .5
ADD TO
.4 200
RED
100
.2 .3 200
.1
9.00 3.00
200 .2
.3 100
200 .4
.5 ADD TO
100 0
YELLOW
ADD TO 8.00 4.00
BLACK 0
100
7.00 5.00 ADD TO
100
6.00 0 WHITE
ADD TO
WHITE 100
100 200
200
200 ADD TO
200 ADD TO BLUE
RED
G18-1007
Figure 505. Main Rotor System Balance Chart
Page 509
MAINTENANCE MANUAL
MD600N VERTICAL TAB CHART 100-130 KIAS
ROTATION 1. TAKE READINGS AT 100-130 KIAS.

BLUE 2. TAB MEASUREMENTS ARE IN 0.001 IN. (0.0254 MM).
VELO. 3. BLADE SEQUENCE IS SHOWN WITH SINGLE INTERRUPTER
4. TAKE READINGS FROM VERTICAL VELOCIMETER MOUNTED ON
WHITE INSTRUMENT PEDESTAL POINTING DOWN.
YELLOW
1 2 3
GREEN
RED
NO BEND
BLACK AREA
1. INNER TAB TWO WIDTHS OF BENDER (STA. 97 - 111)

2. MIDDLE TAB TWO WIDTHS OF BENDER (STA. 111 - 130)
BLADE ORIENTATION WITH 3. OUTER TAB ONE WIDTH OF BENDER (STA. 130 - 142)
MOVE
AIRCRAFT VIEWED FROM ABOVE 6
6
6 WHITE UP
MOVE
4 BLACK UP 6
MOVE 4 4
2 6
RED UP 12.00 2
0
11.00
2 1.00 4
MOVE
MOVE 0
IPS 2 RED UP
BLUE UP
ADJUST 2.00
CLOCK 4 10.00 2
6 5 0
6 2 MOVE
GREEN UP
4 9.00 3.00 4
MOVE
WHITE UP 2 6
0
6
8.00 4.00 4
2 2
MOVE 0 MOVE
YELLOW UP BLACK UP
4
7.00 5.00 2
6 2 0 6.00
4 2 4 MOVE
6 YELLOW UP
MOVE 4
BLUE UP MOVE 6
GREEN UP 6
NOTE:
ARROWS INDICATE DIRECTION POINT SHOULD GO
WHEN ADJUSTMENT TO NOTED BLADE IS MADE.
G18-1006A
Figure 506. Main Rotor Tracking at 100 − 130 KIAS (Inner Tab Adjustment)
Page 510
MAINTENANCE MANUAL
ROTATION
BLUE
1. TAKE READINGS AT 100-130 KIAS.
VELO. 2. TAB MEASUREMENTS ARE IN .001 INCH.
WHITE 3. BLADE SEQUENCE IS SHOWN WITH SINGLE INTERRUPTER
YELLOW
INSTRUMENT PEDESTAL POINTING DOWN.
1 2 3
ÉÉÉÉ
RED
ÉÉÉÉ
GREEN NO BEND
AREA
BLACK TAB BENDER TWO WIDTHS
1. UNDER TAB TWO WIDTHS OF BENDER (STA 97 - 111)

2. MIDDLE TAB TWO WIDTHS OF BENDER (STA 111 - 130)
BLADE ORIENTATION WITH 3. OUTER TAB ONE WIDTH OF BENDER (STA 130 - 142)
.010 WHITE
AIRCRAFT VIEWED FROM ABOVE
RED
.005
BLACK
.005
IPS
ADJUST .010
CLOCK 1.0 IPS 12:00 .005
BLUE 0
11:00 1:00
.005 0 .8
.6 RED
.010
.005
10:00 2:00
.4
WHITE
.005 .2
0
9:00
.2
0 .4 .8
.6 .005
1.0 IPS
GREEN
8:00 4:00
.005
.010
.005
0
YELLOW 7:00 5:00
0 BLACK
.005 6:00
.010
BLUE .005 .005
YELLOW
GREEN .010
6G18-100
Figure 507. Main Rotor Tracking at 100 − 130 KIAS (Mid Tab Adjustment)
Page 511
MAINTENANCE MANUAL
ROTATION
BLUE
VELO.
1. TAKE READINGS AT 100-130 KIAS.
WHITE YELLOW 2. TAB MEASUREMENTS ARE IN .001 INCH
INSTRUMENT PEDESTAL POINTING DOWN.
ÉÉÉ
RED
ÉÉÉ
GREEN NO BEND
AREA
BLACK ONE WIDTH OF TOOL
1. UNDER TAB TWO WIDTHS OF BENDER

(STA. 97 TO 111)
BLADE ORIENTATION WITH 2. MIDDLE TAB TWO WIDTHS OF BENDER
DRIVE LINK INTERRUPTER (STA. 111 TO 130)
OVER MAGNETIC PICKUP 3. OUTER TAB ONE WIDTH OF BENDER
(STA. 130 TO 142) BLACK
AIRCRAFT VIEWED FROM ABOVE WHITE UP
UP .016
.016
RED
.008 .008 UP
RED
IPS
ADJUST UP 0
CLOCK 12:00 .008
.008 11:00 1:00
0
10:00 2:00 GREEN
0 .008 UP
BLUE 1.0 IPS
UP .8 .8
.008 1.0 IPS .6 0 .016
.4 .4 .6
.2 .2
9:00 3:00
.016 .008
1.0 IPS BLACK
.008 UP
0
WHITE 8:00 4:00
0
UP
0
7:00 0 5:00 .008
.008 0
6:00
YELLOW
.008
UP
.008
YELLOW
UP .016
.016
GREEN
BLUE
UP
UP
6G18-101
Figure 508. Main Rotor Tracking at 100 − 130 KIAS (Outer Tab Adjustment)
Page 512
MAINTENANCE MANUAL
Section
18−20−00
Tail Rotor Balance
MAINTENANCE MANUAL
TAIL ROTOR BALANCE

1. Tail Rotor Balancing procedure. Tail rotor balance spare kit
contains extra tip weights and screws.
Special Tools (2). Install combination of weights required.
(Ref. Section 91-00-00) Maximum weight permitted is thirty-
Item Nomenclature four grams at each tip (Ref. Table 201).
ST903 Balancer/analyzer instrument kit Torque screws to 21—24 inch-pounds
(2.37—2.71 Nm).
B. Balance at Blade Pitch Arm
Balancing is accomplished by use of a balanc
ing kit (ST903). The carrying case of this kit (Ref. Figure 201) Weight increase at light pitch
contains all instrumentation, balance charts arm can be obtained by removal of equivalent
and miscellaneous items needed to balance the washer weight from opposite pitch arm.
tail rotor. Also included is a track and balance Always remove washers from opposite pitch
handbook for use with the equipment to arm, if installed, and subtract from weight to
correct balance when such can be obtained by be added before adding more weight. For
addition or subtraction of weight at pitch-arm washer data, refer to Table 201. Main rotor
studs or at blade tips. and tail rotor balancing spare kit contains
extra washers. Maximum washer weight
Since vibration reduction by weight adjust allowed at either pitch arm bolt is 26.91 grams
ment is dependent on proper mechanical (23 washers).
condition of the tail rotor and tail rotor drive
system, troubleshooting information (Ref. NOTE:
Chap. 64) should be used with balancing kit D A tail rotor out-of-balance condition that
instructions. Acceptance criteria for balance cannot be corrected by standard balanc
and vibration are contained in the balancing ing procedures can be an indication of ex
kit and on each balance chart. Main rotor and cessive play in tail rotor hub components.
tail rotor balancing spare kit contains spare
screws, washers and tip weights. D There is possibility of slight weight varia
tion between pitch control links.
NOTE: If tail rotor balance is difficult to (1). If tail rotor has maximum balance
achieve and horizontal stabilizer resonance
washer weight allowed on one pitch
is noted refer to 421-087-505 Horizontal
arm, compare the two links.
Stabilizer Tab Weight Installation.
(2). If pitch link opposite the weight
A. Balance at Blade Tip requirement appears larger, exchange
one link for the other and repeat
When balancing procedures indicate that vibration analysis.
weight should be added to a tip, it is prefer
able, if possible, to instead remove an equiva (3). If, as a result of parts peculiarity,
lent amount from the opposite tip to keep maximum allowable weight at one pitch
overall weight to a minimum. Installation of arm does not correct assembly balance,
tip weights is not mandatory. However, open tail rotor hub can be shifted in fork and
screw holes are not permitted; screws must be hub-to-fork shimming adjusted, if
installed. Shorter than normal screws can be maximum allowable play in fork
used for balance if minimal thread engage bearings is not exceeded. This is done
ment of 5/16 inch (7.9375 mm) exists. by transferring fork-to-hub spacing
shims from balance weighted side to
(1). Remove tip-weight screws and weights opposite side of hub, according to hub
(Ref. Figure 201). Select balancing and fork assembly procedures (Ref.
hardware indicated by balancing CSP-COM-5).
Page 201
MAINTENANCE MANUAL
(a). Chordwise weight shift resulting (6). Initially balance the tail rotor until
from each 0.001 inch (0.0254 mm) vibration level is 0.10 IPS (0.85 MIL)
of spacing thickness transferred or less as follows:
reduces weight requirement at
weighted pitch arm by one (a). Add weights to blade tips only. For
HS306-227L balance washer. four-bladed tail rotor, divide weights
as necessary between the two lower
(b). Transferring one 369A1717-53 blades to make the total weight
spacing shim, 0.010 inch (0.254 vector in the downward direction.
mm) thickness, allows initial remov
al of 10 thin washers from pitch arm NOTE: If more than 15 grams of tip weight (in
and thereby allows more flexibility cluding screw) is necessary on any one
for further balance correction during blade, use the ``long method'' balance proce
vibration analysis. dure.
(4). It should be noted that spanwise (7). After initial balance, reset RPM TUNE
balance is probably affected by any dial, according to Chadwick-Helmuth
chordwise shift of fork. Handbook for final balancing. Direct
strobe at tail rotor and adjust per
(5). If maximum allowable play in fork Chadwick-Helmuth instructions for
bearings is exceeded, bearings must be VERIFY TUNE. Apply the same
replaced (Ref. CSP-COM-5). method used for initial balance to
(6). Replacement or adjustment of parts balance until vibration level is 0.10 IPS
requires balancing of tail rotor follow (0.85 MIL) or less.
ing re-assembly.
D. Long Method Balance Check
C. Short Method Balance Check (Four−Bladed Tail Rotor)
(Ref. Figure 201 and Figure 202) Use tail rotor (Ref. Figure 203 and Figure 204) A long
vibration analyzer (ST903) throughout this method balance check must be accomplished
procedure. each time hubs and fork of four-bladed tail
rotor are reassembled. Use tail rotor vibration
(1). Mount accelerometer into tail rotor analyzer (ST903) throughout the procedure.
gearbox breather plug as noted in
Chadwick-Helmuth Operation and First runup of tail rotor assem
Service Handbook. CAUTION bly should be accomplished in a
cautious manner, increasing tail rotor rpm
(2). Connect accelerometer and balancer DC slowly so that vibrations from out-of-ba
power cables as noted in the Chadwick- lance tail rotor assembly will not cause dam
Helmuth Operation and Service age.
Handbook.
(3). Apply a retro-reflective target material
NOTE: Prior to doing long method balance
on blade root fitting. For four-bladed check, ensure hub is centered on fork and
tail rotor, one blade of the outboard tail elastomeric bearings are preloaded correct
rotor assembly. ly.
(4). Connect cables and instruments and (1). With outboard blade removed, balance
adjust settings as noted in Chadwick- inboard blade by adjusting tip weights
Helmuth Handbook. and washers at pitch arm bolt to
achieve 0.10 IPS (0.85 MIL) or less
(5). Direct strobe at tail rotor and adjust vibration level at 2100 rpm (input shaft
per Chadwick-Helmuth instructions for of transmission). This corresponds to
VERIFY TUNE. tail rotor rpm of 2168.
Page 202
MAINTENANCE MANUAL
(2). Install outboard blade and hub assem assembly and balance the tail rotor
bly; check balance of outboard blades by assembly.
adjusting weights to obtain 0.10 IPS
(0.85 MIL) vibration or less, using (3). After balancing the tail rotor assembly,
same method as used for inboard blade reinstall the horizontal stabilizer.
balancing, except as shown in
Figure 204. (4). Run engine at 102%-105% N2 and
observe horizontal stabilizer tab.
2. Horizontal Stabilizer Tuning
(5). If tab resonance occurs and tail rotor
Installation of tab weight is optional on the balance is no longer acceptable, install
421-087 -505 horizontal stabilizer if difficulty tab weight to horizontal stabilizer right
in tail rotor balance and horizontal stabilizer tab (Ref. Section 53-50-10, Horizontal
tab resonance vibration is encountered. Stabilizer Tab Weight Installation).
(1). With helicopter on flat smooth surface,
operate engine at 102%-105% N2 and (6). If needed, a one ounce weight can also
observe horizontal stabilizer tab. be installed on left tab.
(2). If tab resonance vibration occurs, (7). A maximum of two ounces can be
remove the horizontal stabilizer installed on each tab.
Page 203
MAINTENANCE MANUAL
ACCELEROMETER/VELOMETER
FOR TAIL ROTOR BALANCING.
INSTALL ON BREATHER PLUG OF
TAIL ROTOR GEAR BOX
TAPE
SECURE UNDER LATCH

REFLECTIVE
TAPE
KIT LOCATION FOR TAIL

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

CABLE
SPRING WASHER
PITCH CONTROL
ACCELEROMETER/VELOMETER LINK
(NOTE 1) PITCH ARM
BREATHER/FILLER BALANCE WASHER
INSTALLATION
TIP WEIGHT
NOTE 3
WEIGHT INSTALLATION
ROTATED
NOTES:
1. INSTALLED ONLY FINGER TIGHT.
2. FOR INFORMATION ON MAXIMUM WEIGHT, NUMBERS, TYPES AND
EXACT LOCATIONS OF BALANCING HARDWARE TO BE USED,
REFER TO ASSOCIATED TEXT AND TABLES.
3. TORQUE SCREWS TO 21 - 24 INCH-POUNDS (2.37 - 2.71 NM). G18-2000B
Figure 201. Tail Rotor Assembly Balancing (Two−Bladed Tail Rotor)
Page 204
MAINTENANCE MANUAL
Table 201. Tail Rotor Balance Weight − Value Chart

At Blade Tip (4) At Blade Pitch Arm (3)
Screw (5) Washer (1)(2)
Length Weight Thickness Weight OD
Part Number in (mm) oz (g) Part Number in (mm) oz (g) in (mm)
0.078
NAS1352−08−12P 0.75 (19.05) (2.22) HS306−227L 0.016 (0.4064) 0.041 (1.17) 0.800 (20.32)
0.086
NAS1352−08−14P 0.875 (22.23) (2.44)
Weight
Thickness Weight
in (mm) oz (g)
0.010
369A1622−3 0.016 (0.4064) (0.29)
0.062
369A1622−5 0.036 (0.9144) (1.76)
NOTES:
(1) Used on balance bolt.
(2) Maximum of 23 washers is permitted on each balance bolt.
(3) Minimum of two threads must extend past nut securing balance washers on balance bolt.
(4) Maximum weight, including screws, is 34 grams.
(5) Minimum screw thread engagement is 5/16 inch (7.9375 mm).
TOTAL
TOTAL WEIGHT
TOTAL WEIGHT
SMALLER VECTOR
WEIGHT VECTOR
WEIGHT
VECTOR
EQUAL EQUAL
WEIGHT WEIGHT LARGE WEIGHT
WEIGHT
OR OR
NOTE:
IF, WHEN ADDING WEIGHTS, OUT-OF-BALANCE VIBRATION
LEVEL INCREASES, ADD WEIGHTS TO THE TOP BLADE(S). G18-2001
Figure 202. Short Method Tail Rotor Balancing (Four−Bladed Tail Rotor)
Page 205
MAINTENANCE MANUAL
BALANCE WASHERS
(NOTE 1)
SHIMS
(NOTE 2)
NOTES:
1. MAXIMUM ALLOWABLE NUMBER OF WASHERS AT SHIM
PITCH ARM BOLT IS 23. WHENEVER THIS LIMIT IS
REACHED AND REQUIRED BALANCE CANNOT BE
MET, SHIFT THE CENTER OF THE HUB BY
TRANSFERRING SHIMS, THICKNESS OF 0.010 IN.
(0.254 MM), FROM WEIGHTED PITCH ARM SIDE TO
THE OPPOSITE SIDE AS SHOWN AND RE-CHECK
BALANCE, STARTING FROM ZERO WASHERS.
2. REMOVE 0.010 IN. (0.254 MM) THICK SHIM FROM
PITCH ARM SIDES AND TRANSFER THE SHIM TO G18-2002A
THE OPPOSITE SIDE.
Figure 203. Long Method Tail Rotor Balancing (Inboard Blade)
BALANCE WASHERS
(MAX. 23)
SHIMS
(NOTE 2)
SHIM
NOTES:
1. REMOVE 0.010 IN. (0.254 MM) THICK SHIM
FROM WEIGHTED PITCH ARM SIDE AND
TRANSFER THE SHIM TO THE OPPOSITE SIDE.
2. DURING BALANCE OF OUTBOARD BLADES,
WEIGHTS ON INBOARD BLADES MUST NOT
BE CHANGED.
G18−2003A
Figure 204. Long Method Tail Rotor Balancing (Outboard Blade)
Page 206
MAINTENANCE MANUAL
Section
18−20−30
NOTARr
Fan Balance
MAINTENANCE MANUAL
NOTARR ANTI−TORQUE SYSTEM FAN BALANCE

1. Fan Balancing (4). Install velometer on bracket located at
the 6:00 o'clock position (Ref.
The NOTARR anti-torque system uses a Figure 203).
fan-driven air circulation system within the
tailboom to control the directional heading of (5). Install magnetic pick-up and velometer
the helicopter. The rudder pedals in the cockpit wiring (Ref. Figure 203).
control the blade angle of the fan assembly.
Wiring must be secured to pre
The fan assembly operates at a constant speed CAUTION vent them from being ingested
of 5388 RPM at 100% N2.
into the fan assembly during run-up.
Balancing is accomplished by use of a balanc (6). Position the anti-torque pedals at
ing kit. The carrying case of this kit contains neutral during fan balancing.
all instrumentation, balance charts and
miscellaneous items needed to balance the fan NOTE: The neutral position is 62% from full
assembly. Also included is a track and balance left or approximately one inch of right pedal
handbook for use with the equipment to from pedals centered. This pedal position
correct balance when such can be obtained by produces minimum fan pitch and closes the
addition or subtraction of weight at studs on thruster.
the fan assembly.
WARNING
Since vibration reduction by weight adjust
ment is dependent on proper mechanical D Damage could occur if the anti-
condition of fan drive system, troubleshooting torque pedals are not kept at neutral
information (Ref. Chap. 64) should be used while the helicopter is operating
with balancing kit instructions. Acceptance with the fan/hub transmission fair
criteria for balance and vibration are con ing removed.
tained in the balancing kit and on each D Operators and authorized observers
balance chart. should remain in the designated
areas during balancing operations.
2. Fan Balance Check
D Wearing loose clothing or having ma
terials in shirt pockets during opera
(Ref. Figure 201) tions can result in injury to person
nel and/or damage to aircraft.
Special Tools
(7). Run helicopter to establish N2 speed of
100% percent.
Item Nomenclature
ST903 Balancer/analyzer instrument kit (8). Observe vibration reading.
(a). If vibration reading is greater than
NOTE: Use the vibration analyzer (ST903) 0.2 ips, shut down helicopter and
throughout this procedure. proceed with step (9).
(b). If vibration level is 0.2 ips or less,
(1). Remove fan inlet screen. proceed with step (11).
(2). Remove upper portion of the fan/hub (9). Add hardware to the balancing studs in
transmission fairing. any combination as required using
Table 201 and Figure 202. Torque nuts
(3). Number balancing studs as shown in on studs to 30—40 inch pounds
Figure 201 using a permanent marker. (3.39—4.52 Nm).
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MAINTENANCE MANUAL
Do not over torque the nuts on (11). Remove balancing equipment wiring
CAUTION the balancing studs. An over- and attachments.
torqued nut can cause the stud locking col
lar to become loose the next time the nut is (12). Install the fan/hub transmission fairing
removed. and fan inlet screen.
(10). Repeat steps (6). thru (9). until fan
dynamic balance is 0.2 ips or less.
Table 201. Preferred Hardware for Balancing Fan Assembly
Washer Weight oz (g)
Stainless Thickness ID OD Stainless
Aluminum Steel in (mm) in (mm) in (mm) Aluminum Steel
AN960KD416L 0.016 (0.406) 0.265 (6.731) 0.500 (12.700) 0.004 (0.103)
AN960C416L 0.016 (0.406) 0.265 (6.731) 0.500 (12.700) 0.020 (0.572)
AN960KD416 AN960C416 0.063 (1.600) 0.265 (6.731) 0.500 (12.700) 0.014 (0.407) 0.040 (1.144)
HS306−325L HS306−225L 0.016 (0.406) 0.263 (6.680) 0.528 (13.411) 0.004 (0.121) 0.012 (0.339)
HS306−325 HS306−225 0.032 (0.813) 0.263 (6.680) 0.528 (13.411) 0.009 (0.241) 0.024 (0.677)
HS306−325H HS306−225H 0.063 (1.600) 0.263 (6.680) 0.528 (13.411) 0.017 (0.482) 0.048 (1.355)
HS306−326L HS306−226L 0.016 (0.406) 0.263 (6.680) 0.619 (15.723) 0.006 (0.181) 0.018 (0.507)
HS306−326 HS306−226 0.032 (0.813) 0.263 (6.680) 0.619 (15.723) 0.013 (0.361) 0.036 (1.015)
HS306−326H HS306−226H 0.063 (1.600) 0.263 (6.680) 0.619 (15.723) 0.026 (0.723) 0.072 (2.029)
HS306−327L HS306−227L 0.016 (0.406) 0.263 (6.680) 0.800 (20.320) 0.012 (0.329) 0.033 (0.922)
HS306−327 HS306−227 0.032 (0.813) 0.263 (6.680) 0.800 (20.320) 0.023 (0.657) 0.065 (1.844)
HS306−327H HS306−227H 0.063 (1.600) 0.263 (6.680) 0.800 (20.320) 0.046 (1.314) 0.130 (3.689)
NOTE: Maximum washer stack−up thickness = 0.20 inch (5.08 mm).
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MAINTENANCE MANUAL
FAN ROTATION
MAGNETIC PICKUP
INTERRUPTER
1
13
2
12
11
10
6
8
7
BALANCING STUD
(13 PLCS)
VIEW LOOKING AFT
G18−2006
Figure 201. Fan Balancing Stud Numbering
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MAINTENANCE MANUAL
12
350° 360° 10°

11 IPS GRAMS
340° 20° 1
1.0 5.60
330° 30°
.9 5.04 #3
#4
320° 40°
.8 4.48
310° .7 3.92 50°

#5 #2
.6 3.36
10 2
300° 60°
.5 2.80
.4 2.24
290° 70°
.3 1.68
#6
.2 1.12
280° 80°
#1
.1 .56
9 270° 90° 3
#7
260° 100°
# 13
250° 110°
240° #8 120°
# 12
8 4
230° 130°
220° #9 # 11 140°
# 10
210° 150°
7 200° 160° 5
190° 180° 170°
G18−2007
Figure 202. Fan Balance Chart
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MAINTENANCE MANUAL
MAGNETIC PICK-UP/
VELOMETER CABLES
28 VDC POWER CABLE

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

TRANSMISSION
FAIRING
VELOMETER
BALANCING STUD
(13 PLCS)
G18−2008A
Figure 203. Fan Balancing Equipment Installation
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Chapter
20
Standard Practices
MAINTENANCE MANUAL
TABLE OF CONTENTS
20-00-00 Standard Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Maintenance and Operational Check Requirements and Precautions . . . . . . . . . . . 1
A. Rotorcraft Flight Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Rotorcraft Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Control Rod Thread Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20-10-00 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Torque Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Application of Torque Wrench Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Bearings Installation, Staking or Swaging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Control Tube Jam Nut Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Standard Hardware Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Standard Hardware Torque
(Ref. Table 202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Table 202. Recommended Standard Thread Fasteners Torque . . . . . . . . . . . . . . . 204
Table 203. Torque Values for Tube or Hose Assemblies . . . . . . . . . . . . . . . . . . . . . 208
Table 204. Torque Values for Boss and Bulkhead Fittings . . . . . . . . . . . . . . . . . . . 211
20-20-00 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fuselage Interior Trim and Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Airframe Exterior and Rotor Blades Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Transparent Plastic Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Engine Compressor Contamination Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6. Cleaning Of Engine Air Inlet Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7. Digital Instrument Display Surface Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
20-30-00 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Paint Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Paint Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Paint Touchup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Touchup - Small Sanded Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Touchup - Flaking or Dried Paint or Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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C. Touchup - Primer Not Adhering to Metal Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

D. Touchup - Glass Fiber Laminate Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
E. Touchup - Polycarbonate Plastic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
F. Touchup - ABS Thermoplastic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Main Rotor Blade Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Main Rotor Blade Paint Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Main Rotor Blade Paint Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5. Tail Rotor Blade Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Tail Rotor Blade Paint Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Tail Rotor Blade Paint Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
20-40-00 Corrosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Magnesium Alloys - Insulation Against Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Sealing Compound Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Main Rotor Hub Corrosion Prevention (Tri-Flow Wash Procedure) . . . . . . . . . . . . . 201
5. Main Rotor Blades Corrosion Arresting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Main Rotor Blade and Damper Attach Pins - Corrosion Prevention . . . . . . . . . . 202
6. Magnesium Alloy Exterior Surface Touchup Treatment . . . . . . . . . . . . . . . . . . . . . . . 203
7. Aluminum Alloy Exterior Surface Touchup Treatment . . . . . . . . . . . . . . . . . . . . . . . . 203
8. Steel Alloy Exterior Surface Touchup Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9. Splitter Bungee Spring Corrosion Control (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Table 201. Anti-Corrosion Chemical Finishes - Aluminum . . . . . . . . . . . . . . . . . . 204
20-50-00 Electrical Bond and Environmental Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Electrical Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Electrical Bonding Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Electrical Bond Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Bonding Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 202. Equipment Class Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2. Environmental Sealing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Faying Surface Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Faying Surface Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Fillet Surface Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Fillet Surface Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203. Fillet Sealing Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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C. Gasket Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

D. Mechanical Fastener Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 204. Mechanical Fastener Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
20-90-00 Nondestructive Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Nondestructive Inspection Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Visual Inspection Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Dye Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Coin Tap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. Fluorescent Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
E. Magnetic Particle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Coin Tap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
F. Eddy Current Inspection - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
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Page iv
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Section
20−00−00
Standard Practices
MAINTENANCE MANUAL
STANDARD PRACTICES
INTRODUCTION
1. Maintenance and Operational Check (2). Make sure the the witness hole is
Requirements and Precautions blocked by the rod end fitting so that
you can not insert the lockwire.
All helicopter maintenance personnel must
obey the requirements and precautions given (3). Move flight controls through full travel
in the Rotorcraft Flight Manual and the and examine the control system for
Rotorcraft Maintenance manual. correct clearance.
(4). Make sure the rod end jam nuts are
A. Rotorcraft Flight Manual tight.
When it is necessary to operate the helicopter (5). Only install new lockwire.
to do maintenance tests, you must obey all the
requirements and limits given in the applica D. Operational Check
ble MDHI Rotorcraft Flight Manual and After maintenance, modification, disassembly,
Optional Equipment Supplements. re-assembly, replacement, cleaning, repair or
installation, the affected parts, assemblies,
B. Rotorcraft Maintenance Manual installations or systems must have an inspec
tion and an operational check will be done
When you do maintenance on the helicopter, before the helicopter is released for flight (ref.
you must obey the maintenance and opera Maintenance Information Requests).
tional test requirements and precautions given
for your helicopter model in the MDHI 2. Inspection/Check
Rotorcraft Maintenance Manual.
Inspections specified in this manual are visual
C. Control Rod Thread Engagement inspections for cracks, corrosion, distortion,
security and other obvious defects or damage.
You must have sufficient
WARNING thread engagement to have Visual inspections of fuel and oil system hoses,
safe control-rod operation. If the con tubes and fittings include checks for corrosion,
trol-rod thread engagement is insuffi leakage and distortion.
cient, you will loose control of flight Specific inspection requirements, procedures
systems. and wear tolerances can be provided in the
division text. Where inspection requirements
NOTE: Make sure you use the correct control- are not listed, inspections must be done as
rod adjustable end thread engagement after shown in Sections 05-10-00 thru 05-50-00.
you make the last rod length adjustment.
Replace components that have damage or wear
(1). Try to insert a lockwire through the beyond tolerances, or that negatively effect the
witness hole. correct function or integrity of an assembly.
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MAINTENANCE MANUAL
Page 2
MAINTENANCE MANUAL
Section
20−10−00
Torque
MAINTENANCE MANUAL
TORQUE
1. Torque Wrenches (5). Torque values specified in this manual
are special torque values that apply
Torque wrenches should be of good quality and instead of those listed.
calibration should be verified at regular
intervals to verify accuracy. Torque wrench (6). If adapters are used such that adapter
accuracy at room temperature, 705F (22 5C) and torque wrench are not at right
must be within following limits. angles (90 degrees) to each other,
wrench or indicator reading must be
(1). From zero through 19 percent of torque corrected.
wrench range, error can not exceed ±7
percent of load applied. (7). Any re-use of self-locking nuts over 3/8
inch is governed by values listed in
(2). From 20 thru 79 percent of torque Table 203.
wrench range, error can not exceed ±4
percent load applied. (8). Castellated nuts are torqued to the
minimum side of the recommended
(3). From 80 to 100 percent of torque torque range. Continue to tighten the
wrench range, error can not exceed ±5 nut until the hole of the cotter pin lines
percent of load applied. up with the castellation without
exceeding the maximum specified
2. Application of Torque Wrench Loads torque.
(Ref. Table 201 thru Table 203) Recommended (9). Bolt must not be rotated during
tightening torque values and minimum drag application of torque to mating nut.
torque values for fine and coarse thread nuts,
and minimum breakaway torque for used 3. Bearings Installation, Staking or Swaging
self-locking bolts or screws are listed in Force
Table 201 and Table 202. Requirements
The following procedure explains how to
governing application of torque loads follow.
convert from a given `Force` which is required
These requirements apply throughout this
to do a task to a proper hydraulic pressure
manual except where otherwise specifically
reading.
indicated.
(1). Determine the diameter of the ram
(1). Values apply to cadmium-plated bolts, (staking or swaging contact surface) on
cadmium-plated nuts coated with the hydraulic press to be used.
molybdenum disulfide (MoS2).
NOTE: The hydraulic press to be used must
(2). Manufacturer applied lubricant must have a pressure gauge.
not be removed nor additional lubricant
added. (2). Divide the ram diameter by two to get
the radius.
(3). Bolts, nuts and surfaces they bear on
must be clean, dry and free of lubricant (3). Multiply 3.14159 (pi) times the Radius
except as stated in requirement above. squared (R2). This will give the area of
the ram.
(4). Turning (drag) torque required to
install self-locking nut or bolt up to (4). Divide the force required for the task by
point of final tightening must always be the area of the ram. This gives the
added to final torque value specified or actual PSI reading for the hydraulic
the maintenance instruction, as press pressure gauge needed to do the
applicable. task.
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MAINTENANCE MANUAL
EXAMPLE: 5. Standard Hardware Torque Values

Ram Diameter = 2.65 in. (6.731 cm) The following tables list torque values for
Ram Radius (R) = 1.325 in. (3.366 cm) standard hardware by part number.
Radius squared (R2) = 1.756 in.2 (8.548 cm2) NOTE: If unsure of hardware type, refer to
CSP-IPC-4.
R2 X 3.1416 = 5.517 in. (26.854 cm) (Area of
ram) (1). Table 201 lists self-locking tension-
Force required = 7500-8500 lbs. (3402-3856 type fastener torque values.
kg) (variable)
(2). Table 202 lists shear-type fastener
7500-8500 lbs. (3402-3856 kg) / 5.517 in. torque values.
(26.854 cm) = 1359-1540 PSI (9370-10618
kPa) (3). Table 203 lists maximum and mini
mum self-locking fastener drag
PSI required =1359 PSI (9370 kPa) Min.
(run-on) torque values.
1540 PSI (10618 kPa) Max.
Force needed/(R2) X 3.1416 = Pressure Gauge CAUTION
Table 203 lists self-locking
Reading (run-on) torque values, i.e.;
torque required to overcome the friction of
4. Control Tube Jam Nut Torquing the self-locking feature of fastener threads
prior to clamp-up and final tightening. Any
(1). Tighten jam nuts against control rods self-locking fastener that can be run down
by holding rodend with wrench. with the fingers after the locking feature en
NOTE: Do not tighten with rodend against fit gages must be replaced. Determine final
ting. torque value by adding the run-on torque to
the specified final clamping torque. Final
(2). Ensure rod ends are not preloaded after clamping torque values are listed in
torquing jam nuts. Table 201 and Table 202.
Page 202
MAINTENANCE MANUAL
Table 201. Standard Hardware Torque Item Section /

(Ref. Table 202) Fastener Code* Column
Item Section / NAS1303 HHB IV, 2
Fastener Code* Column
NAS1304 HHB IV, 2
AN310−315 HN II, 2
NAS1351 CS II, 2
AN316−320 HN II, 1
NAS1423 HN II, 1
AN4 HHB II, 2
NAS509 HN II, 1
AN502 FHB II, 2
NAS517 FHS V
MS17826 CN II, 1
NAS563 HHB IV, 2
MS20004 IWB IV, 2
NAS564 HHB IV, 2
MS21042 HN II, 1
NAS600−604 PHS V
MS21043 HN II, 1
NAS6203−6206 HHB IV, 2
MS21044 HN II, 2
NAS623 PHS V
MS21083C HN II, 1
NAS6304 HHB IV, 2
MS21083N HN II, 1
NAS6603−6606 HHB IV, 2
MS24694S FHS V
NAS6706 HHB IV, 2
MS27039C PHS V
NAS673V− HHB IV, 2
MS35691 HN II, 1 676V
* Item Codes
MS9208 12B II, 2
MS9363 HN II, 1 CN = castellated nut;
NAS1096 HHB V CS = cap screw;
NAS1189 FHS V FHB = flush head bolt;
FHS = flush head screw;
NAS1190 PHS V
HHB = hex head bolt;
NAS1203 FHB V
HN = hex nut;
NAS1291C HN II, 1
IWB = internal wrenching bolt;
PHS = pan head screw;
12B = 12 − point bolt
Page 203
MAINTENANCE MANUAL
Table 202. Recommended Standard Thread Fasteners Torque

Section I. Locking Torque Values for Self−Locking Bolts, Screws and Nuts
Fine Thread Coarse Thread
Thread Recommended Maximum Thread Recommended Maximum
Size in−lb (Nm) in−lb (Nm) Size in−lb (Nm) in−lb (Nm)
— — — 0.1640−32 1.5 (0.16) 15 (1.69)
0.1900−32 2.0 (0.22) 18 (2.03) 0.1900−24 2.0 (0.22) 18 (2.03)
0.2500−28 3.5 (0.39) 30 (3.38) 0.2500−20 4.5 (0.50) 30 (3.38)
0.3125−24 6.5 (0.73) 60 (6.77) 0.3125−18 7.5 (0.84) 60 (6.77)
0.3750−24 9.5 (1.07) 80 (9.03) 0.3750−16 12.0 (1.35) 80 (9.03)
0.4375−20 14 (1.58) 100 (11.29) 0.4375−14 16.5 (1.86) 100 (11.29)
0.5000−20 18 (2.03) 150 (16.94) 0.5000−13 24 (2.71) 150 (16.94)
0.5625−18 24 (2.71) 200 (22.59) 0.5625−12 30 (3.38) 200 (22.59)
0.6250−18 32 (3.61) 300 (33.88) 0.6250−11 40 (4.51) 300 (33.88)
0.7500−16 50 (5.64) 400 (45.18) 0.7500−10 60 (6.77) 400 (45.18)
0.8750−14 70 (7.9) 600 (67.77) 0.8750−9 82 (9.26) 600 (67.77)
1.0000−12 90 (10.16) 800 (90.36) 1.0000−8 110 (12.42) 800 (90.36)
1.1250−12 117 (13.21) 900 (101.66) — — —
1.2500−12 143 (16.15) 1,000 (112.96) — — —
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MAINTENANCE MANUAL
Table 202. Recommended Standard Thread Fasteners Torque (Cont.)

Section II. Torque Values for Fine Thread Fasteners (125,000 to 145,000 psi)
Shear Tension
Column Number 1 Column Number 2
Recommended Maximum Recommended Maximum
Thread Size in−lb (Nm) in−lb (Nm) in−lb (Nm) in−lb (Nm)
12—15 25 20—25 40
0.1900−32
(1.35—1.69) (2.82) (2.25—2.82) (4.51)
30—40 60 50—70 100
0.2500−28
(3.38—4.51) (6.77) (5.64—7.90) (11.29)
60—85 140 100—140 225
0.3125−24
(6.77—9.6) (15.81) (11.29—15.81) (25.41)
95—110 240 160—190 390
0.3750−24
(10.73—11.29) (27.11) (18.07—21.46) (44.05)
270—300 500 450—500 840
0.4375−20
(30.49—33.88) (56.48) (50.83—56.48) (94.88)
290—410 660 480—690 1,100
0.5000−20
(32.75—46.31) (74.55) (54.22—77.94) (124.25)
480—600 960 800—1,000 1,600
0.5625−18
(54.22—67.77) (108.44) (90.36—112.96) (180.73)
660—780 1,400 1,100—1,300 2,400
0.6250−18
(74.55—88.1) (158.14) (124.25—146.84) (271.1)
1,300—1,500 3,000 2,300—2,500 5,000
0.7500−16
(146.84—169.44) (338.88) (259.8—282.4) (564.8)
1,500—1,800 4,200 2,500—3,000 7,000
0.8750−14
(169.44—203.32) (474.43) (282.4—338.88) (790.72)
2,200—3,300 6,000 3,700—5,500 10,000
1.0000−12
(248.51—372.76) (677.76) (417.95—621.28) (1129.6)
3,000—4,200 9,000 5,000—7,000 15,000
1.1250−12
(338.88—474.43) (1016.64) (564.8—790.72) (1694.4)
5,400—6,600 15,000 9,000—11,000 25,000
1.2500−12
(609.98—745.53) (1694.4) (1016.64—1242.56) (2824.0)
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MAINTENANCE MANUAL

Section III. Torque Values for Coarse Thread Fasteners (125,000 to 145,000 psi)
Shear Tension
7—9 12 12—15 20
0.1640−32
(0.79—1.01) (1.35) (1.35—1.69) (2.25)
12—15 21 20—25 35
0.1900−24
(1.35—1.69) (2.37) (2.25—2.82) (3.95)
25—30 45 40—50 75
0.2500−20
(2.82—3.38) (5.08) (4.51—5.64) (8.47)
48—55 100 80—90 160
0.3125−18
(5.42—6.21) (11.29) (9.03—10.16) (18.07)
95—110 170 160—185 275
0.3750−16
(10.73—12.42) (19.2) (18.07—20.89) (31.06)
140—155 280 235—255 475
0.4375−14
(15.81—17.5) (31.62) (26.54—28.8) (53.65)
240—290 520 400—480 880
0.5000−13
(27.11—32.75) (58.73) (45.18—54.22) (99.4)
300—420 650 500—700 1,100
0.5625−12
(33.88—47.44) (73.42) (56.48—79.07) (124.25)
420—540 900 700—900 1,500
0.6250−11
(47.44—60.99) (101.66) (79.07—101.66) (169.44)
700—950 1,500 1,150—1,600 2,500
0.7500−10
(79.07—107.31) (169.44) (129.9—180.73) (282.4)
1,300—1,800 2,700 2,200—3,000 4,600
0.8750−9
(146.84—203.32) (304.99) (248.51—338.88) (519.61)
2,200—3,000 4,500 3,700—5,000 7,600
1.0000−8
(248.51—338.88) (508.32) (417.95—564.8) (858.49)
3,300—4,000 7,200 5,500—6,500 12,000
1.1250−8
(372.76—451.84) (813.31) (621.28—734.24) (1355.52)
4,000—5,000 10,000 6,500—8,000 16,000
1.2500−8
(451.84—564.8) (1129.6) (734.24—903.68) (1807.36)
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MAINTENANCE MANUAL

Section IV. Torque Values for Thread Fasteners (160,000 to 180,000 psi)
Shear Tension
15—25 30
0.1640−32 — —
(1.69—2.82) (3.38)
12—15 25 36—46 50
0.1900−32
(1.35—1.69) (2.82) (4.06—5.19) (5.64)
30—40 60 70—90 125
0.2500−28
(3.38—4.51) (6.77) (7.9—10.1) (14.12)
60—85 140 130—180 250
0.3125−24
(6.77—9.6) (15.81) (14.69—20.34) (28.24)
95—110 240 220—360 430
0.3750−24
(10.73—12.42) (27.11) (24.85—40.66) (48.57)
270—300 500 370—610 925
0.4375−20
(30.49—33.88) (56.48) (41.79—68.9) (104.48)
290—410 660 650—950 1,250
0.5000−20
(32.75—46.31) (74.55) (73.42—107.31) (141.2)
480—600 960 1,000—1,300 1,650
0.5625−18
(54.22—67.77) (108.44) (112.96—146.84) (186.38)
660—780 1,400 1,400—1,700 2,400
0.6250−18
(74.55—88.1) (158.14) (158.14—192.03) (271.1)
1,300—1,500 3,000 2,400—3,100 4,600
0.7500−16
(146.84—169.44) (338.88) (271.1—350.17) (519.61)
1,500—1,800 4,200 3,700—4,100 6,100
0.8750−14
(169.44—203.32) (474.43) (417.95—463.13) (689.05)
2,200—3,300 6,000 5,100—7,900 11,500
1.0000−12
(248.51—372.76) (677.76) (576.09—892.38) (1299.04)
3,000—4,200 9,000 6,900—9,500 14,000
1.1250−12
(338.88—474.43) (1016.64) (779.42—1073.12) (1581.44)
5,400—6,600 15,000 11,500—14,000 21,000
1.2500−12
(609.98—745.53) (1694.4) (1299.04—1581.44) (2372.16)
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Section V. Torque Values for Fasteners with Phillips Recesses
Thread Size Recommended in−lb (Nm) Maximum in−lb (Nm)
0.1640−32 12—15 (1.35—1.69) 23 (2.59)
0.1900−32 20—25 (2.25—2.82) 35 (3.95)
0.2500−28 60—70 (6.77—7.90) 90 (10.16)
0.3125−24 110—125 (12.42—14.12) 150 (16.94)
0.3750−24 150—175 (16.94—19.76) 225 (25.41)
0.4375−20 230—280 (25.98—31.62) 450 (50.83 )
0.5000−20 550—650 (62.12—73.42) 850 (96.01)
0.5625−18 750—900 (84.72—101.66) 1,200 (135.55)
0.6250−18 1,100—1,300 (124.25—146.84) 1,600 (180.73)
Table 203. Torque Values for Tube or Hose Assemblies

Section I. Torque Values for Flared Tube or Hose Assemblies
Aluminum Cres
Tube Dash No. Tube O.D. in−lb (Nm) in−lb (Nm) in−lb (Nm) in−lb (Nm)
−2 0.1250 (3.175) 20 30 75 85
(2.25) (3.38) (8.47) (9.6)
−3 0.1875 (4.763) 25 35 95 105
(2.82) (3.95) (10.73) (11.86)
−4 0.2500 (6.35) 50 65 135 150
(5.64) (7.34) (15.24) (16.94)
−5 0.3125 (7.94) 70 90 170 200
(7.9) (10.16) (19.2) (22.59)
−6 0.3750 (9.53) 110 130 270 300
(12.42) (14.68) (30.49) (33.88)
−8 0.5000 (12.7) 230 260 450 500
(25.98) (29.36) (50.83) (56.48)
−10 0.6250 (15.88) 330 360 650 700
(37.27) (40.66) (73.42) (79.07)
−12 0.7500 (19.05) 460 500 900 1,000
(51.96) (56.48) (101.66) (112.96)
−16 1.0000 (25.4) 500 700 1,200 1,400
(56.48) (79.07) (135.55) (158.14)
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MAINTENANCE MANUAL
Table 203. Torque Values for Tube or Hose Assemblies (Cont.)
Section II. Torque Values for Flareless Tube or Hose Assemblies

Tubing (Inch) Aluminum Alloy Stainless and Titanium
Dash Recommended Maximum Recommended Maximum
No. O.D. Wall Thickness in−lb (Nm) in−lb (Nm) in−lb (Nm) in−lb (Nm)
80 90
0.016 (0.406)
(9.03) (10.16)
0.1875 80 90 95 105
−3 0.018 (0.457)
(4.7625) (9.03) (10.16) (10.73) (11.86)
95 105
0.020 (0.508)
(10.73) (11.86)
80 90
0.016 (0.406)
(9.03) (10.16)
95 105
0.020 (0.508)
0.2500 (10.73) (11.86) 135 145
−4
(6.35) 120 135 (15.24) (16.37)
0.028 (0.711)
(13.55) (15.24)
135 145
0.035 (0.889)
(15.24) (16.37)
110 130
0.020 (0.508)
(12.42) (14.68)
0.3125 120 135 150 175
−5 0.028 (0.711)
(7.9375) (13.55) (15.24) (16.94) (19.76)
135 145
0.035 (0.889)
(15.24) (16.37)
110 130
0.020 (0.508)
(12.42) (14.68)
120 135
0.028 (0.711)
0.3750 (13.55) (15.24) 215 245
−6
(9.525) 190 215 (24.28) (27.67)
0.035 (0.889)
(21.46) (24.28)
190 215
0.042 (1.067)
(21.46) (24.28)
190 215
0.020 (0.508)
(21.46) (24.28)
290 310
0.028 (0.711)
0.5000 (32.75) (35.01) 470 510
−8
(12.7) 340 380 (53.09) (57.60)
0.035 (0.889)
(38.4) (42.92)
340 380
0.049 (1.245)
(38.4) (42.92)
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MAINTENANCE MANUAL
Table 203. Torque Values for Tube or Hose Assemblies (Cont.)

Section II. Torque Values for Flareless Tube or Hose Assemblies (Cont.)
Tubing (Inch) Aluminum Alloy Stainless and Titanium
Dash Recommended Maximum Recommended Maximum
No. O.D. Wall Thickness in−lb (Nm) in−lb (Nm) in−lb (Nm) in−lb (Nm)
340 380
0.020 (0.508)
(38.4) (42.92)
340 380
0.028 (0.711)
(38.4) (42.92)
0.6250 380 450 620 680
−10 0.035 (0.889)
(15.875) (42.92) (50.83) (70.03) (76.81)
380 450
0.042 (1.067)
(42.92) (50.83)
380 450
0.049 (1.245)
(42.92) (50.83)
380 450
0.020 (0.508)
(42.92) (50.83)
380 450
0.028 (0.711)
(42.92) (50.83)
380 450
0.035 (0.889)
0.7500 (42.92) (50.83) 855 945
−12
(19.05) 400 470 (96.58) (106.74)
0.042 (1.067)
(45.18) (53.09)
400 470
0.049 (1.245)
(45.18) (53.09)
400 470
0.058 (1.473)
(45.18) (53.09)
470 530
0.020 (0.508)
(53.09) (59.86)
600 660
0.028 (0.711)
(67.77) (74.55)
1.0000 640 700 1,140 1,260
−16 0.035 (0.889)
(25.4) (72.29) (79.07) (128.77) (142.32)
750 850
0.049 (1.245)
(84.72) (96.01)
1,140 1,260
0.065 (1.651)
(128.77) (142.32)
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MAINTENANCE MANUAL
Table 204. Torque Values for Boss and Bulkhead Fittings

Section I. Torque Values for Fitting to Boss for Non−Positioning Union
Aluminum Steel
Tube
Dash Tube Recommended Maximum Recommended Maximum
No. O.D. Thread Size in−lb (Nm) in−lb (Nm) in−lb (Nm) in−lb (Nm)
0.1250 50 55 60 75
−2 0.3125−24
(3.175) (5.64) (6.21) (6.77) (8.47)
0.1875 65 75 90 100
−3 0.3750−24
(4.763) (7.34) (8.47) (10.16) (11.29)
0.2500 95 105 135 150
−4 0.4375−20
(6.35) (10.73) (11.86) (15.24) (16.94)
0.3125 125 135 180 200
−5 0.5000−20
(7.938) (14.12) (15.24) (20.33) (22.59)
0.3750 155 165 270 300
−6 0.5625−18
(9.525) (17.5) (18.63) (30.49) (33.88)
0.5000 280 305 400 450
−8 0.7500−16
(12.7) (31.62) (34.45) (45.18) (50.83)
0.6250 380 405 670 700
−10 0.8750−14
(15.875) (42.92) (45.74) (75.68) (79.07)
0.7500 550 600 900 1000
−12 1.0625−12
(19.05) (62.12) (67.77) (101.66) (112.96)
1.000 800 900 1200 1400
−16 1.3125−12
(25.4) (90.36) (101.66) (135.55) (158.14)
Page 211
MAINTENANCE MANUAL
Table 204. Torque Values for Boss and Bulkhead Fittings (Cont.)
Section II. Torque Values for Fitting to Boss for Positioning Universal Fitting
Aluminum Steel
Tube
Dash Tube Recommended Maximum Recommended Maximum
No. O.D. Thread Size in−lb (Nm) in−lb (Nm) in−lb (Nm) in−lb (Nm)
0.1250 22 24 25 35
−2 0.3125−24
(3.175) (2.48) (2.71) (2.82) (3.95)
0.1875 28 32 50 75
−3 0.3750−24
(4.763) (3.16) (3.61) (5.64) (8.47)
0.2500 38 42 55 80
−4 0.4375−20
(6.35) (4.29) (4.74) (6.21) (9.03)
0.3125 58 63 75 100
−5 0.5000−20
(7.938) (6.55) (7.11) (8.47) (11.29)
0.3750 70 80 100 150
−6 0.5625−18
(9.525) (7.9) (9.03) (11.29) (16.94)
0.5000 145 155 180 230
−8 0.7500−16
(12.7) (16.37) (17.5) (20.33) (25.98)
0.6250 190 210 250 350
−10 0.8750−14
(15.875) (21.46) (23.72) (28.24) (39.53)
0.7500 285 315 420 600
−12 1.0625−12
(19.05) (32.19) (35.58) (47.44) (67.77)
1.000 475 525 600 840
−16 1.3125−12
(25.4) (53.65) (59.3) (67.77) (94.88)
Section III. Torque Values for Bulkhead Fitting Installation

Tube Tube O.D. Bulkhead Hole Diameter Recommended Maximum
Dash No. in (mm) Thread Size in (mm) in−lb (Nm) in−lb (Nm)
−2 0.1250 (3.175) 0.3125−24 0.318—0.338 (8.077—8.585) 35 (3.95) 50 (5.64)
−3 0.1875 (4.763) 0.3750−24 0.380—0.400 (9.652—10.160) 65 (7.34) 80 (9.03)
−4 0.2500 (6.35) 0.4375−20 0.443—0.463 (11.252—11.760) 85 (9.6) 105 (11.86)
−5 0.3125 (7.938) 0.5000−20 0.505—0.525 (12.827—13.335) 105 (11.86) 125 (14.12)
−6 0.3750 (9.525) 0.5625−18 0.568—0.588 (14.427—14.935) 120 (13.55) 150 (16.94)
−8 0.5000 (12.7) 0.7500−16 0.755—0.775 (19.177—19685) 240 (27.11) 280 (31.62)
−10 0.6250 (15.875) 0.8750−14 0.880—0.900 (22.352—22.86) 320 (36.14) 380 (42.92)
−12 0.7500 (19.05) 1.0625−12 1.068—1.088 (27.127—27.635) 500 (56.48) 600 (67.77)
−16 1.0000 (25.4) 1.3125−12 1.318—1.338 (33477—33.985) 720 (81.33) 880 (99.4)
Page 212
MAINTENANCE MANUAL
Section
20−20−00
Cleaning
MAINTENANCE MANUAL
CLEANING
1. Cleaning 3. Airframe Exterior and Rotor Blades
Cleaning
(Ref. Section 91−00−00) Consumable Materials
Item Nomenclature (Ref. Section 91−00−00)
Item Nomenclature
CM234 Solvent, dry-cleaning
General cleaning of oil and dirt deposits from Use care to prevent scratching
the helicopter and its components must be CAUTION of aluminum skin when clean
accomplished by using dry-cleaning solvent ing main rotor blades. Never use volatile
(CM234), standard commercial grade kerosene solvents or abrasive materials. Never apply
or a solution of detergent soap and water. bending loads to blades or blade tabs during
Exceptions that must be observed are specified cleaning.
in the following cleaning paragraphs.
NOTE: Avoid directing soapy or clean water
concentrations toward engine air intake
Some commercial cleaning area and instrument static source ports in
CAUTION agents, such as readily avail aft fairing.
able household cleaners, contain chemicals (1). Wash helicopter exterior, including
that can cause corrosive action and/or leave fiberglass components and rotor blades,
residue that can result in corrosion. Exam when necessary, using solution of clean
ples of cleaning agents that are not to be water and mild soap.
used are ``Fantastic” and ``409” type clean
ers, or locally made strong soap cleaners. (2). Clean surfaces stained with fuel or oil
by wiping with soft cloth dampened by
2. Fuselage Interior Trim and Upholstery solvent (CM234), followed by washing
Cleaning with clean water and mild soap.
(1). Clean dirt or dust accumulations from (3). Rinse washed areas with water and dry
floors and other metal surfaces with with soft cloth.
vacuum cleaner or small hand brush. 4. Transparent Plastic Cleaning
(2). Sponge soiled upholstery and trim (1). Clean outside surfaces of plastic panels
panels with a mild soap and lukewarm by rinsing with clean water and
water solution. Avoid complete soaking rubbing lightly with palm of hand.
of upholstery and trim panels. Wipe
solution residue from upholstery with (2). Use mild soap and water solution or
cloth dampened by clean water. aircraft type plastic cleaner to remove
oil spots and similar residue.
(3). Remove imbedded grease or dirt from Never attempt to dry plastic
upholstery and carpeting by sponging CAUTION panels with cloth. To do so
or wiping with an upholstery cleaning causes any abrasive particles lying on plas
solvent recommended for the `àpplica tic to scratch or dull surface. Wiping with
ble” fabric (nylon, vinyl, leather, etc). dry cloth also builds up an electrostatic
charge that attracts dust particles from air.
NOTE: If necessary, seat upholstery can be
thoroughly dry-cleaned with solvent. When (3). After dirt is removed from surface of
complete dry-cleaning is done, upholstery plastic, rinse with clean water and let
must be re-flameproofed. air-dry or dry with soft, damp chamois.
Page 201
MAINTENANCE MANUAL
(4). Clean inside surfaces of plastic panels cooling air screen (Ref. Chapter 71).
by using aircraft type plastic cleaner
and tissue quality paper wipers. (2). Clean screens with soft brush to remove
dirt accumulations.
5. Engine Compressor Contamination (3). Immerse screen in solution of detergent
Removal and allow to soak approximately 15
minutes. Flush out clear water. Allow
(Ref. Chapter 71 and the applicable Rolls- screen to drain and air-dry thoroughly.
Royce Operation and Maintenance Manual,
Section 01-00-00, Table 201) 7. Digital Instrument Display Surface
Cleaning
6. Cleaning Of Engine Air Inlet Screens
Use only a lint free cloth and ammonia-free
(1). Remove engine air inlet and engine cleaning solution to clean display surfaces.
Page 202
MAINTENANCE MANUAL
Section
20−30−00
Painting
MAINTENANCE MANUAL
PAINTING
1. Paint Finish
Polyurethane paint is used for the helicopter (Ref. Section 91−00−00)
exterior finish. The primary interior finish is Item Nomenclature
acrylic paint. A base coat of primer is used on CM305 Lacquer, acrylic
most helicopter structure. CM318 Primer
CM320 Thinner, lacquer
2. Paint Removal
(1). Apply applicable chemical surface

Consumable Materials treatment (Ref. Section 20-40-00) if
(Ref. Section 91−00−00) metal protection is not adequate. If
Item Nomenclature chemical surface treatment is undam
CM229 Paint remover aged, or has already been applied, wipe
CM230 Paint remover surface clean with thinner (CM320) and
wipe dry immediately.
CM236 Paint remover
(2). Apply coat of primer (CM318). Feather
primer coating onto surrounding color
Use paint remover (CM229, CM230 or CM236) coat. Allow primer to air-dry for 30
when it becomes necessary to remove finish minutes.
paint coatings. Ordinarily, use of paint
remover should be limited to stripping of paint (3). Apply lacquer (CM305) color coats to
from parts that require magnetic-particle or match original finish color.
fluorescent-penetrant inspection and to parts B. Touchup − Flaking or Dried Paint or
that require removal of excessive paint Primer
buildup. When possible, use high-pressure
water spray to rinse off paint remover and Consumable Materials
paint particles and to neutralize paint (Ref. Section 91−00−00)
remover. Solvent type paint remover usually Item Nomenclature
does not remove primer coating; acid type
solvent removes primer. CM801 Abrasive paper, silicon carbide
If paint remover is used in vicin (1). Sand non-adherent surface to smooth

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

The following procedure is for rework of Item Nomenclature
scratches, nicks, gouges and other small CM801 Abrasive paper, silicon carbide
blemishes.
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MAINTENANCE MANUAL
(1). Use 320-grit or finer abrasive paper (4). Lightly sand surface with 320-grit
(CM801) and wet or dry sanding abrasive paper (CM801). Normal grain
method to sand through chemical film appearance does not require further
to bare metal. Feather surrounding filling or sanding.
surface with bare surface.
(5). Apply primer and color finish (CM305)
(2). Re-treat bare metal with applicable (Ref. Touchup - Small Sanded Areas).
chemical film (Ref. Section 20-40-00)
using brush application. E. Touchup − Polycarbonate Plastic Parts
(3). Touchup re-treated surface (Ref.
Touchup - Small Sanded Areas). Consumable Materials
D. Touchup − Glass Fiber Laminate Parts Item Nomenclature
CM220 Naphtha aliphatic
CM217 Isopropyl alcohol
Item Nomenclature CM305 Lacquer, acrylic
CM217 Isopropyl alcohol CM317 Resin primer / Thinner
CM219 Methyl−propyl−ketone (MPK)
CM305 Lacquer, acrylic (1). Wipe surface clean with a 1:1 mixture
CM316 Epoxy coating / Thinner of naphtha (CM220) and isopropyl
CM801 Abrasive paper, silicon carbide alcohol (CM217). Mix equal parts (1:1)
of primer resin (CM317) and thinner.
Apply one coat to surface and allow to
(1). Remove all gloss from area requiring air-dry minimum of 3 hours. Apply
finish with 100-grit or coarser abrasive epoxy primer and color finish (CM305)
paper (CM801) until there is a uniform (Ref. Touchup - Small Sanded Areas).
dull condition.
F. Touchup − ABS Thermoplastic Parts
MPK solvent is flammable.
WARNING Use only in well-ventilated
area and away from heat and flame. Consumable Materials
(2). Wipe surface clean with 1:1 mixture of
Item Nomenclature
MPK (CM219) and isopropyl alcohol
(CM217). CM305 Lacquer, acrylic
(3). Squeeze one coat of Poly-EP (CM316),

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

CAUTION
The following procedures is to be used whenev D When sanding paint from the main rotor
er the main rotor blades require either blade, take care to not damage rivet heads
repainting or paint touch-up. and sealant.
D Do not sand through the paint and primer
NOTE: into the base metal.
D Repaint main rotor blades only in sets to (4). Using 320 grit, or finer, abrasive paper
maintain rotor balance. Never completely (CM801) and wet or dry sanding
repaint only one main rotor blade method, sand areas that require
installed on helicopter. painting.
D New main rotor blades have the inboard (5). Using a soft cloth, dampened in
24 inches (610 mm) painted gloss white. isopropyl alcohol (CM217), thoroughly
This aids in inspection of the blade. clean main rotor blade.
D At owner-operators convenience, in-ser (6). Inspect sanded areas for damage.
vice main rotor blades can have the in
board 24 inches (610 mm) painted gloss B. Main Rotor Blade Paint Application
white.
NOTE: If inboard 24 inches (610 mm) of main
rotor blade is to be painted white, paint is to
Consumable Materials be applied to the entire circumference of the
(Ref. Section 91−00−00) blade. There is to be no ridges in the paint
Item Nomenclature when completed.
CM206 Chemical coating (1). Inspect main rotor blade (Ref. Section
62-10-00, Main Rotor Blade Inspec
tion).
CM304 Enamel, epoxy
(2). Ensure all bushings, bearing, data
CM318 Primer
plates and the abrasion strip are
CM729 Tape, masking, pressure sensitive protected from paint with tape
CM801 Abrasive paper, silicon carbide (CM729).
(3). Using a soft cloth, dampened in
isopropyl alcohol (CM217), thoroughly
A. Main Rotor Blade Paint Removal clean main rotor blade.
(1). Position main rotor blade on a bench of (4). Treat any bare metal areas of main
sufficient length to provide support. rotor blade with chemical coating
(CM206).
(2). Inspect main rotor blade (Ref. Section NOTE: Mix primer (CM318) according to
62-10-00, Main Rotor Blade Inspec manufacturer's recommendations.
tion).
(5). Allow mixed primer to stand for 15 to
When removing paint from 30 minutes prior to use.
CAUTION main rotor blade, do not use any NOTE:
paint remover. Bonding agents used in
manufacture of the blade can be damaged by D Working life of mixed primer is four hours
the chemicals causing the blade to be unser maximum.
viceable. D Primer allowed to stand for more than
two hours must be stirred or shaken be
(3). Apply tape (CM729) to all bushings, fore use.
bearing, data plates and the abrasion D Addition of freshly mixed primer to re
strip. plenish an older mixture is not permitted.
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MAINTENANCE MANUAL
(6). Apply primer (CM318) to sanded areas, When removing paint from tail
feather into surrounding color coat. CAUTION rotor blade, do not use any paint
remover. Bonding agents used in manufac
(7). Allow to air-dry for one hour minimum. ture of the blade can be damaged by the
chemicals causing the blade to be unservice
NOTE: Mix paint (CM304) according to able.
manufacturer's recommendations.
(2). Apply tape (CM729) to all bushings,
(8). Allow mixed paint to stand for 20
data plates and the abrasion strip.
minutes minimum prior to use.
NOTE: (3). Plug root end of tail rotor blade to
ensure no paint enters.
D Working life of mixed paint is four hours
maximum.
CAUTION
D Addition of freshly mixed primer to re
plenish an older mixture is not permitted. D When sanding paint from the tail rotor
blade, take care to not damage rivet heads
(9). Apply paint (CM318) to primed areas. and sealant.
Feather-edge paint while applying.
D Do not sand through the paint and primer
(10). Allow to air-dry for eight hours into the base metal.
minimum.
(4). Using 320 grit, or finer, abrasive paper
(11). Remove protective tape from main rotor (CM801) and wet or dry sanding
blade. method, sand areas that require
painting.
NOTE: Main rotor assembly can need to be re-
balanced after painting. (5). Using a soft cloth, dampened in
5. Tail Rotor Blade Paint clean tail rotor blade.
The following procedures is to be used whenev (6). Inspect sanded areas for damage.
er the tail rotor blades require either repaint
ing or paint touch-up. B. Tail Rotor Blade Paint Application
NOTE: Repaint tail rotor blades only in sets to (1). Inspect tail rotor blade (Ref. Section
maintain rotor balance. Never completely 64-10-00, Tail Rotor Blade Inspection).
repaint only one tail rotor blade installed on
helicopter. (2). Ensure all bushings, data plates and
the abrasion strip are protected from
paint with tape (CM729).
(Ref. Section 91−00−00) (3). Ensure root end of tail rotor blade is
Item Nomenclature plugged to prevent entry of paint.
CM206 Chemical coating
CM217 Isopropyl alcohol (4). Using a soft cloth, dampened in
CM304 Enamel, epoxy
clean tail rotor blade.
CM318 Primer
CM729 Tape, masking, pressure sensitive (5). Treat any bare metal areas of tail rotor
CM801 Abrasive paper, silicon carbide blade with chemical coating (CM206).
NOTE: Mix primer (CM318) according to

A. Tail Rotor Blade Paint Removal manufacturer's recommendations.
(1). Inspect tail rotor blade (Ref. Section (6). Allow mixed primer to stand for 15 to
64-10-00, Tail Rotor Blade Inspection). 30 minutes prior to use.
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MAINTENANCE MANUAL
NOTE: NOTE:
D Working life of mixed primer is four hours D Working life of mixed paint is four hours
maximum. maximum.
D Primer allowed to stand for more than
D Addition of freshly mixed primer to re
two hours must be stirred or shaken be
plenish an older mixture is not permitted.
fore use.
D Addition of freshly mixed primer to re (10). Apply paint (CM318) to primed areas.
plenish an older mixture is not permitted. Feather-edge paint while applying.
(7). Apply primer (CM318) to sanded areas,
feather into surrounding color coat. (11). Allow to air-dry for eight hours
minimum.
(8). Allow to air-dry for one hour minimum.
(12). Remove protective tape from tail rotor
NOTE: Mix paint (CM304) according to
blade.
manufacturer's recommendations.
(9). Allow mixed paint to stand for 20 NOTE: Tail rotor assembly can need to be re-
minutes minimum prior to use. balanced after painting.
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Page 206
MAINTENANCE MANUAL
Section
20−40−00
Corrosion
Prevention
MAINTENANCE MANUAL
CORROSION PREVENTION
1. Corrosion Control (1). Coat contacting surfaces with layer of
sealing compound (CM425), in addition
The airframe is fabricated primarily of to primer (CM318).
aluminum and some magnesium alloys, with Do not use steel washers.
selective use of stainless steel and titanium, CAUTION
and should be checked regularly for any signs
of corrosion, especially at points of dissimilar (2). Use 5056S aluminum alloy washers
and overlapping metal contact. Corrosion of under boltheads and nuts that would
dissimilar metals is the result of several otherwise contact magnesium. If 5056S
conditions; lack of sufficient insulation in aluminum is not available, use 5052S
areas of metal contact, tears or punctures in alloy washers.
metal itself, and areas where protective
finishes have been scuffed, scratched, chipped (3). Apply primer on attaching hardware
or worn away. Do corrosion control according before installation.
to MDHI Corrosion Control Manual
3. Sealing Compound Application
(CSP-A-3) and instructions in the following
paragraphs. Use sealing compound (CM425) to replace
loose or missing sealant on exterior surfaces.
Do not apply potassium hydrox Sealant is used to fill seams and joints that
CAUTION ide to or near bolts, fasteners, might trap water. Apply sealant as follows:
seams, or faying surfaces. Immediately af
ter completing the magnesium and alumi Consumable Materials
num test (Ref. NOTE below), wash the (Ref. Section 91−00−00)
tested area with water to prevent burns and Item Nomenclature
continued action on the material.
CM425 Sealing compound
NOTE: To differentiate between aluminum and
magnesium alloy, apply one drop of ordinary (1). Check that seam or joint is clean and
potassium hydroxide (dropped from a glass free of foreign matter and moisture.
rod) to the surface of the metal being tested.
If the alloy is aluminum, a foaming or boil (2). Apply sealant with putty knife or
ing action of the liquid, accompanied by a similar tool.
black discoloration of the metal, will imme (3). Force sealant well down into seam to
diately occur. If the alloy is magnesium, no eliminate any air pockets.
reaction will be evidenced.
(4). Fillet sealant to give joint or seam a
smooth appearance.
2. Magnesium Alloys − Insulation Against
Corrosion 4. Main Rotor Hub Corrosion Prevention
(Tri−Flow Wash Procedure)
To prevent galvanic corrosion between
magnesium and any dissimilar metals: The following procedure will help prevent
corrosion of main rotor hub components,
especially on helicopters operated in marine
Consumable Materials environments. The procedure should be
(Ref. Section 91−00−00) accomplished following the last flight each day
Item Nomenclature for helicopters operated in marine or other
corrosive environments, and at each 25-hour
CM318 Primer inspection (Ref. Chapter 05), or more often if
CM425 Sealing compound desired, for helicopters not operated in
corrosive environments.
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MAINTENANCE MANUAL
(5). Wash remainder of helicopter exterior

Consumable Materials using fresh water spray.
Item Nomenclature (6). Wash main rotor blades with Zip Wax
(CM227) or equivalent, mixed per
CM104 Lubricant, spray
manufacturer's instructions.
CM227 Washing compound with wax
5. Main Rotor Blades Corrosion Arresting
Use care when working The following procedure will help prevent
WARNING around turning rotor blades. corrosion of main rotor blades. The procedure
Stay low. Remain on right side of heli should be accomplished following the last
copter to avoid tail rotor blades. flight each day on helicopters operated in
marine or other corrosive environments, and
NOTE: Do the first step below prior to engine weekly for helicopters not operated in corrosive
shutdown, following the last flight of the environments.
day if possible. When the rotor stops turn
ing, the laminates of the strap-pack spread
apart slightly. Contaminates collected on Consumable Materials
the edges of the strap-pack assembly can (Ref. Section 91−00−00)
enter the area between the laminates as Item Nomenclature
they spread apart. If the rotor continues CM227 Washing compound with wax
turning until the contaminants are washed CM228 Surface cleaner
away, centrifugal force will keep the lami
nates compressed and not allow the corro
sive substances to enter the area between Wear rubber gloves when us
the laminates. WARNING ing phosphoric solution in
next step.
(1). Bring engine to ground idle (64-65 %
Nl); set SCAV AIR to ON (Ref. applica (1). Wipe down main rotor blades with
ble PFM, Section 01-00-00, Table 201). surface cleaner (CM228).
Do the following:
(2). Rinse main rotor blades immediately
(a). Spray fine fresh water mist on main with water and dry. (Ref. Section
rotor blades. 20-20-00 for additional information on
cleaning main rotor blades.)
(b). Direct a strong stream of fresh water
(3). Wax main rotor blades with Zip Wax
into main rotor hub and control
(CM227) or equivalent, mixed per
system at main rotor hub.
(c). Spray entire rotor hub with lubricant A. Main Rotor Blade and Damper Attach
(CM104). Pins − Corrosion Prevention
(2). Shut down engine and allow rotor If helicopter is subject to salt-laden atmo
blades stop turning. sphere, lubricate mating surfaces of barrel nut
and cam handle at each periodic inspection,
NOTE: In the next step, spray directly between using corrosion preventive oil (CM120) (Ref.
individual laminates. Chap. 62).
(3). Lift main rotor blades to separate strap

pack laminates and spray strap-packs Consumable Materials
with lubricant. (Ref. Section 91−00−00)
Item Nomenclature
(4). Do the engine water wash (Ref. Chap CM120 Oil, corrosion preventive
ter 71).
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MAINTENANCE MANUAL
6. Magnesium Alloy Exterior Surface (2). Using swab, liberally apply chemical
Touchup Treatment film (CM206). Allow solution to remain
on surface for 1 to 3 minutes, or until
surface becomes amber to brown in
Consumable Materials color.
Item Nomenclature
(3). Rinse treated surface thoroughly with
CM207 Chromic acid solution clean water. After rinsing, wipe off
CM320 Thinner, lacquer excess moisture with clean lint-free
cloth. If dry compressed air is available,
blow any moisture from joints or
(1). Wash affected area with solution of crevices and allow to dry completely at
mild soap and clean fresh water. Rinse room temperature for approximately 1
area with clean water and wipe dry hour.
using clean soft lint-free cloth.
(4). Apply paint finish touchup (Ref. Section
(2). Use thinner (CM320) on damaged area 20-30-00).
to remove any grease and old paint.
(3). Apply chromic acid solution (CM207) by 8. Steel Alloy Exterior Surface Touchup
swabbing exposed area for 10 to 30 Treatment
minutes.
(4). Using clean cloth soaked in clean, fresh (Ref. Section 91−00−00)
water, thoroughly rinse area where Item Nomenclature
solution was applied. Allow area to
thoroughly dry. CM228 Surface cleaner
CM801 Abrasive paper, silicon carbide
(5). Apply paint finish touchup (Ref. Section
20-30-00).
(1). Remove loose paint and corrosion
7. Aluminum Alloy Exterior Surface Touchup products by scraping area with sharp
Treatment phenolic scraper, brushing with heavy
fiber brush and light sanding with
320-grit or finer abrasive paper
Consumable Materials (CM801).
Item Nomenclature
(2). Wash off area with mild soap and clean
CM206 Chemical coating fresh water; rinse thoroughly.
(3). Treat surface with surface cleaner

NOTE: If there is any question of whether or (CM228).
not the protective coating is removed, it
should always be assumed that bare metal
is exposed. (4). Allow solution to remain on surface for
approximately 5 minutes. Keep sur
(1). Wash affected area with solution of faces wet.
mild soap and fresh water. Rinse area
with clean water and wipe dry with (5). Rinse thoroughly with clean water. Dry
clean soft lint-free cloth. with clean lint-free cloth and then
allow to air-dry completely.
NOTE: Avoid letting chemical mixture dry on
surface in next step. If it has dried, re-wet (6). Apply paint finish touchup (Ref. Section
surface with solution. 20-30-00).
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MAINTENANCE MANUAL
9. Splitter Bungee Spring Corrosion Control (1). After helicopter shut-down, insert
(500N) absorbent cloth into area around
splitter bungee spring.
It is recommended that after shutdown from
the last flight of the day, for helicopters
operating in a corrosive environment, the (2). Liberally spray spring with lubricant
splitter bungee spring be sprayed with (CM104) until spring inner coils are
Tri-Flow. coated.
(3). Remove absorbant cloth from around
spring.
Item Nomenclature
CM104 Lubricant, spray
(4). Wipe excess spray from aircraft.
Table 201. Anti−Corrosion Chemical Finishes − Aluminum
Process Applicable Specification Normal Coating Thickness and Color
Dow #1 (Chrome Pickel) MIL−M−3171, Type I Removes metal. Iridescent yellow or red;
gray coatings are unacceptable.
Dow #7 (Dichromate MIL−M−3171, Type III No dimensional change. Wrought or
Treatment) extruded parts − chestnut brown; castings
− light brown to black; AZ91C−T6 and
AZ92A−T6 alloys − gray.
Dow #17 (Anodize) MIL−M−45202, Type I − light coat Class C: 0.0002−0.0003 inch
(0.00508−0.00762 mm); light green.
Type II − heavy coat Class D: 0.0002−0.0035 inch
(0.00508−0.08890 mm); dark green.
Dow #19 (Chromic Acid MIL−M−3171, Type VI No dimensional change; gray to black.
Brush−on Treatment)
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MAINTENANCE MANUAL
Section
20−50−00
Electrical Bond and
Environmental Seal
MAINTENANCE MANUAL
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MAINTENANCE MANUAL
ELECTRICAL BONDING AND ENVIRONMENTAL SEALING

1. Electrical Bonding (c). Prior to any bond assembly, the
bonding surfaces must be wiped with
A. Electrical Bonding Preparation a cleaning solvent (CM211).
(d). Whenever bare metal surfaces of

Consumable Materials aluminum alloy are exposed in
(Ref. Section 91−00−00) preparation for electrical bonding, a
Item Nomenclature protective-conductive coating must
CM211 Solvent be applied before you make the bond
CM819 Kimwipe (Ref. Section 20-40-00, Aluminum
Alloy Exterior Surface Touch-up
Treatment.).
Do not use camel hair or natural
CAUTION bristle brushes, carbon steel NOTE: Preparation of surfaces is done to main
brushes, or steel wool. Use of these items tain initial level of electrical bonding protec
may damage the aircraft. tion when replacing or repairing compo
nents on helicopter.
(1). The following are typical items that
(3). If electrical bond is suspect or fault
may be required for use in surface
develops with equipment, do a electrical
preparation.
bond test.
(a). Brushes with nylon or other acid
NOTE: Surfaces to be electrically bonded must
resistant bristles. Rotary or corrosion
be free from finishes, lubricants, or foreign
resistant steel brushes.
matter that will impede electrical current
flow.
(b). Aluminum wool, nylon scrub pads,
garnet paper (7/0), fiberglass brush B. Electrical Bond Testing
es, and similar hand-type abrasive
or burnishing items. (Ref. Table 201 and Table 202)
(c). Use lint free cloth (CM819) , sponges
(plastic) and other water absorption Special Tools
or drying items. (Ref. Section 91-00-00)
Item Nomenclature
NOTE: Items listed are recommendations. ST1010 Volt-ohmmeter
(2). Surface preparation.

(1). A typical electrical bond measurement
(a). Using a nonmetallic scraper to volt-ohmmeter (ST1010) must be
remove adhesive from parts. capable of performing resistance
measurement utilizing a Kelvin
Solvent, Cleaning (CM211) resistive bridge network together with
four terminal measurement for apply
ing constant current across the un
known resistance and measuring
corresponding voltage drop.
(b). Grease, oil, or similar nonconductive (a). Meters must be capable of measuring
films must be removed from surfaces 1 milli-ohm (0.001 ohm) with 20
with a cleaning solvent (CM211). micro-ohm resolution.
Page 201
MAINTENANCE MANUAL
Table 201. Bonding Classes

Maximum DC Resistance
Between Bonded Members
Class Application (ohms)
A Antenna Installation 0.0025
C Current Path Return 0.005
Housing of Line Replaceable Unit (LRU)
Cable Shield to Cable Connector Housing
Common Termination System Ground Module Base
H Shock Hazard 0.100

L Lightning Protection 0.005
R RF Potentials 0.0025
S Static Charge 1.000
Table 202. Equipment Class Requirements

Ref. Equipment Class
CSP−900RMM−2/−3
Section
28−00−00 All Fuel System Components That Must Have Electrical Bonding R
32−00−00 Landing Gear L
53−00−00 All Fuselage Components That Must Have Electrical Bonding R
62−00−00 Main Rotor Blade H
Main Rotor Hub S
63−00−00 Main Transmission L

Rotor Brake Control Valve S
67−00−00 Bonding Strap (W124−J142) on Pilot Cyclic Stick to Bulkhead L

Bonding Strap (W125−J143) on Copilot Cyclic Stick to Bulkhead L
Collective Stick Bracket Assembly L
Lanyards on Expandable Diameter (Quick Release) Bolt Assemblies on
Copilot Cyclic Stick Attach Points to Cyclic Base Assembly L
Directional Pedals Bracket Assemblies, Pilot and Copilot, to Mounting
Airframe Structure. L
All Other Flight Controls That Must Have Electrical Bonding R
71−00−00 Powerplant (Engines) R
95−00−00 Instrument Panel R
All Instruments That Must Have Electrical Bonding R
96−00−00 All Electrical Power Equipment That Must Have Electrical Bonding R
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MAINTENANCE MANUAL
Table 202. Equipment Class Requirements (Cont.)

Ref. Equipment Class
CSP−900RMM−2/−3
Section
97−00−00 Audio Select Panel R
NOTES:
(1) Unless otherwise specified in Table 202, the maximum resistance values across an electrical bond
cannot be more than 2.5 milli−ohms (0.0025 ohms).
(2) Class bond values are located in Table 201.
2. Environmental Sealing Methods (a). Parts without fasteners must be held

in position, mechanically maintain
Surfaces to be sealed must be 50 ing contact pressure, until the
CAUTION to 120°F (10 to 49°C) during ap sealant is sufficiently cured to resist
plication of sealant. normal assembly forces.
Dispose of all unused hazardous (4). Ensure that sealant squeeze-out is

CAUTION materials according to Federal, visible at all seam areas.
State and local regulations.
(a). Remove sealant squeeze-out in
Areas to be sealed must be
CAUTION clean, dry, and free of grease, oil,
excess of 0.125 inch (3.18 mm) with
a non-metallic spatula or equivalent.
and other foreign material which can reduce
the adhesion of the sealing compound.
Clean area for environmental sealing (Ref. SKINS
Section 20-20-00, Cleaning Maintenance
Practices).
A. Faying Surface Sealing

FASTENER
SEAL BETWEEN
(Ref. Figure 201) SKINS
(1). Apply a 0.010 to 0.020 inch (0.25 to

0.51 mm) coat of sealant to all fayed
surfaces of a component which adjoin a
skin splice or other leakage path. G20-5000-201-1
Figure 201. Faying Surface Sealing

(2). Align fayed surfaces carefully and join
in a single operation.
B. Fillet Surface Sealing
(a). Avoid repositioning or shifting of the
fayed surfaces during assembly. (Ref. Figure 202 and Figure 203)
The fayed surfaces must be
CAUTION firmly pressed into position There must be no gaps or
CAUTION bridges in the sealing bead
within the work life of the sealant com
pound. along the seam joint.
(3). After parts are joined, fasteners must (1). Apply a bead of sealing compound to all
be installed within the work life of the seams and joints which are subject to
sealant. incursion of water.
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MAINTENANCE MANUAL
C. Gasket Sealing
ANGLE
(1). Apply sealant to both fayed surfaces.
FORMED FILLET
ABOVE SKIN EDGE
(a). Work out air bubbles with a spatula,
or equivalent, to spread sealant to a
SKIN
uniform thickness of 0.015 inch
(0.28 mm).
(2). Install gasket.
(a). Assemble parts and tighten any
45 DEGREE TAPERED FILLET
mechanical fasteners within the
G20-5000-202-1
period of the work life of the sealant.
Figure 202. Fillet Surface Sealing
(b). Install mechanical fasteners in pairs
approximately 90 degrees apart from
0.12 INCH
(3.1 MM) the preceding pair.
0.06 INCH
MINIMUM
(1.5 MM)
MINIMUM
D. Mechanical Fastener Sealing
(Ref. Figure 204)
(1). Seal mechanical fasteners as shown.
<0.15 INCH 0.12 INCH
(3.1 MM) BOLT HEAD 0.06 INCH
(3.8 MM) 0.25 INCH
(6.4 MM) MINIMUM (1.5 MM)
MINIMUM MINIMUM
0.25 INCH
(6.4 MM)
MINIMUM 0.12 INCH
(3.1 MM)
MINIMUM
0.12 INCH
0.15 TO 0.25 INCH (3.1 MM) NUT AND THREAD
(3.8 TO 6.4 MM) MINIMUM
0.12 INCH (3.1 MM)
MINIMUM
0.25 INCH
0.25 INCH (6.4 MM) 0.06 TO 0.12 INCH
(6.4 MM) MINIMUM (1.5 TO 3.1 MM)
MINIMUM MINIMUM
0.12 INCH
(3.1 MM)
MINIMUM
0.12 INCH
(3.1 MM)
G20-5000-203-1 MINIMUM G20-5000-204-1
Figure 203. Fillet Sealing Dimensions Figure 204. Mechanical Fastener Sealing
Page 204
MAINTENANCE MANUAL
Section
20−90−00
Nondestructive
Inspection
MAINTENANCE MANUAL
NONDESTRUCTIVE INSPECTION
1. Nondestructive Inspection Methods fasteners, security of parts, corrosion,
and damage.
A. Visual Inspection
(3). Treat any corrosion found during
(Ref. Figure 201) preliminary inspection.
(1). Select applicable visual inspection aids (4). Clean the areas or surface of parts to be
from the following list:
inspected.
(a). A flashlight with the correct explo
sive atmosphere rating, beam spread, (a). Remove any contaminates that
efficiency, and brightness for the might hinder surface indications.
inspection being done.. (b). Do not remove protective finishes.
(b). An inspection mirror on a ball joint
(5). Using optical aids as required, inspect
for use in viewing an area that is not
area as follows:
in the normal line of sight.
(c). A 2-10 power magnifying glass to (a). Examine surface for cracks using a
expose defects that cannot be seen by flashlight, and confirm with a
the unaided eye. magnifying glass.
(d). A borescope to allow remote visual (b). Examine surface for other disconti
inspection of internal surfaces or nuities, such as: discoloration from
otherwise inaccessible areas. overheating; buckled, bulging, dented
skin; cracked, chafed, split, or dented
(2). Do a preliminary inspection of overall tubing; chafed electrical wiring;
general area for cleanliness, presence of delaminating of composites; and
foreign objects, deformed or missing damaged protective finishes.
EYE ABOVE REFLECTED

LIGHT BEAM
INCANDESCENT
LIGHT BEAM
LINE OF SIGHT
REFLECTED LIGHT BEAM
5° TO 45°
FAYING SURFACES CRACK OPEN TO SURFACE G20-0001
Figure 201. Visual Inspection Technique
Page 201
MAINTENANCE MANUAL
B. Dye Penetrant Inspection

Consumable Materials Item Nomenclature
(Ref. Section 91−00−00) CM234 Solvent, dry-cleaning
Item Nomenclature
The coin tap method of inspection is used
CM805 Dye penetrant kit evaluate composite structures. The coin tap is
limited to detecting shallow defects.
(1). Using cleaning solvent (CM234), clean When inspecting cored structure, two sided
area to be inspected. access is required. When multiple laminates
are installed over core, the core bond-line
cannot be evaluated.
NOTE:
The sound of an acceptable part can vary
D Manufacturers instructions on Dye Pene
considerably and the entire area must be
trant Kit take precedence over the follow
tapped in order to detect any variance.
ing steps.
Compare the sound of the suspected area with
D Parts to be inspected must be dry and the sound of a known acceptable area.
heated to at least 705F (21.15C) but not
An acceptable area will have a slightly sharper
more than 1305F (54.45C).
or crisper sounding response. A dead or flat
sound is unacceptable, and requires a more
(2). Apply penetrant from dye penetrant kit thorough type of NDI.
(CM805) by brushing, spraying or by
dipping. Allow to stand for a minimum Any suspect areas must be in
of 2 minutes. CAUTION spected by person(s) qualified in
the appropriate NDI. Contact MDHI cog
(3). Remove excess penetrant with remover nizant engineering for recommended NDI
(available with dye penetrant kit procedures and applications.
(CM805)), or by cleaning with plain (1). Thoroughly clean area to be inspected
water. Allow part to dry. with cleaning solvent (CM234).
(4). Apply a light even layer of developer (2). Do a visual inspection for any raised or
from dye penetrant kit (CM805) by blistered appearing areas.
brushing, spraying or by dipping. When
dipping, avoid excess quantity. NOTE: Tap the entire area to be inspected in
cluding any surrounding area of like con
struction.
(5). Penetrant, which has penetrated into
cracks (or other openings) in the surface (3). Using a coin, light hammer, or other
of the part will be drawn out by the suitable blunt object, lightly tap the
developer resulting in a bright red surface of the part to be inspected.
indication.
D. Fluorescent Penetrant Inspection
(6). If part is serviceable or repairable, Refer to the appropriate manufacturer's
clean part free of penetrant and related instructions for type of equipment and
developer with cleaning solvent materials being used.
(CM234).
E. Magnetic Particle Inspection
C. Coin Tap Inspection Refer to the appropriate manufacturer's
related instructions for type of equipment and
(Ref. Figure 202) materials being used.
Page 202
MAINTENANCE MANUAL
0.25 INCH
(6.35 MM)
2.00 INCH
(50.8 MM)
0.375 INCH
(9.52 MM)
DIA BALL
MATERIAL: MILD STEEL OR BRASS
G20-0002
Figure 202. Coin Tap Inspection
F. Eddy Current Inspection − General (a). Personnel doing nondestructive tests

must be qualified and certified in of
This procedure includes general information NAS 410 or ASNT SNT-TC-1A or
on material, equipment and procedures for the equivalent. Personnel making must
detection of surface cracks. be certified to Level 2 minimum.
The Eddy Current test instruments induce an
Eddy Current into a conductive medium and (b). The test facilities written procedure
detect the change in the induced eddy current approved by the Level 3 technician
field which is produced by a defect. must be followed.
Related Publications (2). Equipment

(Ref. Section 01−00−00 (Table 2)
Specification Publication Title Refer to equipment manufacturer's
NAS−410 instructions for type of material
Nondestructive Testing Personnel inspected.
Qualification and Certification
ASNT−SNT−TC−1 (a). Electronic - Electronic - All electron
Nondestructive Testing Personnel ic equipment must be calibrated
Qualification and Certification annually or after repair. Records
ASTM E 1316 must be kept and made available
Standard Terminology for Non−destructive when requested. All calibration must
Examinations be made to a national standard. The
equipment must be approved for the
type of part examined. Maintain a
(1). Personnel Qualification and Certifica 3:1 signal to noise ratio during
tion. inspection.
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MAINTENANCE MANUAL
(b). Probes - Must be correct for the part (4). Standardization

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

alloy of the same base material
The Eddy Current Inspection of
and temper or approximately the
components must be done with the
same electrical conductivity,
test facilities local aviation regulato
surface texture, shape, and defect
ry authority and approved proce
location as the part to be inspect
dures.
ed.
(6). Test Facilities
2). Only the reference standards
calibrated and certified must be (a). Approved facilities must use the
used for the specific component same or equivalent equipment.
examined. All calibration stan
dards must be kept to a national (b). Analysis of all indications must be
standard. Records must be kept made in accordance with the test
and made available when request facilities approved procedures and
ed. with defects.
(c). Parts with defects must be removed
(3). Surface preparation - All surface from service in accordance with the
contamination that could cause an facilities approved procedures.
interference with the inspection must
be removed. Methods of cleaning must (d). Records must be completed in
not damage surface finish or damage to accordance with the facilities ap
the part. proved procedures.
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MAINTENANCE MANUAL
Chapter
21
Environmental
Control System
MAINTENANCE MANUAL
TABLE OF CONTENTS
21-10-00 Ventilation Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Environmental Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Cabin Vent Control Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Cabin Vent Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Cabin Vent Control Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Cabin Ventilating Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Cabin Ventilating Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Cabin Ventilation Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Cabin Ventilation Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Cabin Ventilating Valve Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6. Cabin Ventilating Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7. Cabin Ventilating Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8. Snap-Vent Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Snap-Vent Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Snap-Vent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Ventilating System Pointed Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Ventilating System Round Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
21-40-00 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Heating System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Heating System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Troubleshooting Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Heat Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Heat Control Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Heating Valve and Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Heat Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Heat Control Valve Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Heat Control Valve Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Heat Control Valve Cable - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202. Cabin Heat Control Handle and Diffuser Installation . . . . . . . . . . . . 205
5. Heating System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Heat Control Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Heat Control Valve Cable Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Heating System Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7. Heat Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Page i
MAINTENANCE MANUAL

8. Heat Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Figure 203. Heater Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 204. Control Valve Shim Thickness Determination . . . . . . . . . . . . . . . . . . . 208
9. Heating System Muffler and Ducts Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 205. Hose and Ducting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
1. Heating System Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Preparation for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Heating Valve Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Ducting Installation (-517) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Ducting Installation (-519) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Figure 901. Outlet Installation and Convenience Panel Modification . . . . . . . . . 902
E. Modification of Existing -517 to -519 Configuration . . . . . . . . . . . . . . . . . . . . . . . . 903
F. Ducting Installation (-521) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
G. Cabin Heat Control Cable Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
H. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Table 901. Weight and Balance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Figure 902. Engine Air Bleed Line Installation (250-C20B) . . . . . . . . . . . . . . . . . 905
Figure 903. Engine Air Bleed Line Installation (250-C20R/2) . . . . . . . . . . . . . . . 906
Figure 904. Engine Air Bleed Line Installation (250-C30) . . . . . . . . . . . . . . . . . . . 907
Figure 905. Heating Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
Figure 906. Duct, Hose and Convenience Panel Installation (Sheet 1 of 2) . . . . 909
Page ii
MAINTENANCE MANUAL
Section
21−10−00
Ventilation Systems
MAINTENANCE MANUAL
VENTILATION SYSTEMS
1. Environmental Systems (4). Remove control cable nut from plunger
housing and pull entire control cable
The cabin ventilation system consists of a out aft through instrument panel
ventilation valve, control cable and snapvents mounting hole.
installed in the door windows. The ventilation
valve contains a moveable vane operated by a B. Cabin Vent Control Cable Installation
push-pull cable mounted in the right center of (1). Route replacement control cable
the instrument panel. The control cable locks through instrument panel and secure in
the vane in any selected position, controlling place using lockwasher and control
airflow. Fresh air forced through an opening in cable nut.
the lower front canopy passes through the
valve and is directed into the cabin. (2). Secure control cable sleeve to valve
bracket with clip.
Adjustable snapvents are installed in each
door window. The snapvents can be opened (3). Position shaft arm so that vane assem
and rotated to face the airstream to supple bly is fully closed.
ment fresh air intake, or in the trail position, (4). Insert control cable wire through hole
provide a vent-air exhaust outlet. in swivel and move control knob to fully
closed position.
Before high speed flight; ensure
CAUTION that all snapvents are posi (5). Tighten swivel on control cable wire
tioned up, aft or down with outs in the trail and install cotter pin.
position. Door damage and vibrations could
occur if vent cutouts face the airstream. (6). Check swivel for free rotation by
actuating control knob through full
NOTE: stroke. Inspect valve assembly for
complete closure of inlet opening when
D The following maintenance procedures control knob is pushed forward against
cover round or pointed nose helicopters. cable panel fitting stop. Check valve
Whenever reference is given to diffuser door for looseness on shaft and defor
type valve this is for round nose military mation; valve door must be flat; a firm,
D model, and likewise the “Y” type is for snug fit is required in the inlet.
civil models.
(7). Reinstall right side fairing on instru
D For round nose model with diffuser or “Y” ment panel.
type valve, refer to Figure 202. For
pointed nose “Y” type valve, refer to 3. Cabin Ventilating Valve Replacement
Figure 201.
A. Cabin Ventilating Valve Removal
2. Cabin Vent Control Cable Replacement (1). Remove left and right side fairing from
instrument panel; then remove ducts
A. Cabin Vent Control Cable Removal from rear of ventilating valve.
(1). Ensure that electrical power is OFF. (2). Actuate control cable to full open
position.
(2). Remove right side fairing from instru (3). Remove control cable clip and discon
ment panel. nect control cable from swivel on valve
shaft.
(3). Disconnect control cable from swivel in
valve shaft. Remove clip and separate (4). Drill out rivets and remove valve
control cable from support bracket. assembly from helicopter canopy panel.
Page 201
MAINTENANCE MANUAL
B. Cabin Ventilation Valve Installation (3). Position vane assembly on shaft and
secure with screws using loctite
(1). Position ventilating valve on canopy (CM431).
panel and align rivet holes. Attach
valve to canopy panel with rivets (4). Install washer on end of shaft and
spaced at 90 degrees. insert cotter pin.
NOTE: If rivet holes are elongated or oversize, (5). Operate valve several times to assure
install next larger rivets. freedom of operation and positive
closing.
(2). Secure control cable sleeve to valve
bracket with clip. 6. Cabin Ventilating Valve Inspection
(3). Install swivel assembly loosely in arm (1). Inspect for cracks, secure attachment to
of shaft. canopy panel and separation of bonded
joints.
(4). Position shaft arm so that vane assem
bly is fully closed. NOTE: Very small, widely separated spots or
voids in plastic joints are not separation but
(5). Insert control cable wire into swivel air pockets produced during solvent bonding
assembly and move control knob to at manufacture.
fully closed position.
(2). Inspect for bent shaft or vane assembly
(6). Tighten swivel assembly on control and excessive shaft wear in pivot areas.
cable wire; install cotter pin.
(3). Inspect seal on vane assembly for wear.
(7). Operate valve through several open-
close cycles to assure ease of operation 7. Cabin Ventilating Valve Repair
and to determine that valve locks in
any position when control knob is
released. Consumable Materials
(8). Install ducts on rear of valve; then Item Nomenclature
install instrument panel left and right CM418 Cement, epoxy
side fairings.
4. Cabin Ventilation Valve Disassembly (1). Patch polycarbonate valve body cracks
and repair seam separations according
(1). Remove screws and separate vane to repair methods specified for polycar
assembly from shaft. bonate plastic (Ref. Sec. 20-30-00).
(2). Remove cotter pins and slide shaft from (2). Replace unserviceable seal if installed,
valve body. using cement (CM418) according to
container instructions.
5. Cabin Ventilating Valve Reassembly
8. Snap−Vent Replacement
A. Snap−Vent Removal
Item Nomenclature (1). Push snapvent outward in window
CM431 Sealing, locking and retaining compound (open position).
(2). Grasp open side of snapvent and gently
(1). Install cotter pin in hole at control arm squeeze it into an elliptical shape.
end of shaft. Install washer on shaft to
bear on cotter pin. (3). Slip snapvent out of window hole at
about a 30 degree angle to surface of
(2). Insert shaft in body of valve. window.
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MAINTENANCE MANUAL
B. Snap−Vent Installation (2). Slip snapvent flange into window hole

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

VENT VALVE CONTROL AIR DUCT
CABLE
É
DOOR WINDOW
SNAP VENT
É
ÉÉ CABIN VENT VALVE
ÉÉÉÉ
ÉÉ
BRACKET
CANOPY PANEL
CLIP
SHAFT
ÉÉ
SWIVEL ASSEMBLY RIVET SEAL
OUTSIDE (RAM) AIR VANE
ÉÉ INSIDE (EXHAUST) AIR

VENTILATING VALE VANE ASSEMBLY
G21−1001
Figure 201. Ventilating System Pointed Nose
Page 203
MAINTENANCE MANUAL
ÉÉ ÉÉÉ OUTSIDE (RAM) AIR
ÉÉ
ÉÉ
ÉÉ
ÉÉÉ INSIDE (EXHAUST) AIR
ÉÉ
ÉÉ
DOOR WINDOW
SNAP VENT
CONTROL KNOB
NOTE CONTROL CABLE NUT

VENT VALVE CONTROL
CABLE
SWIVEL CLIP AIR DUCT

ASSEMBLY
INSTRUMENT
PANEL
SHAFT
BRACKET
CANOPY PANEL
RIVET
SEAL VANE
CABIN VENT VALVE
VANE ASSEMBLY
JAM NUT AND SPRING

LOCKWASHER
SWIVEL CONTROL KNOB

ASSEMBLY CLIP
CONTROL CABLE
SHAFT VALVE ASSEMBLY

DIFFUSER
SPRING PIN
NOTE:
369D INSTRUMENT PANEL SHOWN,
CANOPY PANEL 500MD CONFIGURATION VALVE IS
INSTALLED WITH A T-SHAPED
OPEN PANEL.
COLLAR
VALVE PLATE TUBE RIVET
G21−1002
Figure 202. Ventilating System Round Nose
Page 204
MAINTENANCE MANUAL
Section
21−40−00
Heating System
MAINTENANCE MANUAL
HEATING SYSTEM
1. Heating System Description and enclosed behind the heating system
Operation access cover. Air is Ducted overhead
from the muffler into the cargo/pas
(1). The heating system mixes cold air senger and crew compartments. Six
supplied by the oil cooler blower and fan-shaped diffusers distribute air
hot air extracted from the engine throughout the cabin.
compressor scroll. Cabin air tempera
ture is mechanically controlled with a (4). The muffler consists of a laminated
handle in the crew compartment that fiberglass housing, perforated alumi
positions a cable operated mixing valve. num core, and a one inch layer of
The system distributes temperature fiberglass wool around the core.
controlled air via a muffler and ducts to
strategically located cabin outlets. (5). Air outlets are also provided for the
cargo/passenger compartment through
(2). The heat control valve is mounted on an overhead duct diffuser valve
the forward left side of the firewall mounted in the passenger convenience
bulkhead. The valve consists of a panel. Diffuser valve airflow can be
housing that contains air control ports adjusted as required.
for mixing hot and cold air. A 90° inlet (a). The -519 heating system adds
elbow attaches the valve to the com ducting to provide two floor-heated
pressor bleed air tube through the air outlets.
firewall bulkhead. The valve housing
inlet contains a stainless steel bleed air (b). The -521 heating system provides
flow control ball valve that is rotated by ducting for one floor-heated air
an attached drive pulley. A nozzle on outlet.
the inlet body injects hot air down
stream of cold air. A fitting supports the (6). The control handle, control cable and
cold air control vane and drive pulley conduit assembly are incorporated in
that is rotated by a drive belt. Hot air is the left side of the duct attached to the
mixed with cold air at a variable ratio. overhead canopy structure. Moving the
Because engine bleed air temperature control handle forward opens the heat
is approximately 500°F (260°C), cold air control valve. Control handle travel is
is never completely shut off while the approximately 2-3/4 inches (6.985 cm)
system is in use. from open to closed. Cable routing is
along the left side of the main rotor
(3). The duct system and the direct air flow mast support structure and down to the
muffler are forward of the firewall and firewall mounted control valve.
Page 201
MAINTENANCE MANUAL
2. Heating System Fault Isolation

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

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

defective
Heat control clevis improperly Adjust control cable clevis.

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

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

disconnect the hot bleed air line at the
(Ref. Figure 201) heat control valve elbow fitting.
A. Heat Control Valve Removal (5). Loosen the elbow tube nut and remove
elbow fitting and gasket.
(1). Remove interior trim and left aft (6). Remove hardware attaching the upper
bulkhead access cover. and lower end of control valve assembly
to the canted firewall.
(2). Remove cotter pin, washer, and pin
attaching clevis to heat control valve. (7). Remove clamp securing cool air duct to
valve.
(3). If particle separator is installed, loosen
and back off tube coupling nut of (8). Remove attaching hardware connecting
369H90149-51 tube assembly at end the muffler and valve. Remove heat
connected to elbow assembly. control valve and gasket.
Page 202
MAINTENANCE MANUAL
STRAP
(TYP)
GROMMET
CABLE
AFT AIR DUCTS
FWD AIR DUCTS
AIR DIFFUSERS
AIR DIFFUSERS
MUFFLER
BOLT
COLD AIR
INDEX FOR COLD AIR CONNECTOR HOSE
VANE ALIGNMENT IN CLAMP CABLE ASSEMBLY
OPEN POSITION
WASHER
NUT
CLAMP
GASKET SPACER
NUT
CONTROL VALVE
WASHER ASSEMBLY
ROTATED
BOLT NOTE
1/8 IN. (3.175MM) DRILL
JAM NUT
RIGGING PIN HOLES
(OPEN POSITION) COTTER
NOTE: PIN
GASKET
INSTALLED ON AIRCRAFT WITH
AIR PARTICLE SEPARATOR. NUT
CLEVIS
NUT PIN BLEED AIR
BLEED AIR LINE FITTING
BOLT WASHER
ELBOW
G21-4001A
Figure 201. Heating Valve and Cable Installation
Page 203
MAINTENANCE MANUAL
B. Heat Control Valve Installation 4. Heat Control Valve Cable Replacement

(Ref. Figure 202)
(Ref. Section 91−00−00) A. Heat Control Valve Cable Removal
Item Nomenclature
(1). Remove left half of engine air inlet
CM113 Anti-seize compound low temperature forward fairing, interior trim and left
aft bulkhead access cover.
(1). Install control valve assembly on (2). Remove seven screws attaching heat
forward left side of firewall with bolts, duct outer box to heat duct and canopy
washers and nuts, but do not tighten. frame.
NOTE: Use anti-seize compound (CM113) on (3). Remove clamps, straps, and grommets
threaded fittings. that attach cable to structure along its
full length. Remove cotter pin and
(2). For helicopters equipped with particle clevis pin from clevis at heater control
separator kit, re-engage tube coupling valve arm.
nut of the 369H90149-51 tube assem
bly with elbow assembly, and tighten B. Heat Control Valve Cable − Installation
fasteners.
(3). In left side of engine compartment, (Ref. Section 91−00−00)
install elbow, nut and new gasket. Item Nomenclature
Tighten retaining hardware on heating
CM430 Sealant, solvent resistant
valve.
(4). Connect control valve flange to muffler, (1). Route the cable assembly into position.
using new gasket and four nuts, Check that grommet is in place on
washers, and bolts. cable.
(5). Install cool air connector hose on (2). Install clamps and straps that attach
control valve inlet and secure with cable to structure. Install grommet at
clamps. structure fairing that cable passes
through using adhesive (CM430).
(6). Position control handle fully forward.
Position lever on control valve to open, NOTE: The clamp nearest to the valve should
and insert a 1/8 inch (3.175 mm) not be tightened until after travel is
rigging pin through lever and into valve checked.
boss.
(3). Attach heat duct outer box to heat duct
(7). Loosen jam nut on control cable and and canopy frame with seven screws.
adjust clevis so attach holes align with
hole in valve lever. Install pin through (4). For adjustment of clevis refer to initial
clevis and valve lever, and safety with installation.
cotter pin. (5). When assured that cable will operate
the valve freely through full range of
(8). Tighten clevis jam nut. Remove rigging travel, tighten the clamp nearest the
pin from valve lever. valve.
(9). Move control handle full aft and (6). Reinstall aft bulkhead access cover,
forward several times to check ease of interior trim, and left half of engine
heat control operation. inlet fairing.
(10). Reinstall left aft bulkhead cover and (7). After installation, adjust handle to be
interior trim. parallel to windshield glass.
Page 204
MAINTENANCE MANUAL
CANOPY FRAME
RIGID TUBING CANOPY CENTER
FRAME TRIM AND
SPRING PLUNGER HEAT DUCT - LOWER
CABLE SUPPORT BLOCK
(3 PL) (NOTE)
SET SCREW (2 PL)

WASHER
CONTROL HANDLE (NOTE)
HANDLE SHAFT
OUTER BOX
HEAT DUCT/TRIM
(6 PL)
CANOPY CLIP
INCREASE HEAT DIFFUSER
ASSEMBLY
HEAT DUCT MOUNTING
SCREW
CONTROL HANDLE DIFFUSER ASSEMBLY
INSTALLATION INSTALLATION
NOTE:
INSTALL WASHERS AS REQUIRED TO
OBTAIN DIFFUSER-TO-DUCT FIT
G21−4002
Figure 202. Cabin Heat Control Handle and Diffuser Installation

5. Heating System Inspection (f). Inspect rubber hose for tears and
evidence of deterioration.
(Ref. Figure 202)
(g). Inspect all ducts and muffler for
(1). With the helicopter on the ground, security of attachment and coupling
perform the following: hardware and any duct section or
muffler damage that would allow
(a). Inspect heat valve control lever and heated air leaks. Inspect diffuser
cable for freedom of operation. outlets for condition of cemented
joints or distribution ducts.
(b). Remove interior trim and left aft
bulkhead access cover in cargo (h). In engine compartment, inspect tube
compartment. Inspect cable for connecting engine air bleed fitting to
condition and security. control valve for cracks and security
of hex nuts.
(c). Inspect cable clevis for security of
jam nut and cotter pin. (2). Perform an operational check (Ref.
Heating System Operational Check).
(d). Inspect security of heat control valve
A. Heat Control Valve Inspection
to firewall; check pulley belt for
condition. (1). Inspect timing belt for deterioration,
stretching, worn teeth, or evidence of
(e). Inspect flexible fiberglass hose for slipping.
tears and deformation due to failure
of inner supporting wire or short (2). Inspect valve housing for deep dents
radius bends. and cracks, mating flanges and connect
Page 205
MAINTENANCE MANUAL
ing area for bends or dents which would (2). Remove hardware (nut, washer, bolt)
prevent tight connections, bearing attaching elbow to valve housing and
bosses for galling and excessive wear, remove elbow and shims if installed.
and interior seat and ball valve for
galling. (3). The O-ring, wave washer, retainer, ball
valve and coupling are now free for
(3). Inspect pulley shafts for galling and removal.
evidence of wear.
(4). Inspect ball valve and retainer for (4). Cut lockwire and remove three screws
cracks, galling and evidence of wear; from valve lever and drive pulley.
cold air vane for flatness and evidence Remove timing belt.
of excessive edge wear.
(5). Remove pin from drive pulley. Remove
B. Heat Control Valve Cable Inspection shaft from valve housing; inner and
outer washers will fall free.
(1). Inspect cables for kinks, crushed sleeve,
and corrosion. (6). Remove screws attaching cold air valve
vane to shaft. Remove plate spring and
(2). Clean all corrosion from cable. spacers. Remove vane.
(3). If cable is kinked or crushed, locate
problem and repair or replace cable as (7). Remove pulley, shaft, and washers from
required. valve housing.
6. Heating System Operational Check (8). Remove pin from driven pulley to
complete disassembly.
(1). Perform an operational check of the
heating system as follows: 8. Heat Control Valve Repair
(2). Move CABIN HEAT control handle full
forward to open heat valve. Control (1). Repair small dents in valve housing by
handle should not creep away from ON bumping out and burnishing. Repair
position. warped flanges by straightening on a
surface plate. No weld repairs are
(3). Remove left aft bulkhead access cover. permitted.
(4). Check that valve is full open position by (2). No repairs are permitted on moving
inserting a 1/8 inch (3.175 mm) drill parts, ball valve, retainer, coupling, or
shank (or rod) into the drive pulley shafts which are cracked, bent or badly
alignment hole (Ref. Figure 201). The worn.
drill shank should pass through the
pulley and enter a mating alignment (3). Place valve housing upside down on a
hole in the valve housing inlet body. suitable workbench (Ref. Figure 204).
Find the thickness of shims required
(5). Check the cold air vane drive pulley between valve body and elbow fittings
alignment mark. The mark should align as follows.
with a similar mark on the cold air
vane housing.
(a). Measure diameter of the ball valve
using an outside micrometer. Record
7. Heat Control Valve Disassembly
as dimension A.
(Ref. Figure 203)
(b). Place ball valve in housing and use a
(1). Rotate ball valve lever fully counter depth micrometer to measure dis
clockwise to position the ball valve tance from housing flange to top of
open. ball. Record as dimension B.
Page 206
MAINTENANCE MANUAL
VANE SCREW
SPACER
SPRING
SHAFT
HOUSING
WASHER
PIN
BOLT
DRIVEN PULLEY
WASHER WASHER
DRIVE PULLEY
BELT
BLEED AIR
FITTING
SHIM (AR)
ROTATED SCREW
(NOTE)
PIN
RETAINER BALL
LEVER
WASHER
O-RING
WASHER COUPLING
NUT SHAFT
WASHER
NOTE:
ELBOW USED ON AIRCRAFT WITH
PARTICLE SEPARATOR.
G21-4003
Figure 203. Heater Control Valve Assembly
Page 207
MAINTENANCE MANUAL
(c). Multiply dimension A by 0.933; then position ball valve in housing to engage
subtract the result from 1.627 in. coupling (ball valve in open position).
(4.1356 cm). Record as dimension C.
(6). Install new O-ring in elbow flange
Example: groove.
Ball dia. A = 1.441 in. (3.6601 cm)
(7). Install retainer and washer in housing
1.441 in. (3.6601 cm) x 0.933 = 1.344 on ball valve.
in. (3.4138 cm)
NOTE: A 1/2 inch (12.7 mm) wood dowel may
1.627 - 1.344 in. (3.4138 cm) = 0.283 be inserted through top of assembly to tem
in. (7.1882 mm) (dim. C) porarily hold these parts in position.
(d). Compare dimension B with dimen
(8). Install shim(s) of thickness determined
sion C. If B is greater than C, no
in above steps; then install elbow on
shims are required. If C is greater
valve housing flange with four bolts
than B, add shims 369H8007 until B
and nuts. Washers are installed under
is equal to or greater, 0.010 in. (0.254
both the bolt head and the nut. Use
mm) max., than C.
care to avoid nicking or cutting the
Example: O-ring during mating.
B = 0.270 in. (6.858 mm) and C = The flanges of the valve housing
0.283 in. (7.1882 mm) CAUTION and elbow should mate without
the use of undue force. If flanges do not mate
(e). Add a 0.015 in. (0.381 mm) shim to easily, the internal parts of the valve may be
dimension B. B now equals 0.285 in. misaligned. Investigate before tightening
(7.239 mm), or 0.002 in. (0.0508 mm) bolts.
more than dimension C, and is a
correct total shim thickness for use. (9). Install washer and ball valve so that
(4). Install washer (Ref. Figure 203) on ball rigging pin holes in pulley and in valve
valve shaft; then insert this assembly housing boss are aligned (ball valve in
into valve housing boss. open position).
(5). Install coupling on shaft (check that the (10). Install pin through ball valve pulley
ball drive lug is chamfered); then and shaft.
DEPTH MICROMETER
DIMENSION B (FLANGE-TO-BALL)
VALVE HOUSING
DIMENSION A (BALL DIAMETER) NOTE:

FIND DIMENSION C AS FOLLOWS:
C = 1.627 IN. (4.1356 CM) - A X 0.993).
REFER TO TEXT FOR USAGE.
BALL VALVE
BALL VALVE SUPPORT
G21-4004A
Figure 204. Control Valve Shim Thickness Determination
Page 208
MAINTENANCE MANUAL
(11). Remove wood dowel if used to align (20). Reinstall and actuator belt pulley on
internal parts; then rotate pulley ball valve using three screws (Ref.
through full travel several times to Figure 201). Note that the screw
assure ease of operation and positive located 180 degrees from the rigging
closing of ball valve. A valve torque pinhole is 1/8 inch (3.175 mm) longer
check, step (18). below, is made after than the others. Remove rigging pin
the timing belt is installed. installed in step (10). above. Safety
screws to each other with lockwire.
(12). Install cold air pulley and washer on
shaft. 9. Heating System Muffler and Ducts Repair
(13). Install cold air pulley and shaft assem
bly into valve housing. Consumable Materials
(14). Attach cold air vane to shaft using two Item Nomenclature
screws. CM432 Dichloromethane
CM433 Ethylene chloride
(15). Rotate ball valve pulley fully counter
clockwise to full stop.
Repair of heat system ducting will depend
(16). Rotate cold air pulley so that the vane upon the type of material used in the section
is 45 degrees from fully closed, or align that requires repair. Rubber hose or flexible
yellow rigging marks, if present. fiberglass hose that is torn, flattened, or
deteriorated must be replaced. When removing
(17). Install a serviceable timing belt ducting for repair or replacement, use illustra
between pulleys while maintaining tion as a guide (Ref. Figure 205).
valve position located in steps (15).and
(16). above. (1). Repair rigid fiberglass or muffler
according to the fiberglass repair
(18). Check valve operation by applying procedures outlined in the SRM, except
6—11 inch-ounces (0.0423—0.0777 use fire-retardant resin.
Nm) of torque on the ball valve shaft. If
the ball valve does not operate within (2). Repair rigid polycarbonate plastic
this range, change thickness of shims sections by bonding a patch according
between the valve elbow and housing as to the criteria and methods specified for
required. Shims are provided in 0.015 acrylic plastic in FAA AC 43.13-1B,
inch (0.381 mm), 0.010 in. (0.254 mm), Aircraft Inspection and Repair for
and 0.005 inch (0.127 mm) thicknesses. Standard Sheet Metal Repair. Use
dichloromethane (CM432) or ethylene
NOTE: Final total shim thickness should not dichloride (CM433) as the bonding
exceed dimension C (step (c).) by more than agent.
0.10 inch (2.54 mm).
(3). Repair small areas of rib or seam
(19). If rigging marks have not been applied, separation in plastic sections by
paint a yellow index mark, 1/16 inch injecting ethylene dichloride (CM433)
(1.59 mm) wide, on pulley and housing into the void area and clamping
(Ref. Figure 201). together under light pressure.
Page 209
MAINTENANCE MANUAL
NOTES:
1. REMOVE ADHESIVE BACKING COVER AND INSTALL PADS
WHERE INTERFERENCE MAY EXIST BETWEEN HOSE
AND STRUCTURE.
2. INSURE THAT HEATER HOSE DOES NOT CONTACT OIL
DIFFUSER
ASSEMBLY FLEX LINES OR STRUCTURE.
GROMMET SCOTCH FOAM PAD
OIL FLEX LINE

(NOTE 2)
HOSE
DUCT
GROMMET
STANDOFF
CLAMP CLAMP
DUCT ASSEMBLY
MUFFLER
COLD AIR MANIFOLD
COLD AIR HOSE
CONVENIENCE PANEL
CLAMP
HEATING VALVE
DUCTING INSTALLATION
G21-4005
Figure 205. Hose and Ducting Installation
Page 210
MAINTENANCE MANUAL
HEATING SYSTEM
INITIAL INSTALLATION
1. Heating System Initial Installation assembly (Sta. 31.50); retain washers
for use when installing diffuser assem
Procedures in this section can be done at the blies.
operator's discretion and are applicable to
369D/E/FF model helicopters. (4). Remove attaching hardware and outer
box from heat duct and canopy frame.
A. Preparation for Installation
(5). Remove rubber plug from left side of
convenience panel.
(Ref. Section 91−00−00) (6). Remove cap from cool air manifold duct.
Item Nomenclature
B. Heating Valve Initial Installation
CM702 Lockwire CRES
(1). Using hardware, install heating valve,
but do not tighten.
(1). Remove engine (Ref. Chap. 71).
(2). On aircraft equipped with engine air
(a). 250-C20B - 250-C20R/2: (Ref. particle separator only, engage tube
Figure 902 or Figure 903) coupling nut of 369H90149-51 tube
1). Remove existing plugs and install assembly and tighten fasteners.
tee and elbow. (3). Install elbow, nut and gasket from aft
Tee and elbow must be installed side of firewall. Tighten heating valve
CAUTION so that no interference will exist attaching hardware.
between hose assembly and existing bleed (4). Reinstall engine (Ref. Chap. 71).
air tube.
(a). 250-C20B - 250-C20R/2: (Ref.
2). Install hose assembly and tube Figure 902 or Figure 903)
assembly. Do not reinstall engine
at this time. 1). Connect tube assembly to elbow
using nut and gasket. Torque both
(b). 250-C30: (Ref. Figure 904) connecting nuts onto tube assem
bly to 350 inch-pounds (39.54
1). Remove existing plate and install Nm).
fitting, using engine supplied
washers and bolts. Safety with (b). 250-C30: (Ref. Figure 904)
lockwire (CM702).
1). Connect engine bleed assembly to
2). Install engine bleed assembly to elbow. Torque connecting nut to
fitting, and secure tube assembly 350 inch-pounds (39.54 Nm).
by connecting one end of the strap
to the inlet bell with bolt, nut and C. Ducting Installation (−517)
washers, but do not tighten. Attach
clamp to bleed assembly. Secure to (Ref. Figure 906)
strap with attaching hardware.
Tighten nut. Consumable Materials
(2). Remove interior trim panels and aft Item Nomenclature
bulkhead access.
CM411 Adhesive, epoxy
(3). Remove left and right hand guide CM821 Gasket material
assemblies from forward end of duct
Page 901
MAINTENANCE MANUAL
(1). Using clamps, install air hose between NOTE: Ensure that heater hose does not con
heating valve and cold air manifold tact transmission oil lines or structure.
duct (Ref. Figure 905).
(8). Install aft valve assembly (23) in
(2). Install muffler assembly with gasket convenience panel (24) and connect
and hardware; attach hose to muffler valve to duct (3) with hose (25) and
with clamp. clamps (26).
(3). Remove protective cap from existing (9). Install diffuser assemblies (Ref.
duct assembly (1). Install grommets (2) Figure 202); add washers as necessary
with cement (CM411) to prevent to obtain diffuser to duct fit.
chafing.
D. Ducting Installation (−519)
(4). Route heater hose (9) and secure to oil
flex line (10) with clamps (11, 12), (Ref. Figure 906)
bracket (13), and attaching hardware
(14, 15, and 16).
(5). Position standoff (17) on inboard side of (Ref. Section 91−00−00)
channel (18) as shown. Drill two #40 Item Nomenclature
holes and deburr. Attach standoff to
CM318 Primer
channel using two rivets (19).
CM702 Lockwire CRES
(6). Install clamp (20) around hose and
secure to standoff, using attaching
hardware (21 and 22). Install Scotch (1). Do the installation as described (Ref.
Foam (CM821) as required to prevent Ducting Installation (-517), steps (1).
chafing. thru (4). and (6).) except that duct (27),
replaces duct (3) and that hose (5) is not
(7). Connect duct (3) to duct assembly (1), secured to duct (27) at this time.
and hose (5). Attach duct (3) to bulk
head using attaching hardware (6, 7, (2). Install splitter duct (28) with attaching
and 8). Attach hose (5) to duct with hardware (29, 30) and valve (23) into
clamp (4). convenience panel (24).
369D292479-1 OUTLET
INSTALLATION SAME
FOR 369D292479-2
0.188 IN. (4.7752 MM)
HOLE IN PANEL
NAS1402-2 SCREW REIDENTIFY AS 369H90020-5
369A2544-3 AN960-8 WASHER CONVENIENCE PANEL, TO BE
NAS1329A08-75 RIVNUT FITTING
NAS1402-2 SCREW (OPPOSITE SIDE) MADE FROM 369D26553-21 PANEL
AN960-8 WASHER
PICK UP EXISTING RIVET 0.40 IN. (10.16 MM)
LOCATION 1.00 IN.
TRUE HOLE LOCATION (2.54 CM)
1.38 IN. (3.5052 CM) 0.30 IN.

(7.62 MM)
2.75 IN. (6.985 CM)
DRILL 0.020-0.023 IN. 369D292480
(0.508-0.584 MM) HOLE SPLITTER DUCT
NAS1303-4 BOLT
MS21042-3 NUT
AN960KD10 WASHER
PICK UP EXISTING
RIVET LOCATION
G21−4006A
Figure 901. Outlet Installation and Convenience Panel Modification
Page 902
MAINTENANCE MANUAL
(3). Attach hose (25) to valve (23) with F. Ducting Installation (−521)
clamp (26), and hose (31) to splitter
duct (28) with lockwire (CM702). (Ref. Figure 906)
(4). Attach hose (25) to lower outlet on duct Consumable Materials

(27) with clamp (26), and second hose (Ref. Section 91−00−00)
(31) to upper outlet on duct (27) with Item Nomenclature
lockwire. CM318 Primer
(5). Mount convenience panel (24) with

attached duct, valve, and hose to (1). Do the installation as described (Ref.
bulkhead with with attaching hardware Ducting Installation (-519), steps (1).
(32, 33). thru (5). except replace splitter duct
(28) with duct (43) (Ref. Figure 905).
(6). Measure distance between splitter duct
outlets. Using this dimension, position (2). Position duct (35) and outlet duct (36)
ducts (34, 35) and outlet ducts (36) on bulkhead. Match drill three
parallel to each other on bulkhead. 0.221—0.226 inch (5.6134—5.7404
Match drill six 0.221—0.226 inch mm) holes common to clips into
(5.6134—5.7404 mm) holes common to bulkhead. Remove outlet duct (36) and
duct clips to bulkhead. Remove ducts. duct (35). Deburr and apply primer
Deburr and apply primer (CM318) to (CM318) to bare metal surfaces. Install
bare metal surfaces. Install rivnuts rivnuts (37).
(37). Reconnect ducts (34, 35) to splitter (3). Connect duct (43) to duct (35) and
duct (28) and attach ducts to bulkhead secure to bulkhead and convenience
with screws (38) and washers (39). panel with attaching hardware (29, 30,
38, 39, 40, 41, and 42).
(7). Install outlets (36) on ducts (34, 35).
Match drill holes through outlet duct (4). Attach hose (5) to duct (27) with clamp
clips into bulkhead (Ref. Figure 901). (4).
Remove outlets. Deburr and apply
primer to bare metal. Install rivnuts G. Cabin Heat Control Cable Initial
(37) were applicable. Install outlets Installation
with attaching hardware (38, 39, 40, 41,
(Ref. Figure 201)
and 42).
(8). Attach hose (5) to duct (27) with clamp Consumable Materials
(4). (Ref. Section 91−00−00)
Item Nomenclature
E. Modification of Existing −517 to −519 CM425 Sealing compound
Configuration
(Ref. Figure 906) (1). Remove clevis and jam nut assembly;
install grommet on cable, remove
(1). The -517 heating system can be existing plug button in canted frame
modified by replacing duct (3) with duct structure, and route cable through hole
(27), modifying the convenience panel, in structure and hole in structure
as illustrated, and by installing addi fairing.
tional hose (31), splitter duct (28), ducts (2). Remove clamps from duct assembly and
(34 and 35), outlets (36), and associated secure control handle and rigid portion
hardware. of control cable assembly with clamps.
(2). Follow installation instructions (Ref. (3). Tie control cable to existing tubing and
Ducting Installation (-519). cables with straps.
Page 903
MAINTENANCE MANUAL
(4). Secure grommet in structure and seal (c). Tighten clevis jam nut. Remove
hole at structure fairing that cable rigging pin from valve lever.
passes through, using adhesive
(CM425). (d). Move pilot's heat control handle full
aft and forward several times to
(5). Secure lower end of cable assembly to
check ease of heat control operation.
structure with clamp and attaching
hardware.
(e). Tighten clamp nearest clevis end of
NOTE: Do not tighten clamp until after travel control cable.
is checked.
(f). Reinstall aft bulkhead access cover,
(6). Install heat duct outer box to heat duct
interior trim, and left half of engine
and canopy frame with seven screws.
inlet fairing.
(7). Install jam nut and clevis as follows;
(g). After installation, adjust control
(a). Position heat control handle full handle to be parallel with windshield
forward. Position lever on heat glass.
control valve to open and insert a 1/8
inch (0.125 mm) rigging pin through
H. Weight and Balance
lever and valve boss.
(b). Loosen jam nut on control cable and Weight and balance changes resulting from
adjust clevis so attach holes align installation of heating system equipment are
with hole in valve lever. Install pin listed in Table 901. After installation of
through clevis and valve lever. Install heating system equipment, incorporate
washer and secure pin with cotter changes in helicopter weight and balance
pin. record (Ref. Section 08-10-00).
Table 901. Weight and Balance Data
Weight Arm Moment
Configuration
Pounds (kg) Inches (cm) in−lb (kg cm)
369H90020−517
Added +8.2 (+3.719) 106.7 (271.02) +874.9 (+1007.990)
Removed 0.0 − −
Change +8.2 (+3.719) 106.7 (271.02) +874.9 (+1007.990)
369H90020−519
Added +8.6 (+3.901) 110.1 (279−65) +946.9 (+1090.942)
Removed 0.0 − −
Change +8.6 (+3.901) 110.1 (279−65) +946.9 (+1090.942)
Page 904
MAINTENANCE MANUAL
TEE
(NOTE)
HOSE ASSEMBLY
NUT
TUBE ASSEMBLY
GASKET
ROTATED
GASKET
NUT
HOSE ASSEMBLY
ELBOW
(NOTE)
NOTE:
INSTALL TEE AND ELBOW SO NO INTERFERENCE
OCCURS BETWEEN HOSE ASSEMBLY AND EXISTING
ENGINE BLEED AIR TUBE. G21-4007
Figure 902. Engine Air Bleed Line Installation (250−C20B)
Page 905
MAINTENANCE MANUAL
TEE
NUT
GASKET
GASKET
NUT
NOTE:
INSTALL TEE AND ELBOW SO NO INTERFERENCE
OCCURS BETWEEN HOSE ASSEMBLY AND EXISTING
ENGINE BLEED AIR TUBE.
HOSE ASSEMBLY
ELBOW
(NOTE)
G21-4008
Figure 903. Engine Air Bleed Line Installation (250−C20R/2)
Page 906
MAINTENANCE MANUAL
BOLT
(NOTE)
FITTING
ENGINE BLEED
ASSEMBLY
NOTE:
REPLACE EXISTING NUT AND BOLT WITH
NAS1351C08-10 BOLT,
MS21043-C8 NUT AND
AN960-8L WASHER (2 REQD). G21-4009
Figure 904. Engine Air Bleed Line Installation (250−C30)
Page 907
MAINTENANCE MANUAL
HOSE
GROMMET
CLAMP
MUFFLER
COLD AIR HOSE
CLAMP
BOLT
NUT
GASKET
CLAMP
WASHER
NUT
HEATING VALVE
WASHER
BOLT
G21−4010
Figure 905. Heating Valve Installation
Page 908
MAINTENANCE MANUAL
2
1
8
5
7 4
-517 (REF)
27
14
11
15
21
22 15 10
16
15
14
13
20 19 17
16 15
SCOTCH FOAM
12
18
G21-4011
Figure 906. Duct, Hose and Convenience Panel Installation (Sheet 1 of 2)
Page 909
MAINTENANCE MANUAL
32
33
31
27
28
25
26 37
26
24
43
23
42
41
34
30 42
41
29
38 39
42
35 41
40 37
36
39
38
36
41
36 40
G21−4012
Figure 906. Duct, Hose and Convenience Panel Installation (Sheet 2 of 2)
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Legend (Ref. Figure 906)

1. DUCT ASSEMBLY 23. AFT VALVE ASSEMBLY
2. GROMMET 24. CONVENIENCE PANEL
3. DUCT 25. HOSE
4. CLAMP 26. CLAMP
5. HOSE 27. DUCT
6. BOLT 28. SPLITTER DUCT
7. WASHER 29. SCREW
8. NUT 30. WASHER
9. HEATER HOSE 31. HOSE
10. OIL FLEX LINE
32. SCREW
11. CLAMP
33. WASHER
12. CLAMP
34. DUCT
13. BRACKET
14. BOLT 35. DUCT
15. WASHER 36. OUTLET
16. NUT 37. RIVNUT
17. STANDOFF 38. SCREW
18. CHANNEL 39. WASHER
19. RIVET 40. BOLT
20. CLAMP 41. WASHER
21. BOLT 42. NUT
22. WASHER 43. DUCT
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Chapter
25
Equipment/
Furnishings
MAINTENANCE MANUAL
TABLE OF CONTENTS
25-00-00 Equipment/ Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Interior Furnishings Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Upholstered Seat Furnishings Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Mesh Seat Furnishings Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Crew Upholstered Seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Crew Mesh Seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Passenger Upholstered Bench Seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
F. Mid Bench Seat (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
G. Upholstered Passenger Individual Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
H. Passenger Mesh Seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
I. Seat Belts and Shoulder Harnesses (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . 2
J. Seat Belts and Shoulder Harness (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
K. Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
L. Floor Trim and Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
M. Miscellaneous Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
25-10-00 Upholstered Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Upholstered Crew Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Upholstered Passenger Aft Bench Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Mid Bench Seat Assembly Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Mid Bench Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Mid Bench Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Upholstered Passenger Individual Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Upholstered Seat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Upholstered Seat Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6. Upholstered Seat Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7. Optional Mid Business Seat Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Business Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Business Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Upholstered Seat Installation (369D) . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Upholstered Seat Installation (369E/FF - 500/600N) . . . . . . . . . . . . 204
Figure 203. Mid and Aft Seating Configuration (600N) . . . . . . . . . . . . . . . . . . . . . . 205
Figure 204. Mid and Aft Bench Seat Assembly Installation (600N) . . . . . . . . . . . 206
Figure 205. Upholstered Passenger Individual Seat Installation (369D) . . . . . . 207
Figure 206. Mid-Cabin Business Seat Installation (600N) . . . . . . . . . . . . . . . . . . . 208
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25-15-00 Mesh Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Crew/Passenger Mesh Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Crew Mesh Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Passenger Mesh Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Passenger Mesh Seat Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Crew Mesh Seat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6. Passenger Mesh Seat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Mesh Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Passenger Individual Mesh Seat Adjustment and Storage . . . . . . . 203
7. Mesh Seats Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8. Mesh Seats Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203. Passenger Bench Mesh Seat Adjustment . . . . . . . . . . . . . . . . . . . . . . . 204
1. Mesh Seat Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Model Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Preparation for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Helicopter Equipment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Passenger Compartment Bench Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 901
E. Passenger Compartment Individual Seat Installation . . . . . . . . . . . . . . . . . . . . . . . 901
F. Crew Compartment Mesh Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
G. Helicopter Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
H. Weight and Balance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
25-20-00 Seat Belts/Inertia Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Seat Belts/Inertia Reel Description and Operation (369D/E/FF - 500N) . . . . . . . . 201
2. Seat Belts/Inertia Reel Description and Operation (600N) . . . . . . . . . . . . . . . . . . . . . 201
3. Crew Seat Belt/Harness Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Seat Belt/Inertia Reel Replacement (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Seat Belt/Inertia Reel Installation
(Sam Browne Style) (369D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
(Yoke Style) (369D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
(Yoke Style) (369E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Crew Seat Belt/Harness Replacement With Manual Lock Option
(369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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MAINTENANCE MANUAL

Figure 204. Webbed Shoulder Harness and Seat Belt Installation with Manual
Inertia Reel Lock (369D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 205. Crew Inertia Reel Installation with Manual Inertia Reel Lock
(369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Seat Belt/Inertia Reel Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7. Seat Belt/Inertia Reel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8. Seat Belt/Inertia Reel Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9. Seat Belt/Restraint Harness, Crew Seat, Replacement (600N) . . . . . . . . . . . . . . . . . 207
A. Seat Belt/Restraint Harness Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Seat Belt/Restraint Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 206. Seat Belt/Restraint Harness Installation, Crew Seat (600N) . . . . . 207
10. Seat Belt/Restraint Harness, Mid Passenger Seat, Replacement (600N) . . . . . . . . 208
11. Seat Belt/Restraint Harness, Aft Passenger Seat, Replacement (600N) . . . . . . . . . 208
Figure 207. Seat Belt/Restraint Harness Installation, Passenger
Seats (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
12. Comfort Clip Installation and Decal Application (369D/E/FF - 500N) . . . . . . . . . . 210
Figure 208. Comfort Clip Installation and Crew Compartment Decal
Application (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 209. Comfort Clip Decal Application - Passenger Compartment
(369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
25-21-00 Seating/Belts (Four on the Floor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Seating/Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Seating/Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Seating/Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Seating/Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Seating/Belt Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Seating/Belt Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Seating/Belts (Four on the Floor) Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Removal of Existing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Seating and Belts Installation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
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MAINTENANCE MANUAL

D. Cant. Sta. 78.50 Brackets, Fittings and Restraint Panels Installation . . . . . . . . 901
Figure 901. Restraint Panel Assemblies and
Hardware Installation (369D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Figure 902. Restraint Panel Assemblies and
Hardware Installation (369E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . 903
E. Seat Assemblies Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
F. Aft Seat Belt Assemblies and Shoulder Straps Installation . . . . . . . . . . . . . . . . . . 905
G. Forward Seat Belt Assemblies and Shoulder Straps Installation . . . . . . . . . . . . . 905
Figure 903. Seat Belt and Seat Assemblies Installation
(369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Figure 904. Shoulder Straps and Fittings Installation
(369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
25-30-00 Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Cyclic Stick Control Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Copilot's Inboard Collective Pitch Stick Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Interior Trim Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Cyclic Stick Control Cover Replacement (L/H Command) . . . . . . . . . . . . . . . . . . . . 201
B. Copilot's Collective Pitch Stick Cover Replacement (L/H Command) . . . . . . . . . . 201
Figure 201. Crew Compartment Interior Trim (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 202
Figure 202. Passenger Compartment Interior Trim (Sheet 1 of 2) . . . . . . . . . . . . 204
C. Inboard Collective Pitch Stick Cover Replacement (R/H Command) . . . . . . . . . . 206
D. Transmission Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
E. Log Book Holder (Optional for R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
F. Carpeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3. Interior Trim Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Interior Trim Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Crew and Passenger Compartment Interior Trim -
R/H Command (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4. Interior Trim and Carpeting General Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5. Boltaron Trim Panels Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
A. Fiberglass Patch Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 204. Floor Trim and Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
B. Solvent Bonding Patch Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
C. Epoxy Adhesive Patch Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
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Figure 205. Boltaron Panel Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

D. Bond and Rivet Patch Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
25-40-00 Miscellaneous Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Crew Compartment Miscellaneous Furnishings Replacement . . . . . . . . . . . . . . . . . . 201
A. Stowage Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Heat Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Foot Rest (L/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Ash Receiver and Cigarette Lighter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Passenger Compartment Miscellaneous Furnishings Replacement . . . . . . . . . . . . . 201
A. Convenience Panel Replacement (R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Passenger Step Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Passenger Step Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Passenger Step Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Passenger Step Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Passenger Step Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6. Passenger Step Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7. Miscellaneous Furnishings Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8. Miscellaneous Furnishings Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Miscellaneous Furnishings (369D) (Sheet 1 of 2) . . . . . . . . . . . . . . . . 203
Figure 202. Miscellaneous Furnishings
(369E/FF - 500/600N) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 203. Passenger Step Assembly (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
25-50-00 Cargo Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Cargo Hook Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Cargo Hook Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3. Cargo Hook Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4. Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Troubleshooting - Cargo Hook Installation . . . . . . . . . . . . . . . . . . . . . . 102
Table 102. Wire Chart, 369D/E/FF Right or Left Hand Command. . . . . . . . . . . . 102
Table 103. Wire Chart, 369E/FF T-Panel with Center Electrical Console,
R/H Command. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 101. Cargo Hook - Wiring Diagrams (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . 104
1. Cargo Hook Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Cargo Hook Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
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MAINTENANCE MANUAL

B. Cargo Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

Figure 401. Manual Release Cable Routing - Interior . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Manual Release Cable and Electrical Wire
Harness Routing - Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 403. Cargo Hook Electrical Equipment Installation . . . . . . . . . . . . . . . . . . 405
Figure 404. Hook and Pad - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 405. Cargo Hook Manual Release Lever - Installation . . . . . . . . . . . . . . . 407
Figure 406. Cargo Hook Release for 600N Helicopters . . . . . . . . . . . . . . . . . . . . . . 408
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Cargo Hook Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Exterior Components Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4. Interior Components Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
1. Cargo Hook Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Helicopter Equipment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Modification of Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Cargo Hook Provisions Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
E. Electrical Components and Wiring Installation
(Left and Right Hand Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Table 901. Cargo Hook Relay Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Figure 901. Fuselage Skin Cutouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
F. Cargo Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Figure 902. Relay and Bracket Installation Pilots Floor
(369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Table 902. VNE Card Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
G. Helicopter Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
Table 903. Cargo Hook Switch Installations - Stick Grip . . . . . . . . . . . . . . . . . . . . 906
25-60-00 Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Emergency First Aid Kit Contents Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
25-63-00 Hoist Passenger/Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Hoist Passenger/Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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MAINTENANCE MANUAL

Figure 201. Hoist System Components (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . 202

2. Preparation for Hoisting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 202. Winch Cable, Cable Cutter, and Swivel Hook Replacement
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3. Hoist System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4. Cyclic Stick Grip and Cyclic Stick Cable Cutter Switch (S600) Replacement . . . . . 208
5. Hoist Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
A. Hoist Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
B. Hoist Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 203. Passenger/Cargo Door Retainer Installation . . . . . . . . . . . . . . . . . . . . 209
6. Winch Components Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
A. Winch Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
B. Swivel Hook Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
C. Cable Cutter Replacement (Guillotine-Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
7. Hoist System Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
8. Hoist Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Table 201. Troubleshooting Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Figure 204. Wiring Diagram - Hoist System (L/H Command) . . . . . . . . . . . . . . . 214
Figure 205. Wiring Diagram - Hoist System (R/H Command) . . . . . . . . . . . . . . . 215
Figure 206. Schematic Diagram - Hoist System Winch . . . . . . . . . . . . . . . . . . . . . 216
1. Hoist Passenger/Cargo Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Helicopter Equipment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Helicopter Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Electrical Equipment Installation (L/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . 902
Figure 901. Helicopter Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
E. Electrical Equipment Installation (R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . 904
F. Passenger/Cargo Door Retainer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
Figure 902. Passenger/Cargo Door Retainer Tube Installation . . . . . . . . . . . . . . . 907
G. Hoist Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
H. Hoist Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
I. Helicopter Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 909
J. Weight and Balance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 909
Figure 903. Cable Antichafing Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910
Page vii
MAINTENANCE MANUAL

Page viii
MAINTENANCE MANUAL
Section
25−00−00
Equipment/
Furnishings
MAINTENANCE MANUAL
EQUIPMENT/FURNISHINGS
1. Interior Furnishings Description D. Crew Mesh Seating
Standard furnishings on the 369D/E/FF - The crew compartment is equipped with

500/600N Helicopters include seats in the crew two-part seats. Each two-part seat consists of
and passenger compartments, seat belts, a seat back and a seat bottom constructed of
interior trim, floor trim and covering, and aluminum tubing frames with a nylon mesh
other miscellaneous furnishing items. covering and rubber pads cemented to the
frame mounting plates. The seat backs are
A. Upholstered Seat Furnishings mounted on the Station 78.50 canted frame.
Configuration Seat bottoms are secured on top of the pilot's
seat structure.
The helicopters are equipped with the basic
interior furnishings configuration. This E. Passenger Upholstered Bench Seating
includes upholstered seats with a bench type Passenger compartment seating is provided by
in the passenger compartment and three a bench type tubular steel structure furnished
individual seats in the crew compartment. The with upholstered cushions. The bench seat is
center crew seat is removed for the dual adjustable fore and aft as well as up and down,
controls option. Seat belts are provided at all and can be folded or quickly removed when
seat locations. Interior trim finish is provided cargo space is required. All seat cushions are
throughout interior cabin enclosure. either upholstered and trimmed with vinyl, or
can be all vinyl. Velcro strip fasteners secure
The 600N helicopter comes equipped with a seat cushions in place.
mid position bench seat. At this position in the
passenger compartment, the mid seat can be F. Mid Bench Seat (600N)
positioned in either the forward or aft facing
configuration. The mid bench seat provides additional three
abreast seating in the passenger area. This
B. Mesh Seat Furnishings Configuration seat can be positioned in either the forward or
aft facing configuration. The seat belt/harness
The helicopters are equipped with a basic system is completely attached to the seat
interior furnishings configuration. This structure for quick removal and installation of
includes two mesh seats and seat backs in the the entire bench seat assembly.
crew compartment and two stowable mesh
seats in the passenger/cargo compartment. G. Upholstered Passenger Individual Seat
Seat belts are provided at all seat locations. Individual seat installations are also available
Interior trim is provided for the passenger for the passenger compartment. The seat
convenience panel, transmission, passenger aft frames are secured to the bulkhead attach
bulkhead, inboard collective pitch stick, and fittings with ball-lock pins. When each seat is
cyclic controls. folded, the flat surface of the seat back serves
as a barrier for cargo. Ref. P/N 369D290037 in
C. Crew Upholstered Seating
the optional equipment list for a further
description of individual passenger seat
The crew compartment on all models with
installations (Ref. Section 01-00-00, Table
single controls has a three-place seating
202).
arrangement. A two-place seating arrange
ment is provided for optional dual controls. H. Passenger Mesh Seating
Crew compartment seats consist of left and
right side seat cushions and, if applicable, a Two passenger seats are installed in the aft
center seat cushion. Each seat has a seat back compartment of the helicopter. The seats are of
cushion. Crew compartment seat structure is welded tubular aluminum structure with
an integral part of the helicopter fuselage. nylon mesh covers. The seats can be folded for
Page 1
MAINTENANCE MANUAL
clear cargo space and, if desired, are easily equipped with an automatic locking inertia
removed by means of quick disconnect reel mechanism.
attachments.
K. Interior Trim
I. Seat Belts and Shoulder Harnesses
(369D/E/FF − 500N) Interior trim used in the crew compartment
and the passenger compartment is of thermo
In the standard installation, Sam Browne type plastic material contoured to cover interior
seat belts with shoulder harness straps are structure. Trim panels and covers provide
installed at each seat position. Seat belts and interior finish, compartment insulation and
shoulder straps are fabricated from nylon mounting surfaces for convenience items, and
webbing with sewn-in buckles and attach certain optional equipment. Trim panels and
fittings. Lengths of seat belts and shoulder covers are attached with Velcro fasteners and
straps are not adjustable. Inertia reels are with upholstery screws with rivnuts or isolator
provided to take up slack and allow free nut mounts on the fuselage structure.
movement of the seat occupant.
L. Floor Trim and Covering
Comfort clips are available for helicopters
equipped with Sam Browne type seat belt Interior floor trim and covering consists of
assemblies. The comfort clip is designed to fire-resistant carpeting and two foot fairing
maintain proper strap tension and relieve trim assemblies. The lower part of Sta. 78.50
excessive pressure of the inertia reel shoulder bulkhead and access doors are also covered
harness on the crew or passengers during with fire-resistant carpeting.
flight.
M. Miscellaneous Furnishings
After each seat belt and shoulder harness
assembly is fastened and adjusted for individu Miscellaneous furnishings include a stowage
al comfort and safety, the comfort clip is moved compartment, heat duct, VNE card holder, foot
from its original position next to the buckle rest assembly, helicopter checklist, operational
and relocated by sliding up on the harness record holder, ashtrays, and LH/RH passenger
strap as close as possible to the inertia reel. step assemblies. The stowage compartment is
The clip prevents any further retraction of the under the right floor access door (Ref. Section
strap into the inertia reel, thus keeping a 52-50-00). The compartment has a uniformly-
constant yet comfortable tension of the distributed load capacity of 50 pounds maxi
harness strap against the user. After each mum when optional avionics equipment is not
flight, the comfort clip is to be returned to its installed in the crew area underfloor compart
original location. ment. The heat duct provides interior trim for
J. Seat Belts and Shoulder Harness (600N) the canopy frame and mounting surface for the
magnetic compass (Ref. CSP-HMI-3, Section
The crew seats in the helicopter utilize a 95-20-00). The VNE card holder is located on
four-point restraint harness that combines the the left side of the instrument panel. The
lap seat belts with double shoulder straps for helicopter checklist is stored with the magnetic
greater occupant security and comfort. Both compass card in the map case. The operational
mid and aft passenger seats are equipped with record holder is attached to the outboard side
a three-point restraint system. The lap seat of the right instrument panel fairing. Ashtrays
belt and shoulder strap are joined at the end and cigarette lighters are provided in the lower
into a single unit for ease of attachment and portion of the instrument panel and on the
convenience. In one motion, the lap and back side of the station 78.50 canted bulkhead.
shoulder belts together can be attached to the The removable passenger steps are attached to
seat buckle. All seat belt/harness systems are the helicopter side jacking points.
Page 2
MAINTENANCE MANUAL
Section
25−10−00
Upholstered Seats
MAINTENANCE MANUAL
UPHOLSTERED SEATS
1. Upholstered Crew Seat Replacement A. Mid Bench Seat Removal
(Ref. Figure 201, Figure 202 and Figure 204) (1). Remove quick release pins that attach
Upholstered Seats for the 369D/E/FF - seat support fittings to floor rails.
500/600N Helicopters are the same. The (2). Remove seat assembly.
addition of the mid position bench seat is
unique to the Model 600N. B. Mid Bench Seat Installation
(1). Clear seats of seat belts and shoulder (1). Install seat assembly in aircraft.
straps.
(2). Align seat support fittings with floor
(2). Lift seat cushions away from fuselage rails.
seat structure to release Velcro strip (3). Install quick release pins to secure seat
and fasteners. assembly to floor.
(3). To replace, position seat cushions so 4. Upholstered Passenger Individual Seat
that Velcro fastener strips mate. Apply Replacement
slight pressure to secure seat cushions
in place. (Ref. Figure 205)
(1). Clear seat of seat belts and shoulder
2. Upholstered Passenger Aft Bench Seat straps.
Replacement
(2). Remove ball-lock pins from bulkhead
(Ref. Figure 201 or Figure 202) attach fittings.
(1). Clear seats of seat belts and shoulder (3). To replace, position seats so that
straps. quick-disconnect pins align with
bulkhead attach points and lock seats
(2). Release seat quick-disconnect fittings in place.
at bulkhead, then at floor points.
5. Upholstered Seat Inspection
NOTE: For height adjustment, install ball-lock
pins in desired position at support legs and (Ref. Figure 201, Figure 202 and Figure 204)
bulkhead fittings. For fore and aft adjust (1). Inspect upholstery material for cuts,
ment, move and secure seat back at desired loose stitching or other unserviceable
position on lower frame. condition.
(3). To replace, position bench seat so that (2). Inspect Velcro fastener strips for
quick-disconnect fittings align with security of attachment and condition.
floor and bulkhead attach points.
(3). On passenger seat structure, inspect
(4). Lock seat in place, first at floor fittings quick-disconnect mechanisms for
then at bulkhead fittings. proper operation or damage that can
prevent positive locking.
3. Mid Bench Seat Assembly Replacement A. Upholstered Seat Cleaning
(600N)
(Ref. Section 20-20-00, Fuselage Interior Trim
(Ref. Figure 204) and Upholstery Cleaning)
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MAINTENANCE MANUAL
6. Upholstered Seat Repair adjustable seats attached through four seat

tracks that allow seat location adjustment over
a 10 inch span when seats are facing forward.
NOTE:
Item Nomenclature
CM219 Methyl−propyl−ketone (MPK) D With the seats in the full aft position and
facing forward, the rear passenger seats
CM405 Adhesive
become unusable for passenger seating.
D The seats are removable and can be
(1). Lapstitch frayed or worn upholstery. placed in the aft facing position.
MPK solvent is flammable. D In the aft facing position, only two seat
WARNING Use only in well-ventilated locations are available.
area and away from heat and flame.
A. Business Seat Removal
NOTE: Loosened Velcro strips can be reacti
vated for adhesion by wiping original adhe (1). Remove quick release pins that attach
sive film with MPK (CM219). seat support fittings to floor rails.
(2). Replace unserviceable Velcro fastener
(2). Remove seat assembly.
strips. Install new Velcro strips to mate.
Bond in place with adhesive (CM405). B. Business Seat Installation
(3). Make minor welded or riveted sleeve-
type repairs on tubular structure (1). Install seat on tracks with forward
according to FAA AC 43.13-1B Inspec guide pin in track cutout first.
tion and Repair for Standard Sheet
Metal Repair. (2). Once seat guide pin is in track, slide
seat forward until 2 rear guide pins are
7. Optional Mid Business Seat Replacement in the track cutouts.
(600N)
(3). When installing seat facing aft, tilt
(Ref. Figure 206) This option replaces the seat-back full forward during
standard mid bench seat with two fore and aft installation.
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MAINTENANCE MANUAL
SEAT BACK CUSHION
SEAT BACK
NOTE 1
AFT SUPPORT
FITTING AND HEIGHT
ADJUSTMENT
VELCRO STRIP FASTENER

(TYP)
PASSENGER COMPARTMENT
SEAT BOTTOM
CUSHION PIP PINS
LOWER FRAME
NYLON
MESH RELEASE PIN
FORE AND AFT
NOTE 2 ADJUSTMENT
HOLES SUPPORT LEG AND
HEIGHT ADJUSTMENT
SEAT BACK FLOOR STRUCTURE

CUSHION
HIGH SHOULDER BEAM
NOTE 1

(TYP)
NOTES:
1. SHOWN WITHOUT CUSHION
SEAT BOTTOM FOR CLARITY.
CUSHION 2. CENTER CUSHIONS AND SEAT
BELTS ONLY FOR 3-PLACE
SEATING.
CREW COMPARTMENT
SEAT STRUCTURE
G25−1000
Figure 201. Upholstered Seat Installation (369D)
Page 203
MAINTENANCE MANUAL
SEAT BACK CUSHION

(TYP)
CUSHION SUPPORT
AFT SUPPORT FITTING

AND HEIGHT ADJUSTMENT
SEAT BOTTOM CUSHION
SEAT BACK
CUSHION
FLOOR STRUCTURE
LOWER FRAME
LOCKPIN
SEAT BOTTOM RELEASE PIN
CUSHION SUPPORT LEG AND
HEIGHT ADJUSTMENT
LOW SHOULDER BEAM

(TYP)
SEAT STRUCTURE
CREW COMPARTMENT
G25−1001
Figure 202. Upholstered Seat Installation (369E/FF − 500/600N)
Page 204
MAINTENANCE MANUAL
FWD FACING
AFT FACING
OPTIONAL MID-CABIN BENCH SEAT ORIENTATION
6G25-069
Figure 203. Mid and Aft Seating Configuration (600N)
Page 205
MAINTENANCE MANUAL
QUICK RELEASE PIN

WITH LANYARD (6 PLCS)
FORWARD, MID AND AFT

ATTACHMENTS ARE TYPICAL
MID BENCH SEAT ADJUSTMENT
BALL LOCK PIN
AFT SUPPORT FITTING AND

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

ADJUSTMENT
AFT BENCH SEAT ADJUSTMENT
BALL LOCK PIN
RELEASE PIN
NOTE: SEAT SHOWN WITH CUSHIONS REMOVED
6G25-061
Figure 204. Mid and Aft Bench Seat Assembly Installation (600N)
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MAINTENANCE MANUAL
SEAT BACK
ASSY
SEAT BACK CUSHION
VINYL END PIECES

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

(TYP)
SEATS-ERECTED POSITION
SEAT FOLDED POSITION SEAT FOLDED POSITION

R.H. SIDE L.H. SIDE
G25−1002
Figure 205. Upholstered Passenger Individual Seat Installation (369D)
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MAINTENANCE MANUAL
RELEASE PIN AND

SEAT TRACK STOP
AFT
MID
FWD
NOTE: PASSENGER
RESTRAINT NOT SHOWN
RELEASE PIN AND SEAT

TRACK STOP POSITION
FORWARD FACING SEAT

MID: NORMAL POSITION FOR FWD FACING SEAT.
AFT: USED WHEN THE REAR-MOST SEAT POSITION IS DESIRED.
AFT FACING SEAT
FWD: NORMAL POSITION FOR AFT FACING SEAT.
FOLD-UP
ARM REST
SEAT BACK
ADJUSTMENT
HANDLE
OUTER SEAT TRACK
INNER SEAT TRACK
REAR GUIDE PINS
FORWARD GUIDE PIN
TRACK CUTOUT
FORE AND AFT SEAT
ADJUSTMENT HANDLE
(HANDLE SHOWN RAISED)
G25−1006
Figure 206. Mid−Cabin Business Seat Installation (600N)
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MAINTENANCE MANUAL
Section
25−15−00
Mesh Seats
MAINTENANCE MANUAL
MESH SEATS
1. Crew/Passenger Mesh Seats (5). Insert vertical legs into floor structure
and secure.
(Ref. Figure 201 thru Figure 203) The typical
mesh seat installation consists of lightweight (6). If removed, reinstall seat belts and
nylon mesh-covered seats installed in the crew shoulder harness.
and passenger compartments. For description
of the various installations, consult the 4. Passenger Mesh Seat Adjustment
Optional Equipment List (Ref. Section (1). (Ref. Figure 203) The height of the
01-00-00, Table 202). Some installations have bench seat can be adjusted by installing
a bench-type passenger seat, some have the ball lock pins in any of the three
individual passenger seats, and others have no holes in the vertical support legs, and
passenger seats at all. Installations differ by installing the ball lock pins that
depending on whether the helicopter has a support the horizontal legs in any of the
high shoulder beam or a low shoulder beam, three holes in each aft support fitting.
and various seat colors.
(2). For the fore and aft adjustment of the
2. Crew Mesh Seat Replacement bench seat, insert the seat back legs
into either pair of holes in the seat
(Ref. Figure 201) frame.
NOTE: Identify and retain all components and (3). (Ref. Figure 202) The height of the
hardware removed from the helicopter. individual seats can be adjusted by
inserting lock pins into any of three
(1). Remove or clear area of seat belts and pairs of holes in the aft support fittings
shoulder straps. to secure the horizontal legs of the seat.
(2). Remove installing hardware and lift (4). The individual seats can be folded up
seat bottoms and seat backs from the out of the way to permit cargo storage
helicopter. by first releasing the quick-disconnects
at the forward legs and folding the legs
(3). To replace, install seat backs and seat aft. The seat back is then folded
bottoms with attaching hardware. forward at the upper hinge point. As
the seat is swung up at the aft fitting,
(4). When removed, reinstall seat belt and
the seat back and the seat bottom are
shoulder harness.
rotated forward and down at the lower
hinge point.
3. Passenger Mesh Seat Replacement
5. Crew Mesh Seat Inspection
(Ref. Figure 202 or Figure 203)
(1). Inspect upholstery material for cuts or
NOTE: Identify and retain all components and other unserviceable conditions.
hardware removed from helicopter.
(2). Check rubber pads cemented to each
(1). Remove or clear area of seat belts and mounting plate.
shoulder straps.
6. Passenger Mesh Seat Inspection
(2). Release seat quick-disconnects at aft
fittings, then at floor points. (1). Inspect upholstery material for cuts or
other unserviceable conditions.
(3). Lift seats from helicopter.
(2). Inspect quick-disconnect mechanisms
(4). To replace, attach horizontal support for proper operation and for damage
legs to aft attach fittings with lockpins. that can prevent positive locking.
Page 201
MAINTENANCE MANUAL
CREW SEATS BACK CREW SEATS BACK UPPER

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

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

LOWER INBOARD LEG
(LEFT)
NOTE: FASTENER ORIENTATION IS VERTICAL
FOR LOW SHOULDER BEAM INSTALLATION.
G25−1003
Figure 201. Mesh Seat Installation
Page 202
MAINTENANCE MANUAL
NYLON MESH
SEAT BACK
(FOLDS FORWARD)
AFT SEAT
SEAT BOTTOM
(FOLDS FOR STOWAGE) SEAT FITTING AND
HEIGHT ADJUSTMENT
UPPER HINGE POINT
LOWER HINGE POINT
QUICK DISCONNECT
(AT REAR OF LEGS)
PASSENGER INDIVIDUAL MESH SEAT HEIGHT ADJUSTMENT
FOLDING SEAT BACK AND LEGS SEAT STOWAGE
G25−1004
Figure 202. Passenger Individual Mesh Seat Adjustment and Storage
Page 203
MAINTENANCE MANUAL
7. Mesh Seats Cleaning (1). Lap stitch frayed or torn nylon web
bing, or replace if damaged beyond
(Ref. Section 20-20-00, Fuselage Interior Trim repair.
and Upholstery Cleaning)
(2). Install new rubber pads.
8. Mesh Seats Repair (3). Clean seat mounting plate with clean
cloth dampened with solvent (CM234).
Consumable Materials (4). Apply cement (CM405) and attach pad
(Ref. Section 91−00−00) to seat mounting plate.
Item Nomenclature
(5). Replace damaged nutplates.
CM405 Adhesive (6). Minor weld repairs can be done accord
ing to FAA AC 43.13-1B Inspection and
Repair for Standard Sheet Metal
Repair of seats is limited to the following: Repair.
SEAT BACK
AFT SUPPORT FITTING AND

HEIGHT ADJUSTMENT
FRAME
FLOOR STRUCTURE
NYLON MESH
BALL-LOCK PIN
SUPPORT LEG AND

FORE AND AFT HEIGHT ADJUSTMENT
ADJUSTMENT HOLES
RELEASE PIN
G25−1005
Figure 203. Passenger Bench Mesh Seat Adjustment
Page 204
MAINTENANCE MANUAL
MESH SEATS
1. Mesh Seat Initial Installation (2). Install ball lock pins.
Procedures in this section are for initial (3). With release pins raised and locked,
installation of 369H90040-BSC, -501, and insert the two vertical legs into keyhole
-503 mesh seat installations on Model 369D fitting slots in floor.
helicopters with to replace the existing cushion
seats. NOTE: For height adjustment, install ball lock
fittings in any of the three attachment
A. Model Applicability holes, in the vertical support legs, and in the
aft support fittings. For fore and aft adjust
To determine the applicability of the mesh seat ment, insert the seat back lower legs in ei
installation for use on each model helicopter, ther pair of holes in lower frame.
consult the Optional Equipment List (Ref.
Section 01-00-00, Table 202). (4). Move vertical support legs to right in
keyhole fittings and unlock release pins
B. Preparation for Installation in legs. The pins will drop to bottom of
slots and secure support legs to fittings
(1). Check all electrical switches for OFF in floor.
position. Ensure that BATTERY-OFF-
EXT switch is OFF. E. Passenger Compartment Individual Seat
Installation
(2). Identify all components and hardware
to be removed for access to work areas. (Ref. Figure 202)
Protect components from damage and
foreign matter until reinstalled. NOTE: Installation procedures for left and
right seats are identical.
C. Helicopter Equipment Removal
(1). Position passenger seat horizontal
Prior to installing the mesh seats, a limited support legs in aft support fittings.
number of items must be removed from the
helicopter to accommodate seat installation. (2). Install ball lockpins.
(3). Depress pushbutton quick disconnects
(1). Clear seats of seat belts and shoulder
at front legs of seat.
straps.
(4). Insert legs into keyhole fittings in floor.
(2). Lift crew compartment seat cushions
Move legs outboard and release push
away from fuselage seat structure to
buttons to secure legs in place.
release Velcro strips and fasteners.
Remove seats from helicopter (Ref. F. Crew Compartment Mesh Seat
Section 25-10-00). Installation
(3). In passenger compartment, release (Ref. Figure 201) Installation includes
existing seat quick-disconnect fittings installing a shim under the inboard forward
at aft bulkhead, then at floor points. leg of the left crew seat.
Remove existing installed seats from
helicopter. (1). Position mesh seat back halves in crew
compartment.
D. Passenger Compartment Bench Seat
Installation (2). Attach upper ends of seat backs to
canted stations with screws and
(Ref. Figure 203) washers.
(1). Position bench seat horizontal support (3). Attach lower legs to helicopter seat
legs in aft support fittings. structure with screws.
Page 901
MAINTENANCE MANUAL
(4). Position lower halves of mesh seats on (1). Install seat belts and shoulder harness
helicopter seat structure. in crew compartment (Ref. Section
25-20-00, Seat Belt/Inertia Reel
(5). Insert shim under inboard forward leg Replacement).
of left seat. Attach leg to seat structure
with bolt and washer. (2). Install seat belts and shoulder harness
(6). Attach remaining forward legs of seats in passenger compartment.
to seat structure with bolts and wash H. Weight and Balance Data
ers.
G. Helicopter Equipment Installation Weight and balance data resulting from -BSC,
-501 and -503 mesh seat installations are
After installation of mesh seats, a limited listed in Table 901. After installation, incorpo
number of items must be replaced in the rate changes in helicopter weight and balance
helicopter. records (Ref. Section 08-10-00).

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

−501 Installation +20.35 (+9.231) 99.6 (252.98) +2027 (+2335.3)
−503 Installation +20.80 (+9.435) 99.7 (253.24) +2074 (+2389.5)
Page 902
MAINTENANCE MANUAL
Section
25−20−00
Seat Belts/Inertia
Reel
MAINTENANCE MANUAL
SEAT BELTS/INERTIA REEL

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

NOTE 1 ATTACHMENT
INERTIA REEL
INERTIA REEL
FLOOR STRUCTURE HARNESS MUST UNREEL
IN DIRECTION SHOWN
NOTE 2
41° ±3°
90° LIMITS OF CUTOUT

IN ALUM. HOUSING
INERTIA REEL
NOTE 1
NOTES:
1. SHOWN WITHOUT CUSHION
FOR CLARITY.
2. CENTER CUSHIONS AND SEAT
BELTS ONLY FOR 3-PLACE
SEATING.
CREW COMPARTMENT
INERTIA REEL
SEAT STRUCTURE
G25-2002
Figure 201. Seat Belt/Inertia Reel Installation (Sam Browne Style) (369D)
Page 202
MAINTENANCE MANUAL
PASSENGER / CARGO
COMPARTMENT AFT
BULKHEAD
SNAP END FITTING

(HOOK UP)
SEAT BELTS AND SHOULDER HARNESSES
SNAP END FITTING

(HOOK DOWN)
SNAP END FITTING
(HOOK UP) NYLON WEBBING
SHOULDER STRAP
ADAPTER
NOTE: SLIDE BAR HARNESS (NOTE)
SNAP END FITTING
LENGTH ADJUSTER. (HOOK UP)
SNAP END FITTING

(HOOK DOWN)
NYLON WEBBING
SEAT BELT
INERTIA REEL
BUCKLE
LATCH
ADAPTER
ADAPTER SNAP END FITTING

(NOTE) ADAPTER (HOOK DOWN)
(NOTE)
NYLON WEBBING
SNAP END SHOULDER STRAP
FITTING
HARNESS MUST UNREEL
IN DIRECTION SHOWN
41° ±3°
90° LIMITS OF CUTOUT

IN ALUM. HOUSING
BUCKLE
ADAPTER
LATCH
ADAPTER FITTING
(NOTE) INERTIA REEL
SNAP END FITTING
NYLON WEBBING
SEAT BELT
PILOT AND COPILOT SEAT BELT AND SHOULDER HARNESS ASSEMBLY G25−2003
Figure 202. Seat Belt/Inertia Reel Installation (Yoke Style) (369D)
Page 203
MAINTENANCE MANUAL
INERTIA REEL (2)
SEAT BACK CUSHION
VELCRO STRIP
FASTENER (TYP)
SUPPORT CUSHION
SEAT BOTTOM CUSHION AFT SUPPORT

FITTING AND HEIGHT
ADJUSTMENT
INERTIA REEL (2)

LOCK PIN
SEAT BACK
CUSHION LOWER FRAME
FLOOR STRUCTURE
RELEASE PIN
SUPPORT LEG AND
HEIGHT ADJUSTMENT
SEAT BOTTOM
CUSHION
INERTIA REEL (2)
CREW COMPARTMENT
VELCRO STRIP
FASTENER (TYP) SEAT STRUCTURE
G25−2004
Figure 203. Seat Belt/Inertia Reel Installation (Yoke Style) (369E/FF − 500N)
Page 204
MAINTENANCE MANUAL
5. Crew Seat Belt/Harness Replacement With (2). Remove inertia reel, with harness, from
Manual Lock Option (369D/E/FF − 500N) fiberglass mount by loosening four bolts
and upper ferrule nut.
(Ref. Figure 204 and Figure 205) (3). Install seatbelts by fastening snap type
end fittings to bulkhead structure
fittings.
(1). Remove seatbelts by unfastening snap (4). Install inertia reel, with harness, to
type end fittings from bulkhead fiberglass mount with ferrule nut and
structure fittings. four bolts, nuts and washers.
CONTROL HEAD ROTATED

90° CW FOR CLARITY
UPPER FERRULE NUT
AUTOMATIC
MANUAL LOCK
LOWER
INERTIA FERULE
REEL ASSY CABLE NUT
CONTROL ASSY
ADJUSTER TAB RELEASE
(TYP) (TYP)
0101935-1 SHOULDER
HARNESS ASSY
1.88-2.12 IN. (4.776-5.385 CM)

WIDE WEBBING
ADJUSTER
2.88-3.12 IN. (7.315-7.925 CM)
END FITTING WIDE WEBBING LAP BELT ASSY
LINK LATCH (0101936-1 ASSY)
ADJUSTER
G25−2006A
Figure 204. Webbed Shoulder Harness and Seat Belt Installation with Manual
Inertia Reel Lock (369D)
Page 205
MAINTENANCE MANUAL
LOW SHOULDER BEAM INSTALLATION HIGH SHOULDER BEAM INSTALLATION G25−2005
Figure 205. Crew Inertia Reel Installation with Manual Inertia Reel Lock
(369D/E/FF − 500N)
6. Seat Belt/Inertia Reel Testing leased, harness strap should automati
cally reel back into reel. Exert a sudden
(Ref. Pull tests of seat belts and shoulder strap forward pull on seat belt or shoulder
harnesses shall be accomplished in accordance strap to ensure inertia reel locks.
with FAA AC 43.13-1B, Aircraft Inspection
and Repair for Standard Sheet Metal Repair (2). Inspect inertia reels, snap end fittings,
and TSO C22. adjusters, links, buckles, latches and
belt attachment fittings for cracks,
7. Seat Belt/Inertia Reel Inspection wear, corrosion and deformation. Check
Ensure center passenger lap for freedom from binding, ease of
WARNING belt is installed with tongue adjustment and operation as applicable.
portion to the right of the seat and If doubt exists as to strength, do the
buckle portion to the left. (Quick re pull test (Ref. Seat Belts/Inertia Reel
lease of the lap belt and shoulder strap Testing).
can be impaired if the assembly is im
properly installed.) If tongue and (3). Inspect shoulder harnesses and seat
buckle portions are reversed, remove belts for worn, frayed or deteriorated
and reinstall in correct positions and condition, and loose stitching.
document reinstallation in Compliance
Record of Helicopter Log Book. (4). (Manual Lock Option) Check mechani
cal inertia lock mechanism for proper
(1). Pull seat belt or shoulder strap out of operation, with handle up and with
inertia reel to full extended length. handle down. Inspect fiberglass mounts
Ensure harness strap cannot be pulled for cracking and separation. Inspect
out of inertia reel. With tension re laminates for debonding.
Page 206
MAINTENANCE MANUAL
8. Seat Belt/Inertia Reel Repair (2). Remove hardware that attaches inertia
reel to mounting surface.
(1). Replace seat belts and shoulder straps
if fabric is frayed, worn, deteriorated,
stitching is loose, or if enertia reels are (3). Remove complete seat belt restraint
destroyed or do not function properly. harness from seat.
(2). Polish minor nicks and scratches. B. Seat Belt/Restraint Harness Installation
Restore protective finish to aluminum
parts as required.
(1). Position lap seat belt and shoulder
(3). Repair fiberglass mounts (Ref. Section harness into seat assembly.
25-30-00, Boltaron Trim Panels
Repair). (2). Engage end fittings attaching lap seat
belts.
9. Seat Belt/Restraint Harness, Crew Seat,
Replacement (600N)
(3). Install hardware attaching inertia reel
(Ref. Figure 206) to mounting surface.
A. Seat Belt/Restraint Harness Removal
(4). Ensure proper engagement and release
(1). Release end fittings to remove lap seat of seat buckle and inertia reel mecha
belts. nism.
ADJUSTOR
ADJUSTOR
SHOULDER
HARNESS
SHOULDER
HARNESS
LAP ADJUSTOR ADJUSTOR LAP

END FITTING SEAT BELT END FITTING
SEAT BELT
BUCKLE
6G25-070
Figure 206. Seat Belt/Restraint Harness Installation, Crew Seat (600N)
Page 207
MAINTENANCE MANUAL
10. Seat Belt/Restraint Harness, Mid 11. Seat Belt/Restraint Harness, Aft
Passenger Seat, Replacement (600N) Passenger Seat, Replacement (600N)
(Ref. Figure 207) These three individual seat (Ref. Figure 207)
belt harnesses are completely contained in the
seat assembly and attach to the seat frame. A. Seat Belt/Restraint Harness Removal
This feature aids in the quick removal and
installation of the mid bench seat assembly. (1). Remove hardware that attaches inertia
reel end of harness to mounting
A. Seat Belt/Restraint Harness Removal surface.
(1). Remove hardware that attaches inertia
reel end of harness to seat back. (2). Release end fitting that attaches lap
belt to mounting surface.
(2). Release end fitting that attaches lap
seat belt to seat frame. (3). Release end fitting that attaches buckle
end of harness to mounting surface.
(3). Release end fitting that attaches buckle
end of harness to seat frame. (4). Remove seat belt/restraint harness.
(4). Remove seat belt/restraint harness. B. Seat Belt/Restraint Harness Installation
B. Seat Belt/Restraint Harness Installation
(1). Position seat belt/restraint harness into
(1). Position seat belt/restraint harness into seat assembly.
seat assembly.
(2). Engage end fitting attaching buckle end
(2). Engage end fitting attaching buckle end of harness to mounting surface.
of harness to seat frame.
(3). Engage end fitting attaching lap belt to
(3). Engage end fitting attaching lap belt to
mounting surface.
seat frame.
(4). Install hardware attaching inertia reel (4). Install hardware attaching inertia reel
end of harness to seat back. end of harness to mounting surface.
(5). Ensure proper engagement and release (5). Ensure proper engagement and release
of seat buckle and inertia reel mecha of seat buckle and inertia reel mecha
nism. nism.
Page 208
MAINTENANCE MANUAL
MID SEAT AFT SEAT
END FITTING
INERTIA REEL
MOUNT
INERTIA REEL
ADJUSTOR
END FITTING
BUCKLE
6G25-086
Figure 207. Seat Belt/Restraint Harness Installation, Passenger

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

DOOR FRAME AND FIRST SCREW
VIEW LOOKING OUTBOARD FROM

CL OF SHIP TO LH SIDE
COMFORT CLIP INSTALLATION
G25-2001
Figure 208. Comfort Clip Installation and Crew Compartment Decal

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

(12.70 ±0.635 CM)
G25-2000A
Figure 209. Comfort Clip Decal Application − Passenger Compartment

(369D/E/FF − 500N)
Page 211
MAINTENANCE MANUAL
Page 212
MAINTENANCE MANUAL
Section
25−21−00
Seating/Belts (Four
on the Floor)
MAINTENANCE MANUAL
SEATING/BELTS (FOUR ON THE FLOOR)

1. General (3). Remove seat belt assemblies and
shoulder straps by unsnapping hooks at
NOTE: This option has an aircraft effectivity structure-mounted fittings.
limit. Refer to CSP-IPC-4 for effectivity.
B. Seating/Belt Installation
The four on the floor seating and belt installa
tion is designed for maximum use of the (Ref. Figure 902 and Figure 903)
passenger compartment for transportation of
personnel. The installation consists of four (1). Install seat assemblies by placing seat
floor-installed seat assemblies with seat belts in position and inserting tabbed rivets
and shoulder straps at each position. The two into holes in floor stiffeners (Ref.
aft-facing seat positions include head and Figure 903).
back restraint panels mounted on Cant. Sta. (2). Install restraint panels by securing
78.50 structure. each panel at bracket assemblies with
The shoulder strap is adjusted to cross the four screws and washers (Ref.
passenger's chest from outboard shoulder to Figure 902).
center of lap where it joins the seat belt (3). Install seat belt assemblies and
assembly. Seat belts are adjusted by individual shoulder straps by snapping hooks to
passengers for a close and comfortable fit. structure-mounted fittings.
The installation for the early configuration is 3. Seating/Belt Inspection
designed for use with a high shoulder beam.
The current configuration installation is used (Ref. Section 25-20-00, Seat Belt/Inertia Reel
for a low shoulder beam. Inspection)
NOTE: Shoulder straps for aft-facing passen 4. Seating/Belt Cleaning
gers are installed on early configuration he
licopters only. (Ref. Section 20-20-00, Fuselage Interior Trim
or Upholstery Cleaning or 25-20-00, Crew
2. Seating/Belt Replacement Seat Belt/Harness Cleaning)
A. Seating/Belt Removal 5. Seating/Belt Repair
(Ref. Figure 902 and Figure 903) (1). Repair minor tears and cuts to the seat
and restraint panel coverings (Ref.
(1). Remove seat assemblies by lifting Section 25-20-00, Seat Belt/Inertia
tabbed rivets from holes in floor Reel Repair).
stiffeners (two per seat), then lift seat
up (Ref. Figure 903). (2). Replace unserviceable seats and
restraint panels.
(2). Remove restraint panels by removing
four screws and washers from each (3). Seat belts or shoulder straps that show
panel bracket assembly (Ref. signs of wear, deterioration, fraying, or
Figure 902). loose stitching must be replaced.
Page 201
MAINTENANCE MANUAL
Page 202
MAINTENANCE MANUAL
SEATING/BELTS (FOUR ON THE FLOOR)

1. Seating/Belts (Four on the Floor) Initial (3). Remove passenger compartment carpet
Installation floor covering.
NOTE: This option has an aircraft effectivity (4). Remove aft trim panel from Cant. Sta.
limit. Refer to CSP-IPC-4 for effectivity. 78.50 and disconnect cigarette lighter
wiring.
Consult the optional equipment table (Ref.
Table 202, Section 01-00-00) for model (5). Remove bulkhead trim panels or
applicability for seating/belts (369H90035) insulation blankets at Sta. 124.00 in
installations. The -501 and -503 installations area of WL 40.00 and BL 20.00 right
are covered in the following paragraphs. and left seats.
A. Preparation for Installation (6). (369D only) Remove crew compartment
outboard seat backs.
(Ref. Section 91−00−00) C. Seating and Belts Installation − General
Item Nomenclature Installation of the seating and belts for four
CM318 Primer includes procedures for installing restraint
panels on Cant. Sta. 78.50, seat assemblies,
shoulder straps, and seat belt assemblies.
(1). Ensure all electrical switches are set to
OFF position. Recheck master switch
for OFF position. Consumable Materials
(2). Identify all components and attaching Item Nomenclature
hardware to be removed for access to
CM318 Primer
work areas. Protect components from
damage and foreign matter until
reinstalled. NOTE:
(3). After drilling or cutting, remove burrs D Use Cleco clamps and fasteners as re
and metal particles. Apply a thin coat of quired to facilitate rivet installation, and
primer (CM318) to all bare metal areas. install rivets with wet primer (CM318).
NOTE: An application of color-matched paint D Rivets are equally spaced and are normal
can be applied to primer painted reworked ly positioned twice the diameter of the riv
areas and to installed hardware. et shank from the outside edge of the ma
terial, edge joggle, or flange radius.
B. Removal of Existing Equipment
D. Cant. Sta. 78.50 Brackets, Fittings and
Prior to installing the seating and belts for Restraint Panels Installation
four, a limited number of items must be
removed from the helicopter passenger (Ref. Figure 901, Figure 902 and Figure 904)
compartment to accommodate installation.
(1). On Cant. Sta. 78.50, WL 22.45, remove
(1). Remove passenger compartment seats four existing bracket rivets in area of
by releasing quick-disconnects on LBL 8.25 and four rivets in area of LBL
seating structure at floor and firewall 19.25.
fittings.
(2). Position bracket assemblies to match
(2). Remove existing passenger compart holes in removed rivet pattern. Locate
ment seat belt and shoulder strap and drill four 0.1285 inch (3.2639
assemblies. mm) holes in each bracket.
Page 901
MAINTENANCE MANUAL
BRACKET ASSEMBLY LBL 15.50 BRACKET

RIVET (2) LBL 8.50
ASSEMBLY
0.50 IN. (12.7 MM) (TYP)
CANT. STA 78.50

0.75 IN. (19.05 MM) RIVET (2)
0.83 IN. (21.082 MM)
LH SHOWN 0.50 IN. (12.7 MM) 0.42 IN. (10.668 MM)

RH OPPOSITE
RIVET (4) RIVET (4)

CANT. STA 78.50
BRACKET ASSEMBLY
BRACKET ASSEMBLY
NOTES: DRILL 0.217-0.229 IN.

(5.5118-5.8166 MM) HOLES (4) IN EACH
RESTRAINT PANEL ASSEMBLY; LOCATE
FROM BRACKETS. DRILL HOLES IN TRIM
PANEL ASSEMBLIES AS APPLICABLE. PICK UP EXISTING RIVETS
LBL LBL LBL LBL LBL LBL
20.75 19.25 LH SHOWN
17.00 RH OPPOSITE 11.30 8.25 6.00
LBL LBL BL RBL

15.50 8.50 0.00 8.50
LH LH RH RESTRAINT PANEL
RESTRAINT PANEL D ASSEMBLY
ASSEMBLY
BRACKET ASSEMBLY
RESTRAINT PANEL
BRACKET ASSEMBLY
ASSEMBLY
WL 45.36
BRACKET WL 45.30
ASSEMBLY
BRACKET ASSEMBLY
FITTING
SUPPORT FITTING SUPPORT
TRIM
PANEL
SHOULDER STRAP
SHOULDER
STRAP
WL 28.44
BRACKET
ASSEMBLY
WL 22.45
WL 21.50 SEAT
ASSEMBLY
BRACKET ASSEMBLY
LBL 20.75 LH RBL 20.75 RH
D BRACKET
LBL 19.25 LH ASSEMBLY RBL 19.25 RH
RESTRAINT PANELS BRACKET CANT. STA 78.50
LOCATION HIGH BULKHEAD WL 13.10
SECTION D-D
G25−2008A
Figure 901. Restraint Panel Assemblies and Hardware Installation (369D)
Page 902
MAINTENANCE MANUAL
BRACKET ASSEMBLY LBL 19.50 LBL 8.50 BRACKET

ASSEMBLY
0.50 IN. (12.7 MM) (TYP)
RIVET (2) CANT. STA 78.50 RIVET (2)

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

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

BRACKET ASSEMBLY CANT. STA 78.50
BRACKET ASSEMBLY
NOTES: DRILL 0.217-0.229 IN.

(5.5118-5.8166 MM) HOLES (4) IN EACH
RESTRAINT PANEL ASSEMBLY; LOCATE
FROM BRACKETS. DRILL HOLES IN TRIM PICK UP EXISTING RIVETS
PANEL ASSEMBLIES AS APPLICABLE.
LBL LBL LBL LBL LBL LBL
17.00 LH SHOWN 11.30 8.25 6.00
20.75 19.25 RH OPPOSITE
RBL
LBL LBL BL RBL 19.50
19.50 8.50 0.00 8.50 RH
LH LH RH
D RESTRAINT PANEL
RESTRAINT PANEL ASSEMBLY
ASSEMBLY
RESTRAINT PANEL
BRACKET ASSEMBLY
ASSEMBLY
BRACKET
ASSEMBLY
BRACKET ASSEMBLY
WL 37.85
TRIM
PANEL
BRACKET WL 28.44
ASSEMBLY
WL 22.45
WL 21.50 SEAT
ASSEMBLY
BRACKET ASSEMBLY
LBL 20.75 LH D RBL 20.75 RH
BRACKET
LBL 19.25 LH ASSEMBLY RBL 19.25 RH
RESTRAINT PANELS BRACKET CANT. STA 78.50
LOCATION HIGH BULKHEAD WL 13.10
SECTION D-D
G25-2007A
Figure 902. Restraint Panel Assemblies and Hardware Installation (369E/FF − 500N)
Page 903
MAINTENANCE MANUAL
(3). Hold brackets in position with Cleco (8). (369D only) Install shoulder strap
fasteners and drill four 0.1285 inch fittings for aft-facing passenger seat as
(3.2639 mm) holes through upper follow:
flange of each bracket and through
Cant. Sta. 78.50 web. (a). On left side of Cant. Sta. 78.50
bulkhead frame, locate four existing
(4). Install bracket assemblies with 16 nutplates in area of WL 41.06 and BL
rivets. 24.74.
(5). Repeat last four steps to install two (b). Attach shoulder strap fitting with
bracket assemblies to opposite side. four screws.
(6). (369D only) Install bracket assemblies (c). On right side of Cant. Sta. 78.50
as follows: bulkhead frame, locate four existing
nutplates in area of WL 41.06 and BL
(a). On WL 45.33, position bracket 24.74.
assembly at LBL 15.50 and drill two
0.1285 inch diameter holes through (d). Attach shoulder strap fitting with
bracket and Cant. Sta. 78.50 channel. four screws.
(b). Install bracket assembly with two (e). Attach L/H fitting to nutplates in L/H
blind rivets. tee using four screws.
(c). On WL 45.33 L/H, position bracket (f). Attach R/H fitting to nutplates in
assembly at LBL 8.50 and drill two R/H tee using four screws.
0.1285 inch diameter holes through (g). Cut out slots in removed passenger
bracket and Cant. Sta. 78.50 channel. compartment forward trim panels to
accommodate lugs of shoulder strap
(d). Install bracket assembly with two
fittings.
blind rivets.
(9). Drill four 0.217—0.229 inch
(e). Repeat last four steps to install two (5.5118—5.8166 mm) holes in forward
bracket assemblies R/H opposite. trim panel, and four holes in each
(7). (369E/FF only) Install bracket assem restraint panel. Locate holes from
blies as follows: bracket assemblies and install as in
steps (1). thru (8).
(a). On WL 37.85, position bracket
(10). Reinstall forward trim panel (connect
assembly at LBL 19.50 L/H. Drill two
cigarette lighter wiring).
0.1285 inch (3.2639 mm) holes
through bracket and Sta. 78.50 (11). Install passenger compartment carpet
channel. floor covering.
(b). Install bracket assembly with two (12). (369D only) Install fitting cap to L/H
blind rivets. and R/H shoulder strap fittings with
two screws each side.
(c). On WL 37.85, position bracket
assembly at LBL 8.50 L/H. Drill two (13). Install restraint panel to L/H side over
0.1285 inch (3.2639 mm) holes trim panel with four washers and
through bracket and Cant. Sta. 78.50 screws.
channel.
(14). Install restraint panel to R/H side over
(d). Install bracket assembly with two trim panel with four washers and
blind rivets. screws.
(e). Repeat last four steps to install R/H (15). Reinstall crew compartment seat back
bracket assemblies. assemblies.
Page 904
MAINTENANCE MANUAL
E. Seat Assemblies Installation NOTE: All seat belt assemblies are to be in
stalled as shown and as noted on cloth iden
(Ref. Figure 903) tification labels attached to each seat belt
NOTE: Seat assemblies are position-inter assembly. The two center belts are installed
changeable. with hooks down.
(1). Position seat assemblies on floor (7). Connect adjustable portion of seat belt
structure to locations specified. assembly to the R/H fitting and nonad
justable portion to center fitting.
(2). Secure seats in position by pressing
tabbed rivets into holes in floor stiffen (8). Connect adjustable portion of seat belt
ers. assembly to L/H fitting and nonadjust
able portion to center fitting.
F. Aft Seat Belt Assemblies and Shoulder
Straps Installation G. Forward Seat Belt Assemblies and
Shoulder Straps Installation
(Ref. Figure 903)
(Ref. Figure 904)
(1). On both left and right sides of Cant.
Sta. 128.00 locate four existing nut (1). (369D only) Connect a shoulder strap to
plates in areas of WL 40.0 and BL 20.0. each shoulder strap fitting on Cant.
Sta. 78.50.
(2). Attach a shoulder strap support fitting
on each side, using four washers and NOTE: Adjust shoulder strap to cross passen
screws for each fitting. ger's chest from outboard shoulder to inner
center lap area.
(3). Cut out slots in removed trim panels or
insulation blankets to accommodate (2). Locate the four tiedown fitting holes on
lugs of new support fittings. the first floor stiffener aft of Cant. Sta.
78.50.
(4). Reinstall trim panels or insulation
blankets. (3). Install a cargo tiedown fitting in each
floor stiffener hole.
(5). Connect a shoulder strap to each
fitting. (4). Connect adjustable portion of seat belt
assembly to the L/H fitting and the
NOTE: Adjust shoulder strap to cross passen nonadjustable portion to the L/H center
ger's chest from outboard shoulder to inner fitting.
center of lap.
(5). Connect adjustable portion of seat belt
(6). Locate the three existing cargo floor assembly to the R/H fitting and the
seat belt fittings on the passenger nonadjustable portion to the R/H center
compartment floor at Sta. 124.00. fitting.
Page 905
MAINTENANCE MANUAL
H. Weight and Balance Data

(Ref. Table 901) After installation, incorporate
changes to helicopter weight and balance
records as instructed (Ref. Section 08-10-00).

Weight Arm Moment
Configuration
369H90035−501
Added +30.2 (+13.698) +93.5 (+237.49) +2824 (+3253.6)
Removed − 32.7 (−14.832) +108.6 (+275.84) − 3551 (−4091.2)
369H90035−503
Added +31.2 (+14.152) +92.1 (+233.93) +2874 (+3311.2)
Removed
Seat Belts (2) − 5.1 (−2.313) +117.2 (+297.69) − 598 (−689.0)
Bench Seat − 24.7 (−11.204) +111.0 (+281.94) − 2742 (−3159.1)
Page 906
MAINTENANCE MANUAL
RIVET
GROMMET
CARGO TIE-DOWN FITTING

(4 PL) NUT
STA. 78.50
BELT ASSEMBLY STA. 124.00 RIVET TAB (TYP 4 PL)
BELT ASSEMBLY
SEAT ASSEMBLY
(4 PL)
4.0 IN.
(10.16 CM) 4.0 IN.
(10.16 CM)
CL EXISTING CARGO FLOOR

SEAT BELT FITTINGS
(3 PL)
4.0 IN.
(10.16 CM) 1.25 IN.
(3.175 CM)
BELT ASSEMBLY BELT ASSEMBLY
SEAT LOCATIONS
G25-2010A
Figure 903. Seat Belt and Seat Assemblies Installation (369D/E/FF − 500N)
Page 907
MAINTENANCE MANUAL
SHOULDER STRAP
ATTACH FITTING
L.H. SHOWN
R.H. OPPOSITE
SCREW (4 REQ'D)
HIGH BULKHEAD WASHER (4 REQ'D)
STA. 124.00 SHOULDER STRAP FITTING
SHOULDER STRAP
ATTACH FITTING
R.H. SHOWN
L.H. OPPOSITE
FITTING CAP
R.H. SHOWN
L.H. OPPOSITE
SCREW (2 REQ'D)
SCREW (4 REQ'D)
LOW BULKHEAD
STA. 78.50 SHOULDER STRAP FITTING
SHOULDER STRAP
(TYP)
SHOULDER STRAP
(TYP)
STA. 78.50 WL 28.44 WL 32.00 STA. 124.00
STA. 78.50 SHOULDER STRAP AND FITTINGS STA. 124.00 SHOULDER STRAP AND FITTINGS
NOTE: PICK UP EXISTING NUTPLATES

LOCATED ON CANT. STA. 78.50 BULKHEAD
FRAME AND CANT. STA. 124 BULKHEAD FRAME. G25−2009
Figure 904. Shoulder Straps and Fittings Installation (369D/E/FF − 500N)
Page 908
MAINTENANCE MANUAL
Section
25−30−00
Interior Trim
MAINTENANCE MANUAL
INTERIOR TRIM
1. Interior Trim A. Cyclic Stick Control Cover Replacement
(L/H Command)
Trim panels, covers, and applicable attaching
devices are found in the following locations:
(Ref. Figure 201)
(1). Models 369D/E/FF - 500N crew
compartment (Ref. Figure 201). (1). Remove four upper attaching cover
screws. Remove velcro attached boot
(2). Models 369D/E/FF - 500N passenger assemblies from cover. Tip cover
compartment (Ref. Figure 202). forward to remove two lower attaching
(3). Model 369D crew and passenger screws.
compartments - R/H command helicop
ters with center console (Ref. (2). Remove cover from cyclic stick assem
Figure 203). bly and slip boot assemblies over cyclic
stick grips.
(4). Floor trim covering and applicable
methods of attachment (Ref.
Figure 204). (3). To replace, slip boot assemblies over
cyclic stick grips and position cover in
A. Cyclic Stick Control Cover place. Attach boot assemblies to cover
with the velcro fasteners.
(Ref. Figure 201) A cyclic stick control cover
protects the cyclic control linkage from objects (4). Tip cover forward and install two lower
that might jam or foul control linkage. The attaching screws. Install four upper
cover extends between the pilot's and copilot's attaching screws.
cyclic sticks at the seat bulkhead and covers
the cyclic control linkage. Cyclic stick openings
in the cover are protected by boot assemblies B. Copilot’s Collective Pitch Stick Cover
(dust covers) secured to the cover with Velcro Replacement (L/H Command)
hook and pile fasteners. The cyclic sticks pass
through elastic ringed openings in the dust (Ref. Figure 201)
covers.
(1). Remove crew seats.
B. Copilot’s Inboard Collective Pitch Stick
Cover
(2). Remove attaching hardware. While
The inboard collective pitch stick cover on L/H carefully removing cover, ensure sliding
command helicopters provides access to the protective cover remains fixed to
underseat flight controls linkage and forms a collective pitch stick. Partial removal of
protective guard for the collective friction the cyclic stick control cover can be
mechanism on the inboard collective pitch required.
stick. A sliding protective cover at the collec
tive pitch stick slotted opening guards against (3). Spread sliding cover at collective stick
foreign object entry. and remove. If necessary, remove nylon
grommet on stick (Ref. Section
2. Interior Trim Replacement 67-10-00, Pilot's Collective Pitch Stick
NOTE: Electrical wires from passenger com Replacement).
partment cigarette lighter, optional utility
light, and running time meter must be dis (4). To replace, install nylon grommet on
connected before removing and reconnected collective stick. Spread sliding cover at
before installing associated trim panel or collective stick hole and fit over nylon
cover (Ref. Chapter 96). grommet.
Page 201
MAINTENANCE MANUAL
VELCRO FASTENER
CONTROL TUNNEL PANEL

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

TRIM COVER
(NOTE 4) 6 PLCS
MAP POCKET
LH BOOT
ASSEMBLY
RH BOOT
ASSEMBLY
CYCLIC STICK CONTROL COVER LID

3 PLCS
VELCRO
FASTENER
MAP CASE COVER
COLLECTIVE STICK COVER
NOTES:
1. USED ONLY WITH OPTIONAL DUAL CONTROLS.
2. USED ONLY WITH SINGLE CONTROLS.
3. REMOVED FOR OPTIONAL UTILITY LIGHTS.
4. TRIM COVER SHORTER ON HIGH BULKHEAD MODELS.
5. TRIM COVER LONGER ON HIGH BULKHEAD MODELS. COPILOT'S COLLECTIVE PITCH STICK COVER
(NOTE 1) G25−3001−1
Figure 201. Crew Compartment Interior Trim (Sheet 1 of 2)
Page 202
MAINTENANCE MANUAL
VELCRO FASTENER
CANTED BULKHEAD PANEL

(RIGHT SIDE)
ASSIST STRAP
2 PLCS
3 PLCS
2 PLCS
DOOR PANEL
ASSIST HANDLE UPPER SIDE PANEL

NOTE 6
VELCRO FASTENER
4 PLCS
LOWER INSTRUMENT
8 PLCS HOUSING PANEL
FORWARD PANEL
NOTES: (CONT.)
6. USED FOR RUNNING TIME METER ON MODEL 369D ONLY.
7. UNLESS OTHERWISE INDICATED, LEFT SIDE ITEMS ARE
SHOWN (EQUIVALENT RIGHT SIDE ITEM IS APPROXIMATELY OUTBOARD AFT PANEL
MIRROR IMAGE OPPOSITE).
8. DOOR MAIN TRIM PANELS NOT SHOWN. G25−3001−2
Figure 201. Crew Compartment Interior Trim (Sheet 2 of 2)
Page 203
MAINTENANCE MANUAL
VELCRO FASTENER
VELCRO FASTENER (8 PL) COVER
(2 PL)
SCREW
(4 PL)
STANDOFF
BRACKET (2 PL)
SCREW
HIGH FORWARD BULKHEAD PANEL (2 PL)
(LOOKING FORWARD)
VELCRO FASTENER
STANDOFF
(2 PL)
SCREW
(2 PL)
BRACKET
LOW FORWARD BULKHEAD PANEL
(LOOKING FORWARD)
BRACKET
LIGHTER
BLANK COVER
SCREW
(6 PL)
ASHTRAY
LOW BULKHEAD CONVENIENCE PANEL
WASHER
SCREW (12 PL)
(4 PL)
SCREW
AFT DOOR FRAME PLUG (12 PL)
NUT
(LEFT SIDE) (12 PL)
HIGH BULKHEAD CONVENIENCE PANEL COVER

(NOTES 1, 2)
BULKHEAD PANEL
NOTES: POCKET
1. NOT USED WITH OPTIONAL ROTOR BRAKE EQUIPMENT.
2. FOR INFORMATION ON OPTIONAL EQUIPMENT USED ON
THIS PANEL, REFER TO OPTIONAL EQUIPMENT LIST LITERATURE POCKET
(REF. SEC. 01-00-00).
G25−3002−1
Figure 202. Passenger Compartment Interior Trim (Sheet 1 of 2)
Page 204
MAINTENANCE MANUAL
SCREW SCREW
(5 PL) (16 PL)
EARLY CONFIGURATION CURRENT CONFIGURATION
UPPER AFT BULKHEAD PANEL

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

(TYP)
G25−3002−2
Figure 202. Passenger Compartment Interior Trim (Sheet 2 of 2)
Page 205
MAINTENANCE MANUAL
(5). Position cover over collective stick and F. Carpeting

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

NOTE: Carpeting is secured in place with dou
C. Inboard Collective Pitch Stick Cover ble-faced tape or bonded with adhesive, and
Replacement (R/H Command) should not be removed unless replacement
or repair is required.
(Ref. Figure 203) At installation, tuck bottom
(1). Tear away carpeting (if bonded) and
edge of lower curtain under support.
clean surface with wire brush. Bond
Curtains must not fold inward replacement carpeting using adhesive
CAUTION through full travel of the collec (CM718).
tive stick. Folding inward can result in en (2). Lift carpeting (if taped) away from floor
tanglement with collective stick friction and remove double-faced tape. Apply
gear mechanism. new double-faced tape (CM718) and
press replacement carpeting in position.
D. Transmission Panel
3. Interior Trim Inspection
(Ref. Figure 203) Remove low or high bulkhead
convenience panel before removing transmis (1). Inspect interior trim for tears, cuts,
sion panel. breaks, or other evidence of unservice
able condition.
E. Log Book Holder (Optional for R/H
(2). Inspect trim panels and covers for
Command)
loose, damaged, or missing Velcro
(Ref. Figure 203) fasteners, as applicable.
(3). Inspect fuselage structure for loose,
Consumable Materials damaged, or missing Velcro fasteners,
(Ref. Section 91−00−00) rivnuts or isolator nut mounts, as
Item Nomenclature applicable.
CM217 Isopropyl alcohol (4). Inspect carpeting for cuts, tears, or
CM432 Dichloromethane other unserviceable condition.
CM433 Ethylene chloride (5). Inspect foot fairings, floor trim, and
access doors for cuts, breaks or cracks.
(1). Remove upper two screws and loosen (6). Inspect Velcro fasteners on access flap
the bottom screws. for security of attachment or other
damage.
(2). Lift holder up and out.
(7). (L/H command helicopters) Inspect
(3). Repair cracks or separation by cleaning sliding cover of copilot's collective pitch
with isopropyl alcohol (CM217); then stick cover for freedom of movement in
apply ethylene dichloride (CM433) or cover tracks. Inspect stowage lid for
dichloromethane (CM432) to patch or condition and positive fastening.
mate surfaces. A. Interior Trim Cleaning
(4). Join immediately with light pressure to (Ref. Section 20-20-00, Fuselage Interior Trim
cement joint. and Upholstery Cleaning)
Page 206
MAINTENANCE MANUAL
OIL LEVEL
CHECK COVER
PLUG BUTTON
(BOTH SIDES)
MAIN TRANSMISSION
CHIP DETECTOR ACCESS PANEL
COVER PLUG
TRANSMISSION
PANEL
UPPER BULKHEAD PANEL
(RIGHT HAND)
TRANSMISSION PANEL
INSTALLATION
UPPER BULKHEAD PANEL
(LEFT HAND)
CHECKLIST
LOWER BULKHEAD PANEL

SEAT FITTING
COVER
MAGNETIC
COMPASS
CARD
AFT BULKHEAD INSTALLATION
LOGBOOK HOLDER
LOGBOOK HOLDER
INSTALLATION
PLUGS
CONVENIENCE PANEL
BLANK COVER
TRIM PANEL NUT

MOUNT
CONVENIENCE
PANEL COVER ISOLATOR NUT MOUNT
INSTALLATION
CONVENIENCE PANEL
INSTALLATION
G25-3003-1
Figure 203. Crew and Passenger Compartment Interior Trim − R/H Command (Sheet 1 of 2)
Page 207
MAINTENANCE MANUAL
CIRCUIT BREAKER
PANEL
ASH RECEIVER AND

CIGARETTE LIGHTER
PANEL
STICK COVER
SUPPORT TUBE
CLAMP
SUPPORT TUBE
PILOT COLLECTIVE PITCH ASSEMBLY
STICK COVER ASSEMBLY
FLEXIBLE CLOSURE
ASSEMBLY
LOWER CURTAIN
PILOT'S INBOARD COLLECTIVE
PITCH STICK COVER
UPPER CURTAIN CURTAIN STOP
COTTER PIN
SLIDER
FASTENER STUD
FASTENER BUTTON
EXPLODED VIEW
(ROTATED)
PILOT'S CYCLIC
STICK GUARD
CYCLIC CONTROLS
CENTER GUARD
COPILOT'S CYCLIC
STICK GUARD
CYCLIC STICK GUARDS
(ROTATED)
G25-3003-2
Figure 203. Crew and Passenger Compartments Interior Trim − R/H Command (Sheet 2 of 2)
Page 208
MAINTENANCE MANUAL
4. Interior Trim and Carpeting General (1). Remove damaged panel.

Repair
(2). Stop-drill end(s) of crack.
Item Nomenclature (3). Deburr stop drill(s) and clean any
jagged area of crack.
CM405 Adhesive
CM718 Tape, double-faced
(4). Cut patch from fiberglass cloth to
overlap damaged area or crack, mini
mum 1 inch (2.54 cm) in all directions.
(1). Remove and replace broken or missing
rivnuts or isolator nut mounts, as (5). Cut second patch to overlap first,
applicable. minimum 1/2 inch (12.7 mm) in all
directions. If required, cut third patch
(2). Bond loose insulation material on to overlap second, minimum 1/2 inch
underside of trim panel or cover using (12.7 mm) in all directions.
adhesive (CM405).
(3). Repair cut or torn floor trim or carpet (6). Abrade surface of panel in area to be
ing with new application of double- patched with emery cloth (CM804).
faced tape (CM718) or adhesive
(CM405), as applicable.
(7). Clean surface by wiping with cloth,
dampened not saturated, with isopropyl
MPK solvent is flammable.
WARNING Use only in well-ventilated alcohol (CM217) or surface cleaner
(CM228).
area and away from heat and flame.
NOTE: Loosened Velcro fasteners can be reacti (8). Place panel in horizontal position. Tape
vated for adhesion by wiping original adhe around area to be repaired with
sive with MPK (CM219). masking tape, to catch residual resin.
(4). Replace unserviceable Velcro fasteners

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

(11). Continue adding material and resin
until desired thickness has been
Consumable Materials achieved.
Item Nomenclature
NOTE: Heat lamp should be placed a minimum
of 12 inches from fiberglass repair area.
CM228 Surface cleaner
CM501 Fiberglass cloth
(12). Allow repair to cure, minimum 45
CM505 Polyester laminating resin minutes, at 255—2755F (124—1345C).
CM804 Emery cloth, fine Or alternatively, heat lamp can be used
(minimum 2 hours).
Page 209
MAINTENANCE MANUAL
NAUGAHYDE
HANDLE (2)
FLOOR CARPETING
STA. 78.50
BULKHEAD
ACCESS DOOR
FOOTWELL PANEL CARPETING
DOUBLE
ASSEMBLY FACE TAPE
FLOOR STRUCTURE
ACCESS FLAP RIGHT SIDE TRIM

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

CARPETING
FLOOR CARPETING
CENTER TRIM FLOOR STRUCTURE
CARPETING
BULKHEAD TRIM (NOTE)
DOUBLE
FLOOR PAN FACE TAPE
NOTE: PASSENGER COMPARTMENT

CARPETING IN THIS AREA IS BONDED IN PLACE. G25-3004A
Figure 204. Floor Trim and Covering
Page 210
MAINTENANCE MANUAL
B. Solvent Bonding Patch Method (10). After forcing out bubbles, adjust clamps
to minimum pressure required to hold
(Ref. Figure 205) parts together.
(11). If solvent has evaporated at or near

edge of patch, apply more solvent
between mating surfaces using syringe
Item Nomenclature
or eye dropper.
CM435 Tetrahydrofuran (12). Leave clamps in place for a minimum of
20 minutes.
(1). Remove damaged panel. (13). Allow the panel to cure for 24 hours
prior to reinstallation.
(2). Stop-drill end(s) of crack.
C. Epoxy Adhesive Patch Method
(3). Deburr stop drill(s) and clean any
jagged area of crack. (Ref. Figure 205)
(4). Select a piece of boltaron material with
same contour as patch area. Plating Consumable Materials
surfaces must provide a snug fit. Patch (Ref. Section 91−00−00)
material to overlap damaged area a Item Nomenclature
minimum of 1 inch (2.54 cm) in all CM228 Surface cleaner
directions. CM411 Adhesive, epoxy
(5). Clean mating surfaces with aliphatic CM804 Emery cloth, fine
naphtha (CM220). Ensure surfaces are
free from oil, grease or other contami
nates. (1). Remove damaged panel.
(6). Assemble patch with mating surface of (2). Stop-drill end(s) of crack.
patch in contact with panel but without
(3). Deburr stop drill(s) and clean any
application of pressure.
jagged area of cracks.
Tetrahydrofuran bonding
WARNING solvent is a flammable liq (4). Select a piece of boltaron material with
same contour as patch area. Mating
uid. Care must be exercised in handl
surfaces must provide a snug fit. Patch
ing.
to overlap damaged area a minimum of
Solvent shall be applied careful 1 inch (2.54 cm) in all directions.
CAUTION ly so no excess material will run
over other surfaces and mar the finish. (5). Lightly abrade mating surfaces with
emery cloth (CM804) and clean with
NOTE: On larger parts, solvent shall be applied surface cleaner (CM228).
evenly to mating surfaces with brush.
(6). Air dry for 30 minutes at ambient
(7). Inject tetrahydrofuran (CM435) temperature. Apply adhesive (CM411)
between mating surfaces by means of within 2 hours of drying.
syringe or eye dropper.
(7). Thoroughly mix equal parts of adhesive
(8). Assemble mating surfaces as quickly as by weight. Color should be uniform
possible by firmly pressing together. green. Use unwaxed disposable contain
er and wooden tongue depressor or
(9). Apply clamps to assembly immediately metal spatula for mixing. Pot life of
after solvent application. Use sufficient mixed adhesive is 45 minutes at
pressure to force out air bubbles. ambient temperature.
Page 211
MAINTENANCE MANUAL
FIBERGLASS PATCH METHOD A

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

ADHESIVE PATCH METHOD B & C
1.0 IN.
(2.54 CM)
1.0 IN.
(2.54 CM)
STOP DRILL
BOND AND RIVET PATCH METHOD D
4-6 X O.D.
PANEL
PATCH
RIVETS
2 X O.D. BOND AND RIVET PATCH METHOD D

STOP DRILL
+0.030 IN.
(0.762 MM) 2 X O.D.
+0.030 IN.
(0.762 MM)
WASHER
(NOTE)
4-6 X O.D.
NOTE: USE AN960 WASHER, OF PROPER SIZE TO FIT RIVET DIAMETER, TO
PRECLUDE RIVET TAIL FROM PULLING THROUGH BOLTARON PANEL.
G25-3005A
Figure 205. Boltaron Panel Repair
Page 212
MAINTENANCE MANUAL
(8). Spread thin uniform layer (3). Lay out rivet pattern on patch and drill
(0.002—0.010 inch (0.0508—0.254 holes. Position patch on panel and drill
mm)) of adhesive lightly on mating holes.
surfaces and clamp lightly together.
(4). Deburr all holes on both sides of patch
(9). Wipe excess adhesive from bond line. and panel.
(5). Countersink holes on patch if using
(10). The clamps are to remain in place for 8 MS20426A4 rivets.
hours minimum at ambient tempera
ture or 2 hours at 150—170F (6). Comply with the following procedures if
(67—77C). using Solvent Bonding Patch Method
(tetrahydrofuran).
(11). Allow panel to cure for 24 hours prior to
installation. (a). Clean mating surfaces with naphtha
aliphatic (CM220). Ensure surfaces
are free from oil, grease or other
D. Bond and Rivet Patch Method
contaminates.
(Ref. Figure 205) The following procedure can (b). Set patch in place. Use a minimum
be used in conjunction with one of the above amount of clecos required to hold
bonding procedures (Ref. Solvent Bonding patch in contact with panel without
Patch Method or Epoxy Adhesive Patch applying too much pressure.
Method). If cracks are excessive and/or a piece
of boltaron is not available that fits contour in Tetrahydrofura bonding sol
repair area, rivets can be used to help secure WARNING vent is a flammable liquid.
patch to panel. Care must be exercised in handling.
Solvent shall be applied careful
CAUTION ly so no excess material will run
(Ref. Section 91−00−00) over other surfaces and mar the finish.
NOTE: On larger parts, solvent shall be applied
Item Nomenclature
CM220 Naphtha aliphatic evenly to mating surfaces with brush.
(c). Inject tetrahydrofuran (CM435)
CM411 Adhesive, epoxy between mating surfaces by means of
CM435 Tetrahydrofuran syringe or eye dropper.
CM804 Emery cloth, fine
(d). Assemble mating surfaces as quickly
as possible by firmly pressing togeth
er.
(1). Cut patch to proper size.
(e). Apply clamps to assembly immedi
(2). Determine rivet spacing. ately after solvent application, with
sufficient pressure to force out air
(a). Rivet spacing to be 4-6 times rivet bubbles.
diameter.
(f). After forcing out bubbles, adjust
(b). Minimum edge distance to be 2 times clamps to minimum pressure re
rivet diameter ±0.030 inch (0.762 quired to hold parts together.
mm). (g). If solvent has evaporated at or near
edge of patch, apply more solvent
Example :For #4 rivet, minimum between mating surfaces using
edge distance is 0.028 inch (0.7112 syringe or eye dropper.
mm). Rivet diameter 0.125 inch
(3.175 mm) X 2 + 0.030 inch (0.762 (h). Leave clamps in place for a minimum
mm) = 0.280 inch (7.112 mm). of 20 minutes.
Page 213
MAINTENANCE MANUAL
NOTE: If gap exists between patch and panel (c). Thoroughly mix equal parts, of
prior to installing rivets, inject tetrahydro adhesive by weight. Color should be
furan between mating surfaces in immedi uniform green. Use unwaxed dispos
ate area of each rivet hole that has a gap us able container and wooden tongue
ing a syringe or eye dropper. depressor or metal spatula for
mixing. Pot life of mixed adhesive is
(i). Rivet patch to panel. 45 minutes at ambient temperature.
(d). Spread a thin uniform layer,
(j). Allow panel to cure for a minimum of
0.002—0.010 inch (0.0508—0.254
24 hours prior to installation.
mm), of adhesive on mating surfaces.
Try to keep adhesive out of the rivet
(7). Comply with the following procedures if
holes.
using the Epoxy Adhesive Patch
Method. (e). Install the patch on the panel with
clecos.
(a). Lightly abrade mating surfaces with
emery cloth (CM804) and clean with (f). Rivet the patch to the panel.
surface cleaner (CM228). (g). Wipe excess adhesive from bond line
and from around the rivets.
(b). Air dry for 30 minutes at ambient
temperature. Apply adhesive (h). Allow the panel to cure for 24 hours
(CM411) within 2 hours of drying. prior to installation.
Page 214
MAINTENANCE MANUAL
Section
25−40−00
Miscellaneous
Furnishings
MAINTENANCE MANUAL
MISCELLANEOUS FURNISHINGS
1. Crew Compartment Miscellaneous between foot rest and bulkhead for correct
Furnishings Replacement four-point contact.
Methods for removal and installation are D. Ash Receiver and Cigarette Lighter Panel
obvious for most miscellaneous furnishing
items. Some maintenance instructions are (1). The cigarette lighter panel can be
provided in the following procedures. removed by releasing four turnlock
fasteners.
Crew compartment furnishings for the 600N
Helicopter are the same as for the 369D/E/FF (2). Disassembly of the cigarette lighter and
- 500N Helicopters. panel for maintenance purposes is
shown in the figure.
A. Stowage Box
2. Passenger Compartment Miscellaneous
Access to stowage box is thru crew compart Furnishings Replacement
ment right side floor access door (Ref. Section
52-50-00). Methods for removal and installation are
obvious for most miscellaneous furnishing
items. Some maintenance instructions are
Consumable Materials provided in the following procedures.
Item Nomenclature Passenger compartment furnishings for the
600N Helicopter are the same as for the
CM717 Tape, pressure sensitive 369D/E/FF - 500N Helicopters except, where
applicable, panels and ducting is 30 inches
NOTE: Helicopters equipped with certain op longer.
tional communications and avionics instal A. Convenience Panel Replacement (R/H
lations do not have stowage box installed. Command)
When installing replacement stowage box, (1). Remove attachment screws. Lower
cover screwheads with tape (CM717). panel and disconnect any wiring and
heat valve connectors before removing
B. Heat Duct panel.
The heat duct consists of an upper and lower (2). Reinstall using reverse procedure.
section with a magnetic compass mounted on
the lower section just above the instrument 3. Passenger Step Assembly Description
panel. The anti-icing control (Ref. Section
75-10-00) and cabin heat control (Ref. Section (Ref. Figure 203) Due to the extended fuselage
21-40-00) mount on the upper section of the of the 600N Helicopter, the addition of an
heat duct. Removal of magnetic compass is not elongated passenger step is unique to this
required for removal of heat duct. However, aircraft. The step is secured at two positions
wiring to the light must be disconnected at the on each side of the fuselage, as compared to
splices. one position on the 369D/E/FF - 500N
Helicopters. The step is available in either a
C. Foot Rest (L/H Command) high or low step configuration depending on
the landing gear option installed.
For access to foot rest attaching hardware,
remove stowage box. Position replacement foot 4. Passenger Step Assembly Inspection
rest on floor support bulkhead and install
attaching hardware. When necessary, use (1). Inspect step attach point(s) for security
additional thin aluminum washers to shim of installation and general condition.
Page 201
MAINTENANCE MANUAL
(2). Inspect ”no skid” surface of step for (1). To replace worn or lost safety-walk
general condition. Replace or reattach if tape, carefully scrape away damaged
worn excessively. tape. Remove all residual adhesive by
wiping with naphtha (CM220) wetted
5. Passenger Step Assembly Replacement cloth.
A. Passenger Step Assembly Removal
(2). Install new tape (CM724) and press
(1). Gain access to passenger step assembly firmly into place. Expel air bubbles by
attaching hardware under floor cover pressing down tape from center out to
ing of passenger/cargo compartment. the edges.
(2). Remove quick release pin(s) that secure
step assembly in mounting hole(s).
7. Miscellaneous Furnishings Inspection
(3). Remove step assembly.
B. Passenger Step Assembly Installation (1). Inspect for cracks, breaks or other
unserviceable condition.
(1). Align and insert passenger step
assembly into mounting hole(s) in (2). Inspect helicopter checklist and
fuselage. magnetic compass card for condition
(2). Insert quick release pin(s) to secure and legibility.
step assembly.
(3). Secure floor covering in passenger/cargo (3). Inspect for loose, damaged or missing
compartment. rivnuts and other attaching hardware
as applicable.
6. Passenger Step Assembly Repair
The passenger step has black, non-slip, 8. Miscellaneous Furnishings Repair
pressure-sensitive, safety-walk tape applied
to the upper surface of the step plate. (1). Repair cracks or breaks in thermoplas
tic material (Ref. Section 20-30-00,
Consumable Materials Boltaron Trim Panels Repair).
Item Nomenclature
(2). Do the minor weld and rivet repairs
CM220 Naphtha aliphatic according to FAA AC 43.13-1B Inspec
CM724 Tape, non-slip tion and Repair for Standard Sheet
Metal Repair.
Page 202
MAINTENANCE MANUAL
SWIVEL BRACKET
VNE CARD
VNE CARD HOLDER
OUTER BOX
ANTI-ICING CONTROL (6 PL)

UPPER SECTION
CABIN HEAT CONTROL
(NOTE 1)
LOCKING PIN
LOWER SECTION
JACKING
END CAP FITTING
(4 PL)
MAGNETIC COMPASS (10 PL)
HEAT DUCT AND

MAGNETIC COMPASS STEP SUPPORT SHAFT
CREW COMPARTMENT
STOWAGE BOX
PASSENGER COMPARTMENT STEP
NOTES:
1. OPTIONAL EQUIPMENT, (REFER TO
APPLICABLE OPT EQPT MANUAL.)
G25-4001-1A
Figure 201. Miscellaneous Furnishings (369D) (Sheet 1 of 2)
Page 203
MAINTENANCE MANUAL
MAP POCKET
MAP CASE TRIM

COVER
HELICOPTER
MAGNETIC CHECK LIST
COMPASS CARD
COMPASS CARD AND CHECK LIST
(2 PL)
ASHTRAY
BONDED
(2 PL)
CIGARETTE LIGHTER
RECORD HOLDER ASHTRAY PASSENGER COMPARTMENT
FLOOR SUPPORT
BULKHEAD
ASHTRAY
HOLDER
BULKHEAD COVER
(NOTE 2) LIGHTER
(4 PL)
FOOT REST ASHTRAY CREW COMPARTMENT
NOTES: (CONT)
2. NOTE USED WHEN STROBE LIGHTS
POWER SUPPLY OF NIGHT LIGHTING
SYSTEM IS INSTALLED.
G25-4001-2A
Figure 201. Miscellaneous Furnishings (369D) (Sheet 2 of 2)
Page 204
MAINTENANCE MANUAL
SWIVEL BRACKET
VNE CARD
COVER
VNE CARD HOLDER
ANTI-ICING CONTROL
UPPER SECTION
(6 PL) 10 PL
CABIN HEAT
CONTROL
LOWER SECTION
MAGNETIC COMPASS
LOCKING PIN
CREW COMPARTMENT
STOWAGE BOX
HEAT DUCT AND

MAGNETIC COMPASS
JACKING
FITTING
STEP SUPPORT SHAFT
PASSENGER COMPARTMENT STEP

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

TO 369D/E/FF - 500/600N HELICOPTERS
EXCEPT WHERE NOTED. G25-4002-1A
Figure 202. Miscellaneous Furnishings (369E/FF − 500/600N) (Sheet 1 of 2)
Page 205
MAINTENANCE MANUAL
MAP CASE TRIM

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

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

LIGHTS POWER SUPPLY OF NIGHT ASHTRAY CREW COMPARTMENT
LIGHTING SYSTEM IS INSTALLED.
G25-4002-2A
Figure 202. Miscellaneous Furnishings (369E/FF − 500/600N) (Sheet 2 of 2)
Page 206
MAINTENANCE MANUAL
QUICK
RELEASE PIN
4 PL
(TYP)
6G25-080
Figure 203. Passenger Step Assembly (600N)
Page 207
MAINTENANCE MANUAL
Page 208
MAINTENANCE MANUAL
Section
25−50−00
Cargo Hook
MAINTENANCE MANUAL
CARGO HOOK
FAULT ISOLATION
1. Cargo Hook Description located on the left side of the hook body.
Regardless of the method used to release the
The cargo hook provides a means of transport hook, the hook will return to the closed
ing external cargo. The cargo hook installation (retracted) position.
consists of a cargo hook assembly, electrical
hook release equipment and backup emergen 3. Cargo Hook Fault Isolation
cy manual release equipment. The cargo hook
assembly is externally attached to the center (Ref. Table 101) Cargo hook system malfunc
beam of the helicopter at Station 99.325. The tions might be caused by any one of several
cargo hook operational rating (external load general conditions which are easily corrected.
limit) is 2000 pounds. Before starting specific troubleshooting
procedures, make the following checks and
The cargo hook and swivel assembly are take indicated action for troubleshooting
mounted on the helicopter center beam by four procedures.
bolts at Station 99.325. The swivel assembly
allows the cargo hook to swing in any direction (1). Refer to applicable wiring diagram and
through a 30-degree arc. check for loose or damaged wires and/or
terminals and connectors; reconnect or
2. Cargo Hook Operation replace as required.
The cargo hook is normally operated electrical (2). Check for damaged interconnect wires
ly by pressing the CARGO HOOK switch on and/or equipment (Ref. Chapter 96).
the pilot's cyclic stick grip (Ref. Figure 403). (3). Check for loose or defective terminal
Actuation of the CARGO HOOK switch board connections; repair or replace as
energizes a solenoid in the cargo hook. The required.
maximum electrical current required to
operate the cargo hook solenoid is 14 amperes (4). Check for loose ground wires.
at 28 Vdc. however, the solenoid is designed to
operate with voltage as low as 23 Vdc. Actua (5). Make certain circuit breaker is pushed
tion of the cargo hook solenoid releases the to full in (closed) position.
hook (load beam). (6). Check system power source.
In the event of an electrical malfunction, the 4. Wiring Diagrams
hook can be released (opened) by pulling a
manual release cable lever attached to the (Ref. Figure 101) Wiring diagrams of the
pilot's cyclic stick (Ref. Figure 401). The various cargo hook electrical system circuits
manual release cable releases (opens) the have been illustrated. Wire charts are provided
cargo hook in the same manner as the electri in Table 102 and Table 103. For helicopter
cally operated solenoid. The hook can be electrical system interface information refer to
released for testing or by cargo personnel by DC Electrical Load Distribution (Ref. Chapter
turning (clockwise) a cargo hook release knob 96).
Page 101
MAINTENANCE MANUAL
Table 101. Troubleshooting − Cargo Hook Installation

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

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

From To
Wire No.* Terminal Termination Terminal Termination
M532A20 TB1−18D MPCM20M−H2** K201−X1 Solder
TB1−19B MPCM20M−H2** K201−X1 Solder
M531A16 TB3−1D AYH11−H1** K201−D2 Solder

M523A20N J104−X2*** Solder E24 MS25036−103
M522C16 K201−D1*** Solder TB3−4A AYH14−H1**
M520AA16 SP92−B 32447 TB3−1C AYH14−H1**
J616−q Crimp TB3−1C AYH14−H1**
M520A16 CB603−2 MS25036−106 SP92−A 32447
CB603−2 MS25036−106 P616−q −−
M520B20 TB1−18C MPCM20M−H2** TB3−1D AYH14−H1**
TB1−18A MPCM20M−H2** TB3−1D AYH14−H1**
TB1−19A MPCM20M−H2** TB3−1D AYH14−H1**
*(Ref. Figure 101 sheets 1 & 2) for applicable wiring diagrams.

**Burndy Corp., Norwalk, Conn.
***K312−X2, _D1 for helicopters equipped with 369D24153 ‘‘Tee’’ console.
Page 102
MAINTENANCE MANUAL
Table 103. Wire Chart, 369E/FF T−Panel with Center Electrical Console, R/H Command.
From To
Wire No.* Terminal Termination Terminal Termination
M520AA16 K201−X2 Solder E24 MS25036−103
M532A20 K201−X1 Solder TB1−8F M39029/22−192
M531A16 K201−D2 Solder TB3−1C M39029/22−193
M531B16 K201−D1 Solder TB3−8B M39029/22−193
M520B20 TB3−1E M39029/22−193 TB1−8E M39029/22−192
M523C20N J605−C MS3193A16−16A E20 M7928/1−24
M520A16 CB118−2 M7928/1−41 P616− Q M39029/31−228
M520AA16 J616− Q M39029/32−247 TB3−1 M39029/22−193
*(Ref. Figure 101 sheet 3) for applicable wiring diagram.
Page 103
MAINTENANCE MANUAL
P605J
TB3-4 TB1-18
A M522D16 A M522C16 M523A20 D
B C
TB3-1
C M523B16N E20
K104 M531A16 D M520B20 SP92
M523BB20
C M520AA16 B A
CARGO HOOK D1 D3 D2
X1
C1 C3 C2 CB603
CR3 1 2
369D STANDARD CYCLIC STICK GRIP B1 B3 B2 M520A16
HOOK RELEASE 15A
3-1149, 1151-1184 X2 SWITCH (S114)
A1 A3 A2 P130J
10-20 A M522A20
E24 M523A20N 9-20 B M521E20
P605J
TB3-4 TB1-18
A M522D16 A M522C16 M523A20 D
B A
TB3-1
C M523B16N E20
K104 M531A16 D M520B20 SP92
D1 D3 D2 C M520AA16 B A
CARGO HOOK
X1
C1 C3 C2 CB603
CR3 1 2
369D OPTIONAL CYCLIC STICK GRIP B1 B3 B2 HOOK RELEASE M520A16
15A
RIGHT OF LEFT HAND COMMAND X2 SWITCH (S4)
A1 A3 A2 P130J
10-20 E M520C20
E24 M523A20N 9-20 A M522A20
P605J NOTE 1
TB3-4 TB1-19
A M522D16 A M522C16 M523A20 B
B A
TB3-1
C
M523B16N E20 M531A16 D M520B20
K104 J616P
M523BB20
C M520AA16 Q
CARGO HOOK D1 D3 D2
X1
C1 C3 C2 CB603
CR3 1 2
369D RIGHT HAND COMMAND B1 B3 B2 M520A16
HOOK RELEASE 15A
CYCLIC STICK GRIP X2 SWITCH
3-1149, 1151-1184 A1 A3 A2 P109J
WHT/VIO
OR BLUE D M521F20
E24 M523A20N WHT/GRAY E M520F20
NOTES: OR GRAY
1. 369D294402 CENTER ELECTRICAL CONSOLE:
-703 WITH ARMAMENT PANEL P109J TB1-19
-701 WITHOUT ARMAMENT PANEL
B M521F20 C NOTE 2
2. 369D294500 CENTER ELECTRICAL CONSOLE
WITH VHF-FM RADIO SET AND ASW EQUIPPED A D
M520F20
HELICOPTERS.
G25-5005-1
Figure 101. Cargo Hook − Wiring Diagrams (Sheet 1 of 4)
Page 104
MAINTENANCE MANUAL
CARGO HOOK RE J130P TB1-12

LEASE SWITCH A J109-A (REF)
10 OR BLU A M522A20 B
C J109-B (REF)
S4 B D
9 OR GRY M521E20 M520B20
M532A20 TB3-1 J9P

K104 C M520AA16 L
D
D1 D3 X1 D2 M531A16
C1 C3 C2
CR3 CB603
B1 B3 B2 E24 1 2
15A M520A16
A1 A3 X2 A2
M523A20N CARGO HOOK RELEASE
TB3-4 P605J
M522C16 A M522D16 A BLK
M523BB20N C
369D CYCLIC STICK GRIP
LEFT OR RIGHT HAND COMMAND E20 M523B16N B WHT
1150, 1185-1204
E24 TB1-12
K312
C
A
A1 A3 A2 D
X2 M523A20 B
B1 B3 B2 M520B20
CR3
C1 C3 C2
J9P
X1
D1 D3 D2 M531A16 D C M520AA16 L
TB3-1
CB603
1 2
M531B16 15A
J605P HOOK RELEASE

SWITCH (PILOT'S) M520A16
A M522D16 A S4 J130P
B TB3-4
C M523C20N A M522A20
B M521E20
HOOK RELEASE
SWITCH (CO-PILOT'S)
CARGO HOOK E20 S4 J109P
ASSEMBLY
A M522C20
369E/FF CYCLIC STICK GRIP B M521G20
LEFT OR RIGHT HAND COMMAND
G25-5005-2
Page 105
MAINTENANCE MANUAL
P616J TB3-1 PILOT

CB118
J109P S4
REF 1 M520A16 Q M520AA16 A
15A 2 TB1-8 M522C20 A
M531A16 C M521G20 B
E B
E M520B20 CO-PILOT
F C J130P S4
X1
M532A20 L H M522A20 A
M J M521E20 B
CR3
X2
M523A20N
A1 E24
A2
A3
B1 16 AWG BUS WIRE
B2
B3
C1
C2
C3 TB3-8 J605P
D1
D2 M531B16 B A M522D16 A
D3 M523B16N B
M523C20N C
K104
HOOK
369E/FF RIGHT HAND COM
MAND CONFIGURATION
E20
G25-5005-3
Page 106
MAINTENANCE MANUAL
CARGO HOOK
1. Cargo Hook Replacement cable, installation and adjustment of the
manual release lever as follows:
A. Cargo Hook Removal
(1). Secure base of cargo hook assembly
Remove the cargo hook assembly including the (Ref. Figure 404) to fuselage underside
cargo hook manual release cable and electri with bolts and washers.
cal harness as follows:
(2). Remove protective cap from cargo hook
(1). Remove cotter pin (Ref. Figure 405), electrical receptacle (J605); check that
washer, and slotted bushing from BATTERY switch is in OFF position
manual release lever on pilot's cyclic and connect plug (P605) to receptacle.
stick. (3). Insert free end of hook manual release
cable through elongated hole adjacent
(2). Loosen locking nut securing adjustment
to electrical receptacle (Ref.
nut shaft to release lever bracket.
Figure 402). Push manual release cable
(3). Remove screws (Ref. Figure 401), nuts, up into fuselage and insert cable
washers, and clamps securing manual through hole in pilot's floor.
release cable to cyclic stick. (4). Loosely attach harness and manual
release cable using clamps (Ref.
(4). Remove adjustment nut shaft (Ref.
Figure 402) screws, washers, and nuts.
Figure 405) from release lever bracket.
Adjust harness and cable to allow
(5). Loosen dust cover from pilot's cyclic sufficient slack for hook to swing 30
stick control trim cover (Ref. Section degrees conically from centerline
25-30-00). without creating strain on harness and
cable. Arrange harness and cable to
(6). Remove passenger/cargo compartment form smooth flow to cutouts in fuselage
left foot fairing trim (Ref. Section skin; tighten clamps. Install tie straps
25-30-00). approximately as shown (Ref.
Figure 402).
(7). Carefully push manual release cable
(Ref. Figure 401) down through grom NOTE: The 600N helicopters equipped with
mets in pilot's floor and fuselage skin. emergency floats require the manual re
Do not pull on cable housing. lease handle to be mounted on the collective
stick (Ref. Figure 406).
(8). Remove cargo hook electrical harness
(5). Loosely attach manual release cable to
plug from receptacle in fuselage; install
cyclic stick with clamps, screws,
protective caps on receptacle and plug.
washers, and nuts (Ref. Figure 401).
(9). Remove clamps (Ref. Figure 402) (6). Engage approximately half of the
securing cable and harness to clips on threads on the manual release cable
fuselage underside. adjustment nut shaft into the bracket
portion of the manual release lever
(10). Remove four bolts (Ref. Figure 404)
assembly (Ref. Figure 405).
securing cargo hook base to attach
holes in fuselage keel. (7). Engage swaged ball on release cable in
lever bushing (Ref. Figure 405). Secure
B. Cargo Hook Installation bushing with washer and cotter pin.
Installation of the cargo hook kit consists of (8). Attach manual release lever assembly
attaching the hook, and electrical/manual to cyclic stick with clamp and screws.
release cables on the underside of the helicop Adjust cable and/or release lever as
ter, routing and securing the manual release shown (Ref. Figure 405).
Page 401
MAINTENANCE MANUAL
(9). Tighten three sets of clamps securing (12). Install grommet (Ref. Figure 401) in
release cable to cyclic stick. crew compartment floor cutout.
(10). Do the adjustment/test of cargo hook (13). Install grommet (Ref. Figure 402) in
installation. elongated hole in fuselage lower skin
(11). Readjust cable lever (Ref. Figure 405) and doubler.
as required to obtain smooth consistent
release of hook. (14). Safetywire manual release lever clamp
screws with lockwire (Ref. Figure 405).
NOTE: The manual release lever clamp can be
loosened and the lever assembly moved on
cyclic stick to simplify adjustment, provid
ing the 2.00—2.50 inch (5.08—6.35 cm) di
mension limit is maintained (Ref.
Figure 405).
Page 402
MAINTENANCE MANUAL
CLAMP
SCREW
NUT
HOOK RELEASE DECAL (NOT REQUIRED
WITH OPTIONAL EQUIPMENT GRIP) WASHER
CLAMP
CLAMP INSTALLATION
CARGO HOOK (TYP - THREE PLACES)
EMERGENCY
RELEASE DECAL
PILOT'S CYCLIC STICK
CANTED STATION 64.365
CREW COMPARTMENT FLOOR
GROMMET
MANUAL RELEASE CABLE
ELECTRICAL RECEPTACLE (J605)
FUSELAGE SKIN LINE
ELECTRICAL PLUG (P605)

STA 63
G25-5000
Figure 401. Manual Release Cable Routing − Interior
Page 403
MAINTENANCE MANUAL
CARGO HOOK

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

11.5 ±0.5 INCHES STRAP (NOTE 3)
CREW COMPARTMENT ELECTRICAL WIRE HARNESS

FLOOR
FUSELAGE STRAP
SKIN LINE
STATION
84.79
STRAP
GROMMET CANTED STATION 78.50
ELECTRICAL EXTERIOR ATTACHMENT OF MANUAL

RECEPTACLE RELEASE CABLE AND ELECTRICAL WASHER
WIRE HARNESS
CLAMP (ELECTRICAL)
CLIP
CLAMP
(MANUAL)
NUT
NOTES:
1. LEFT HAND COMMAND ILLUSTRATED. RIGHT HAND COMMAND
DIMENSIONS THE SAME EXCEPT ON OPPOSITE SIDE. SCREW
2. EXISTING RIVET LOCATION AT STATION 84.79.
3. P4 HUCK RIVET MAY BE USED INSTEAD AT STATION 84.79. RIVET (NOTES 1, 2)
4. HARNESS AND CABLE TIED TOGETHER MIDWAY BETWEEN
STATION 84.79 AND HOOK ASSEMBLY.
5. MAINTAIN SUFFICIENT SLACK IN NOTED SECTION OF CABLE
AND HARNESS TO ALLOW HOOK TO SWING 30 DEGREES
CONICALLY FROM CENTERLINE WITHOUT CREATING STRAIN CLAMP ATTACHMENT
ON CABLE AND HARNESS. (TYPICAL) G25-5001
Figure 402. Manual Release Cable and Electrical Wire Harness Routing − Exterior
Page 404
MAINTENANCE MANUAL
CARGO HOOK RELEASE

CIRCUIT BREAKER
AUDIO RAD ALT BATTERY
O CARGO
F HOOK
F
1-COMM-2
EXT PWR
1-NAV -2
ADF XPNDR
369D LEFT-HAND
COMMAND CONFIGURATION
HOOK FLOATS
CARGO HOOK RELEASE

CIRCUIT BREAKER
369E/FF ”TEE” PANEL

REMOVE PLUG BUTTON LEFT-HAND COMMAND CONFIGURATION
AND INSTALL CARGO
HOOK RELEASE SWITCH
HOOK CIRCUIT BREAKER PANEL

RELEASE
CARGO
HOOK RELEASE DECAL CARGO HOOK HOOK

RELEASE SWITCH
CARGO HOOK RELEASE RIGHT-HAND COMMAND
CIRCUIT BREAKER WITH CENTER ELECTRICAL
CONSOLE CONFIGURATION
STANDARD GRIP
HOOK
RELEASE
HOOK RELEASE DECAL
HOOK
RELEASE
OPTIONAL
”T” GRIP
HOOK RELEASE DECAL CARGO HOOK
RELEASE SWITCH
HOOK RELEASE SWITCH
OPTIONAL PILOT'S CYCLIC STICK GRIP

EQUIPMENT GRIP
G25−5002
Figure 403. Cargo Hook Electrical Equipment Installation
Page 405
MAINTENANCE MANUAL
DECAL
DECAL
FUSELAGE LOWER
A SKIN SURFACE
NEOPRENE PAD
0.090 X 1.75 X 4.0 IN.
(0.229 X 4.445 X
10.16 CM) (NOTE)
NEOPRENE PAD
0.090 X 1.75 X 1.75
IN. (0.229 X 4.445 X
WASHERS (4 PLACES) 4.445 CM) (NOTE)
BOLT (4 PLACES) EXTERNAL RELEASE

(TURN CLOCKWISE)
SWIVEL
ELECTRICAL WIRE
HARNESS STA 99.325
KEEPER
2000 POUNDS
EXTERNAL LOAD LIMIT
1.62 ±0.12 IN.

(4.1148 ±0.3048 CM) 1.12 ±0.12 IN.
(2.8448 ±0.3048 CM)
HOOK (LOAD BEAM) 1.00 ±0.12 IN.
(2.54 ±0.3048 CM)
LONGITUDINAL
CENTERLINE OF
FWD 4-HOLE LAYOUT
1.88 ±0.12 IN. (4.7752 ±0.3048 CM)
2.00 ±0.12 IN.
(5.08 ±0.3048 CM)
EXTERNAL LOAD LIMIT

2000 POUNDS
3.75 ±0.12 IN.
(9.525 ±0.3048 CM)
LATERAL CENTERLINE (2 PLCS)
OF 4-HOLE LAYOUT
A-A
NOTE:
PADS PREVENT FUSELAGE SKIN
DAMAGE AT HOOK CONTACT POINTS. G25-5003A
Figure 404. Hook and Pad − Installation
Page 406
MAINTENANCE MANUAL
20° (NOTE 2)
CARGO HOOK MANUAL
RELEASE LEVER ASSEMBLY
SLOTTED BUSHING
(NOTE 5)
CARGO HOOK
RELEASE CABLE
2.250 ±0.250
INCHES
POSITIONING LEVER ON STICK
CLAMP
LOCKWIRE HOOK-ENGAGED LEVER

POSITION (NOTES 3, 6)
LOOKING AFT AND DOWN

CARGO HOOK
RELEASE LEVER
BALL TERMINAL
(NOTE 1) COTTER PIN
LOCKING NUT
(NOTE 4) WASHER
ADJUSTMENT
NUT (NOTE 4)
NOTES:
1. CABLE BALL TERMINAL RETAINED IN SLOTTED BUSHING OF RELEASE LEVER.
2. APPROXIMATE ANGULAR POSITION OF LEVER REQUIRED FOR
CONVENIENCE AND RELEASE OF CARGO HOOK. RELEASE
3. CABLE BALL TERMINAL AFT TRAVEL SHOULD BE APPROXIMATELY BRACKET
1/2 INCH TO RELEASE HOOK.
4. WITH LOCKING NUT LOOSENED, TURN ADJUSTMENT NUT TO PULL RELEASE
LEVER TO FULL FORWARD (HOOK ENGAGED) POSITION WITH SLIGHT
TENSION ON CABLE; TIGHTEN LOCKING NUT. IF REQUIRED, ADJUST LOOKING INBOARD FROM
POSITION OF LEVER ASSEMBLY ON CYCLIC STICK. LEFT SIDE OF HELICOPTER
5. BUSHING 369H92631 MAY BE USED AS ALTERNATE.
6. LEVER SHOULD NOT MOVE FROM HOOK-ENGAGED POSITION WHEN
CYCLIC STICK IS MOVED THROUGH FULL TRAVEL IN ALL DIRECTIONS. G25−5004
Figure 405. Cargo Hook Manual Release Lever − Installation
Page 407
MAINTENANCE MANUAL
CARGO HOOK
MECHANICAL RELEASE
CARGO HOOK
ELECTRICAL RELEASE
CYCLIC-MOUNTED ELECTRICAL HOOK RELEASE CARGO HOOK

RELEASE CABLE
STANDARD CYCLIC-MOUNTED MECHANICAL HOOK RELEASE
CARGO HOOK
MECHANICAL RELEASE
CARGO HOOK RELEASE CABLE
COLLECTIVE-MOUNTED MECHANICAL HOOK RELEASE (NOTE)
NOTE: FOR 600N MODEL HELICOPTERS EQUIPPED WITH THE

OPTIONAL EMERGENCY FLOAT INSTALLATION, STC# SR00471LA. 60−052−1
Figure 406. Cargo Hook Release for 600N Helicopters
Page 408
MAINTENANCE MANUAL
CARGO HOOK
INSPECTION/CHECK
1. Cargo Hook Operational Check Cargo hook must remain
WARNING closed while moving
Do the following operational check procedure through all positions of extreme travel
whenever it is necessary to verify that the fore and aft as well as side-to-side.
cargo hook system is operating properly:
(8). Grasp load ring and pull downward
while moving cargo hook manually full
(1). Place battery switch in BATTERY travel side-to-side. Ensure hook (load
position. beam) remains in locked position.
(2). Check that CARGO HOOK/HOOK 2. Adjustment

circuit breaker is pressed to full in
position (Ref. Figure 402). Adjust the manual release cable so that the
2.00—2.50 inch (5.085—6.35 cm) dimension
shown (Ref. Figure 405) is maintained.
NOTE: Cargo load rings (or equivalent check
tool) with a maximum cross-section thick 3. Exterior Components Inspection
ness of 3/4 inch can be used for testing or for
cargo transport operations. On cargo hooks, manufac
WARNING tured by Breeze-Eastern,
(3). Push cargo load ring forward into hook Model 2A20B, P/N 17149-1 thru -5, en
throat (Ref. Figure 404); keeper should sure Warning Plate P/N 13830-1 is at
permit easy entrance to hook throat. tached to the manual release side of the
cargo hook. If Warning Plate is not
installed, contact Breeze-Eastern for
(4). Pull aft and downward on load ring;
Warning Plate and installation instruc
hook must remain in locked position.
tions.
(5). Rotate external release knob located on (1). Make certain that neoprene pads (Ref.
left side of cargo hook body, while Figure 404) are securely bonded to skin.
pulling downward on load ring; hook Check pads for excessive wear.
(load beam) bar should drop and release
load ring. (2). Verify security of four bolts attaching
hook assembly to fuselage (Ref.
Figure 404); examine hook assembly for
(6). Reinsert load ring in hook throat. Pull
damage or excessive wear. Check that
CARGO HOOK EMERGENCY RE
hook body swivels freely in all direc
LEASE (manual release) lever on pilot's
tions.
cyclic stick while load ring is being
pulled downward; hook (load beam) (3). Verify security of clips and clamps
should release load ring. Reinsert load attaching electrical wire harness and
ring and move pilot's cyclic stick to all manual release cable housing to
extreme positions; CARGO HOOK fuselage (Ref. Figure 402).
EMERGENCY RELEASE lever must
not move from hook-engaged position (4). Verify presence and security of grom
and hook load beam must remain in met (Ref. Figure 401) through which
locked position. manual release cable passes at fuselage
skin.
(7). Press CARGO HOOK switch on pilot's (5). Check electrical wire harness for cuts,
cyclic stick grip (Ref. Figure 403) while wear, and skinned insulation.
load ring is being pulled downward;
hook load beam should release load (6). Examine manual release cable housing
ring. for nicks, cuts, kinks, dents, or general
Page 601
MAINTENANCE MANUAL
damage that would restrict movement NOTE: The 600N helicopters equipped with
of cable within housing. emergency floats require the manual re
lease handle to be mounted on the collective
4. Interior Components Inspection stick (Ref. Figure 406)
(1). Verify security of electrical receptacle (6). Verify security of clamps attaching
(J605) at fuselage connection (Ref. manual release cable housing to pilot's
Figure 401). cyclic stick (Ref. Figure 401); check for
damage to manual release cable
(2). Examine electrical wire harness for housing that might restrict movement
cuts, wear, or skinned insulation. of cable.
(3). Check manual release cable housing for (7). Check security of manual release lever
nicks, cuts, kinks, dents, or general attachment to pilot's cyclic stick (Ref.
damage that would restrict movement Figure 405).
of cable within housing. (8). Examine decals (Ref. Figure 403) for
secure attachment and legibility.
(4). Verify presence and security of grom
met where manual release cable passes (9). Examine cargo hook circuit wiring for
through pilot's floor (Ref. Figure 401). damage and/or loose connections.
(5). Check security of manual release cable (10). Verify secure installation of CARGO
housing adjustment nut; verify that HOOK circuit breaker and HOOK
release lever freely returns to hook-en RELEASE push-button switch (Ref.
gaged position (Ref. Figure 405). Figure 403).
Page 602
MAINTENANCE MANUAL
CARGO HOOK
1. Cargo Hook Initial Installation NOTE: Fuselage cutouts for left and right hand
command are as illustrated (Ref.
Procedures in this section can be done at the Figure 901). Use applicable dimensions ac
operator's discretion and are applicable to cording to the model helicopter being modi
369D/E/FF - 500N helicopters. These instruc fied.
tions provide for the installation of the cargo
hook assembly. (1). Make cutouts in three places as
illustrated (Ref. Figure 901).
A. Preparation for Installation
Preparation for installation of the cargo hook Consumable Materials

assembly includes the following: (Ref. Section 91−00−00)
Item Nomenclature
(1). Identify all components, including CM318 Primer
attaching hardware, or components to
be removed for access to work areas.
Protect components from damage and (2). Deburr cutouts and apply thin coat of
contamination until installed. primer (CM318) to exposed bare metal.
(2). Check that all electrical switches are in D. Cargo Hook Provisions Installation
OFF position.
(Ref. Figure 404) The following procedure
(3). Make certain BATT-OFF-EXT switch involves installation of the cargo hook provi
is in OFF position. sions exclusive of the cargo hook assembly kit.
To complete installation of the cargo hook
B. Helicopter Equipment Removal system, both cargo hook provisions, and the
cargo hook assembly kit installations must be
(Ref. Figure 404) Prior to installing the cargo accomplished. Hook provision equipment
hook, a limited number of items must be omitted in the following procedure is included
removed from the helicopter to accommodate in the cargo hook installation procedure.
cargo hook installation. Install cargo hook provisions as follows:
(1). Remove plug button from cargo switch

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

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

removed; use surface cleaner (Ref. Section 91−00−00)
(CM228). Item Nomenclature
(c). Bond neoprene pads to skin at CM614 Sleeving, heat-shrink
locations shown; use adhesive CM704 Tie strap, nylon
(CM418).
NOTE: The order and manner of installation

(2). Prime and touch-up border areas
for left or right hand command is the same.
around pads as follows: Refer to dimensions given in applicable fig
ures, for model of helicopter being modified.
(a). Wash affected area with solution of
mild soap and fresh water. Rinse (1). Make certain BATTERY switch is in
area with clean water and wipe dry OFF position.
with clean lint-free cloth. (2). Disconnect battery connector.
(b). Using swab, liberally apply chemical (3). Connect cargo hook switch to existing
film (CM206). wires according to stick grip and model
helicopter being modified. Insulate
wires and contacts on switch with
(c). Allow solution to remain on surface sleeving (CM614). Ref. Table 901 and
for 1 to 3 minutes, or until surface applicable wiring diagrams (Ref.
becomes amber to brown in color. Figure 101).
(4). Install switch guard on switch. Apply
NOTE: Avoid letting chemical mixture dry on
small amount of adhesive (CM404) to
surface. If it has dried, re-wet surface with
O.D. of switch.
solution.
(5). Install switch in grip. Allow minimum
(d). Rinse treated surface with clean cure time of 24 hours ±30 minutes.
water. After rinsing, wipe off excess
(6). Install relay on bracket with screws,
moisture with clean lint-free cloth.
Allow area to dry completely at room
temperature for 1 hour. Table 901. Cargo Hook Relay Installation
(e). Wipe surface clean with thinner and Relay Model Location Remarks
dry off immediately. K201 D 369A2519 Slim console
Bulkhead
(f). Apply primer (CM318) and allow to
dry for 30 minutes. K201 E/FF 369H2500 T−Panel
Bulkhead
(g). Apply lacquer to match original (7). Locate existing mounting holes accord
factory finish color. ing to model of helicopter being modi
fied. (Ref. Table 901 and Figure 902).
NOTE: Installation of the cargo hook manual Using relay bracket as a template,
release lever assembly and clamp assem mark and drill attachment hole(s)
blies is accomplished during installation of 0.165—0.177 inch (4.191—4.4958
the cargo hook kit. mm) in bulkhead as required.
Page 902
MAINTENANCE MANUAL
STA. 64.365
CREW COMPARTMENT
DOOR
10.00 LBL CHANNEL PILOT'S FLOOR
GROMMET
4.25 IN.
5.00 ±0.25 IN. (10.795 CM) PILOT'S FLOOR
(12.7 ±0.635 CM)
3.00 ±0.25 IN. 0.555-0.562 IN.
(7.62 ±0.625 CM) (14.0970-14.2748 MM)
HOLE
GROMMET
10.00 RBL
CLIP 0.555-0.562 IN. CHANNEL
0.88 IN. (14.0970-14.2748 MM) 0.88 IN.
(22.352 MM) HOLE (22.352 MM)
CREW COMPARTMENT FLOOR CUTOUT CREW COMPARTMENT FLOOR CUTOUT

(LEFT-HAND COMMAND) (RIGHT-HAND COMMAND)
LONGERON
GROMMET GROMMET
12.05 LBL
0.68 X 1.18 IN.
(17.272 X
STIFFENER 29.972 MM)
0.68 X 1.18 IN. (NOTE 1)
(17.272 X
29.972 MM) 0.890-0.901 IN.
(NOTE 1) (22.606-
12.05 RBL 22.8854 MM)
0.890-0.901 IN. (NOTE 2)
(22.606-
22.8854 MM)
(NOTE 2) STIFFENER
LONGERON
0.38 IN. DOUBLER 0.38 IN. DOUBLER
(9.652 MM) (9.652 MM)
DOUBLER INSTALLATION DOUBLER INSTALLATION

(LEFT-HAND COMMAND) (RIGHT-HAND COMMAND)
NOTES:
1. SLOT IN SKIN TO MATCH SLOT IN DOUBLER.
2. HOLE IN SKIN TO MATCH HOLE IN DOUBLER. G25-5006A
Figure 901. Fuselage Skin Cutouts
Page 903
MAINTENANCE MANUAL
(8). Attach relay bracket to bulkhead with manual release cables on the underside of the
screws, washers and nuts. Identify helicopter, routing and securing the manual
relay as indicated (Ref. Table 902), release cable, and installation and adjustment
using a suitable contrasting permanent of the manual release lever.
ink.
(1). Secure base of cargo hook assembly to
(9). On left hand command helicopters, fuselage underside with bolts and
remove edgelighted panel from lower washers (Ref. Figure 404).
switch and circuit breaker panel: loosen
lower circuit breaker panel. Remove (2). If installed, remove protective cap from
hole cover button; install circuit cargo hook electrical receptacle (J605);
breaker (CB603) (Ref. Figure 402). check that BATTERY switch is in OFF
position and connect plug (P605) to
(10). On right hand command helicopters receptacle.
with center electrical console, remove
edgelighted panel from circuit breaker (3). Insert free end of hook manual release
panel located on the pilot's collective cable through elongated hole adjacent
pitch stick cover; loosen circuit breaker to electrical receptacle; push manual
panel remove hole cover button; install release cable up into fuselage and
circuit breaker (Ref. Figure 402). insert cable through hole in pilot's floor
(11). On right or left hand command helicop (Ref. Figure 401).
ters with standard cyclic stick grip, (4). Install electrical harness and manual
install module and cover on TB3. release cable clamp (provision) clips
(12). Install cargo hook circuit wiring; see with rivets (Ref. Figure 402).
applicable wiring diagram (Ref.
Figure 101). For wire termination and (5). Loosely attach harness and cable
terminal hardware, refer to Table 102. clamps with screws, washers and nuts;
adjust harness and cable to allow
(13). Install cargo hook electrical connector sufficient slack for hook to swing 30
with washer and connector nut. Install degrees conically from centerline
protective cap on receptacle if cargo without creating strain on harness and
hook kit is not being installed concur cable. Arrange harness and cable to
rent with provisions. form smooth flow to cutouts in fuselage
skin; tighten clamps. Install tie straps
(14). Secure cargo hook circuit wiring with (CM704) approximately as shown (Ref.
tie-straps (CM704) as required. Check Figure 402).
that wires and terminals are not
stressed. (6). Loosely attach manual release cable to
cyclic stick with clamps, screws,
(15). Check all wiring for correct installation
(16). Connect battery connector. (7). Engage swaged ball on release cable in
lever bushing; secure bushing with
F. Cargo Hook Installation washer and cotter pin (Ref. Figure 405).
(8). Attach manual release lever assembly
to cyclic stick with clamp and screws;
adjust cable and/or release lever as
Item Nomenclature
shown (Ref. Figure 401).
CM429 Sealing compound, silicone
CM702 Lockwire CRES (9). Tighten three sets of clamps securing
CM704 Tie strap, nylon release cable to cyclic stick.
(10). Check that hook does not release when
The cargo hook installation consists of cyclic stick is moved to extremes in all
attaching the hook and emergency electrical/ directions.
Page 904
MAINTENANCE MANUAL
SCREW 2.25-2.50 IN.

(5.715-6.35 CM)
NUT
0.25 IN.
(6.35 MM)
RELAY
0.165-0.177 IN.
(4.191-4.4958 MM)
HOLE
WASHER SCREW
WASHER
SCREW
WASHER
NUT WASHER
NUT WASHER
SCREW
2.03 IN.
(5.1562 CM) RELAY
STA. 44.65
K312 RELAY INSTALLATION
WASHER (369E/FF - 500N)
NUT
K104 RELAY INSTALLATION
(369D)
EXISTING
HOLES
WL 10.00
BL 10.00
G25−5007A
Figure 902. Relay and Bracket Installation Pilots Floor (369D/E/FF)
Page 905
MAINTENANCE MANUAL
(11). Pull manual release lever; check that (16). Install HOOK RELEASE decal on left
hook load beam opens. Repeat opera or right hand cyclic stick grip (Ref.
tion several times to ensure proper Figure 403).
release of hook.
(17). Install CARGO HOOK EMERGENCY
(12). Re-adjust cable/lever as required to RELEASE decal on cyclic stick (Ref.
obtain smooth consistent release of Figure 405).
hook. (18). Install EXTERNAL LOAD LIMIT 2000
POUNDS decal (Ref. Figure 404).
NOTE: The manual release lever clamp can be
loosened and the lever assembly moved on Table 902. VNE Card Installation
cyclic stick to simplify adjustment, provid
ing the 2.00—2.50 inch (5.085—6.350 cm) Part Number Model Effectivity
dimension limit is maintained (Ref.
369D29571 D 003 − 523
Figure 405).
−17, −19
(13). Install grommet in crew compartment −21, −23 D/E D 524 & Subs
floor cutout (Ref. Figure 401). Fill any E 001 & Subs
voids between grommet and cable. Use
sealant (CM429). 369D292588 FF 001 & Subs
(14). Install grommet in elongated hole in (19). Replace VNE card on instrument panel
fuselage lower skin and doubler (Ref. as applicable (Ref. to Table 903).
Figure 402). Fill any voids between
grommet and manual release cable. Use G. Helicopter Equipment Installation
sealant (CM429). Reinstall equipment initially removed in
reverse order of removal.
(15). Safety manual release lever clamp
screws with lockwire (CM702), (Ref. NOTE: At completion of installation, do the an
Figure 405). operational check of cargo hook installation.
Table 903. Cargo Hook Switch Installations − Stick Grip

Part Number Model Remarks
369H90153−BSC D/E/FF For models equipped with emergency floats, left or right hand
command (Ref. Figure 403).
−3 D/E/FF For models equipped with hoist, left or right hand command
(Ref. Figure 403).
369D27133 D/E/FF Standard grip, left hand command (Ref. Figure 403).
369D297846−BSC D Center electrical console, ‘‘T’’ grip right hand command (Ref.
Figure 403).
−3 D Center electrical console, ‘‘T’’ grip right hand command (Ref.

Figure 403).
369H92805 D Center electrical console, ‘‘T’’ grip right hand command (Ref.
Figure 403).
Page 906
MAINTENANCE MANUAL
H. Weight and Balance Data Table 904. After installation of the cargo hook
Weight and balance changes resulting from incorporate changes in helicopter weight and
installation of the cargo hook are listed in balance record as instructed.

Weight Arm Moment
Added +6.3 (+2.858) +87.0 (+220.98) +548.1 (+631.48)
Page 907
MAINTENANCE MANUAL
Page 908
MAINTENANCE MANUAL
Section
25−60−00
Emergency First Aid
Kit
MAINTENANCE MANUAL
EMERGENCY FIRST AID KIT

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

velcro tape mount by a firm pull on the 5000 East McDowell Road,
handle. The case is opened by off-set Mesa, AZ 85205,
ting the snap fastener. Att: New Parts Sales.
Page 201
MAINTENANCE MANUAL
G25−6010
Figure 201. Emergency First Aid Kit
Page 202
MAINTENANCE MANUAL
Section
25−63−00
Hoist
Passenger/Cargo
MAINTENANCE MANUAL
HOIST PASSENGER/CARGO
1. Hoist Passenger/Cargo mounted on a support tube attached
with quick-release pins to three fittings
(Ref. Figure 201) located on the exterior of the fuselage
on either side and above the passenger/
cargo door. The support tube positions
(1). The hoist configuration is installed on
the winch to allow raising and lowering
the right side of L/H command helicop
the cable between the side of the
ters. The configuration for R/H com
fuselage and landing gear skid. Two
mand is identical except that the hoist
modified mounting brackets are used to
is installed on the opposite (left) side of
accommodate installation of the winch
the helicopter. The passenger/cargo
on the support tube. The winch incorpo
hoist assembly consists of an electrical
rates a disc-type brake, housed on the
ly-operated winch mounted on a
end of the hoist drum, which consists of
support tube, a hoist operator's safety
spring-loaded friction plates and an
harness, a passenger door (hold open)
actuating solenoid. The solenoid is
retainer assembly, a passenger door sill
energized to release the brake at the
antichafing bar assembly, a control
same time the motor is energized. Once
pendant, and associated electrical
the control pendant switch is released
equipment. The hoist provides a means
to the off position, the brake solenoid is
for lifting and lowering personnel or
deenergized and the brake sets,
objects weighing up to 300 pounds (136
preventing any possibility of uncon
kg). The hoist system employs light
trolled cable payout. Cable up (full-in)
weight, readily-attachable and -de
and down (full out) limit switches are
tachable exterior-mounted equipment
incorporated in the winch brake
without using passenger or cargo space
system. When either limit switch is in
in the helicopter. For safety purposes, a
the closed position, the brake solenoid
guillotine-type cable cutting device is
is energized, releasing the brake discs
incorporated in the hoist winch assem
and allowing the winch drum to rotate.
bly. The hoist function is identical when
Conversely, when either limit switch is
operated from either side of the helicop
in the open position the brake solenoid
ter.
is deenergized and the winch brake
automatically sets and stops the winch.
NOTE: When the hoist is installed on L/H com
mand helicopters equipped with emergency
floats, the floats must be in a stowed condi (3). (Ref. Figure 203) The passenger/cargo
tion during hoisting operations. Emergency door retainer assembly consists of a
floats must be removed from R/H command tubular housing attached with four
before conducting hoisting operations. clamps securing the housing horizontal
ly across the canted bulkhead in the
(2). (Ref. Figure 202) The weatherproof passenger/cargo compartment. With the
winch consists of a 28 Vdc motor that passenger/cargo door in full open
drives a cable drum to which a 110 foot position, a smaller tube stowed inside
(33.5 M) stainless steel cable with a the tubular housing extends in a
swivel hook is attached. The winch is telescoping effect and engages a bracket
equipped with an automatic brake located on the outboard frame of the
system; up (full-in) and down (full out) door, thus retaining the door in an open
limit stop switches; and an explosive, position. The telescoping tube can be
electrically-activated guillotine-type used in either end of the tubular
cable cutter for cutting the cable in an housing to hold the left or right passen
emergency. The hoist assembly is ger/cargo door open as required.
Page 201
MAINTENANCE MANUAL
HOIST
PWR CTR
CYCLIC
STICK
GRIP
LEFT-HAND COMMAND HELICOPTERS

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

HOIST CABLE ANTI-CHAFING BAR CICUIT BREAKER PANELS
G25-6001-1
Figure 201. Hoist System Components (Sheet 1 of 3)
Page 202
MAINTENANCE MANUAL
WINCH
HANGER
FWD BRACKET AFT BRACKET
WINCH SUPPORT
TUBE
HOOK
BEARING PIN FITTING
LINK ASSY
FITTING
ELECTRICAL PLUG
HOIST SUPPORT AND ATTACHMENTS

(ROTATED)
FITTING
SAFETY PIN
CABLE ANTI-SNAG PROVISIONS

(ROTATED)
G25−6001−2
Page 203
MAINTENANCE MANUAL
WINCH CONTROL
SWITCH
UP
PENDANT
DOWN
UP
CABLE CUTTER
SWITCH
DOWN
WARNING
CONTROL PENDANT CABLE CUTTER
SWITCH ACCESS DOOR ASSEMBLY HOIST CABLE
CUTTER
SWITCH
UNDER COVER
PROTECTIVE CAP
RECEPTACLE
(XJ2)
NUT
PENDANT CONTROL CONNECTOR

WASHER
RECEPTACLE
(J28)
ELECTRICAL GROUNDING STUD HOIST CONNECTOR

(TYP)
G25-6001-3
Page 204
MAINTENANCE MANUAL
(4). (Ref. Figure 201) An antichafing bar, 2. Preparation for Hoisting Operations
installed just below the passenger/cargo
door sill, prevents the hoist cable from To avoid inadvertent firing of
CAUTION cable cutter, ensure cable cutter
cutting the door frame during hoisting
operations. A hoist operator's safety electrical circuits are not energized.
harness. provided with the hoist, is
connected to the seat belt anchor fitting (1). Connect external electrical power to
on the side of the passenger/cargo helicopter.
compartment opposite the side where
the hoist is installed. (2). Place BATTERY switch in EXT posi
tion.
(5). The hoist system electrical equipment (3). Open passenger/cargo door; extend and
secure door (hold-open) retainer tube.
consists of a hand held electrical
pendant control for use in the passen
(4). Using hoist system control pendant,
ger/cargo or crew compartments to exercise winch by paying out 3 or 4 feet
operate the winch, an emergency cable of cable under approximately 15 pounds
cutter switch on the pilot's cyclic stick, (6.8 kg) tension, pulling cable straight
circuit breaker equipment, and asso down to avoid rubbing cable on cable
ciated electrical wiring. The pendant bellmouth. Reverse control and reel
control contains a three position switch, cable in. Check that cable winds on
spring loaded to the off position, for winch drum evenly and that winch
raising and lowering the swivel hook, operation is smooth and consistent.
and a guarded switch for cutting the Make certain winch stops automatically
cable at the winch in an emergency. The when top of swivel hook pushes against
pilot's cyclic stick cable cutter switch winch bumper pad.
allows the pilot to cut the hoist cable
independent of the pendant control. The (5). If installed, remove cable cutter jumper
circuit breakers are mounted on the wire (Ref. Figure 202).
lower switch and circuit breaker panel
in L/H command, and on the circuit Cable cutter jumper wire
breaker panel located aft of the pilot's WARNING must be removed to allow
collective stick on R/H command. The cable cutter electrical circuit to be
cable cutter circuits are independently completed by switch control, providing
protected by a separate lower-amper instantaneous in-flight cable cutting
age circuit breaker located adjacent to capability should such emergency ac
the hoist power circuit breaker. Electri tion be required.
cal wiring, plugs, receptacles, and
(6). If winch has not been used for an
terminals interconnect the various
extended period of time, or if cable has
electrical components.
been replaced, do an operational check
(Ref. Hoist System Operational Check).
(6). Differences in hoist installations and (7). Check that winch support tube attach
electrical circuitry for L/H and R/H safety pins are secure and fully seated.
command is described in subsequent
text and illustrations. Refer to man (8). Check that winch electrical connector
ufacturer's publications (Ref. Section plug is secure on receptacle on side of
01-00-00, Table 201, BL-16600 Series fuselage.
300 Lb Capacity Hoist Operating
lnstructions - Hoist Winch Assembly, (9). Connect hoist system operator's safety
Breeze Corporation, Inc)) for additional harness to seat belt fitting on opposite
hoist, hook, cable, and parts informa side of passenger/cargo compartment
tion. from where winch is installed.
Page 205
MAINTENANCE MANUAL
WINCH
HOIST SUPPORT
TUBE
DOUBLE HELICAL
SCREW SHAFT CABLE GUIDE
ASSEMBLY
IDLER GUIDE
ROLLER
TRACTION ROLLER TORQUE NUT TO

70 - 100 INCH-POUNDS
(7.91 - 11.30 NM)
PRESSURE ROLLER
ALLEN HEAD SET SCREW

INDENT
FILL-IN (UP)
LIMIT SWITCH
CABLE CUTTER
(GUILLOTINE)
BELLMOUTH
BUMPER RING
PROTECTIVE
ELECTRICAL
JUMPER
(REF. RUBBER BUMPER
WARNING) PAD
WARNING: REMOVE JUMPER WIRE AFTER

1/8 IN. (3.175 MM) SYSTEM INSTALLATION OR MAINTENANCE
DIA. CABLE (REFER TO TEXT)
POSITIVE WIRE (BLACK,
GROUND WIRE GREEN, OR WHITE/GREEN) CAUTION: CONNECT POSITIVE WIRE ONLY
(WHITE, BLUE (REF. CAUTION) CABLE CUTTER (BLACK, GREEN, OR WHITE/GREEN) TO
OR WHITE/BLUE) REPLACEMENT POSITIVE (+) POST OF CABLE CUTTER.
ELECTRICAL
WIRING
G25-6002-1A
Figure 202. Winch Cable, Cable Cutter, and Swivel Hook Replacement (Sheet 1 of 2)
Page 206
MAINTENANCE MANUAL
RUBBER BUMPER
KEYWAY HOOK HOUSING

CABLE
SWIVEL HOOK
SWAGED BALL SOCKET

END FITTING
SAFETY KEEPER
CABLE-TO-HOOK
ATTACHMENT
ROLLER WHEEL TOP COVER

FIRST DRUM GROOVE
FULL-OUT (DOWN
CABLE END LIMIT SWITCH)
(NOTE 1)
ALLEN HEAD SETSCREW

NUT, WASHER
(4 PL) (NOTE 1)
HOOK HANGER
(NOTE 2)
CABLE WINDING
(ON DRUM) DRUM
CABLE DRUM FLANGE
CABLE GUIDE ASSEMBLY

DRUM CABLE END
ANCHOR HOLE
CABLE-TO-DRUM
ATTACHMENT
NOTES:
1. EXCESSIVE TIGHTENING MAY AFFECT
FULL-OUT SWITCH SETTING.
2. USED FOR HOOK STOWAGE. G25-6002-2
Figure 202. Winch Cable, Cable Cutter, and Swivel Hook Replacement (Sheet 2 of 2)
Page 207
MAINTENANCE MANUAL
(10). Place BATTERY switch in OFF posi NOTE: If support tube fittings are to be re
tion. moved from fuselage, make certain nylon
screws are installed in attachment holes.
(11). Remove external electrical power from
helicopter. (8). Remove bolts securing winch to support
tube brackets.
3. Hoist System Troubleshooting
B. Hoist Assembly Installation
(Ref. Table 201) Wiring diagrams are provided
for the hoist systems used on L/H command Consumable Materials
(Ref. Figure 204) and R/H command helicop (Ref. Section 91−00−00)
ters (Ref. Figure 205). A schematic diagram of Item Nomenclature
the winch is also provided (Ref. Figure 206).
CM703 Tie strap
(Ref. Chap. 96 for interfacing schematics and
wiring diagrams)
NOTE: If support tube fittings (Ref.
Figure 201) were removed from fuselage, re
4. Cyclic Stick Grip and Cyclic Stick Cable move nylon screws installed in support fit
Cutter Switch (S600) Replacement ting attachment holes on fuselage.
(Ref. Section 67-10-20) (1). If required, install winch support tube
attach fittings on fuselage using screws
5. Hoist Assembly Replacement and washers.
A. Hoist Assembly Removal (2). Attach winch to support tube using

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

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

(ROTATED)
DOUBLER ANGLE
STRUCTURAL
CLAMP REINFORCEMENT
BRACKET
CLAMP
RIGHT INBOARD
TUBE CLAMP RIGHT OUTBOARD
TUBE CLAMP
G25-6003
Figure 203. Passenger/Cargo Door Retainer Installation
Page 209
MAINTENANCE MANUAL
6. Winch Components Replacement (c). Continue unwinding cable until down

(full-out) limit switch (Ref.
A. Winch Cable Replacement Figure 202) activates (opens) and
allows brake to engage, thus stopping
(Ref. Replacement of the winch cable (Ref. cable payout.
Figure 202) is required if cable is damaged, NOTE: Three turns of cable will remain on
worn excessively, or cable cutter has been fired winch drum when down limit switch opens.
(Ref. Hoist Equipment Inspection for inspec
tion requirements and for cable replacement (d). Remove winch cable drum cover.
criteria). (e). Manually raise roller wheel, at top
right rear of winch drum, to close the
(1). Install hoist and support on helicopter down limit switch (release brake) and
(Ref. Hoist Assembly Installation). allow remaining cable to be reeled off
cable drum.
When electrical power is pres (f). Using control pendant, finish un
CAUTION ent, make certain cable cutter winding cable. Stop winch when
electrical circuits remain deenergized to cable is fully unwound from drum.
eliminate the possibility of inadvertent ac
tuation of cable cutter. To avoid possibility of (5). Remove winch cable from drum as
cutting cable, install jumper wire between follows:
cable cutter electrical terminals. (a). Loosen Allen head setscrew securing
cable end in drum anchor hole.
NOTE: An external power source should be Remove cable end from winch by
connected to the helicopter to prevent exces pulling cable down through cable
sive battery discharge. Hoist uses up to 40 guide, cable cutter, and bumper
amperes electrical current during operation. guide.
Anchor hole setscrew should be
(2). Connect external electrical power CAUTION temporarily tightened to pre
source to helicopter. vent fouling winch mechanism if winch is
inadvertently operated.
(3). Place BATTERY switch in EXT posi
(b). Retighten setscrew in anchor hole.
tion.
(6). Remove swivel hook from cable (Ref.
(4). Using hoist pendant control (Ref. Swivel Hook Replacement).
Figure 201), reel off all cable from NOTE: Replacement cable must be 0.125 inch
winch drum as follows: (3.175 mm) diameter stainless steel, 19 by 7
cable strand, extra strength, antispin cable
NOTE: Two persons can facilitate cable remov with a minimum breaking strength of 1800
al; one person to operate winch and a second pounds. Make certain any replacement
person to handle and coil cable. cable, other than cable supplied by winch
manufacturer, is approximately 113 feet
(a). Operate winch and start reeling cable (34.442 M) long, is equipped with a swaged
off winch drum. ball fitting, and is proof-tested to a mini
mum load of 1850 pounds (840 kg).
To prevent bellmouth wear,
CAUTION cable should not be pulled
(7). Install swivel hook on replacement
cable (Ref. Swivel Hook Replacement).
against side of bellmouth on cable guide.
(8). Attach new replacement cable to winch
(b). As cable unwinds, maintain straight as follows:
downward tension, approximately 15 (a). Insert free end of replacement cable
pounds (6.8 kg); lay or coil cable in a up through bumper pad guide center,
clean clear area. Position cable so bellmouth, switch, cable cutter, and
that cable will not kink or tangle, to between cable rollers in the cable
facilitate rewinding. guide assembly (Ref. Figure 202).
Page 210
MAINTENANCE MANUAL
(b). Ensure cable guide assembly is NOTE: The up limit switch should actuate be
centered and aligned with first fore excessive cable pressure is applied to
groove on double helical screw shaft. vertically compress bumper pad. Permanent
Facing cable guide mechanism, check damage can result if rubber bumper pad is
that guide will travel from right to stowed in a compressed state over an ex
left when winding cable on drum. tended period of time; rubber bumper will
remain in a compressed (set) state.
(c). Secure cable to drum by loosening set (d). Install cover on winch.
screw and inserting cable end into
drum cable anchor hole until cable (10). Do an operational check of hoist system
end bottoms, approximately 3/8 inch (Ref. Hoist System Operational Check).
(9.525 mm); tighten setscrew. B. Swivel Hook Replacement
(d). Check that replacement cable is (Ref. Figure 202)

positioned in first drum groove at
right when facing cable guide mecha Consumable Materials
nism. (Ref. Section 91−00−00)
Item Nomenclature
(9). Operate hoist and wind replacement CM114 Petrolatum
cable on winch as follows:
(1). Remove swivel hook assembly from
(a). Deactivate down limit switch by cable as follows:
manually raising teflon roller wheel (a). Remove rubber bumper covering
at top right rear of winch drum; use swivel hook housing by pulling
control pendant to wind replacement bumper upward off top of hook
cable on winch. Release the down housing.
limit switch after three turns of cable
are on drum. (b). Remove cable swaged ball end fitting
from hook housing socket: pull cable
(b). Maintain sufficient tension, approxi swaged ball fitting through rubber
mately 15 pounds (6.8 kg) on cable bumper.
while winding cable on drum; check (2). Install swivel hook on cable as follows:
that cable winds straight, smooth,
and snug, without kinking against (a). Lubricate cable swaged ball end
cable windings on drum. Avoid cable fitting with petrolatum (CM114).
rubbing on side of bellmouth during
cable winding. (b). Insert cable through top of rubber
bumper.
(c). Continue winding operation until (c). Insert cable ball fitting in hook
entire cable is wound on drum: check housing keyway and socket.
that winch stops automatically when Ensure hook rubber bumper
top of swivel hook pushes against CAUTION completely covers hook housing.
winch rubber bumper pad. (Bumper
pad upward movement actuates (d). Secure cable ball fitting in housing
(opens) full-in (up) limit switch at socket by sliding rubber bumper
cable guide base. down over hook housing.
Page 211
MAINTENANCE MANUAL
NOTE: Hook rubber bumper should completely Setscrew mates with indent on cable
cover housing, and bumper base will overlap cutter.
inward around housing base by approxi
mately 1/16 inch when fully seated on hous (6). Connect one electrical terminal lug to
ing. cable cutter terminal, leaving protective
short-circuiting jumper installed on
C. Cable Cutter Replacement cable cutter. Then connect second wire
(Guillotine−Type) to remaining cable cutter terminal in
the same way.
(Ref. Figure 202)
Protective jumper wire should
CAUTION remain connected to cable cutter
electrical terminals until hoist is to be used.
Item Nomenclature (7). Cover exposed electrical terminal areas
CM425 Sealing compound with sealing compound (CM425).
7. Hoist System Operational Check
Cable must be removed from winch (Ref.
Winch Cable Replacement) before guillotine- The following procedure is used to verify the
type cable cutter can be replaced. Replace a capability of the hoist system to function
spent cable cutter guillotine on winch as correctly. The procedure should be done any
follows: time a malfunction is suspected, and prior to
normal use after repair.
The cable cutter contains an
WARNING explosive squib that is elec Remove protective electri
WARNING cal jumper wire (Ref.
trically fired. A protective short-cir
cuiting electrical jumper should re Figure 202) from cable cutter whenev
main connected to cable cutter, not er winch is installed on helicopter.
installed on the winch, to eliminate Jumper wire will prevent operation of
possibility of inadvertent accidental cable cutter in an in-flight emergency.
firing. (1). Open applicable passenger/cargo door;
(1). Disconnect two electrical wire terminal extend door retainer tube to hold door
lugs from spent cable cutter. in full open position.
Avoid inadvertent operation of
(2). Loosen two Allen head setscrews at side CAUTION cable cutter. Make certain cable
of movable cable guide and remove
cutter switches are not actuated when hoist
spent cable cutter from guide.
system circuits are energized.
(3). Check that all electrical power is OFF.
(2). Energize helicopter electrical system;
Do not use an ohmmeter or check that both HOIST PWR (power)
WARNING any other device containing and CBL CTR (cable cutter) circuit
an internal voltage source which could breakers are in closed position (Ref.
fire cable cutter. Figure 201).
(4). Using a voltmeter, check for zero (3). Using hoist system control pendant,
voltage between electrical wiring exercise hoist winch by paying out 3 to
terminal lugs; also check for zero 4 feet (1.2 M) of cable under approxi
current between lugs with a milliamme mately 15 pounds (6.8 kg) tension; pull
ter. cable straight down to avoid cable
rubbing on cable bellmouth. Reverse
(5). Insert cylindrical end of new cable control and reel cable in. Check that
cutter into winch movable cable guide, cable winds on winch drum evenly and
with shorting jumper positioned that winch operation is smooth and
downward, and secure cable cutter to consistent. Check that winch stops
guide with two Allen head setscrews. automatically when top of swivel hook
Page 212
MAINTENANCE MANUAL
rubber bumper pushes against winch (6). Stow door retainer tube; close passen
bumper pad. ger/cargo door.
(4). Test hoist lifting capability with 300 8. Hoist Equipment Inspection
pound weight. Check that hoist oper
ates smoothly throughout hoisting and General inspection procedure for the hoist
lowering operations. system is as follows:
NOTE: Cable retraction rate should be approxi (1). Inspect components for security of
mately 55—60 feet (16.8—18.3 M) per attachment, damage, deformation,
minute. The full usable cable length should cracks, and excessive wear.
unwind in approximately 95 seconds and re
wind in approximately 103 seconds.
WARNING
(a). With helicopter hovering approxi
mately 100 feet (45.4 M) above test D Human life might depend on cable
weight, lower hoist hook between condition. Inspect full length of cable
fuselage and landing gear skid. carefully and thoroughly.
Continue lowering hook until hook D Use heavy leather gloves to protect
can be connected to test weight. hands from injury due to broken
cable strands.
(b). Gradually maneuver helicopter to
remove cable slack and to center Keep cable clean. Provide a
hoist over test weight. CAUTION clean area to coil cable during
inspection. Dirt and oil grime will create an
(c). Slowly elevate helicopter to raise test
abrasive wear on cable and winch compo
weight approximately 20 feet (6.1 M)
nents.
from ground.
(d). Using pendant control, payout full (2). Inspect cable for fraying, corrosion,
usable length of cable. Check that broken strands, and security of attach
hoist down limit switch stops winch ment to winch drum and cable ball
with three turns of cable on winch swivel hook attachment. General
drum. If required, adjust position at criteria for cable replacement are as
which down limit switch activates. follows:
(e). Reverse pendant control. Lift test (a). Any single broken strand (cluster of 7
weight to within approximately 10 individual wires) requires cable
feet (3.0 M) of helicopter skid. replacement.
(f). Lower helicopter and remove hoist (b). Both ends of individual broken wires
hook from test weight; raise hoist should be tucked into cable to
hook and check that hoist winch prevent fouling when cable travels
automatically stops when top of through cable guides and nonfouling
swivel hook rubber bumper pushes mechanisms. Breaks of individual
up against hoist bumper pad. wires are allowable, unless the
number is excessive as defined in
NOTE: Up limit switch should actuate before next criterion.
excessive cable pressure is applied to verti
cally compress bumper pad (Ref. (c). Generally, one individual broken wire
Figure 202). (two ends) for each foot of cable is
permissible, up to a total of 20
(g). Land helicopter; deenergize electrical individual wire breaks for each 100
system. foot (30.5 M) length of cable. A
greater number of breaks requires
(5). Stow pendant control. cable replacement.
Page 213
MAINTENANCE MANUAL
Table 201. Troubleshooting Hoist System

Winch will not raise or lower cable. Tripped circuit breaker. Reset circuit breaker.
Defective pendant control. Repair pendant control.
Defective winch assembly. Repair winch assembly.
Improper lower cable travel limit. Down (full−out) limit switch out of Reset lower limit adjustment.
adjustment.
Figure 204. Wiring Diagram − Hoist System (L/H Command)
Page 214
MAINTENANCE MANUAL
Figure 205. Wiring Diagram − Hoist System (R/H Command)
Page 215
MAINTENANCE MANUAL
P28 FULL-IN
(NOTE) LIMIT SWITCHES
F AWG 20 ORG OR WHT/ORG BRAKE
UP DOWN
G AWG 12 WHT
C AWG 12 RED OR WHT/RED

DOWN UP
MOTOR
FULL-OUT
LIMIT SWITCH
E AWG 20 YEL OR WHT/YEL

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

B
NOTE: REFER TO HOIST SYSTEM INTERCONNECT WIRING

DIAGRAMS (REF CHAP. 96) FOR EXTERNAL CONNECTION.
WARNING: REMOVE JUMPER WIRE AFTER INSTALLATION
OR MAINTENANCE (REF. TEXT).
G25-6005
Figure 206. Schematic Diagram − Hoist System Winch
Page 216
MAINTENANCE MANUAL
HOIST PASSENGER/CARGO
1. Hoist Passenger/Cargo Initial Installation (2). Remove left and right foot support
fairings in passenger/cargo compart
The passenger/cargo hoist can be installed on ment.
any L/H command or R/H command Model
369D helicopter. On L/H command, the hoist (3). Remove passenger/cargo compartment
winch is installed on the right side of the forward bulkhead trim panel (L/H
fuselage. On R/H command, the hoist winch is command) and controls access door.
installed on the left side of the fuselage. (4). Remove fuel cell forward vent from
Subsequent procedures provide separate control tunnel (Ref. Section 28-00-00).
instructions for electrical installations in L/H
command and R/H command to accommodate NOTE: Fuel vent must be removed to avoid
differences in component location and wire damage during structural modification hole
routing. drilling operations.
Installation instructions include procedures for (5). Remove crew compartment seat and
installing a passenger/cargo door retainer back cushions.
assembly, a door sill antichafing bar assembly, (6). Remove left (outboard) collective stick
a winch and winch support tube assembly, and cover.
the electrical wiring and components required
for operation of the hoist system. (7). Remove crew compartment lower aft
trim panels (left and right).
The hoist passenger/cargo installations can be
done at the discretion of the operator, or the (8). Remove crew compartment left or right
helicopter can be returned to the factory for bulkhead panel and lower portion of
modification. The instructions which follow are right upper side panel.
for the 369H90070-521 and -522 installations (9). Remove edgelighted panel face from
only. lower switch and circuit breaker panel
(Ref. Chapter 96). Loosen lower switch
A. Preparation for Installation and circuit breaker panel to accommo
Instructions in the following paragraphs are date installation of additional circuit
applicable to both left and right hoist installa breakers.
tions, except as noted. C. Helicopter Modification
(1). Identify all components that are to be (Ref. Figure 901) Modification of the helicopter
installed, along with those removed to involves cutting a hole in the fuselage skin to
gain access to work areas. Protect facilitate installation of an electrical receptacle
components from damage and contami (J28) to receive a winch electrical plug, and a
nation. hole in the lower left area of the canted
bulkhead and forward bulkhead trim panel to
(2). Check that all electrical switches are in facilitate installation of an electrical receptacle
OFF position. (XJ2) to receive a control pendant plug.
Ensure BATTERY switch is in
CAUTION OFF position. Consumable Materials
B. Helicopter Equipment Removal Item Nomenclature
CM318 Primer
Remove following panels, access doors, and
equipment as applicable to accommodate
installation of the hoist system components: (1). Cut and deburr holes, remove chips,
and apply a thin coat of primer
(1). Remove battery (Ref. Chapter 96). (CM318) to exposed metal surfaces.
Page 901
MAINTENANCE MANUAL
(2). Fit forward bulkhead trim panel to (Ref. Figure 201) and receptacle nut
canted bulkhead; locate and cut hole in externally to retain J28 receptacle in
trim panel to match XJ2 receptacle hole place.
in bulkhead. Remove trim panel to
accommodate installation of door NOTE: The J28 receptacle is temporarily in
retainer assembly. stalled to provide a means of determining
wire length to receptacle.
NOTE: Hoist electrical connector (J28) doubler
is located in the crew compartment, below (3). Install circuit breakers in positions
the aft lower corner of the upper canopy CB60l and CB600 respectively, on
windshield, and immediately forward of the lower switch and circuit breaker panel
canted frame (Sta. 78.50) for either right (Ref. View A).
side (L/H command) or left side (R/H com
mand) hoist winch installation.
(4). (Ref. Figure 204) Install terminal on
circuit breaker jumper wire; install
D. Electrical Equipment Installation (L/H jumper wire on contact 1 of CB60l.
Command)
(5). Install terminal on wire P506AH12 and
Install hoist kit electrical wire harness install on contact 1 of CB600 together
assembly, general wiring, and components on with jumper wire fabricated in previous
L/H command as follows: step. Route wire P506AH12 to contact 7
of BUSS W3; cut wire to length and
Consumable Materials install terminal. Connect wire
(Ref. Section 91−00−00) P506AH12 to contact 7 of BUSS W3.
Item Nomenclature
(6). Install terminal on wire M535A12 and
CM614 Sleeving, heat-shrink
connect wire to contact 1 of TB10.
CM703 Tie strap Route wire M535A12 to contact 2 of
CM807 Twine, nylon CB600 and install terminal. Connect
CM815 Solder wire M535A12 to contact 2 of CB600.
(7). Install terminal on wire M503B20 and

Ensure wires and/or wire connect to contact 2 of CB601. Route
CAUTION bundles do not chafe or bind opposite end of wire M503B20 to
control mechanisms. TB1-16, install pin and insert pin in
TB1-16, contact A.
NOTE: When providing ground contact for elec
trical components, clean the contacting sur (8). Connect terminal of wire A526A12 to
faces to bare metal (Ref. Chapter 96). Route TB10, contact 1, and route wire below
wire and wire bundles with existing wires floor through center beam, below crew
and bundles. Temporarily tie wires in place compartment right seat and up right
with existing bundles until installation is side aft of door frame to J28 receptacle.
complete, then secure wires with nylon
twine (CM807), tie-straps (CM703), or NOTE: Temporarily tie wires in place. Do not
clamps as required. cut wires until all wires are adjusted and
tied in place.
(1). Install cyclic stick grip (Ref. Figure 201
and Section 67-10-20). (9). Insert pin of wire CC10A20 in TB1-16,
contact C. Connect terminal on shield
(2). From inside crew compartment, ing of wire CC10A20 to ground stud
temporarily install J28 receptacle E24. Do not tighten ground stud nut.
through hole provided in right side of Route wire CC10A20 to J28 receptacle
ship (Ref. Figure 901). Install washer and tie in place.
Page 902
MAINTENANCE MANUAL
CUT HOLE IN SKIN TO

MATCH HOLE IN DOUBLER
HOIST ELECTRICAL
CONNECTOR DOUBLER
UPPER CANOPY
WINDSHIELD
E19
CREW COMPARTMENT
RIGHT DOOR FRAME NOTE: LH COMMAND VERSION SHOWN. RH
COMMAND VERSION IS INSTALLED AT SAME
LOCATION OR LEFT SIDE OF HELICOPTER.
LH COMMAND HELICOPTER
CONFIGURATION, CUT
1.00 IN. (2.54 CM) HOLE IN SKIN
WINCH ELECTRICAL RECEPTACLE
(J28) CUTOUT LOCATION
(NOTE)
WL 21.50
2.00 IN.
XJ2 (5.08 CM)
0.970 IN.
(24.638 MM)
(TYP)
2.00 IN.
(5.08 CM)
2.00 IN.
(5.08 CM)
1.50 IN.
XJ2 (3.81 CM)
0.970 IN.
(24.638 MM)
(TYP)
RH COMMAND HELICOPTER
CONFIGURATION, CUT
VIEW LOOKING FORWARD, LOWER LEFT 1.00 IN. (2.54 CM) HOLE IN SKIN
CORNER OF CANTED BULKHEAD STA. 78.50
0.121-0.135 IN.
PENDANT CONTROL ELECTRICAL (3.0734-3.429 MM)
RECEPTACLE - CUTOUT LOCATION HOLE (4 PL) G25−6006A
Figure 901. Helicopter Modification
Page 903
MAINTENANCE MANUAL
(10). Install XJ2 receptacle. A527H20N, A527J20N, CCl0A20,

CC8A20, and CC9A20 to J28 receptacle
(a). Insert XJ2 receptacle (Ref.
contacts as indicated (Ref. Figure 203).
Figure 201) in hole provided in lower
left corner of canted bulkhead (Ref. (15). Install J28 receptacle and secure with
Figure 901). Using XJ2 receptacle washer and nut. Install protective cap
bracket as a template, mark and drill (Ref. Figure 201).
four 0.121—0.133 inch
(3.0734—3.3782 mm) attach holes. (16). Install ground stud on forward side of
Protect attached wires during drilling canted bulkhead frame (Ref.
operation. Figure 901). Identify ground stud as
E19.
(b). Install XJ2 receptacle (Ref.
Figure 201) from forward side of (17). Install wires A527G12N, A527H20N,
canted bulkhead, with screws, and A527J20N, from J28 receptacle, on
washers, and nuts. ground stud E19. Adjust and trim
(11). Route wires CC1AA20 and CC2AA20 insulation tubing (CM614) to accommo
(Ref. Figure 203) from XJ2 receptacle date ground wire connection as re
to TB1-16; install pin of wire CC1AA20 quired; heat shrink tubing.
in contact B and pin of wire CC2AA20 (18). Replace existing cyclic stick grip with
in contact D. Connect terminal on part number 369H90129-505 (Ref.
shielding of wire CC2AA20 to ground Section 67-10-20). Wire cyclic stick
stud E24; tighten ground stud nut. cable cutter switch S600 as shown (Ref.
(12). Route wires CC8A20 and CC9A20 to Figure 204).
J28 receptacle and tie in place. E. Electrical Equipment Installation (R/H
(13). Wire J28 receptacle. Command)
(a). Cut and strip wires at J28 recep Install hoist kit electrical wire harness
tacle. Ensure sufficient wire length to assembly, general wiring, and components on
provide a smooth right angle wire R/H command helicopters, as follows:
flow to J28 receptacle.
(b). Install approximately 6 inches (15.24 Consumable Materials
cm) of 0.50 inch (12.7 mm) insulation (Ref. Section 91−00−00)
tubing (CM614) on wire bundle to Item Nomenclature
cover all wires extending from J28 CM614 Sleeving, heat-shrink
receptacle. CM703 Tie strap
(c). Ensure that all electrical contact CM725 Tape, electrical, plastic
installations are correct and secure. CM807 Twine, nylon
(d). Adjust wires at J28 receptacle and CM815 Solder
make certain sufficient wire slack
remains to avoid stress on terminals
Ensure wires and/or wire
and contacts below floor and seat CAUTION bundles do not chafe or bind
areas. Use twine (CM807) and
tie-straps (CM703) to secure wires in control mechanisms.
place. NOTE: When providing ground contact for elec
Ensure wires do not chafe or trical components, clean the contacting sur
CAUTION bind throughout full travel of faces to bare metal (Ref. Chapter 96). Route
any control mechanism. wire and wire bundles with existing wires
and bundles. Temporarily tie wires in place
(14). Remove J28 receptacle from side of with existing bundles until installation is
ship. Install insulation sleeving complete, then secure wires with nylon
(CM614) and, using solder (CM815), twine (CM807), tie-straps (CM703), or
connect wires A526A12, A527G12N, clamps as required.
Page 904
MAINTENANCE MANUAL
(1). From inside crew compartment, Install pin and insert pin in contact A of
temporarily install J28 electrical TB1-40.
receptacle (Ref. Figure 201) through
hole provided in left side of ship (Ref. (8). Remove existing wire M520B20 from
Figure 901). Install washer (Ref. TB1-19A. Wire end is left open insu
Figure 201) and receptacle nut exter lated with tape (CM725), and secured to
nally to retain J28 receptacle in place. basic electrical system tie-strap
(CM703). Install pin on wire K504M20
NOTE: The J28 receptacle is temporarily in and insert in contact A of TB1-19.
stalled to provide a means of determining Route wire K504M20 to TB1-40, install
proper length of wires to be connected to re pin, and insert pin in contact C of
ceptacle. TB1-40.
(2). On standard R/H command equipped (9). Insert pin of wire CC10A20 in contact C
with 369H92143 circuit breaker panel, of TB1-40, route wire to J28 recep
install circuit breaker CB600 (Ref. tacle, and temporarily tie in place.
View B), and a circuit breaker CB601 Connect terminal on shielding of wire
in circuit breaker panel located on the CC10A20 to ground stud E24. Do not
pilot's collective pitch stick cover. Make tighten ground stud nut.
certain circuit breaker connections to (10). Install XJ2 receptacle.
buss bar are secure.
(a). Insert XJ2 receptacle in hole pro
(3). On SLAE-equipped R/H command with vided in lower left corner of canted
369D294566 circuit breaker panel, bulkhead (Ref. Figure 901). Using
install circuit breaker CB133 and XJ2 receptacle bracket as a template,
circuit breaker CB134 in circuit mark and drill four 0.121—0.133
breaker panel located on the pilot's inch (3.0734—3.3782 mm) attach
collective pitch stick cover. Make holes.
certain circuit breaker connections to
buss bar are secure. (b). Install XJ2 receptacle (Ref.
Figure 201) from forward side of
(4). (Ref. Figure 205) Install terminal on canted bulkhead, using screws,
wire A526A12 and connect to contact 2 washers, and nuts.
of CB600 on standard R/H command,
or to contact 2 of CB133 on SLAE- (11). Route wires CC1AA20 and CC2AA20
equipped R/H command. Route opposite (Ref. Figure 205) from XJ2 receptacle
end of wire A526A12 with existing wire to TB1-40, install pin of wire CC1AA20
bundles to J28 receptacle and tempo in contact B, and pin of wire CC2AA20
rarily tie in place. in contact D. Contact terminal on
shielding of wire CC2AA20 to ground
(5). On standard R/H command, locate stud E24; tighten ground stud nut.
existing wire M503A20, install terminal
on wire M503A20, and connect to (12). Route wires CC8A20 and CC9A20 to
contact 2 of CB601. Locate existing J28 receptacle and temporarily tie in
wire M503AA20, remove from TB16 place.
contact A, and relocate to TB1-40, (13). Wire J28 receptacle.
contact A.
(a). Cut and strip wires at J28 recep
(6). On SLAE-equipped R/H command, tacle. Ensure sufficient wire length to
install pin on wire M503A20, insert pin form a smooth right angle wire flow
in contact A of TB1-40. Route wire to J28 receptacle.
M503A20 to CB134; install terminal
and connect to contact 2 of CB134. (b). Install approximately 6 inches (15.24
cm) of 0.50 inch (12.7 mm) insulation
(7). Install pin on wire M504K20, insert in tubing (CM614) on wire bundle to
contact B of TB1-19, and route opposite cover all wires extending from J28
end of wire M504K20 to TB1-40. receptacle.
Page 905
MAINTENANCE MANUAL
(c). Ensure that all hoist system electri F. Passenger/Cargo Door Retainer
cal installations are correct and Installation
secure.
The passenger/cargo door retainer installation
(d). Adjust wires at J28 receptacle and consists of a tubular assembly attached to the
make certain sufficient wire slack aft side of Sta. 78.50 canted bulkhead with
remains to avoid stress on terminals four clamps. With the passenger/cargo doors in
and contacts below floor seat areas. the open position, a telescoping tube slides out
Use twine (CM807) and tie straps of the tubular assembly to engage a bracket
(CM703) to secure wires in place. attached to the door frame, and thus retains
the door in an open position. Install the
Ensure wires do not chafe or
CAUTION bind throughout full travel of
passenger/cargo door retainer as follows:
any control mechanism. (1). Install doubler angles.
(14). Remove J28 receptacle from side of (a). Locate doubler angles (Ref.
ship. Install insulation sleeving Figure 203) on forward side of Sta.
(CM614) and, using solder (CM815), 78.50 canted bulkhead, using two
connect wires A526A12, A527G12N, existing 0.070 inch (1.778 mm)
A527H20N, A527J20N, CC10A20, tooling holes (Ref. Figure 902). Use
CC8A20, CC9A20 to J28 receptacle angles (Ref. Figure 203) as templates
contacts as indicated (Ref. Figure 205). and determine rivet hole locations on
(15). Install J28 receptacle and secure with Sta. 78.50 bulkhead.
washer (Ref. Figure 201) and nut.
Install protective cap. (b). Drill rivet attach holes, 0.069—0.074
inch (1.7526—1.8796 mm).
(16). Install ground stud on forward side of
canted bulkhead frame (Ref. (c). Attach angles to Sta. 78.50 bulkhead
Figure 901). Identify stud as E19. using rivets.
(17). Install wires A527G12N, A527H20N, (2). Install structural reinforcement

and A527J20N from J28 receptacle on brackets.
ground stud E19. Adjust and trim
insulation tubing (CM614) to accommo (a). Position structural reinforcement
date ground wire connection as re brackets on forward side of Sta. 78.50
quired; heat shrink tubing. canted bulkhead as shown (Ref.
Figure 902). Locate nine existing
(18). (Ref. Figure 205) Check switch rivets which must be removed prior
MS25089-4AR (S600) on cyclic stick to installation of reinforcement
grip to verify that button is flush with brackets. Remove rivets using drill
guard. If it is not, the switch must be motor and appropriate drill bit.
reworked, as follows:
(b). Use brackets as templates and
(a). Remove switch from grip (unsolder determine rivet hole locations on Sta.
wiring). 78.50 bulkhead. Drill rivet attach
holes, 0.069—0.074 inch
(b). Grind off end of switch button as (1.7526—1.8796 mm).
shown.
Do not allow file chips to get into (c). Attach brackets to Sta. 78.50 canted
CAUTION switch base. bulkhead using rivets.
(c). Install modified switch in grip and (3). Drill eight 0.190—0.199 inch
resolder wiring as shown. (4.826—5.0546 mm) holes through Sta.
78.50 canted bulkhead and structural
(d). Install decal 369H90070-67 to grip reinforcement angles and brackets at
as shown. locations shown (Ref. Figure 902).
Page 906
MAINTENANCE MANUAL
BL
6.50 CANTED BULKHEAD
(STA. 78.50)
EXISTING
TOOLING BL
HOLES 22.60
9.375 IN.
(23.8125 CM)
DOUBLER 11.44 IN.

ANGLE (29.0576 CM)
WL 34.36
REMOVE EXISTING
RIVETS (9 PL)
STRUCTURAL REINFORCEMENT LOCATION REINFORCEMENT

BRACKET
WL 21.50
PASSENGER/CARGO 0.190-0.199 IN.

REINFORCEMENT DOOR RETAINER TUBE
BRACKET (4.826-5.0546 MM)
HOLE (8 PL)
WL 34.36
BL
22.60 PASSENGER/CARGO DOOR RETAINER
TUBE ALIGNMENT AND ATTACHMENT BL DOUBLER
(VIEW LOOKING FORWARD - LEFT SIDE) 6.50 ANGLE
G25-6007A
Figure 902. Passenger/Cargo Door Retainer Tube Installation
Page 907
MAINTENANCE MANUAL
NOTE: Drill retainer tube outboard clamp (1). Remove nylon screws installed in
holes first; install retainer tube and out support fitting attachment holes on
board clamps to ensure proper alignment for fuselage.
marking and drilling inboard clamp holes.
(2). Install support tube attachment fittings
(4). Install the retainer assembly (Ref. (Ref. Figure 201) on fuselage using
Figure 203) on Sta. 78.50 canted screws and washers.
bulkhead, using clamps, washers, (3). Attach winch to support tube, using
spacers, screws, and nuts. bolts, washers, and nuts. Torque bolts
to 70—100 inch-pounds (7.91—11.30
(5). Locate bracket on applicable passenger/ Nm).
cargo door in such a manner as to allow
tube to engage bracket when door is in (4). Attach link assembly to support tube
open position. Install bracket on using bearing pin, washer, and cotter
passenger/cargo door frame using pin.
rivnuts, washers, and screws. (5). Attach winch support tube to fuselage
fittings, using quick-disconnect pins.
G. Hoist Assembly
NOTE: Install pins in position shown (Ref.
(Ref. Figure 201) The hoist assembly consists Figure 201).
of a winch assembly, pendant control assembly, Ensure all electrical power is
hook, hanger, and two attach brackets. To CAUTION off, eliminating possibility of in
assemble the hoist, proceed as follows: advertent firing of cable cutter.
NOTE: Pendant assembly is shipped as (6). Remove protective cap from electrical
sembled with no additional assembly re receptacle on side of fuselage. Connect
quired. winch electrical plug to fuselage
receptacle. Secure wire harness to
(1). Install hanger on winch, using screws, support tube, using tie-straps (CM703).
lockwashers, and washers. Remove protective electri
WARNING cal jumper wire (Ref.
(2). Remove existing attach brackets from Figure 202) from cable cutter whenev
winch. Install replacement brackets on er winch is installed on helicopter.
winch frame, using existing hardware. Jumper wire will prevent operation of
cable cutter in an emergency.
H. Hoist Installation
(7). Install the hoist operator's body
The hoist system winch is mounted on a harness (Ref. Figure 201).
support tube and attached with quick-release
safety pins to three fittings installed on either (8). Install flush rivets in wheel fittings
side and above the passenger/cargo compart after removing existing rivets from
ment door. The support tube positions the locations shown (Ref. Figure 903).
winch to raise and lower the cable between the NOTE: Do not install rivets if wheel fittings
side of the fuselage and the landing gear skid. have been previously equipped with flush
The winch and support can be installed for use rivets.
on either the left or right side of the helicopter
as applicable. Install the hoist system as (9). Install rivnuts at locations shown (Ref.
follows: Figure 903). Secure clips (Ref.
Figure 201) to fuselage, using screws
and washers. Install bar assembly,
Consumable Materials using screws, washers, and nuts.
(10). On R/H command, install landing gear
Item Nomenclature
skid chafing bar assembly
CM703 Tie strap (369D292556) as follows (Ref.
Figure 903):
Page 908
MAINTENANCE MANUAL
(a). Remove bolts from inboard side of aft (2). Install edgelighted and circuit breaker
abrasion strip (369H6102), and aft panels as applicable (Ref. Chapter 96).
bolt from inboard side of forward
abrasion strip (369H6102), on left (3). Install crew compartment left or right
landing gear skid. bulkhead panel and lower portion of left
or right upper side panel as applicable.
(b). Install screw (NAS603-8) in forward
attach hole of aft abrasion strip (4). Install crew compartment lower aft
(369H6102). trim panels (left and right).
(c). Position chafing bar on inboard side (5). Install left (outboard) collective stick
of left skid with bent end of bar aft, cover.
and 3/8 inch (9.525 mm) recess hole
in chafing bar over aft abrasion strip (6). Install seats and back cushions.
forward attach screw.
(d). Align chafing bar aft screwhole with (7). In passenger/cargo compartment,
aft abrasion strip aft attach hole; install fuel cell forward vent in control
install screw (NAS603-8) to secure tunnel (Ref. Section 28-00-00).
aft portion of chafing bar. (8). In passenger/cargo compartment,
(e). Hold chafing bar against skid; locate install controls access door and foot
bar forward screw hole over forward support fairings.
abrasion strip aft attach hole; drill
0.190—0.200 inch (4.826—5.08 NOTE: The forward bulkhead, Sta. 78.50, trim
mm) screw hole through chafing bar. panel is not installed during use of the hoist
system door retainer equipment.
(f). Install screw (NAS603-8) to secure
forward end of chafing bar. (9). Install battery.
I. Helicopter Equipment Installation (10). Do an operational check of the hoist
system (Ref. Hoist System Operational
Install equipment and panels as follows:
Check).
Remove all tools and foreign
CAUTION materials from helicopter before J. Weight and Balance Data
panel installations.
(Ref. After installation of the hoist system,
(1). Prior to closing access areas, check incorporate changes in the helicopter weight
integrity of entire hoist system installa and balance records as instructed (Ref. Section
tion. 08-10-00).
Weight Arm Moment
Configuration
Pounds (kg) inches (cm) in−lb (kg cm)
369H90070−521
+42.3 (+19.187) +98.0 (+248.92) +4145 (+4775.5)
(R/H Command)
369H90070−522
+39.3 (+17.826) +98.7 (+250.70) +3879 (+4469.1)
(L/H Command)
Page 909
MAINTENANCE MANUAL
WHEEL FITTING
LANDING GEAR SKID REMOVE EXISTING RIVETS

(INBOARD SIDE) (2 PLCS), INSTALL FLUSH RIVETS
CABLE ANTI-SNAG PROVISIONS

(ROTATED)
AFT ABRASION FORWARD ABRASION

STRIP STRIP
LEFT SKID
(INBOARD SIDE)
CHAFING BAR
LEFT LANDING GEAR SKID CHAFING BAR PROVISION

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

(40.7162 CM) (28.448 CM)
STA.
112.92
DOOR SILL ANTI-CHAFING BAR PROVISIONS
G25-6008A
Figure 903. Cable Antichafing Bar Installation
Page 910
MAINTENANCE MANUAL
Chapter
26
Fire Protection
MAINTENANCE MANUAL
TABLE OF CONTENTS
26-10-00 Engine Fire Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Fire Detector System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fire Detector System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Fire Detection System Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Fire Detection System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Fire Detection System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Fire Detection System Interconnect Data . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Fire Detection System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
26-20-00 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Fire Extinguisher Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fire Extinguisher Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Fire Extinguisher Servicing/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Fire Extinguisher Installation (R/H Command) . . . . . . . . . . . . . . . . . 202
Page i
MAINTENANCE MANUAL

Page ii
MAINTENANCE MANUAL
Section
26−10−00
Engine Fire
Detection System
MAINTENANCE MANUAL
FIRE DETECTION SYSTEM

1. Fire Detector System Description and 3. Fire Detection System Replacement
Operation
(Ref. Figure 202)
The fire detection system is located in the aft
section of the fuselage encircling the engine A. Fire Detection System Removal
bay area. The fire detector cable is looped
around the inboard structure of the engine (1). Disconnect wire harness from fire
compartment. The fire detection system is held detector unit.
in place by stainless steel positive locking
cable clips and clamps attached to the air (2). Remove hardware securing clamps from
frame. cable and fire detector unit.
The detector consists of a pressure switch (3). Disconnect fire detection cable quick
connected to a small diameter tube. Inside the release clips.
tube is helium gas and a core material that
contains trapped hydrogen. The detector can (4). Careful remove fire detection cable
provide an output signal when heat is applied from engine compartment.
to it in two ways. If the detector tube average
temperature exceeds a preset amount, the (5). Replace any broken quick release clips.
helium gas pressure increase will trigger the B. Fire Detection System Installation
output signal. If there is a local hot spot on the
detector tube, the core will outgas hydrogen. NOTE:
The release of hydrogen gas will cause a
pressure increase inside the tube, triggering D Replace any damaged or broken quick re
the output signal. Both of these processes are lease clips.
reversible. When the tube cools, the output D Do not exceed minimum bend radius
signal ceases, the hydrogen is reabsorbed into 0.375 inch (9.53 mm) when installing fire
the core, and the system is reset. The detector detection cable.
core has a spiral groove cut into its outside
diameter, so that crushing, flattening, or (1). Form fire detection cable to fit original
kinking of the detector tube will not prevent mounting locations.
gas pressure from reaching the pressure
switch. Loss of tube integrity through cracking (2). Secure fire detector cable in quick
or breakage will make the detector inopera release clips.
tive, but the detector incorporates a built in
test for tube integrity. (3). Install clamps to fire detector unit
using previously removed hardware.
2. Fire Detector System Troubleshooting
(4). Attach electrical connector to fire
(Ref. Figure 201) detection cable connector.
Page 201
MAINTENANCE MANUAL
J1201
TB201-1 P19 VOICE/WARNING LRU

89 FIR 002AA22 E F G H FIR 002AAA22 S
P/J 30
FIR 002A22 D
78 FIR 001A22 C
79 FIR 001F22 B
1 FIR 003A22 A
FIRE DETECTOR
6G26−095A
Figure 201. Fire Detection System Interconnect Data
Page 202
MAINTENANCE MANUAL
FIRE DETECTOR UNIT
VIEW ROTATED
MS21919WCH2 CLAMP
MS21919WCH16 CLAMP
3001-31-900/400
FIRE DETECTOR
MS21919WCH2 CLAMP
NAS1096-3-12 SCREW
MS21042-3 NUT
NAS43HT3-20 SPACER MS3456KT14S-5S PLUG
AN960C10L WASHER M85049/52S14W BACKSHELL
MS9029/30-217 SOCKETS (X5)
LOOKING OUTBOARD
LEFT SIDE
6G26-094
Figure 202. Fire Detection System Installation
Page 203
MAINTENANCE MANUAL
Page 204
MAINTENANCE MANUAL
Section
26−20−00
Fire Extinguisher
MAINTENANCE MANUAL
FIRE EXTINGUISHER
1. Fire Extinguisher Description (2). Remove fire extinguisher from mount
ing bracket.
(Ref. Figure 201) The early model helicopters (3). Remove safety pin from handle. Point
use the pressurized, dry chemical type of fire nozzle toward base of flame and
extinguisher. The current models use a squeeze the handle.
liquified gas which discharges as a vapor at
high nozzle velocity (Halon 1211). The L/H and 3. Fire Extinguisher Servicing/Inspection
R/H command fire extinguishers mount on the
forward door frame between the crew door and The fire extinguishers are equipped with a
the canopy. The fire extinguisher quickly pressure gage that indicates normal, charge,
detaches from the mounting bracket by and overcharge pressures.
unfastening the quick-release clasps. Note the
current fire extinguishers are equipped with (1). Dry chemical type - white area indi
two straps for extra high vibration applica cates normal operating range of 150 psi
tions. (1034 kPa). Red area indicates
CHARGE or OVERCHARGE.
2. Fire Extinguisher Operation (2). Halon type - green area indicates

normal operating range of 125 psi (862
kPa). Red area indicates CHARGE or
(1). Grasp fire extinguisher handle with one OVERCHARGE.
hand. Use the thumb and forefinger of
the other hand to unfasten the quick- Service the fire extinguishers in accordance
release clasp. with manufacturer's instructions.
Page 201
MAINTENANCE MANUAL
EARLY ASSEMBLY
CURRENT ASSEMBLY
G26−2001
Figure 201. Fire Extinguisher Installation (R/H Command)
Page 202
MAINTENANCE MANUAL
Chapter
28
Fuel System
MAINTENANCE MANUAL
TABLE OF CONTENTS
28-00-00 Fuel System (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

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

A. Fuel Shutoff Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Fuel Shutoff Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Left Fuel Cell Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
3. Fuel Tank Vent System Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Vent Tube/Emergency Valve Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Forward Vent Crossover Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
C. Aft Vent Crossover Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 403. Vent System (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
D. Fuel Tank Vent System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
E. Vent Tube/Emergency Valve Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 408
4. Fuel Supply Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Fuel Supply Lines Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Fuel Supply Lines Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
5. Start Pump Replacement (Model 250-C20B/R2 /
250-C30 Engine Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Start Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Table 401. Fuel Line Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Start Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Figure 404. Start Pump and Fuel Lines Installation (Sheet 1 of 2) . . . . . . . . . . . 411
6. Fuel Quantity Transmitter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
A. Fuel Quantity Transmitter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
B. Fuel Quantity Transmitter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
7. Fuel System Drain Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
A. Fuel System Drain Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
B. Fuel System Drain Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
8. Fuel Cell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
A. Fuel Cell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
B. Fuel Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
C. Fuel Cell Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Figure 405. Fuel Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Figure 406. Fuel Cell Support Lacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
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Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Fuel Level Low Caution Light System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2. Fuel Quantity Transmitter Calibration and Adjustment . . . . . . . . . . . . . . . . . . . . . . . 501
Figure 501. Fuel Quantity Transmitter Calibration (Sheet 1 of 2) . . . . . . . . . . . . 502
A. Fuel Level Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
B. Fuel Level Low Warning Light Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
3. Fuel Quantity Transmitter Functional Check - (600N) . . . . . . . . . . . . . . . . . . . . . . . . 504
4. Fuel Quantity Testing - 369F (Glass Cockpit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
A. Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
B. Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
C. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
5. Fuel Filter (Bypass) Caution Light Pressure Switch Test . . . . . . . . . . . . . . . . . . . . . . 508
Figure 502. Fuel Filter Caution Light Pressure Switch Test
(C20/C30 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
Figure 503. Fuel Filter Caution Light Pressure Switch (C30 Engine) . . . . . . . . . 511
Figure 504. Fuel Filter Caution Light Pressure Switch (C20 Engines) . . . . . . . . 511
Figure 505. Fuel Filter Caution Light Pressure Switch (C20R/2 Engines
with CECO Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
6. Fuel Quantity Indicator Verification Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
A. Prepare Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
B. Test Fuel Quantity Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
1. Fuel System General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Fuel Shutoff Valve Control Cable Swage Test (369D/E) . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Fuel Shut-Off Control Cable, PN 369A8137-503 Pull Test . . . . . . . 602
3. Fuel Shutoff Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4. Fuel Quantity Transmitter Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
5. Tank Vent System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
6. Fuel System Vacuum Leak Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
7. Start Pump Operational Check (Model 250-C20 Series Engines or 250-C30
Engine With Optional Maintenance Fuel Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
8. Drain Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
9. Fuel Cell Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
10. Fuel Cell Leak Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
A. Soap Bubble Leak Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
B. Phenolphthalein Stain Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
C. Liquid Stand Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
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11. Fuel Tank Pressure Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Fuel Shutoff Valve Control Cable Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Fuel Shutoff Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Fuel Cell Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
4. Uniroyal Self-Sealing and Non-Self-Sealing Cell Repairs . . . . . . . . . . . . . . . . . . . . . 801
A. Scuff Mark Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
B. Reinforcements, Hangers and Splice Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
C. Loose Patch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
D. Patch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
E. Loose Edge and Lap Seam Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
F. Blister Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
5. Fuel Quantity Transmitter Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
A. Resistor installation, Transmitters PN 369D296303,
369D296303-701 and 369A4245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
B. MIL-S-8802 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
28-00-60 Fuel System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Fuel Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Fuel Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Fuel Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5. Fuel Quantity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6. Fuel Shutoff Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. Fuel Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8. Fuel Filter Caution Light Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9. Drain System and Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10. Fuel Supply Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Fuel System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Fuel Supply System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 102. Fuel Quantity System Wire Data List . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 101. Fuel Quantity System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 103
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1. Fuel Cell Cleaning - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Engineered Fabrics Corp. Fuel Cell Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Fuel Cell Handling, Storage and Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Fuel Cell Preservation and Storage (Engineered Fabrics Corp. Cells) . . . . . . . . . . . 201
5. Fuel System Air Bleed (Model 250-C47 Engine Installation) . . . . . . . . . . . . . . . . . . 201
Figure 201. Field Fabricated Fuel System Bleeding Tool . . . . . . . . . . . . . . . . . . . . 202
1. Fuel Shutoff Valve Control Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Fuel Shutoff Valve Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Fuel Shutoff Valve Control Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Fuel Shutoff Valve Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Fuel Shutoff Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Fuel Shutoff Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Fuel Shutoff Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Fuel Shutoff Valve and Fuel Cell Cover Installation . . . . . . . . . . . . . 404
3. Fuel Cell Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Fuel Cell Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Fuel Cell Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
4. Fuel Supply Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Fuel Supply Lines Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Fuel Supply Lines Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 403. Fuel Lines Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 404. Ejector Pump and Fuel Lines Installation . . . . . . . . . . . . . . . . . . . . . . 409
5. Fuel Cell Vent System Components Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Fuel Cell Vent System Components Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Fuel Cell Vent System Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Figure 405. Fuel Cell Vent System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
6. Fuel Cell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Fuel Cell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Fuel Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Figure 406. Fuel Cell Interconnect and Support Lacing (Sheet 1 of 3) . . . . . . . . 416
7. Fuel Filler Neck Gravity Fill Port Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. Fuel Filler Neck Gravity Fill Port Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Fuel Filler Neck Gravity Fill Port Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Page v
MAINTENANCE MANUAL

8. Fuel System Drain Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

A. Fuel System Drain Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Fuel System Drain Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
9. Fuel Quantity Probe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Forward Fuel Quantity Probe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Forward Fuel Quantity Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
C. Aft Fuel Quantity Probe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Figure 407. Fuel Quantity Probes (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
D. Aft Fuel Quantity Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Fuel Level Low Light/Fuel Quantity Indicator
System Test and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2. Fuel Filter (Bypass) Caution Light Pressure Switch Test . . . . . . . . . . . . . . . . . . . . . . 502
Figure 501. Fuel Filter Caution Light Pressure Switch Test Apparatus
(C47 Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
1. Fuel System General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Fuel Shutoff Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Tank Vent System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
4. Fuel Quantity Probe Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
5. Fuel System Vacuum Leak Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 601. Fuel System Vacuum Leak Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6. Drain Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
7. Fuel Cell Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
8. Fuel Cell Leak Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
A. Soap Bubble Leak Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
B. Phenolphthalein Stain Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
C. Liquid Stand Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
9. Fuel Tank Pressure Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
10. Fuel Transfer System Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Figure 602. Fuel Transfer System Functional Check . . . . . . . . . . . . . . . . . . . . . . . . 606
A. Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Figure 603. Fuel Transfer Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
B. Check Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
Page vi
MAINTENANCE MANUAL

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Fuel Shutoff Valve Control Cable Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Fuel Cell Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Scuff Mark Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
4. Reinforcements, Hangers and Splice Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
5. Loose Patch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
6. Patch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
7. Loose Edge and Lap Seam Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
8. Blister Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
28-25-00 Anti-Ice / Airframe Fuel Filter (369D/E - 500/600N) . . . . . . . . . . . . . . . . . . . . A
Table 1. Anti-Ice/Airframe Fuel Filter Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Anti-Ice Fuel Filter System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Anti-Ice Fuel Filter System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . 101
1. Anti-Ice Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Anti-Ice Fuel Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Anti-Ice Fuel Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fuel System Air Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Anti-Ice Fuel Filter (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1. Anti-Ice Fuel Filter System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Anti-Ice Fuel Filter Installation Operational Check: 369H90022-BSC . . . . . . . . . 602
3. Anti-Ice Fuel Filter Installation Operational Check:
369H90022-503, -505 and 600N98110-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
4. Fuel System Vacuum Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Table 601. Fuel Supply System Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 601. Anti-Ice Fuel Filter Controls (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 604
1. Anti-Ice Fuel Filter Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Preparations for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Anti-Ice Fuel Filter Control Panel Installation:
369H90022-BSC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Anti-Ice Fuel Filter Control Panel Installation:
369H90022-503, and -505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
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MAINTENANCE MANUAL

D. Anti-Ice Fuel Filter Control Panel Installation:

600N98110-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
E. Firewall Modifications and Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
F. Fuel Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Figure 901. Anti-Ice Fuel Filter Modifications and Installation
(369D/E - 500N) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Figure 902. Anti-Ice Fuel Filter Modifications and Installation
(600N) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Figure 903. Anti-Ice Fuel Filter Wiring Diagram
(369D S/N 0001 - 1204) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 910
(369D S/N 1205 & Subs and 369E S/N 001 - 383) . . . . . . . . . . . . . . . . 912
(369E S/N 384 & Subs and 500N S/N 001 & Subs) . . . . . . . . . . . . . . . 913
(600N S/N 003 & Subs) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 914
G. Post-Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 916
H. Furnishings, Panels and Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 916
2. Anti-Ice Fuel Pump Initial Installation (600N98110-501 Installation) . . . . . . . . . 916
A. Fuel Cell Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 916
Figure 907. Fuel Pump Initial Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . 917
B. Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917
C. Fuel Cell Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917
3. Anti-Ice Fuel Filter Installation Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . 918
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MAINTENANCE MANUAL
Section
28−00−00
Fuel System
(369D/E/FF − 500N)
MAINTENANCE MANUAL
FUEL SYSTEM
1. Engine Fuel System (6). Fuel tank servicing is through the tank
filler neck on the right side of the
(1). Engine fuel system operational infor fuselage.
mation is provided in the applicable
Rolls-Royce Operation and Mainte 3. Fuel Quantity System
nance Manuals (Ref. Section 01-00-00). (1). The fuel quantity system is powered by
24 - 28 Vdc current and consists of a
2. Fuel Cells float operated quantity transmitter
mounted on the left fuel cell cover and a
(1). The MDHI helicopter standard fuel quantity indicator gauge and FUEL
tank consists of two interconnected LEVEL LOW caution light on the
non-self-sealing bladder cells having a instrument console. Early series
total capacity of 64 gallons (242.3 L), helicopters incorporate the gauge as
with 62 gallons (234.7 L) usable. part of a three-pack instrument cluster.
Alternate self-sealing cells can be Current helicopters feature an individ
installed having a capacity of 62 ual quantity gauge. The system is
gallons (234.7 L), with 60.7 gallons protected by the INSTR CLUSTER 5
(229.7 L) usable. Bladder and self ampere circuit breaker. Power is
sealing fuel cells are supplied by supplied to the system from the DC bus
Engineered Fabrics Corporation and through the INSTR CLUSTER circuit
Uniroyal, Inc. (Ref. Section 01-00-00). breaker, CB101. With power on and
approximately 35 or 70 pounds of fuel
(2). Cells are located in separate fiberglass remaining, depending on customer
lined bays below the passenger com requirements, the fuel quantity trans
partment floor. Both cells are supported mitter float arm contacts a spring wire
by a system of airframe brackets, that completes a circuit to ground
hangers, grommets and nylon suspen through a transistor located on a circuit
sion cords. board inside the transmitter assembly.
The transistor switches on the FUEL
(3). Each fuel cell is equipped with an LEVEL LOW caution light. Refueling
access cover fitting, cover, forward and raises the float, breaks the transistor
aft vent crossover fittings, fuel intercon circuit and switches off the FUEL
nect fittings, internal baffles and baffle LEVEL LOW caution lamp. The float
support rods. operates a rheostat that controls
electrical current through the quantity
(4). The right fuel cell contains the male indicator circuit. Fuel level changes
portion of the cell interconnect fitting, alter transmitter resistance values that
filler neck, cap and attached filler effect the fuel quantity indicator needle
shield. position.
4. Vent System
(5). The left fuel cell contains the female
half of the cell interconnect fitting, (1). Tank cells are vented to atmosphere
sump plate, sump/tank drain valve, through bottom and side fuselage ports
engine start fuel pump (C20 series by a system of interconnected hoses and
engine installation) or fuel inlet fitting tubes attached to the forward and aft
(C30 engine installation). The left cell ends of each fuel cell. A fuel vent
cover supports the fuel quantity emergency shutoff valve automatically
transmitter, manually actuated fuel closes to prevent fuel loss through the
shutoff valve, fuel supply tubes, hoses vent system when a 45° helicopter pitch
and attaching hardware. or roll angle limit is exceeded.
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MAINTENANCE MANUAL
5. Fuel Shutoff Valve Control filter pressure AF (after filter) and BF

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

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

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

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

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

cable failed or disconnected.
FUEL FILTER warning light Clogged engine fuel filters. Replace pump and gas producer fuel control
ON. filters. Clean fuel control pneumatic (air)
circuits (Ref. to Rolls−Royce Operation and
Maintenance Manual). When installed, replace
anti−ice (airframe) filter. Bench check FUEL
FILTER caution light pressure switch.
Fuel contamination Examine the connections and internal

pathways of fuel lines, the start pump or fuel
pickup fitting, the fuel shutoff valve, the drain
valve, and the engine filter inlet.
Clean the fuel cell and start pump inlet screens
if foreign material is found in the engine−driven
fuel pump filter (or the optional airframe fuel
filter if installed).
Defective fuel filter pressure Replace pressure switch.

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

Engine power surge or Water/ice in fuel system. Drain water out of tank and fuel supply system.
flameout with start pump OFF.
(Ref. NOTE.) Air in fuel system. Bleed fuel system.
Air leaking into system. Vacuum leak check fuel supply system.
Bottom of fuselage stays wet Loose or broken lines or Inspect and repair as necessary.
with fuel. fittings.
Fuel tank leak. Remove, test and repair, or replace cells.
FUEL LEVEL LOW caution Transistor current leakage Install resistor in transmitter circuit.
light stays ON, glows or through FUEL LEVEL LOW
flickers with known quantity caution lamp.
above low level.
Defective fuel quantity Remove, test, calibrate and repair or replace
transmitter. fuel quantity transmitter.
Erroneous fuel quantity gauge Loose or defective wiring or Inspect wiring and repair.
readings. connections.
Defective gauge. Remove, test and replace a defective gauge.
Defective fuel quantity Remove, test, calibrate and repair or replace

transmitter. transmitter.
NOTE: 369FF Helicopters are not equipped with a start pump.
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MAINTENANCE MANUAL
Figure 101. Fuel System Wiring Diagram (Model 250−C20B/R2 Engines)
Figure 102. Fuel Quantity System Wiring Diagram
Page 103
MAINTENANCE MANUAL
Figure 103. Fuel System Schematic
Page 104
MAINTENANCE MANUAL
FUEL SYSTEM
1. Fuel Cell Cleaning − General 4. Fuel Cell Handling, Storage and Shipping
Do not use cell fittings as hand
(1). Fuel cells are susceptible to fungus CAUTION holds. Do not store fuel cells un
growth after contact with contaminated crated or exposed to direct sunlight, ozone,
fuel. Fungus trapped in the fuel filters dirt, moisture, solvents, chemicals, or ex
indicates fuel tank contamination. tremes of heat and humidity.
Remove, inspect, clean or replace filter
elements per applicable Rolls-Royce (1). Store and ship cells in a suitable
Operation and Maintenance Manual. protective container.
Where installed, service anti-ice
(a). Apply protective tape over all cell
(airframe) filter (Ref. Section
machined fittings.
28-25-00).
(b). Use packing material to keep the cell
from shifting in transit.
(2). Periodic incorporation of an FAA
approved anti-fungal fuel additive will (c). Suspended self-sealing cells to
kill and prevent new fungus growth. maintain cell shape.
5. Fuel Cell Preservation and Storage

2. Uniroyal Fuel Cell Cleaning (Uniroyal Cells)
Steam cleaning can cause irrep CAUTION

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

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

WARNING during bleeding is a fire haz
(c). In crew compartment; push FUEL
ard. Prevent fuel vapor accumulation, shutoff valve knob in to open shutoff
ignition and fire. Do work in an open, valve.
well ventilated area away from all po
tential ignition sources. Attach heli (d). Set helicopter master switch to
copter to an approved electrical BATTERY.
ground. Wear approved eye protection.
(e). Set START PUMP switch ON to
(1). Helicopters with C30 engines fuel pressurize fuel system. Check; start
supply systems are not equipped with a pump is operating.
start pump. However, the helicopter
fuel system has an engine driven self
NOTE: Refer to applicable Rolls-Royce Opera
tion and Maintenance Manual for specific
priming pump that will fill the fuel
engine fuel system air bleed information.
system when the engine is motored
with the starter. Motor engine per the (f). Purge air from engine fuel system
appropriate Pilot's Flight Manual. per Rolls-Royce Operation and
Maintenance Manual.
(2). Bleed air out of helicopter engine fuel
controls per Rolls-Royce Operation and (3). Set START PUMP and battery
Maintenance Manual. switches OFF.
Page 202
MAINTENANCE MANUAL
FUEL SYSTEM
1. Fuel Shutoff Valve Control Cable (1). Thread cable assembly aft through
Replacement instrument panel or console, lockwash
er, jamnut and grommets to fuel shutoff
A. Fuel Shutoff Valve Control Cable valve. Maintain a cable bend radius
Removal greater than 3.5 inches (8.89 cm).
(Ref. Figure 401) (2). Secure forward end of cable with
(1). Remove left fuel cell floor access panel. lockwasher and jamnut.
(2). Disconnect control wire from fuel (3). Slip control cable wire through fuel
shutoff valve swivel. shutoff valve lever swivel.
(3). Remove control cable ty-raps and (4). Secure end of cable housing to cell cover
clamps. with a clamp, washer and screw.
(4). Remove instrument panel left fairing (5). Install remaining clamps and ty-raps.
and lower cover panels (instrument (6). Rig cable with shutoff valve lever hard
panel mounted). against open stop. Adjust cable to get a
(5). Completely back jamnut away from 0.090—0.150 inch (2.286—3.810 mm)
cable plunger housing (Ref. Figure 401, gap between bottom of control knob
view A). and cable housing end fitting. Tighten
cable swivel pinch nut. Install cotter
(6). Remove straps securing cable in nose pin.
(instrument panel mounted) or remove
Control action must move valve
clamp in compartment under pilot's CAUTION to full open against mechanical
seat (console mounted).
stop without bottoming control knob on
NOTE: Attach a trace wire or cord to the valve cable housing. Control cable operation shall
end of the cable before pulling assembly out be smooth with no binding.
of the instrument panel. Trace will guide re
placement cable into correct position. (7). Pull valve control knob out with a
spring scale. Required valve actuation
(7). Pull cable assembly out through force to be not more than 12 pounds
washer, jamnut and instrument panel. (53.38 N).
B. Fuel Shutoff Valve Control Cable (8). Repair, adjust or replace valve control
Installation system components to meet force limit.
(Ref. Figure 401) (9). Reinstall left fuel cell floor access panel.
Pulling detent knob out of cable (10). Reinstall instrument panel left fairing
CAUTION housing two or more inches can and lower cover panels (instrument
result in loss of the detent ball. panel mounted).
Page 401
MAINTENANCE MANUAL
DETENT RELEASE
DETENT RELEASE
CABLE PLUNGER
PLUNGER HOUSING DETENT BALL
0.090-0.150 INCH PLUNGER HOUSING SPRING

(2.286-3.810 MM)
INSTRUMENT PANEL
CABLE PLUNGER
INSTRUMENT PANEL
NUT
CABLE RIGGING
HOLE
OPEN LOCKWASHER
LEVER
CL VALVE CABLE HOUSING
CONTROL KNOB ASSEMBLY

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

CABLE STA. 50.50
G28-0001A
Figure 401. Fuel Shutoff Valve Cable Installation
Page 402
MAINTENANCE MANUAL
2. Fuel Shutoff Valve Replacement (5). Unplug fuel quantity transmitter

connector from cell cover receptacle.
A. Fuel Shutoff Valve Removal
(Ref. Figure 402) (6). Unclamp and disconnect control cable
from fuel shutoff valve.
Avoid fuel vapor ignition
WARNING and fire. Use only nonspark
(7). Unfasten and remove Sta. 91.00 and
ing tools and explosion proof work 102.00 left fuel cell cover support
lights. Attach helicopter to an ap brackets.
proved electrical ground. Switch OFF
all electrical power. Disconnect exter
nal power and battery before opening CAUTION
fuel system. Ensure work area is ade
quately ventilated. D Do not strain or bend fuel quantity trans
mitter float arm.
CAUTION D Handle fuel cell cover with care. Prying
D Air in fuel system can cause power surges cover from cell opening or rough handling
or flameout. Bleed off trapped air after can damage seal or cell fitting.
opening system at any point between fuel
tank and engine fuel nozzle. (8). Remove fuel quantity transmitter
flange screws. Lift transmitter assem
D Prevent fuel system contamination. In
bly out of cover opening.
stall caps on the ends of hoses, tubes and
fittings as parts are removed. Bag and
identify small parts to prevent loss or (9). Unbolt cell access cover. Prop cover
damage. open with suitably padded blocks.
(1). Defuel helicopter. Drain remaining fuel (10). Using a backup wrench on valve,
from tank sump drain valve into a separate fuel supply hose from fuel
suitable container. shutoff valve.
(2). Remove left fuel tank access panel from
passenger/cargo compartment floor. (11). Remove fuel shutoff valve and attach
ing hardware.
(3). Unclamp fuel supply tube between fuel
shutoff valve and Sta. 124.00 bulkhead B. Fuel Shutoff Valve Installation
elbow. Using backup wrench on bulk
head elbow so it will not rotate, discon (Ref. Figure 402)
nect and remove tube.
(4). With 250-C20B/R2 Engine or 250-C30 NOTE: Fuel shutoff valve installation steps are
Engine With Optional Maintenance given in Fuel Cell Cover Installation proce
Fuel Pump: Unclamp start pump wire dures.
harness and disconnect plug from cell
cover receptacle. (Ref. Fuel Cell Cover Installation)
Page 403
MAINTENANCE MANUAL
SCREW, TORQUE; 20-25 IN. LB

(2.26 - 2.82 NM) (TYP)
SETSCREW CABLE
(NOTE) WIRE
BOLT, TORQUE; 70-90 IN. LB VALVE LEVER PIN
(7.91 - 10.17 NM) (TYP) AND SWIVEL
BUSHING
ELECTRICAL WIRING
HARNESS
ENGINE FEED HOSE
SUPPORT BRACKET (3 SHUTOFF VALVE TO
PLACES) FIREWALL
TUBE NUT, TORQUE;
230-260 IN. LB (25.99 - 29.38 NM)
CONTROL
CABLE
CARGO ELECTRICAL CONNECTOR
COMPARTMENT
FLOOR
FUEL SHUTOFF VALVE

SEAL WASHER
JAMNUT, TORQUE; 240-280 IN. LB
(27.12-31.64 NM)
HOSE NUT, TORQUE; 230-260 IN. LB FUEL QUANTITY
(25.99-29.38 NM) TRANSMITTER
FUEL INLET HOSE
ELECTRICAL
ELECTRICAL
RECEPTACLE
RECEPTACLE
START PUMP ELECTRICAL
WIRING HARNESS
NOTE:
REQUIRED AT LOCATION SHOWN.
G28-0002A
Figure 402. Left Fuel Cell Cover Installation
Page 404
MAINTENANCE MANUAL
3. Fuel Tank Vent System Component (7). Remove vent tube/emergency valve
Replacement assembly attaching hardware. Remove
flexible tubing from lower vent tube tee.
WARNING and fire. Use only nonspark (8). Rotate emergency shutoff valve inboard
ing tools and explosion proof work and slip assembly down over landing
lights. Attach helicopter to an ap gear structure. Remove tube assembly
proved electrical ground. Switch OFF through controls access panel opening.
nal power and battery before opening (9). Unclamp flexible tubing from side vent
fuel system. Ensure work area is ade fairing. Remove tubing through controls
quately ventilated. access opening.
Prevent fuel system contamina B. Forward Vent Crossover Fitting Removal

CAUTION tion. Install caps on the ends of
hoses, tubes and fittings as parts are re (Ref. Figure 403)
moved. Bag and identify small parts to pre
(1). Unbolt forward vent crossover fitting
vent loss or damage.
flanges.
(1). Defuel helicopter. Drain remaining fuel
from tank sump drain valve into a (2). Remove fitting, clamps, seals and
suitable container. washers.
Prevent spontaneous com (3). Cover cell vent fittings and aft vent line
WARNING bustion or explosion. Never tube openings.
use oxygen to purge or ventilate fuel C. Aft Vent Crossover Fitting Removal
tank or fuel system components. Fuel,
either vapor or liquid, will violently (Ref. Figure 403)
react with an oxygen rich atmosphere.
NOTE: Left and right fuel cell access covers
(2). Ventilate fuel tank with an inert gas, must be removed to get at aft vent crossover
such as nitrogen, or low pressure U-tube attaching hardware.
compressed air applied through filler
neck. (1). Remove left and right fuel cell floor
access panels.
A. Vent Tube/Emergency Valve Assembly
Removal (2). Unclamp fuel supply tube between fuel
shutoff valve and Sta. 124.00 bulkhead
(Ref. Figure 403) elbow. Using backup wrench on bulk
(1). Unbolt and remove right fuel cell access head elbow so it will not rotate, discon
cover. nect and remove tube.
(2). Remove right foot support, controls, (3). With 250-C20 Series Engines or
and fuel vent access panels. 250-C30 Engine With Optional Mainte
nance Fuel Pump: Unclamp start pump
(3). Remove right seat from crew compart wire harness and disconnect plug from
ment. cell cover receptacle.
(4). Move collective pitch stick full down. (4). Unplug fuel quantity transmitter
(5). In passenger/cargo compartment;
remove right and left fuel tank floor (5). Unclamp and disconnect control cable
access panels. from fuel shutoff valve.
(6). Remove lockwire from vent connector (6). Unfasten and remove Sta. 91.00 and
hoses and main rotor mast pan drain 102.00 left fuel cell cover support
tube. brackets.
Page 405
MAINTENANCE MANUAL
PAN
DRAIN TUBE
LOCKWIRE
CLIP
(2 PLACES)
BOLT
WASHER
LACING CORD
(TYPICAL)
WASHER
BOLT
CLAMP
BOLT WASHER
WASHER NUT
FROM AFT VENT
VENT TUBE
SCREW
LOCKWIRE
(TYPICAL) WASHER
CONNECTOR HOSE BOLT, TORQUE; 36-46 IN. LB
SIDE VENT FAIRING
(NOTE 2) (4.06-5.20 NM)
WASHER
CLAMPS
SCREW
SUPPORT COIL CLIP
WASHER
ANTI-SIPHON FUEL VENT

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

EMERGENCY VALE ASSY
1. ROUTED THRU LANDING GEAR BRACE.
2. NOT TO BE PAINTED.
G28-0003-1B
Figure 403. Vent System (Sheet 1 of 2)
Page 406
MAINTENANCE MANUAL
VALVE CLOSED WHEN TILT

EXCEEDS 45° FROM VERTICAL CLAMP INTERCONNECT
OVERBOARD
HOSE
VALVE SEAT
SEAL WASHER
VALVE
CELL
TUBE (REF)
WEIGHT
FUEL VENT
IN NUT, TORQUE; 40-60 IN. LB
(4.52-6.78 NM)
G28-0003-2B
EMERGENCY VENT AFT INTERCONNECT
SHUTOFF VALVE
Figure 403. Vent System (Sheet 2 of 2)

(12). Cap tube and cell openings.
CAUTION
(13). Inspect all vent system components
D Do not strain or bend fuel quantity trans (Ref. Fuel Tank Vent System Inspec
mitter float arm. tion).
D Do not damage cell cover bonded seal. D. Fuel Tank Vent System Installation
Handle fuel cell covers with care. Prying
covers from cell openings or rough handl (Ref. Figure 403)
ing can damage seal or cell fitting.
(7). Remove fuel quantity transmitter (Ref. Section 91−00−00)
flange screws. Lift transmitter assem Item Nomenclature
CM124 Kerosene
(8). Unbolt and prop fuel cell access cover
open with suitably padded blocks. Avoid fuel vapor ignition
(9). Use a backup wrench on valve and ing tools and explosion proof work
separate fuel supply hose from fuel lights. Attach helicopter to an ap
shutoff valve. Move fuel cell cover to get proved electrical ground. Switch OFF
at remaining hardware. all electrical power. Disconnect exter
nal power and battery before opening
(10). Reach back inside cells and remove fuel system. Ensure work area is ade
vent interconnect nuts. Separate aft quately ventilated.
U-tube interconnect from cells.
(1). Wipe forward and aft cell vent
(11). Unclamp and remove hose between fittings and crossover tube flanges
U-tube interconnect tee and straight clean with kerosene (CM124) or
tube. Remove U-tube interconnect. equivalent on a clean shop towel.
Discard sealwashers. Wipe dry.
Page 407
MAINTENANCE MANUAL
NOTE: Do not lubricate fitting sealwashers. E. Vent Tube/Emergency Valve Assembly

Lubricants can cause seal cold flow and sub Installation
sequent leakage.
(Ref. Figure 403)
(2). Install new sealwashers on aft vent
tube ends. Insert tube ends through cell (1). Move collective pitch stick full down.
fittings. Reach inside cell and install
(2). Remove protective covers from fittings
nuts.
and tubes.
(3). Torque aft vent U-tube interconnect
(3). Work emergency valve and vent tube
assembly through landing gear brace
(4.52—6.78 Nm).
then into position in tunnel.
(4). Install hose and clamps between
interconnect U-tube and straight tube. (4). Insert vent tube assembly in bottom
vent fairing.
(5). Position new sealwashers on cell
forward vent fittings. Slip vent tube (5). Loosely install vent tube support
into cell fitting. clamps, washers and bolts.
NOTE: Permatex Form-A-Gasket No.1 can be (6). Install flexible tubing between side vent
used to hold metal stand-off washers in fairing and vent tube assembly tee.
place. (7). Clamp flex tube ends in position with
(6). Sandwich one AN960-10 washer on two or three wraps of lockwire.
each side of seal washer between vent (8). Tighten vent tube assembly support
tube flanges and cell fittings. Align clamp and bracket fasteners.
washers with bolt holes. Install bolts
with one washer under each bolt head. (9). Install and secure remaining vent
system connector hoses with lockwire.
(7). Torque forward vent interconnect tube
flange bolts to 36—46 inch-pounds (10). Operate all flight controls through full
(4.07—5.20 Nm). range of motion to ensure no interfer
ence exists between control linkages
(8). Connect powerplant supply tube to Sta.
and vent system. No interference is
124.00 bulkhead elbow. Loosely install
allowed. Adjust vent system hardware
tube support clamps, screws, washers
as required.
and nuts. Using backup wrench on
bulkhead elbow so it will not rotate, (11). Install fuel vent access panel.
torque tube nut to 230—260 inch-
pounds (25.99—29.38 Nm). (12). Install controls access and foot support
panels.
(9). Install fuel cell covers (Ref. Fuel Cell
Cover Installation). (13). Install crew seat.
Page 408
MAINTENANCE MANUAL
4. Fuel Supply Lines Replacement (4). Apply a torque alignment stripe to fuel
line tube, hose and fitting fasteners.
A. Fuel Supply Lines Removal
(Ref. Figure 404) 5. Start Pump Replacement (Model
250−C20B/R2 / 250−C30 Engine Installation)
WARNING and fire. Use only nonspark NOTE: Use these start pump removal and
ing tools and explosion proof work installation procedures for helicopters with
lights. Attach helicopter to an ap 250-C30 engines equipped with optional
proved electrical ground. Switch OFF maintenance fuel pump.
nal power and battery before opening A. Start Pump Removal
quately ventilated. (Ref. Figure 404)
CAUTION WARNING and fire. Use only nonspark
D Air in fuel system can cause power surges ing tools and explosion proof work
or flameout. Bleed off trapped air after lights. Attach helicopter to an ap
opening system at any point between fuel proved electrical ground. Switch OFF
tank and engine fuel nozzle. all electrical power. Disconnect exter
D Prevent fuel system contamination. In fuel system. Ensure work area is ade
stall caps on the ends of hoses, tubes and quately ventilated.
identify small parts to prevent loss or Prevent fuel system contamina
damage. CAUTION tion. Install caps on the ends of
hoses, tubes and fittings as the parts are re
from tank sump drain valve into a
suitable container.
(2). Disconnect, remove and cap fittings and (1). Defuel helicopter. Drain remaining fuel
lines as required. from tank sump drain valve into a
suitable container.
B. Fuel Supply Lines Installation
(2). Remove left fuel tank access panel from
(Ref. Figure 404) passenger/cargo compartment floor.
(1). Install and torque engine fuel supply
(3). Unclamp fuel supply tube between fuel
lines (Ref. Table 401).
shutoff valve and Sta. 124.00 bulkhead
NOTE: It can be necessary to install a peelable elbow. Using backup wrench on bulk
shim washer between the Sta. 124.00 fire head elbow so it will not rotate, discon
wall and the bulkhead elbow washer to ob nect and remove tube.
tain the proper clocking angle and clearance
needed for line installation. (4). Unclamp start pump wire harness and
disconnect plug from cell cover recep
(2). Install Sta. 124.00 firewall elbow, with tacle.
jam nut on forward side of firewall, flat
of nut against stiffener, and washer (5). Unplug fuel quantity transmitter
against elbow. Torque elbow to connector from cell cover receptacle.
145—155 inch-pounds (16.38—17.51
Nm). Ensure elbow is clocked 12° - 16° (6). Unclamp and disconnect control cable
to the right from vertical after torquing. from fuel shutoff valve.
(3). Connect flexible drain lines to drain (7). Unfasten and remove Sta. 91.00 and
valves and clamp in place with lock 102.00 left fuel cell cover support
wire. brackets.
Page 409
MAINTENANCE MANUAL
Table 401. Fuel Line Torque Values

Torque
Item/Position Inch−Pounds (Nm)
Tube end−nuts; fuel shutoff valve; Sta. 124.00 Bulkhead elbow 230—260 (25.99—29.38)
Bulkhead elbow jamnut; Sta. 124.00 145—155 (16.38—17.51)
Three−port elbow jamnut; Sta. 124.00 (if equipped) 145—155 (16.38—17.51)
Drain valves (all) 95—105 (10.73—11.86)
Hose end−nuts; firewall/engine 230—260 (25.99—29.38)
(1). Apply a thin coat of petrolatum

CAUTION (CM114) to a new O-ring and pump
pressure port union threads. Install
D Do not strain or bend fuel quantity trans
O-ring on union. Install union in start
mitter float arm.
pump pressure port and torque to
D Handle fuel cell covers with care. Prying 280—305 inch-pounds (31.64—34.46
covers from cell openings or rough handl Nm).
ing can damage the cover seal or cell fit
ting. (2). Attach fuel supply hose to start pump
pressure port union. Torque hose nut to
(8). Remove fuel quantity transmitter 230—260 inch-pounds (25.99—29.38
flange screws. Lift transmitter assem Nm).
(9). Unbolt and prop fuel cell access cover CAUTION

open with suitably padded blocks.
D Make sure start pump wire lead cannot
(10). Use a backup wrench on valve and catch fuel quantity transmitter float to
separate fuel supply hose from fuel prevent an incorrect fuel quantity indica
shutoff valve. tion.
(11). Remove pump electrical receptacle from D Do not mark torque alignment stripes on
cover. Remove fuel cell cover. fuel cell internal hardware.
(12). Unbolt fuel pump from sump mount (3). Install pump wire around fuel supply
plate. Remove fuel pump and hose. hose. (Ref. Figure 404)
(13). Remove hose and union from pump
pressure port. (4). Clean start pump and sump plate
mount contact surfaces to establish an
electrical bond per requirements of FAA
B. Start Pump Installation
publication, EA-AC43.13-1A and 2A.
(Ref. Figure 404)
(5). Install start pump on sump plate with
bolts and washers. Torque bolts to
Consumable Materials 36—46 inch-pounds (4.06—5.20
(Ref. Section 91−00−00) Nm).
Item Nomenclature
CM114 Petrolatum (6). Install fuel cell cover (Ref. Fuel Cell
Cover Installation).
Page 410
MAINTENANCE MANUAL
TO ENGINE
HOSE AND FIRE

SLEEVE
WASHER
SHIM WASHER
(AS REQ'D)
NUT
HOSE ELBOW
STA 124.00
BULKHEAD
SUPPLY TUBE
HOSE
FUEL SUPPLY LINES INSTALLATION
BOLT, TORQUE; 36-46 IN. LB

HOSE NUT, TORQUE;
(4.06-5.20 NM)
230-260 IN. LB
(25.99-29.38 NM) WASHER
UNION, TORQUE;
280-305 IN. LB FUEL PICKUP FITTING
(31.64-34.46 NM) START PUMP
O-RING HOSE NUT, TORQUE;
230-260 IN. LB BOLT, TORQUE; 36-46 IN. LB
(25.99-29.38 NM) (4.06-5.20 NM)
TANK SUMP PLATE
STRUCTURE
UNION, TORQUE;
280-305 IN. LB
(31.64-34.46 NM)
WASHER
FUEL CELL O-RING
O-RING
TANK SUMP PLATE
TANK SUMP DRAIN VALVE,
TORQUE; 95-105 IN. LB
WASHER (10.73-11.86 NM)
BOLT, TORQUE; 36-46 IN. LB

(4.06-5.20 NM)
FUEL PICKUP INSTALLATION (369FF) O-RING
WASHER
TANK SUMP DRAIN VALVE,
BOLT, TORQUE; 36-46 IN. LB TORQUE; 95-105 IN. LB
(4.06-5.20 NM) (10.73-11.86 NM)
START PUMP INSTALLATION
G28-0004-1C
Figure 404. Start Pump and Fuel Lines Installation (Sheet 1 of 2)
Page 411
MAINTENANCE MANUAL
TOP VIEW
FUEL HOSE
BATHTUB FITTING
START PUMP
START PUMP WIRE
FLOAT ASSEMBLY
NOTE:
INSTALL WIRE AROUND FUEL INLET HOSE TO
PREVENT INTERFERENCE WITH FLOAT. G28-0000-404-1
Figure 404. Start Pump and Fuel Lines Installation (Sheet 2 of 2)
Page 412
MAINTENANCE MANUAL
6. Fuel Quantity Transmitter Replacement (7). Calibrate quantity transmitter as

required (Ref. Fuel Quantity Transmit
A. Fuel Quantity Transmitter Removal ter Calibration and Adjustment).
(Ref. Figure 404) B. Fuel Quantity Transmitter Installation
Avoid fuel vapor ignition (Ref. Figure 404)
ing tools and explosion proof work Consumable Materials
lights. Attach helicopter to an ap (Ref. Section 91−00−00)
proved electrical ground. Switch OFF Item Nomenclature
nal power and battery before opening CM124 Kerosene
quately ventilated. (1). Wipe fuel quantity transmitter flange
and cell fitting clean with kerosene
(CM124) on a clean lint free cloth. Wipe
parts dry.
suitable container.
(2). Position fuel quantity transmitter and
Prevent spontaneous com flange gasket on cell with float inboard
WARNING bustion or explosion. Never
and clear of obstructions.
use oxygen to purge or ventilate fuel
tank or fuel system components. Fuel, (3). Install screws and washers. Progres
either vapor or liquid, will violently sively torque screws to 20—25 inch-
react with an oxygen rich atmosphere. pounds (2.26—2.82 Nm). Lockwire
screws.
(2). Ventilate fuel tank with an inert gas
such as nitrogen or low pressure (4). Attach fuel quantity electrical connec
compressed air applied through filler tor to receptacle. Lockwire connector.
neck.
(5). Do a Fuel Quantity Transmitter
(3). Remove left fuel tank access panel from Functional Check.
passenger/cargo compartment floor.
(6). Install left fuel tank floor access panel
(4). Unplug fuel quantity transmitter (Ref. Fuel Cell Cover Installation).
7. Fuel System Drain Valve Replacement
Unclamp wire harness.
A. Fuel System Drain Valve Removal
CAUTION Avoid fuel vapor ignition
mitter float arm. ing tools and explosion proof work
lights. Attach helicopter to an ap
D Prevent fuel system contamination. In proved electrical ground. Switch OFF
stall a cover over quantity transmitter all electrical power. Disconnect exter
cell opening. Bag small parts to prevent nal power and battery before opening
loss or damage. fuel system. Ensure work area is ade
quately ventilated.
(5). Remove fuel quantity transmitter
flange screws. Lift transmitter assem Helicopter must be defueled and
bly out of cover opening. Discard CAUTION drained prior to removing tank
gasket. sump drain valve.
(6). Inspect fuel quantity transmitter as (1). Defuel helicopter, as required. Drain
required (Ref. Fuel Quantity Transmit remaining fuel from tank sump drain
ter Inspection). valve into a suitable container.
Page 413
MAINTENANCE MANUAL
(2). Remove lockwire from tank sump drain A. Fuel Cell Removal
valve.
(3). Using appropriate socket or wrench,
remove drain valve. ing tools and explosion proof work
lights. Attach helicopter to an ap
B. Fuel System Drain Valve Installation proved electrical ground. Switch OFF
Consumable Materials fuel system. Ensure work area is ade
(Ref. Section 91−00−00) quately ventilated.
Item Nomenclature
Prevent fuel system contamina
CM114 Petrolatum CAUTION tion. Install caps on the ends of
CM124 Kerosene hoses, tubes and fittings as parts are re
CM702 Lockwire CRES moved. Bag and identify small parts to pre
(1). Replace drain valve O-ring packings. from tank sump drain valve into a
Lubricate packings with kerosene suitable container.
(CM124), petrolatum (CM114) or jet
fuel. Prevent spontaneous com
(2). Install and torque sump drain valve to use oxygen to purge or ventilate fuel
95—105 inch-pounds (10.73—11.86 tank or fuel system components. Fuel,
Nm). Lockwire valve. either vapor or liquid, will violently
(3). Apply a torque alignment stripe to fuel
(2). Ventilate fuel tank with low pressure
line tube, hose and fitting fasteners.
forced air or an inert gas such as
(4). Refuel helicopter. nitrogen through filler neck.
(3). Remove right and left fuel tank access
(5). Check drain valve for leakage. panels from passenger/cargo compart
ment floor.
(6). Apply external power.
NOTE: The following procedures are required
(7). In crew compartment; set battery to access and separate the fuel cell intercon
switch to EXT PWR position. nect fitting and vent system aft crossover
before either cell can be removed from its
(8). Push fuel shutoff valve control knob in bay.
to open valve. (4). Unclamp fuel supply tube between fuel
shutoff valve and firewall Sta. 124.00
(9). With 250-C20B/R2 Engine: Set START
bulkhead elbow. Using a backup
PUMP switch ON to pressurize fuel
wrench on bulkhead elbow so it will not
system.
rotate, disconnect and remove tube.
8. Fuel Cell Replacement (5). With 250-C20B/R2 Engine or 250-C30
Engine With Optional Maintenance
Fuel Pump: Unclamp start pump wire
CAUTION harness and disconnect plug from cell
cover receptacle.
D Do not work on Uniroyal fuel cell in ambi
ent temperatures below 505F (105C). (6). Unplug fuel quantity transmitter
D Do not work on Engineering Fabric Corp.
fuel cell in ambient temperatures below (7). Unclamp and disconnect control cable
705F (215C). from fuel shutoff valve.
Page 414
MAINTENANCE MANUAL
(8). Unfasten and remove Sta. 91.00 and NOTE: At this point either cell can be removed,
102.00 left fuel cell cover support as required.
brackets from airframe structure.
(19). Remove left fuel cell as follows:
CAUTION (a). Remove cell suspension cords (Ref.
Figure 406).
mitter float arm. (b). Remove and discard forward and aft
D Handle fuel cell covers with care. Prying vent sealwashers.
covers from cell openings or rough handl (c). Lift inboard and outboard cell clips at
ing can damage the cover seal or cell fit each end of baffle support rod out of
ting. airframe hangers (Ref. Figure 405).
(9). Remove fuel quantity transmitter (d). Inside cell, work baffle support rod
flange screws. Lift transmitter assem ends out of cell nipples (Ref.
bly out of cover opening. Figure 405, detail B).
(10). Unbolt and prop fuel cell access cover (e). Remove support rod and baffle.
Cells are thin-walled and frag
(11). Using a backup wrench on valve, CAUTION ile. Avoid snagging or dragging
separate fuel supply hose from fuel cell over pointed or sharp edges. Do not
shutoff valve. Move fuel cell cover to get scratch or nick any of the cell's metal fit
at remaining hardware. tings.
(12). With 250-C20B/R2 Engine or 250-C30 (f). Collapse and fold cell lengthwise and
Engine With Optional Maintenance remove through floor access opening.
Fuel Pump: Unbolt start pump from
sump mount plate. Remove start pump, (20). Remove right fuel cell as follows:
hose and cell cover. Remove pump
electrical receptacle from cover. (a). Remove fuel filler cap and shield.
Unclamp and remove filler from cell
(13). With 250-C30 Engine: Unbolt fuel inlet filler neck.
fitting from sump plate. Remove fuel
inlet fitting, hose and cell cover. (b). Remove cell suspension cords.
(14). Unbolt and remove right fuel cell access (c). Remove and discard forward and aft
cover. vent sealwashers.
(d). Lift inboard and outboard cell clips at
(15). Mop up any remaining fuel in both cells each end of baffle support rod out of
with clean lint free cloth. Purge fuel airframe hangers.
cells with dry, forced air or inert gas.
(e). Inside cell, work baffle support rod
(16). Have an assistant hold the male end of ends out of cell nipples.
the cell interconnect fitting with the
special spanner wrench. Disassemble (f). Remove support rod and baffle.
fuel cell interconnect fitting (Ref.
Figure 405). Discard packing. Cells are thin-walled and frag
CAUTION ile. Avoid snagging or dragging
(17). Remove aft vent crossover U-tube nuts cell over pointed or sharp edges. Do not
from inside cells. scratch or nick any of the cell's metal fit
tings.
(18). Remove forward vent crossover tube
flange bolts and washers (Ref. (g). Collapse and fold cell lengthwise and
Figure 403). remove through floor access opening.
Page 415
MAINTENANCE MANUAL
B. Fuel Cell Installation (6). Insert baffle rod ends in nipples.

(7). Attach baffle external support hooks to
Consumable Materials airframe hangers.
Item Nomenclature (8). Wipe cell forward and aft vent fittings
and vent tube flanges clean with
CM114 Petrolatum
kerosene (CM124) or equivalent on a
CM124 Kerosene clean shop towel. Wipe dry.
CM809 Nylon cord
NOTE: Do not lubricate fitting sealwashers.
Lubricants can cause seal cold flow and sub
Special Tools
sequent leakage.
Item Nomenclature (9). Install new sealwashers on aft vent
ST802 Spanner wrench tube ends. Insert tube ends through cell
fittings and install nuts finger tight. Do
not torque at this time.
WARNING and fire. Use only nonspark (10). Position new sealwashers on cell
ing tools and explosion proof work forward vent fittings. Slip cell fitting
lights. Attach helicopter to an ap over vent tube.
proved electrical ground. Switch OFF NOTE: Permatex Form-A-Gasket No. 1 can be
all electrical power. Disconnect exter used to hold stand-off washers in place.
fuel system. Ensure work area is ade (11). Sandwich one AN960-10 washer on
quately ventilated. each side between vent tube flanges
and cell fittings. Align washers with
NOTE: bolt holes. Install bolts with one washer
D Discard used O-rings and sealwashers. under each bolt head and engage
Apply a thin coat of petrolatum (CM114) several threads to keep bolt in place. Do
to all new O-rings except cell vent system not torque bolts at this time.
sealwashers and interconnect fitting gas
ket. (12). Fasten fuel cell sump plate to airframe
with washers and bolts. Torque bolts to
D Always test and inspect a repaired fuel 36—46 inch-pounds (4.07—5.20
cell for leaks using soap bubble, phe Nm). Lockwire bolts.
nolphthalein or liquid stand method be
fore installing the cell in the helicopter. (13). Install a new O-ring on sump drain
valve. Install valve and torque to
(1). Air-vacuum all debris from cell bays. 95—105 inch-pounds (10.73—11.86
Ensure compartment liner will protect Nm). Lockwire valve.
cell from airframe points and edges.
Repair liner as required. NOTE: Do not lubricate fuel cell interconnect
fitting gasket. Lubrication can cause seal
(2). Wipe left and right cell interconnect cold flow and subsequent leakage.
fitting halves clean with kerosene
(CM124) on a clean lint free shop towel. (14). Thread gasket and nut onto cell
Wipe dry. interconnect fitting. While having an
assistant hold the opposite end of
(3). Fold cell lengthwise and position in bay fitting with spanner wrench (ST802)
through floor opening and unfold cell. tighten nut. Gap between nut and
female fitting shall not be more than
(4). Align cell openings with airframe 0.005 inch (0.127 mm) after tighten
openings. ing.
(5). Insert baffle support rods through (15). Connect powerplant supply tube to
baffle tabs (Ref. Figure 405).. firewall Sta. 124.00 bulkhead elbow.
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MAINTENANCE MANUAL
Loosely install tube support clamps, (24). Install filler on right fuel cell filler neck
screws, washers and nuts (Ref. with clamp and fuel filler shield. Install
Figure 404, detail A). Using a backup filler cap (Ref. Figure 405).
wrench on bulkhead elbow so it will not
rotate, torque tube nut to 230—260 C. Fuel Cell Cover Installation
inch-pounds (25.99—29.38 Nm).
(16). Torque aft vent U-tube interconnect
Item Nomenclature
(4.52—6.78 Nm).
CM114 Petrolatum
(17). Torque forward vent interconnect tube CM124 Kerosene
flange bolts to 36—46 inch-pounds
(4.07—5.20 Nm) (Ref. Figure 403).
(1). Inspect both cell cover seals for debond
(18). Install nylon support lacing (CM809). ing, nicks or cuts and any other damage
Anchor both ends of cord with a bowline having a leak producing potential.
knot (Ref. Figure 406). Replace covers as required.
(19). With 250-C20B/R2 Engine or 250-C30 (2). Wipe fuel cell and cover sealing sur
Engine With Optional Maintenance faces clean with kerosene (CM124) on a
Fuel Pump: Install union in start pump clean lint free cloth.
pressure port with a new O-ring
packing. Torque union to 280—305 (3). Install right cell cover bolts and
inch-pounds (31.64—34.46 Nm) (Ref. washers (Ref. Figure 405). Torque cover
Figure 404, detail B). Attach fuel bolts in increments to 35—45 inch-
supply hose to start pump pressure port pounds (3.95—5.08 Nm) in a cross
union. Torque hose nut to 230—260 pattern.
(4). Apply a coating of petrolatum (CM114)
Ensure start pump wire lead is to a new fuel shutoff valve/cover
CAUTION wrapped around or tie-wrapped sealwasher. Install valve on cell cover
(using only MS3367 Ty-Raps) to fuel supply with sealwasher next to valve body and
hose so that there is no possibility of its in valve properly aligned to make connec
terfering with fuel quantity transmitter tion with valve control cable. Install
float mechanism. Ensure electrical connec and torque valve jamnut to 240—280
tions will not be strained by G-induced hose inch-pounds (27.12—31.64 Nm) (Ref.
movements. Figure 402).
(20). Wrap pump wire around supply hose or (5). With 250-C20B/R2 Engine or 250-C30
secure wire with ty-raps as required. Engine With Optional Maintenance
Fuel Pump: Plug start pump wire
(21). Clean start pump and sump plate harness cell cover hole with a bulkhead
mount contact surfaces to establish an union, sealwasher inside cover and a
electrical bond per requirements of FAA plain washer outside. Install jamnut
publication, EA-AC43.13-1A and 2A. and torque to 120—150 inch-pounds
(13.56—16.95 Nm). Install cap outside
(22). Install start pump on sump plate with of cell. Torque cap to 120—150 inch-
bolts and washers. Torque bolts to pounds (13.56—16.95 Nm).
36—46 inch-pounds (4.07—5.20
Nm). (6). Position cover over cell opening.
Connect fuel supply hose to fuel shutoff
(23). With 250-C30 Engine: Attach fuel inlet valve. Torque hose nut to 230—260
fitting to cell sump plate with bolts and inch-pounds (25.99—29.38 Nm).
washers. Torque bolts to 36—46 Ensure hose will not be twisted when
inch-pounds (4.07—5.20 Nm). cover is installed.
Page 417
MAINTENANCE MANUAL
(7). With 250-C20B/R2 Engine or 250-C30 (25.99—29.38 Nm). Tighten supply

Engine With Optional Maintenance tube clamp fasteners.
Fuel Pump: Install start pump wiring
harness receptacle on fuel cell cover. (14). Slip control cable through hole in fuel
shutoff valve lever swivel.
(8). Install three support brackets on Sta.
(15). Rig cable control system (Ref. Fuel
91.00 and 102.00 floor cross-members
Shutoff Valve Control Cable Installa
with washers and screws. Torque
tion).
screws to 20—25 inch-pounds
(2.26—2.82 Nm). (16). Attach fuel quantity electrical connec
tor to receptacle. Lockwire connector.
(9). Finger tighten fuel supply tube nut
onto fuel shutoff valve. Position control (17). With 250-C20B/R2 Engine or 250-C30
cable and electrical harness clamps on Engine With Optional Maintenance
cover. Fuel Pump: Complete a start pump
operation and system pressurization
(10). Install cover bolts and washers. Install check with a concurrent leak inspection
drilled-head bolt one bolt hole inboard (Ref. Start Pump Operational Check
of pump electrical receptacle. Progres (Model 250-C20 Series Engines).
sively torque cover bolts to 35—45
inch-pounds (3.95—5.08 Nm) in a (18). With 250-C20B/R2 Engine or 250-C30
cross pattern. Engine With Optional Maintenance
Fuel Pump: Attach start pump electri
(11). Lockwire electrical receptacle nut to cal connector to receptacle. Lockwire
drilled bolt. connector.
(12). Inspect fuel quantity transmitter flange NOTE: To ensure that the C30 engine installa
gasket for condition. Replace gasket if tion fuel system is free of leaks you must do
damaged or deteriorated. Position fuel a vacuum leak test.
quantity transmitter in cell with float
(19). Complete a vacuum leak inspection on
inboard and clear of obstacles. Install
all helicopter models.
screws and washers. Progressively
torque screws to 20—25 inch-pounds (20). Apply a torque alignment stripe to fuel
(2.26—2.82 Nm). Lockwire screws. line tube, hose and fitting fasteners.
(13). Torque power plant fuel supply tube (21). Install left and right cell access panels
nut to 230—260 inch-pounds on cargo compartment floor.
Page 418
MAINTENANCE MANUAL
0.005 IN. (0.127 MM) MAXIMUM GAP

BETWEEN NUT AND FITTING
CELL INTERCONNECT NUT

FITTING
GASKET HELICOPTER
CL
BAFFLE NIPPLE
SUPPORT ROD
FUEL CELL INTERCONNECT
BOLT
FILLER GROMMET
FUEL FILLER CAP BAFFLE SUPPORT HOOK
RIGHT FUEL CELL

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

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

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

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

NUT
G28−0005C
Figure 405. Fuel Cells
Page 419
MAINTENANCE MANUAL
CELL TOP ATTACHMENT

(TYP)
CELL SIDE ATTACHMENT

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

BOWLINE KNOT
NYLON LACING
LOOP
START LACING WITH

BOWLINE KNOT
(FOLLOW ARROWS)
END LACING WITH

BOWLINE KNOT G28-0006
Figure 406. Fuel Cell Support Lacing
Page 420
MAINTENANCE MANUAL
FUEL SYSTEM
ADJUSTMENT AND TEST
1. Deleted B. Test
Power On
NOTE: This procedure has been moved (ref.
Section 28-00-10, Adjustment and Test,
Procedure 1., Fuel Quantity Test).
2. Deleted (1). Set the BAT switch to EXT PWR.

(2). Set the INSTR circuit breaker.
NOTE: This procedure has been deleted.
(3). Set the CAUTION and WARNING light
3. FUEL LEVEL LOW WARNING Light Test dimmer control to BRT.
(4). Do a check of the CAUTION and
WARNING light array.
Special Tools
(Ref. Section 91-00-00) (a). As necessary, replace defective lamps.
Item Nomenclature
(5). With a known fuel quantity above 35
N/A Inclinometer, Sperry Model 45 pounds, the WARNING lamp must be
OFF.
Do not let fuel vapor accu (6). Make sure the WARNING light does
WARNING mulate. Ignition and fire can not glow or flicker:
occur. Attach the helicopter to an ap
proved electrical ground. Set power to (a). A current leak past the low level
OFF. Disconnect external power and WARNING transistor can cause the
battery before opening fuel system. WARNING lamp to glow when the
Work in an open, well-ventilated area, fuel quantity is above the low level
away from possible ignition sources. calibration value (35 pounds).
Only use tools that do not cause sparks (b). Install a 510-ohm resistor in the
and explosion-proof work lights. transmitter CAUTION light circuit
(ref. Repairs, Fuel System).
Power Off
(c). If a resistor was installed before,
replace the fuel quantity transmitter
(ref. Removal / Installation, 6. Fuel
Quantity Transmitter Replacement),
and calibrate the system (ref. Adjust
ment / Test, 4. Fuel Quantity Trans
A. Setup mitter Calibration and Adjustment).
(1). Defuel and refuel the helicopter to (7). Remove the left fuel cell floor access
bring the fuel quantity above the 35 LB panel.
low level WARNING point (ref.
12-00-00, 3.D. Fuel System Draining, (8). Make sure the fuel quantity transmit
and 1.C. Fuel System Filling). ter Terminal D is grounded to the
airframe with a jumper wire.
(2). Connect external ground power to the (9). The FUEL LEVEL LOW WARNING
helicopter. light must be a steady bright light.
Page 501
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MAINTENANCE MANUAL
Power Off B. Fuel Level Calibration

An incorrectly calibrated
WARNING Fuel Quantity Transmitter
can cause the helicopter to lose engine
operation because of fuel starvation.
(a). If the light is intermittent or does not Obey the recommended Fuel Quantity
come ON at all, disconnect all power Transmitter calibration values in the
and troubleshoot the wiring (ref. applicable Rotorcraft Flight Manual.
Fault Isolation).
(1). Let the float arm rest on the lower stop.
(b). If the wiring and light are not
defective, do Procedure 4., Fuel (2). Measure the resistance across pins B
Quantity Transmitter Calibration and H on the fuel quantity transmitter
and Adjustment. with an ohmmeter:
4. Fuel Quantity Transmitter Calibration and (a). Part Number (PN) 369A4245 trans
Adjustment mitter resistance must be 0 to 3
ohms.
(Ref. Figure 501)
(b). PN 369D296303 transmitter resis
Special Tools tance must be 0.10 to 2.00 ohms.
NOTE: Bend the float-stop down to decrease,
Item Nomenclature
or up to increase, resistance.
N/A Test harness and No. 328 lamp
(3). Lift the float arm to contact with the
upper stop.
Do not let fuel vapor accu
WARNING mulate. Ignition and fire can (a). 369A4245 Transmitters Only —
proved electrical ground. Set power to 1). Measure the resistance between
OFF. Disconnect external power and the steel wire spring support
battery before opening fuel system. bracket and the mount flange.
Work in an open, well-ventilated area,
away from possible ignition sources. 2). The resistance must be more than
Only use tools that do not cause sparks 2 Megohms.
and explosion-proof work lights. (b). Both 369A4245 and 369D296303
Power Off Transmitters —
1). Measure the resistance across pins
B and H on the fuel quantity
transmitter with an ohmmeter.
A. Setup 2). Raise the float arm against the

upper stop.
(1). Remove the fuel quantity transmitter
from the tank (ref. Removal / Installa a). The resistance must be 88 to 95
tion, 6.A. Fuel Quantity Transmitter ohms.
Removal).
b). Bend the stop to adjust the
(2). Install a cover on the cell opening. resistance value.
(3). Fabricate a stand to support quantity 3). Measure the float travel between
transmitter level about 11 inch (28 the empty and full stops.
cm) above the work table surface.
a). Make sure the travel is within
(4). Allow access to the float arm. limits (ref. Figure 501).
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MAINTENANCE MANUAL
NO. 328 A R
LAMP B BLU
+ D RED
Q
24 VDC
POWER B
SUPPLY E G
BLK
- H BLK
P251
CONNECTOR
FUEL QUANTITY
TRANSMITTER
TEST CONNECTIONS
1.75 IN. (4.45 CM)
DIA (MAX.
CONNECTOR SEALANT
ENVELOPE)
0.75 IN. (4.45 CM) MAX.

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

(25.60 CM)
BRACKET RADIUS
FLOAT STOP
(EMPTY)
8.99-9.11 IN.
(22.84-23.134CM)
SPRING CONTACT
FLOAT 2.15 IN. (5.46 CM)
(NOTE 2)
A
GROUND TERMINAL
G
EMPTY
1.25 IN.
TRANSISTOR SWITCH (3.175 CM)
B (ON UNDERSIDE) (NOTE 1)
CALIBRATION 369A4245 (EARLY UNIT)
NOTES:
1. CAUTION LIGHT ON, 35 LBS REMAINING.
TANK UNIT 2. CAUTION LIGHT ON, 70 LBS REMAINING.
CONNECTIONS NOT APPROVED FOR COMMERCIAL
APPLICATION.
G28−0007−1A
Figure 501. Fuel Quantity Transmitter Calibration (Sheet 1 of 2)
Page 503
28-00-00 TR18-001
MAINTENANCE MANUAL
0.62 IN.
CONNECTOR (15.75 MM)
MOUNTING FLANGE
FLOAT STOP FULL

(FULL)
BOTTOM OF FLOAT
10.08 IN.
(25.60 CM)
SPRING RADIUS
FLOAT STOP
8.41-8.45 IN.
(EMPTY)
(21.36-21.46 CM)
2.13-2.17 IN.
(5.41-5.51 CM)
SPRING CONTACT (NOTE 2)
(NOTE 1)
0.91-0.95 IN.
(23.11-24.13 MM)
NOTES: FLOAT
1. CAUTION LIGHT ON, 35 LBS REMAINING. EMPTY
2. CAUTION LIGHT ON, 70 LBS REMAINING.
NOT APPROVED FOR COMMERCIAL
APPLICATIONS. CALIBRATION 369D296303 (CURRENT UNIT) G28−0007−2A
Figure 501. Fuel Quantity Transmitter Calibration (Sheet 2 of 2)
C. Transmitter Adjustment Power Off
Fuel Quantity Transmitter

WARNING incorrect adjustment:
(2). Attach the test harness to transmitter
D Commercial helicopter: 35 pounds connector pins B and H and a power
source.
D Non-commercial helicopter: 70
pounds (NOT APPROVED FOR COM (3). Connect external ground power to the
MERCIAL APPLICATION) helicopter.
Power On
(1). Fabricate a test harness with a No. 328
lamp bulb and P251 female connector
half.
(4). Set BAT to EXT PWR.
NOTE: An alternative test harness can be (5). Use an ohmmeter to measure resis
made with individual insulated tubular pin tance across pins B and H on the fuel
connectors. quantity transmitter.
Page 504
TR18-001 28-00-00
MAINTENANCE MANUAL
(6). (PN 369A4245) Do a test of transmit 4). If a resistor was installed before,
ter units: replace the quantity transmitter
and calibrate the system (ref.
(a). Hold the float arm between the stops. Removal and Installation, 6. Fuel
1). Test lamp must be OFF. Quantity Transmitter Replace
ment).
(b). Lower the float arm until the test
lamp illuminates (just as it contacts (b). Lower the float arm until the test
the bracket-supported steel wire). lamp illuminates (just as it contacts
the bracket-supported steel wire).
(c). Mark the float arm centerline
position on a ruler or stick at the (c). Mark the float arm centerline
point where the lamp comes on. position on a ruler or stick where
lamp comes ON.
(d). Lower the float.
(d). Lower the float.
(e). Mark the ruler at the float arm
centerline position with the float (e). Mark the ruler at the float arm
stopped at the bottom. centerline position with the float
stopped at the bottom.
(f). The distance between the upper and
lower marks must be: (f). The distance between the upper and
lower marks must be:
1). 1.25 inch (31.8 mm) for 35
pounds (nominal) fuel remaining. 1). 0.91 to 0.95 inch (23.1 to 24.1
mm) for 35 pounds (nominal) fuel
2). 2.15 inch (54.6 mm) for 70 remaining .
pounds (nominal) fuel remaining.
2). 2.13 to 2.17 inch (54.1 to 55.1
(7). (PNs 369D296303 or mm) for 70 pound (nominal) fuel
369D296303-701) Do a test of trans remaining.
mitter units:
(8). Bend the transmitter bracket spring
(a). Hold the float arm between the stops. wire to adjust the light-ON position.
1). Make sure the test lamp is OFF. (9). Make sure that lamp operation and
2). A glowing WARNING lamp with float dimensions are within the speci
the fuel quantity above the low fied tolerances.
level calibration value is an indica Power Off
tion that the current leaks past the
low level WARNING transistor
(switch).
3). Install a 510-ohm resistor in the
transmitter CAUTION light circuit (10). Disconnect the electrical power and test
(ref. Repairs, Fuel System). equipment.
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MAINTENANCE MANUAL
5. Transmitter Functional Check (d). As necessary, put blocks on the

ground against the forward and aft
side of the ground handling wheels to
Special Tools keep the helicopter stable.
Item Nomenclature B. Check
ST203 Hydraulic jack: 1-5 ton (900-4500 kg) (1). Reset the INST and PNL LT circuit
ST205 Inclinometer breakers.
Power On
Do not let fuel vapor accu
WARNING mulate. Ignition and fire can
proved electrical ground. Set power to
OFF. Disconnect external power and (2). Set the BAT switch to EXT PWR.
battery before opening fuel system.
Work in an open, well-ventilated area, NOTE: All gauge readings are taken from the
away from possible ignition sources. centerline of the fuel quantity indicator
Only use tools that do not cause sparks pointer.
and explosion-proof work lights.
(3). Make sure that the fuel quantity gauge
needle points to E (empty) with the
Power Off pointer centerline between the outer
and inner edge of the E graduation
mark.
(4). Make sure that the FUEL LEVEL
LOW WARNING light is ON.
A. Setup
NOTE: Do not bend float arm for adjustment of
(1). Move the helicopter to level ground (ref. fuel quantity indicating system.
09-00-00, Maintenance Practices,
Procedure 2. Helicopter Towing and (5). If adjustments are necessary, shut
Manual Moving). down the external electrical power, and
remove transmitter, bend the float
stops as necessary and re-install
(2). Attach the helicopter to an approved
transmitter.
electrical ground.
(6). Pump seven gallons of fuel into tank.
(3). Drain the fuel from the fuel tank while
the helicopter is at normal ground Power On
attitude (ref. 12-00-00, Procedure 3.D.
Fuel System Draining).
(4). Adjust the helicopter level attitude (ref.

08-00-00, Procedure 1. Helicopter (7). Set the BAT switch to EXT PWR.
Leveling):
(8). The FUEL LEVEL LOW WARNING
(a). Put ST205 inclinometer on the rear light must be out, and the gauge must
deck between Sta. 100 and 104. indicate approximately 45 LB.
(9). Disconnect the fuel supply hose from
(b). Lift the helicopter with ST203 the engine.
hydraulic jack to get a 2° nose down
attitude on the inclinometer. (10). Have an assistant hold the end of the
fuel hose in a suitable 10 gallon (37.85
(c). Make the helicopter level laterally. liter) container.
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MAINTENANCE MANUAL
(11). Push in the fuel control valve knob to NOTE: Additional adjustments to the float arm
open the fuel shutoff valve. or low level contact wire must have a verifi
cation check and the complete check proce
(12). (C20 Series Engines) Set fuel start dure sequence done again.
pump switch to START PUMP.
(19). Connect the fuel supply hose to the
(13). (C30 Engine) Attach a siphon pump to engine inlet port.
the fuel supply hose to drain the fuel
tank. (a). Torque the hose nut 230 to 260
inch-pound (25.99 to 29.38 Nm).
(14). Monitor the fuel quantity gauge as you
slowly drain fuel into a clean calibrated (20). Install the quantity transmitter (ref.
container. Fuel Quantity Transmitter Installa
tion).
(15). When the FUEL LOW CAUTION light
comes ON, immediately stop the fuel 6. FUEL FILTER (Bypass) CAUTION Light
flow. Test
(a). The container must have 3 to 10 A. Setup
pounds (1.4 to 4.5 kg) of fuel.
Power Off
(b). If the container has more or less than
3 to 10 pounds (1.4 to 4.5 kg) of
fuel, adjust the low-fuel whisker:
1). Disconnect the fuel transmitter
from the fuel cell cover. (1). Connect external ground power to the
helicopter.
2). If the container has less than 3
pounds (1.4 kg) of fuel, bend the B. Test
low-fuel whisker on the transmit Power On
ter down.
3). If the container has more than 10
pounds (4.5 kg) of fuel, bend the
low-fuel whisker on the transmit
ter up. (1). Set the BAT switch to EXT PWR.
(c). Install the transmitter. (2). Set the INSTR circuit breaker.
(16). Drain addition fuel into the calibrated (3). Set the CAUTION and WARNING light
container until the fuel level is at the dimmer control to BRT.
10 pounds (4.5 kg) mark. (4). Do a check of the CAUTION and
(a). The needle pointer must align on the WARNING light array.
center of the 35 pound red dot mark. (a). As necessary, replace defective lamps.
(b). The FUEL LOW CAUTION light (5). If the light is intermittent or does not
must still be ON. come ON at all, disconnect all power
(17). Drain the remaining fuel: and do the wiring troubleshooting
procedure (ref. Fault Isolation).
(a). Observe that gauge needle falls to E
(empty) as the tank becomes empty. (6). If the wiring and light are not defective,
do Procedure 7. Fuel Filter (Bypass)
(18). Do the adjustments again, as necessary. Pressure Switch Test.
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28-00-00 TR18-001
MAINTENANCE MANUAL
7. Fuel Filter (Bypass) Pressure Switch Test (3). Disconnect the battery.
(Ref. Figure 502, Figure 503, or Figure 504) (4). Open the engine access doors.
B. Test
WARNING
(1). Locate the pressure switch on the
D Air in the fuel system will cause a engine fuel pump filter (ref. Figure 502,
power reduction or flameout. Do a Figure 503, or Figure 504).
fuel system vacuum leak check and
system air bleed after the fuel system (2). Disconnect the bypass switch wire
is opened to the atmosphere and be splice.
fore the helicopter is released for
flight. The pressure switch is easily
CAUTION damaged if a slight shearing
D (Model 250-C20 Series Engines)
force is applied. Keep both halves of the
Make sure the start pump operates
switch hex flats stable with a wrench when
before you take fuel samples from
hardware is connected or disconnected.
the system supply line drain valves.
A. Setup NOTE: Do not disassemble the bypass pressure
switch. The switch is not field repairable.
Power Off Return defective switches to the vendor for
repair.
NOTE: For all torque values in this procedure,
ref. Figure 502, Figure 503, or Figure 504.
(1). Set all switches to OFF. (3). Disconnect the hose from from the
switch bushing.
(2). Remove external ground power from
the helicopter. (a). Put a cap on the hose.
ENGINE FUEL
PUMP FILTER AFTER FILTER
O-RING
BEFORE FILTER PORT (AF)
REDUCER, TORQUE 40-50 INCH-POUND PORT (BF)
(4.52-5.65 NM)
HOSE
FITTING, TORQUE 40-50 INCH-POUND
(4.52-5.65 NM)
O-RING
FUEL FILTER PRESSURE SWITCH,
TORQUE 40-50 INCH-POUND
ELBOW, TORQUE 20-25 INCH-POUND (4.52-5.65 NM)
(2.26-2.82 NM) (2 PL) O-RING
BUSHING, TORQUE 40-50 INCH-POUND
(4.52-5.65 NM) G28−0000−502−1
Figure 502. Fuel Filter Caution Light Pressure Switch (C20 Engines)
Page 508
TR18-001 28-00-00
MAINTENANCE MANUAL
AFTER FILTER
PRESSURE TAP
BEFORE FILTER
PRESSURE TAP O-RING
FUEL PUMP
SEAL DRAIN
O-RING FITTING, TORQUE 40-50 INCH-POUND
(4.52-5.65 NM)
O-RING
REDUCER, TORQUE 40-50 INCH-POUND FUEL FILTER PRESSURE SWITCH,
(4.52-5.65 NM) TORQUE 40-50 INCH-POUND
(4.52-5.65 NM)
(2.26-2.82 NM) O-RING
(4.52-5.65 NM)

(2.26-2.82 NM)
HOSE
G28−0000−503−1
Figure 503. Fuel Filter Caution Light Pressure Switch (C20R/2 Engines with CECO Pump)
ELBOW, TORQUE 20-25 INCH-POUND

(2.26-2.82 NM)
BEFORE FILTER
PORT (BF) REDUCER, TORQUE 20-25 INCH-POUND
(2.26-2.82 NM)
FITTING, TORQUE 40-50 INCH-POUND
(4.52-5.65 NM) ENGINE FUEL
PUMP FILTER
FUEL FILTER PRESSURE SWITCH,
(4.52-5.65 NM)

(4.52-5.65 NM)
ELBOW, TORQUE 20-25 INCH-POUND

(2.26-2.82 NM)
HOSE
G28−0000−504−1
Figure 504. Fuel Filter Caution Light Pressure Switch (C30 Engine)
Page 509
28-00-00 TR18-001
MAINTENANCE MANUAL
(4). Remove the fuel pressure switch with

the bushing intact from the after filter
(AF) port adapter.
(5). Install the plug with an O-ring in the

adapter fitting.
C. Bench Test of PN 369H8144 Pressure 36 INCH

Switch SCALE
(1). Assemble the test equipment (ref. 3/8 INCH TYGON TUBING
(OR EQUIVALENT)
Figure 505). 36 INCH
(2). Connect the tester to the switch lead.
(3). Connect the ground test lead to one of

the the screws in the housing.
PORT A
(4). Remove the bushing and O-ring from
the switch.
(5). Attach tubing to the switch inlet port. SCREW (TYP)
SWITCH
(6). Fully dry the switch so leakage can be
detected during the test.
OHMMETER
OR
(7). Add fuel to the tube. CONTINUITY TESTER
PORT B
(OPEN TO
ATMOSPHERE)
(8). Make sure the switch closes as the fuel
column height is between 24.5 and
35.0 inch (62.23 and 88.90 cm) with
G28−0000−505−1
an ohmmeter.
Figure 505. Test for the 369H8144 Engine
(9). Examine the switch for leakage around Fuel Filter Pressure Switch
the diaphragm.
D. Bench Test of PN 369D28144 Pressure
Switch
(a). No leaks are permitted.
(1). Assemble the test equipment (ref.
Figure 506).
(b). Replace a switch with a leak.
(a). Connect the tester to the pressure
(10). Remove the switch from the test switch lead.
apparatus. (b). Connect the ground test lead to one
of the screws on the housing.
(11). Install a new O-ring and bushing on (2). Pressure Method:
the switch.
(a). Remove the bushing and O-ring from
the switch.
(12). Torque switch bushing (ref. Figure 502,
Figure 503, or Figure 504). (b). Attach the tubing to Port A.
Page 510
TR18-001 28-00-00
MAINTENANCE MANUAL
(c). The tubing must be airtight. (i). Make sure the switch opens when the
vacuum goes near 4 psig (8.1
(d). Port B must be open to atmosphere. inch-hg) with an ohmmeter.
(e). Add pressure to the tube.
(4). Remove the switch from the test
(f). The switch must close when the apparatus.
pressure is 8 to 9 psig (16.3 to 18.3
inch-hg) with an ohmmeter. (5). Install a new O-ring and bushing on
the switch.
(g). Hold the pressure for five minutes.
(h). Do a check for bleed-off. (a). Torque the switch bushing.
NOTE: If there is bleed-off, there can be a leak

in the switch. PRESSURE METHOD:
APPLY 8-9 PSIG (16.3-18.3 IN. HG.) TO CLOSE SWITCH
1). If there is bleed-off, replace the BLEED OFF TO 4 PSIG (8.1 IN. HG.) TO OPEN SWITCH
switch.
(i). Slowly release the pressure.
(j). Use an ohmmeter to make sure the
switch opens as the pressure goes
near 4 psig (8.1 inch-hg).
(3). Vacuum Method:
PORT A
(a). Remove the bushing and O-ring from
the switch.
(b). Attach tubing to switch port B as
shown. SCREW (6 PL)
SWITCH
(c). Port A must be open to atmosphere
NOTE: The tubing must be airtight.
OHMMETER
(d). Pull a vacuum on the tube. OR
CONTINUITY TESTER
(e). Make sure the switch closes when the PORT B
vacuum is between 8 to 9 psig (16.3
to 18.3 inch-hg) with an ohmmeter.
(f). Hold the vacuum for five minutes.
VACUUM METHOD:
(g). Do a check for bleed-off. APPLY 8-9 PSIG (16.3-18.3 IN. HG.) TO CLOSE SWITCH
BLEED OFF TO 4 PSIG (8.1 IN. HG.) TO OPEN SWITCH
NOTE: If there is bleed-off, there can be a leak
in the switch.
G28−0000−506−1
1). If there is bleed-off, replace the
switch.
Figure 506. Test for the 369D28144 Engine
(h). Slowly release the vacuum. Fuel Filter Pressure Switch
Page 511
28-00-00 TR18-001
MAINTENANCE MANUAL
E. Operational Check of Switches on (a). Replace a switch with a leak.

250−C20/C20R2 Engines
(15). Disconnect the jumper wire between
Power Off pressure switch and ground.
Power Off
(1). Uncap and attach a bypass hose to the

bushing.
(16). Set the start pump switch to OFF.
(a). Torque the hose nut.
(2). Install a plug and O-ring in the (17). Set the BAT switch to OFF.
adapter fitting. (18). Disconnect the external power and
(3). Connect and insulate the switch wire battery.
splice.
(19). Disconnect the bypass hose from the
(4). Have an assistant hold the switch clear switch bushing.
of adjacent structures.
(20). Install an airtight cap on the hose.
(5). Connect the battery.
(21). Remove the plug from the adapter
(6). Connect external ground power to the fitting.
helicopter.
(22). Install the bypass switch assembly with
Power On a new O-ring in the adapter fitting.
(23). Torque the switch assembly.
(24). Remove the plug from the bypass hose.
(7). Set the BAT switch to EXT PWR.
(25). Attach the hose to the switch bushing.
(8). Reset the INSTR circuit breaker.
(a). Torque the hose nut.
(9). Set the CAUTION and WARNING light
dimmer control to BRT. (26). Install the insulating sleeve.
(10). Do a check of the CAUTION and (27). Connect the switch wire knife splice.
WARNING light array.
F. Close−Up
(a). As necessary, replace defective lamps.
(1). Bleed the fuel system (ref. Maintenance
(11). Connect a jumper wire between the Practices, 7. Fuel System Air Bleed
switch body and Airframe Ground E12. (Model 250-C30 Engine Installation) or
8. Fuel System Air Bleed (Model
(12). Set the start pump switch to ON.
250-C20B/R2 Engine Installation)).
(13). Make sure FUEL FILTER (bypass)
CAUTION light illuminates. (2). Operate the engine (ref. the applicable
Rotorcraft Flight Manual).
(a). If light does not illuminate, replace
fuel filter bypass switch. (3). Do a check of the fuel system for correct
operation.
(b). Do an operational check.
(4). Stop the engine (ref. the applicable
(14). Make sure there is no leakage from the Rotorcraft Flight Manual).
switch diaphragm through the open
port while pressurized. (5). Examine the fuel system for leaks.
Page 512
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MAINTENANCE MANUAL
FUEL SYSTEM
INSPECTION/CHECK
WARNING Consumable Materials

D Avoid fuel vapor ignition and fire. Item Nomenclature
Use only nonsparking tools and ex
plosion proof work lights. Attach he CM309 Lacquer, green
licopter to an approved electrical N/A Lockwire CRES
ground. Switch OFF all electrical
CM714 Tape, pressure sensitive
power. Disconnect external power
and battery before opening fuel sys
tem. Ensure work area is adequately
ventilated. (1). Remove left instrument panel fairing.
Check for control cables marked (Jairen
D Air entering the airframe fuel supply Inc. 16722 PN 110262-15N) with a date
lines can cause a power reduction or of (5/18) or later, and has a swage less
flameout. Fuel system vacuum leak than 0.50 inch (12.70 mm) in length.
check and fuel air bleed procedures These cables are MDHI part numbers
must be done after opening fuel the 369A8137-503 and -603.
supply system for any reason, prior
to releasing helicopter for flight. (a). Inspect cable casing for a green
stripe. The green stripe indicates
1. Fuel System General Inspection that cable has been previously pull
tested.
(1). Remove right and left fuel tank floor
access panels. (2). Unpainted control cables, P/N
369A8137-503 and -603 fitting the
(2). Inspect fuselage bottom skin for preceding description require a manda
evidence of fuel leakage. No leaks tory 50 pound (222.4 N) pull test to
allowed. Determine source and repair determine cable swage integrity.
as required.
(3). Inspect fuel lines, fittings, cell access (a). Unclamp cable from canopy or
covers, fuel quantity unit, clamps and instrument panel support structure
attaching hardware for leakage, (Ref. Figure 401).
corrosion and security. Inspect fire
sleeves for cuts, tears and punctures. (b). Behind instrument panel; back cable
No leakage allowed. Repair or replace retaining nut completely off threaded
components as required. portion of casing.
(4). Inspect electrical wiring and connectors (c). Wrap a 12 inch (30.48 cm) length of 2
for corrosion and security. Replace or inch (5.08 cm) wide duct tape or
repair wiring as required. equivalent around cable casing about
0.50 inch (12.70 mm) behind casing
(5). If start pump wire is ty-rapped to start swage or instrument panel, whichev
pump line, inspect security and condi er is furthest from front of instru
tion of ty-raps. ment panel.
2. Fuel Shutoff Valve Control Cable Swage (d). Wrap one end of 0.042 lockwire
Test (369D/E) around cable and attach the other
end to the spring scale (Ref.
(Ref. Figure 601) Figure 601).
Page 601
MAINTENANCE MANUAL
INSTRUMENT PANEL
CLAMP
FRONT OF INSTRUMENT
CABLE CASING PANEL
NOTCHED WASHER
TAPE LOCKWIRE
SWAGE
0.265 INCH (6.731 MM)
THREADS
FLANGE
NUT
NOTCHED WASHER TO SLIP
OVER CABLE CASING
BACK OF INSTRUMENT
PANEL
G28-0011B
Figure 601. Fuel Shut−Off Control Cable, PN 369A8137−503 Pull Test
Page 602
MAINTENANCE MANUAL
(e). Notch a 0.265 ID x 0.063 inch (6.73 (5). Ensure shutoff valve control knob is
ID x 1.60 mm) thick washer and pushed in. Valve ball must be wide
position over cable between tape and open.
back of instrument panel.
(6). Pull control knob out to stop. Valve ball
Sudden cable separation should be closed.
WARNING can cause serious personal
injury. Be properly braced while pull (7). Valves that can not be fully closed or
ing on the cable. opened must be overhauled or replaced
prior to further flight.
(f). Apply a steady tension through the
spring scale up to 50 pounds (222.4 (8). Disconnect control cable from valve.
N). Relax the tension.
(9). Inspect shutoff valve lever and cable
(g). Inspect cable casing swage for swivel hardware for corrosion and wear.
separation. Check lever for smooth movement from
closed to open stops.
(h). Replace separated/unserviceable
cable assemblies. (10). Use a spring scale to check tension
required to move valve lever from full
(i). If the swage held without apparent
open to closed. Design force require
damage, paint a green lacquer
ment is 1.5—3.5 pounds (6.7—15.6 N)
(CM309) stripe around the swage/
maximum.
casing joint.
(3). Install and secure cable hardware. (11). Inspect valve for evidence of external
leakage. External leakage not allowed.
(4). Do the following inspections and checks
on all model helicopters. (12). Check that lever detents at open and
closed positions. Repair or replace valve
(a). Remove left fuel cell floor access as required.
panel.
(13). Connect and rig valve control cable.
(b). Inspect fuel shutoff cable, nylon Install cotter pin on cable swivel.
grommets and attaching hardware
for condition and security. 4. Fuel Quantity Transmitter Inspection
(c). Operate cable and check for binding. (1). Remove left fuel cell floor access panel.
Cable bend radius to be 3.5 inches,
minimum. (2). Check 369D helicopters for potting
compound on top of transmitter. Apply
(d). Push knob in and check for missing potting compound per repair
0.090—0.150 inch (2.286—3.81 instructions. Check transmitter
mm) gap between bottom of plunger electrical terminals and wire harness
and top of plunger housing (Ref. where exposed for security and condi
Figure 401). tion.
3. Fuel Shutoff Valve Inspection (3). Where potting compound has been
installed, use a pointed probe and
(1). Shut down and disconnect all electrical
bright light to inspect interface between
power.
potting compound and flange plate for
(2). In cargo/passenger compartment, open voids, debonding and separations.
left fuel cell access panel. Inspect area around terminal fasteners
for voids. No separations or voids are
(3). Disconnect fuel supply tube from fuel allowed.
shutoff valve.
(4). Remove and test unit as required.
(4). Use an inspection mirror and flashlight
to check shutoff valve ball position. (5). Repair or replace potting compound.
Page 603
MAINTENANCE MANUAL
5. Tank Vent System Inspection Reconnect hose P/N 369D281071 at the

forward vent crossover fitting.
(1). Remove the controls access door,
forward fuel vent crossover cover, right (9). Check lower and side overboard vent
hand fuel compartment access door and fairing passages for obstructions and
the compartment beneath the right condition. Repair or replace fairings as
hand flight crew member's structural required (Ref. Section 53-20-00).
seat.
(10). Emergency rollover valve part numbers
(2). Inspect visible portions of the vent OTHER than 369H8108M,
system hoses for deterioration and look 369H8108501M, 369H8108503M
for surface cracks. Replace hoses if 369H8108505 and 369D281081 are
cracks are apparent. subject to the functional check in step
(a). below.
(3). Inspect visible portions of the vent
tubes and crossover fittings for dents, (a). With vent tube removed, inspect vent
cracks, deformation or corrosion. tube emergency shutoff valve for
Smooth nonrestrictive dents are condition. Valve should remain open
permissible. when held vertical. Valve should be
closed when held in the 45° from
(4). Inspect visible portions of the emer vertical position. While held in the
gency shutoff valve for dents, cracks, 45° position, blow in the valve
deformation or corrosion. None allowed. assembly and check that valve is
(5). Disconnect hose P/N 369D28107-1 from closed (do not use compressed air).
the forward crossover fitting and plug Valve shall open when returned to
the hose end. the 25° position. If obstructed,
replace valve.
(6). Open the fuel filler port. Blow low-
pressure compressed air (less than 2.0 (11). Reinstall the controls access door, the
psig) into the open end of the forward forward fuel vent crossover cover, the
vent crossover fitting and listen for air right hand fuel compartment access
passing through the tank vent to verify door and the compartment beneath the
the passage is clear and unobstructed. right hand flight crew member's
structural seat.
(7). Plug the side overboard vent fairing
openings and blow low pressure 6. Fuel System Vacuum Leak Inspection
compressed air (less than 2.0 psig) into
the lower overboard vent fairing. Listen Fuel is drawn out of the tank by the engine
for air passage thru the fuel tank at the driven fuel pump when the START PUMP is
filler port. This verifies the aft vent switched OFF on Model 250-C20 Series
system and emergency shutoff valve engine installations and at all times in Model
will pass air and system is clear and 250-C30 engine installations. Water, ice, dirt,
unobstructed. Unplug the side over fungus or a few pinhole leaks in the supply
board vent fairing openings, plug the system between the fuel tank sump pickup and
lower overboard vent fairing openings engine driven fuel pump can cause power
and blow low pressure compressed air surges, deceleration and, or flameout. A
into the side overboard vent fairing. vacuum leak inspection will determine
Verify unobstructed airflow. whether or not air is being drawn into the
engine fuel supply system.
(8). Unplug hose P/N 369D281071 and
blow low pressure air (less than 2.0
psig) into the side overboard vent Special Tools
fairing. Feel for air coming out of the (Ref. Section 91-00-00)
open end of the hose, verifying unob Item Nomenclature
structed airflow. Unplug the lower ST801 Hand operated vacuum pump kit
overboard vent fairing openings.
Page 604
MAINTENANCE MANUAL
Air entering the airframe (12). If system continues to leak, disconnect

WARNING fuel supply lines can cause a and install airtight caps on lines and
power reduction or flameout. Fuel sys fitting ports in a progressive sequence
tem vacuum leak check and fuel air from fuel shutoff valve toward engine.
bleed procedures must be done after The fuel shutoff and drain valve
opening the fuel supply system for any installations should be especially
reason, prior to releasing helicopter suspect. Apply vacuum at each stage
for flight. until leak has been isolated. Replace
parts as required.
(1). Remove left fuel cell floor access panel.
NOTE: If the vacuum held at 7.5 Hg or better,
(2). Pull FUEL shutoff valve knob out to airframe system seal is satisfactory and
stop. Verify that fuel shutoff valve lever leak is due to an engine fuel system prob
is hard against its OFF stop. lem. Refer to the applicable Rolls-Royce and
(3). In engine compartment; remove the Bendix manuals for additional information.
upper drain plug from the fuel pump
filter bowl. (13). Apply a torque stripe to all effected fuel
line fittings and nuts.
(4). On C30 and C20R installations, remove
and plug the fuel vapor return line. 7. Start Pump Operational Check (Model
250−C20 Series Engines or 250−C30 Engine
(5). Assemble vacuum pump (ST801) hoses, With Optional Maintenance Fuel Pump)
filter port adapter, shutoff valve and
vacuum gauge.
(1). Remove fuel cell floor access panels.
(6). Install the vacuum gauge in the line
between the filter port adapter and Do not operate start pump in an
CAUTION empty fuel tank.
shutoff valve. Attach the vacuum pump
above the shutoff valve.
(2). Refuel helicopter.
(7). Attach vacuum test vacuum pump to
engine fuel filter upper drain port. (3). Connect battery and external power.
Apply 8.0 Hg vacuum. Close vacuum
line shutoff valve. (4). Set battery switch to EXT PWR.
(8). Fuel system shall hold vacuum between (5). Push FUEL shutoff valve knob in to
8.0 and 7.5 Hg for two minutes. open shutoff valve.
NOTE: Vacuum loss exceeding 0.5 Hg in two
minutes indicates a leak in the system be (6). Set START PUMP switch ON to
tween, and including, the fuel shutoff valve pressurize fuel system.
and engine.
(7). Inspect all line connections for leaks.
(9). If test is satisfactory, remove test
vacuum. Inspect and replace filter plug (8). Shut down start pump.
O-ring as required. Install filter plug.
(a). Repair leaks as required.
(10). On C30 and C20R installations,
reconnect and torque the fuel vapor
return line. 8. Drain Valve Inspection
(11). Retorque fuel line connections (Ref. (1). Inspect tank sump drain valve for
Table 401) and where installed, anti-ice leakage and security. No leakage
(airframe) fuel filter fittings and line allowed.
nuts (Ref. Section 28-25-00). Repeat
vacuum test. (2). Replace valve as required.
Page 605
MAINTENANCE MANUAL
9. Fuel Cell Inspection 10. Fuel Cell Leak Inspection
CAUTION (Ref. Section 91−00−00)
Item Nomenclature
N/A Ammonia
D Do not work on Uniroyal fuel cell in ambi
ent temperatures below 505F (105C). N/A Cloth, cotton flannel
N/A Phenolphthalein, crystalline
D Do not work on Engineering Fabric Corp. CM218 Alcohol, denatured
fuel cell in ambient temperatures below CM810 Leak detector, liquid
705F (215C). CM820 Cheesecloth
D Do not remove fuel cells unless absolutely

required. Any one of three techniques can be used to find
leaks in non-self-sealing and self-sealing fuel
D The barrier can be invisibly torn, punc cells. The methods are listed in ascending
tured or cracked by careless handling. order of effectiveness and complexity in terms
of required equipment, materials, time, and
effort.
D Do not carry or move cell by its metal fit
tings. Soap bubble leak inspection.
D Never probe cell material with sharp Phenolphthalein stain inspection.

edged or pointed tools.
Liquid stand inspection.
NOTE: The soap bubble and phenolphthalein
NOTE: inspections require the cell to be inflated
with air.
D Non-self-sealing and self-sealing cells
are primarily a 0.002 inch (0.051 mm) (1). Manufacture or supply the following
thick nylon barrier membrane sand equipment necessary to do soap bubble
wiched between lightweight construc or phenolphthalein inspections:
tions of either rubberized (Uniroyal) or
(a). Rigid, airtight closures or plugs to
plasticized (Engineered Fabrics Corp.) seal all cell openings. Fit one cover
nylon fabric that protects and strength plate with:
ens the barrier.
(b). An air pressurization inlet fitting.
D Self-sealing cells can have one or more
thin layers of natural rubber sandwiched (c). A manometer or an extremely
between the barrier and fabric plies. accurate and sensitive low pressure
air gauge.
A. Soap Bubble Leak Test Procedures
(1). Apply protective tape to all machined
metal fittings. NOTE: Soap bubble test reliability is good for
bladder type non-self-sealing cells.
(2). Do cell inspection on a padded, clean, (1). Remove cell from helicopter.
craft paper covered surface. (2). Lay cell out on a padded table. Install
cell closures.
(3). Inspect fuel cells per applicable man (3). Inflate cell to 1/4 psi (1.7 kPa), maxi
ufacturers requirements. mum.
Page 606
MAINTENANCE MANUAL
(4). Unless leak is immediately evident, (e). A red spot will appear on the cloth
maintain 1/4 psi (1.7 kPa) pressure for where there is a leak in the cell wall.
two hours to allow any air trapped in Mark each leak.
cell exterior laps and seams to escape.
(f). Inspect the entire exterior surface of
(5). Run soap solution around all patches,
the cell.
lap joints, seams, fittings, creases,
abrasions and any other suspicious
areas. Bubbles will appear over a leak. (5). Repair cell as required.
(6). Mark leak areas with a white or yellow C. Liquid Stand Inspection
crayon.
(7). Repair cell as required. NOTE:
B. Phenolphthalein Stain Inspection D Engineered Fabrics Corp. recommends
Procedures VITHANE\R cells be supported in a fix
ture for the liquid stand inspection.
(1). Remove cell from helicopter.
D Uniroyal rubberized fabric cells do not re
(2). Lay cell out on a padded table. Install quire support for this test.
all but one of the cell closures.
(1). Remove cell from helicopter and place
(3). Make phenolphthalein solution as on a clean, padded, kraft paper covered
follows: table.
(a). Add 40 grams phenolphthalein
crystals to 1/2 gallon (1.9 L) of (2). Fabricate closure plates for each cell
denatured alcohol (CM218) and stir. opening as follows:
(b). Add 1/2 gallon (1.9 L) of water. Allow (a). The object is to completely fill the cell
to stand 30 minutes. Stir before and eliminate all air pockets.
using.
(4). Pour commercial ammonia on an (b). Equip one of the plates with liquid
absorbent cloth in a ratio of 1 tea filler and vent stand pipes at least 6
spoon (3 ml) per cubic foot of cell inches (15 cm) tall.
capacity (minimum of 10 ml or 3.3
teaspoons). (3). Fill the cell with Stoddard solvent,
Stanisol or Varsoline.
(a). Place the ammonia saturated cloth
inside the cell and install the remain
(4). Permit cell to stand undisturbed for 24
ing cover.
hours.
(b). Inflate cell with air to 1/4 psi (1.7
kPa) maximum. Maintain 1/4 psi (1.7 (5). Inspect paper to determine where cell is
kPa) pressure for 15 minutes mini leaking.
mum, before proceeding.
(6). Change paper as required. Drain, turn
(c). Soak a large white cloth in the
over, refill and let cell stand for another
phenolphthalein solution. Thoroughly
24 hours to ensure liquid has contacted
wring cloth out.
all cell surfaces.
(d). Spread and smooth cloth onto cell. Do
not let cloth dry out. (7). Repair cell as required.
Page 607
MAINTENANCE MANUAL
11. Fuel Tank Pressure Leak Test forces trapped air from between fuel
cells and helicopter structure. If
Check installed fuel tanks and plumbing for necessary, repeat until cells adjust to
leaks as follows: contour of cell bay.
Special Tools (5). Apply 2 psi (14 kPa) air pressure for 15
(Ref. Section 91-00-00) minutes with no visible, less than 1/4
Item Nomenclature inch (6.35 mm) drop on manometer.
N/A Manometer
NOTE: If pressure drop occurs, check all vent
plugs, fittings and re-test cells.
(1). Plug vent system.
(6). Repair or replace parts as necessary to
(2). Remove left and right cell floor access eliminate pressure drop.
panels.
(3). Install manometer and air pressuriza (7). Unplug vent system. Remove manome
tion equipment. ter and pressurization equipment.
(4). Apply 2 psi (14 kPa) air pressure for 10 (8). Install left and right cell floor access
minutes to precondition cells. This panels.
Page 608
MAINTENANCE MANUAL
FUEL SYSTEM
REPAIRS
1. Fuel Shutoff Valve Control Cable Repair (a). Only trained personnel are allowed to
inspect and repair the fuel cells
installed in 369/500 series helicopters
do the work.
Item Nomenclature (b). Customers doing fuel cell repairs
CM118 Grease must order manuals from the appli
cable fuel cell manufacturer before
beginning repair tasks (Ref. Section
NOTE: Worn fuel shutoff valve control cables 01-00-00).
are normally replaced as an assembly.
(c). Fuel cell inspections, maintenance
(1). The only authorized repair is replace and repair must be done in accor
ment of a missing detent ball, as dance with the fuel cell manufactur
follows: ers instructions.
(a). Disconnect cable from fuel shutoff (3). Bladder or self sealing fuel cells are
valve lever swivel. supplied to MDHI by Uniroyal, Inc.,
and Engineered Fabrics Corporation.
(b). Pull plunger out until detent ball
hole is visible. Insert detent release Engineered Fabrics Corp., and
CAUTION Uniroyal fuel cell construction
rod in plunger. Align notch in detent
release rod with plunger detent ball materials, inspection requirements, repair
hole. methods and requirements, supplies and
materials are not compatible or inter
(c). Apply grease (CM118) between changeable.
plunger and plunger housing.
(4). Fuel cells manufactured by Uniroyal
(d). Insert detent ball in plunger hole. are an assembly of nitrile rubber
Push release rod and plunger to full impregnated woven nylon inner and
open position. outer coverings with an impervious
0.002 inch (0.051 mm) thick, nylon
(e). Rig fuel shutoff valve cable. barrier membrane sandwiched between
the coverings.
2. Fuel Shutoff Valve Repair
(5). Fuel cells produced by Engineered
(1). Overhaul Dukes Inc. valves with repair Fabrics Corp. are constructed of
kit, part No. 1595-1000. No other VITHANE/R polyurethane plastic
repairs are authorized. impregnated fabric.
(2). Electric pencil the letter M at the end of 4. Uniroyal Self−Sealing and
the part number, i.e., 369A8104-5M. Non−Self−Sealing Cell Repairs
3. Fuel Cell Repair Procedures in this section cover Uniroyal
self-sealing and non-self-sealing fuel cell
(1). MDHI cannot guarantee the accuracy of repairs as follows:
the following fuel cell repair proce
dures. Fuel cell repair materials, D Scuff Mark Repairs.
techniques, and procedures can be D Reinforcements, Hangers and Splice
changed or deleted by the fuel cell Repairs.
manufacturer without notice to MDHI
technical publications. D Loose Patch Repair.
(2). MDHI recommends the following: D Patch Installation.
Page 801
MAINTENANCE MANUAL
D Loose Edges and Lap Seam Repair. A. Scuff Mark Repair
D Blister Repairs. (1). Fabric exposed by a scuff mark can be

buffed, cleaned, coated with cement and
Fuel cells are fragile. Do not at allowed to air-dry for 8 hours.
CAUTION tempt to fold/unfold or handle (2). No patch is required unless fabric is
cells in temperatures below 505F (105C). torn.
Cell material is easily cut, torn or punc
tured. Never use sharp edged or pointed (3). Install patches where required (Ref.
tools to probe damage or to puncture blis Patch Installation).
ters. Puncturing the 0.002 inch (0.051 mm) B. Reinforcements, Hangers and Splice
thick nylon fuel barrier of a non-self-seal Repairs
ing cell will cause the cell to leak. Punctur
ing the nylon barrier of a self-sealing cell (1). Loose reinforcement edges, hangers or
will allow fuel to activate the rubber sealing lap splices must be lifted, buffed,
agent that will swell over time and possibly cleaned, cemented and cured under
rupture the cell. In any case, cells with acti pressure per applicable instructions
vated seal compound are not repairable. provided (Ref. Patch Installation).
Barrier membrane can be invisibly torn by C. Loose Patch Repair
rough handling or impact. Handle cells with
care and no more than necessary. Protect (1). Replace loose patches with new patch
metal fittings from damage. installations (Ref. Patch Installation).
(2). Where two opposing patches have been
NOTE: Accomplish fuel cell repair work in tem
installed over cell wall damage, unless
peratures ranging from 60—805F
otherwise indicated by inspection,
(16—275C) and in less than 50% humidity.
replace only the loose patch.
D. Patch Installation
(Ref. Section 91−00−00) (1). Drain, remove and thoroughly dry cell
Item Nomenclature as soon as possible after determining
N/A Polyethylene plastic, sheet or roll cell repair is required. Drying time can
be accelerated by keeping cell at 805F
CM211 Solvent (275C) and ventilating interior with
CM219 Methyl−propyl−ketone (MPK) dry, low pressure air.
CM603 Patching material (2). Inspect fuel cell.
CM604 Patching material
CM605 Fuel cell repair kit CAUTION
CM607 Cement
D Do not repair tears or holes over two in
CM608 Cement ches long using cold patch repair. Do not
CM609 Repair kit attempt to repair bonded fittings or cor
CM804 Emery cloth, fine ners. Contact Uniroyal, Inc. when corner
or fitting damage is discovered or when
CM820 Cheesecloth
cell wall damage exceeds 2 inch (5.08 cm)
length limit.
Special Tools D Never expose a dry cell to high tempera
(Ref. Section 91-00-00) tures and, or direct sunlight for long peri
Item Nomenclature ods of time. If repairs will not be started
N/A C-Clamp, 8 - 12 inch within ten days, prepare cell for storage.
N/A Patch pressure plates, 1/2 inch thick NOTE: Damp air, especially in combination
aluminum stock with low temperatures, will cause water to
N/A Brayer condense on cement applications. Water in
hibits patch adhesion.
Page 802
MAINTENANCE MANUAL
(3). Both sides of a cell must be patched to (12). Continue to wipe cell and patch,
repair any one hole or tear. changing cheesecloth and applying
clean solvent as required, until no stain
(4). Thoroughly clean cell internal and or particles appear on cheesecloth pad
external repair areas with cheese cloth after the last wipe.
(CM820) dampened with solvent
(CM211) or MPK (CM219). Use cement sparingly. Two,
CAUTION thin, even coats provide better
(5). Collapse cell and expose external adhesion than one thick coat.
damage area on a clean, flat working
surface. (13). Position a sheet of polyethylene plastic
beneath cell damage to keep cement off
(6). Use a greaseless silver pencil to outline opposite cell wall.
patch installation area two inches NOTE: Determine cement adhesive tack with a
beyond damage in all directions. test specimen. Apply cement to a piece of
(7). Hand-buff an area 1/2 inch (12.7 mm) buffed, scrap patch material each time ce
larger than space occupied by patch ment is spread on cell and repair patch.
with fine emery cloth (CM804) to (14). Coat patch, test specimen, and fuel cell,
provide a roughened substrate for including edges of damage, with EC678
cement application. Do not cut through cement (CM607) or Uniroyal #3230
cell fabric. cement (CM608). Allow cement to dry
15 minutes before application of a
(8). Select a patch (CM604) of #5218 second coat. Allow second coat to dry 15
material for non-self-sealing cell minutes.
exterior, or Uniroyal #5241/5241
sandwich material for self-sealing cells. (15). Press a bare knuckle into cement on
Trim patch to extend two inches (5.08 test specimen. Cement that tears away
cm) beyond edges and ends of damage from skin leaving a rough, finely
in all directions. Tilt scissors to bevel peaked imprint without transferring to
patch edges away from cell surface. knuckle, is ready for patch installation.
Radius all patch corners. (16). Wipe cement with cheesecloth moist
(9). Hand-buff patch gummed surface with ened with solvent to reactivate adhesive
fine emery cloth. Ensure entire patch when required.
joint surface has been abraded. NOTE: A brayer or similar tool is required to
systematically roll patch into contact with
(10). Repeat buffing procedures on cell cell. Apply patch as follows:
interior surface. Buff internal patch
(CM603) trimmed from Uniroyal (17). Center patch on repair area. Stick one
#5200/5187/5194 sandwich material. edge down and double check patch
alignment. If required, release adhesive
Fuel cell and patch contact sur by flooding joint with solvent. Check
CAUTION faces must be perfectly clean adhesive tack again before proceeding
and dry prior to adhesive and patch applica with patch installation.
tion. Rubber and fabric particles, moisture,
and fuel or oil from fingers will prevent NOTE: The object of the next step is to get the
proper patch/cell adhesive cure and can sub patch down without trapping any air under
sequently provide a leak path. Wear clean, it.
lint free gloves to handle patch and cell after (18). Hold free edge of patch off cell. Follow
preparing surfaces for cement and patch one line and roll tool back and forth
application. over patch. Advance toward loose end,
1/4 inch (6.35 mm) per pass until patch
(11). Install exterior patch first. Wipe cell
is down and free of trapped air.
exterior and patch faying surfaces with
clean cheesecloth dampened with (19). An alternate technique is to lay
Uniroyal #3339 solvent or MPK. prepared patch on a perfectly clean
Page 803
MAINTENANCE MANUAL
sheet of polyethylene plastic about E. Loose Edge and Lap Seam Repairs
twice the size of the patch. Locate
Loose lap seams should be re
plastic sheet and patch over cell repair CAUTION paired as soon as possible after
area; then, slip sheet from under patch
discovery.
as patch is rolled down, 1/4 inch (6.35
mm) at a time. NOTE: Loose lap seam edges not more than two
inches long on cell interior or exterior sur
(20). Fabricate two smooth, flat, rigid, metal faces can be repaired. Contact Uniroyal, Inc.
plates with no sharp edges or corners. for repair data addressing lap seam separa
Plates must be larger than cemented tions exceeding 2 inch (5.08 cm) length lim
repair area. it. Seam separation repairs require buffing,
cementing and a patch installation.
Excessive clamp pressure can (1). Lift seam separation and buff flap and
CAUTION deform cell and, or squeeze ce cell faying surfaces with emery cloth
ment out of joint. (CM804).
(2). Buff an area on exterior surface
(21). Cover both sides of repair with sheet extending 2 inch (5.08 cm) in all
polyethylene plastic or oiled paper large directions from seam separation.
enough to cover entire cemented area.
CAUTION
NOTE: Do not include opposite cell wall in
clamp up. Work through cell access opening D Fuel cell and patch contact surfaces must
and arrange cell as necessary to clamp only be perfectly clean and dry prior to adhe
the wall with the patch installation. sive and patch application. Rubber and
fabric particles, moisture, and fuel or oil
from fingers will prevent proper patch/
(22). Sandwich repair area and barrier cell adhesive seal and can subsequently
material between pressure plates. provide a leak path. Wear clean, lint free
Install at least two C-clamps over gloves to handle patch and cell after pre
pressure plates. Equalize clamp paring surfaces for cement and patch
pressure. application.
D Careless application of compressed air be
(23). Do not disturb cell. Maintain pressure tween lap joints can separate seam fur
for six hours, minimum, after which cell ther.
is ready for internal patch installation.
(3). Either air-vacuum or blow buffing dust
(24). Remove clamps and plates. out of separation with dry, low pressure
compressed air.
(25). Clean patch and cell internal repair (4). Wipe inside and outside of repair area
area with solvent or MPK saturated clean with cheesecloth (CM820)
cheesecloth swabs. moistened with solvent (CM211) or
MPK (CM219). Continue wiping with
(26). Apply two coats of cement, allowing 15 fresh solvent dampened cheesecloth as
minutes drying time between coats. required until no stain or particle
Allow 15 minutes for second coat to set. appears on the swab after the last wipe.
Allow area to dry.
(27). Install and roll out patch. Use cement sparingly. Two,
adhesion than one thick coat.
(28). Position a barrier sheet under each
pressure plate. Clamp and cure instal NOTE: Determine cement adhesive tack with a
lation for a minimum of 24 hours at test specimen. Apply cement to a piece of
60—805F (16—275C) before leak buffed, scrap patch material each time ce
testing and returning cell to service. ment is spread on cell and repair patch.
Page 804
MAINTENANCE MANUAL
(5). Apply two coats of EC678 cement (15). Prepare cell wall and patch for installa
(CM607) or Uniroyal #3230 (CM608) tion (Ref. Patch Installation). Install
allowing 15 minutes between applica patch.
tions. Allow second coat to dry 15
minutes. F. Blister Repair
(1). Blisters can occur on cell interior and
(6). Roll separation together starting from exterior surfaces. blisters are caused by
the bottom of the pocket toward the a separation of the cell laminates and
open end, 1/4 inch (6.35 mm) per pass. can contain air or a combination of air
Ensure no air is trapped underneath. and fuel.
(7). Cover repair with a sheet of polyethyl NOTE: Exterior blisters that contain fuel indi
ene plastic or oiled paper large enough cate that the barrier has been penetrated.
to cover entire cemented area. Contact Uniroyal for repair information be
fore proceeding. Blisters inside cell measur
(8). Fabricate two smooth, flat, rigid, metal ing under 1 inch (2.54 cm) diameter are ac
plates with no sharp edges or corners. ceptable and need not be disturbed.
Plates must be larger than cemented (2). Buff surface of blister and area extend
repair area. ing 2 inch (5.08 cm) in all directions
from its edge.
Excessive clamp pressure can
CAUTION deform cell and, or squeeze ce Avoid damaging nylon barrier
ment out of joint. CAUTION membrane. Do not probe, cut, or
puncture blisters with tool perpendicular to
(9). Cover both sides of repair with polyeth cell wall.
ylene plastic or oiled paper sheets large
enough to cover entire cemented area. (3). Slit blister open with an X cut to expose
all of the delaminated surface. Lift flaps
NOTE: Do not include opposite cell wall in and mop interior with clean cheesecloth
clamp up. Work through cell access opening (CM820) and solvent (CM211) or MPK
and arrange cell as necessary to clamp only (CM219). Buff underlying cell surface
the wall containing the seam repair. and blister flaps with emery cloth
(CM804). Air-vacuum or blow away all
(10). Sandwich cell wall repair area and traces of buffing dust.
barrier material between pressure (4). Wipe inside and outside of repair area
plates. Install at least two C-clamps clean with cheesecloth moistened with
over pressure plates. Equalize clamp solvent or MPK. Continue wiping with
pressure. fresh solvent dampened cheesecloth as
required until no stain or particle
(11). Do not disturb cell. Maintain pressure appears on the swab after the last wipe.
for six hours, minimum, after which cell Allow area to dry.
is ready for patch installation.
Use cement sparingly. Two,
(12). Remove clamps and plates.
(13). Use Uniroyal #5200/5187/5194 sand NOTE: Determine cement adhesive tack with a
wich patch material (CM603) on test specimen. Apply cement to a piece of
non-self-sealing and self-sealing cell buffed, scrap patch material each time ce
interiors. ment is spread on cell and repair patch.
(14). Use Uniroyal #5241/5241 sandwich (5). Apply two coats of EC678 cement
patch material (CM604) on self-sealing (CM607) or Uniroyal #3230 (CM608)
cell exterior surfaces or Uniroyal #5218 allowing 15 minutes between applica
patch material on non-self-sealing cell tions. Allow second coat to dry 15
exterior surfaces. minutes.
Page 805
MAINTENANCE MANUAL
(6). Roll blister together starting from the 5. Fuel Quantity Transmitter Repair
bottom of each flap pocket toward the
open end, 1/4 inch (6.35 mm) per pass. Consumable Materials
Ensure no air is trapped underneath. (Ref. Section 91−00−00)
Item Nomenclature
(7). Fabricate two smooth, flat, rigid, metal CM220 Naphtha aliphatic
plates with no sharp edges or corners. CM425 Sealing compound
Plates must be larger than cemented CM815 Solder
repair area.
Special Tools
CAUTION deform cell and, or squeeze ce
Item Nomenclature
ment out of joint. N/A Solder gun
A. Resistor installation, Transmitters

(8). Cover both sides of repair with polyeth
PN 369D296303, 369D296303−701 and
ylene plastic or oiled paper sheets large
369A4245
enough to cover entire cemented area.
(1). Remove transmitter from helicopter.
NOTE: Do not include opposite cell wall in (2). Remove potting compound from top of
clamp up. Work through cell access opening transmitter to expose terminals and
and arrange cell as necessary to clamp only circuit board.
the wall containing the blister repair.
(3). Solder resistor to transmitter circuit
with tin alloy solder (Ref. Figure 505).
(9). Sandwich cell wall repair area and (4). Do the FUEL LEVEL LOW Caution
barrier material between pressure Light System Test and Fuel Quantity
plates. Install at least two C-clamps Transmitter Calibration and Adjust
over pressure plates. Equalize clamp ment procedures.
pressure.
Naptha is a fire hazard. Do
WARNING work in a well ventilated
(10). Do not disturb cell. Maintain pressure area away from potential sources of ig
for six hours, minimum, after which cell nition.
is ready for patch installation; remove
clamps and plates. NOTE: All transmitters with exposed wire ter
minals and, or circuit boards must be sealed
(potted) before they can be returned to ser
(11). Use #5200/5187/5194 sandwich patch vice.
material (CM603) on non-self-sealing
(5). Remove all grime and oily residue from
and self-sealing cell interiors.
sealing compound application area with
naptha (CM220) and a soft bristle
(12). Use Uniroyal #5241/5241 sandwich brush. Blow away excess solvent with
patch material (CM604) on self-sealing dry low pressure compressed air.
cell exterior surfaces or Uniroyal #5218 (6). Ensure transmitter terminal connec
patch material (51) on non-self-sealing tions are clean, tight, free of corrosion
cell exterior surfaces. and dry.
(7). Heat soak transmitter assembly in an
(13). Prepare cell wall and patch for installa oven set at 1005F (385C) maximum for
tion per instructions (Ref. Patch one hour to vaporize trapped volatiles.
Installation). Install patch. A heat gun can be used as an alternate
Page 806
MAINTENANCE MANUAL
drying method. Pot transmitter electri pound components per manufacturers

cal connections with sealing compound instructions.
(CM425).
(2). Apply to top of transmitter (Ref.
Figure 505).
B. MIL−S−8802 Application
(3). Cure material per instructions before
(1). Combine MIL-S-8802 sealing com returning transmitter to service.
Page 807
MAINTENANCE MANUAL
Page 808
MAINTENANCE MANUAL
Section
28−00−10
Fuel System
(Glass Cockpit)
MAINTENANCE MANUAL
FUEL SYSTEM (GLASS COCKPIT)

ADJUSTMENT AND TEST
1. Fuel Quantity Test (a). Put ST205 inclinometer on the rear
deck between Sta. 100 and 104.
(Ref. Figure 501)
(b). Jack the helicopter with ST203
hydraulic jack to get a 2° nose down
Special Tools attitude on the inclinometer.
Item Nomenclature (c). Make the helicopter level laterally.
ST203 Hydraulic jack: 1-5 ton (900-4500 kg) (d). As necessary, put blocks on the
ST205 Inclinometer ground against the forward and aft
side of the ground handling wheels to
keep the helicopter stable.
Do not let fuel vapor accu Power On
WARNING mulate. Ignition and fire can
proved electrical ground. Set power to
OFF. Disconnect external power and
battery before opening fuel system.
Work in an open, well-ventilated area, (5). Set the BAT switch to EXT PWR.
away from possible ignition sources. (6). Make sure the external power voltage is
Only use tools that do not cause sparks 27.0 to 28.0 Vdc.
and explosion-proof work lights.
(7). Make sure the INST and PNL LT
Power Off circuit breakers are pushed IN.
B. Engine Instrument System Calibration
NOTE: Have MDHI Field Service Representa
tive, with the configuration tool and soft
ware, on-site to have a full calibration check
A. Setup done.
(1). Move the helicopter to level ground (ref. (1). Make sure that the FUEL indicator
09-00-00, Maintenance Practices, 2. shows 0 LB on the Engine Instrument
Helicopter Towing and Manual Mov Display (EID).
ing).
(2). Measure the resistance between pins B
(2). Connect the helicopter to an approved and E on the fuel transmitter with a
electrical ground. digital multimeter.
(a). The resistance between pins B and E
(3). Drain the fuel from the fuel tank while must be 2.0 to 4.0 ohms.
the helicopter is at normal ground
attitude (ref. CSP-HMI-2, 12-00-00, (b). If the resistance is more than 4.0
Procedure 3.D. Fuel System Drain- ohms:
ing).
Power Off
NOTE: There will be 0.2 gallon (0.8 liter) of
trapped fuel left in the tank after the sump
is drained.
(4). Adjust the helicopter level attitude (ref. 1). Remove the external electrical
08-00-00, 1. Helicopter Leveling): power.
Page 501
28-00-10 TR18-001
MAINTENANCE MANUAL
2). Remove the fuel transmitter from

the fuel cell cover.
NO. 328 A R
LAMP B BLU
+ D RED
Q
24 VDC
POWER B
SUPPLY G
E BLK
- h BLK
P251
CONNECTOR
FUEL QUANTITY
TRANSMITTER
TEST CONNECTIONS
0.62 INCH
CONNECTOR (15.75 MM)
MOUNTING FLANGE
FLOAT STOP FULL

(FULL)
BOTTOM OF FLOAT
10.08 INCH
(25.60 CM)
SPRING RADIUS
FLOAT STOP
(EMPTY) 8.41-8.45 INCH
(21.36-21.46 CM)
2.13-2.17 INCH
(5.41-5.51 CM)
SPRING CONTACT (NOTE 2)
(NOTE 1)
0.91-0.95 INCH
(23.11-24.13 MM)
NOTES: FLOAT
1. CAUTION LIGHT ON, 23 LB USABLE FUEL REMAINING. EMPTY
2. CAUTION LIGHT ON, 58 LB USABLE FUEL REMAINING.
NOT APPROVED FOR COMMERCIAL APPLICATIONS.
G28−0010−501−1
Figure 501. Fuel Quantity Transmitter Calibration
Page 502
TR18-001 28-00-10
MAINTENANCE MANUAL
Do not bend the float arm to ad Power On

CAUTION just the fuel quantity indication
system.
3). As necessary, bend the lower float

arm stop down, until the resistance (4). Set the BAT switch to EXT PWR.
is 2.0 to 4.0 ohms when the arm is
on the stop. (5). Make sure the FUEL indicator shows 0
LB.
4). Install the transmitter.
(6). Add an additional 5.2 gallons (19.7
liters) of fuel in the fuel tank.
(c). If the resistance is less than 2.0
ohms: NOTE: You must have a full 7.0 gallons (26.5
liters) of fuel in the fuel tank.
Power Off
(7). Make sure the FUEL LOW CAUTION
light is OFF.
NOTE: The FUEL LOW CAUTION light is on

the Master Caution, Master Warning
(MCMW) annunciator.
1). Set the BAT switch to OFF.
(8). Monitor the fuel quantity gauge as you
2). Disconnect the fuel transmitter slowly drain fuel into a clean calibrated
from the fuel cell cover. container.
(9). When the FUEL LOW CAUTION light

3). Remove the fuel transmitter. comes ON, immediately stop the fuel
flow.
Do not bend the float arm to ad
CAUTION just the fuel quantity indication (a). The container must have 3 to 10
system. If the arm is bent and not the stop, pounds (1.4 to 4.5 kg) of fuel.
there can be an incorrect adjustment.
(b). If the container has more or less than
3 to 10 pounds (1.4 to 4.5 kg) of
4). As necessary, bend the lower float fuel, adjust the low-fuel whisker:
arm stop up until the resistance is
2.0 to 4.0 ohms when the arm is 1). Disconnect the fuel transmitter
on the stop. from the fuel cell cover.
2). If the container has less than 3

5). Install the transmitter.
low-fuel whisker on the transmit
(3). If fuel was drained in Step A.(3). add ter down.
1.6 gallons (6.1 liters) of fuel to the
tank. 3). If the container has more than 10
If the fuel tank is a new install or low-fuel whisker on the transmit
completely dry, add 1.8 gallons (6.8 ter up.
liters of fuel to the tank.
4). Install the fuel transmitter.
(a). Make sure there is approximately 1.8 (c). Do the check again and again until
gallons (6.8 liters) total fuel in the the LOW FUEL CAUTION light
tank during this test. comes ON at the correct level.
Page 503
28-00-10 TR18-001
MAINTENANCE MANUAL
(10). Put the removed fuel in the tank. (2). Remove the external ground power
from the helicopter.
(11). Fill the tank to full capacity with
additional fuel. (3). If necessary, move the helicopter (ref.
09-00-00, Maintenance Practices, 2.
C. Close−Up Helicopter Towing and Manual Mov
ing).
Power Off (a). Remove the jacks.
(b). Remove the blocks from the forward
and aft side of the ground handling
wheels.
(1). Set the BAT switch to OFF. (c). Move the helicopter.
Page 504
TR18-001 28-00-10
MAINTENANCE MANUAL
Section
28−00−60
Fuel System (600N)
MAINTENANCE MANUAL
FUEL SYSTEM
1. Engine Fuel System (8). A check valve attaches to the filler neck
fitting. The check valve located within
(1). Engine fuel system operational infor the fuel cell. opens when the fuel cap is
mation is provided in the applicable removed by pulling a lanyard for
Rolls-Royce Operation and Mainte refueling and defueling operations. The
nance Manuals (Ref. Section 01-00-00). valve closes when the fuel cap is
secured to the filler neck fitting pre
2. Fuel Cells venting fuel leakage.
(9). The left-rear cell cover supports the
(1). The MDHI helicopter standard fuel cell
manually actuated fuel shutoff valve,
consists of two interconnected crash-re
fuel supply hose, motive flow hose, fuel
sistant non-self-sealing bladder type
quantity probe wire harness and
cells having a total capacity of 116.2
attaching hardware.
U.S. gallons (439.9 Liter), with 114.6
U.S. gallons (433.8 Liter) usable. 3. Fuel Distribution
(2). Bladder crash-resistant non-self (1). The fuel distribution system supplies
sealing fuel cells are supplied by fuel to the engine. The engine driven
Engineered Fabrics Corporation (Ref. fuel pump sucks fuel from the fuel cell.
Section 01-00-00).
(2). Fuel is supplied from the fuel cell
(3). Cells are located in separate fiberglass through supply lines located under the
lined bays below the passenger com passenger/cargo compartment floor and
partment floor. Both cells are supported within the fuel cell.
by a system of airframe brackets, (3). The ejector pump is driven by pressur
hangers, grommets and nylon suspen ized fuel (motive flow) returning from
sion cords. the engine driven fuel pump.
(4). Each fuel cell is equipped with two (4). The ejector pump scavenges fuel from
access covers, forward fuel vent aft fuel the forward portion of fuel cell and
vent forward vent crossover fittings and transfer fuel to the aft portion of the
fuel interconnect fittings. cell, thus motive flow.
(5). Each fuel cell contains two sump plates 4. Fuel Vent System
and two fuel drain valves
(1). Fuel cells are vented to the atmosphere
(6). Each fuel cell is divided by an internal through the bottom and side fuselage
lateral baffle which reduces fuel ports by a system of interconnected
sloshing during changes in flight hoses and tubes attached to the forward
attitudes. The baffles have openings inboard and aft inboard ends of each
across their face to allow fuel to pass fuel cell.
through them. This reduces the load on (2). The fuel vent float/rollover valves are
the baffles and provides even fuel located internally at each inboard
distribution within the cell. upper corner of the fuel cell. The vent
float/rollover valve allows the fuel cell
(7). Fuel tank servicing is through the cell to vent to the atmosphere during
filler neck on the right side of the aircraft fueling/defueling.
fuselage. The right side fuel cell
contains the gravity filler port, filler (3). Each vent float/rollover valve is
check valve, neck, cap and attachment designed so that when not submerged
hardware. in fuel and with airflow through the
Page 1
MAINTENANCE MANUAL
valve between zero and the rated flow, the instrument panel face. The flexible
the valve remain open within 25° cable and housing is routed aft under
conical angle from vertical. the floor to the shutoff valve lever on
the left fuel cell access cover.
(4). The valve automatically closes when
the fuel level is at or above the float 7. Fuel Shutoff Valve
actuation level to prevent fuel loss
through the vent system. The valve will (1). The cable actuated, mechanically
also close with changes in aircraft detented fuel shutoff valve is located on
ground attitudes from 25° to 180° with the left fuel cell access cover. Valve
fuel present. lever arm travel from full open to closed
is 90°.
(5). Flame arrestors located in the outlet
vent tube or standpipe prevents any 8. Fuel Filter Caution Light Pressure Switch
potential flames from reaching the vent
float/rollover valves and fuel cell. (1). A differential pressure switch is
installed across the engine fuel pump
filter pressure AF (after filter) and BF
5. Fuel Quantity System (before filter) ports just upstream of the
engine fuel pump. The switch is
(1). The fuel quantity system is powered by sensitive to a preset differential
24 - 28 Vdc current and consists of an pressure. An increase in BF pressure
electromechanical fuel quantity with a concurrent decrease in AF
indicator, a signal conditioner, two pressure due to partial or complete
capacitance type fuel quantity probes filter blockage can intermittently or
mounted in the left fuel cell, a float completely close the switch depending
switch located on the aft fuel quantity on the nature of the filtered material.
probes, a FUEL LEVEL LOW caution Switch contacts complete an electrical
light on the instrument console and circuit through a case ground that
interconnecting wire harness. switches on the FUEL FILTER
caution lamp, a part of the instrument
(2). The system is protected by a 5 ampere
console caution and warning light
circuit breaker. Power is supplied to the
array.
system from the DC bus, through a
circuit breaker. 9. Drain System and Drain Valves
(3). The float switch provides a electrical (1). Two spring loaded plunger tank sump
signal to the FUEL LEVEL LOW drain valve are installed in each cell
caution light panel located on the sump mount plate on the bottom of the
instrument panel. Refueling breaks the left and right fuel cell. The valve is
float switch circuit and switches off the accessed from under the helicopter.
FUEL LEVEL LOW caution lamp. The
switch is fixed to the aft fuel quantity 10. Fuel Supply Lines
probe and is not adjustable.
(1). The engine fuel supply lines consist of:
(4). Calibrating of the fuel system is
accomplished on the fuel quantity (a). A fuel inlet hose between the inlet
indicator calibration switch. By holding screen to the fuel shutoff valve.
the switch in the empty or full calibra
tion positions a resistance is stored in (b). A engine feed hose between the fuel
the gauge memory circuit. shutoff valve and firewall fitting.
(c). A hose from the firewall fitting to the
6. Fuel Shutoff Valve Control engine filter inlet port.
(1). A red fuel shutoff control knob labeled (d). A return flow hose from engine to the
FUEL, PULL TO CLOSE is located on firewall fitting.
Page 2
MAINTENANCE MANUAL
(e). A motive flow hose assembly between (g). A scavenge fuel cell hose from the
the firewall fitting and a flow check ejector pump to the bottom of aft cell
valve on the left aft cell cover. cover.
(f). A submerged motive flow hole from (h). Associated elbows, fittings and
aft cell cover to the ejector pump. unions.
Page 3
MAINTENANCE MANUAL
Page 4
MAINTENANCE MANUAL
FUEL SYSTEM
FAULT ISOLATION
1. Fuel System Fault Isolation
Insufficient or no fuel to engine. Fuel tank empty. Refuel helicopter.
Disconnected or ruptured fuel line. Check all fuel lines for security and
condition. Repair or replace parts as
required.
Clogged fuel line. Repair as required.
Clogged fuel cell and start pump Clean as required.

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

failed or disconnected.
FUEL FILTER warning light on. Clogged engine fuel filters. Replace pump and gas producer fuel
control filters. Clean fuel control
pneumatic (air) circuits (refer to
Rolls−Royce Operation and
Maintenance Manual). When
installed, replace anti−ice (airframe)
filter (Ref. Section 28−25−00). Bench
check FUEL FILTER caution light
pressure switch.
Fuel contamination. Inspect and clean the fuel cell and

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

system.
Page 101
MAINTENANCE MANUAL
Table 101. Fuel Supply System Fault Isolation (Cont)

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

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

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

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

Wire No. From Termination To Termination Specification
FQ1A22−WHT J251−1 HSD4123−915 600N8107−7−1 87F5544 M27500−22SP2T23
FQ1A22−BLU J251−2 HSD4123−915 600N8107−7−2 87F5544 M27500−22SP2T23
FQ2A22−WHT J251−3 HSD4123−915 600N8107−7−S 87F5547 M27500−22SP2T23
FQ3A22−WHT 600N8107−9−S 87F5547 600N8107−7−S 87F5547 M27500−22SP3T23
FQ2A22−BLU J251−4 HSD4123−915 600N8107−7−R 87F5546 M27500−22SP2T23
FQ3A22−BLU 600N8107−9−R 87F5546 600N8107−7−R 87F5546 M27500−22SP3T23
FQ2A22−ORN J251−5 HSD4123−915 600N8107−7−L 87F5548 M27500−22SP2T23
FQ3A22−ORN 600N8107−9−L 87F5548 600N8107−7−L 87F5548 M27500−22SP3T23
JMPR J251−6 HSD4123−915 OUTER SHLD
FQ4A22N OUTER SHLD OVERBRAID 600N8107−7 NOTE M27500−22SP2T23
FQ5A22N OUTER SHLD OVERBRAID 600N8107−9 NOTE M27500−22SP2T23
JMPR J251−2 SHLD HSD4123−830 J251−5 SHLD HDS4123−915
JMPR J251−5 SHLD HSD4123−830 J251−7 SHLD HDS4123−817
JMPR P1A22 SHLD HSD4123−830 P2A22 SHLD HDS4123−817
J251−8 SPARE
J251−9 SPARE
J251−10 SPARE
J251−11 SPARE
J251−12 SPARE
J251−13 SPARE
NOTE: To −3 probe flange mount bolt.
OUTER
MS27474P10F35 SHIELD BRAID
P OUTER
SHIELD BRAID
J25
11 WHT
TO LOW LEVEL SWITCH TERM.. 1 (#4 LUG)
FQ1A2 BLU
2 2 TO LOW LEVEL SWITCH TERM.. 2 (#4 LUG)
WHT
3 TO PROBE TERM.. S (#8 LUG)
BLU AFT PROBE
4 FQ2A2 TO PROBE TERM.. R (#6 LUG)
ORN 2
5 TO PROBE TERM.. L (#10 LUG)
8
7
10 FQ4A2 TO AFT PROBE FLANGE MOUNTING BOLT
11 2
12 OUTER SHIELD
BRAID
13
ORN
6 TO PROBE TERM.. L (#10 LUG)
BLU
9 FQ3A2 TO PROBE TERM.. R (#6 LUG) FORWARD PROBE
2 WHT
TO PROBE TERM.. S (#8 LUG)
FQ5A2 TO FORWARD PROBE FLANGE MOUNTING BOLT

2
6G28-020A
Figure 101. Fuel Quantity System Wiring Diagram
Page 103
MAINTENANCE MANUAL
Page 104
MAINTENANCE MANUAL
FUEL SYSTEM
1. Fuel Cell Cleaning − General (2). If a fuel cell that has previously
contained fuel is to be stored for longer
(1). Fuel cells are susceptible to fungus than three days, coat inside of cell with
growth after contact with contaminated a light coating of #10 weight, non-syn
fuel. Fungus trapped in the fuel filters thetic engine oil.
indicates fuel tank contamination.
Remove, inspect, clean or replace filter CAUTION
elements per applicable Rolls-Royce
Operation and Maintenance Manual. D Engineered Fabrics Corp. cells removed
Where installed, service anti-ice from service must not be left dry for more
(airframe) filter (Ref. Section than 3 days without the application of oil
28-25-00). as a plasticizing agent. The cell liner will
loose pliability if left dry for extended pe
(2). Periodic incorporation of an FAA riods and subsequent flexing can cause
approved anti-fungal fuel additive will the material to crack.
kill and prevent new fungus growth.
D Do not work on fuel cell in ambient tem
2. Engineered Fabrics Corp. Fuel Cell peratures below 705F (215C).
Cleaning (a). Fold cell over protective wadding as
loosely as possible and with a mini
Do not steam clean Engineered
CAUTION Fabrics Corp. fuel cells. Steam
mum number of folds.
cleaning can cause irreparable damage. (b). Wrap the cell in a protective cover.
(1). Clean cell exterior and interior surfaces (c). Put cell in a suitable storage/ship
with warm soapy water and clean lint ping container. Use wadding as
free cloth. Rinse away all soap residue required to prevent movement. Do
and wipe dry. not stuff cell into an undersized
container.
3. Fuel Cell Handling, Storage and Shipping (d). Store cell at 705F (215C) away from
sunlight and moisture.
Do not use cell fittings as hand
CAUTION holds. Do not store fuel cells un 5. Fuel System Air Bleed (Model 250−C47
crated or exposed to direct sunlight, ozone, Engine Installation)
dirt, moisture, solvents, chemicals, or ex
tremes of heat and humidity. Fuel/air vapor discharged
WARNING during bleeding is a fire haz
(1). Store and ship cells in a suitable ard. Prevent fuel vapor accumulation,
protective container. ignition and fire. Do the work in an
open, well ventilated area away from
(a). Apply protective tape over all cell all potential ignition sources. Attach
machined fittings. helicopter to an approved electrical
ground. Wear approved eye protection.
(b). Use packing material to keep the cell
from shifting in transit. (1). Helicopters with C47 engines and
standard fuel supply systems are not
(c). Suspended self-sealing cells to equipped with a start pump.
maintain cell shape.
(2). Helicopters equipped with an airframe
4. Fuel Cell Preservation and Storage mounted fuel filter are equipped with
(Engineered Fabrics Corp. Cells) an airframe mounted fuel pump inside
the left fuel cell and can be primed
(1). Thoroughly clean cell with warm soapy using the same procedure as helicopters
water. Wipe completely dry. with the 250-C20 Series engines.
Page 201
MAINTENANCE MANUAL
(3). The standard helicopter fuel system (e). Open fuel shutoff valve.
only has an engine driven self priming
pump that will fill the fuel system when (f). Open throttle to ground idle position.
the engine is motored with the starter. (g). Squeeze primer bulb until fuel comes
Motor engine per the appropriate Pilot's out of fuel line.
Flight Manual.
NOTE: When reinstalling fuel lines, refer to ap
(4). Bleed air out of helicopter engine fuel propriate Rolls-Royce Operation and Main
controls per Rolls-Royce Engine tenance Manual for proper torques.
Operation and Maintenance Manual.
(h). Remove primer bulb assembly from
(5). If fuel system fails to bleed properly, fuel line and reconnect fuel line to
proceed as follows: HMU.
(a). Field fabricate a primer bulb assem (i). Crank engine for approximately 15
bly (Ref. Figure 201). seconds to verify fuel to fuel nozzle is
(b). Disconnect fuel line between CEFA free of air in the system.
and HMU at HMU side. (j). Repeat above procedure as required.
(c). Disconnect fuel line from fuel nozzle. (k). Reinstall fuel line to fuel nozzle.
(d). Install primer bulb assembly in line (l). Close throttle.
between HMU GEAR INLET and the
CEFA. (m). Close fuel shutoff valve.
CLAMPS
BULB PRIMER 5/16

AN807-8 ADAPTER SEASIDE #73800 AN818-8 NUT
TYGON-TYPE TUBING
(FUEL RESISTANT)
FUEL SYSTEM BLEEDING TOOL

(FIELD FABRICATE)
6G28-076
Figure 201. Field Fabricated Fuel System Bleeding Tool
Page 202
MAINTENANCE MANUAL
FUEL SYSTEM
1. Fuel Shutoff Valve Control Cable and grommets to fuel shutoff valve.
Replacement Maintain a cable bend radius greater
than 3.5 inches (8.89 cm).
A. Fuel Shutoff Valve Control Cable
Removal (2). Secure forward end of cable in instru
ment panel with lockwasher and
(Ref. Figure 401) jamnut.
(1). Remove left aft access panel from
(3). Slip control cable wire through fuel
(2). Disconnect control cable from fuel
shutoff valve swivel. (4). Secure end of cable housing to cell cover
with a clamp, washer and screw.
(3). Remove control cable ty-raps and
clamps. (5). Install remaining clamps and ty-raps.
(4). Remove instrument panel left fairing (6). Rig cable with shutoff valve lever hard
and lower cover panels. against open stop. Adjust cable to get a
0.090—0.150 inch (2.29—3.81 mm)
(5). Completely back jamnut away from gap between bottom of control knob
cable plunger housing (Ref. Figure 401, and cable housing end fitting. Tighten
view A). cable swivel pinch nut. Install cotter
pin.
NOTE: Attach a trace wire or cord to the valve
end of the cable before pulling assembly out Control action must move valve
of the instrument panel. Trace will guide re CAUTION to full open against mechanical
placement cable into correct position. stop without bottoming control knob on
cable housing. Control cable operation shall
(6). Pull cable assembly out through be smooth with no binding.
washer, jamnut and instrument panel.
(7). Pull valve control knob out with a
B. Fuel Shutoff Valve Control Cable
spring scale. Required valve actuation
Installation
force not to be more than 12 pounds
(Ref. Figure 401) (5.443 kg).
Pulling detent knob out of cable (8). Repair, adjust or replace valve control
CAUTION housing two or more inches can system components to meet force limit.
result in loss of the detent ball.
(9). Install left aft fuel cell access panel
(1). Thread cable assembly aft through from passenger/cargo compartment
instrument panel, lockwasher, jamnut floor.
Page 401
MAINTENANCE MANUAL
PLUNGER
HOUSING
CABLE
PLUNGER DETENT
INSTRUMENT RELEASE
PANEL
0.090-0.150 INCH
(2.29-3.81 MM) SPRING
DETENT
BALL DETENT
RELEASE
LOCKWASHER
CABLE
PLUNGER
PLUNGER
NUT HOUSING
HOL INSTRUMENT
E PANEL
CABLE
HOUSING
ENGINE FEED HOSE SHUTOFF
VALVE TO FIREWALL
FUEL SHUTOFF CONTROL KNOB ASSEMBLY
VALVE
MOTIVE FLOW HOSE WASHER

FIREWALL TO FUEL CELL NUT
WASHER
SUPPORT CLAMP
BRACKET
FUEL SHUTOFF
CABLE SCREW SCREW
SCREW
WASHER
SCREW CABLE CLAMP WASHER
HOUSING
WASHER CLAMP
CLAMP
BRACKET
WASHER GROMMET
NUT
PLUG STA
0.000
6G28-021A
Figure 401. Fuel Shutoff Valve Cable Installation
Page 402
MAINTENANCE MANUAL
2. Fuel Shutoff Valve Replacement (6). Unclamp and disconnect control cable
from fuel shutoff valve (Ref. Fuel
Avoid fuel vapor ignition Shutoff Valve Control Cable Replace
WARNING and fire. Use only nonspark ment).
ing tools and explosion proof work
lights. Attach helicopter to an ap Handle fuel cell cover with care.
proved electrical ground. Switch OFF CAUTION Prying cover from cell opening
all electrical power. Disconnect exter or rough handling can damage seal or cell
nal power and battery before opening fitting.
quately ventilated. (7). Unbolt cell access cover. Prop cover
CAUTION (8). Using a backup wrench on valve,
separate engine feed fuel cell supply
D Air in fuel system can cause power surges hose from fuel shutoff valve.
or flameout. Bleed off trapped air after
opening system at any point between fuel (9). Remove fuel shutoff valve attaching
tank and engine fuel nozzle. hardware.
stall caps on the ends of hoses, tubes and B. Fuel Shutoff Valve Installation
fittings as parts are removed. Bag and (Ref. Figure 402)
identify small parts to prevent loss or
damage.
(1). Defuel helicopter. Drain remaining fuel (Ref. Section 91−00−00)
from cell sump drain valve into a Item Nomenclature
suitable container. CM114 Petrolatum
(2). Disconnect electrical power.
A. Fuel Shutoff Valve Removal (1). Apply a coating of petrolatum (CM114)
to a new fuel shutoff valve/cover
(Ref. Figure 402) sealwasher.
(1). Remove left aft fuel cell access panel (2). Install fuel shutoff valve with seal
from passenger/cargo compartment washer and nut. Use a backup wrench
floor. on shutoff valve so it will not rotate.
Torque nut 240—280 inch-pounds
(2). Disconnect fuel quantity probe wire (27.12—31.64 Nm).
harness connector from cell cover
receptacle. (3). Connect engine feed fuel supply hose to
fuel shutoff valve. Using a backup
(3). Unfasten and remove Sta. 91.00 and wrench on valve, torque fuel supply
102.00 left aft fuel cell cover support hose 230—260 inch-pounds
brackets. (25.99—29.38 Nm).
(4). Disconnect motive flow fuel hose (4). Start bolts onto aft fuel cell access
assembly between Sta 124.00 bulkhead cover.
and fuel cell access cover. Use backup
wrench on check valve so it will not (5). Install and fasten Sta. 91.00 and 102.00
rotate. left fuel cell cover support brackets.
(5). Disconnect engine feed fuel supply hose (6). Connect engine feed fuel supply hose
assembly between fuel shutoff valve assembly between fuel shutoff valve
and Sta. 124.00 bulkhead. Use backup and Sta. 124.00 bulkhead. Torque hose
wrench on fuel shutoff valve so it will assembly 230—260 inch-pounds
not rotate. (25.99—29.38 Nm).
Page 403
MAINTENANCE MANUAL
CAP ENGINE FEED HOSE

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

HOSE ASSEMBLY WASHER WASHER
SEALING WASHER
NUT
SUBMERGED SEALING
MOTIVE FLOW WASHER BULKHEAD
HOSE ASSEMBLY ELBOW
REF. CARGO
FLOOR STRUCTURE
CHECK
VALVE
BOLT
WASHERS
BRACKET
ASSEMBLY
WASHER
NUT
FUEL CELL SCAVENGE
HOSE ASSEMBLY BRACKET ASSEMBLY
6G28−022
Figure 402. Fuel Shutoff Valve and Fuel Cell Cover Installation
Page 404
MAINTENANCE MANUAL
(7). Connect motive flow fuel hose assembly (a). Remove right side floor panels from
between Sta 124.00 bulkhead and fuel passenger/cargo compartment floor.
tank access cover. Torque hose assem
bly 55—65 inch-pounds (6.21—7.34 (b). Remove bonding jumpers then
Nm). remove fuel cell access cover bolts
and washers.
(8). Connect fuel quantity transmitter
(2). To remove left aft fuel cell access cover
(Ref. Figure 402):
(9). Progressively torque fuel cell cover (a). Remove left aft fuel cell access panel
bolts to 70—90 inch-pounds from passenger/cargo compartment
(7.91—10.17 Nm) in a cross pattern. floor.
(10). Clamp and connect control cable to fuel (b). Unclamp and disconnect control
shutoff valve. Rig fuel shutoff valve cable from fuel shutoff valve (Ref.
control cable (Ref. Fuel Shutoff Valve Figure 401).
Control Cable Replacement).
(c). Disconnect engine feed fuel supply
(11). Install left aft access passenger/cargo hose assembly between fuel shutoff
compartment floor panel. valve and Sta. 124.00 bulkhead. Use
backup wrench on fuel shutoff valve
3. Fuel Cell Cover Replacement so it will not rotate.
Avoid fuel vapor ignition (d). Disconnect motive flow fuel hose
WARNING and fire. Use only nonspark assembly between Sta 124.00 bulk
ing tools and explosion proof work head and fuel cell access cover.
lights. Attach helicopter to an ap (e). Disconnect fuel quantity probe wire
proved electrical ground. Switch OFF harness connector from fuel cell cover
all electrical power. Disconnect exter receptacle.
fuel system. Ensure work area is ade (f). Unfasten and remove Sta. 91.00 and
quately ventilated. 102.00 left aft fuel cell cover support
brackets.
CAUTION (g). Remove cover bolts and washers.
Prop cover open with suitably padded
D Air in fuel system can cause power surges blocks.
or flameout. Bleed off trapped air after
opening system at any point between fuel (h). Using a backup wrench on valve,
tank and engine fuel nozzle. separate engine feed fuel cell supply
hose from fuel shutoff valve and fuel
inlet from fuel cell access cover.
stall caps on the ends of hoses, tubes and
fittings as parts are removed. Bag and (i). Disconnect submerged motive flow
identify small parts to prevent loss or fuel hose assembly between fuel
damage. check valve and ejector pump from
fuel cell access cover.
from cell sump drain valve into a (j). Disconnect fuel cell scavenge hose
suitable container. assembly from bottom of fuel cell
access cover bracket assembly to
(2). Disconnect electrical power. ejector pump (Ref. Figure 404).
A. Fuel Cell Cover Removal (k). Cut safety wire from fuel probe
electrical connector base nut and
(1). To remove right side fuel cell access remove connector from fuel cell
covers (Ref. Figure 406). access cover.
Page 405
MAINTENANCE MANUAL
(l). If applicable, remove fuel cell scav jamnut to 240—280 inch-pounds

enge hose bracket assembly,bulkhead (27.12—31.64 Nm).
union and fuel shutoff valve from fuel
cell cover. (d). Install support bracket to cover with
bolts, washer, and sealwashers.
Apply a coating of petrolatum
B. Fuel Cell Cover Installation
(CM114) to sealwasher. Torque bolts
36—46 inch-pounds (4.06—5.19
Consumable Materials Nm).
(Ref. Section 91−00−00) (e). Install bulkhead union to cover with
Item Nomenclature sealwasher next to union. Apply a
CM114 Petrolatum coating of petrolatum (CM114) to
CM124 Kerosene sealwasher. Install washer and
jamnut. Torque jamnut to 120—150
CM702 Lockwire CRES
Install cap outside of cell. Torque cap
to 110—130 inch-pounds
(1). Wipe fuel cell and cover sealing sur
(12.43—14.69 Nm).
faces clean with kerosene (CM124) on a
clean lint free cloth. (5). Place left forward fuel cell access cover
into position on fuel cell.
(2). Inspect fuel cell cover seals for debond
ing, nicks or cuts and any other damage (6). Connect fuel quantity probe wire
having a leak producing potential. harness connector to cell cover. Torque
Replace covers or left aft cover as connector jamnut and safetywire to
required. bulkhead union with (CM702) lockwire.
(3). Install bonding jumper with right cell CAUTION

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

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

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

COVER
WASHER
NUT
6G28-024-1
Figure 403. Fuel Lines Installation
Page 408
MAINTENANCE MANUAL
HOSE ASSEMBLY
BOLT
WASHER
SEALING WASHER
FUEL INLET
SUPPLY HOSE CHECK
ASSEMBLY VALVE NUT
AFT FUEL SUBMERGED

PROBE MOTIVE FLOW WASHER
HOSE ASSEMBLY
BOLT BULKHEAD ELBOW
WASHER
BONDING
JUMPER
BOLT BOLT BRACKET
ASSEMBLY
WASHER
FUEL INLET WASHERS NUTPLATE
FITTING ASSEMBLY WASHER
NUT
FUEL CELL SCAVENGE
HOSE ASSEMBLY
BRACKET ASSEMBLY
EJECTOR
NUTPLATE PUMP
BOLT
WASHER
EJECTOR FUEL CELL

BRACKET ASSEMBLY SCAVENGE
HOSE ASSEMBLY
SPACER
SUBMERGED
MOTIVE FLOW CLAMP
HOSE ASSEMBLY
O-RING WASHER
BOLT
EJECTOR PUMP
ELBOW
REDUCER FORWARD
BUSHING FUEL PROBE
NUT
O-RING
6G28-024-2
Figure 404. Ejector Pump and Fuel Lines Installation
Page 409
MAINTENANCE MANUAL
(4). Apply a torque alignment stripe to fuel A. Fuel Cell Vent System Components
line tube, hose and fitting fasteners. Removal
(5). Apply chaffing tape between hose (Ref. Figure 405)

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

WARNING bustion or explosion. Never (1). Coat O-rings with (CM114) lubricant
use oxygen to purge or ventilate fuel and install on vent valves.
tank or fuel system components. Fuel, (2). Insert vent valves thru cell from inside
either vapor or liquid, will violently and secure using springs and retainers.
(3). Bond prep aft vent fittings at bond
(3). Ventilate fuel tank with an inert gas, jumper location.
such as nitrogen, or low pressure
compressed air applied through filler (4). Coat O-rings with lubricant (CM114)
neck. and install on vent fittings.
Page 410
MAINTENANCE MANUAL
BOLT
WASHER
SCREW BONDING
REF. FS 78.50 JUMPER
CANTED BULKHEAD WASHER
BOLT FLAME VENT CLAMP

WASHER ARRESTOR TUBE
(3 PL) WASHER
CLAMP
SCREW NUT
WASHER VENT
WASHER NUT FITTING
(3 PL)
TUBE ASSEMBLY
NUT
(3 PL)
CLAMP
CLAMP SCREW
(3 PL) WASHER
NUT
GROMMET
CONNECTOR
NUT
(2 PLCS)
WASHER
(2 PL) BOLT
CLAMP (2 PL)
(2 PL) HOSE WASHER
TUBE ASSEMBLY (2 PL) (2 PL)
WASHER CLAMP
(2 PL) (2 PL)
FLAME
ARRESTOR CROSSOVER
(2 PL) ASSY
BOLT (2 PL) 0-RING
WASHER
(2 PL) RETAINING
SPACER (2 PL) WASHER RING (2 PL)
NUT
(2 PL) (2 PL)
SPRING
BOLT RETAINER
CLAMP PIN (2 PL) 0-RING
WASHER
WASHER NUT
VENT VALVE
(2 PL)
6G28-023
Figure 405. Fuel Cell Vent System Components
Page 411
MAINTENANCE MANUAL
(5). Install aft vent fittings and bond (21). Safety connector to cross-over tube
jumpers to vent valves with hardware. with lockwire (CM702).
Torque bolts to 36—46 inch-pounds
(4.0—5.2 Nm). (22). Tie-rap tube assembly to forward
bulkhead of Sta. 78.50.
(6). Bond prep six vent tube clamp screw
(23). Route tube assembly to vent fairing and
holes on cargo deck.
bond using sealant (CM425).
(7). Install hoses to aft vent fittings with (24). Bond prep fuel cell access covers.
lockwire (CM702), two wrap around
turns minimum. (25). Install bonding jumpers and fell cell
access covers. Torque bolts 70—90
(8). Slide vent tubes under cargo floor and inch-pounds (7.91—10.17 Nm).
connect to hoses with lockwire Install fuel vent access cover.
(CM702), two wrap around turns
minimum. (26). Install passenger/cargo compartment
floor access panels.
(9). Attach forward end of tube to cargo
floor with clamps. 6. Fuel Cell Replacement
(10). Install bonding jumpers at aft clamps. Avoid fuel vapor ignition
(11). Install hoses on forward ends of vent ing tools and explosion proof work
tubes and safety using lockwire lights. Attach helicopter to an ap
(CM702), two wrap around turns proved electrical ground. Switch OFF
minimum. all electrical power. Disconnect exter
(12). Coat O-rings with lubricant (CM114) fuel system. Ensure work area is ade
and install on cross-over tube. quately ventilated.
(13). Attach vent cross-over tube with
hardware to tops of vent valves. Torque CAUTION
bolts to 36—46 inch-pounds D Do not work on cell in ambient tempera
(4.06—5.19 Nm). tures below 705F (215C).
(14). Bond prep two nutplate holes for D Prevent fuel system contamination. In
attaching cross-over tube. stall caps on the ends of hoses, tubes and
(15). Install clamps on cross-over tube and identify small parts to prevent loss or
attach to airframe. damage.
(16). Install grommet in Sta. 78.50 skin at (1). Defuel helicopter. Drain remaining fuel
vent outlet using epoxy adhesive from tank sump drain valve into a
(CM411). suitable container.
(17). Attach connector to the flame arrestor (2). Disconnect electrical power.
and safety with lockwire (CM702), two A. Fuel Cell Removal
wrap around turns minimum.
(Ref. Figure 406)
(18). Attach tube to flame arrestor and
safety with lockwire (CM702) two wrap NOTE: The following procedures are required
around turns minimum. to access and separate the fuel cell intercon
nect fitting, vent system and gravity fill port
(19). Bond prep one of the three attaching before either cell can be removed from its
screw holes for the flame arrestor. bay.
(20). Install flame arrestor/tube assembly (1). Remove forward fuel vent crossover
with clamps. tube cover, right and left fuel cell access
Page 412
MAINTENANCE MANUAL
panels from passenger/cargo compart (11). Disconnect submerged fuel cell scav
ment floor. enge hose assembly from bottom of fuel
cell access cover bracket assembly to
(2). Disconnect fuel quantity probe wire ejector pump (Ref. Figure 404).
harness connector from fuel cell access
cover receptacle. (12). Cut safety wire from fuel probe electri
cal connector base nut and remove
(3). Unclamp and disconnect control cable connector from fuel cell access cover.
from fuel shutoff valve. (13). Unbolt and remove right hand fuel cell
access cover(s) and bonding jumpers.
(4). Unfasten and remove Sta. 91.00 and Remove left hand forward fuel cell
102.00 left fuel cell cover support access cover.
brackets from passenger/cargo floor
structure (Ref. Figure 402). Prevent spontaneous com
(5). Remove attaching hardware from Sta use oxygen to purge or ventilate fuel
102.230 and Sta 113.850 passenger/car tank or fuel system components. Fuel,
go compartment floor structure that either vapor or liquid, will violently
secures engine feed fuel supply hose react with an oxygen rich atmosphere.
and motive flow firewall to fuel cell
hose to bottom of floor (Ref. (14). Mop up any remaining fuel in both cells
Figure 403). with clean lint free cloth. Purge fuel
cells with dry, forced air or inert gas
(6). Disconnect engine feed fuel supply hose such as nitrogen through filler neck.
between fuel shutoff valve and firewall
(15). Disconnect wire harness from forward
Sta. 124.00 bulkhead union. Using a
and aft fuel quantity probe and remove
backup wrench on bulkhead union so it
wire harness (Ref. Fuel Quantity Probe
will not rotate, disconnect and remove
Replacement).
engine feed fuel supply hose assembly
(Ref. Fuel Supply Line Replacement). (16). Remove aft fuel quantity probes, fuel
inlet with fuel supply hose and bracket
(7). Disconnect motive flow fuel hose assembly, forward fuel quantity probe,
assembly between fuel cell access cover ejector pump with submerged motive
and Sta 124.00 bulkhead. Using a flow fuel hose assembly and fuel cell
backup wrench on bulkhead union so it scavenge hose as a subassembly (Ref.
will not rotate, disconnect and remove Figure 404 and Figure 407).
motive flow fuel hose assembly.
(17). Disconnect and remove fuel vent
Handle fuel cell covers with system components necessary to
CAUTION care. Prying covers from cell remove fuel cell (Ref. Fuel Cell Vent
openings or rough handling can damage the System Component Replacement).
cover seal or cell fitting.
NOTE: At this point either cell can be removed,
(8). Unbolt and prop left aft fuel cell access as required.
cover open with suitably padded blocks. (18). Remove sump drain valve.
(9). Disconnect fuel inlet supply hose (19). Remove retaining ring and spring from
between fuel shutoff valve fuel cell fuel cell interconnect fittings (Ref.
access cover and fuel inlet support Figure 406).
bracket (Ref. Figure 402 and
Figure 404). (20). Remove cell suspension cords.
(21). For right fuel cell removal:
(10). Disconnect submerged motive flow fuel
hose assembly between fuel check valve (a). Remove fuel filler neck fairing from
fuel cell access cover and ejector pump. passenger/cargo compartment floor.
Page 413
MAINTENANCE MANUAL
(b). Unclamp fuel gravity filler port from cell. Coat O-rings with lubricant
fill valve, remove hose from fill valve (CM114) and install O-ring, spring and
and disconnect lanyard. retaining ring.
Cells are thin-walled and frag Cells are thin-walled and frag
CAUTION CAUTION ile. Avoid snagging or dragging
ile. Avoid snagging or dragging
cell over pointed or sharp edges. Do not cell over pointed or sharp edges. Do not
scratch or nick any of the cell's metal fit scratch or nick any of the cell's metal fit
tings. tings. Avoid hard contact between cell and
fuselage structure when inserting.
(22). Collapse and fold cell lengthwise and
remove through floor access opening. (4). Fold cells lengthwise and position in
bay through floor opening. Unfold cell
B. Fuel Cell Installation and smooth out all creases.
(Ref. Figure 406) (5). Align cell openings with airframe
openings. Hook up fuel cell cross over
Consumable Materials interconnects into right fuel cell. Coat
(Ref. Section 91−00−00) O-rings with lubricant (CM114) and
Item Nomenclature install O-ring, spring and retaining
CM114 Petrolatum ring.
CM220 Naphtha aliphatic (6). Install a new O-ring on sump drain
CM702 Lockwire CRES valve. Install valve and torque to
CM809 Nylon cord 95—105 inch-pounds (10.73—11.86
Nm). Safety wire drain valve with
lockwire (CM702).
WARNING and fire. Use only nonspark (7). For right fuel cell installation:
ing tools and explosion proof work (a). Install rubber hose to fill valve and
lights. Attach helicopter to an ap filler neck, hose should be approxi
proved electrical ground. Switch OFF mately 6.5 inches (16.5 cm) long.
all electrical power. Disconnect exter Secure hose to fill valve and filler
nal power and battery before opening neck with clamps.
quately ventilated. (b). Insure lanyard on filler valve is
accessible with fill cap removed. Slip
NOTE: Discard used O-rings and sealwashers. lanyard on fuel cap onto ring of fill
Apply a thin coat of petrolatum (CM114) to valve. Install fuel cap.
all new O-rings except cell vent system
(c). Connect lanyard of fill valve to
sealwashers.
gravity filler port. Install hose and
(1). Air-vacuum all debris from cell bays. clamp.
Ensure compartment liner will protect (8). Connect engine feed fuel supply hose
cell from airframe points and edges. and motive flow fuel hose assembly to
Repair liner as required. Sta. 124.00 bulkhead union (Ref. Fuel
(2). Bond prep fill valve with fuel cell Supply Line Replacement).
fitting. Coat O-rings with lubricant (9). Install fuel vent system components
(CM114) and install fill valve into right (Ref. Fuel Vent System Components
fuel cell with O-ring, spring and Replacement).
retaining ring. Ensure clocking of fill
valve with flat at top lines up with (10). Route suspension nylon cord (CM809)
shoulder on fuel cell fitting. thru grommet of fuel cell and thru
eyelets of fuselage. Tighten and tie cord
(3). Hook up fuel cell interconnect fittings using a bowline knot. Cut excess cord
into left fuel cell. Ensure short end of after knot to approximately 3—4 inches
interconnects are facing into left fuel (7.6—10.2 cm) in length.
Page 414
MAINTENANCE MANUAL
(11). Secure opposite end of cord using a (13). Aft fuel probe and fuel supply inlet hose
trucker's slip knot. Cut excess cord installation (Ref. Ejector Pump and
after knot to approximately 3—4 inches Fuel Line Installation):
(7.6—10.2 cm) in length.
(a). Bond attachment holes on fuel cell
(12). Forward fuel probe and ejector pump aft sump fitting assembly, bracket
subassembly installation (Ref. Ejector assembly, aft fuel probe attachment
Pump and Fuel Line Installation): holes and fuel inlet fitting assembly.
(a). Bond prep ejector pump bracket
assembly with forward fuel probe and (b). Install fuel inlet fitting assembly to
ejector pump assembly. bracket assembly with four washers
each between fuel inlet fitting and
(b). Coat O-rings with lubricant (CM114) bracket assembly.
and install reducer bushing with
O-rings into ejector pump. Torque to (c). Install aft fuel probe to bracket
50—65 inch-pounds (5.65—7.34 assembly and fuel cell aft sump
Nm). fitting with bolts and two washers
(c). Coat O-rings with lubricant (CM114) under the head of each bolt, except
and install jamnut, bulkhead elbow bolt with ground wire, only one
to reducer bushing. Torque jamnut to washer is required.
85—105 inch-pounds (9.60—11.86
Nm). (d). Connect wire harness to aft fuel
probe. Attach bonding jumper to
(d). Install fuel cell scavenge hose to outboard bolt of probe. Torque bolts
ejector pump. Torque hose nut to to 36—46 inch-pounds (4.06—5.19
230—260 inch-pounds Nm) (Ref. Fuel Quantity Probe
(25.99—28.81 Nm). Replacement).
(e). Install submerged motive flow fuel (14). Install attaching hardware from Sta
hose assembly to elbow and torque to 102.230 and Sta 113.850 passenger/car
50—65 inch-pounds (5.65—7.34 go compartment floor structure that
Nm). secures engine feed fuel supply hose
(f). Bond prep ejector pump in area of and motive flow firewall to fuel cell
clamp up and install forward fuel hose to bottom of floor (Ref.
quantity probe, ejector pump with Figure 403).
submerged motive flow hose assem
bly and fuel cell scavenge hose (15). Install right hand fuel cell access
assembly as a subassembly. covers, left hand forward and left hand
aft access cover (Ref. Fuel Cell Cover
(g). Install ejector pump subassembly to Replacement).
bracket assembly with clamps, bolts
and washers. Torque bolts to 36—46 (16). Connect fuel quantity probe wire
inch-pounds (4.06—5.19 Nm). harness connector from fuel cell access
(h). Connect wire harness to forward fuel cover receptacle.
probe. Wind wire harness around
scavenge hose without causing (17). Connect and clamp control cable from
tension at the attachment points. fuel shutoff valve (Ref. Fuel Shutoff
Route submerged motive flow fuel Valve Control Cable Replacement).
hose assembly, fuel cell scavenge hose
assembly and wire harness thru fuel (18). Install forward fuel vent crossover tube
cell fabric retaining loops and baffle cover, right and fuel cell access panels
(Ref. Fuel Quantity Probe Replace from passenger/cargo compartment
ment). floor.
Page 415
MAINTENANCE MANUAL
RETAINING
RING
SPRING
INTERCONNECT
SPRING RETAINING
RING
BL
0.000
CENTER BEAM O-RING
ASSEMBLY
RETAINING
RING SPRING
RETAINING
RING
INTERCONNECT
SPRING
RIGHT
LEFT
FUEL CELL
FUEL CELL
O-RING
6G28-025-1
Figure 406. Fuel Cell Interconnect and Support Lacing (Sheet 1 of 3)
Page 416
MAINTENANCE MANUAL
START HERE
BOWLINE KNOT END HERE
TRUCKER SLIPKNOT
BONDING
JUMPER
END HERE START HERE

TRUCKER SLIPKNOT BOWLINE KNOT
FUEL CAP
FILL PORT
HOSE
RETAINING
RING
CLAMP SPRING
LANYARD O-RING
CLAMP
BOWLINE KNOT
RIGHT
FUEL CELL
FILL
VALVE
VIEW LOOKING AFT

AT VALVE INLET
6G28-025-2
Page 417
MAINTENANCE MANUAL
TRUCKER SLIPKNOT
6G28-025-3
LEFT
BAFFLE
RIGHT
BAFFLE
GROMMET
(6 PLCS)
FLAPPER CHECK VALVE

IN CLOSED POSITION
FLAPPER CHECK VALVE

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

Installation (Ref. Section 91−00−00)
Item Nomenclature
(1). Bond prep attach points for bonding
jumper near fuel fill area. Attach CM114 Petrolatum
bonding jumper to fuel cell with screw CM124 Kerosene
and washer. Attach opposite end of CM702 Lockwire CRES
bonding jumper to passenger/cargo
compartment flooring with screw, (1). Replace drain valve O-ring packings.
washers and nut. Lubricate packings with kerosene
(2). Install bolts and washers from filler (CM124), petrolatum (CM114) or jet
neck mounting flange and install fuel.
gravity fill port. (2). Install and torque sump drain valve to
95—105 inch-pounds (10.73—11.86
(3). Install rubber hose to fill valve and
Nm). Safety valve with lockwire
filler neck. Note, hose should be
(CM702).
approximately six an one half inches
long. Secure hose to fill valve and filler (3). Apply a torque alignment stripe to fuel
neck with clamps. line tube, hose and fitting fasteners.
Page 419
MAINTENANCE MANUAL
(4). Refuel helicopter. B. Forward Fuel Quantity Probe Installation

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

FABRIC LOOPS
FUEL CELL SCAVENGE

HOSE ASSEMBLY
EJECTOR
BRACKET
ASSEMBLY SCAVENGE
HOSE ASSEMBLY
BOLT SUBMERGED MOTIVE
FLOW HOSE
WASHER
BOLT WIRE HARNESS
WASHER
EJECTOR FORWARD
PUMP FUEL PROBE
FUEL CELL FITTING
FORWARD FUEL PROBE
6G28-051-1A
Figure 407. Fuel Quantity Probes (Sheet 1 of 2)
Page 421
MAINTENANCE MANUAL
AFT FUEL PROBE
BOLT
BOLT WASHER
WASHER
GROUND
JUMPER
WASHER
FUEL INLET SUPPLY

HOSE ASSEMBLY
FUEL INLET FITTING ASSEMBLY
BRACKET
ASSEMBLY
AFT FUEL PROBE

6G28-051-2
Figure 407. Fuel Quantity Probes (Sheet 2 of 2)

D. Aft Fuel Quantity Probe Installation (2). Connect wire harness connector ends to
forward fuel probe in the same locations
as removed.
(Ref. Figure 407)
(3). Install left aft fuel cell access cover
(Ref. Fuel Cell Cover Replacement).
(1). Install fuel quantity probe ground wire
and attaching hardware. Torque bolts (4). Install left forward fuel cell access
to 36—46 inch-pounds (4.06—5.19 panel from passenger/cargo compart
Nm). ment floor.
Page 422
MAINTENANCE MANUAL
FUEL SYSTEM
ADJUSTMENT/TEST
1. Fuel Level Low Light/Fuel Quantity (5). Level the helicopter laterally across the
Indicator System Test and Calibration passenger/cargo compartment floor.
The following procedure is for calibrating the (6). Plug in and switch on 27.5 ±0.5 Vdc
fuel quantity system when the fuel cell, fuel external power. Set BAT master switch
probes or fuel quantity indicator have been to EXT PWR. Make sure the INST and
replaced. PNL LT circuit breakers are pushed in.
NOTE: All readings are taken from the center
Special Tools line of the fuel quantity indicator pointer.
(Ref. Section 91-00-00) (7). Verify the FUEL LEVEL LOW light is
Item Nomenclature illuminated.
ST203 Hydraulic jack: 1-5 ton (900-4500 kg)
(8). Add 1.3 gals (4.92 Liter) of fuel from a
ST205 Inclinometer
calibrated delivery system to the fuel
cell. This amount of fuel is trapped fuel
Prevent fuel vapor accumu or unusable fuel. Calibrate empty.
WARNING lation, ignition and fire. At (a). Calibrate zero on the fuel quantity
tach helicopter to an approved electri indicator by holding the fuel quantity
cal ground. Switch OFF and disconnect gauging system calibration switch in
external power and battery before the empty calibration position (down)
opening fuel system. Do the work in an for a minimum of 5—10 seconds.
open, well ventilated area away from
all potential ignition sources. Use only (b). Verify the the fuel quantity indicator
nonsparking tools and explosion proof now reads empty. Empty is the E
work lights. with the pointer centerline between
the outer and inner edge of the E
(1). Attach helicopter to a approved electri graduation mark.
cal ground.
(9). Add 11.4 gals (44.3 Liter) of fuel from
(2). Defuel and drain fuel cell sumps of all a calibrated delivery system to the fuel
fuel from all four sump drains with the cell.
helicopter at normal ground attitude. (10). Verify the FUEL LEVEL LOW light is
not illuminated.
(3). Place an aircraft jack (ST203) under the
aft jacking point. (11). Wait 15 minutes and verify the FUEL
LEVEL LOW light is not illuminated. If
Do not apply more than 500 lb. light illuminates:
CAUTION (227 kg) pressure on aft jacking (a). Inspect baffles for damage, tears,
point, damage to tailboom and attachment punctures or delamination.
points will occur.
(b). Inspect flappers for proper seating.
(4). Locate a inclinometer (ST205) on the Flappers should seat flush with
passenger/cargo compartment floor at gravity or very light finger pressure
approximately fuselage Sta. and should move freely.
100.00—104.00. Raise the helicopter at (12). Fill the fuel cell and secure the fuel
Sta. 303.03 with jack (ST204) and filler cap.
P.Sta. 18.76 with jacks (ST203) to
obtain a 3 degree nose down simulated (a). Calibrate full on the fuel quantity
flight attitude as observed on the indicator by holding the fuel quantity
inclinometer scale. gauging system calibration switch in
Page 501
MAINTENANCE MANUAL
the full calibration position (up) for a (6). With reducer bushing removed from tee
minimum of 5 seconds. fitting, install an O-ring on a suitable
airtight plug and tighten into tee
(b). Verify the the fuel quantity indicator fitting.
now reads approximately 759
pounds (344.28 kg). (7). Bench test 600N8131 bypass pressure
switch as follows (denoted by six
(13). Place the BAT master switch to OFF housing screws):
position. Disconnect external power.
(a). Assemble test equipment shown in
2. Fuel Filter (Bypass) Caution Light Figure 501. Connect tester to pres
Pressure Switch Test sure switch lead and connect ground
test lead to one of three screws on the
(Ref. Figure 501) housing body.
Air in the fuel system will (b). Remove reducer bushing and O-ring
WARNING cause a power reduction or from switch. Wipe switch completely
flameout. Do a fuel system vacuum leak dry so any leakage can be detected
check and system air bleed after open during the test.
ing fuel system to atmosphere and (c). Apply 2.0—3.0 psig (13.8—20.68
prior to releasing helicopter for flight. Kpa) at port `À'' .
NOTE: For all torques in the following proce 1). There shall be no evidence of
dures, refer to Engine Build-Up, Section leakage. Replace a leaky switch.
71-00-47.
2). When air pressure is applied,
(1). Set all switches; OFF. Disconnect switch shall be close when pres
external electrical power. Disconnect sure at port `À'' is 2.1—2.9 psid,
battery. pound per square inch differ
ential (4.3—5.9 in. Hg, inch of
(2). Open engine access doors. mercury).
(3). Locate pressure switch on engine fuel 3). When air pressure is bled off,
pump filter. Disconnect bypass switch switch shall be open when pres
wire knife splice. sure at port `À'' is 1.0 psid (2.0 in.
Hg).
CAUTION (d). Remove test equipment.
D Pressure switch is easily damaged. A (8). Remove plug from tee fitting. Install
slight shearing force applied to half the reducer bushing and bypass switch
pressure switch can cause leakage and, or assembly with new O-rings on reducer
operational failure. Always grip both bushing and bypass switch. Torque
halves of pressure switch hex flats with switch assembly.
wrench when loosening or torquing at
taching hardware. (9). Remove plug from bypass hose. Attach
D Bypass pressure switch is not field repair hose to switch bushing. Torque hose
able. Do not disassemble switch. Return nut.
faulty switches to vender for repair (Ref. (10). Install insulating sleeve and connect
Section 01-00-00). switch wire knife splice.
(4). Disconnect hose from fuel filter pres (11). Bleed fuel system.
sure switch. Install an airtight plug to
hose. (12). Operate engine per Pilot's Flight
Manual and check fuel system for
(5). Remove fuel pressure switch with correct operation. Shut down engine.
reducer bushing. Inspect fuel system for leaks.
Page 502
MAINTENANCE MANUAL
PRESSURE METHOD:
APPLY 2-3 PSIG (4.3 TO 5.9 IN HG) TO
PORT `À'' THE SWITCH SHALL CLOSE.
BLEED OFF 1 PSIG (2.0 IN HG) THE
SWITCH SHALL OPEN.
HOSE
FUEL SWITCH
CEFA FILTER
PORT A
FUEL FILTER
PRESSURE SWITCH
NOTE
HOSE
OHMMETER
LOOKING FORWARD OR
CONTINUITY TESTER
PORT B
NOTE:
CONNECT GROUND TEST LEAD TO ONE OF SIX SCREW
HEADS ON THE HOUSING BODY. 6G28-075
Figure 501. Fuel Filter Caution Light Pressure Switch Test Apparatus (C47 Engine)
Page 503
28-00-60 TR18-001
MAINTENANCE MANUAL
3. Deleted (Ref. 28−00−00, Adjustment / Test,

1. Fuel Quantity Transmitter Functional
Check)
Page 504
TR18-001 28-00-60
MAINTENANCE MANUAL
FUEL SYSTEM
INSPECTION/CHECK
2. Fuel Shutoff Valve Inspection
WARNING
(1). Shut down and disconnect all electrical
D Avoid fuel vapor ignition and fire. power.
Use only nonsparking tools and ex (a). In cargo/passenger compartment,
plosion proof work lights. Attach he open left aft fuel cell access panel.
licopter to an approved electrical
ground. Switch OFF all electrical (b). Disconnect fuel supply tube from fuel
power. Disconnect external power shutoff valve.
and battery before opening fuel sys
(c). Use an inspection mirror and flash
tem. Ensure work area is adequately
light to check shutoff valve ball
ventilated.
position.
D Air entering the airframe fuel supply (d). Ensure shutoff valve control knob is
lines can cause a power reduction or pushed in. Valve ball must be wide
flameout. Fuel system vacuum leak open.
check and fuel air bleed procedures
must be done after opening fuel the (e). Pull control knob out to stop. Valve
supply system for any reason, prior ball should be closed.
to releasing helicopter for flight.
(2). Valves that can not be fully closed or
opened must be overhauled or replaced
1. Fuel System General Inspection prior to further flight.
(3). Disconnect control cable from valve.
(1). Remove all fuel tank floor access
panels. (a). Inspect shutoff valve lever and cable
swivel hardware for corrosion and
wear. Check lever for smooth move
(2). Inspect fuselage bottom skin for ment from closed to open stops.
evidence of fuel leakage. No leaks
allowed. Determine source and repair (b). Use a spring scale to check tension
as required. required to move valve lever from full
open to closed. Design force require
(3). Inspect fuel lines, fittings, cell access ment is 1.5—3.5 pounds (6.7—15.6
covers, fuel quantity unit, clamps and N) maximum.
attaching hardware for leakage, (c). Inspect valve for evidence of external
corrosion and security. Inspect fire leakage. External leakage not
sleeves for cuts, tears and punctures. allowed.
No leakage allowed. Repair or replace
components as required. (d). Check that lever detents at open and
closed positions. Repair or replace
valve as required.
(4). Inspect electrical wiring and connectors
for corrosion and security. Replace or (4). Connect and rig valve control cable.
repair wiring as required. Install cotter pin on cable swivel.
Page 601
MAINTENANCE MANUAL
3. Tank Vent System Inspection hardware. Repair or replace vent

float/rollover valve as required.
WARNING and fire. Use only nonspark 4. Fuel Quantity Probe Inspection
lights. Attach helicopter to an ap (1). Inspect probe wire harness electrical
proved electrical ground. Switch OFF connector for serviceable conditional.
nal power and battery before opening (2). Inspect for bent or broken pins, frayed
fuel system. Ensure work area is ade or broken wires. Repair or replace as
quately ventilated. required,
Prevent fuel system contamina 5. Fuel System Vacuum Leak Inspection
hoses, tubes and fittings as parts are re (Ref. Figure 601) Water, ice, dirt, fungus or a
moved. Bag and identify small parts to pre few pinhole leaks in the supply system
vent loss or damage. between the fuel tank sump pickup and engine
driven fuel pump can cause power surges,
(1). Defuel helicopter. Drain remaining fuel deceleration and, or flameout. A vacuum leak
from tank sump drain valve into a inspection will determine whether or not air is
suitable container. being drawn into the engine fuel supply
system.
(3). Remove all four passenger/cargo access Special Tools
panels. (Ref. Section 91-00-00)
Item Nomenclature
(4). Remove fuel vent cross over tube access
cover and disconnect hoses from ST801 Hand operated vacuum pump kit
forward vent crossover tubes.
(5). Blow low-pressure compressed air Air entering the airframe
through vent system to verify passages WARNING fuel supply lines can cause a
are clear. power reduction or flameout. Fuel sys
tem vacuum leak check and fuel air
(6). Check vent fairing passages for obstruc bleed procedures must be done after
tions and condition. Repair or replace opening the fuel supply system for any
fairings as required. reason, prior to releasing helicopter
for flight.
(7). Inspect vent system hoses for deteriora
tion. Pinch or bend hoses and look for (1). Remove left fuel cell floor access panel.
surface cracks. Replace hose if cracks
are apparent. (2). Pull FUEL shutoff valve knob out to
stop. Verify that fuel shutoff valve lever
(8). Inspect vent tubes for dents, cracks, is hard against its OFF stop.
deformation or corrosion. Smooth
nonrestrictive dents are permissible (3). In engine compartment; remove and
except at lower vent end which must fit plug the motive fuel line at the CEFA.
flush within vent fairing flared riser.
(4). Assemble vacuum pump (ST801) hoses,
(9). Inspect crossover fittings for cracks, filter port adapter, shutoff valve and
dents or corrosion. Smooth nonrestric vacuum gauge.
tive dents are permissible.
(a). Install the vacuum gauge in the line
(10). Inspect fuel vent float/rollover valves between the filter port adapter and
for serviceable condition, leakage and shutoff valve. Attach the vacuum
corrosion. Inspect for loose or missing pump above the shutoff valve.
Page 602
MAINTENANCE MANUAL
MOTIVE FUEL LINE

FUEL FILTER UPPER
DRAIN PORT FUEL FILTER OIL FILTER
VACUUM GAGE
SHUT-OFF VALVE
FUEL IN PORT
VACUUM
OIL OUT PORT
PUMP
TEE FITTING
FUEL OUT PORT
FILTER PORT ADAPTER OIL IN PORT

6G28-077
Figure 601. Fuel System Vacuum Leak Inspection

(5). Attach vacuum test pump to engine The fuel shutoff and drain valve
fuel filter upper drain port. Apply 8.0 installations should be especially
Hg vacuum. Close vacuum line shutoff suspect. Apply vacuum at each stage
valve. until leak has been isolated. Replace
parts as required.
(6). Fuel system shall hold vacuum between
8.0 and 7.5 Hg for two minutes. NOTE: If the vacuum held at 7.5 Hg or better,
airframe system seal is satisfactory and
(7). If test is satisfactory, remove test leak is due to an engine fuel system prob
vacuum. lem. Refer to the applicable Rolls-Royce and
(8). Reconnect and torque the fuel vapor Bendix manuals for additional information.
return line.
(11). Apply a torque stripe to all effected fuel
NOTE: Vacuum loss exceeding 0.5 Hg in two line fittings and nuts.
minutes indicates a leak in the system be
tween, and including, the fuel shutoff valve 6. Drain Valve Inspection
and engine.
(9). Retorque fuel line connections and WARNING cause a power reduction or
where installed, anti-ice (airframe) fuel flameout. Do a fuel system vacuum leak
filter fittings and line nuts (Ref. Section check and fuel system air bleed after
28-25-00). Repeat vacuum test. opening fuel system to atmosphere and
prior to releasing helicopter for flight.
(10). If system continues to leak, disconnect
and install airtight caps on lines and (1). Inspect tank sump drain valves for
fitting ports in a progressive sequence leakage and security. No leakage
from fuel shutoff valve toward engine. allowed. Replace valve as required.
Page 603
MAINTENANCE MANUAL
7. Fuel Cell Inspection 8. Fuel Cell Leak Inspection
CAUTION (Ref. Section 91−00−00)
Item Nomenclature
N/A Ammonia
D Do not work on Engineered Fabric Corp.
N/A Cloth, cotton flannel
fuel cell in ambient temperatures below
N/A Phenolphthalein, crystalline
705F (215C).
CM218 Alcohol, denatured
D Do not remove fuel cells unless absolutely CM810 Leak detector, liquid
required. CM820 Cheesecloth
D The barrier can be invisibly torn, punc Any one of three techniques can be used to
tured or cracked by careless handling. find leaks in non-self-sealing and self-sealing
fuel cells. The methods are listed in ascending
D Do not carry or move cell by its metal fit order of effectiveness and complexity in terms
tings. of required equipment, materials, time, and
effort.
D Never probe cell material with sharp
edged or pointed tools. Soap bubble leak inspection.
Phenolphthalein stain inspection.
NOTE: Liquid stand inspection.
NOTE: The soap bubble and phenolphthalein
D Non-self-sealing and self-sealing cells
inspections require the cell to be inflated
are primarily a 0.002 inch (0.051 mm) with air.
thick nylon barrier membrane sand
wiched between lightweight construc (1). Manufacture or supply the following
tions of either rubberized (Uniroyal) or equipment necessary to do soap bubble
plasticized (Engineered Fabrics Corp.) or phenolphthalein inspections:
nylon fabric that protects and strength (a). Rigid, airtight closures or plugs to
ens the barrier. seal all cell openings. Fit one cover
plate with:
D Self-sealing cells can have one or more
thin layers of natural rubber sandwiched (b). An air pressurization inlet fitting.
between the barrier and fabric plies. (c). A manometer or an extremely
accurate and sensitive low pressure
air gauge.
(1). Apply protective tape to all machined
metal fittings. A. Soap Bubble Leak Test Procedures
NOTE: Soap bubble test reliability is good for
bladder type non-self-sealing cells.
(2). Do the cell inspection on a padded,
clean, craft paper covered surface. (1). Remove cell from helicopter.
(2). Lay cell out on a padded table. Install
cell closures.
(3). Inspect fuel cells per applicable man
ufacturers requirements (Ref. Section (3). Inflate cell to 1/4 psi (1.7 kPa), maxi
01-00-00). mum.
Page 604
MAINTENANCE MANUAL
(4). Unless leak is immediately evident, (f). Inspect the entire exterior surface of
maintain 1/4 psi (1.7 kPa) pressure for the cell.
two hours to allow any air trapped in
cell exterior laps and seams to escape. (5). Repair cell as required.
(5). Run soap solution around all patches, C. Liquid Stand Inspection
lap joints, seams, fittings, creases, (1). Remove cell from helicopter and place
abrasions and any other suspicious on a clean, padded, kraft paper covered
areas. Bubbles will appear over a leak. table.
(6). Mark leak areas with a white or yellow (2). Fabricate closure plates for each cell
crayon. opening.
(7). Repair cell as required. (a). The object is to completely fill the cell
B. Phenolphthalein Stain Inspection and eliminate all air pockets. Equip
one of the plates with liquid filler and
Procedures
vent stand pipes at least six inches
(1). Remove cell from helicopter. (15 cm) tall.
(2). Lay cell out on a padded table. Install (b). Fill the cell with Stoddard solvent,
all but one of the cell closures. Stanisol or Varsoline.
(3). Make phenolphthalein solution as (c). Permit cell to stand undisturbed for
follows: 24 hours.
(a). Add 40 grams phenolphthalein (d). Inspect paper to determine where cell
crystals to 1/2 gallon (1.9 L) of is leaking.
denatured alcohol (CM218) and stir. (e). Change paper as required. Drain,
(b). Add 1/2 gallon (1.9 L) of water. Allow turn over, refill and let cell stand for
to stand 30 minutes. Stir before another 24 hours to ensure liquid has
using. contacted all cell surfaces.
(4). Pour commercial ammonia on an (f). Repair cell as required.

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

10 minutes to precondition cells. This WARNING
forces trapped air from between fuel
cells and helicopter structure. If D Avoid fuel vapor ignition and fire.
necessary, repeat until cells adjust to Use only nonsparking tools and ex
contour of cell bay. plosion proof work lights. Attach he
licopter to an approved electrical
(e). Apply 2 psi (14 kPa) air pressure for
ground. Switch OFF all electrical
15 minutes with no visible, less than
1/4 inch (6.35 mm), drop on manome power. Disconnect external power
ter. If pressure drop occurs, check all and battery before opening fuel sys
vent plugs, fittings and re-test cells. tem. Ensure work area is adequately
Repair or replace parts as necessary ventilated.
to eliminate pressure drop.
D Engine operation or helicopter flight
(f). Unplug vent system. Remove ma must be accomplished in accordance
nometer and pressurization equip with requirements and limitations
ment. specified in the 600N Rotorcraft
(g). Install cell floor access panels. Flight Manual and applicable sup
plements.
10. Fuel Transfer System Functional Check
NOTE: This check is only done on aircraft Prevent fuel system contamina
without the airframe fuel filter option. CAUTION tion. Install caps on the ends of
(Ref. Figure 602) hoses, tubes and fittings as parts are re
Special Tools vent loss or damage.
Item Nomenclature NOTE: Gross weight, fuel load and ambient
ST803 Fuel Transfer System Functional Tester conditions are optional for this functional
check.
FUEL PRESSURE
SWITCH HOSE
FUEL PRESSURE SWITCH
UNION
CEFA BEFORE FILTER
CEFA PORT
MOTIVE FLOW
SUPPLY HOSE
LOOKING FORWARD 6G28-078
Figure 602. Fuel Transfer System Functional Check
Page 606
MAINTENANCE MANUAL
A. Test Setup
(Ref. Figure 602 and Figure 603)
CEFA
TESTER INLET A
LINE
TESTER INLET
LINE
TESTER OUTLET
LINE FLOW METER
MOTIVE FLOW
SUPPLY HOSE
6G28-079
Figure 603. Fuel Transfer Test Setup
Page 607
MAINTENANCE MANUAL
(1). Make sure fuel transfer system tester lective to increase N1 speed. Reduce throttle
calibration is current. twist grip to decrease N1 speed.
(2). Disconnect motive flow supply hose (5). Record N1, pressure altitude, outside
from CEFA before filter port union. air temperature, motive flow rate and
motive flow pressure.
(3). Connect inlet line of tester to CEFA
before filter port union. (6). Use the calibration chart provided with
the fuel transfer system tester and
(4). Torque tester fitting to 50—65 inch- calculate the calibrated motive flow
pounds (5.64—7.34 Nm). rate.
(5). Connect motive flow supply hose to (7). The minimum calibrated motive flow
outlet line of tester. rate shall be 0.18 GPM.
(8). If the calibrated motive flow rate is less
(6). Torque motive flow supply hose fitting
than 0.18 GPM, check the following
to 50—65 inch-pounds (5.64—7.34
components for correct operation.
Nm).
(a). Check valve
B. Check Procedures
(b). Jet (ejector) pump
(c). Motive flow hoses
(1). Make sure test setup is complete.
(9). Shut down engine ground run in
(2). Ground run engine in accordance with accordance with Rotorcraft Flight
Rotorcraft Flight Manual. Manual.
(3). Operate the helicopter on the ground at (10). Disconnect motive flow supply hose
100 percent main rotor speed (Nr) with from outlet line of tester.
collective down. (11). Disconnect inlet line of tester from
CEFA before filter port union.
(4). Stabilize motive flow pressure from
42.0 PSIG minimum to 44.0 PSIG (12). Connect motive flow supply hose to
maximum. N1 at approximately 81 CEFA before filter port union.
percent.
(13). Torque motive flow supply hose fitting
NOTE: Motive flow pressure increases or de to 50—65 inch-pounds (5.64—7.34
creases with engine N1 speed. Increase col Nm).
Page 608
MAINTENANCE MANUAL
FUEL SYSTEM
REPAIRS
1. Fuel Shutoff Valve Control Cable Repair NOTE: MDHI cannot guarantee the accuracy of
the following fuel cell repair procedures. Fu
el cell repair materials, techniques, and pro
Consumable Materials cedures can be changed or deleted by the fu
(Ref. Section 91−00−00) el cell manufacturers without notice to
Item Nomenclature MDHI technical publications.
CM118 Grease
(1). MDHI recommends the following:
NOTE: Worn fuel shutoff valve control cables (a). Only trained personnel are allowed to
are normally replaced as an assembly. inspect and repair the fuel cells
installed in 369/500/600 series
(1). The only authorized repair is replace helicopters.
ment of a missing detent ball, as (b). Customers doing the fuel cell repairs
follows: must order manuals from the appli
cable fuel cell manufacturer before
(a). Disconnect cable from fuel shutoff beginning repair tasks (Ref. Section
valve lever swivel. 01-00-00).
(b). Pull plunger out until detent ball (c). Fuel cell inspections, maintenance
hole is visible. Insert detent release and repair must be done per the fuel
rod in plunger. Align notch in detent cell manufacturers instructions.
release rod with plunger detent ball
hole. (2). Bladder or self sealing fuel cells are
supplied to MDHI by Engineered
(c). Apply grease (CM118) between Fabrics Corporation.
plunger and plunger housing.
Use only approved inspection
CAUTION requirements, repair methods,
(d). Insert detent ball in plunger hole.
Push release rod and plunger to full materials and supplies designed for Engine
open position. ered Fabrics Corp.
(e). Rig fuel shutoff valve cable. (3). Fuel cells produced by Engineered
Fabrics Corp. are constructed of Nitrile
polyurethane plastic impregnated
2. Fuel Cell Repair fabric.
Consumable Materials 3. Scuff Mark Repair

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

outline patch installation area two
Replace loose patches with new patch installa inches beyond damage in all direc
tions (Ref. Patch Installation). Where two tions.
opposing patches have been installed over cell
wall damage, unless otherwise indicated by (6). Hand-buff an area 1/2 inch (12.7 mm)
inspection, replace only the loose patch. larger than space occupied by patch
with fine emery cloth (CM804) to
provide a roughened substrate for
6. Patch Installation cement application. Do not cut through
cell fabric.
(1). Drain, remove and thoroughly dry cell
as soon as possible after determining (7). Select a patch of #5218 material
cell repair is required. Drying time can (CM604) for cell exterior. Trim patch to
be accelerated by keeping cell at 80°F extend two inches beyond edges and
(27°C) and ventilating interior with dry, ends of damage in all directions. Tilt
low pressure air. scissors to bevel patch edges away from
cell surface. Radius all patch corners.
(2). Inspect fuel cell.
(8). Hand-buff patch gummed surface with
Do not repair tears or holes over fine emery cloth. Ensure entire patch
CAUTION 2 inches (5.08 cm) long using joint surface has been abraded.
cold patch repair. Do not attempt to repair
(9). Repeat buffing procedures on cell
bonded fittings or corners. Contact Engine
interior surface. Buff internal patch
ered Fabrics Corporation when corner or fit
(CM603) trimmed from
ting damage is discovered or when cell wall
#5200/5187/5194 sandwich material.
damage exceeds two inch length limit.
Fuel cell and patch contact sur
(3). Accomplish fuel cell repair work in CAUTION faces must be perfectly clean
temperatures ranging from 60—805F and dry prior to adhesive and patch applica
(16—275C) and in less than 50% tion. Rubber and fabric particles, moisture,
humidity. and fuel or oil from fingers will prevent
proper patch/cell adhesive cure and can sub
NOTE: Damp air, especially in combination sequently provide a leak path. Wear clean,
with low temperatures, will cause water to lint free gloves to handle patch and cell after
condense on cement applications. Water in preparing surfaces for cement and patch
hibits patch adhesion. application.
Never expose a dry cell to high (10). Install exterior patch first. Wipe cell
CAUTION temperatures and, or direct sun exterior and patch faying surfaces with
light for long periods of time. If repairs will clean cheesecloth (CM820) dampened
not be started within ten days, prepare cell with MPK (CM219).
for storage.
(a). Continue to wipe cell and patch,
(4). Both sides of a cell must be patched to changing cheesecloth and applying
repair any one hole or tear. clean solvent as required, until no
stain or particles appear on cheese
cloth pad after the last wipe.
(5). Thoroughly clean cell internal and
external repair areas with cheese cloth Use cement sparingly. Two,
(CM820) dampened with solvent MPK CAUTION thin, even coats provide better
(CM219). adhesion than one thick coat.
(a). Collapse cell and expose external (11). Position a sheet of polyethylene plastic
damage area on a clean, flat working beneath cell damage to keep cement off
surface. opposite cell wall.
Page 802
MAINTENANCE MANUAL
NOTE: Determine cement adhesive tack with a Plates must be larger than cemented
test specimen. Apply cement to a piece of repair area.
buffed, scrap patch material each time ce
ment is spread on cell and repair patch. Excessive clamp pressure can
(12). Coat patch, test specimen, and fuel cell, ment out of joint.
including edges of damage, with EC678
cement (CM607). Allow cement to dry (a). Cover both sides of repair with sheet
15 minutes before application of a polyethylene plastic or oiled paper
second coat. Allow second coat to dry 15 large enough to cover entire cem
minutes. ented area.
(13). Press a bare knuckle into cement on NOTE: Do not include opposite cell wall in
test specimen. Cement that tears away clamp up. Work through cell access opening
from skin leaving a rough, finely and arrange cell as necessary to clamp only
peaked imprint without transferring to the wall with the patch installation.
knuckle, is ready for patch installation.
(b). Sandwich repair area and barrier
NOTE: Wipe cement with cheesecloth moist material between pressure plates.
ened with solvent to reactivate adhesive Install at least two C-clamps over
when required. pressure plates. Equalize clamp
pressure.
(14). A brayer or similar tool is required to
systematically roll patch into contact (16). Do not disturb cell. Maintain pressure
with cell. Apply patch as follows: for six hours, minimum, after which cell
is ready for internal patch installation.
(a). Center patch on repair area. Stick
one edge down and double check (17). Remove clamps and plates.
patch alignment. If required, release (18). Clean patch and cell internal repair
adhesive by flooding joint with area with MPK saturated cheesecloth
solvent. Check adhesive tack again swabs.
before proceeding with patch installa
tion. (a). Apply two coats of cement, allowing
15 minutes drying time between
NOTE: The object of the next step is to get the coats. Allow 15 minutes for second
patch down without trapping any air under coat to set.
it.
(b). Install and roll out patch.
(b). Hold free edge of patch off cell.
Follow one line and roll tool back- (19). Position a barrier sheet under each
and-forth over patch. Advance pressure plate. Clamp and cure instal
toward loose end, 1/4 inch (6.35 mm) lation for a minimum of 24 hours at
per pass until patch is down and free 60—805F (16—275C) before leak
of trapped air. testing and returning cell to service.
(c). An alternate technique is to lay 7. Loose Edge and Lap Seam Repairs
prepared patch on a perfectly clean
sheet of polyethylene plastic about Loose lap seams should be re
twice the size of the patch. Locate CAUTION paired as soon as possible after
plastic sheet and patch over cell discovery.
repair area; then, slip sheet from
under patch as patch is rolled down, NOTE: Loose lap seam edges not more than two
1/4 inch (6.35 mm) at a time. inches long on cell interior or exterior sur
faces can be repaired. Seam separation re
(15). Fabricate two smooth, flat, rigid, metal pairs require buffing, cementing and a
plates with no sharp edges or corners. patch installation.
Page 803
MAINTENANCE MANUAL
(1). Lift seam separation and buff flap and (f). Cover repair with a sheet of polyeth
cell faying surfaces with emery cloth ylene plastic or oiled paper large
(CM804). enough to cover entire cemented
area.
(a). Buff an area on exterior surface
extending 2 inches (5.08 cm) in all (2). Fabricate two smooth, flat, rigid, metal
directions from seam separation. plates with no sharp edges or corners.
Plates must be larger than cemented
repair area.
CAUTION
D Fuel cell and patch contact surfaces must CAUTION deform cell and, or squeeze ce
be perfectly clean and dry prior to adhe ment out of joint.
sive and patch application. Rubber and
fabric particles, moisture, and fuel or oil (a). Cover both sides of repair with
from fingers will prevent proper patch/ polyethylene plastic or oiled paper
cell adhesive seal and can subsequently sheets large enough to cover entire
provide a leak path. Wear clean, lint free cemented area.
gloves to handle patch and cell after pre
paring surfaces for cement and patch NOTE: Do not include opposite cell wall in
application. clamp up. Work through cell access opening
and arrange cell as necessary to clamp only
D Careless application of compressed air be the wall containing the seam repair.
tween lap joints can separate seam fur
ther. (3). Sandwich cell wall repair area and
barrier material between pressure
(b). Either air-vacuum or blow buffing plates. Install at least two C-clamps
dust out of separation with dry, low over pressure plates. Equalize clamp
pressure, compressed air. pressure.
(c). Wipe inside and outside of repair (4). Do not disturb cell. Maintain pressure
area clean with cheesecloth (CM820) for six hours, minimum, after which cell
moistened with MPK (CM219). is ready for patch installation.
Continue wiping with fresh solvent
dampened cheesecloth as required (a). Remove clamps and plates.
until no stain or particle appears on (5). Use #5200/5187/5194 sandwich patch
the swab after the last wipe. Allow material on cell interiors.
area to dry.
(6). Use #5218 patch material on cell
Use cement sparingly. Two thin, exterior surfaces.
CAUTION even coats provide better adhe
sion than one thick coat. (7). Prepare cell wall and patch for installa
tion per (Ref. Patch Installation):
NOTE: Determine cement adhesive tack with a Install patch.
test specimen. Apply cement to a piece of
buffed, scrap patch material each time ce 8. Blister Repair
ment is spread on cell and repair patch. Blisters can occur on cell interior and exterior
surfaces. blisters are caused by a separation of
(d). Apply two coats of EC678 cement
the cell laminates and can contain air or a
(CM607) allowing 15 minutes be
combination of air and fuel.
tween applications. Allow second coat
to dry 15 minutes. NOTE: Exterior blisters that contain fuel indi
cate that the barrier has been penetrated.
(e). Roll separation together starting Blisters inside cell measuring under one
from the bottom of the pocket toward inch diameter are acceptable and need not
the open end, 1/4 inch (6.35 mm) per be disturbed.
pass. Ensure no air is trapped
underneath. (1). Repair blisters as follows:
Page 804
MAINTENANCE MANUAL
(a). Buff surface of blister and area (2). Fabricate two smooth, flat, rigid, metal
extending 2 inches (5.08 cm) in all plates with no sharp edges or corners.
directions from its edge. Plates must be larger than cemented
repair area.
Avoid damaging nylon barrier
CAUTION membrane. Do not probe, cut, or Excessive clamp pressure can
puncture blisters with tool perpendicular to
cell wall. ment out of joint.
(b). Slit blister open with an X cut to (a). Cover both sides of repair with
expose all of the delaminated surface. polyethylene plastic or oiled paper
Lift flaps and mop interior with clean sheets large enough to cover entire
cheesecloth (CM820) and MPK cemented area.
(CM219). Buff underlying cell surface NOTE: Do not include opposite cell wall in
and blister flaps with emery cloth clamp up. Work through cell access opening
(CM804). Air-vacuum or blow away and arrange cell as necessary to clamp only
all traces of buffing dust. the wall containing the blister repair.
(c). Wipe inside and outside of repair (3). Sandwich cell wall repair area and
area clean with cheesecloth moist barrier material between pressure
ened with solvent or MEK. Continue plates. Install at least two C-clamps
wiping with fresh solvent dampened over pressure plates. Equalize clamp
cheesecloth as required until no stain pressure.
or particle appears on the swab after
the last wipe. Allow area to dry. (4). Do not disturb cell. Maintain pressure
for six hours, minimum, after which cell
Use cement sparingly. Two, is ready for patch installation; remove
CAUTION thin, even coats provide better clamps and plates.
(5). Use #5200/5187/5194 sandwich patch
NOTE: Determine cement adhesive tack with a material on cell interiors.
test specimen. Apply cement to a piece of (6). Use #5218 patch material on non-self-
buffed, scrap patch material each time ce sealing cell exterior surfaces.
ment is spread on cell and repair patch.
(7). Prepare cell wall and patch for installa
(d). Apply two coats of EC678 cement tion per instructions for Patch Installa
allowing 15 minutes between applica tion. Install patch.
tions. Allow second coat to dry 15
minutes. (8). Heat soak transmitter assembly in an
oven set at 1005F (385C) maximum
(e). Roll blister together starting from the for one hour to vaporize trapped
bottom of each flap pocket toward the volatiles. A heat gun can be used as an
open end, 1/4 inch (6.35 mm) per alternate drying method. Pot transmit
pass. Ensure no air is trapped ter electrical connections with sealing
underneath. compound MIL-S-8802 (CM425).
Page 805
MAINTENANCE MANUAL
Page 806
MAINTENANCE MANUAL
Section
28−25−00
Anti−Ice / Airframe
Fuel Filter (369D/E −
500/600N)
MAINTENANCE MANUAL
ANTI−ICE/AIRFRAME FUEL FILTER

Table 1. Anti−Ice/Airframe Fuel Filter Effectivity
Installation Model & Production Number Features
369H90022−BSC 369D, 003 and subsequent Helicopters equipped with slimline instrument panel.
369H90022−503 369E, 001 and subsequent Helicopters equipped with T−instrument panel.
369H90022−503 500N, 001 and subsequent Helicopters equipped with T−instrument panel.
600N98110−501 600N, 003 and subsequent Helicopters equipped with T−instrument panel.
NOTE: Anti−ice / airframe fuel filter is not certified for installation on C30 engine installation.
NOTE: On the 600N helicopter, the airframe pilot of an impending or total fuel filter
fuel filter is not certified as an anti-ice fuel blockage by lighting the AIRFRAME
filter. Throughout this section, the airframe FILTER caution lamp in the caution/
fuel filter will be referred to as an anti-ice warning panel. The pilot must manual
fuel filter. ly set the START PUMP switch ON to
pressurize the fuel system.
1. Description
(4). On all installations, total filter blockage
(1). The airframe mounted anti-ice fuel forces a filter bypass valve in the filter
filter is installed on the aft face of the body open to second supply unfiltered
firewall upstream of the engine fuel fuel to the engine.
pump filter. The 10 micron, 500 square
inch disposable filter element strips ice (5). Pressing the FUEL FILTER caution
and other solids from the fuel before it light/switch supplied with
enters the engine fuel system. 369H90022-BSC installations resets
relay K254 and the time delay relay,
2. Operation shuts down the start pump and START
PUMP ON light and switches off the
(1). A flow pressure sensing switch in the FUEL FILTER caution light.
filter body furnished with all installa
tions closes when flow differential (6). The caution light dimmer switch on the
pressure across the filter drops to a lower left control panel of -BSC
preset level. installations controls only FUEL
FILTER caution light intensity with
(2). On the 369H90022-BSC installation, DIM or BRT positions. FUEL FILTER
pressure switch contact closure directs caution lamp test is executed with the
28Vdc current across the S2 contacts of PRESS TO TST WARN LT switch on
the FUEL FILTER relay K254 to the caution/warning light panel.
activate the RT170-277 time delay
relay (TDR). The TDR energizes relay (7). On -503, -505 and -501 installations,
K254 after a two to five second delay, caution light intensities, including the
closing switches S1, S2, and S3; AIRFRAME FILTER light are
energizing the FUEL FILTER caution controlled through the WARN LT DIM
light, start pump and START PUMP potentiometer on the pedestal switch
ON light. panel.
(3). On 369H90022-503, -505 and (8). Circuit protection is provided by the 7.5
600N98110-501 fuel filter installations, ampere anti-ice FUEL FILTER circuit
pressure switch closure only advises the breaker on the anti-ice fuel filter panel.
Page 1
MAINTENANCE MANUAL
Determine why a circuit break Air in the fuel system will

CAUTION er popped before pushing the re WARNING cause a power reduction or
set button (Ref. Table 101). flameout. Do a fuel system vacuum leak
check and system air bleed after open
(9). A press-to-test button located on top of
ing fuel system to atmosphere and
the filter body is featured in all installa
tions. Pressing the button simulates a
Ensure start/boost pump is operating
blocked filter condition for power-on
ground test. before taking fuel samples from system
drain valves.
(10). On all installations, a filter bowl drain
valve plumbed into the drain manifold
provides for filter draining and fuel (11). Refer to Table 101 for anti-ice fuel filter
sampling. fault isolation information.
Page 2
MAINTENANCE MANUAL

FAULT ISOLATION
NOTE: On the 600N helicopter, the airframe
fuel filter is not certified as an anti-ice fuel
filter. Throughout this section, the airframe
fuel filter will be referred to as an anti-ice
fuel filter.
1. Anti−Ice Fuel Filter System Fault Isolation
Table 101. Anti−Ice Fuel Filter System Fault Isolation
FUEL FILTER caution lamp No power. Battery switch OFF. Supply power. Set battery switch to BATT or
does not light. EXT PWR position.
Circuit breaker reset button Press circuit breaker reset button.
pulled out. (369D/E − 500N)
Defective wiring or connection. Locate circuit defect and repair as required.
FUEL FILTER caution light on. System not reset. Press FUEL FILTER caution light to reset.
Clogged fuel filter. Drain filter bowl into a suitable container.
Inspect sample for foreign substances.
Remove and replace filter element.
Defective wiring. Locate circuit defect and repair as required.
START PUMP ON lamp fails No power. Battery switch OFF. Supply power. Set battery switch to BATT or
to light. EXT PWR.
Circuit breaker reset button Press circuit breaker reset button.
pulled out. (369D/E − 500N)
Defective lamp. Replace lamp.
Defective wiring. Locate circuit defect and repair as required.
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MAINTENANCE MANUAL
Page 102
MAINTENANCE MANUAL

NOTE: On the 600N helicopter, the airframe B. Anti−Ice Fuel Filter Installation
fuel filter is not certified as an anti-ice fuel
fuel filter will be referred to as an anti-ice Consumable Materials
fuel filter. (Ref. Section 91−00−00)
Item Nomenclature
CM113 Anti-seize compound low temperature
1. Anti−Ice Fuel Filter Replacement
(Ref. Figure 201) (1). Attach assembled filter to bracket with

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

(1). Disconnect battery and external power CAUTION ing hose nuts. Use a backup
(Ref. CSP-HMI-3, Section 96-05-10). wrench to stabilize hose.
(a). Pull FUEL VALVE knob to close fuel (b). Install hose between filter and
shut off valve. engine. Install hose between filter
and firewall fitting. Torque hose nuts
(b). Open engine access doors. 230—260 inch-pounds
(25.99—29.38 Nm).
(c). Drain fuel from filter bowl and
supply line drain valves. (c). Connect wire harness connector to
fuel filter plug.
(d). Unclamp and disconnect filter drain (d). Connect drain tube to filter drain
tube. valve. Clamp tube to valve with
lockwire.
(e). Remove fuel supply hose between
engine driven fuel pump and anti-ice Air in the fuel system will
filter. Cap hose ends and fittings. WARNING cause a power reduction or
flameout. Do a fuel system vacuum leak
(f). Remove hose assembly between check and system air bleed after open
anti-ice filter and firewall fitting. ing fuel system to atmosphere and
Cap hose ends and fittings. prior to releasing helicopter for flight.
Ensure start pump is operating before
(g). Remove anti-ice filter electrical taking fuel samples from system drain
connector. valves.
(e). Do a fuel system vacuum leak check

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

BATT.
Prevent fuel vapor accumu
WARNING lation, ignition and fire. Do (e). Set START PUMP switch ON to
the work in an open, well ventilated pressurize fuel system. Check start
area away from all potential ignition pump for operation.
sources. Attach helicopter to an ap
(f). Loosen engine filter bowl plug. Let
proved electrical ground. Wear ap
fuel flow until a steady, bubble free,
proved eye protection.
uninterrupted fuel stream emerges
Do not operate start pump in an without any evidence of trapped air.
CAUTION empty fuel tank. Tighten plug.
(2). Refer to applicable Rolls-Royce Opera
NOTE: The object of fuel system bleeding is to tion and Maintenance Manual for
remove all air trapped in the fuel supply specific engine fuel system air bleed
system. information.
(1). Refuel helicopter as required. (a). Purge air from engine fuel system
per Rolls-Royce Operation and
(a). Connect battery. Maintenance Manual.
(b). Open engine access doors. (3). Set START PUMP and battery
switches OFF.
(c). In crew compartment; push FUEL
shutoff valve knob in to open shutoff (4). Reassemble drain system as required
valve. and install lockwire.
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MAINTENANCE MANUAL
BOLT
CONNECTOR
WASHER
CLAMP TEST
BUTTON
NUT
NUT
BRACKET
O-RING
SCREW
REDUCER
CLAMP FIREWALL
WASHER
WASHER SCREW
NUT HOSE
FILTER TUBE
ELEMENT
WIRE BOWL NUT
HARNESS
SHIM WASHER
(AS REQ'D)
GASKET
WASHER
NUT FITTING
WASHER HOSE
O-RING HOSE
ELBOW
CLAMP
SCREW SCREW
GASKET
CLAMP
ANTI-ICE WASHER
DRAIN VALVE NUT
BOLT
EFFECTIVITY: 369D/E - 500N G28−2000−1B
Figure 201. Anti−Ice Fuel Filter (Sheet 1 of 3)
Page 203
MAINTENANCE MANUAL
CAUTION LIGHT
T-PEDESTAL
(369H90022-503, -505)
ANTI - ICE
FUEL FILTER
INSTL
FOR
PLACARD SPACER
WASHER
SCREW
SCREW
RIVNUT
DIODE CR26
TIME-DELAY
RELAY
CAUTION LIGHT/
RELAY K254
CIRCUIT BREAKER
DIMMER SWITCH
SCREW
COVER
SCREW SLIMLINE PEDESTAL
(369H90022-BSC)
EFFECTIVITY: 369D/E - 500N G28-2000-2A
Page 204
MAINTENANCE MANUAL
B
A
B
FUEL HOSE
TO ENGINE
FUEL HOSE FROM

ENGINE-TO-TANK
CONNECTOR +
CLAMP
SCREW
WASHER
NUT
REDUCER
O-RING
FUEL HOSE
FROM TANK
FILTER
DRAIN VALVE
FUEL FILTER
DRAIN HOSE
GROMMET
VIEW A - A
AIRFRAME FILTER
CAUTION LIGHT
VIEW B - B
EFFECTIVITY: 600N G28-2000-3
Page 205
MAINTENANCE MANUAL
Page 206
MAINTENANCE MANUAL

INSPECTION/CHECK
NOTE: On the 600N helicopter, the airframe (g). Do an anti-ice fuel filter functional
fuel filter is not certified as an anti-ice fuel check (Ref. Anti-Ice Fuel Filter
filter. Throughout this section, the airframe Installation Operational Check:
fuel filter will be referred to as an anti-ice 369H90022-BSC).
fuel filter.
(2). Inspect wiring for damage and security.
1. Anti−Ice Fuel Filter System Inspection Repair or replace damaged components.
A one time diode inspection and WARNING cause a power reduction or
CAUTION polarity check is mandatory for
flameout. Do a fuel system vacuum leak
helicopters equipped with a
check and system air bleed after open
369H90022-BSC anti-ice fuel filter instal
ing fuel system to atmosphere and
lation and, or 369H90118 auto-reignition
installation on helicopters delivered in
Ensure start pump is operating before
1979. The following procedures address only
taking fuel samples from system drain
the anti-ice fuel filter installation.
valves.
Special Tools
(3). Inspect fuel system as follows:
(Ref. Section 91-00-00) (a). Apply external power to the helicop
Item Nomenclature ter.
N/A Ohmmeter (b). Open the engine compartment doors.
N/A Voltmeter
(c). Set battery switch to EXT PWR.
(1). Determine ohmmeter lead polarity with (d). Push FUEL VALVE knob in to open
voltmeter. fuel shutoff valve.
(e). Set START PUMP switch; ON.
(a). In crew compartment; remove cover
Check start pump operation.
from anti-ice caution/warning light
panel. NOTE: Failure to drain in freezing tempera
tures can be due to ice buildup.
(b). Find part number stamped on diode
C26 (Ref. Figure 201). (f). Drain several ounces of fuel from
filter bowl into a suitable container.
(c). Diodes, part numbers 1N3210 do not Inspect sample for solids and water
require a polarity check. contamination. Dismantle and clean
filter bowl as required. Replace filter
(d). Replace diodes, part number
element.
1N3210R with a new part number
1N3210 diode. (g). Inspect hose assemblies for evidence
of leakage, swelling or dampness,
(e). If the diode is unidentifiable, test kinks, cuts, twists, tears and fraying.
diode to determine polarity. Check hose nut threads for damage.
1). Check for low forward resistance Replace damaged parts.
with ohmmeter positive lead (h). Disconnect drain tubes from drain
attached to terminal end and valves. Check each drain valve for
negative lead attached to stud end. leakage. Replace damaged drain
Reverse leads and check for very valves.
high resistance.
(i). Inspect filter fuel line fittings for
(f). Replace diode with a new 1N3210 leakage. Repair or replace parts as
unit if polarity is reversed. required.
Page 601
MAINTENANCE MANUAL
(j). Connect drain tubes to drain valves. (c). Start pump stops running.
Inspect drain tubes for security and
(5). Inspect fuel system for leakage.
correct routing without fluid traps or
kinks. 3. Anti−Ice Fuel Filter Installation
Operational Check: 369H90022−503, −505
(k). Inspect fuel filter press-to-test and 600N98110−501
button for security.
(1). Apply external power to the helicopter.
2. Anti−Ice Fuel Filter Installation Set battery switch to EXT PWR.
Operational Check: 369H90022−BSC (a). Reset PNL LT circuit breaker.
NOTE: The system can be operated with a fully (b). Press PRESS TO TST WRN LT on
charged battery that can provide more than the caution/warning light panel.
the 23.8 Vdc required to actuate system so Check entire caution/warning light
lenoids. If battery state is an unknown, use array. Replace lamps as required.
external power. (c). Push FUEL VALVE knob in to open
(1). Apply external power to the helicopter. fuel shutoff valve.
Set battery switch to EXT PWR. (2). Set START PUMP switch ON.
(a). Reset PNL LT and FUEL ANTI- (a). START PUMP ON indicator light
ICE circuit breakers. comes on and start pump pressurizes
fuel system.
(b). Press PRESS TO TST WRN LT on
(3). Open the engine compartment doors.
the caution/warning light panel.
Check entire caution/warning light (4). Press the red press-to-test button on
array. Replace lamps as required. top of airframe filter body. Result shall
be:
(c). Push FUEL VALVE knob in to open
fuel shutoff valve. (a). AIRFRAME FILTER caution light
comes on.
(d). Open the engine compartment doors. (5). Release the press-to-test button.
(2). Press the red press-to-test button on (a). AIRFRAME FILTER caution light
top of the filter body for five or more goes out.
seconds. Test results shall be as follows:
(6). Set START PUMP switch OFF.
(a). FUEL FILTER caution light comes (7). Inspect fuel system for leaks.
on.
4. Fuel System Vacuum Leak Check
(b). START PUMP ON indicator light
(1). Fuel is drawn out of the tank by the
comes on and start pump pressurizes
engine driven fuel pump when the start
fuel system.
pump is switched off. Water, ice, dirt,
(3). Release the press-to-test button. fungus, trapped air or a few pinhole
leaks in the supply system between the
(a). FUEL FILTER and START PUMP fuel tank sump pickup and engine
ON lights remain on and start pump combustion chamber nozzles can cause
continues to operate. power surges, deceleration and, or
flameout. A vacuum leak inspection will
(4). Press FUEL FILTER caution light to determine whether or not air can be
reset system. Result shall be: drawn into the fuel system by the
engine driven fuel pump.
(a). FUEL FILTER caution light goes
out. (2). An automotive vacuum test pump and
hardware that will provide 8 Hg
(b). START PUMP ON indicator light vacuum or better is required to do the
goes out. vacuum leak check.
Page 602
MAINTENANCE MANUAL
(3). Assemble vacuum pump, hoses, filter (b). Fuel system shall hold vacuum
port adapter, shutoff valve and vacuum between 8 and 7.5 Hg for two min
gage as follows: utes.
(a). Insert a vacuum gage in the vacuum (c). If test is satisfactory, remove test
hose between the engine fuel filter apparatus. Inspect and replace filter
port adapter and vacuum shutoff plug O-ring as required. Install filter
valve. Attach the vacuum pump to plug.
the vacuum hose above the shutoff
valve. (6). Vacuum loss exceeding 0.5 Hg in two
(b). Plug vacuum hose and pull 5 - 10 Hg minutes indicates a leak somewhere in
vacuum. Apparatus should hold the the system between the fuel shutoff
selected pressure indefinitely. Repair valve and engine.
leaky equipment before proceeding
with fuel system test. (a). Torque fuel line connections (Ref.
Table 601). Repeat vacuum test.
(c). Open engine access doors.
(b). If system continues to leak, discon
(d). Remove left fuel cell floor access nect and install airtight caps or plugs
panel. in tubes, hoses and fitting ports in a
(e). In crew compartment; pull FUEL progressive sequence from fuel
shutoff valve knob out to stop. Verify shutoff valve toward engine. The fuel
that fuel shutoff valve lever on left shutoff and drain valve installations
fuel cell access cover is hard against should be especially suspect. Apply
its OFF stop. Rig control cable as vacuum at each stage until leak has
required. been isolated. Replace parts as
required.
(f). In engine compartment; remove the
upper drain plug from the fuel pump (c). Apply a torque stripe to all effected
filter bowl. fuel line fittings and nuts.
(4). Disconnect the fuel bleed return line at (d). If the airframe system vacuum held
Sta. 124.00 (if equipped) and cap off. at 7.5 Hg or better, system seal is
(5). Attach vacuum test apparatus to satisfactory and malfunction is
engine fuel filter upper drain port. probably due to an engine system
leak. Refer to the applicable Rolls-
(a). Apply 8 Hg vacuum. Close vacuum Royce and Bendix manuals for
line shutoff valve. additional information.
Table 601. Fuel Supply System Torque Values
Torque Range
Item & Location Inch−Pounds (Nm)
Tube end−nuts; fuel shutoff valve; Sta. 124.00 Blkhd elbow 230—260 (25.99—29.38)
Blkhd elbow jamnut; Sta. 124.00 145—155 (16.38—17.51)
Three−port elbow jamnuts 145—155 (16.38—17.51)
Anti−ice filter drain fitting bolt 185—200 (20.90—22.60)
Anti−ice filter in/out reducers 550—600 (62.14—67.79)
Hose end−nuts; firewall/filter 230—260 (25.99—29.38)
Hose end−nuts; filter/engine 230—260 (25.99—29.38)
Drain valves (all) 95—105 (10.73—11.86)
Page 603
MAINTENANCE MANUAL
AIRFRAME FILTER CAUTION

CAUTION LIGHT LIGHT TEST
CAUTION LIGHT CAUTION

RESET SWITCH LIGHT TEST
FUEL
SHUTOFF
PNL LT
BATTERY CIRCUIT
SWITCH BREAKER PRESS
TO
TEST
START
PUMP
SWITCH
DIMMER
POT
DIMMER
SWITCH
CIRCUIT
BREAKER
369H90022-503, -505
PULL
TO
P CLOSE
U ON
S START
H
PUMP
FUEL
SHUTOFF
START PUMP
SWITCH BATTERY
O
F
F
BATTERY
SWITCH
369H90022-BSC
G28-2004-1
Figure 601. Anti−Ice Fuel Filter Controls (Sheet 1 of 2)
Page 604
MAINTENANCE MANUAL
AIR FRAME FILTER

(DS21)
CAUTION LIGHT
AIR FILTER CLOGGED TEST
(DS22)
FUEL
SHUTOFF
BATTERY
SWITCH
FUEL PUMP SWITCH
(CB118)
FUEL PUMP LIGHT

(XDS7)
600N98110-501
G28-2004-2
Figure 601. Anti−Ice Fuel Filter Controls (Sheet 2 of 2)
Page 605
MAINTENANCE MANUAL
Page 606
MAINTENANCE MANUAL

NOTE: On the 600N helicopter, the airframe tal and drill three 0.219 inch (5.56
fuel filter is not certified as an anti-ice fuel mm) diameter holes in pedestal.
fuel filter will be referred to as an anti-ice (3). Make cutout shown in instrument
fuel filter. pedestal fairing.
(4). Deburr holes and cutout edges. Remove
1. Anti−Ice Fuel Filter Initial Installation debris.
A. Preparations for Installation (5). Install rivnut and attach anti-ice fuel
filter panel to instrument pedestal with
Prevent fuel vapor ignition. screws, washers and spacers.
WARNING Turn OFF and disconnect all
electrical power. Attach helicopter to (6). Connect wires (Ref. Figure 903).
approved grounding points before
opening fuel system. (7). Install cover and screws.
(8). Install ANTI-ICE FUEL FILTER
(1). Disconnect external power and battery.
INSTALLATION placard decal on
(2). Remove aft compartment seats. heater duct 3 inches (7.62 cm) above
standby compass bracket. Roll placard
(3). Remove aft upper left bulkhead panel. edges to follow duct contour.
(4). Remove lower aft bulkhead panel. (9). Seal both ends of electrical conduit with
silicone adhesive/sealant (CM430).
(5). Remove pilot compartment left floor
C. Anti−Ice Fuel Filter Control Panel
access door.
Installation: 369H90022−503, and −505
(6). Remove instrument panel hood and left
fairing. Consumable Materials
(7). Pull FUEL VALVE knob to close fuel Item Nomenclature
shut off valve.
CM430 Sealant, solvent resistant
B. Anti−Ice Fuel Filter Control Panel
Installation: 369H90022−BSC (1). Pull fuel filter wire harness forward
through conduit and along an existing
Consumable Materials wire bundle to instrument pedestal.
(Ref. Section 91−00−00) (2). Secure wire to engine compartment
Item Nomenclature airframe with clamps, screws, washers
CM430 Sealant, solvent resistant and nuts and to wire bundle with
ty-raps (Ref. Figure 901).
(1). Pull filter wire harness forward (3). Install 20 gage bus wire and insulating
through conduit and along an existing sleeve on back side of caution light
wire bundle to instrument pedestal. DS31 (Ref. Figure 904).
Secure to engine compartment airframe
(4). Remove fourth plug from the right on
with clamps, screws, washers and nuts
caution/warning light panel.
and to wire bundle with ty-raps (Ref.
Figure 901). (5). Wire and connect electrical system (Ref.
Figure 904).
(2). Use anti-ice fuel filter subpanel as a
template on left side of slimline pedes (6). Install caution light in panel.
Page 901
MAINTENANCE MANUAL
(7). Install ANTI-ICE FUEL FILTER E. Firewall Modifications and Bracket

INSTALLATION placard decal on Installation
heater duct 3 inches (7.62 cm) above
standby compass bracket. Roll placard (Ref. Figure 901 for 369H90022-BSC, -503
edges to follow duct contour. and -505)
(8). Seal both ends of electrical conduit with (Ref. Figure 902 for 600N96110-501)
silicone adhesive/sealant (CM430).
D. Anti−Ice Fuel Filter Control Panel (Ref. Section 91−00−00)
Installation: 600N98110−501 Item Nomenclature
(Ref. Figure 601) CM318 Primer
(1). To install caution/warning light:

(1). Open engine access doors.
(a). Remove third plug from the right on (2). Drain fuel from supply lines into a
caution/warning light panel. suitable container.
(b). Install caution light in panel. (3). Remove fuel supply hose between
engine driven fuel pump and firewall
(c). Install 22 gage jumper wire on back
fitting elbow. Cap hose ends, firewall
side of caution lights between DS21C
elbow and fuel pump port.
and DS22C.
(4). Reposition firewall elbow 18—22°
(d). Run O506D22 wire from DS21-2 to clockwise (Ref. view A).
P12-14 and secure to existing wires.
Do not score, scratch or gouge
(2). To install fuel pump switch and light: CAUTION firewall surface when trimming
insulation blanket.
(a). Remove edge-lighted switch panel.
(5). Lay out and remove insulation strips
(b). Remove tape from start pump switch from firewall to eliminate interference
and light holes in instrument panel. with filter support bracket installation.
(c). Install CB118 in panel. (6). Position doubler on Sta. 124.00 firewall.
Identify, mark and drill-out existing
(d). Run 22 gage jumper wire from rivets used in doubler installation. Do
CB115-1 to CB118-1. not enlarge rivet holes.
(e). Run Q1169A22 wire from CB118-2 (7). Locate doubler on firewall forward
to TB503-2-2. surface. Drill doubler through existing
rivet holes.
(f). Install light (XDS7) from back side of
panel. (8). Deburr holes and remove debris.
(g). Run E1181A22 wire from P13-46 to (9). Cleco doubler to firewall.
XDS7.
(10). Apply primer (CM318) to rivet holes
(h). Run E1181B22N wire from XDS7 to and rivets.
E31-E.
(11). Install rivets while primer is wet.
(i). Reinstall edge-lighted switch panel.
(12). Use filter support bracket as a tem
(3). Install ANTI-ICE FUEL FILTER plate. Mark and drill filter bracket rivet
INSTALLATION placard decal on holes.
heater duct 3 inches (7.62 cm) above (13). Deburr holes and remove debris.
standby compass bracket. Roll placard
edges to follow duct contour. (14). Cleco bracket in position.
Page 902
MAINTENANCE MANUAL
(15). Apply primer to rivet holes and rivets. (4). Apply a thin coat of anti-seize com
pound (CM113) to fitting-bolt threads.
(16). Rivet bracket in place while primer is Stack fitting and gaskets on bottom of
wet. filter. Install and torque bolt 185—200
(17). Install electrical bonding jumper
between bracket and airframe. (5). Lubricate drain valve O-ring packing
with clean jet fuel and install on drain
(18). Position double aft of Sta. 124.00 valve. Apply a thin coat of anti-seize
between LBL 4.250 and LBL 8.450. compound to drain valve threads.
Drill rivet holes and cleco in place.
(6). Install drain valve with O-ring packing
(19). Drill hole for drain hose. on fuel filter drain fitting. Torque drain
valve 95—105 inch-pounds
(20). Remove doubler , deburr and remove (10.73—11.86 Nm).
debris.
(7). Install and clamp drain tube to drain
(21). Apply primer (CM318) to rivet and valve with lockwire.
drain holes.
NOTE: Provide enough slack in drain tubes to
(22). Install doubler while rivets are still allow unrestrained drain valve operation.
wet.
(8). On 600N96110-501 installation, install
F. Fuel Filter Installation mount to firewall using adhesive
(CM438).
WARNING cause a power reduction or (9). Clamp tube to bulkhead frame or
flameout. Do a fuel system vacuum leak mount at LBL 8.45 with TY-25M
check and system air bleed after open TYRAP.
ing fuel system to atmosphere and (10). Lubricate the two reducer O-rings with
prior to releasing helicopter for flight. clean jet fuel. Install O-rings on large
Ensure start pump is operating before ends of reducers. Apply a thin coat of
taking fuel samples from system drain anti-seize compound to reducer
valves. threads.
(Ref. Figure 901 for 369H90022-BSC, -503 (11). Install reducers with O-rings in filter
and -505) inlet and outlet ports. Torque reducers
to 550—600 inch-pounds
(Ref. Figure 902 for 600N96110-501) (62.14—67.79 Nm).
Do not allow hose to twist when
Consumable Materials CAUTION torquing hose nuts. Use a back
(Ref. Section 91−00−00) up wrench to stabilize hose.
Item Nomenclature
CM113 Anti-seize compound low temperature (12). Connect hose between filter outlet port
and engine fuel pump filter inlet port.
Torque hose nuts 230—260 inch-
pounds (25.99—29.38 Nm).
(1). Remove engine gearcase cooling duct (13). Install hose between filter inlet port
clip and attaching hardware. and firewall fitting elbow. Torque hose
(2). Drill a 0.250 inch (6.35 mm) diameter nuts 230—260 inch-pounds
hole and relocate clip. (25.99—29.38 Nm).
(14). Secure hoses with clamps, screws,
(3). Install filter assembly on bracket with washers and nuts.
bolts, washers and spacers. Torque
bolts 50—70 inch-pounds (5.65—7.91 (15). Install wire connector plug on filter
Nm). Install lockwire. receptacle.
Page 903
MAINTENANCE MANUAL
BOLT, WASHER,
LOCKWIRE
RIVET HOSE
(7 PLCS)
(NOTE 1)
BRACKET
(NOTE 2)
HOSE
(TANK TO FILTER)
LOOKING DOWN
CLAMP, SCREW, 0.75 INCH
WASHER, NUT (17.05 MM)
(NOTE 10) CLAMP, SCREW
WASHER, (2 REQD) 0.260 INCH (6060 MM)
RIVET NUT DIA HOLE
RIVET RIVET
(NOTE 9) (NOTE 8)
CLAMP (NOTE 8)
(2 PLCS) ENGINE FUEL
DUCT (REF) PUMP (REF)
WL 22.85
WIRE HARNESS
RIVET
(NOTE 8)
CLIP (NOTE 3) RIVET
RIVET (NOTE 1)
(NOTES 8, 9)
INSULATION
(REF) FILTER ASSY
RIVET ELBOW
(NOTE 8) (NOTE 4)
WL 13.10
LANDING GEAR DAMPER
(REF)
FITTING, BOLT
TORQUE TO 185-200 IN-LBS
(20.90-22.60 NM) A A
GASKET (2 REQD) (NOTE 7) 18°
20°
TUBE TY-25N TY-RAP
(NOTE 5)
CONDUIT
(REF)
WL 5.14
STA 124.0 CONDUIT (REF)
CLAMP, SCREW, (NOTE 6)
WASHER, NUT LBL 13.23
(NOTE 10) WIRE HARNESS ASSY
0.00-0.12 INCH
LBL 8.45 (0.00-3.05 MM)
(NOTE 15)
SCREW, CLAMP, LOOKING FORWARD
WASHER, NUT
(NOTE 10)
STA 137.50
VIEW A-A
EFFECTIVITY: 369D/E - 500N G28-2003-1D
Figure 901. Anti−Ice Fuel Filter Modifications and Installation (369D/E − 500N) (Sheet 1 of 2)
Page 904
MAINTENANCE MANUAL
0.25 INCH
(6.35 MM)
STIFFENER 1.00 INCH
1.00 INCH (2.54 CM)
PANEL
(2.54 CM) 1.75 INCH
(4.445 CM)
NOTE 13
INSULATION
PANEL
REDUCER (2 REQD) 5.00 INCH

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

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

(18.415 CM) (TYP)
5.50 INCH
(13.97 CM)
DOUBLER
EFFECTIVITY: 369D/E - 500N G28-2003-2D
Figure 901. Anti−Ice Fuel Filter Modifications and Installation (369D/E − 500N) (Sheet 2 of 2)
Page 905
MAINTENANCE MANUAL
NOTE:
(1) Pick up existing rivet locations, seven places. Install MS29615−4M rivets or NAS1738 M4 alternates. Install
rivets in wet MIL−P−23377 Type 1, Class 1, epoxy primer or, MIL−P−8585 primer.
(2) Electrically bond bracket to firewall with an approved bonding jumper installed per requirements of FAA
publication EA−AC43.13−1A and 2A.
(3) Reposition clip 0.75 inch (19.05 mm) inboard.
(4) Shim elbow to 18−22 degrees clockwise.
(5) Route filter drain tube to clear landing gear damper while allowing unrestrained drain valve operation.
(6) Seal both ends of conduit with RTV 732 sealant/adhesive after wire harness installation.
(7) Apply low temperature anti−seize compound, MIL−T−5544B Thread Lube or equivalent to assembly
threads prior to installation. Torque bolt 185—200 inch−pounds (20.90—22.60 Nm).
(8) Install MS20615−3M rivets in wet MIL−P−23377, Type 1, Class 1, epoxy primer or, MIL−P−8585 primer.
(9) Install MS20615−4M or alternate NAS−1738M4 rivets in wet MIL−P−23377, Type 1, Class, 1 epoxy primer
or, MIL−P−8585 primer.
(10) Clamp wire harness in place as shown using existing tool holes.
(11) Roll placard edges to follow heater duct contour.
(12) Apply MIL−T−5544B low temperature anti−seize compound to threads prior to assembly.
(13) Cut away insulation blanket per dimensions shown for bracket installation. Remove blanket debris. Do not
scratch firewall surface.
(14) Install doubler on forward firewall surface as shown. Pick up all existing rivet holes in doubler installation.
(15) Trim drain tube protrusion flush to 0.12 inch (3.048 mm) below grommet surface.
Page 906
MAINTENANCE MANUAL
ENGINE INSTALLATION
CLAMP, SCREW
WASHER (2 REQD) LBL
NUT RIVET
8.450
(NOTE 8) CONNECTOR (NOTE 6)
WL
22.850
REDUCER
O-RING
(NOTE 9)
HOSE
FILTER
MOUNT
(NOTE 4)
BOLT NUT
WASHER HOSE 0.00-0.12 INCH
O-RING
RIVET (7 PL) BUSHING LBL (NOTE 3) (0.00-3.05 CM)
(NOTE 1) O-RING 8.450 BULKHEAD ELBOW (NOTE 12)
FS
124.000 LOOKING FORWARD
CLAMPS,
HOSE SCREW
(TANK-TO-FILTER) WASHERS,
NUT
FS
137.500
BRACKET
(NOTE 2)
LOOKING DOWN
Figure 902. Anti−Ice Fuel Filter Modifications and Installation (600N) (Sheet 1 of 2)
Page 907
MAINTENANCE MANUAL
1.00 INCH
STIFFENER (2.54 CM)
1.75 INCH
(4.45 CM)
STIFFENER
PANEL NOTE 10
STIFFENER 0.25 INCH

(6.35 MM) 1.00 INCH
(2.54 CM)
INSULATION
5.00 INCH
(12.70 CM)
PANEL
SPACER
(3 REQD)
PANEL PANEL
LOOKING FORWARD
WL
13.100
FITTING, BOLT
TORQUE TO 185 - 200 INCH-POUNDS
(20.90 - 22.60 NM)
GASKET (2 REQD) (NOTE 5) DRAIN VALVE O-RING
(NOTE 9)
DOUBLER
LBL (NOTE 11) RIVET
8.450 (NOTE 1) FS
137.000
RIVET
(NOTE 7) LOOKING INBOARD
FS LEFT SIDE
WL 124.000
22.850
RIVET RIVET
(NOTE 6) (NOTE 1)
LBL LBL
8.450 4.250
RIVET
(NOTE 6, 7) RIVET FS
RIVET (NOTE 1) 124.000
(NOTE 6)
LOOKING AFT
DOUBLER
RIVET GROMMET
LOOKING DOWN
Figure 902. Anti−Ice Fuel Filter Modifications and Installation (600N) (Sheet 2 of 2)
Page 908
MAINTENANCE MANUAL
NOTE:
(1) Pick up existing rivet locations, seven places. Install MS29615−4M rivets or NAS1738 M4 alternates. Install
rivets in wet MIL−P−23377 Type 1, Class 1, epoxy primer or, MIL−P−8585 primer.
(2) Electrically bond bracket to firewall with an approved bonding jumper installed per requirements of FAA
publication EA−AC43.13−1A and 2A.
(3) Route filter drain tube to clear landing gear damper while allowing unrestrained drain valve operation.
(4) Install with adhesive CM438.
(5) Apply low temperature anti−seize compound, MIL−T−5544B Thread Lube or equivalent to assembly
threads prior to installation. Torque bolt 185—200 inch−pounds (20.90—22.60 Nm).
(6) Install MS20615−3M rivets in wet MIL−P−23377, Type 1, Class 1, epoxy primer or, MIL−P−8585 primer.
(7) Install MS20615−4M or alternate NAS−1738M4 rivets in wet MIL−P−23377, Type 1, Class, 1 epoxy primer
or, MIL−P−8585 primer.
(8) Clamp wire harness in place as shown using existing tool holes.
(9) Apply MIL−T−5544B low temperature anti−seize compound to threads prior to assembly.
(10) Cut away insulation blanket per dimensions shown for bracket installation. Remove blanket debris. Do not
scratch firewall surface.
(11) Install doubler on forward firewall surface as shown. Pick up all existing rivet holes in doubler installation.
(12) Trim drain tube protrusion flush to 0.12 inch (3.048 mm) below grommet surface.
Page 909
MAINTENANCE MANUAL
369H90161-3 HARNESS ALL

PANEL NUMBERED WIRE - 20 GA
369H4742 SWITCH ASSEMBLY MS17821-1-9 STRAP A/R
Q510D20N
2 AMBER 2
7
E23 Q501CC20
C D CR25 6
B A CR23
2 2 CR26
Q503B20
NC
C 1
S3 NO
NC 5
E509B20
C Q501A20
S1 NO
NC Q506A20
C
S2 NO
CR27 X1+
NOTE 2 VARISTOR
K254 Q507A20
3
X2-
LOAD - + TB22
PRESS-TO-TEST
KD1
CB135
P506BA20 7.5
ANTI-ICE BRIGHT
FUEL FILTER
R254
DIM R
ANTI-ICE CAUTION LIGHT TB101
DIMMER SWITCH 100 OHM 5 1/4W
3
G28-2001-1
Figure 903. Anti−Ice Fuel Filter Wiring Diagram (369D S/N 0001 − 1204) (Sheet 1 of 2)
Page 910
MAINTENANCE MANUAL
TB6
Q510D20N 3
START PUMP
SP24 ”ON” LT SP23
2 1
Q501CC20 A B E561B22 E560B22 B A E560A22N 6
ZDS7
NOTE 1
XDS9
START PUMP NC
1 2
28 VDC NOTE 1 S2 -GRD
CB118 NO S21
7.5A (REF) WARNING LGT.
Q503B20 NC LAMP TEST
S1 +28 VDC
NO
E509B20
Q501A20 TO START PUMP
369H8021 FILTER
P252 SPLICE PERMISSIBLE
Q506A20 A
NO
C
NC
Q507A20 PRESSURE SWITCH

AIFRAME FUEL NOTES:
FILTER 1. CAP AND STOW ENDS OF EXISTING WIRES
Q501C20 AT CB118-2 AND EXISTING WIRE
E561A22 AT SP24A.
2. RT170-277 TIME DELAY RELAY (REF)
CA3108ER12S-3S
CONNECTOR
G28-2001-2
Wire Data List

Wire No. From Termination To Termination
Q507A20 CB135−2 MS25036−149 P252−B CRIMP
Q506A20 TB22−3 MS25036−101 P252−A CRIMP
Q501A20 (REF) TB22−1 MS25036−101 TO START PUMP
E509B20 TB22−5 MS25036−101 S21−S1 (NO) SOLDER
Q503B20 TB22−6 MS25036−101 CB118−2 MS25036−149
Q501CC20 TB22−7 MS25036−101 SP24A 32445 (AMP)
Q510D20N E23 MS25036−101 TB6−3 MS25036−101
P506BA20 CB135−1 MS25036−149 TB101−3 MS25036−101
Figure 903. Anti−Ice Fuel Filter Wiring Diagram (369D S/N 0001 − 1204) (Sheet 2 of 2)
Page 911
MAINTENANCE MANUAL
E31 A B C P514A20
WARNING LIGHT
D E F
TEST SWITCH
G H J ZDS-21-S2 (REF)
NC
K L M
E511B20 C
NO
TB503-12 A B C
CA3108ER12S-3S
CONNECTOR
D E F
P252
G H J P9J NO
K K A
M531C20 K L M C
E511BB20 B
L
NC
F A Q506B20 E13 GRND 369H8021 PRESSURE SWITCH
M
AIRFRAME FUEL FILTER
G B
N
H C Q506C20 3 C 2
P
TB505-1/2 J
D
4 1
R 20 GA BUS WIRE
K
E AND SLEEVING
D531 AIRFRAME FILTER

A B C
CAUTION INDICATOR
D E F (REAR VIEW)
TB503-4 Q514B20
G H J
P12
DIMMER
K L M
B DC GROUND TEST
CB104
1 2 E508A20 V +28 VDC PWR
A B C
L532A20
5A E518A20 T PRESSURE TEMP WARN
D E F
WARNING SIGNAL
PNL LTS G H J E559A20 D WARNING LT. DIMMER
TB503-6 K L M
Q514A20
DASHED LINES ARE EXISTING WIRES
G28-2002
Wire Data List

Wire No. Wire Type From Termination To Termination
Q506A230 M81381/11−20N J9−K MS3192A20A P252−A CRIMP
Q510F20N M81381/11−20N E13 M7928/1−24 P252−B CRIMP
Q506C20 M81381/11−20N TB505−1/2B M39029/22−20−20 TB503−4E MS39029/22−20−20
Q514B20 M81381/11−20N TB503−4D M39029/22−20−20 DS31−2 SOLDER
Q514A20 M81381/11−20W TB503−6L M39029/22−20−20 DS31−C SOLDER
Figure 904. Anti−Ice Fuel Filter Wiring Diagram (369D S/N 1205 & Subs and 369E S/N 001 − 383)
Page 912
MAINTENANCE MANUAL
Figure 905. Anti−Ice Fuel Filter Wiring Diagram (369E S/N 384 & Subs and 500N S/N 001 & Subs)
Page 913
MAINTENANCE MANUAL
Figure 906. Anti−Ice Fuel Filter Wiring Diagram (600N S/N 003 & Subs) (Sheet 1 of 2)
Page 914
MAINTENANCE MANUAL
Wire Data List

Wire No. From Termination To Termination
JUMPER−22 CB115−1 HDS4123−126 CB118−1 HDS4123−126
O1169A22 CB118−2 HDS4123−126 TB503−2−2 HDS4123−904
(1) O1170A22 TB503−2R HDS4123−904 P1201−27 HDS4123−916
O1236C22 TB503−2N HDS4123−904 P13−39 HDS4123−926
(2) JUMPER P12−39 HDS4123−926 P12−46 HDS4123−926
(3) E1181A22 P13−46 HDS4123−926 XDS7 HDS4123−999
E1181B22N XDS7 HDS4123−999 E31−E HDS4123−904
(2) JUMPER−22 DS22−C HDS4123−999 DS21−C HDS4123−999
(1) O506D22 DS21−2 HDS4123−999 P12−14 HDS4123−926
(1) O506A22 J1201−69 HDS4123−915 P252−A CRIMP
(3) O510F22N P252−B CRIMP (4) E13 HDS4123−135
NOTES:
(1) Wire capped and stowed (part of existing wire harness).
(2) Do not exceed three inches (7.62 cm).
(3) Wire connected to ground.
(4) E13 Ground stud mounted on left oleo support.
Figure 906. Anti−Ice Fuel Filter Wiring Diagram (600N S/N 003 & Subs) (Sheet 2 of 2)
Page 915
MAINTENANCE MANUAL
(16). Measure electrical resistance between Prevent fuel system contamina

filter bowl and firewall. Resistance will CAUTION tion. Install caps on the ends of
not be more than 0.003 ohms. hoses, tubes and fittings as the parts are re
G. Post−Installation Inspection vent loss or damage.
(1). Ensure that all installation debris has (1). Defuel helicopter (Ref. Sec 12-00-00).
been removed. Drain remaining fuel from tank sump
drain valve into a suitable container.
(2). Check all electrical connections for
correct routing and security. (2). Disconnect electrical power.
A. Fuel Cell Cover Removal
(3). Ensure that all hardware, tubes, and
hoses are properly secured. (1). To remove left aft fuel cell access cover:
(a). Remove left aft fuel cell access panel
(4). Ensure that no fuel can be trapped by from passenger/cargo compartment
the drain system. floor.
H. Furnishings, Panels and Equipment (b). Unclamp and disconnect control
Installation cable from fuel shutoff valve.
(1). Install instrument panel hood and (c). Disconnect engine feed fuel supply
instrument panel left side fairing. hose assembly between fuel shutoff
valve and Sta. 124.00 bulkhead. Use
(2). Install pilot's compartment left floor backup wrench on fuel shutoff valve
access panel. so it will not rotate.
(3). Install upper left aft bulkhead panel (d). Disconnect motive flow fuel hose
and lower aft bulkhead panel. assembly between Sta 124.00 bulk
head and fuel cell access cover.
(4). Install aft compartment seats. (e). Disconnect fuel quantity probe wire
(5). Close engine access doors. harness connector from fuel cell cover
receptacle.
(6). Connect battery. (f). Unfasten and remove Sta. 91.00 and
102.00 left aft fuel cell cover support
2. Anti−Ice Fuel Pump Initial Installation
brackets.
(600N98110−501 Installation)
(g). Remove cover bolts and washers.
(Ref. Figure 907) Prop cover open with suitably padded
blocks.
Consumable Materials (h). Using a backup wrench on valve,
(Ref. Section 91−00−00) separate engine feed fuel cell supply
Item Nomenclature hose from fuel shutoff valve and fuel
CM114 Petrolatum inlet from fuel cell access cover.
CM124 Kerosene (i). Disconnect submerged motive flow
CM702 Lockwire CRES fuel hose assembly between fuel
check valve and ejector pump from
fuel cell access cover.
WARNING and fire. Use only nonspark (j). Disconnect fuel cell scavenge hose
ing tools and explosion proof work assembly from bottom of fuel cell
lights. Attach helicopter to an ap access cover bracket assembly to
proved electrical ground. Switch OFF ejector pump.
all electrical power. Disconnect exter (k). Cut safety wire from fuel probe
nal power and battery before opening electrical connector base nut and
fuel system. Ensure work area is ade remove connector from fuel cell
quately ventilated. access cover.
Page 916
MAINTENANCE MANUAL
FUEL PROBE FS
93.15
HOSE
BL
P250 WIRE HARNESS
0.00
FUEL CELL WIRE HARNESS
COVER
WL 13.10
BOLT
WASHER
LBL 13.00
PUMP
WL 0.00 UNION
O-RING
SPACER
BRACKET
VIEW LOOKING AFT
FS
95.628
VIEW LOOKING DOWN G28-2007
Figure 907. Fuel Pump Initial Installation (600N)
(l). Remove fuel cell scavenge hose pressure port and torque to 280—305
bracket assembly, bulkhead union inch-pounds (31.64—34.46 Nm).
and fuel shutoff valve from fuel cell
cover. (5). Attach fuel supply hose to pump
pressure port union. Torque hose nut to
(2). Remove unused bulkhead union from 230—260 inch-pounds (25.99—29.38
cover. Nm).
C. Fuel Cell Cover Installation
B. Pump Installation
(1). Wipe fuel cell and cover sealing sur
(1). Disconnect fuel feed hose from fuel inlet faces clean with kerosene (CM124) on a
plate and remove plate. clean lint free cloth.
(2). Clean pump and sump plate mount (2). Inspect fuel cell cover seals for debond
contact surfaces to establish an electri ing, nicks or cuts and any other damage
cal bond. having a leak producing potential.
Replace covers or left aft cover as
Do not mark torque alignment required.
CAUTION stripes on fuel cell internal (3). Install left aft fuel cell access cover as
hardware. follows:
(3). Install pump on sump plate with bolts, (a). Apply a coating of petrolatum
washers and spacers. Torque bolts to (CM114) to a new fuel shutoff valve/
36—46 inch-pounds (4.07—5.20 cover sealwasher. Install valve on cell
Nm). cover with sealwasher next to valve
body and valve properly aligned to
(4). Apply a thin coat of petrolatum make connection with valve control
(CM114) to a new O-ring and pump cable. Torque valve jamnut to
pressure port union threads. Install 240—280 inch-pounds
O-ring on union. Install union in pump (27.12—31.64 Nm).
Page 917
MAINTENANCE MANUAL
(b). Apply a coating of petrolatum to (9). Install three support brackets on Sta.
sealwasher. Install check valve and 91.00 and 102.00 floor cross-members
sealwasher to inside cover and a with washers and screws. Torque
plain washer outside. Torque jamnut screws to 20—25 inch-pounds
to 85—105 inch-pounds (2.26—2.82 Nm).
(9.6—11.86 Nm).
(10). Install cover bolts and washers. In a
(c). Install bulkhead elbow to support cross pattern, progressively torque
bracket. with washer and nut. Torque cover bolts to 70—90 inch-pounds
jamnut to 240—280 inch-pounds (7.91—10.17 Nm).
(27.12—31.64 Nm).
(11). Connect engine feed fuel supply hose to
(d). Install support bracket to cover with fuel shutoff valve. Torque hose nut to
bolts, washer, and sealwashers. 230—260 inch-pounds (25.99—29.38
Apply a coating of petrolatum to Nm).
sealwasher. Torque bolts to 36—46
inch-pounds (4.06—5.19 Nm). (12). Connect fuel motive flow hose to access
cover/check valve. Torque hose nut
(4). Place left aft fuel cell access cover into (50—65 inch-pounds (5.65—7.34
position on fuel cell. Nm).
NOTE: Install new seal washer, AS3578-024, (13). Connect fuel quantity probe and pump
on wire harness connector. connectors to wire harness receptacles.
(5). Connect fuel quantity probe and pump (14). Slip control cable through hole in fuel
wire harness connectors to cell cover. shutoff valve lever swivel.
Torque connector jamnuts and safety
wire to bulkhead union with lockwire (15). Rig cable control system. (Ref. Sec.
(CM702). 28-00-60, Fuel Shutoff Valve Control
Cable Installation).
(6). Install fuel cell inlet hose assembly to
access cover fuel shutoff valve. Torque (16). Apply a torque alignment stripe to fuel
hose assembly 230—260 inch-pounds line tube, hose and fitting fasteners.
(25.99—29.38 Nm).
(17). Install access panels on passenger
(7). Install submerged motive flow hose cargo compartment floor.
assembly to access cover check valve.
Torque hose assembly 50—65 inch- 3. Anti−Ice Fuel Filter Installation Weight
pounds (5.65—7.34 Nm). and Balance
(8). Install scavenge fuel cell hose assembly (1). After installation of the anti-ice fuel
to access cover bulkhead elbow. Torque filter, incorporate changes to helicopter
hose assembly 230—260 inch-pounds weight and balance record (Ref. Section
(25.99—29.38 Nm). 08-10-00).

Configuration Weight Arm Moment
Pounds (kg) inches (cm) in.−lb (kg cm)
369H90022−BSC +6.6 (+2.996) 107.8 (273.81) +711.48 (+819.710)

369H90022−503 +5.3 (+2.406) 122.7 (311.66) +650.31 (+749.235)
369H90022−505 +5.3 (+2.406) 122.7 (311.66) +650.31 (+749.235)
600N98110−501 +7.3 (+3.311) 112.7 (286.26) +822.7 (+947.807)
Page 918
MAINTENANCE MANUAL
Chapter
32
Landing Gear
MAINTENANCE MANUAL
TABLE OF CONTENTS
32-10-00 Landing Gear System (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Entry Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. Landing Gear Damper Nitrogen Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Figure 301. Landing Gear Damper Nitrogen Servicing - On Helicopter . . . . . . . 302
Table 301. Nitrogen Service Schrader Valve Equipped 369D26301
Extended Landing Gear Dampers - on Helicopter . . . . . . . . . . . . . . . . 303
Table 302. Nitrogen Service Schrader Valve Equipped 369D26300
Standard Landing Gear Dampers - on Helicopter . . . . . . . . . . . . . . . . 306
1. Landing Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Landing Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Landing Gear and Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Landing Gear Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Landing Gear Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Landing Gear Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Landing Gear Skid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Landing Gear Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Landing Gear Skid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4. Landing Gear Fairing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Landing Gear Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Landing Gear Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 402. Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
5. Cabin Entry Step Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Cabin Entry Step Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Cabin Entry Step Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
1. Landing Gear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Landing Gear Skid Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Landing Gear Strut Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
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Figure 601. Landing Gear Strut Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604

4. Landing Gear Damper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
5. Cabin Entry Step Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
6. Landing Gear Fairing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Table 601. Minimum Damper Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Table 602. Landing Gear Damper Bench Test Requirements . . . . . . . . . . . . . . . . 606
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Landing Gear System Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Skid Adapter Sleeve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Abrasion Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Table 801. Maximum Damage Limits - Landing Gear Components . . . . . . . . . . 802
Figure 801. Landing Gear Repairs (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
4. Ground Handling Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
5. Safety Walk Tape Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
6. Landing Gear Fairing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
7. Landing Gear Fairing Fillet Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8. Landing Gear Strut Drag Brace Hole Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
A. Landing Gear Strut with Bushing Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
B. Landing Gear Strut with No Bushing Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 802. Landing Gear Fairing Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
1. Extended Landing Gear Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Standard Landing Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Standard Landing Gear Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Extended Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Figure 901. Extended Landing Gear Assembly (Early Configuration) . . . . . . . . . 902
Figure 902. Extended Landing Gear Assembly (Current Configuration) . . . . . . 904
D. Early Configuration Extended Landing Gear Assembly Buildup . . . . . . . . . . . . . 906
E. Current Configuration Extended Landing Gear
Skid Tube Assembly Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
F. Extended Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
G. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Figure 903. Extended Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
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32-10-60 Landing Gear System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Landing Gear System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Entry Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. Landing Gear Damper Nitrogen Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Figure 301. Landing Gear Damper Nitrogen Servicing - On Helicopter . . . . . . . 302
Table 301. Nitrogen Recharge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1. Landing Gear Strut Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Landing Gear Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Landing Gear Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Landing Gear Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Landing Gear Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Landing Gear Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401. Landing Gear and Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Landing Gear Skid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Landing Gear Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Landing Gear Skid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4. Landing Gear Fairing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Landing Gear Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Landing Gear Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 402. Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. Landing Gear Rubber Washer Locations . . . . . . . . . . . . . . . . . . . . . . . 407
1. Landing Gear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Landing Gear Skid Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Landing Gear Strut Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4. Landing Gear Damper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
5. Forward Cabin Entry Step Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
6. Landing Gear Fairing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Table 601. Minimum Damper Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
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Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Landing Gear System Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Abrasion Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Ground Handling Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
4. Safety Walk Tape Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
5. Landing Gear Fairing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Table 801. Maximum Damage Limits - Landing Gear Components . . . . . . . . . . 802
32-40-00 Ground Handling Wheels (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Ground Handling Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Ground Handling Wheel Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Standard Ground Handling Wheel Installation and Use . . . . . . . . . . . . . . . . . . . . . . . 201
3. Special Ground Handling Wheel Installation and Use . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Ground Handling Wheel Assembly (Standard) . . . . . . . . . . . . . . . . . . 202
4. Standard Ground Handling Wheel Disassembly (Early Configuration) . . . . . . . . . . 202
5. Standard Ground Handling Wheel Re-assembly (Early Configuration) . . . . . . . . . 202
Figure 202. Ground Handling Wheel Assembly/Disassembly . . . . . . . . . . . . . . . . 203
6. Standard Ground Handling Wheel Disassembly (Current Configuration) . . . . . . . 204
7. Standard Ground Handling Wheel Re-assembly (Current Configuration) . . . . . . . 204
8. Standard Ground Handling Wheel Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
9. Special Ground Handling Wheel Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
10. Special Ground Handling Wheel Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
11. Special Ground Handling Wheel Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 203. Special Ground Handling Wheel Assembly (Float Type) . . . . . . . . . . 205
Figure 204. Special Ground Handling Wheel Assembly/Disassembly . . . . . . . . . 206
32-40-60 Ground Handling Wheels (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Ground Handling Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Ground Handling Wheel Assembly Description and Operation . . . . . . . . . . . . . . . 201
2. Ground Handling Wheel Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Ground Handling Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
32-81-00 Utility Float System (369D/E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Utility Float Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Utility Float Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Utility Float Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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A. Skid Tube and Extension Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

B. Utility Float Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Utility Float Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Troubleshooting Utility Floats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Utility Float Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Utility Float Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Utility Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Skid Tube Extension Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Skid Tube Extension Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Skid Tube Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Utility Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1. Utility Float Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Disassembly of Extended Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Figure 901. Extended Landing Gear - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 903
C. Landing Gear Strut Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
D. Landing Gear Skid Extension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Figure 902. Extended Landing Gear Modification . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Figure 903. Skid Tube Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
E. Utility Float to Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
F. Utility Floats/Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Figure 904. Utility Float Buildup (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 909
32-82-00 Emergency Float System (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Emergency Float System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Emergency Float Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Certification and Shelf/Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Emergency Float Inspection (Stowed Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Emergency Float Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Troubleshooting Emergency Flotation Equipment . . . . . . . . . . . . . . . . 203
5. Emergency Float Compartment Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6. Emergency Float Inspection (After Inflation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
7. Emergency Float Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8. Float Compartments Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page v
MAINTENANCE MANUAL

9. Emergency Float Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

10. Solenoid-to-Squib Rework Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1. Emergency Float Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Emergency Float Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Emergency Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Emergency Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Emergency Float Pressure Vessel Servicing and Replacement . . . . . . . . . . . . . . . . . 403
Figure 402. Solenoid Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
3. Squib and Squib Actuated Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 403. Squib Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
4. Emergency Float Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 404. Emergency Float Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
1. Emergency Float System Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Initial Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Existing Equipment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Landing Gear Skid Extension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
E. Emergency Float System Electrical Equipment Installation . . . . . . . . . . . . . . . . . 901
Figure 901. Emergency Float Kit - Electrical Installation . . . . . . . . . . . . . . . . . . . 902
F. Emergency Float System Electrical Wiring Installation . . . . . . . . . . . . . . . . . . . . . 903
Figure 902. Emergency Float Inflation System Wiring Diagram
(369D290121-501 and -505) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
(369D290121-515, -517 and -519) (Sheet 1 of 2) . . . . . . . . . . . . . . . . 905
(369D290121-521, -523, -525 and -527) (Sheet 1 of 2) . . . . . . . . . . . 907
Figure 905. Emergency Float Installation with Generic Wire Harness . . . . . . . . 909
G. Emergency Float Electrical System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910
H. Emergency Float System Strut Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . 910
Figure 906. Emergency Float System Strut Fairing Installation . . . . . . . . . . . . . 911
I. Emergency Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
Page vi
MAINTENANCE MANUAL
Section
32−10−00
Landing Gear
System
(369D/E/FF − 500N)
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

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

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

SERVICING
1. Landing Gear Damper Nitrogen Servicing servicing hose-schrader valve connec
tion.
(Ref. Figure 301) Service landing gear damp
ers equipped with schrader valve according to (6). Tighten servicing hose while nitrogen is
the following steps. flowing. Allow nitrogen pressure to
build to the valve according to dash
Do not recharge a damper if number and part number of damper
CAUTION there is evidence of fluid leak (Ref. Table 301 or Table 302).
age. Recharging of damper will cause fur
ther leakage of both gas and damper fluid, To prevent damage to damper or
CAUTION loss of damper fluid do not open
posing a danger to the helicopter.
schrader valve without pressurizing the
(1). Place helicopter on jacks or hoist. servicing line. If fluid loss occurs, damper
will require overhaul.
NOTE: A minimum of two dampers shall be re
charged; either the two forward dampers, (7). Once pressure level is reached open
two aft dampers, or both forward and aft schrader valve by turning outside nut
dampers. counter clockwise, allowing system and
damper pressure to equalize for a
(2). For forward damper servicing, remove minimum of 2 minutes. If slightly over
footwell panel located in passenger pressurized, bleed off excess very
compartment (Ref. Section 25-30-00). slowly.
For aft damper servicing, open engine
access doors. (8). Close schrader valve by turning the
outside nut clockwise. Torque nut to 60
(3). Remove cap from schrader valve and inch pounds (6.78 Nm) and safety
connect servicing hose, but do not wire.
tighten.
(9). Reduce charge pressure to zero, and
(4). Ensure low side of nitrogen pressure remove servicing hose. Install cap on
regulator is backed off to the unpres schrader valve.
surized position. Slowly open the high
pressure nitrogen bottle valve. (10). Inspect damper for leakage approxi
mately two hours after servicing. Check
(5). Slowly turn regulator control until damper extension according to
nitrogen begins to flow at the loose Table 601 of this section.
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MAINTENANCE MANUAL
DAMPER
CAP
SCHRADER
VALVE OUTSIDE
NUT
SERVICING
HOSE
HIGH
PRESSURE
VALVE
REGULATOR
CONTROL
Figure 301. Landing Gear Damper Nitrogen Servicing − On Helicopter
Page 302
MAINTENANCE MANUAL
Table 301. Nitrogen Service Schrader Valve Equipped 369D26301 Extended Landing Gear
Dampers − on Helicopter
Degrees Winterized Recharge Mid−Temp Recharge Ambient Recharge
Pressure (1) Pressure (2) Pressure (3)
°F °C psi kPa psi kPa psi kPa
−40 −40 1,262 8,702
−38 −39 1,264 8,715
−36 −38 1,266 8,728
−34 −37 1,268 8,740
−32 −36 1,270 8,753
−30 −34 1,271 8,766
−28 −33 1,273 8,778
−26 −32 1,275 8,791 1,051 7,247
−24 −31 1,277 8,804 1,052 7,255
−22 −30 1,279 8,816 1,053 7,262
−20 −29 1,281 8,829 1,054 7,270
−18 −28 1,282 8,842 1,056 7,278
−16 −27 1,284 8,855 1,057 7,286
−14 −26 1,286 8,867 1,058 7,293
−12 −24 1,288 8,880 1,059 7,301
−10 −23 1,290 8,893 1,060 7,309
−8 −22 1,292 8,905 1,061 7,316
−6 −21 1,293 8,918 1,062 7,324
−4 −20 1,295 8,931 1,063 7,332
−2 −19 1,297 8,943 1,065 7,340
0 −18 1,299 8,956 1,066 7,347
2 −17 1,301 8,969 1,067 7,355
4 −16 1,303 8,981 1,068 7,363
6 −14 1,305 8,994 1,069 7,371
8 −13 1,306 9,007 1,070 7,378
10 −12 1,308 9,019 1,071 7,386 1,145 7,891
12 −11 1,310 9,032 1,072 7,394 1,146 7,900
14 −10 1,312 9,045 1,074 7,401 1,147 7,908
16 −9 1,314 9,057 1,075 7,409 1,148 7,917
18 −8 1,316 9,070 1,076 7,417 1,150 7,925
20 −7 1,317 9,083 1,077 7,425 1,151 7,934
22 −6 1,319 9,096 1,078 7,432 1,152 7,943
24 −4 1,321 9,108 1,079 7,440 1,153 7,951
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MAINTENANCE MANUAL
26 −3 1,323 9,121 1,080 7,448 1,154 7,960
28 −2 1,325 9,134 1,081 7,455 1,156 7,968
30 −1 1,327 9,146 1,082 7,463 1,157 7,977
32 0 1,328 9,159 1,084 7,471 1,158 7,985
34 1 1,330 9,172 1,085 7,479 1,159 7,994
36 2 1,332 9,184 1,086 7,486 1,161 8,002
38 3 1,334 9,197 1,087 7,494 1,162 8,011
40 4 1,336 9,210 1,088 7,502 1,163 8,019
42 6 1,338 9,222 1,089 7,510 1,164 8,028
44 7 1,339 9,235 1,090 7,517 1,166 8,037
46 8 1,341 9,248 1,092 7,525 1,167 8,045
48 9 1,343 9,260 1,093 7,533 1,168 8,054
50 10 1,345 9,273 1,094 7,540 1,169 8,062
52 11 1,347 9,286 1,095 7,548 1,171 8,071
54 12 1,349 9,299 1,096 7,556 1,172 8,079
56 13 1,351 9,311 1,097 7,564 1,173 8,088
58 14 1,352 9,324 1,098 7,571 1,174 8,096
60 16 1,354 9,337 1,099 7,579 1,176 8,105
62 17 1,356 9,349 1,100 7,587 1,177 8,113
64 18 1,358 9,362 1,102 7,594 1,178 8,122
66 19 1,360 9,375 1,103 7,602 1,179 8,131
68 20 1,362 9,387 1,104 7,610 1,181 8,139
70 21 1,363 9,400 1,105 7,618 1,182 8,148
72 22 1,365 9,413 1,106 7,625 1,183 8,156
74 23 1,367 9,425 1,107 7,633 1,184 8,165
76 24 1,369 9,438 1,108 7,641 1,185 8,173
78 26 1,109 7,649 1,187 8,182
80 27 1,110 7,656 1,188 8,190
82 28 1,112 7,664 1,189 8,199
84 29 1,113 7,672 1,190 8,208
86 30 1,114 7,679 1,192 8,216
88 31 1,115 7,687 1,193 8,225
90 32 1,116 7,695 1,194 8,233
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MAINTENANCE MANUAL
92 33 1,195 8,242
94 34 1,197 8,250
96 36 1,198 8,259
98 37 1,199 8,267
100 38 1,200 8,276
102 39 1,202 8,284
104 40 1,203 8,293
106 41 1,204 8,302
108 42 1,205 8,310
110 43 1,207 8,319
112 44 1,208 8,327
114 46 1,209 8,336
116 47 1,210 8,344
118 48 1,212 8,353
120 49 1,213 8,361
122 50 1,214 8,370
124 51 1,215 8,379
126 52 1,216 8,387
NOTES:
(1) For 369D26301−221, and −231 extended landing gear dampers.
(2) For 369D26301−241, and −251 extended landing gear dampers.
(3) For 369D26301−211 extended landing gear dampers.
Page 305
MAINTENANCE MANUAL
Table 302. Nitrogen Service Schrader Valve Equipped 369D26300 Standard Landing Gear
−40 −40 704 4,854
−38 −39 705 4,864
−36 −38 707 4,873
−34 −37 708 4,882
−32 −36 709 4,891
−30 −34 711 4,901
−28 −33 712 4,910
−26 −32 714 4,919 704 4,855
−24 −31 715 4,929 705 4,862
−22 −30 716 4,938 706 4,869
−20 −29 718 4,947 707 4,876
−18 −28 719 4,956 708 4,883
−16 −27 720 4,966 709 4,889
−14 −26 722 4,975 710 4,896
−12 −24 723 4,984 711 4,903
−10 −23 724 4,994 712 4,910
−8 −22 726 5,003 713 4,916
−6 −21 727 5,012 714 4,923
−4 −20 728 5,021 715 4,929
−2 −19 730 5,031 715 4,936
0 −18 731 5,040 716 4,942
2 −17 732 5,049 717 4,949
4 −16 734 5,058 718 4,955
6 −14 735 5,068 719 4,962
8 −13 736 5,077 720 4,968
10 −12 738 5,086 721 4,974 637 4,392
12 −11 739 5,096 722 4,980 638 4,397
14 −10 740 5,005 723 4,987 639 4,403
16 −9 742 5,114 724 4,993 639 4,409
18 −8 743 5,123 725 4,999 640 4,415
20 −7 744 5,133 725 5,005 641 4,420
22 −6 746 5,142 726 5,011 642 4,426
24 −4 747 5,151 727 5,017 643 4,432
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MAINTENANCE MANUAL
26 −3 748 5,160 728 5,023 644 4,438
28 −2 750 5,170 729 5,029 645 4,444
30 −1 751 5,179 730 5,035 645 4,449
32 0 753 5,188 731 5,041 646 4,455
34 1 754 5,198 732 5,047 647 4,461
36 2 755 5,207 732 5,052 648 4,467
38 3 757 5,216 733 5,058 649 4,473
40 4 758 5,225 734 5,064 650 4,478
42 6 759 5,235 735 5,070 650 4,484
44 7 761 5,244 736 5,075 651 4,490
46 8 762 5,253 737 5,081 652 4,496
48 9 763 5,263 737 5,087 653 4,502
50 10 765 5,272 738 5,092 654 4,507
52 11 766 5,281 739 5,098 655 4,513
54 12 767 5,290 740 5,103 655 4,519
56 13 769 5,300 741 5,109 656 4,525
58 14 770 5,309 741 5,114 657 4,531
60 16 771 5,318 742 5,120 658 4,536
62 17 773 5,327 743 5,125 659 4,542
64 18 774 5,337 744 5,130 660 4,548
66 19 775 5,346 744 5,136 660 4,554
68 20 777 5,355 745 5,141 661 4,559
70 21 778 5,365 746 5,146 662 4,565
72 22 779 5,374 747 5,152 663 4,571
74 23 781 5,383 747 5,157 664 4,577
76 24 782 5,392 748 5,162 665 4,583
78 26 749 5,167 666 4,588
80 27 750 5,172 666 4,594
82 28 750 5,177 667 4,600
84 29 751 5,182 668 4,606
86 30 752 5,188 669 4,612
88 31 753 5,193 670 4,617
90 32 753 5,198 671 4,623
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MAINTENANCE MANUAL
92 33 671 4,629
94 34 672 4,635
96 36 673 4,641
98 37 674 4,646
100 38 675 4,652
102 39 676 4,658
104 40 676 4,664
106 41 677 4,670
108 42 678 4,675
110 43 679 4,681
112 44 680 4,687
114 46 681 4,693
116 47 681 4,698
118 48 682 4,704
120 49 683 4,710
122 50 684 4,716
124 51 685 4,722
126 52 686 4,727
NOTES:
(1) For 369D26300−221, and −231 standard landing gear dampers.
(2) For 369D26300−241, and −251 standard landing gear dampers.
(3) For 369D26300−211 standard landing gear dampers.
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MAINTENANCE MANUAL
LANDING GEAR SYSTEM

1. Landing Gear Replacement doors, engine access doors and foot
supporting fairings.
(Ref. Figure 401)
(2). With helicopter supported by jacks,
A. Landing Gear Removal position landing gear to align struts
with openings in fuselage structure.
Consumable Materials NOTE: Check that fairing fillet guide pins en
(Ref. Section 91−00−00) gage fairing guide holes before positioning
Item Nomenclature struts for attachment to structure.
CM729 Tape, masking, pressure sensitive
(3). Lift and carefully position landing gear;
then place supports beneath landing
NOTE: Following procedures apply to removal gear to hold it in place.
of entire right or left landing gear assembly.
For component disassembly, refer to appli NOTE: Install left forward damper upper bolt
cable section. For removal, two persons are with bolt head aft. Bolt direction on right
needed. side is optional.
(4). Be sure that slotted bushing (view C) is
(1). Jack up helicopter until landing gear
in place. Align lower bearing of damper
dampers are fully extended (Ref. Sec.
with mating holes in strut and install
07-00-00). Place support beneath skid
attaching hardware.
tubes at strut locations.
(5). Align struts with mating bearings in
(2). Pull strut fairing fillet downward fuselage support fittings. Install bolt,
against spring tension and secure with slotted bushing, two washers, nut and
tape (CM729). cotter pin.
(3). Open compartment access doors for (6). Align inboard end of each brace with
access to forward brace, strut and mating bearing in fuselage supporting
damper. Disconnect brace, strut and fitting. Install slotted bushing and
damper from attachment points. attaching hardware.
(4). For access to aft landing gear attach (7). Secure electrical bonding jumper with
ment points, open engine access doors. clamp and attaching hardware to aft
Disconnect aft brace, strut and damper strut.
from attachment points.
Do not over-tighten brace-to-
(5). Remove clamp attaching electrical CAUTION strut hardware. Torque nut to
bonding jumper to aft strut. 2—5 inch-pounds (0.23—0.56 Nm); then
back off to nearest cancellation to install
(6). Disconnect electrical wiring connections cotter pin.
at upper area forward strut.
(8). If brace is detached from strut, align
(7). Remove supports from below skid and outboard end of each brace with mating
carefully remove struts, skid and holes in strut. Attach brace to strut
fairings as an assembled unit. with attaching hardware. Torque nut to
B. Landing Gear Installation 5 inch-pounds (0.56 Nm) maximum.
(9). Connect wiring at forward strut.
NOTE: Following procedures apply to installa
tion of right or left landing gear assemblies. (10). Remove skid supports, lower helicopter,
and remove jacks.
(1). For access to landing gear attachment
points, open or remove fuselage access (11). Close or replace all access doors.
Page 401
MAINTENANCE MANUAL
FILLET
FAIRING
SKID
EXTENSION
CABIN ENTRY STEP
KNIFE SPLICE
GROUND HANDLING
FITTINGS
SAFETY
WALK TAPE
ABC BOLTS ABRASION STRIP
SEALING COMPOUND
LANDING GEAR SKID
POSITION LIGHT
ELECTRICAL HARNESS
TORQUE STRIPE
(NOTE 3) SERVICE LOOP DAMPER
0.37-0.62 INCH CENTER BEAM

(9.398-15.748 MM)
DIMENSION
A SLOTTED
BUSHING
(NOTE 1)
BARREL CLAMP
BONDING
JUMPER
0.37-0.62 INCH
(9.398-15.748 MM)
STRUT
5 IN.-LB.
(0.56 NM)
TORQUE MAXIMUM
STRIPE BRACE
(NOTE 3) STRUT AND BRACE ATTACHMENT
NOTE 2
BUSHING
(NOTE 1)
NOTES:
1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF 0.010 INCH
(0.254 MM) TO A MAXIMUM OF 0.060 INCH (1.524 MM) ABOVE
0.030 INCH (0.762 MM) OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.
MAXIMUM DEFECT 2. LEFT FORWARD DAMPER ATTACHING BOLT HEAD AFT FOR
DEPTH (TYPICAL) REMOVAL CLEARANCE.
3. TORQUE STRIPES PAINTED CONTRASTING BLACK OR WHITE,
DAMPER UPPER ATTACHMENT AS APPLICABLE.
G32-1000B
Figure 401. Landing Gear and Damper Installation
Page 402
MAINTENANCE MANUAL
2. Landing Gear Damper Replacement 3. Landing Gear Skid Replacement
(Ref. Figure 401) (Ref. Figure 401)
A. Landing Gear Damper Removal A. Landing Gear Skid Removal

(1). If landing gear assembly is attached to
(1). Jack up or hoist helicopter on level
helicopter, jack up helicopter until
surface until landing gear skids just
dampers are fully extended (Ref.
clear resting surface.
Section 07-00-00). Place supports
(2). For forward damper removal, remove beneath skid tubes at strut locations.
foot well fairings located in passenger (2). Remove lower fairing from two-piece
compartment. For access for aft damper fairing assembly.
removal, open engine access doors.
(3). Remove bolts attaching forward
(3). Remove hardware (except bushings) skid-to-foot assembly.
attaching forward damper assemblies
to fuselage attachment fittings and (4). Disconnect electrical connections at
landing gear struts. forward strut.
(4). Remove hardware from damper (5). Remove bolts attaching extension to
attachment points. skid adapter sleeve. Remove extension,
index plug and bearing from skid.
B. Landing Gear Damper Installation B. Landing Gear Skid Installation
(1). Jack up helicopter on level surface until
landing gear skids (Ref. Sec. 07-00-00) Consumable Materials
just clear resting surface. (Ref. Section 91−00−00)
Item Nomenclature
NOTE: CM318 Primer
D Always be sure that replacement damper CM420 Sealant
is correct for the helicopter. Ensure that CM425 Sealing compound
cap torque stripes will be visible for in
spection after installation.
D If installing schrader valve equipped NOTE: Left or right replacement skids are in
dampers, ensure fwd damper is installed terchangeable by using or removing nylon
with schrader valve facing forward and screws from side of skid at forward strut.
aft damper with schrader valve facing aft. (1). Position skid in place with aft foot
bearing installed over skid adapter
(2). Install replacement damper in upper sleeve. Connect electrical connections
and lower mounting position with for skid position light at forward strut.
attaching hardware. Ensure bushings
are in place. (2). Apply thin coating of primer (CM318)
to forward strut and skid tube mating
NOTE: Left forward damper upper bolt must surfaces.
be installed with bolt head aft. Bolt direc
tion on right side is optional. (3). Align mating parts and install bolts
with wet coating of zinc chromate
(3). Torque nuts to 48—55 inch-pounds primer. Torque bolts 40—60 inch-
(5.42—6.21 Nm) and cotter pin. pounds (4.52—6.78 Nm). Apply
sealant (CM420) to head of bolt and to
(4). Check installation for proper alignment nuts.
of torque stripes.
(4). Align skid extension with skid tube
(5). Install foot support fairings and close adapter sleeve. Coat attaching bolts
engine access doors. with primer and install while wet.
Page 403
MAINTENANCE MANUAL
(5). Seal edges of all rigid parts on skid (e). Carefully spread fillet at trailing
with an approximate 0.060 inch (1.524 edge and remove in forward direc
mm) fillet of sealing compound tion.
(CM425).
(3). Remove upper part of fairing as follows.
(6). Install lower fairing.
(a). Remove rivets that secure trailing
4. Landing Gear Fairing Replacement edge of fairing.
(b). Remove rivets that secure fairing to

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

tions at trailing edge are retained for reuse. (Ref. Section 91−00−00)
Item Nomenclature
(2). Remove fillet from upper part of fairing CM318 Primer
assembly as follows. CM411 Adhesive, epoxy
(a). Remove rivets from trailing edge of
fillet. (1). Install upper part of the fairing as
follows.
(b). Drill out one of the rivets securing
fillet to upper guide. Replace rivet (a). Assemble upper guide, pin assembly,
with sheet metal hole fastener (Cleco, inner guide half, outer guide half,
or equivalent). Repeat this step on springs and lower guide on landing
other rivets. gear strut. Install rivets with wet
primer (CM318) to secure lower
(c). Open underfloor compartment or guide to strut.
engine compartment doors for access
to strut cutout in fuselage skin. Have (b). Push guide pins into matching holes
an assistant push down on upper of lower guide. Wedge temporary
guide with suitable tool (wood dowel holding device between upper guide
or equivalent), to relieve spring and strut to keep pins engaged.
tension.
NOTE: Use two small wood blocks or any simi
(d). With spring tension off guide, remove lar suitable means to keep springs com
fasteners. Slowly relax dowel pres pressed. Device used must be small enough
sure on guide until springs fully to be removed through strut cutout in skin
expand. after fillet is assembled.
Page 404
MAINTENANCE MANUAL
NUTPLATE
RIVET
FAIRING
ASSY
FAIRING ASSY
SEAL
WASHER
SCREW
NUT
WASHER
WASHER
SCREW
COVER (EXTENDED
LANDING GEAR ONLY)
WASHER
SCREW SEAL
SEAL
G32-1001
Figure 402. Fairing Installation
Page 405
MAINTENANCE MANUAL
(c). Install blind hole transfer punches (b). Carefully spread trailing edge of fillet
(two or four places, as applicable) or and position about upper guide.
fabricate suitable tools as shown Clamp lower end of fillet trailing
(Ref. Figure 802). Install tool(s) edge to upper end of fairing trailing
between opposing holes in strut edge. Clamping prevents fillet
bracket(s). movement when fillet rivets are
installed. Have an assistant remove
temporary holding device and push
(d). Carefully spread trailing edge of down on upper guide with suitable
fairing and position fairing on strut tool (wood dowel, etc). Have guide
bracket(s) and lower guide. Have an pushed down where a pencil line
drawn on guide flange is visible
assistant hold fairing in this position.
through one #40 hole in fillet.
Match-drill guide and secure fillet
and guide with hole fastener (Cleco,
(e). Back up fairing with a fiber block at or equivalent). Repeat procedure for
transfer punch location. Using plastic all rivet locations. Remove pushing
hammer, carefully strike opposite tool from strut opening.
side of fairing to transfer hole
centers. (c). Remove one fastener at a time, and
install screws and washers (Ref.
Landing Gear Fairing Fillet Modifi
(f). Remove fairing and check that all cation).
transfer marks appear within outline
of small laminated doublers. Drill out (d). Install screws, washers and nuts to
located holes. secure fillet trailing edge together.
(e). Check for smooth telescoping action

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

(h). Install rivets to secure fairing to as follows.
strut bracket(s).
(a). Carefully spread trailing edge of
fairing and position on upper fairing
(i). Install rivets to secure trailing edge and lower strut bracket; at correct
of fairing. position there should be 0.020—0.080
inch (0.508—2.032 mm) compres
sion of fairing seal against skid tube.
(j). Using soft lead pencil, draw a Have an assistant hold fairing at this
continuous line along horizontal position.
center of upper guide flange. (b). Back up fairing with fiber block at
transfer punch location. Using plastic
hammer, carefully strike opposite
(2). Install fillet as follows. side of fairing to transfer hole
centers.
(a). Drill a #40 hole in center of each 3/8 (c). Remove fairing and check that all
inch (9.525 mm) square doubler in transfer marks appear within outline
fillet. (There are six doublers in the of small laminated doublers. Drill out
fiberglass fairings.) located holes.
Page 406
MAINTENANCE MANUAL
(d). Reinstall fairing in mounting position B. Cabin Entry Step Installation

and secure to upper and lower strut
brackets with screws and washers. Consumable Materials
(e). Secure fairing trailing edge with Item Nomenclature
attaching hardware. CM318 Primer
NOTE: Be sure doublers are installed between (1). Install replacement step on forward
laminations at trailing edge. landing gear strut, using four lockbolts
with wet primer (CM318). Four holes in
step collar must be drilled out to
5. Cabin Entry Step Replacement 0.164—0.167 inch (4.166—4.242 mm)
for installation of lockbolts. If holes are
(Ref. Figure 801) elongated, use next size larger lock
bolts.
A. Cabin Entry Step Removal NOTE: At strut replacement, locate step by us
ing skid centerline-to-step centerline mea
surement of 11.78 inches (29.92 cm).
(1). Remove landing gear fairing.
(2). Install step on aft landing gear strut,
using two bolts, washers and nuts with
(2). Remove four lockbolts and step from wet primer. Torque nuts to 60—85
forward landing gear strut, or two inch-pounds 6.78—9.60 Nm).
bolts, washers and nuts from aft
landing gear strut (extended gear only). (3). Install lower fairing on strut.
Page 407
MAINTENANCE MANUAL
Page 408
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

INSPECTION/CHECK
1. Landing Gear Inspection (2). Remove lower fairing from two-piece
fairing assembly.
(Ref. Figure 801)
(3). Inspect for dents. If dents exceed a
NOTE: Inspection should be done with helicop depth of 0.20 inch (5.08 mm), they will
ter skids clear of ground. require repair.
(1). Inspect skids, skid abrasion strips, (4). Inspect for punctures and cracks.
struts, feet, braces and fairings for
dents, cracks, loose components or (5). Do the fluorescent penetrant inspection
rivets, loose nuts and for missing of all crack areas, and of those areas
hardware. adjacent to all punctures. These areas
will require repair (Ref. Section
(2). Inspect skid-to-foot and foot-to-strut 20-90-00).
attachments for loose bolts. Check aft
foot-to-bearing rivet installation for (6). Inspect from aft end of tube to a point
security. 10 inches (25.40 cm) forward of aft strut
for scratches and nicks. If scratches and
NOTE: Loose or defective bolts at forward foot- nicks are more than a length of 0.25
to-skid locations requires replacement of inch (6.35 mm) and a depth of 0.015
nutplates. inch (0.381 mm), they will require
(3). Using 10X glass and bright light, repair.
visually inspect area at, around and (7). Inspect from forward end of tube to 10
between foot-to-strut attach bolts not inches (25.40 cm) forward of aft strut
covered by sealant for cracks and for scratches and nicks. If scratches and
corrosion. nicks are more than a length of 0.25
NOTE: If cracks or corrosion other than light inch (6.35 mm) and a depth of 0.020
surface corrosion is found, replace affected inch (0.508 mm), they will require
part. repair.
(4). Inspect keel beam areas where the (8). Inspect ground handling fittings for
strut assemblies attach for loose cracks, loose rivets, corrosion and other
bearings, condition of hardware and damage.
strut adapters.
(9). Inspect abrasion strips for damage,
(5). Check condition of beaded seal around excessive wear, and for loose bolts and
edges of all rigid-mounted skid tube screws.
components.
(10). Check skid adapter sleeve rivet attach
2. Landing Gear Skid Inspection ment for security. On early configura
tions, check sleeve slots for wear and
(Ref. Figure 801) damage.
NOTE: If landing gear assembly has not been (11). Check condition of plug installed in
removed from helicopter, do the following skid adapter sleeve.
steps (1). and (2). before proceeding with in
spection. (12). Check aft foot bearing and extension for
wear, damage and corrosion. On early
(1). Jack helicopter until landing gear configurations, check condition of
dampers are fully extended. extension packing.
Page 601
MAINTENANCE MANUAL
3. Landing Gear Strut Inspection 3). If cracks are found, rework the
strut. (Ref. Paragraph 8., Landing
(Ref. Table 801 and Figure 601) Gear Strut Drag Brace Hole
Repair)
Consumable Materials 4). Check drag brace attach holes in
(Ref. Section 91−00−00) strut for elongation.
Item Nomenclature a). Make sure the diameter of the
CM318 Primer top hole (DIM. A) is not larger
than a maximum limit of
0.5313 inch (13.495 mm) in
(1). Inspect the helicopter landing gear any direction.
dampers for correct stance: b). Make sure the diameter of the
(a). Check the rear dampers for correct bottom hole (DIM. B) is not
extension. larger than a maximum of 0.50
inch (12.70 mm) in any direc
(b). Look for signs of leakage. tion.
c). If the strut hole of DIM. A or
(2). Remove foot support fairings in passen DIM. B is larger than the maxi
ger/cargo compartment and open engine mum limit, rework the strut.
access doors. (Ref. Paragraph 8., Landing
(3). Visually inspect strut attachment Gear Strut Drag Brace Hole
points and pivot bearing for signs of Repair)
fretting, wear and damage. (c). If no cracks are found around drag
brace attach hole in strut and the
NOTE: Fretting will be evident by gray or attach hole is not elongated, install a
black material around bearing, rivets or new bushing in the attach hole with
seams. wet primer (CM318).
(d). If no bushing is installed in the drag
(4). Jack helicopter until landing gear
brace attach hole in the strut,
dampers are fully extended. (Ref.
proceed as follows:
Section 07-00-00, Lifting and Jacking)
1). Use a 10X glass and bright light
(5). Shake landing gear assemblies and look and inspect the strut around drag
for looseness at pivot bearings, inboard brace attach holes (top and bottom
strut assembly fittings and drag brace surfaces) for cracks.
holes. 2). If cracks are found that are longer
than the maximum limit of 0.030
(6). If looseness is found, inspect the drag inch (0.762 mm), discard the
brace and strut for damage as follows: strut and replace it with a service
(a). Remove the landing gear. (Ref. able strut. (Ref. Paragraph 1.,
Paragraph 1., Landing Gear Replace Landing Gear Replacement)
ment) 3). If any cracks are 0.030 inch
(0.762 mm) in length or less,
(b). If a bushing is installed in the drag rework the strut (Ref. Landing
brace attach hole in the strut, Gear Strut Drag Brace Hole
proceed as follows: Repair).
1). Check bushing for looseness and 4). Check drag brace attach holes in
remove it if it is loose. strut for elongation.
2). Use a 10X glass and bright light 5). If drag brace attach holes are
and inspect the strut around the elongated, rework the strut (Ref.
drag brace attach holes (top and Paragraph 8., Landing Gear Strut
bottom surfaces) for cracks. Drag Brace Hole Repair).
Page 602
MAINTENANCE MANUAL
(7). After the drag brace attach hole is (d). If a dent is more than the maximum
repaired, install the landing gear. (Ref. depth, discard the strut and install a
Paragraph 1., Landing Gear Replace new serviceable strut. (Ref. Para
ment) graph 1., Landing Gear Replacement)
(8). Inspect the strut for cracks or dents as (e). If scratches and repair area depth
follows: would exceed 0.010 inch (0.254 mm)
(a). If a strut is cracked, discard the strut when measured to surrounding
and replace it with a serviceable unrepaired surface strut must be
strut. (Ref. Paragraph 1., Landing scrapped and serviceable strut
Gear Replacement) installed.
(b). Look for dents in the strut surface.
(c). If dents are found, make sure that
each dent is not more than the
maximum depth of 0.060 inch (1.524
mm) when compared to the surface
around the repair area.
Page 603
MAINTENANCE MANUAL
DIM. A
(TOP HOLE) DAMP-
ER
( REF )
DIM. B
(BOTTOM HOLE)
SECT
B−B
BOLT
WASHER
DRA STRUT
G
BRAC
E
WASHER
COTTER PIN
NUT
STRUT AND BRACE ATTACHMENT
88−779
Figure 601. Landing Gear Strut Inspection
Page 604
MAINTENANCE MANUAL
(9). For aircraft 369D; 001 & subs, 369E; nose up/nose down attitude, do a
0001 thru 0528, 369FF; 0001 thru 0114 damper extension check.
and 500N; 001 thru 077: Remove plug
button from underside of fairing NOTE:
assembly. Using a bright light and 10X D The landing gear damper assemblies are
magnifying glass, inspect rivet hole in to be checked at a helicopter gross weight
underside of strut for cracks. If crack is of 1925—2075 pounds (874—942 kg) at
found, strut must be scrapped and a longitudinal CG of approximately 103,
serviceable strut installed. exclusive of skid mounted flotation gear.
The empty weight of the 369D with full
4. Landing Gear Damper Inspection fuel, but no passengers or cargo, is
1775—1925 pounds (806—874 kg).
(Ref. Table 601, Table 602 and Figure 401) Therefore achieve the test configuration
by adding 75 pounds (34 kg) of ballast to
NOTE: It is normal for a thin hydraulic oil film both sides of the cabin floor, just aft of the
to remain on damper as a result of wiping tail rotor pedals, 150 pounds (68 kg) total.
contact with piston seal. Newly-installed Place the helicopter on a smooth concrete
dampers can also have slight oil seepage or equivalent surface (not asphalt).
from oil trapped in end cap threads during D Dampers which have been modified (win
damper assembly. Neither of these should terized) for cold weather operation are to
be considered damper leakage or cause for be checked out no more than 305F (-15C)
damper replacement. above the coldest temperature at which
the helicopter is operated.
(1). Inspect for hydraulic oil leakage. If
leakage is visible, wipe oil from damper (a). Raise and lower tailboom above and
after last flight of the day. Re-inspect below the normal at-rest position
the following day for oil leakage. If three times. On the last cycle, allow
leakage persists, do a bench check (Ref. the tailboom to slowly settle to the
CSP-COM-5). at-rest position.
(2). With helicopter on jacks, inspect (b). Measure and record dimension from
damper assemblies for evidence of upper end cap to upper end of barrel
bearing looseness in upper and lower on all four damper assemblies.
caps, worn bearings (excessive radial
play), loose or cracked caps and oil (c). Repeat steps (a). and (b). two more
leakage. Any misalignment of torque times.
stripes on caps, piston and barrel
indicates loosening of caps. Replace (d). Lower and raise tailboom below and
immediately and repair removed above the normal at-rest position
damper. three times. On the last cycle, allow
the tailboom to slowly rise to the
at-rest position.
(3). Inspect damper attaching hardware for
security. (e). Measure and record dimension from
upper end cap to upper end of barrel
NOTE: Dampers which have been modified on all four damper assemblies.
(winterized) for cold weather operation are
to be checked at not more than 30°F (-1°C) (f). Repeat steps (d). and (e). two more
above the coldest temperature at which the times.
helicopter is operated.
(g). Determine average extension from all
(4). Inspect landing gear dampers for six readings for each damper assem
condition by observing stance of bly. Remove and overhaul any
helicopter (normal stance is slightly damper assembly not meeting
nose up). If stance indicates excessive dimensions (Ref. Table 601).
Page 605
MAINTENANCE MANUAL
NOTE: If two damper assemblies fail to meet (4). Inspect safety walk tape for condition
the minimum extension (Ref. Table 601), re and security. Replace unserviceable
place the damper having the greater tape.
amount of deflection with a known service
able damper and repeat steps (a). thru (g). If (5). Inspect fairing seal for condition.
the original damper again fails to meet min
(6). Install landing gear fairing assembly.
imum extension requirements, replace it
with the known serviceable damper, rein
6. Landing Gear Fairing Inspection
stall the first damper and repeat steps (a).
thru (g). This will determine whether one or (Ref. Figure 802)
both dampers require overhaul. For owners
and operators having suitable equipment, (1). Inspect fairing support brackets for
any damper not meeting minimum exten security of attachment to strut, cracks
sion requirements can be bench-checked by and deformation.
applying a single load and measuring the
deflection when compressed. (Ref. Table 602 (2). Inspect fairing-to-skid seal for deterio
for load and compression requirements.) ration and bonding.
Dampers meeting specifications in
(3). Inspect fuselage rubbing plate for
Table 602 can be returned to service if other
security of bond and excessive wear.
defects are not noted.
(4). On forward fairings (aft fairings with
5. Cabin Entry Step Inspection steps attached to struts), inspect fairing
(Ref. Figure 801) step seal for deterioration and bonding.
(1). Remove landing gear fairing assembly.

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

Damper P/N (1) Test Load Compression Stroke
Pounds (kg) Inches (mm/cm)
369D26300 (2) 1200 (545) 0.80 (20.32 mm)
369D26300−31 1320 ±100 (599 ±45) 0.80 (20.32 mm)

3780 ±400 (1716 ±182) 2.75 (6.99 cm)
369D26301 (2) 1700 (772) 0.80 (20.32 mm)
369D26301−31 1900 ±100 (863 ±45) 0.80 (20.32 mm)

3950 ±400 (1793 ±182) 2.75 (6.99 cm)
NOTES:
(1) Do all tests at 70 ±2° F except as noted.
(2) Cold−soak winterized dampers at 0 ±3° F for 24 hours minimum before testing.
Page 606
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

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

braces. (Ref. Figure 801)
(8). Repair or replace damaged skid tube.
(9). Replace center beam-to-landing-gear (Ref. Section 91−00−00)
attachment bearings that exceed 0.040 Item Nomenclature
inch (1.016 mm) axial play.
CM209 Zinc chromate putty
(10). Repair loose or defective rivets securing CM318 Primer
foot to bearing; replace defective CM425 Sealing compound
bearing.
2. Skid Adapter Sleeve Replacement (1). Remove bolts securing defective

abrasion strip(s) to skid.
(Ref. Figure 801)
(2). Remove screws securing abrasion strip
to skid extension sleeve. Completely
Consumable Materials remove any residual zinc chromate
(Ref. Section 91−00−00) putty.
Item Nomenclature
CM318 Primer (3). Apply putty (CM209) to any bare metal.
CM425 Sealing compound (4). Coat new screws or bolts for replace
ment abrasion strip with primer
Page 801
MAINTENANCE MANUAL
(CM318) and install while primer is edges of abrasion strip next to skid tube
still wet. with an approximate 0.060 inch (1.524
mm) bead (fillet) of sealing compound
(5). After installation, seal all of parting (CM425) to make watertight.
Table 801. Maximum Damage Limits − Landing Gear Components
Dents Nicks Scratches Cracks Holes
Component in (mm) in (mm) in (mm) in (mm) in (mm)
Skid tube (2) 0.200 (5.08) 0.010 (0.254), from aft side of (Same as for No cracks 0.250 (6.350)
(1) aft strut to 10 inches (25.4 cm) nicks) (1) allowed (1) (3)
forward of the strut, with
cleanup not exceeding 0.015
(0.381); 0.015 (0.381) if forward
of that point to start of curved
section, with cleanup not
exceeding 0.020 (0.508) (1)
Forward foot 0.060 (1.524) 0.060 (1.524) 0.010 No cracks No holes

(0.254) allowed allowed
Strut 0.060 (1.524) (1) (1) No cracks No holes

allowed allowed
Brace 0.050 (1.270) 0.010 (0.254) 0.005 No cracks No holes

Damper assembly 0.060 (1.524) 0.010 (0.254) 0.010 No cracks No holes

Fittings 0.010 (0.254) 0.010 (0.254) 0.010 No cracks No holes

Aft foot 0.060 (1.524) 0.060 (1.524) 0.010 No cracks No holes

Foot bearing 0.010 (0.254) 0.010 (0.254) 0.010 No cracks No Holes

Indexing plug 0.040 (1.016) 0.040 (1.016) 0.040 No cracks No holes

Skid extension 0.010 (0.254) 0.010 (0.254) (4) 0.010 No cracks No holes
(4) (0.254) (4) allowed allowed
NOTES:
(1) For other repair data, refer to CSP−SRM−6.
(2) Repair of minor skid tube damage aft of rear strut and on forward (curved) section is not required, but
surface finish must be restored.
(3) Hole must be plugged with correct size blind rivet.
(4) No damage is allowed on skid extension where skid and sleeve are attached.
Page 802
MAINTENANCE MANUAL
BONDING JUMPER CENTER BEAM
DAMPER
CLAMP
FAIRING BRACKET
(8 PL)
STRUT
BOLT NUT
DAMPER
ABRASION STRIP BOLT
RIVET
(TYP) FOOT
GROUND HANDLING
FITTINGS SPACER
BRACE STRUT CABIN ENTRY SAFETY WALK ABRASION STRIP

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

FOR ABRASION STRIP MOUNTING LANDING GEAR G32−1002−1A
Figure 801. Landing Gear Repairs (Sheet 1 of 2)
Page 803
MAINTENANCE MANUAL
RIVET FOOT
SPACER BOLT
WASHER
SPACER
SPACER FOOT
`
RIVET SCREW
EARLY CURRENT
CONFIGURATION CONFIGURATION
PIN RIVET
RIVETS (UPPER BRACKET)

HUCKBOLTS (LOWER BRACKET)
(NOTES 3 AND 6)
PACKING
FAIRING (NOTES 5 AND 6)
BRACKET
SKID EXTENSION
SLEEVE
FOOT
BOLT
SKID ADAPTER INDEXING
SLEEVE PLUG
RIVET COLLAR
PIN ABRASION
DOUBLER STRIP SCREW
FORWARD FAIRING PLUG
ATTACHMENT
BEARING
EARLY CONFIGURATION
SKID
COLLAR
PLUG
FOOT NUT
WASHER
SKID ADAPTER
RIVET SLEEVE BEARING
SPACER NOTES:
1. BOLT AND WASHER 4 PLACES. 8 PLACES ON
PIN EARLY CONFIGURATION.
2. HUCKBOLT 4 PLACES. 8 PLACES ON EARLY
SKID CONFIGURATION.
EXTENSION 3. INSTALL NEW RIVETS WITH WET PRIMER
SLEEVE BOLT (CM318).
4. 3/16 INCH (4.7625 MM) WELDING ROD OR
OTHER SUITABLE DEVICE (4 PLACES).
CURRENT CONFIGURATION 5. FORWARD FAIRING ONLY.
SKID SCREW 6. HUCKBOLT HEAD COUNTERSUNK INSIDE
STRUT; NO PORTION OF HEAD TO PROTRUDE
INSIDE STRUT.
SKID TUBE ADAPTER AND PIVOT COMPONENTS
G32−1002−2A
Figure 801. Landing Gear Repairs (Sheet 2 of 2)
Page 804
MAINTENANCE MANUAL
4. Ground Handling Fitting Replacement

(Ref. Figure 801) (Ref. Section 91−00−00)
Item Nomenclature
Consumable Materials CM418 Cement, epoxy
Item Nomenclature (1). Replace an excessively damaged lower
CM209 Zinc chromate putty fairing.
CM318 Primer
(2). Replace damaged fairing bracket or
CM425 Sealing compound lower guide. Remove rivets, locate new
part and install blind rivets. Use next
larger size rivets if mating holes in
(1). Drill out rivets securing defective strut are enlarged.
fitting.
(3). Replace damaged guide/pin assembly or
(2). Coat mating surfaces with zinc chro guide half if guide is cracked, pins are
mate putty (CM209) and install bent or badly worn or teflon pad is loose
replacement fitting in place. or badly worn.
(3). Coat new rivets with primer (CM318) (4). Replace springs that are badly worn or
and install while primer is wet. rusty, or if free length is less than 8.72
inches (22.15 cm).
(4). Seal edges with an approximate 0.060
(1.524 mm) inch bead of sealing (5). Replace fillet if teflon strip is loose or
compound (CM425) for waterproofing. badly worn.
(6). Replace damaged strut bracket.
5. Safety Walk Tape Replacement Remove rivets, locate new part and
install blind rivets. Use next larger size
(Ref. Figure 801) rivets if mating holes in strut are
enlarged.
(7). Replace unserviceable rubber seals; use
cement (CM418).
Item Nomenclature
CM220 Naphtha aliphatic 7. Landing Gear Fairing Fillet Modification
CM724 Tape, non-slip The following is a procedure for modifying the
landing gear fairing fillet for easy removal and
better access to the landing gear struts.
(1). Carefully pull or scrape away damaged
tape. (1). Remove fillet from upper part of fairing
assembly (Ref. Landing Gear Fairing
(2). Remove all residual adhesive from skid Removal).
tube by wiping with a clean cloth
wetted by naphtha (CM220). (2). Enlarge existing holes in fairing fillets
and fillet guides to 0.220—0.230 inch
(3). Install new tape (CM724) and press (5.588—5.842 mm).
firmly into place. Expel air bubbles
while pressing down tape. (3). Install A1133-4-3 Nut-Clips on fillet
guides over enlarged holes.
6. Landing Gear Fairing Repair (4). Reinstall fillets using NAS603-6P
screws and AN960KD10L washers
(Ref. Figure 802) Repair fairings according to through fillet into fairing guides.
SRM. If upper fairing is damaged beyond
fiberglass repair limits, the fillet and fairing (5). Secure trailing edge of fillet using
must be removed. NAS603-6P screws, AN960KD10L
Page 805
MAINTENANCE MANUAL
washers and MS21042-3 nuts (washer B. Landing Gear Strut with No Bushing
under screw head and nut). Installed
(6). Finish reinstalling fillet (Ref. Landing (1). Ream out top hole (DIM. A) to
Gear Fairing Installation). 0.5308—0.5313 inch (13.482—13.495
mm) and ream out bottom hole (DIM.
8. Landing Gear Strut Drag Brace Hole B) to 0.4995—0.50 inch
Repair (12.687—12.70 mm).
(Ref. Figure 601) The following procedure is for
repair of the bolt hole in the landing gear strut (2). Do the fluorescent penetrant inspection
where the drag brace attaches. This rework is of repaired areas for cracks. (Ref.
for either elongated or cracks in the bolt hole Section 20-90-00).
area (Ref. Landing Gear Strut Inspection).
(a). If any cracks are noted, rework strut
per step (3).
(Ref. Section 91−00−00) (b). If no cracks are noted, install new
Item Nomenclature 369H6002-11 bushing in hole with
CM318 Primer wet primer (CM318).
(3). Ream out top hole (DIM. A) to

A. Landing Gear Strut with Bushing 0.5608—0.5613 inch (12.244—14.257
Installed mm) and ream out bottom hole (DIM.
B) to 0.5295—0.530 inch
(1). Ream out top hole (DIM. A) to (13.449—13.462 mm).
0.5608—0.5613 inch (12.244—14.257
mm) and ream out bottom hole (DIM. (4). Do the fluorescent penetrant inspection
B) to 0.5295—0.530 inch of repaired areas for cracks. (Ref.
(13.449—13.462 mm). Section 20-90-00).
(2). Do the fluorescent penetrant inspection
(a). If any cracks are noted, proceed with
of repaired areas for cracks. (Ref.
step (5).
Section 20-90-00).
(a). If any cracks are noted, rework strut (b). If no cracks are found around drag
per step (3). brace attach hole in strut and hole is
not elongated, install new
(b). If no cracks are noted, install new 369H6023-1 bushing in hole with
369H6023-1 bushing in hole with wet primer (CM318).
wet primer (CM318).
(5). Ream out top hole (DIM. A) to
(3). Ream out top hole (DIM. A) to 0.5908—0.5913 inch (15.006—15.019
0.5908—0.5913 inch (15.006—15.019 mm) and ream out bottom hole (DIM.
mm) and ream out bottom hole (DIM. B) to 0.5595—0.560 inch
B) to 0.5595—0.560 inch (14.211—14.224 mm).
(14.211—14.224 mm).
Section 20-90-00).
Section 20-90-00).
(a). If crack is found, strut must be (7). If crack is found, strut must be
scrapped and serviceable strut scrapped and serviceable strut
installed. installed.
(b). If no cracks are noted, install new (8). If no cracks are noted, install new
369H6023-3 bushing in hole with 369H6023-3 bushing in hole with wet
wet primer. primer.
Page 806
MAINTENANCE MANUAL
CHAFING PAD
TEFLON STRIP
FILLET
(NOTE 3)
RIVETS
RETAINING BLOCKS
AND CLAMP
NOTE 4
0.35 INCH (8.89 MM)
TEFLON PAD FAIRING TO LOWER GUIDE
UPPER (INSIDE GUIDES) (NOTE 1)
FAIRING 0.80 INCH (20.32 MM)
UPPER GUIDE UPPER FAIRING
PIN ASSEMBLY, (NOTE 3)
0.35 INCH (8.89 MM) LOWER FAIRING INNER GUIDE HALF
AND SPRINGS RIVET
(FWD FAIRING, 1 RIVET)
(AFT FAIRING, 2 RIVETS)
OUTER GUIDE HALF
UPPER AND LOWER FAIRING RIVETS 1-7/16 INCH (3.65 CM)

INSTALLATION (NOTE 2) DOUBLER (TYP)
LOWER GUIDE LOWER FAIRING

(NOTE 1) (NOTE 3)
RIVETS (UPPER BRACKET)
HUCKBOLTS (LOWER BRACKET)
(NOTES 2 AND 8) 3/4 INCH (19.05 MM)
RIVET DOUBLER (TYP)
(2 PL)
SCREW, WASHER
HOLE (4 PLACES)
AND SEAL
(NOTES 6, 7)
1/2 X 3/4 INCH

FAIRING DOUBLER
BRACKET (TYP)
FORWARD FAIRING SKID
ATTACHMENT
SKID CL
COVER (EXTENDED
LANDING GEAR ONLY)
NOTES:
NUTPLATE 1. BONDED AREA; USE EPOXY ADHESIVE (CM411).
(9 PL) 2. INSTALL NEW RIVETS WITH WET PRIMER (CM318).
3. REFER TO CSP-SRM-6 FOR FIBERGLASS REPAIR.
4. CLAMP FILLET AND FAIRING TRAILING EDGES DURING INSTALLATION
OF FILLET RIVETS.
5. PENCILED CENTERLINE ALONG FLANGE.
6. 3/16 INCH (4.7625 MM) WELDED ROD OR OTHER SUITABLE DEVICE.
7. FORWARD FAIRING ONLY.
8. HUCKBOLT HEAD COUNTERSUNK INSIDE STRUT; NO PORTION OF HEAD
WASHER TO PROTRUDE INSIDE STRUT.
(9 PL) 9. DIMENSIONS FOR BRACKET AND GUIDE LOCATIONS ON NEW STRUT
RIVET INSTALLATION.
(18 PL)
SCREW
(9 PL) G32-1003A
Figure 802. Landing Gear Fairing Repairs
Page 807
MAINTENANCE MANUAL
Page 808
MAINTENANCE MANUAL
EXTENDED LANDING GEAR

1. Extended Landing Gear Initial Installation for reuse. Remove skid assemblies with
foot assemblies attached.
The following instructions are for both left and
right landing gear assemblies. B. Standard Landing Gear Disassembly
Complete disassembly of landing gear is not
(1). Identify all components, including required; however, certain items must be
attaching hardware, or components removed.
removed for access to work area.
Protect components from damage and (1). On current configuration standard
foreign matter until installed. landing gear, disassemble as follows:
(2). Ensure all cockpit electrical switches (a). Remove bolt, washer and nut attach
are OFF. ing aft foot assembly and skid
extension to skid tubes.
NOTE: Ensure BATT-OFF-EXT switch is (b). Remove bolts and washers attaching
OFF. forward foot assembly to skid tubes.
(3). Using jacking or hoisting methods, (2). On early configuration standard
raise helicopter clear of ground. landing gear, disassemble as follows:
A. Standard Landing Gear Removal (a). Remove screws and abrasion strip at
aft section of skid tubes.
Removal of complete landing gear is not (b). Remove bolts attaching skid exten
required. sion, indexing plug and aft foot
assembly to skid tube.
(1). Open engine access doors.
(c). Remove bolts and washers attaching
(2). Remove hardware attaching aft damper forward foot assembly to skid tube.
assemblies to fuselage fittings and
landing gear struts; remove aft damper C. Extended Landing Gear Assembly
assemblies. Retain attaching hardware Extended landing gear is shipped with as
for reuse. many parts assembled as practical; however,
certain items require assembly at installation.
(3). Remove screws attaching position light
assemblies to skid assembles. Retain Early configuration forward foot assembly and
screws for reuse. Disconnect electrical skid tube have an eight-hole mounting
harness and remove position light pattern; current configuration foot assembly
assemblies. and skid tube have a four-bolt mounting
pattern.
(4). Remove hardware that secures trailing
edge of forward and aft lower fairings. Consumable Materials
Remove hardware attaching lower (Ref. Section 91−00−00)
fairings to strut assemblies. Carefully Item Nomenclature
spread trailing edge of lower fairings
CM318 Primer
and remove in forward direction.
NOTE: If preload condition prevents removal of
skid assemblies, disconnect forward foot as (1). If early foot assembly is used with
semblies from skid assemblies to eliminate current skid tube:
preload.
(a). Drill out four rivets (48, Figure 902)
(5). Remove ABC bolts from forward and aft and remove two spacers (49) from
strut assemblies. Retain ABC hardware skid tube.
Page 901
MAINTENANCE MANUAL
25
26
55
9 56
10 23
22
21 20
24
57
11
58
47 7 19
45 6
5 4 43
8 44
38 2
46 3 42
39
33
17
41
54 1 40
16
32
37 59 18
30
36
35
34 15
13
12
14
52
29
50 27
51 31
28
53
48
49
Figure 901. Extended Landing Gear Assembly (Early Configuration)
Page 902
MAINTENANCE MANUAL

1. Bolt (MS21250−04006) 30. Doubler (369D26031)
2. Washer (MS20002C4) 31. Bearing (369D26030−1 LH)
3. Foot assy (369D292113−1 LH FWD) (369D26030−2 RH)
(369D292113−2 RH FWD) 32. Foot (369D29113−3 LH AFT)
4. Screw (NAS1403−1) (369D29113−4 RH AFT)
5. Lockwasher (MS35338−43) 33. Skid assy (369D292114)
6. Bracket (369H92111−11) 34. Bolt (NAS1223C1)
7. Rivet (NAS1921M04−03) 35. Washer (HS306−222)
8. Nutplate (369H92507) 36. Abrasion strip (369H92583)
9. Rivet (CCR26455−3−5) 37. Abrasion strip (369H6102)
10. Nutplate (NAS1068A3) 38. Tape (369D292114−3)
11. Foot (369D29113−3 LH FWD) 39. Tube assy (369D292114−5)
(369D29113−4 RH FWD) 40. Screw (NAS1190C3P3)
12. Bolt (NAS1223C1) 41. Rivet (NAS1921M04−03)
13. Washer (HS306−222) 42. Nutplate (369H92507)
14. Abrasion strip (369H6102) 43. Rivet (NAS1919M04−03)
15. Screw (NAS56HK3−6) 44. Fitting (369A6107−3)
16. Bolt (NAS1223C8P) 45. Rivet (NAS1399D4−4)
17. Extension assy (369D26038) 46. Spacer (369A6100−7)
18. Index plug (369D26037) 47. Spacer (369A6100−5)
19. Foot assy (369D292111−101 LH AFT) 48. Rivet (NAS1399C5−3)
(369D292111−102 RH AFT) 49. Rivet (NAS1399C5−2)
20. Screw (NAS1403−1) 50. Rivet (NAS1398C5−3)
21. Lockwasher (MS35338−43) 51. Rivet (NAS1398C5−2)
22. Bracket (369H92111−11) 52. Plug (369D26040)
23. Rivet (ML5100M4−3) 53. Adapter sleeve (369D26032)
24. Nutplate (369H92507) 54. Tube (369D292115)
25. Rivet (MS20605AD3C3) 55. Nut (MS21045−5)
26. Nutplate (NAS1068A3) 56. Washer (AN960KD513)
27. Pin rivet (HL3375K8A6) 57. Bolt (NAS1305−36)
28. Packing (H53113E142) 58. Step assy (369D292028)
29. Rivet (MS20426AD4) 59. Screw (1030−428−8M)
Page 903
MAINTENANCE MANUAL
29
30
34
58
59
28
22
61 23
11 25
27
60
12
24
13 21 26
33
10
46
4
44 7 5
6 47
31
35 32
9
36
39 8
3 19
43 37
42 19
41
2
20
40 1 14
18
57 19
62 21
37 55 15
36
38
49 54 16
17
53
19
56
50
45
48
51 52
G32−1010
Figure 902. Extended Landing Gear Assembly (Current Configuration)
Page 904
MAINTENANCE MANUAL

1. Bolt (MS2125004006) 30. Nutplate (NAS1068A3)
2. Washer (MS20002C4) 31. Pin rivet (HL3375K8A6)
3. Foot assy. (369D292113−103 LH FWD) 32. Pin rivet (HL3375K8A6)
(369D292113−104 RH FWD) 33. Bearing (369D26010−1 LH)
(369D292113−101 LH FWD) (369D26010−2 RH)
(369D292113−102 RH FWD) 34. Foot (369D292113−5 LH AFT)
4. Screw (NAS1403−1) (369D292113−6 RH AFT)
5. Screw (NAS1403−5) 35. Skid assy (369D292114−101/−103)
6. Lockwasher (MS35338−43) 36. Bolt (NAS1223C1 (−101 assy))
7. Bracket (369H92111−11) (NAS1223C4 (−103 assy))
8. Rivet (NAS1921M04−03) 37. Washer (HS306−222)
9. Nutplate (369H92507) 38. Abrasion strip (369H92583)
10. Rivnut (NAS1329C3KB180) 39. Tape (369D292114−3)
11. Rivnut (CCR26455−3−5) 40. Tube assy (369D292114−7/−9)
12. Nutplate (NAS1068A3) 41. Screw (NAS1190C3P3 (−101 assy))
13. Foot (369D292113−5 LH FWD) (NAS1130C3P8 (−103 assy))
(369D292113−6 RH FWD) 42. Rivet (NAS1921M04−03)
14. Bolt (NAS1223C1 (−101 assy)) 43. Nutplate (369H92507)
(NAS1223C5 (−103 assy)) 44. Rivnut (C2R1947−1)
15. Washer (HS306−222) 45. Rivnut (C2R1947−2)
16. Bolt (NAS1104−44) 46. Rivet (NAS1919M04−03)
17. Spacer (369D26013) 47. Fitting (369A6107−3)
18. Nut (NAS21042−4) 48. Rivet (NAS1399D4−4)
19. Abrasion strip (369H6102) 49. Spacer (369D26014)
20. Extension assy (369D26045) 50. Spacer (369D26015)
21. Foot assy (369D292111−105 LH AFT) 51. Rivet (NAS1399C5−3)
(369D292111−103 LH AFT) 53. Rivet (NAS1398C5−3)
22. Screw (NAS1403−1) 55. Plug (369D26040)
23. Screw (NAS1403−5) 56. Adapter sleeve (369D26012)
24. Lockwasher (MS35338−43) 57. Tube (369D292115)
25. Bracket (369H92111−11) 58. Nut (MS21045−5)
26. Rivet (ML5100−M4−3) 59. Washer (AN960KD516)
27. Nutplate (369H92507) 60. Bolt (NAS1305−36)
28. Rivnut (NAS1329C3KB180) 61. Step (369D292028)
29. Rivet (MS20605AD3C3) 62. Screw (1030−428−8M)
Page 905
MAINTENANCE MANUAL
(b). Apply primer (CM318) to replace (b). Coat screw (15) and bolts (16) with
ment spacers (47, Figure 901) and primer and install.
install into skid tube with four
NAS1399D4-4 rivets. (3). Coat mating surface of abrasion strip
and hardware with primer.
(c). Position foot assembly on skid tube
and locate center four holes. (a). Position abrasion strip (14) on aft
section of skid tube.
(d). Mark holes and drill the needed (b). Install abrasion strip using bolts (12)
0.254—0.260 inch (6.452—6.604 and washers (13).
mm) holes as required.
(c). Seal mating edge of abrasion strip
(2). If current foot assembly is used with with 0.060 inch (1.524 mm) bead of
early skid tube: sealing compound (CM425).
(a). Fill center four holes with sealing E. Current Configuration Extended Landing
compound (CM425). Gear Skid Tube Assembly Buildup
(3). Attach extended wire harness to (Ref. Figure 903)

position light and install light in
forward end of skid tube (Ref. Consumable Materials
Figure 903) using screws retained from (Ref. Section 91−00−00)
standard landing gear. Item Nomenclature
CM318 Primer
D. Early Configuration Extended Landing
Gear Assembly Buildup CM425 Sealing compound
(Ref. Figure 901)

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

(Ref. Section 91−00−00) cover splice with silicon tube
Item Nomenclature (CM612) and tie tube with strap
(CM703).
CM318 Primer
CM420 Sealant (b). Cover entire length of extended
CM612 Tube, silicone electrical harness with vinyl sleeve
CM613 Sleeve, vinyl (CM613).
CM703 Tie strap (7). Install extended landing gear aft
CM812 Splice, knife damper assemblies using serviceable
N/A Wire, AWG 20, 47108-B-20 hardware removed from standard
landing gear (Ref. Landing Gear
Damper Replacement).
(1). Align foot and skid assembly with strut
assembly. (8). Apply 0.060 inch (1.524 mm) bead of
sealant (CM420) to mating edge of foot
(2). Slide foot assembly into strut assembly. assemblies and strut assemblies.
(3). Coat ABC bolts with primer (CM318).
(9). Install fairings (Ref. Landing Gear
(4). While primer is wet, install ABC bolts; Fairing Replacement).
torque bolts to 40—60 inch-pounds
(4.52—6.78 Nm). G. Weight and Balance
(5). Seal ABC bolts with sealant (CM420). Weight and balance changes that result from
installation of extended landing gear are listed
NOTE: Leave a minimum of one full service in Table 901. After installation of extended
loop in electrical harness to ensure that ten landing gear, incorporate changes to helicopter
sion is not applied to position lights, if weight and balance record as instructed in
installed. Section 08-10-00.
Weight Arm Moment
lbs (kg) in. (cm) in.−lb/100 (kg mm/100)
Added +94 (+42.638) 92.3 (234.44) +86.8 (+10000.04)
Removed −73 (−33.112) 97.0 (246.38) −70.8 (−815.70)
Change +21 (+9.525) 76.0 (193.04) +16.0 (+184.34)
Page 907
MAINTENANCE MANUAL
AFT DAMPER ASSEMBLY

(BLACK)
LOWER FAIRING
ASSEMBLY STRUT
(TYP)
SEALING
COMPOUND
ABC BOLT
KNIFE SPLICE
STEP
LOWER FAIRING
ASSEMBLY
SEALING COMPOUND
ABC BOLT FOOT ASSEMBLY

(TYP)
SEALING COMPOUND
SKID ASSEMBLY
POSITION
LIGHT
ELECTRICAL HARNESS
SERVICE LOOP
G32−1008
Figure 903. Extended Landing Gear
Page 908
MAINTENANCE MANUAL
Section
32−10−60
Landing Gear
System (600N)
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

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

SERVICING
1. Landing Gear Damper Nitrogen Servicing servicing hose-schrader valve connec
tion.
(Ref. Figure 301) Service landing gear damp
ers equipped with schrader valve according to (6). While the nitrogen is still flowing,
the following steps. tighten servicing hose. Allow nitrogen
pressure to build to the value according
Do not recharge a damper if to part and dash number of damper
CAUTION there is evidence of fluid leak (Ref. Table 301).
age. Recharging of damper will cause fur
To prevent damage to damper or
ther leakage of both gas and damper fluid, CAUTION loss of damper fluid do not open
posing a danger to the helicopter.
schrader valve without pressurizing the
(1). Place helicopter on jacks or hoist and servicing line. If fluid loss occurs, damper
elevate until dampers are fully ex will require overhaul.
tended.. (7). Once pressure level is reached, open
(2). For forward damper servicing, remove schrader valve by turning outside nut
foot support fairings located in passen counter clockwise. Allow system and
ger compartment. For aft damper damper pressure to equalize for a
servicing, open engine access doors. minimum of 2 minutes. If slightly over
pressurized, bleed off excess very
(3). Remove cap from schrader valve and slowly.
connect servicing hose, but do not (8). Close schrader valve by turning the
tighten. outside nut clockwise. Torque nut to
50—60 inch pounds (5.65—6.78 Nm).
(4). Ensure low side of nitrogen pressure
Remove servicing hose and install valve
regulator is backed off to the unpres
cap finger-tight.
surized position. Slowly open the high
pressure nitrogen bottle valve. (9). Remove aircraft from jacks or hoist.
(5). Slowly turn regulator control until (10). Inspect damper for leakage approxi
nitrogen begins to flow at the loose mately two hours after servicing.
Page 301
MAINTENANCE MANUAL
DAMPER
CAP
OUTSIDE NUT
SERVICING HOSE
SCHRADER VALVE
HIGH PRESSURE VALVE
REGULATOR CONTROL
6G32−045
Figure 301. Landing Gear Damper Nitrogen Servicing − On Helicopter
Page 302
MAINTENANCE MANUAL
Table 301. Nitrogen Recharge Pressure

Ambient Temperature 600N6050−33 600N6050−31
° F (° C) Psig (kPa) Psig (kPa)
−40 (−40) 263 (1813) 151 (1041)
−35 (−37) 268 (1848) 153 (1055)
−30 (−34) 272 (1875) 156 (1076)
−25 (−32) 277 (1910) 158 (1089)
−20 (−29) 281 (1937) 161 (1110)
−15 (−26) 286 (1972) 163 (1124)
−10 (−23) 291 (2006) 166 (1145)
−5 (−21) 295 (2034) 169 (1165)
0 (−18) 300 (2068) 171 (1179)
5 (−15) 305 (2103) 174 (1200)
10 (−12) 310 (2137) 177 (1220)
15 (−9) 315 (2172) 179 (1234)
20 (−7) 320 (2206) 182 (1255)
25 (−4) 325 (2241) 185 (1276)
30 (−1) 330 (2275) 188 (1296)
35 (2) 335 (2310) 191 (1317)
40 (4) 340 (2344) 194 (1338)
45 (7) 345 (2379) 197 (1358)
50 (10) 351 (2420) 199 (1372)
55 (13) 356 (2455) 202 (1393)
60 (16) 361 (2489) 205 (1413)
65 (18) 367 (2530) 208 (1434)
70 (21) 372 (2565) 211 (1455)
75 (24) 378 (2606) 215 (1482)
80 (27) 383 (2641) 218 (1503)
85 (29) 389 (2682) 221 (1524)
90 (32) 395 (2723) 224 (1544)
95 (35) 400 (2758) 227 (1565)
100 (38) 406 (2799) 230 (1586)
105 (41) 412 (2841) 234 (1613)
110 (43) 418 (2882) 237 (1634)
115 (46) 424 (2923) 240 (1655)
120 (49) 430 (2965) 244 (1682)
125 (52) 436 (3006) 247 (1703)
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MAINTENANCE MANUAL
Page 304
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LANDING GEAR SYSTEM

1. Landing Gear Strut Replacement (10). Gently work strut around bearing in
fuselage support fitting and remove.
(Ref. Figure 401)
B. Landing Gear Strut Installation
Consumable Materials (1). For access to forward brace, strut and
(Ref. Section 91−00−00) damper, open compartment access
Item Nomenclature doors.
CM318 Primer
(2). For access to aft landing gear attach
CM729 Tape, masking, pressure sensitive ment points, open engine access doors.
NOTE: New bushings must be installed when
A. Landing Gear Strut Removal installing struts. Torquing of the bolt will
press bushing into place.
NOTE: For component disassembly, refer to
applicable section. For removal, two persons (3). Gently work struts around bearings in
are needed. fuselage support fittings.
(1). Jack up or hoist helicopter until skid (4). Install attaching hardware with new
assemblies clear surface by 10—20 bushing coated with wet primer
inches (25—50 cm) (Ref. Section (CM318).
07-00-00).
(5). Torque nut to 85—110 inch-pounds
(2). Remove skid assemblies (Ref. Para (9.60—12.43 Nm) plus drag torque
graph 3, Landing Gear Skid Replace and install cotter pin.
ment).
(6). Check for minimum 0.010 inch (0.254
(3). Pull strut fairing fillet downward mm) gap between washer and air
against spring tension and secure with frame clevis at slotted bushing.
tape (CM729).
NOTE: Install forward damper upper bolts
NOTE: Bushings must be removed from strut with bolt heads facing aft. Install all other
to enable strut to clear bearing in fuselage damper bolts with bolt head facing forward.
support fittings. (7). Install damper (Ref. Paragraph 2,
(4). For access to forward brace, strut and Landing Gear Damper Replacement).
damper, open compartment access (8). Align inboard end of each brace with
doors. mating bearing in fuselage supporting
fitting and install attaching hardware.
(5). For access to aft landing gear attach
ment points, open engine access doors. (9). Torque nut to 60—85 inch-pounds
(6.78—9.60 Nm) plus drag torque
(6). Disconnect brace and damper from and install cotter pin.
strut.
(7). Remove hardware from strut pivot mm) gap between washer and air
point. frame clevis at slotted bushing.
(8). Use an ezy-out to pull both bushings (11). Secure electrical bonding jumpers to
from strut clevis at pivot point. airframe.
(9). Remove electrical bonding jumper (12). Align outboard end of each brace with
attaching aft strut to airframe. mating holes in strut.
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MAINTENANCE MANUAL
Do not over-tighten brace-to- NOTE:

CAUTION strut hardware. D Always be sure that replacement damper
is correct for the helicopter.
(13). Attach brace to strut with attaching D Check for proper alignment of cap torque
hardware. stripes before installation.
D Install aft dampers with schrader valves
(14). Torque nut to 2—10 inch-pounds facing aft.
D Install fwd dampers with schrader valves
and install cotter pin.
facing forward.
(15). Reinstall skid assemblies (Ref. Para (2). Install replacement damper in upper
graph 3, Landing Gear Skid Replace and lower mounting position with
ment). attaching hardware. Ensure bushings
are in place.
(16). Remove skid supports, lower helicopter, NOTE: Install forward damper upper bolts
and remove jacks. with bolt heads facing aft. Install all other
damper bolts with bolt head facing forward.
(17). Close or replace all access doors. (3). Align forward upper damper bearing
with airframe and install attaching
hardware.
2. Landing Gear Damper Replacement
(4). Torque nuts to 60—85 inch-pounds
(Ref. Figure 401) (6.78—9.60 Nm) plus drag torque
A. Landing Gear Damper Removal (5). Check for minimum 0.010 inch (0.254
mm) gap between washer and air
frame clevis at slotted bushing.
(1). Jack up or hoist helicopter on level
surface until landing gear skids just (6). Align aft upper damper bearing with
clear resting surface. (Ref. Section airframe and install attaching hard
07-00-00) ware.
(7). Torque nuts to 95—110 inch-pounds
(2). For forward damper removal, remove (10.73—12.43 Nm) plus drag torque
footwell fairings located in passenger and install cotter pin.
compartment. For access for aft damper
removal, open engine access doors. (8). Check for minimum 0.010 inch (0.254
(3). Remove hardware (except bushings) frame clevis at slotted bushing.
attaching damper assemblies to (9). Align lower bearing of damper (forward
fuselage attachment fittings and and aft) with mating holes in strut and
landing gear struts. install attaching hardware.
(10). Torque nut to 95—110 inch-pounds
(4). Remove damper from aircraft.
B. Landing Gear Damper Installation
(1). Jack up or hoist helicopter on level frame clevis at slotted bushing.
surface until landing gear skids (Ref.
Section 07-00-00) just clear resting (12). Install footwell fairings and close
surface. engine access doors.
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MAINTENANCE MANUAL
AFT FOOT
ASSEMBLY (REF)
LANDING GEAR
SKID
FRONT FOOT ABRASION

ASSEMBLY (REF) STRIP
ABRASION
STRIP
ABRASION
STRIP
ABRASION
STRIP
AFT BRACE
ASSEMBLY
AFT DAMPER
ASSEMBLY
FUSELAGE
FITTING FRONT DAMPER
ASSEMBLY
AFT STRUT
ASSEMBLY
BONDING
JUMPER
FRONT STRUT
ASSEMBLY
FRONT BRACE
ASSEMBLY
AFT DAMPER AFT BRACE

ASSEMBLY (REF) ASSEMBLY (REF)
FRONT DAMPER AFT STRUT

ASSEMBLY (REF) ASSEMBLY (REF)
FRONT STRUT
ASSEMBLY (REF) MID FAIRING
MID FAIRING
STEP BOLT
ASSEMBLY WASHER LOWER FAIRING
NUT
LOWER FAIRING
BOLT
WASHER
NUT
G32-1060_401_1
Figure 401. Landing Gear and Damper Installation
Page 403
MAINTENANCE MANUAL
3. Landing Gear Skid Replacement (b). Open underfloor compartment or

engine compartment doors for access
(Ref. Figure 401) to strut cutout in fuselage skin. Have
an assistant push down on upper
A. Landing Gear Skid Removal guide with suitable tool (wood dowel
or equivalent), to relieve spring
(1). Jack up or hoist helicopter until skid tension.
assemblies clear surface by 10—20
inches (25—50 cm). (Ref. Section (c). With spring tension off guide, remove
07-00-00) screws attaching fillet to upper guide.
Slowly relax dowel pressure on guide
(2). Remove mid and lower fairings. until springs fully expand.
(3). Remove bolts attaching forward and aft (d). Carefully spread fillet at trailing
feet to forward and aft struts. edge and remove in forward direc
tion.
(4). Simultaneously, slide front and rear (3). Remove mid fairing as follows.
feet from struts.
(a). Remove hardware that secure
B. Landing Gear Skid Installation trailing edge of mid fairing.
(1). Simultaneously, slide front and rear (b). Remove hardware that secure fairing
feet onto struts. to strut bracket.
(c). Carefully spread trailing edge of
(2). Install bolts attaching forward and aft
fairing and remove in forward
feet to forward and aft struts; torque
direction.
bolts to 95—110 inch-pounds
(10.73—12.43 Nm) plus drag torque. B. Landing Gear Fairing Installation
(3). Install mid and lower fairings. (Ref. Figure 402 and Figure 403) Following
instructions apply to all four fairing assem
4. Landing Gear Fairing Replacement blies.
(1). Install mid fairing as follows.
A. Landing Gear Fairing Removal
(a). Assemble upper guide, pin assembly,
(Ref. Figure 402 and Figure 403) The following inner guide half, outer guide half,
instructions are typical for and apply to all springs and lower support on landing
four fairing assemblies. gear strut (guide pins must be
installed through matching holes of
(1). Remove lower fairing from fairing lower guide).
assembly as follows.
(b). Wedge temporary holding device
(a). Remove attaching hardware that between upper guide and strut to
secures lower fairing to two strut keep pins engaged.
brackets, and that secures trailing
edge of lower fairing.
NOTE: Use two small wood blocks or any simi
lar suitable means to keep springs com
(b). Carefully spread trailing edge of pressed. Device used must be small enough
lower fairing and remove in forward to be removed through strut cutout in skin
direction. after fillet is assembled.
(c). Carefully spread trailing edge of
(2). Remove fillet from upper fairing fairing and position fairing on strut
assembly as follows. bracket(s) and lower guide.
(a). Remove hardware that secure (d). Install hardware in top hole of
trailing edge of fillet. trailing edge of mid fairing.
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MAINTENANCE MANUAL
(2). Install fillet as follows. (e). Check for smooth telescoping action
of fairing into fillet by manually
sliding fillet up and down several
(a). Carefully spread trailing edge of fillet times.
and position about upper guide.
(f). Close access doors.
(b). Have an assistant remove temporary (3). Install lower fairing as follows.
holding device and push down on
upper guide with suitable tool (wood (a). Carefully spread trailing edge of
dowel, etc). fairing and position under the mid
fairing and over the lower strut
bracket.
(c). Install hardware securing fillet to
upper guide. (b). Secure to upper and lower strut
brackets with hardware.
(d). Install hardware to secure fillet (c). Secure fairing trailing edge with
trailing edge together. attaching hardware.
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MAINTENANCE MANUAL
AFT FILLET
ASSEMBLY
FORWARD
FILET ASSEMBLY
MID FAIRING
STRUT
AFT STRUT
MID FAIRING
SEAL
LOWER FAIRING
FLAP
LOWER FAIRING
SCREW
A WASHER
NUT (5 PL)
SCREW A
WASHER A
(2 PL)
A
SCREW
WASHERS (2 EA) SCREW
NUT (5 PL) WASHERS (2 EA) (2 PL)
FORWARD LEFT SIDE SHOWN AFT LEFT SIDE SHOWN

FORWARD RIGHT SIDE IS OPPOSITE AFT RIGHT SIDE IS OPPOSITE
BRACKET
ASSEMBLY
SCREW
WASHER (2 PL)
FAIRING ASSEMBLY
STRUT RIVET
FLAP
(AFT FAIRING ONLY)
SECTION A - A
6G32 047A
Figure 402. Fairing Installation
Page 406
MAINTENANCE MANUAL
NAS603-9P SCREW
AN970-3 WASHER
600N6081-1
WASHER (RUBBER)
NAS603-9P SCREW
AN970-3 WASHER
600N6081-1
LOWER FORWARD FAIRING WASHER (RUBBER)
600N6081-1 EARLY CONFIGURATION
WASHER (RUBBER)
NAS603-9P SCREW
AN970-3 WASHER
LOWER FORWARD FAIRING 600N6081-1

CURRENT CONFIGURATION WASHER (RUBBER)
NAS603-9P SCREW
AN970-3 WASHER
600N6081-1
WASHER (RUBBER)
600N6081-1
WASHER (RUBBER)
UPPER FORWARD FAIRING

ALL CONFIGURATIONS
600N6081-1
AFT FAIRING WASHER (RUBBER)
G32-1060-403-1
Figure 403. Landing Gear Rubber Washer Locations
Page 407
MAINTENANCE MANUAL
Page 408
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

INSPECTION/CHECK
1. Landing Gear Inspection (3). Inspect skid for dents. If dents are more
than a depth of 0.20 inch (5.08 mm),
(Ref. Figure 401) they will require repair.
NOTE: If landing gear is installed, do the in (4). Inspect for punctures and cracks.
spection with helicopter skids clear of
ground. (5). Do the fluorescent penetrant inspection
of all crack areas, and of those areas
(1). Inspect skids, skid abrasion strips, adjacent to all punctures. These areas
struts, feet, braces and fairings for will require repair (Ref. Section
dents, cracks, loose components or 20-90-00).
rivets, loose nuts and for missing
hardware. (6). Inspect from aft end of tube to a point
10 inches (25.4 cm) forward of aft
(2). Inspect skid-to-foot and foot-to-strut strut for scratches and nicks.
attachments for loose bolts. Check aft
foot-to-bearing rivet installation for (7). Inspect from forward end of tube to 10
security. inches (25.4 cm) forward of aft strut for
scratches and nicks. If scratches and
(3). Using 10X glass and bright light, nicks are more than a length of 0.25
visually inspect area at, around and inch (6.35 mm) and a depth of 0.020
between foot-to-strut attach bolts not inch (0.508 mm), they will require
covered by sealant for cracks and repair.
corrosion.
(8). Inspect abrasion strips for minimum
NOTE: If cracks or corrosion other than light
thickness of 0.040 inch (1 mm), damage
surface corrosion is found, replace affected
and for loose bolts and screws.
part.
(4). Inspect keel beam areas where the (9). Check skid extension rivet attachment
strut assemblies attach for loose for security.
bearings, condition of hardware and
(10). Check condition of plug installed in
strut adapters.
skid extension.
(5). Check condition of beaded seal around
(11). Check aft foot bearing and extension for
edges of all rigid-mounted skid tube
wear, damage and corrosion.
components.
2. Landing Gear Skid Inspection 3. Landing Gear Strut Inspection
(Ref. Figure 401) (Ref. Table 801)
NOTE: If landing gear assembly has not been (1). Repair elongated, enlarged or worn
removed from helicopter, do the following holes in strut, either inboard or out
steps (1). and (2). before proceeding with in board (Ref. CSP-SRM-6).
spection.
(2). Replace strut if cracked; if dents in
(1). Jack helicopter until landing gear strut are more than 0.060 inch (1.524
dampers are fully extended. (Ref. mm) depth; or, if scratches and repair
Section 07-00-00) area depth would be more than 0.010
inch (0.254 mm) when measured to
(2). Remove lower fairing from two-piece surrounding unrepaired surface. (Ref.
fairing assembly. Section 32-00-00)
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MAINTENANCE MANUAL
4. Landing Gear Damper Inspection (d). Lower and raise tailboom below and
above the normal at-rest position
(Ref. Table 601 and Figure 401) three times. On the last cycle, allow
the tailboom to slowly rise to the
NOTE: It is normal for a thin hydraulic oil film at-rest position.
to remain on damper as a result of wiping (e). Measure and record dimension from
contact with piston seal. Newly-installed bottom of upper end cap to top of
dampers can also have slight oil seepage barrel on all four damper assemblies.
from oil trapped in end cap threads during
damper assembly. Neither of these should (f). Repeat steps (d). and (e). two more
be considered damper leakage or cause for times.
damper replacement. (g). Determine average extension from all
six readings for each damper assem
(1). Inspect for hydraulic oil leakage. If bly. Remove and overhaul any
leakage is visible, wipe oil from damper damper assembly not meeting
after last flight of the day. Re-inspect dimensions (Ref. Table 601).
the following day for oil leakage. If NOTE: If two damper assemblies fail to meet
leakage persists, replace damper. the minimum extension (Ref. Table 601), re
place the damper having the greater
(2). With helicopter on jacks, inspect amount of deflection with a known service
damper assemblies for evidence of able damper and repeat steps (a). thru (g). If
bearing looseness in upper and lower the original damper again fails to meet min
caps, worn bearings (excessive radial imum extension requirements, replace it
play), loose or cracked caps and oil with the known serviceable damper, rein
leakage. Any misalignment of torque stall the first damper and repeat steps (a).
stripes on caps, piston and barrel thru (g). This will determine whether one or
indicates loosening of caps. Replace both dampers require overhaul. For owners
immediately and repair removed and operators having suitable equipment,
damper. any damper not meeting minimum exten
sion requirements can be bench-checked.
(3). Inspect damper attaching hardware for Dampers meeting specifications can be re
security. turned to service if other defects are not not
ed.
NOTE: The landing gear damper assemblies 5. Forward Cabin Entry Step Inspection
are to be checked at a helicopter gross
weight of 2130—2230 pounds (967—1012 (1). Remove landing gear fairing assembly.
kg) at a longitudinal CG of 94 ±1, exclusive (2). Inspect step-to-strut attachment for
of skid mounted flotation gear. Place the he loose attaching hardware by checking
licopter on a smooth concrete or equivalent for relative motion between mating
surface (not asphalt). parts.
(a). Raise and lower tailboom above and (3). Inspect welded joint of step for cracks.
below the normal at-rest position (4). Inspect safety walk tape for condition
three times. On the last cycle, allow and security. Replace unserviceable
the tailboom to slowly settle to the tape.
at-rest position.
(5). Install landing gear fairing assembly.
(b). Measure and record dimension from 6. Landing Gear Fairing Inspection
bottom of upper end cap to top of
barrel on all four damper assemblies. (Ref. Figure 402)
(1). Inspect fairing support brackets for
(c). Repeat steps (a). and (b). two more security of attachment to strut, cracks
times. and deformation.
Page 602
MAINTENANCE MANUAL
(2). Inspect fairing seals for deterioration Table 601. Minimum Damper Extension
and bonding.
(3). Inspect fuselage rubbing plate for inches (cm)
security of bond and excessive wear.
Fwd 1.60 (4.06)
(4). Inspect rubber washers for cracks or
deterioration. Aft 1.71 (4.34)
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Page 604
MAINTENANCE MANUAL
LANDING GEAR SYSTEM

REPAIRS
1. Landing Gear System Repairs (3). Install new abrasion strip. Torque bolts
to 12—15 inch-pounds (1.36—1.69
(1). Repair scratches and nicks by smooth Nm) plus drag torque.
ing sharp edges.
(4). After installation, seal around bolts and
(2). Repair elongated, enlarged or worn all of parting edges of abrasion strip
holes in strut, either inboard or out next to skid tube with an approximate
board. 0.060 inch (1.524 mm) bead (fillet) of
(3). Repair bolt holes at large end of brace sealing compound (CM426) to make
that attaches to strut. watertight.
(4). Replace strut; if cracked, if dents in 3. Ground Handling Bolt Replacement

strut are more than 0.060 inch (1.524
mm) depth or if scratched and re (Ref. Figure 401)
paired area depth would be more than
0.010 inch (0.254 mm) when mea (1). Remove nut, washers and spacer from
sured to surrounding unrepaired skid tube.
surface.
(2). Slide bolt with washers and spacer from
(5). Replace defective or badly damaged skid tube.
fairing.
(3). Install, in order, bolt, washer, new
(6). Replace cracked, dented or distorted spacer and washer through skid tube
braces. from outside-to-inside.
(7). Repair or replace damaged skid tube. (4). Install, in order, washer, spacer, washer
and nut onto bolt. Torque nut to 10—20
(8). Replace center beam-to-landing gear inch-pounds (1.13—2.26 Nm) plus
attachment bearings that are more drag torque.
than 0.040 inch (1.016 mm) axial
play. 4. Safety Walk Tape Replacement
(9). Repair loose or defective pins and nuts (Ref. Figure 401)
securing foot to bearing; replace
defective bearing.
2. Abrasion Strip Replacement (Ref. Section 91−00−00)
Item Nomenclature
(Ref. Figure 401)
CM724 Tape, non-slip
Item Nomenclature (1). Carefully pull or scrape away damaged
CM426 Sealing compound tape.
(2). Remove all residual adhesive from step

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

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

Consumable Materials rusty, or if free length is less than 8.72
(Ref. Section 91−00−00) inches (22.149 cm).
Item Nomenclature
CM412 Adhesive, bonding, vulcanized (5). Replace fillet if teflon strip is loose or
badly worn.
(1). Replace an excessively damaged lower (6). Replace damaged strut bracket.
fairing. Remove rivets, locate new part and
install blind rivets. Use next larger size
(2). Replace damaged fairing bracket or rivets if mating holes in strut are
lower guide. Remove rivets, locate new enlarged.
part and install blind rivets. Use next
larger size rivets if mating holes in (7). Replace unserviceable rubber seals; use
strut are enlarged. adhesive (CM412).

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

Strut 0.060 (1.524) (1) (1) No cracks No holes

allowed allowed
Brace 0.050 (1.270) 0.010 (0.254) 0.005 No cracks No holes

Damper assembly 0.060 (1.524) 0.010 (0.254) 0.010 No cracks No holes

(5) (0.254) allowed allowed
Fittings 0.010 (0.254) 0.010 (0.254) 0.010 No cracks No holes

Aft foot 0.060 (1.524) 0.060 (1.524) 0.010 No cracks No holes

Foot bearing 0.010 (0.254) 0.010 (0.254) 0.010 No cracks No Holes

Page 802
MAINTENANCE MANUAL

Skid extension 0.010 (0.254) 0.010 (0.254) (4) 0.010 No cracks No holes
(4) (0.254) (4) allowed allowed
NOTES:
(1) For other repair data, refer to CSP−SRM−6.
(2) Repair of minor skid tube damage on forward (curved) section is not required, but surface finish must be
restored.
(3) Hole must be plugged with correct size blind rivet.
(4) No damage is allowed on skid extension where skid and sleeve are attached.
(5) No dents allowed in damper barrel.
Page 803
MAINTENANCE MANUAL
Page 804
MAINTENANCE MANUAL
Section
32−40−00
Ground Handling
Wheels
(369D/E/FF − 500N)
MAINTENANCE MANUAL

1. Ground Handling Wheel Assembly (2). With ground handling wheels in the
retracted position, align and engage the
The standard ground handling wheel assem skid fittings.
blies provide a means of moving the helicopter
by hand or by towing. NOTE: Slide wheel assembly for and aft to en
sure locking mechanism is securely locked
The special ground handling wheel assemblies into place.
for use with helicopters equipped with
emergency or utility floats provide a means of (3). Install jack handle over the wheel
moving the helicopter by hand only. assembly socket, install lock pin and
rotate handle downward to lower the
A. Ground Handling Wheel Description and
wheels and raise the helicopter.
Operation
(1). Standard ground handling wheel Hold downward pressure on
WARNING jack handle until the extend
assembly consists of one detachable
jack handle and two two-wheeled lock snaps into locked position. If the
jacking assemblies that can be lock is not properly engaged and the
straddle-mounted to the left and right handle is released, the upward swing of
landing gear skids by use of existing the handle could cause serious person
ground handling wheel fittings. The al injury.
wheels are manually lowered with a
detachable jack handle and are held in (4). Check that the extend lock is engaged;
the down position (helicopter raised on then release downward pressure and
wheels) by a mechanical lock. The remove jack handle.
jacking assemblies are equipped with
two tow bar attach fittings for towing. (5). Install second ground handling wheel
assembly on the other skid in the same
(2). Special ground handling wheels are manner.
needed in place of standard ground
handling wheel assemblies for moving a 3. Special Ground Handling Wheel
helicopter equipped with emergency or Installation and Use
utility floats. These wheel assemblies
are specially designed for use with (Ref. Figure 201)
emergency floats and raise the landing
skids higher off the ground than Damage can result from push
standard ground handling wheels. A
CAUTION ing up and/or pulling down on
channel provides support for the the tail boom to facilitate installation of spe
underside of the landing gear skid. A cial ground handling wheels.
rubber pad on the channel furnishes
sufficient skid retaining friction NOTE: When the helicopter is jacked from one
without need for attachment of wheel side only, a cushion saddle-type support
assembly to skid. Guards above the should be placed under the tail boom at the
wheel on each side of the channel jacking pad location for extra stability.
prevent wheel chafing of floats.
(1). Install and use special ground handling
2. Standard Ground Handling Wheel wheel assemblies as follows.
Installation and Use
(a). Jack up one side of the helicopter for
(1). Position ground handling wheel clearance to place ground handling
assembly over the skid tube at the wheel assembly under the landing
location of the skid fittings. gear skid.
Page 201
MAINTENANCE MANUAL
WHEEL ASSEMBLY
HANDLE
G32-4000-201-1
Figure 201. Ground Handling Wheel Assembly (Standard)

(b). Position ground handling wheel (6). To remove axle shaft from housing,
assembly below the ground handling remove roll pin and slide shaft from
fittings, which is the approximate housing.
center of gravity (CG) point.
5. Standard Ground Handling Wheel
4. Standard Ground Handling Wheel Re−assembly (Early Configuration)
Disassembly (Early Configuration) (1). If previously removed, install axle shaft
into housing and secure with roll pin.
(1). Remove cotter pin and washer from
axle shaft and slide hub-and-wheel (2). Using suitable bearing press, install
assembly off axle. bearings in hub.
(2). Remove three nuts securing wheel to (3). Install washer, hub assembly and
hub. washer on axle. Shim hub assembly,
0.010 inch maximum, using AB2578-24
Severe personal injury or washers, as required, between bearing
WARNING damage to property can oc and outer washer and install cotter pin.
cur if tire is not deflated before at
tempting to separate wheel halves. (4). Using talcum powder, insert tube into
tire and install on wheel halves.
(3). Deflate tire and remove six nuts, (5). Secure wheel halves together using six
washers and screws securing wheel screws, washers and nuts.
halves.
(6). Inflate tire in accordance with man
(4). Remove tire and tube from wheel. ufacturers specifications.
(5). Using suitable bearing press, remove (7). Install wheel on hub assembly using
bearings from hub. three nuts and washers.
Page 202
MAINTENANCE MANUAL
BUSHING
LOCK
RETAINER ROLL PIVOT PIN
PIN SPRING
ROLL PIN
LOCK PIN
HANDLE
INNER
WHEEL
TIRE
OUTER WHEEL TUBE BASE BUSHING
ROLL
PIN HUB
RACE
BEARING
WASHER
NUT
DUST CAP
COTTER PIN
ROLL PIN
AXLE
SEAL
BEARING
RACE
G32-4000-202-1
Figure 202. Ground Handling Wheel Assembly/Disassembly
Page 203
MAINTENANCE MANUAL
6. Standard Ground Handling Wheel (7). Secure wheel halves together using six
Disassembly (Current Configuration) screws, washers and nuts.
(Ref. Figure 202) (8). Inflate tire in accordance with man
ufacturers specifications.
(1). Remove three nuts and washers
securing wheel and tire assembly to (9). Install wheel on hub assembly using
hub and axle assembly. three nuts and washers.
(2). Remove dust cap, cotter pin, nut and 8. Standard Ground Handling Wheel
washers from hub and axle assembly. Servicing
Severe personal injury or At regular intervals, Ground Handling Wheel

WARNING damage to property can oc Assemblies should be maintained to provide
cur if tire is not deflated before at safe use and longer life of components.
tempting to separate wheel halves. (1). Ensure tire pressure is within manufac
turer's specifications.
(3). Deflate tire and remove six nuts,
washers and screws securing wheel (2). Grease bearing using MIL-G-81322,
halves. Mobil Grease 28 or alternate grease
MIL-G-25537, Aero Shell using
(4). Remove tire and tube from wheel. available grease zerk (primary method)
Do not remove spacer from hub or hand pack (alternate method).
CAUTION body. Spacer is a close tolerance (3). Remove excess play of hub-to-axle by
press fit and should not be removed. inserting AB2578-24 washers, as
required, between bearing and outer
(5). Remove seal, bearings and races from washer to maintain 0.010 inch (0.254
hub body. mm) axial play.
(6). To remove axle shaft from housing, 9. Special Ground Handling Wheel
remove roll pin and slide shaft from Disassembly
housing.
(Ref. Figure 204)
7. Standard Ground Handling Wheel
Re−assembly (Current Configuration) (1). Remove cotter pin, nut and washer and
remove wheel assembly.
(Ref. Figure 202)
(2). To remove axle shaft, remove slotted
(1). If previously removed, install axle into pin and slide shaft from housing.
housing and secure with roll pin.
(3). Using suitable bearing press, remove
(2). Install races, bearings and seal in hub. bearings from hub.
(3). Install hub assembly on axle shaft and 10. Special Ground Handling Wheel
secure with washer and nut. Re−assembly
(4). Tighten nut until there is a maximum (Ref. Figure 204)

of 0.010 inch (0.254 mm) axial play. (1). Insert axle shaft into housing and
Remove unwanted axial play by insert slotted pin.
inserting AB2578-24 washers, as
required, between bearing and outer (2). Using suitable bearing press, install
washer. bearings into hub.
(5). Install cotter pin and dust cap. (3). Install wheel on axle using washer, nut
and cotter pin. Adjust axial play, 0.010
(6). Using talcum powder, insert tube into inch (0.254 mm) maximum, using
tire and install on wheel halves. AN960C1016 washers as required.
Page 204
MAINTENANCE MANUAL
11. Special Ground Handling Wheel Servicing solid rubber tires and therefore require no
(Ref. Figure 204) The special ground handling servicing.
wheel assemblies have sealed bearings and
SKID TUBE
RUBBER PAD
(NOTE 1)
SKID FITTING
(REF) (NOTE 2)
FAIRING GUARD
WELD SUPPORT
STRUT
EMERGENCY FLOAT
CONTAINMENT COVER
SHAFT
RUBBER TREAD WHEEL
NOTES:
1. LANDING GEAR SKID TUBE UNDERSIDE RESTS ON
RUBBER PAD AND IS SUPPORTED BY WELD SUPPORT
WITHOUT RESTAINING ATTACHMENT.
CAUTION: BE SURE THAT FLOAT CONTAINMENT 2. NOT USED WITH GROUND HANDLING WHEELS SHOWN.
COVER CLEARS AND IS NOT PINCHED BY 3. MAXIMUM LOAD RATE 800 LBS. (363 KG) AT 8 RPM.
HANDLING WHEEL ASSEMBLY.
G32-4000-203-1
Figure 203. Special Ground Handling Wheel Assembly (Float Type)
Page 205
MAINTENANCE MANUAL
PAD
WELD ASSEMBLY
WHEEL
WASHER COTTER PIN
SLOTTED PIN
WHEEL SHAFT
NUT
G32-4000-204-1
Figure 204. Special Ground Handling Wheel Assembly/Disassembly
Page 206
MAINTENANCE MANUAL
Section
32−40−60
Ground Handling
Wheels (600N)
MAINTENANCE MANUAL

1. Ground Handling Wheel Assembly The jack retains a vertical position
during raising and lowering of the
The standard ground handling wheel assem wheels.
blies provide a means of moving the helicopter
by hand or by towing. The ram of the jack is in constant
contact with the upper cross frame of
A. Ground Handling Wheel Assembly the main body, providing vertical
Description and Operation pumping leverage forcing the wheels
down.
The ground handling wheel set consists of two (4). Attach Cradle and Main Frame Body:
dual wheel assemblies, which are designed to
support a fully equipped helicopter. The wheel The attach cradle is attached to the
assembly consists of two pneumatic tires, rims, main frame body by means of two pins
spindles, hydraulic jack and attach cradle. with cotter pins. The contoured cradle
is slotted to lock onto the skids.
(1). Tires:
2. Ground Handling Wheel Assembly
The tires are 10 ply with a maximum Maintenance
rating of 1120 lb at 65 psi (508 kg at (1). Ensure tire pressure is within manufac
448 kPa). turer's specifications.
(2). Rims: (2). Inspect tires for wear and cuts, none
allowed.
The rim rotates on a spindle by means
of inner and outer tapered roller (3). Inspect wheels for cracks and defects,
bearings with an external grease fitting none allowed.
on the hub for periodic servicing. (4). At regular intervals, repack wheel
bearings and grease spindle assembly
(3). Hydraulic Jacks: guides.
A six ton jack is held in place on the (5). At regular intervals, inspect hydraulic
main frame by a support plate. jacks for proper fluid levels.
Page 201
MAINTENANCE MANUAL
NOTE
JACK FRAME ASSEMBLY
GUIDE
NUT
SPINDLE ASSEMBLY
SEAL
HANDLE ASSEMBLY WHEEL BEARING
TIRE
WHEEL BEARING
GUIDE
CLEVIS HUB CAP
COTTER PIN
CARRIER
SPINDLE
WASHER
NOTE:
PERIODICALLY GREASE SPINDLE-TO-GUIDE
INTERFACE FOR PROPER OPERATION. G32-4060-201-1
Figure 201. Ground Handling Wheel Assembly
Page 202
MAINTENANCE MANUAL
Section
32−81−00
Utility Float System
(369D/E)
MAINTENANCE MANUAL
UTILITY FLOAT SYSTEM

1. Utility Float Description and Operation (3). Place BATTERY-OFF-EXT PWR
switch at BATTERY. Actuate POS LT
Utility floats consists of neoprene airtight switch to the ON position. Observe that
chambers separated by internal walls that left and right position lights illuminate.
provide six individual watertight compart Place all switches at OFF position.
ments. Skid attachment strips (girts), bonded
to underside of floats, are bolted to landing 2. Utility Float Inspection
gear skids and extensions. Floats are inflated
to a normal operating pressure of 2.0 psig (14 (1). Inspect float chambers for correct air
kPa). Relief valves release air pressure if pressure.
compartment pressure becomes excessive. A
stabilizer assembly is attached at the aft end (2). Inspect float bags for abrasion and
of the skid tube extension. chafing.
NOTE: If a helicopter with utility floats is tilted (3). Inspect pressure relief and fill valves
back on the tail skid to install ground handl for condition and closure.
ing wheels, approximately 1 pint (0.437 li
ter) of oil is trapped in the tail rotor trans A. Skid Tube and Extension Assembly
mission. This condition gives a false sight Inspection
plug oil level indication immediately after
return to a level attitude. After ground ru Inspection of skid tube and extension assembly
nup, oil level indication is normal. is identical to that described in Section
32-10-00.
A. Utility Float Operational Check
B. Utility Float Repair
With helicopter on the ground and utility
floats inflated to normal operating pressure, do Repair materials and information are avail
the following operational checks: able from the float manufacturer. Make
repairs to utility floats using materials
(1). Check all float compartments for 2.0
according to manufacturer's instructions.
psig (14 kPa).
NOTE: Changes in atmospheric pressure, and 3. Utility Float Troubleshooting
temperature of float compartments affects
pressure gage readings. A temperature Refer to Table 201 for troubleshooting informa
change of 1 degree equals 0.032 psig (0.2206 tion. Troubles presented are listed in order of
kPa). possible occurrence during performance of
operational check. This information is pro
(2). Check for pressure drop with pressure vided to aid in isolating faults found during
gage that indicates 0—15 psi (0—103 operational check or normal operation of the
kPa), graduated in 0.5 psi (3.447 kPa) system. The fault is then removed by repair or
increments. Maximum allowable replacement to return the system to trouble-
pressure drop in 24 hours is limited to free operation. Troubleshooting and repair of
0.5 psig (3.447 kPa) for each compart internal components of the float is beyond the
ment. scope of this section.
Page 201
MAINTENANCE MANUAL
Table 201. Troubleshooting Utility Floats

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

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

A. Utility Float Removal Item Nomenclature
Prior to removal of utility floats, jack or hoist
CM318 Primer
helicopter until landing gear dampers are fully
extended and landing gear skid tubes are at CM425 Sealing compound
least six inches (15cm) from ground. Skid and CM717 Tape, pressure sensitive
fairing assemblies must be removed to remove
float assemblies Ref. Section 32-10-00). NOTE: Prior to assembly, apply primer
(CM318) to all mating surfaces.
Maintain helicopter in level at
CAUTION titude during jacking or hoist (1). On early configuration extended
ing. Do not raise one side of helicopter at a landing gear, coat abrasion strip with
time. zinc chromate putty (CM209) and
install using screws.
(1). Remove position light cover screws, (2). Install bolt covers using existing screws
then remove cover. Remove position and wrap with two overlapping layers
light mounting screws and position of tape (CM717).
light. Retain electrical wire for installa
tion. (3). Install tyrap bracket on forward struts.
(4). Align extension and bearing sleeve
(2). Remove bolts and washers attaching
holes; install rivets using wet primer
stabilizer assembly to aft section of
(CM318).
floats.
(5). On early configuration extended
(3). Open fill valve at each of six float landing gear, install skid tube extension
chambers. A suction device such as a as follows:
vacuum cleaner speeds air evacuation.
(a). Install indexing plug in float kit
extension tube.
(4). Remove bolts, washers, gravel guards
and abrasion strip attaching float to (b). Align indexing plug tabs with slots in
skid assembly and skid extension. foot bearing sleeve on helicopter;
install indexing plug and forward end
(5). Depress float around strut assemblies of extension tube over bearing sleeve.
and pull float free from skid tube Use care not to damage packing
assembly and skid extension. during installation.
Page 202
MAINTENANCE MANUAL
(c). Align bolt holes in bearing sleeve, bolts to 25—35 inch-pounds

indexing plug and extension tube; (2.82—3.95 Nm).
install rivets with wet primer.
(9). Connect wiring to position light then
(d). Coat mating surfaces of abrasion install position light with screws.
strip with zinc chromate putty. Install cover and secure with screws.
(e). Install abrasion strip on extension 5. Skid Tube Extension Replacement
tube with rivets and wet primer.
(Ref. Figure 901)
(f). Seal all edges of abrasion strip with
approximately 0.060 (1.524 mm) bead A. Skid Tube Extension Removal
of sealing compound (CM425). (1). Remove bolts and washers; then
remove stabilizer support from aft end
(6). Position floats on skid and extension
of skid extension.
assembly. Align bolt holes in float girt
and skid assembly. Secure floats in (2). Remove bolts and nuts attaching
place using gravel guards, abrasion extension to skid tube assembly.
strips, bolts and washers. Coat bolts
and washers with primer and torque to (3). Separate skid extension from skid tube.
25—35 inch-pounds (2.82—3.95
B. Skid Tube Extension Installation
Nm).
(1). Insert skid extension into aft section of
(7). Position stabilizer cap on skid tube skid tube.
extension. Coat mating surfaces with
sealing compound and secure with bolts (2). Align bolt holes and secure in place
and washers. using bolts and nuts as applicable.
(8). Position stabilizer assembly on aft (3). Position stabilizer support on aft end of
section of skid extension and secure in skid extension and secure in place
place using bolts and washers. Torque using bolts and washers.
Page 203
MAINTENANCE MANUAL
STABILIZER
ASSEMBLY
SKID TUBE
EXTENSION
LOWER
FAIRING
FLOAT
FILL VALVE
(TYP)
PRESSURE RELIEF
VALVE (TYP)
ABRASION STRIP
STEP ASSEMBLY
BOLT COVER
GIRT (TYP)
POSITION LIGHT
GRAVEL GUARD
(NOTE)
BOLT COVER
EXTENDED LANDING GRAVEL GUARD

ELECTRICAL (NOTE)
GEAR SKID TUBE WIRE
RUBBER PAD
LANDING GEAR STRUT
ABC BOLTS
(TYP)
RUBBER PAD
LANDING GEAR
FOOT
TAPE OVER PADS

AND BOLTS
BOLT PAD INSTALLATION

NOTE
Figure 201. Utility Float Installation
Page 204
MAINTENANCE MANUAL
UTILITY FLOAT SYSTEM

1. Utility Float Initial Installation harness and remove position light
assemblies.
The utility float kit can not be installed in
combination with the following: (6). Remove cargo compartment and aft
Passenger steps landing gear steps.
Hoist kit
Litter kit NOTE: Passenger steps, 369D26505 and
Four-bladed tail rotor 369D292028, can not be installed in combi
nation with utility floats. Upon removal of
A. Preparation for Installation 369D292028 step assembly, install
PLT210-10-3 bolts (2 per assembly) coated
with sealing compound (CM425) into holes
Consumable Materials where step attaching hardware was located.
Item Nomenclature (7). Remove hardware that secures trailing
edge of lower fairings to strut assem
blies. Carefully spread trailing edge of
lower fairings and remove fairings.
Instructions in the following paragraphs are NOTE: If preload condition prevents removal of
applicable to both left and right landing gear skid assemblies, disconnect one brace as
assemblies. Preparation for installation of sembly from skid assemblies to eliminate
utility floats includes the following: preload (Ref. Section 32-10-00).
NOTE: Make sure that the BATT-OFF-EXT (8). Remove ABC bolts from forward and aft
switch is set to OFF. strut assemblies (Ref. Section
32-10-00). Retain ABC hardware for
(1). Check all cockpit electrical switches in reuse. Remove skid assemblies with
the OFF position. foot assemblies attached.
(2). Identify all components, including B. Disassembly of Extended Landing Gear
attaching hardware, or components
removed for access to work areas. (Ref. Figure 901) Complete disassembly of
Protect components from damage and landing gear is not required; however, certain
foreign matter until installed. items must be removed.
(3). Using jacking or hoisting methods, Consumable Materials

raise helicopter 6 inches (15 cm) clear of (Ref. Section 91−00−00)
ground. Item Nomenclature
(4). Remove landing gear (Ref. Section CM318 Primer
32-10-00). Removal of landing gear is
identical to that described in Section
32-10-00, except that removal of (1). Remove screws from float attach
complete landing gear is not required. fittings.
Remove extended landing gear accord (2). Remove bolts and abrasion strip from
ing to Section 32-10-00, except as skid extension.
follows:
(3). Remove bolts attaching skid tube
(5). Remove screws attaching position light extension.
assemblies to skid assemblies. Retain
screws for reuse. Disconnect electrical (4). Remove skid tube extension.
Page 901
MAINTENANCE MANUAL
SHIELD
(INSTALL)
DOUBLER
(REMOVE)
GASKET
WIRE HARNESS
FAIRING ATTACH BRACKET

(NOTE 3)
STROBE LIGHT DETAILS
FOOT ASSEMBLY
SKID TUBE
FLOAT ATTACH FITTING
(TYP)
SKID EXTENSION
ABRASION STRIP
NOTE 1 (NOTE 2)
NOTES: SCREW
1. RETAIL BOLTS FOR REUSE (NOTE 3)
ONLY AT THIS LOCATION. FORWARD FOOT ASSEMBLY
2. DO NOT REMOVE ABRASION
STRIP AT THIS LOCATION.
3. REMOVE LOWER ATTACH
FITTINGS AND REINSTALL
SCREWS. BOLT
4. REPLACE EXISTING SLEEVE EXTENSION
WITH NEW (UNDRILLED) FOOT ASSEMBLY ASSEMBLY
-5 SLEEVE.
INDEXING PLUG
NOTE 3
SKID ASSEMBLY EARLY CONFIGURATION
SKID ASSEMBLY FOOT ASSEMBLY
AFT FOOT AND SKID TUBE EXTENSION ABRASION STRIP

SLEEVE ADAPTER (REMOVED)
(NOTE 4)
CURRENT CONFIGURATION
G32-8008
Figure 901. Extended Landing Gear − Disassembly
Page 902
MAINTENANCE MANUAL
NOTE: When installing the 369D292808-17 D. Landing Gear Skid Extension Assembly
and -18 extension tubes, it will be necessary
to remove and replace the 369D26012 or the (Ref. Figure 903)
369D26012-5 sleeve adapter with a new -5
(undrilled at aft end) sleeve adapter (Ref. Consumable Materials
Section 32-10-00). (Ref. Section 91−00−00)
Item Nomenclature
(5). Remove bolts attaching abrasion strip CM209 Zinc chromate putty
to skid tube. Do not remove abrasion CM318 Primer
strips. Retain four bolts for reuse. CM425 Sealing compound
(6). Remove fairing attach brackets from

foot assemblies. Coat screws and (1). On all types of landing gear skid tube
washers with primer (CM318) and extensions:
reinstall screws and washers. (a). Coat mating surfaces of the correct
plug with zinc chromate putty
C. Landing Gear Strut Modification (CM209); assemble plug to tube with
rivets coated with primer (CM318).
(Ref. Figure 902) For modification of landing Seal edges with sealing compound
gear strut assemblies to accommodate installa (CM425).
tion of utility floats and return to extended
landing gear configuration when utility floats (b). Coat mating surface of support
are removed, perform the following: assembly and tube with zinc chro
mate putty; install using bolts and
washers.
(Ref. Section 91−00−00) (2). Assembly of landing gear skid exten
Item Nomenclature sion (369D292808-17 and -18) on
current configuration landing gear:
CM318 Primer
NOTE: The 369D292808-17 and -18 skid tube
extension assemblies can only be installed
on extended skid gear having new (un
drilled) 369D26012-5 adapter, sleeve-skid
(1). Using drill motor and number 15 drill
installed. For replacing the 369D26012 ba
bit, drill two holes through lower
sic sleeve with the -5 sleeve (Ref. Section
fairing attach brackets and aft wall of
32-10-00).
landing gear strut assemblies (view A).
Enlarge holes to 0.250 inch (6.350 mm) (a). Insert skid tube extension on to -5
diameter using 1/4 inch (6.35 mm) drill adapter sleeve. Align skid tube
bit. rivnut centerline with extension tube
rivnut centerline. Secure both
(2). Using number 30 drill bit, drill out assemblies with a suitable fixture.
huckbolts attaching bracket to strut.
Remove bracket. Seal huckbolt attach (b). Mark and match drill eight
holes in strut with sealing compound 0.1945—0.1965 inch
(CM425). Coat bare metal with primer (4.9403—4.9911 mm) diameter holes
(CM318). through tube and sleeve (use loca
tions and dimensions as stated in
Figure 903); separate skid tube
(3). Remove rivets attaching nutplates
extension from adapter sleeve.
(view B).
(c). Countersink holes, 100° x 0.378 -
NOTE: When floats are removed from landing 0.385 inch (100° x 9.6012 - 9.779
gear assembly, modified foot assembly mm) diameter in skid tube extension,
brackets can be reinstalled by using screws deburr and apply primer to bare
and washers. metal surfaces.
Page 903
MAINTENANCE MANUAL
STRUT
CL
BRACKET CL
SILASTIC
25° 50'
STRUT ASSEMBLY
(TYP)
REMOVE NUT PLATE KNIFE SPLICE LOWER FAIRING 0.59

ATTACH BRACKET
SEALANT 2.41
1.28 1.13
TYRAP BRACKET
0.250 DIAMETER 2
HOLES
BRACKET CL
STRUT MODIFICATION
FORWARD FOOT MODIFICATION
Figure 902. Extended Landing Gear Modification
Page 904
MAINTENANCE MANUAL
5.98 INCH 3.92 INCH

(15.189 CM) (9.957 CM)
0.40 INCH
(10.16 MM) NOTE 1 369D26012-5 SLEEVE
(REF)
SUPPORT ASSEMBLY
(NOTES 3, 4)
2.90 INCH BOLT

(7.37 CM) (NOTE 2)
RIVNUT
(NOTE 2)
RIVET
COMPONENT OF 369D292808-17 AND -18 (NOTE 2)
(FOR UTILITY FLOATS ONLY)
VISU-LOK
(8 PLCS) (NOTE 2)
PLUG
(NOTES 3, 4)
EXTENSION TUBE
(NOTES 3, 5)
(NOTES 3, 5)
369D26012-5
ADAPTER SLEEVE
ABRASION STRIP
(NOTES 3, 4)
VISU-LOK
(8 PLCS) (NOTE 2)
BOLT
(NOTE 2)
NOTES:
1. MATCH-DRILL 8 - 0.1945/0.1965 INCH (4.9403/4.9911 MM) DIAMETER HOLES THRU
BOTH TUBES AND CSK, 1005 X 0.378/0.385 INCH (9.6012/9.779 MM) DIAMETER.
APPLY PRIMER TO BARE METAL SURFACES.
2. COAT ATTACHING HARDWARE WITH PRIMER.
3. COAT MATING SURFACES WITH ZINC CHROMATE PUTTY.
4. SEAL MATING EDGES WITH SEALING COMPOUND.
5 SEAL MATING EDGES WITH SEALING COMPOUND G32 8010
Figure 903. Skid Tube Extension Installation
Page 905
MAINTENANCE MANUAL
(d). Reinstall skid tube extensions on to E. Utility Float to Landing Gear Assembly
-5 adapter sleeve using a thin coat of
sealing compound on mating sur (Ref. Figure 904) The Utility Float Kit is shipped
faces. Seal with sealing compound. with as many parts assembled as practical;
Secure with eight visu-lok fasteners however, certain items require assembly at
coated with primer. installation.
(e). Install abrasion strip to each exten Consumable Materials

sion tube with bolts and washers. (Ref. Section 91−00−00)
Coat attaching hardware with Item Nomenclature
primer. Coat mating surfaces with CM209 Zinc chromate putty
zinc chromate putty and seal mating CM318 Primer
edges with approximately 0.060 inch
(1.524 mm) bead of sealing compound
to insure watertight fit. CM717 Tape, pressure sensitive
(3). Assembly of landing gear skid exten NOTE: Prior to installation, apply primer
sion - On current configuration ex (CM318) to all attaching hardware.
tended landing gear:
(1). On early configuration extended
(a). Insert float kit extension tube over landing gear, coat abrasion strip with
adapter sleeve. zinc chromate putty (CM209) and
install with screws (view D).
(b). Align extension tube and sleeve (2). Install bolt cover pads using existing
holes, attach tube to skid with bolt screws and wrap with two overlapping
spacer and nut. layers of tape (CM717) (view B).
(4). Assembly of landing gear skid exten (3). Coat mating surfaces of cap with
sion - On early configuration extended sealing compound (CM425) and install
landing gear: using position light attaching screws.
(4). Temporarily install tyrap bracket with
(a). Seal all edges of skid plug with screw (view E).
sealing compound; install in tube by
using using rivets. (5). Position utility floats over landing gear
skids.
(b). Coat all surfaces of indexing plug and (6). Align bolt holes in floats with bolt holes
sleeve with sealing compound. in skid assembly. Position gravel
guards, coat bolts and washers with
(c). Insert sleeve adapter in tube and primer (CM318); attach floats, gravel
install using rivets. guards and abrasion strip using bolts
and washers. Torque bolts to 25—35
(d). Install packing and indexing plug in inch-pounds (2.82—3.95 Nm).
tube; align holes in sleeve, plug
(7). Position cap assembly (view C) on skid
assembly and tube with skid assem
tube extension. Coat mating surfaces
bly. Install rivets and bolts with
with sealing compound and secure with
primer (4).
bolts and washers.
(e). Coat mating surfaces of abrasion (8). Assemble structure assembly and
strip with zinc chromate putty (71). support assembly (view C). Coat mating
Install abrasion strips with screws surfaces with sealing compound and
and primer (4). Seal all edges with secure with bolts, washers, nuts and
approximately 0.06 in. bead of plate. Secure assembled stabilizer
sealant (3). assembly using bolts and washers.
Page 906
MAINTENANCE MANUAL
F. Utility Floats/Landing Gear Installation If a preload condition prevents alignment,

disconnect one brace from strut assembly to
(Ref. Figure 902 and Figure 904) eliminate preload (Ref. Section 32-10-00).
(4). Secure new wire to forward foot using
Consumable Materials tyrap bracket and screw (view E). Route
(Ref. Section 91−00−00) wire to position light location through
Item Nomenclature tunnel provided in float. Use tie strap
CM318 Primer as required. Attach wire to position
light.
CM430 Sealant, solvent resistant (5). Install bracket using screws. Secure tab
and position light to bracket using
screws, washers and nuts. Install cover
using screws (view A).
(1). At forward strut, install approximately (6). Install bolt cover pads using tape
3 feet (92 cm) of wire to position light (CM717) (view B).
electrical harness using splice and
silicone tube. Apply sealant (CM430) to (7). Locate strobe light (Ref. Figure 901
ends of splice. Route wire through view A). Remove attaching hardware
nutplate hole in forward foot (Ref. and disconnect wire harness. Remove
Figure 902, view A) and seal gaps and strobe light and doubler. Retain
holes with sealing compound (CM425). attaching hardware and strobe light.
(8). Position shield and strobe light (Ref.
(2). Connect wire harness to position light Figure 904). Connect wire harness to
using bracket, screw, washer and nut strobe light and install shield and
(Ref. Figure 904, view A). Secure wire strobe light using hardware retained
harness to bracket with strap. Seal from removal.
connection with sealant (CM430).
(9). Install landing gear fairings (Ref.
(3). Apply sealing compound (CM425) to Section 32-10-00).
mating surfaces of foot and strut G. Weight and Balance
assemblies. Insert forward and aft foot
assemblies into strut assemblies. Align Weight and balance changes that result from
bolt holes, apply thin coat of primer installation of utility floats are listed in Table
(CM318) to ABC bolts and install bolts 901. After installation of utility floats, incor
while primer is still wet. Torque bolts to porate changes to helicopter weight and bal
40—60 inch-pounds (4.52—6.78 ance record as instructed in Section
Nm). 08-10-00.

Weight Arm Moment
Configuration lbs (kg) in. (cm) in.−lb/100 (kg mm/100)
369D290086−Basic
Added +131.8 (59.783) 122.2 (310.39) +161.06 (1855.60)
Removed −9.5 (4.309) 103.9 (263.91) −9.87 (113.71)
Change +122.3 (55.474) 123.6 (313.94) +151.19 (1741.89)
369D290086−501
Added +143.1 (64.909) 125.5 (318.77) +179.59 (2069.09)
Removed −8.1 (3.674) 99.8 253.49) −8.08 (93.09)
Page 907
MAINTENANCE MANUAL

Configuration lbs (kg) in. (cm) in.−lb/100 (kg mm/100)
Change +135.0 (61.235) 127.0 (322.58) +171.51 (1976.00)
369D290086−503
Same as −501 except delete: −143.1 (64.909) 125.5 (318.77) −179.59 (2069.09)
369D292035−3 −71.5 (32.432) 125.5 (318.77) −8.97 (103.35)
369D292035−4 −71.5 (32.432) 125.5 (318.77) −8.97 (103.35)
and install:
369D292035−5 +25.7 (11.657) 162.0 (411.48) +4.16 (47.93)
369D292035−6 +25.7 (11.657) 162.0 (411.48) +4.16 (47.93)
Change +51.5 (23.360) 161.9 (411.23) +8.33 (95.97)
Page 908
MAINTENANCE MANUAL
SKID TUBE
EXTENSION
WASHER
BOLT
WASHER
STROBE LIGHT
SHIELD
ABRASION STRIP
BOLT
GRAVEL GUARD
BOLT COVER
BOLT
BOLT
GRAVEL GUARD
WASHER
GRAVEL GUARD WASHER

BOLT
BOLT COVER
GRAVEL SCREW
CAP GUARD WASHER
BOLT NUT
WASHER
BRACKET
STRAP
BOLT COVER
PAD BRACKET TAB
COVER
SCREW
SCREW NUT WASHER
SCREW
Figure 904. Utility Float Buildup (Sheet 1 of 2)
Page 909
MAINTENANCE MANUAL
STRUCTURE ASSEMBLY
BOLT NUTPLATE STRUCTURE

WASHER ASSEMBLY
WASHER
SUPPORT NUT
ASSEMBLY
WASHER
BOLT
WASHER
CAP ASSEMBLY
WASHER
TYRAP
BRACKET BOLT
SCREW
VISU-LOK
BOLT
NUT
INDEXING PLUG
ABRASION
SPACER STRIP
BOLT
SCREW
Figure 905. Utility Float Buildup (Sheet 2 of 2)
Page 910
MAINTENANCE MANUAL
Section
32−82−00
Emergency Float
System
(369D/E/FF − 500N)
MAINTENANCE MANUAL
EMERGENCY FLOAT SYSTEM

1. Emergency Float System Description and (2). Flotation Equipment Emergency
Operation flotation equipment consist of two
inflatable emergency floats, electroni
A collapsed emergency float with an emergen cally controlled inflation equipment,
cy inflation system (stowed condition) is four landing gear fairings and landing
attached to each landing gear skid. The floats gear skid tube extensions. Nutplates on
can be fully inflated during flight in approxi each skid tube and extension provide
mately five seconds. The electrically controlled for float attachment. A cabin entry step
inflation system includes a self-test capability can be used with the landing gear
to provide the pilot with a visual indication of without interference with the floats.
the electrical circuit reliability. Landing on
water or land is permitted when emergency (3). Inflatable Emergency Floats Each of
floats are inflated. the two inflatable neoprene emergency
floats consists of sealed airtight
Emergency flotation equipment in the stowed chambers separated by internal walls
condition does not restrict normal land that provide five individual watertight
operation of the helicopter. When inflated, the compartments. Skid attachment strips
floats will support the helicopter on water at (girts), bonded to the underside of the
maximum gross weight. After emergency floats, are bolted to the landing gear
inflation, the inflation system can be serviced skids. In addition, fore and aft web
with fully charged dry air or nitrogen pressure support straps secure the floats to the
vessels, and the floats repackaged to a skids. The floats are inflated to a
streamlined stowed condition. nominal operating pressure of 4.0 psig
(28 kPa) by the emergency inflation
A. Emergency Float Description system upon pilot activation of the
inflation system electrical control
(1). Electrical System The emergency float equipment. Relief valves provide for air
electrical installation assumes prior pressure release at a compartment
incorporation of the 369H90129-31, pressure of 4.5 psi (31 kPa) or above.
369H90129-505 or 369H90129-511
pilot's cyclic stick grip kit. The emer A snap-on containment cover with
gency float electrical system includes a lacing restrains the float in the stowed
circuit breaker, visual indicator switch configuration until the emergency
for testing circuit operation reliability, inflation system inflates the float. The
and a relay. The pilot's cyclic stick grip containment cover inboard side auto
is equipped with an EMERG/FLOAT matically unsnaps and is pushed
push-button switch. When the pilot's outboard as the float inflates. After
grip switch is actuated, the electrical emergency float use, deflation, pressure
system energizes and provides electrical vessel recharging and folding, the cover
power for simultaneous operation of the is again snapped in place over the float
left and right emergency float inflation and replaced for subsequent reuse.
system. The float inflation system
consists of an electrically operated A mooring ring atop each end of the
solenoid valve, or squib valve, attached float is furnished for towing and
to a compressed dry air or dry nitrogen mooring. An extended landing gear skid
pressure vessel. When the solenoid is tube extension supports the float aft
energized or the squib is actuated, the section on the landing gear. Forward
pressure vessel valve opens and and aft restraining straps are provided
releases compressed dry air or dry at landing gear strut and fairing
nitrogen into compartments of each locations. Gap covers close off the
float. inboard cutouts for the strut fairings.
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MAINTENANCE MANUAL
(4). Emergency Inflation System The (2). Check girt to skid attaching hardware
emergency inflation system consists of for condition and corrosion.
a charged compressed pressure vessel,
air hoses, valves and associated (3). Check float cover fasteners and lacing
components for inflation of the emer for security.
gence floats. A complete emergency
inflation system is installed on and is (4). Examine float stowage cover for
part of each float. abrasive damage that can have dis
turbed package float.
When actuated by inflation system
electrical control equipment, a solenoid (5). Do an operational check of float
valve or squib valve attached to the inflation system electrical control
pressure vessel releases compressed dry equipment.
air or dry nitrogen for distribution
through the air hoses and inlet check 4. Emergency Float Inspection
valves for the five float compartments.
NOTE: To be done every six months or as neces
A relief valve on each float compart
sary.
ment opens if compartment pressure
exceeds 5 ±0.5 psi (34.5 ±3.5 kPa). (1). Check for proper air pressure indication
on pressure gage.
The pressure vessel operating pressure
is 3000—3575 psig (20684—24649 (2). If float is stowed, unsnap containment
kPa) at 65—855F (18—305C); cover and loosen restraining lacing for
3425—3575 psig (23615—24649 kPa) access to emergency inflation system
at 65—855F (18—305C) is preferred. components.
The manifold is attached to the pres
sure vessel along with an indicating (3). Remove pressure vessel, inspect for
pressure gage, filler valve and a damage and scratched, nicked or
pressure relief valve. The pressure otherwise damaged paint coating.
vessel relief valve operates at and above
4000—4500 psig (27579—31027 kPa). NOTE: Superficial paint coating damage
Detachable rubber boots cover the filler should be repaired by paint touchup.
and pressure relief valves for protection
against chafing. The pressure vessel (4). Inspect valves, air hoses and other air
can be detached from the float for distribution components for damage,
servicing. deformity, strain, chafing or corrosion.
NOTE: Corrosion of the electrically operated
2. Certification and Shelf/Service Life solenoid/squib valve can occur as a result of
improper charging of the pressure vessel.
The Federal Aviation Administration (FAA)
Ensure that only dry air or dry nitrogen is
has granted Squib PN 5003527-1 of the
used to charge the pressure vessel.
squib-actuated emergency float valve a
provisional five-year life limit. This life limit (5). Do an inflation system electrical control
is established by date of manufacture, which is equipment operational check to ensure
ink-stamped on the body of the squib (Ref. electrical continuity and connection of
Section 04-00-00). solenoid/squib valve.
3. Emergency Float Inspection (Stowed Ensure that pressure vessel
Configuration) CAUTION gage is visible through inspec
tion window.
NOTE: The following inspections must be done
daily and before each flight. (6). Tighten and re-tie the lacing and snap
the containment cover in place if not
(1). Observe vessel pressure through continuing to Float Compartment
inspection window. Pressure Test.
Page 202
MAINTENANCE MANUAL
Table 201. Troubleshooting Emergency Flotation Equipment

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

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

Test Inflation)
To be done every 6 months or after 5 inflations
(Ref. Section 04-00-00). Consumable Materials
(1). Inflate all float compartments at the fill Item Nomenclature
valves to 4.5 psi (31 kPa) for one hour. CM220 Naphtha aliphatic
Check for leaks and condition.
(2). Continue inflation to 5.5 psi (38 kPa) (1). Clean float as follows:
and check that chamber pressure relief
valves operate. (a). Clean away any oil or grease with
naptha (CM220).
(3). Lower pressure in all five float com
(b). Wash down with soapy water; flush
partments to 2.0 psi (14 kPa) and let
with clear fresh water and allow to
stand for 24 hours.
air dry.
NOTE: Changes in atmospheric pressure and (c). Clean air pressure gage inspection
temperature during pressure test of float window with a clean cloth and fresh
compartments will affect pressure gage water.
readings. A temperature change of 1 degree
equals 0.032 psig (0.2206 kPa). (d). After inspection is complete, dust
with talc.
(4). Check the pressure drop with a pres
sure gage that indicates 0—15 psi (2). Recharge pressure vessel to 3500 psig
(0—103 kPa), graduated in 0.5 psi (5 (24132 kPa) at 755F (245C).
kPa) increments. The maximum
allowable pressure drop in 24 hours is (3). Inspect float bags for abrasion and
limited to 0.5 psi (5 kPa) per compart chafing.
ment. (4). Inspect pressure relief valves for
condition and closure.
(5). If a pressure drop occurs, check floats
for soundness. (5). Inspect check valves for condition.
(6). Tighten and re-tie the lacing and snap (6). Inspect all hoses and connectors for
the containment cover in place. condition and security.
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MAINTENANCE MANUAL
(7). Check float girts, web support and NOTE: Changes in atmospheric pressure and
restraining straps for condition and temperature during pressure test of float
secure attachment to skid tube. compartments will affect pressure gage
readings. A temperature change of 1 degree
(8). Check all release snaps and fasteners equals 0.032 psig (0.2206 kPa).
for condition and serviceability.
(2). Check the pressure drop with a pres
(9). Check that pressure vessel relief valve sure gage that indicates 0—15 psi
and filler valve boots are installed. (0—103 kPa), graduated in 0.5 psi (5
(10). Repack floats. kPa) increments. The maximum
allowable pressure drop in 24 hours is
7. Emergency Float Test limited to 0.5 psi (5 kPa) per compart
ment.
The squib is an electrically
WARNING fired explosive device. Keep (3). If a pressure drop occurs, check floats
squibs away from all sources of heat, for soundness.
open flame, sparks and electrical con
tacts. Squib plugs are to be in place un 9. Emergency Float Repair
til squibs are installed in aircraft.
Contact MDHI Field Service Department for
(1). Do the inflation operational reliability repair information.
test of float inflation electrical system
as follows: 10. Solenoid−to−Squib Rework Procedure
(a). Press LH/FLT and RH/FLT combi The following is a procedure to replace the
nation press-to-test switch located solenoid, which is no longer manufactured, to
below the lower switch and circuit the squib valve.
breaker panel on the sllmline instru
ment panel and at the top-center of (1). Turn off electrical power.
the ”T” panel, to test float inflation
electrical circuit reliability. (2). Unpack emergency floats.
NOTE: Pressing the press-to-test switch ap (3). Remove valve protector and unlace
plies low voltage (insufficient to energize/ cylinder sling lacing cords (Ref.
actuate the pressure vessel valve solenoid/ Figure 402).
squib) to the emergency float circuit.
Internal light bulbs in the switch will illu (4). Disconnect solenoid valve electrical
minate if the circuit is operational. wiring knife splice at (SP4, SP5, SP9
and SP10) solenoid.
(b). Observe that each switch faceplate is
illuminated when pressed and goes (5). Loosen nut at outlet port of solenoid
out when switch is released. valve. Disconnect valve assembly from
union by unscrewing cylinder and valve
NOTE: Failure to illuminate indicates a bur assembly in counterclockwise direction.
ned-out light bulb in the switch or a defec Remove cylinder and valve assembly.
tive circuit. Extreme brightness indicates a
defective circuit. (6). If cylinder is not empty, discharge as
follows:
(2). Check each pressure vessel for proper
(normal) air pressure, 3500 psig Exercise care when dis
(24132 kPa) at 705F (245C). WARNING charging cylinder. Person
nel can be injured by high pressure air
8. Float Compartments Pressure Test or flying debris.
(1). Inflate all five float compartments to (a). Secure cylinder in chain vise or
2.0 psi (14 kPa) and let stand for 24 equivalent. Point filler valve outlet in
hours. safe direction.
Page 204
MAINTENANCE MANUAL
(b). Use two open end wrenches, one on 1). Check ship voltage with VOM.
filler valve body and one on nut. Turn Voltage should be 27.5 Vdc.
nut slowly counterclockwise 2-1/4
turns and allow all pressure to 2). Open emergency float circuit
escape. Check gage to verify that no breaker (CB121).
pressure remains in cylinder. 3). Install one lead of 0.5 ohm ±5%,
10W resistor in pin A of left‐hand
(7). Remove solenoid valve from cylinder.
connector (P101). Connect one test
Discard solenoid valve and packing.
lead of ammeter (VOM) to other
(8). Install new squib valve (PN 23111380-3 lead of resistor. Connect other test
LH float, PN 23111380-4 RH float) with lead of ammeter (VOM) to pin D of
PN MS28778-12 packing on cylinder. connector (P101).
Torque to 360—504 inch pounds 4). Close emergency float circuit
(40.67—56.95 Nm) (Ref. Figure 403). breaker (CB121).
(9). Install fitting with PN MS28778-6 5). Press PRESS-TO-TEST switch
packing on existing union. and observe current reading on
ammeter and brilliance of lamps.
(10). Recharge cylinder and test for air leaks.
Current should be 75 MA mini
(11). Install charge cylinder and squib valve mum and brilliancy of lamps
assembly with PN MS28778-6 packing should be fairly bright.
on fitting. 6). Open emergency float circuit
(12). Revise emergency float electrical breaker (CB121).
system as follows: 7). Remove meter and resistor from
connector (P101).
(a). Remove access panels and/or covers
as necessary to expose emergency 8). Repeat steps 3). through 7). for
float wiring. right‐hand connector (P102).
(b). Remove all emergency float wiring (b). System check;
except as noted in Figure 903.
1). Ensure that circuit breaker
(c). Remove and discard relay installa (CB121) is open and connectors
tion, doubler and attaching hardware (P101 and P102) are disconnected.
located on pilot's floor support, left
2). Install one lead of 40 ohm ±1%,
bulkhead.
20W resistor in pin A of left‐hand
(d). Remove emergency float switch light connector (P101) and install other
assembly and install new switch light lead of resistor in pin D of connec
assembly. tor (P101).
3). Connect test leads of voltmeter
(e). Install wiring as shown in
(VOM) across resistor.
Figure 902. Do not plug in electrical
connectors (P101 and P102) until 4). Close emergency float circuit
after electrical system check. breaker (CB121).
(f). Reinstall access panels and/or covers. 5). Press firing switch on pilot's grip
and observe voltage on meter.
(13). Turn on electrical power. Voltage should be 25.5 Vdc mini
mum.
(14). Do the inflation system electrical
control equipment operational check as 6). Open circuit breaker (CB121).
follows:
7). Remove meter and resistor from
(a). Test light check; connector (P101).
Page 205
MAINTENANCE MANUAL
8). Repeat steps 2). through 7). for inspection window when floats are
right‐hand connector (P102). stowed, pressure gage axis inclined
outboard approximately 40°.
(c). Connect connectors (P101 and P102)
to squib valves. (16). Repack emergency floats (Ref.
Figure 404).
(d). Close emergency float circuit breaker
(CB121). (17). Remove existing VNE cards (solenoid
(e). Press PRESS-TO-TEST switch and valve, floats stowed (3) and solenoid
observe that lamps light. valve, floats inflated (1)).
(f). Open circuit breaker (CB121). (18). Install PN 369D292574-49, -51 and
-53 VNE cards (squib valve, floats
(15). Ensure that cylinder is positioned so stowed) and PN 369D292573-19 VNE
that pressure gage is visible through card (squib valve, floats inflated).
Page 206
MAINTENANCE MANUAL

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

INLET CHECK VALVE
(TYP)
NOTE:
PRESSURE RELIEF FORWARD FITTINGS ATTACHED AT FIRST NUTPLATE
VALVE (TYP) FORWARD OF STRUT FOOT. REAR FITTINGS ATTACHED
AT FIRST NUTPLATE AFT OF STRUT FOOT. G32-8002
Figure 401. Emergency Float Installation
Page 402
MAINTENANCE MANUAL
2. Emergency Float Pressure Vessel D Squib valve: If actuated, replace with a

Servicing and Replacement serviceable valve. Install valve on pres
sure vessel and torque to 380—420 inch-
(Ref. Figure 401) Maximum allowable temper pounds (42.93—47.45 Nm).
ature during charging is 165°F (75°C).
Detaching the pressure vessel from the float
during charging is the preferred procedure. (5). Detach restraining lacing and remove
Maximum pressure vessel pressure is 3500 pressure vessel from float.
psig (24132 kPa) at room temperature,
705F (215C). As outside air temperature will (6). Recharge pressure vessel with dry
affect the day-to-day gage reading, tempera nitrogen or compressed dry air to
ture versus pressure readings are important 3000—3500 psi (20684—24132 kPa)
during servicing or inspection of the pressure at 755F (245C); 3500 psig (24132 kPa)
vessel air pressure. The indicated pressure on at 755F (245C) is preferred. Cool
the gage will increase or decrease 6.6 psig cylinder with water and charge slowly
(45.5 kPa) per 15F (0.45C) increase or to maintain vessel surface temperature
decrease, respectively, in vessel air tempera below 2505F (1225C).
ture. Slow variations in ambient air tempera
ture will be reflected in the vessel air tempera
ture; however, it must be considered that NOTE: The pressure vessel can also be serviced
direct or reflected solar radiation will result in by weight. When servicing by weight, use a
higher pressure than would be anticipated for scale and weigh the empty vessel with at
the existing ambient air temperature. taching hardware installed. Charge the
empty vessel until a weight increase of
3.7—4.4 pounds (1.68—2.0 kg) is ob
tained; 4.3—4.5 pounds (1.95—2.05 kg) is
preferred. When charging by weight, air
Item Nomenclature
temperature variation will have no affect.
CM810 Leak detector, liquid Observe vessel cooling precaution.
(1). If float is stowed, unsnap containment (7). Test for air leaks by applying liquid
cover to extent required for access to leak detector (CM810) to the valve-
pressure vessel. pressure vessel interface. No air
(2). Open manifold change valve to verify bubbles are permitted.
that there is no pressure remaining in
pressure vessel. (8). Dry with clean lint-free cloth and then
allow to air-dry completely.
(3). Remove the three air hoses at air
manifold. Do not allow the manifold to
turn when disconnecting the hoses. (9). Inspect the emergency inflation system.
(4). Disconnect solenoid valve electrical
wiring knife splice at solenoid or (10). Cover vessel with bag and tie closure
disconnect squib valve electrical lacing.
connector at squib and install plug.
Use a wide-strap wrench, 2 inch (11). Reinstall vessel and bag on float;
CAUTION (5 cm) minimum width, to apply re-connect air hose fittings and
torque on the pressure vessel, taking care solenoid/squib valve electrical wiring
not to damage it. Use crowfoot adapter on knife splice/squib valve electrical
the torque wrench at the valve body. connectors. The pressure vessel must be
positioned so that air hose connections
NOTE: place no strain on the solenoid/squib
D Solenoid valve: Do not remove solenoid and the pressure gage is visible through
and relief valve assembly from pressure the pressure gage inspection window
vessel. when the floats are stowed.
Page 403
MAINTENANCE MANUAL
VALVE PROTECTOR
SOLENOID VALVE PROTECTOR
NUT
UNION CROSS
PRESSURE VESSEL
G32-8200-402-1
Figure 402. Solenoid Valve Assembly
(12). Reinstall manifold cover. (4). Spread plastic cover at it's parting line
until small round end of white plastic
(13). Do an inflation system electrical control buttons pull through the black plastic
equipment reliability test. and over the squib connector, allowing
access to four screws that retain the
3. Squib and Squib Actuated Valve actuating valve body.
Replacement
(5). Using Allen wrench, remove four
(Ref. Figure 402 and Figure 403) Each time screws near the outlet port retaining
the emergency floats are inflated using the the actuated valve body. Retain screws
emergency float inflation system, the squib for installation of new valve.
and squib actuating valve must be replaced.
(6). Pull spent valve and squib off vessel.
NOTE: Solenoid valves used in the emergency Discard activated valve and squib.
float system are no longer available from
the manufacturer. Emergency float systems
(7). Lightly lubricate O-ring on new valve
equipped with the solenoid valve must be
with MIL-G-4343 or equivalent
converted to the squib valve system when
pneumatic grease.
the service life of the solenoid valve is ex
ceeded.
The squib is an electrically
(1). Open manifold change valve to verify WARNING fired explosive. Ensure con
that there is no pressure remaining in nector plug is installed in connector
pressure vessel. prior to installation.
(2). Remove pressure vessel with squib (8). Maintain squib orientation noted in
valve assembly attached. step (3).. Install squib actuated valve,
with squib installed, into manifold.
(3). Note orientation of squib with respect Squib actuated valve must bottom
to pressure gage. metal-to-metal on face of manifold.
Page 404
MAINTENANCE MANUAL
SQUIB OUTLET
SCREW
VALVE BODY-TO-
MANIFOLD JOINT
TAVCO
FITTING
PRESSURE VESSEL
ATTACHMENT
PRESSURE GAGE
SQUIB VALVE
CONNECTOR
BENDIX
PRESSURE
VESSEL
PACKING SQUIB VALVE ASSY (LH)

SQUIB VALVE ASSY (RH)
FITTING
NUT
PACKING UNION
CROSS
PACKING
SQUIB VALVE ROTATED AND INSTALLED IN PRESSURE VESSEL
G32-8006A
Figure 403. Squib Valve Assembly
Page 405
MAINTENANCE MANUAL
(9). Install four screws removed in step e. cover, all snaps must be closed and the
hand tight until locking thread of pressure vessel pressure gage must be
helicoil insert in manifold is engaged. visible in the inspection window.
Special attention should be paid to the
(10). Using Allen wrench, tighten the four following information which is pres
screws evenly until bottomed. Torque ented as an aid in establishing a final
screws to 38—43 inch-pounds float folding technique.
(4.29—4.86 Nm).
(a). Accomplish float folding in two
(11). Remove plug from squib connector.
stages, first do the float arrangement
Note that plug only fits one way. (pre-folding) to the extent necessary
Realign black plastic cover and pull it
to position the float and float compo
back over the squib connector. Replace
nents in approximate required
squib connector plug.
positions and then proceeding with
(12). Snap white plastic buttons back the final folding.
through holes in black plastic cover.
Check plug in squib connector to ensure NOTE: Partial inflation of float compartments
it is bottomed. is required to enable float arrangement dur
ing initial pre-folding.
(13). Charge pressure vessel and reinstall on
emergency float assembly. (b). During pre-folding and before air
evacuation of the forward compart
4. Emergency Float Folding ments (cells) as outlined in step 4, do
the following. Gather and compress
(Ref. Figure 404) Folding instructions con the float fabric tightly against the
tained in this procedure are provided as a vessel and pull the cover over the
general guide for float packing. Float folding inboard-facing pressure gage to
will require the aid of an assistant and estimate final cover window-to-gage
considerable care in preparing the smallest relationship. This fabric bunching/
float package possible during the initial folding cover pulling action can be required
steps. A minimum amount of wrinkles and several times before an approxima
complete air evacuation is essential to final tion (best guess) of final window
closure of cover snap fasteners. position is established. When cover
position appears good, evacuate all
(1). Position deflated float (five fill valves
air from the forward cells and
OPEN).
recheck the window-to-gage rela
NOTE: The float assembly must be removed tionship.
from the stowage envelope for installation.
Do not attempt to position the float for pack (c). As soon as a float chamber is ar
aging with the float chambers fully col ranged in the desired position, hold
lapsed. the components in place, flatten as
many wrinkles as possible and
(2). Fold the float as outlined in the figure. evacuate air from the float chamber.
On completion, the folded float must be While the vacuum is still being
contained within the float stowage applied, close the fill valves.
Page 406
MAINTENANCE MANUAL
STEP 7
FOLD HERE
STEP 2
LANDING GEAR AFT
STRUT (REF)
LANDING GEAR
FORWARD STRUT STEP 3
(REF) STEP 5 SKID TUBE
EXTENSION
(REF)
STEP 8
STEP 10 AND 11
STEP 4
STEP 6
STEP 1
STEP 9
FOLD HERE
LANDING GEAR SKID (REF) G32-8005
STEP 1 OPEN ALL FILL VALVES OF INFLATED FLOAT AND COMPRESS CELLS LIGHTLY BY HAND SO THAT FLOAT IS FLAT
AND AS SMOOTH AS POSSIBLE.
STEP 2 PLACE FOLD AT AFT END OF SKID EXTENSION THEN EVACUATE AFT OUTBOARD AIR COMPARTMENT (CELL) UNTIL
FOLD IS FIRM AND SHARP. CLOSE FILL VALVE.
STEP 3 WHILE COMPRESSING SUPPORT TUBE AND HOLDING FLOAT CENTER FORWARD AND DOWN, PLACE A FOLD IN
INBOARD CENTER CELL BETWEEN INLET CHECK VALVE AND FILL VALVE. REARRANGE AIR HOSE AS REQUIRED.
CONTINUE HOLDING PRESSURE ON SUPPORT TUBE. EVACUATE CENTER CELL THEN AFT INBOARD CELL UNTIL
FOLDS ARE SHARP AND SUPPORT TUBE IS FIRMLY HELD FROM MOVING AFT. CLOSE FILL VALVE.
STEP 4 POSITION PRESSURE VESSEL SNUG AGAINST OUTBOARD SIDE OF FORWARD STRUT. WHILE HOLDING VESSEL IN
POSITION, EVACUATE FORWARD OUTBOARD CELL THEN FORWARD INBOARD CELL UNTIL CREASES ARE FIRM
AND SHARP. CLOSE FILL VALVE.
STEP 5 RECHECK FLOAT. CHECK THAT FLOAT IS AS FLAT AS POSSIBLE AND FREE OF ALL AIR POCKETS. DOUBLE CHECK
FIRMNESS OF ALL CREASES AND RE−EVACUATE CELLS AS NECESSARY.
NOTE: ANY REMAINING AIR MIGHT CAUSE FLOAT OPENING AT ALTITUDE AND DIFFICULTY IN PACKING.
STEP 6 FOLD FLOAT AFT AT FORWARD END. REPOSITION HOSES AS REQUIRED. STOWAGE COVER MUST BE OUTSIDE OF
FOLD LINE.
STEP 7 FOLD FLOAT FORWARD AT AFT END. REPOSITION AIR HOSES AS REQUIRED. STOWAGE COVER MUST BE OUTSIDE
OF FOLD LINE.
STEP 8 ROLL AND FOLD LENGTH OF FLOAT TOWARDS CENTER. DO NOT COVER PRESSURE GAGE.
STEP 9 ROLL AND FOLD LENGTH OF FLOAT TOWARDS CENTER. FASTEN SNAPS STARTING AT FORWARD END. ENSURE
THAT PRESSURE GAGE IS VISIBLE IN INSPECTION WINDOW. DO NOT FASTEN END COVER SNAPS.
STEP 10 TIGHTEN LACING. ENSURE THAT SNAP FASTENERS REMAIN CLOSED.
STEP 11 SECURE END COVER SNAPS. ALL SNAP FASTENERS MUST BE USED.
Figure 404. Emergency Float Folding
Page 407
MAINTENANCE MANUAL
Page 408
MAINTENANCE MANUAL

1. Emergency Float System Initial (a). Ensure that all flight compartment
Installation switches are in OFF position.
A. General Make certain BATT-OFF-EXT

CAUTION switch is in OFF position.
Procedures in this section can be done at the
operator's discretion. Instructions are provided (2). Remove landing gear strut fillets and
for installation of emergency float kit on either fairings (Ref. Section 32-10-00). Retain
the current or early configurations of the all doublers, guides, pins and springs
extended landing gear. Subsequent installation for reinstallation.
instructions for the emergency floats and the
float electrical control system are identical for (3). On current configuration landing gear,
the current and early extended landing gear remove forward nut, bolt and spacer
configurations. Equipment removal and attaching existing extension to aft end
modification differences between the current of skid tube; retain nut for reinstalla
and early configurations are noted in the tion.
subsequent instructions. (4). On early configuration landing gear,
remove abrasion strip attached to
The emergency float kits are provided with as existing skid tube extension (Ref.
many assembled parts as practicable to Section 32-10-00).
facilitate initial installation on the helicopter.
Installation of electrical equipment assumes (5). Remove screws and bolts securing skid
prior incorporation of pilot's cyclic stick grip tube extension; retain early configura
kit (369D90129-507 or 369D90129-511). tion indexing plugs for reinstallation.
B. Initial Preparation (6). Remove skid abrasion strips below for
and aft fairings; retain abrasion strips
Instructions in the following paragraphs are for reinstallation.
applicable to both left and right landing gear
assemblies. Prepare the aircraft for installa D. Landing Gear Skid Extension Assembly
tion of emergency floats as follows:
NOTE: When installing emergency floats, the
VNE cards must be replaced with the cards E. Emergency Float System Electrical
that come with the floats (Ref. appropriate Equipment Installation
PFM). (Ref. Figure 901)
(1). Identify all components, including (1). Remove attaching hardware and
attaching hardware, and components separate lower switch and circuit
removed for access to work areas. breaker panel from instrument panel
Protect components from damage and structure.
contamination until installed.
(2). Remove covers from emergency float
(2). Raise aircraft clear of ground; Use press-to-test switch and circuit
authorized hoisting or jacking methods breaker cutouts from lower switch and
(Ref. Section 07-00-00). Place support circuit breaker panel.
beneath skid tubes at strut locations.
(3). Install emergency float circuit breaker
C. Existing Equipment Removal in panel.
(1). Remove Battery (Ref. CSP-HMI-3, NOTE: Press-to-test switch is installed during
Section 96-05-00). subsequent wiring installation procedure.
Page 901
MAINTENANCE MANUAL
PILOT'S CYCLIC
STICK GRIP
GROMMET
FLOAT
CLIP SWITCH
FLOAT
SWITCH
FORWARD STRUT OPTIONAL ``T'' GRIP STANDARD GRIP
DOUBLER MOUNTING
SLEEVE
PILOT'S FLOOR SUPPORT EXISTING SWITCH
FORWARD LEFT BULKHEAD HOLE HOUSING
LAMP (4)
INDICATOR
LOCKING MODULE
CAM LEGEND
RELAY LOCKING CAM FACE
BRACKET SCREW (2)
RELAY
SWITCH INSTALLATION
PILOT'S FLOOR SUPPORT (SLIMLINE PANEL)
FORWARD LEFT BULKHEAD
1 NAV 2
ADF XPDR
HOOK FLOATS
CIRCUIT
FLOAT BREAKER
PRESS-TO-TEST
INSTRUMENT PANEL (COMM. ``T'' PNL.)
G32-8007A
Figure 901. Emergency Float Kit − Electrical Installation
Page 902
MAINTENANCE MANUAL
F. Emergency Float System Electrical (6). Install wiring through landing gear
Wiring Installation struts as follows:
(Ref. Figure 902 thru Figure 905) (a). Drill 0.442 inch (11.2268 mm) hole
centered on outboard side of forward
struts located 5 inches (12.7 cm)
Consumable Materials above centerline of skid tube; deburr
(Ref. Section 91−00−00) holes internally and externally.
Item Nomenclature
CM318 Primer (b). Coat bare metal in holes with primer
(CM318); allow primer to dry.
CM601 Insulation sleeving, electrical
(c). Remove left and right foot support
fairing in passenger compartment for
(1). Identify wires as required and form access to landing gear forward struts.
wire bundle of applicable wires to
emergency float circuit breaker and (d). Install insulation sleeving on float
press-to-test switch on lower switch valve squib wires.
and circuit breaker panel.
(e). Locate position light wire bundle exit
(2). From battery compartment area, route holes on top inboard portion of left
wire bundle forward and up through and right landing gear struts; Insert
instrument panel support structure; respective float squib wire bundles
route wire bundle with existing bundles through position light wire bundle
where possible. exit holes. Locate wires through
previously drilled wire exit hole at
(3). Install insulation sleeving (CM601) and bottom of each strut. Carefully pull
connect applicable wires to contacts on wires through holes allowing suffi
press-to-test switch and circuit cient length for connections at either
breaker; assemble and secure press-to- end.
test switch to panel.
(f). Slide grommet over wire bundle on
(4). Adjust wire bundle and allow sufficient both struts; Install grommet in
slack for maintenance; strap and string previously drilled wire exit holes.
tie bundle to form smooth flow of wires
(g). Attach clip (Ref. Figure 901, view G).
to battery compartment area.
(h). Coil and stow wires to avoid damage
(5). Ensure all switch and circuit breaker during float equipment installation.
contacts are secure and that sleeving is
properly installed; remove paint from (7). Complete balance of all wiring. Install
panel and console in upper screw area insulation sleeving as required to
to ensure good ground contact. Install prevent shorting and chafing through
panel on console. out circuit wiring.
Page 903
MAINTENANCE MANUAL
NOTES:
1. THIS WIRING DIAGRAM SHOULD BE USED WITH THE J130P
TB1-9
ELECTRICAL SYSTEM WIRING DIAGRAM IN CSP-HMI-3 A508B20 J 16-20
A
FOR COMPLETE CIRCUIT IDENTIFICATION.
B
2. DASHED LINE (- - -) ITEMS ARE PART OF HELICOPTER
BASIC ELECTRICAL SYSTEM, UNLESS OTHERWISE NOTED.
TB1-18
3. PART OF SOLENOID FLOAT VALVE.
4. ENDS OF WIRE A507B20 (PART OF BASIC ELECTRICAL C M531E20 B 12-20
SYSTEM) MUST BE DISCONNECTED AND INSULATED. TB1-10
C
D N
A506B20 15-20
BUS
28 VDC CB121 TB1-7
P506M20 5A SP20
1 2 M503A20 A B M506B20 D A510A20 H 18-20
OR
P506AD20 C
M506H20
TB1-18
M510F20 B M521C20 D 11-20
TB1-10
SWITCH TOP (NOTE 4)
5 2 3 1 4 A A507A20 M 17-20
B
A507B20
NC NC TB1-17 (NOTE 4)
NC
M530B20 C
M509F20 S5 EMERGENCY
NO NO NO
JMPR AWG 22 FLOAT SWITCH
(4 PLCS) (PART OF 369H90129
C C C GRIP KIT)
S9-1 S9-2 M510K20

RELIABILITY (PRESS-TO-TEST)
SWITCH-INDICATOR (DS8, S9) M509C20
JMPR AWG 20
M510C20 (6 PLCS)
TB1-15
A B D C RELAY
M509K20
A1 B1 C1 D1
M506C20 M506E20 M519A20N
M511A20N M512A20N A3 B3 C3 D3
B A A B E25 E24 X2 X1
E20 A SP6 B SP3 B SP8 A SP11 CR3
GND GND GND M506N20 A2 B2 C2 D2
BLK-A20 YEL-A20 YEL-AA20 BLK-AA20
B A A B
A SP5 B SP4 B SP9 A SP10
BLK (NOTE 3) YEL YEL (NOTE 3) BLK
LEFT SOLENOID LEFT SOLENOID

FLOAT VALVE L1 FLOAT VALVE L2
G32-8013A
Figure 902. Emergency Float Inflation System Wiring Diagram (369D290121−501 and −505)
Page 904
MAINTENANCE MANUAL
RED OR YELLOW
BLACK OR BLUE
TB1-15
A A NOTE 2
SP3 A B C D
B B SP3
SQUIB FLOAT
PILOT'S INFLATE FLOAT SWITCH VALVE R.H.
1 2 S5 M512A20N P102
369H90129-505 E25 B
GRIP (REF) NOTE 2 D
3 4 C
M509B20
FOR 369H92557-511 SEE 17.20 NOTE 3 A
SHEET 2 FOR 12.20 16.20 18.20 11.20 NOTE 3
369H92557-513 (NOTE 1) 15.20 M925181-1 SPLICE
B J H N D M NOTE 3 4 REQD
J130 JMPR GA.20
8 REQD SQUIB FLOAT
VALVE L.H.
BENDIX PLUG
NOTE 3 M521E20 E5 P101
M508B20 M510B20
MPCM20M-H2 PIN NOTE 2 A
1 REQD NOTE 2 C
P506M20 EMERGENCY M511AN20 D
FLOAT SYSTEM BUS WIRE TB1-18 C A M506M20 CABLE E20 B
TB101 (REF) 28 V. BUS TB1-9

MS 25036-103 TERMINAL
33 M506N20 2 REQD
E2 BLACK D121 SOLDER SLEEVE 2.0 MAX BENDIX PLUG
CABLE P/N PT06P-8-4-S
(REF) OR BLUE 8 REQD
MS25036-103
TERMINAL
M506A20
1 2 NO RNF 100X1/4 SLEEVE
C S3 (A/R LH AND RH SIDES)
CB121 NOTE 2
NC
7.5A R1
NO
2TC13-7.5 CIR. BRK M506H20 S2
MS25036-149 TERMINAL C NC
RED OR
YELLOW NO
FOR -511 S1
C NC
NOTE 1 R2
4 1 5
MS25036-149 TERMINAL 2
2 REQD MS25244-7.5
7.5A CIRCUIT BRK.
1 2
CB111 P506M20
EMERGENCY FLOAT L.H. R.H.
28V BUS SYSTEM BUS WIRE
(REF) CB118 3
(REF)
FOR -513 369H92557-61
SWT/LT ASSY
NOTE 1
SYSTEM TEST PRESS
NOTES: PARTS REQUIRED:

1. EXISTING EMERGENCY FLOAT SYSTEM WIRING. DO NOT REMOVE. JUMPER #22 GA. 4 REQ'D
2. SHIELDS TO BE TERMINATED 0.50 INCH (12.70 MM) MAX. FROM END 3/16 PD CAPS 4 REQ'D
OF INSULATION ON WIRE (EXCEPT AS NOTED). JUMPERS TO BE 32445 SPLICE 4 REQ'D
MIN. LENGTH. SLEEVING A/R
3. REMOVE WIRE A510A20 FROM PIN J130-H, M521C20 FROM PIN MS 25036-103 TERMINAL 2 REQ'D
J130-D, A507A20 FROM PIN J130M, A506B20 FROM J130-N AND MPCM20M-H2 PIN2 REQ'D
STOW WITH 3/16 PD CAPS. D121 SOLDER SLEEVE 2 REQ'D G32-8014-1B

(369D290121−515, −517 and −519) (Sheet 1 of 2)
Page 905
MAINTENANCE MANUAL
S5
1 2
20 GA
369D297846 GRIP
(REF) 3 4
12-20 16-20 18-20 15-20 11-20 17-20

SP101 SP103 SP106 SP105 SP104 SP102
J109 B B B B B B
(REF) A A A A A A
32445 SPLICE
10 REQD
E5
M506C20 M506G20 RED OR BLACK OR BLACK OR RED OR

MPCM20MH2 PIN YELLOW BLUE BLUE YELLOW
TB1-8 TB1-9
C A
M506M20 CABLE
(REF)
M506N20
(REF)
SP3 SP9
A A
A B C D
TB1-15
(REF)
FOR 369H92557-513
(NOTE 1)
BLACK
5 2 3 1 4 M506N20
CABLE
NOTE 2
NC NC NC
NOTE 2
NO NO NO
RED
C C C
MPCM20MH2 PIN 1 REQ'D
(S9-3) (S9-2) (S9-1) MS 25036-103 TERMINAL 1 REQ'D
R.H. FLOAT L.H. FLOAT D121 SOLDER SLEEVE 2 REQ'D
(REF) (REF) JUMPER #22 GA
M506H20
369H92557-61 SWITCH LIGHT ASSY

G32-8014-2A

(369D290121−515, −517 and −519) (Sheet 2 of 2)
Page 906
MAINTENANCE MANUAL
TB503-11
CB121 A D
M506A20 M506B20
1 2
C M J
M511G20 E511F20 TB505-3/4
1 4
A
LH RH
2 3 TB503-10
F
A B C
R2 R1 +28V M531B20
22 Ω 22 Ω
5 1/4 W 5 1/4 W
BLU OR BLK BLU OR BLK
NC C TB503-5 V
S3
NO M L K FOR DIAGRAM
Y BEYOND P110,
C M506N20 J H G M506NN20 SEE SCHEMATIC
S1 NC X
NO BELOW
C B A (515 VERSION)
C Z
NC RED OR WHT F E D RED OR WHT
S2 M506H20
NO W
E33-K
-81 SWITCH LIGHT ASSY
5 GREEN LIGHTS
4 3 BUS
TB101 P110
LH RH CB121
3 1 2
1 2 M506A20 V A
7.5A
R2 R1 TB503-8
22 Ω 22 Ω
5 1/4 W 5 1/4 W A M506HH20 W B
RED OR WHT
NC C
S2 B
NO M506H20
RED OR WHT C X C
C CABLE
S1 NC D M506NN20 Z
NO CABLE E Y D
C M506N20
NC F
S3
BLU OR BLK BLU OR BLK
NO
XDS9
TB503-9
-61 SW/LT ASSY
E
E2 F
G32-8015-1

(369D290121−521, −523, −525 and −527) (Sheet 1 of 2)
Page 907
MAINTENANCE MANUAL
4 3 C 2 1
C C C
M511G20 (TB503-11M)
NO NO NO
(E33K)
(TB503-5C)
NC NC NC (TB503-5J)
S3 S2 S1 RED OR WHT
XDS8 M506N20
BLU OR BLK (TB503-5M)
M506H20 (TB503-5F)
S5
PILOT'S INFLATE
FLOAT SWITCH
P102
B D C A
SP103
SP104
J130
E J H D N M
TB1-19 RED OR WHT

A M506AA20 A E30 CABLE M512A20N
BLU OR BLU OR BLK
M506J20 B TB1-20 SQUIB FLOAT
BLK
A506J20 C VALVE RH
A BLU OR BLK
M520F20 D CABLE CABLE A507C20 CABLE M509B20
B
RED OR A510A20 B RED OR WHT
WHT TB1-22
A 90° BOOT (REF)
RED OR RED OR
C B WHT WHT
BLU OR BLK
CABLE TB1-20 CABLE M510B20
A510B20 C
A RED OR WHT
D SQUIB FLOAT
B D VALVE LH
BLU OR RED OR WHT
C E30 CABLE M511A20N
BLK CABLE
BLU OR BLK
D A507C20
BLU OR
BLK BLU OR BLK
RED OR WHT REF
CABLE TB1-22
A510C20 A P101 B D C A
B
J109 J E H D N M
SP101
SP102
G32-8015-2

(369D290121−521, −523, −525 and −527) (Sheet 2 of 2)
Page 908
MAINTENANCE MANUAL
Figure 905. Emergency Float Installation with Generic Wire Harness
Page 909
MAINTENANCE MANUAL
G. Emergency Float Electrical System Ensure that the BATT-OFF-

Inspection CAUTION EXT switch is in the OFF posi
tion.
Before connecting battery plug, the following
wiring installation inspection must be done. H. Emergency Float System Strut Fairing
Installation
(1). Inspect all wiring connections for (Ref. Figure 906)
security and insulation.
(2). Inspect all wiring for interference with
moving parts and for areas where
Item Nomenclature
chafing could occur.
(3). Inspect all wiring for conformance with
wiring diagrams. The following installation instructions are
typical for all four strut fairing assemblies.
(4). Install all access panels, doors and Where riveting is required, Refer to referenced
access covers previously removed. instructions for proper rivet types.
(5). Remove insulation and temporarily (1). Install center fairing, fillet and lower
connect each set of float squib wires. fairing in respective order, and general
ly in accordance with instructions (Ref.
(6). Install battery, connect battery plug Sectioin 32-10-00).
and place BATT-OFF-EXT switch in (2). During installation of fairings, ensure
BATT position. that doublers, removed during disas
sembly, are installed between fairings
(7). Momentarily press emergency float and fillers at screw attach points.
press-to-test switch to verify proper
wiring continuity; all four switch lamps (3). Ensure blocks are installed at lower
should illuminate. trailing edge of fillets to ensure free
action of fillet with strut movement.
(8). Separate float squib wires at base of
(4). Ensure that float solenoid/squib wire
struts.
bundles are free at bottom of lower
fairings on forward struts.
(9). Actuate EMERG/FLOAT switch on
pilot's cyclic stick grip; use voltmeter to (5). Install bolt covers over inboard bolt
check for proper voltage and continuity heads on strut foot/skid attach point.
through float squib valve circuits. Apply sufficient zinc chromate putty
(CM209) to fill all voids between cover
(10). Pull out emergency float circuit breaker and bolt head area; secure forward
to remove power and release relay; strut bolt covers with existing nylon
push circuit breaker in again to prepare hardware. Torque screws to 25—35
circuit for emergency use. inch-pounds (2.82—3.95 Nm).
Page 910
MAINTENANCE MANUAL
DOUBLER
FAIRING
NUTPLATE
WASHER
CHAFING PAD DOUBLER
SCREW
(FORWARD FAIRING)
FAIRING
TEFLON STRIP
(FORWARD FAIRING) 0.50 IN. 0.50 IN.
FILLET RIVET
1.25 IN.
FILLER
BLOCK
FILLER-TO-FAIRING
ATTACHMENT (TYP)
CENTER FILLER FAIRING

CENTER
NUTPLATE
FAIRING
DOUBLER
FAIRING
FAIRING
MOUNTING
BRACKET
LANDING SCREW
DOUBLER
GEAR WASHER
STRUT LOWER FAIRING
FILLER
SCREW
CENTER-TO-LOWER FAIRING
FILLER ATTACHMENT
LOWER FAIRING
STRUT-TO-SKID STRUT FOOT

BOLT COVER
STRUT FOOT
SKID TUBE
FOOT STRUT-TO-SKID
CONTAINMENT BOLT COVER
COVER
SKID
SEAL
NYLON SCREW
BOLT COVER INSTALLATION
G32-8016
Figure 906. Emergency Float System Strut Fairing Installation
Page 911
MAINTENANCE MANUAL
I. Emergency Float Installation (6). Loosen float forward web strap fittings
and position abrasion strip on skid
below strut; position web strap fitting
over forward attach hole on abrasion
Item Nomenclature
strip and secure strip to skid with bolts
and washers. Install remaining abra
CM209 Zinc chromate putty sion strips; remove excess zinc chro
mate putty.
Installation of the left and right emergency
floats is identical except for opposite positions. (7). Install balance of bolts and washers
securing float girts to skid tube exten
(1). Open float package and release re sions. Torque all bolts to 25—35
straining straps. inch-pounds (2.82—3.95 Nm).
(2). Position float girts over skid tube
attach points. (8). Adjust and secure float landing gear
strut cutout restraining straps.
(3). Temporarily attach float web support
strap fittings at forward location; (9). Unsnap float containment cover and
secure strap fitting at aft attach loosen restraining lacing to gain access
location with bolts and washers. to emergency inflation system compo
nents.
(4). Place gravel guards over float girts and
secure with bolts and washers.
(10). Connect squib valve electrical connector
(5). Apply zinc chromate putty (CM209) to at squib.
contact surfaces of previously removed
abrasion strips, and skid extension (11). Do the inspection of emergency float
abrasion strips, to ensure watertight fit inflation system (Ref. Emergency Float
on landing gear skids. Inspection - Stowed Configuration).
lbs (kg) in. (cm) in.−lb/100 (kgmm/100)
−501 +151.7 (+68.872) 95.9 (243.59) +145 (+1670.57)

−505 +150.8 (+68.463) 96.0 (243.84) +145 (+1670.57)
−515 +129.1 (+58.611) 99.1 (251.71) +128 (+1474.71)
−517 +127.7 (+57.976) 98.9 (251.21) +126 (+1451.67)
−519 +152.7 (+69.326) 96.4 (244.86) +147 (+1693.62)
−521 +152.6 (+69.280) 96.5 (245.11) +147 (+1693.62)
−523 +152.5 (+69.235) 96.5 (245.11) +147 (+1693.62)
−525 +127.5 (+57.885) 99.0 (251.46) +126 (+1451.67)
−527 +152.5 (+69.235) 96.5 (245.11) +147 (+1693.62)
−529 +152.5 (+69.235) 96.5 (245.11) +147 (+1693.62)
−531 +152.5 (+69.235) 96.5 (245.11) +147 (+1693.62)
Page 912
MAINTENANCE MANUAL
Chapter
52
Doors
MAINTENANCE MANUAL
TABLE OF CONTENTS
52-10-00 Crew, Passenger, Cargo Doors and Windows . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Crew and Passenger/Cargo Door Description and Operation . . . . . . . . . . . . . . . . . . . 201
A. Early Door-Latching System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Current Door Latching System (Hook-Latch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Hook-Latch Automatic Door Latching System Troubleshooting . . . . . . . . . . . . . . . . 202
Table 201. Hook-Latch Automatic Door Latching System Troubleshooting . . . 202
3. Crew Compartment Door Replacement (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . 203
A. Crew Compartment Door Removal (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . 203
B. Crew Compartment Door Installation (369D/E/FF - 500/600N) . . . . . . . . . . . . . . 203
4. Passenger/Cargo Compartment Door Replacement (369D/E/FF - 500N) . . . . . . . . 203
A. Passenger/Cargo Compartment Door Removal (369D/E/FF - 500N) . . . . . . . . . . 203
B. Passenger/Cargo Compartment Door Installation (369D/E/FF - 500N) . . . . . . . 203
5. Mid and Aft Door Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Mid and Aft Door Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Mid and Aft Door Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6. Door Seal Compression Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Crew and Passenger/Cargo Door Installation (Sheet 1 of 2) . . . . . . 204
7. Mid and Aft Door Strut Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Mid and Aft Door Strut Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Mid and Aft Door Strut Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8. Snapvent Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Snapvent Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Snapvent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
9. Outside Handle or Spindle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Outside Handle or Spindle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Outside Handle or Spindle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10. Automatic Latch Block Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Automatic Latch Block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Automatic Latch Block Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
11. Cam Lock Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Cam Lock Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Cam Lock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
12. Latch Assembly or Striker Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Door Seal Compression Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 202. Door Latching System Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . 208
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B. Engagement Depth of Latch Bolts with Striker Adjustment . . . . . . . . . . . . . . . . . 210

C. Connector Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
D. Latch Compression Adjustment (Early System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
13. Latching Mechanism Operational Check (Early System) . . . . . . . . . . . . . . . . . . . . . . 210
14. Hook-Latch Door Latching System Operational Check . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 203. Door Handle Positions and Latch Engagement (Sheet 1 of 3) . . . . . 211
15. Autolatching Pilot and Cargo Doors Operational Check . . . . . . . . . . . . . . . . . . . . . . . 213
16. Door-Latching Mechanism Inspection (All Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . 214
17. Anti-Chafing Tape on Door Frame Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
18. Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
A. Early Style Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
B. Current Style Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
19. Hinge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
A. Preload Spring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Figure 204. Door Hinge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Figure 205. Window and Hinge Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Figure 206. Current Style Window Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
B. Rubber Stop Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
20. Automatic Latch Block Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
21. Strike Pin Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
22. Litter Door Inspection (50 Hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Figure 207. Automatic Latch Block and Striker Repairs (Sheet 1 of 2) . . . . . . . . 220
Figure 208. Door Seal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
23. Pilot and Cargo Door Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
A. Seal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
B. Partially-Separated Seal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
24. Improved Door Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Figure 209. Improved Door Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
52-40-00 Engine Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Engine Access Door - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Engine Access Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Engine Access Door Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Engine Access Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Engine Access Door Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Engine Access Door Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Sheet Metal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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B. Abrasion Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

C. Hinge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. Catch/Latch Hook Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Engine Access Door Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Engine Access Doors (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
52-50-00 Miscellaneous Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Access and Inspection Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. General Access Doors Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Pilot Compartment Floor Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Pilot Compartment Floor Access Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Pilot Compartment Floor Access Door Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Pilot Compartment Floor Access Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Access and Inspection Provisions Information . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Access and Inspection Provisions and Locations
(369D/E/FF) (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202. Access and Inspection Provisions and Locations
(500N) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203. Access and Inspection Provisions and Locations (600N) . . . . . . . . . . 209
Figure 204. Floor Access Covers and Engine Bypass Door (600N) . . . . . . . . . . . . 210
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Section
52−10−00
Crew, Passenger,
Cargo Doors and
Windows
MAINTENANCE MANUAL
CREW, PASSENGER, CARGO DOORS AND WINDOWS

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

System Troubleshooting
Table 201. Hook−Latch Automatic Door Latching System Troubleshooting
Problem Probable Cause Repair
Hooks fail to engage striker Door seal swollen or bonding Repair seal (Ref. Door Seal Repair).
pin, or more than 0.050 inch to door frame failed.
(1.27 mm) gap between latch
hook and striker pin (Latch Striker assembly mounted too Loosen striker assembly mounting screws and
hooks extend normally). far inboard or outboard on adjust striker assembly position.
door frame.
Latch block assembly too far Add or remove 0.063 inch (1.60 mm) and
from striker pin. 0.032 inch (0.81 mm) washers as shims under
latch block mounting screws, as required (1).
Remove or add shims under striker assembly,
as required.
Striker assembly hitting or Route out waffle enough to clear.
rubbing on door waffle.
Striker assembly hitting latch Check latch covers for dents or chipped paint
cover (2). that indicates contact between latch cover and
striker assembly. Remove material from latch
cover to allow striker assembly clearance.
Latches fail to extend from Latch hooks or latch sliders Lubricate latch block moving parts.
latch block when handle sticking in latch block.
moved to open position.
Connector rod(s) improperly Adjust connector rod(s) by removing clevis
adjusted. from sliding cam and raising or lowering
threaded connector as required on threaded
portion of rod. Threads of rod and connector
must be engaged through solid portion of
connector. Rod end can be flush with or extend
beyond bottom, of solid part of connector.
Connector rod bent or Check connector rods and clevis. Replace
damaged. damaged part.
Door does not safelock when Connector rod(s) improperly Check witness hole in latch blocks.
door handle is moved to lock adjusted. Semi−circle cutout in each latch slider must be
position. fully seated around pin when safe locking is
engaged. Adjust connector rods until correct
pin engagement is achieved for each latch
slider.
NOTES:
(1) If latch block protrudes beyond middle line or door after shimming, slot mounting holes in latch block
cover 0.20 inch (5.08 mm) downward from center of existing hole to allow cover to shift up above middle
line of door waffle.
(2) Door should be closed from inside helicopter to determine if striker pin assembly is hitting or rubbing latch
cover. Enough force can be applied when closing door from outside to prevent detection of contact
between striker pin assembly and latch cover.
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3. Crew Compartment Door Replacement (4). Re-safety from top hinge pin.
(369D/E/FF − 500/600N)
(5). Install interior trim covers.
(Ref. Figure 201)
5. Mid and Aft Door Replacement (600N)
A. Crew Compartment Door Removal
A. Mid and Aft Door Removal (600N)
(369D/E/FF − 500/600N)
(1). Remove nuts and washers from door
(1). Remove cover plates from interior trim hinge bolts.
forward of crew doors.
(2). While supporting door, slide bottom
(2). While supporting door, turn hinge pins bolt, and then top bolt from hinges.
to unlock the tabs.
(3). Remove door from helicopter.
(3). Remove lower pin, then remove top pin.
B. Mid and Aft Door Installation (600N)
(4). Remove door from helicopter.
(1). Position door so door-mounted hinge
B. Crew Compartment Door Installation aligns with airframe-mounted hinge.
(369D/E/FF − 500/600N) (2). Insert bolt, with washer, into each
(1). Slide door hinges into slots on side of hinge.
airframe. (3). Install washer and nut on bolt and
(2). Insert pins, from inside the aircraft, torque to 50—70 inch-pounds
into airframe holes and though hinges. (5.65—7.91 Nm).
(3). Turn hinge pins to lock tabs into slots 6. Door Seal Compression Check
in airframe. (Ref. Figure 208) Inspect rubber weatherstrip
compression seal for tight compression
(4). Install interior trim covers.
between the door and frame as follows:
4. Passenger/Cargo Compartment Door (1). Open door.
Replacement (369D/E/FF − 500N)
(2). Hold a strip of heavy paper against
A. Passenger/Cargo Compartment Door door seal so that strip extends approxi
Removal (369D/E/FF − 500N) mately 1/4 inch (6.35 mm) beyond seal
toward outside of doorway.
(1). Remove cover plates from interior trim
aft of crew doors. (3). While holding paper strip in place, close
door.
(2). Remove safety from top hinge pin.
(4). Attempt to pull paper strip from
(3). While supporting door, turn hinge pins between door frame and seal. Strip
to unlock the tabs. should not pull out unless a moderately
heavy pull is exerted.
(4). Remove lower pin, then remove top pin.
NOTE: Correct fit is indicated by an approxi
(5). Remove door from helicopter. mate 0.060 inch (1.524 mm) interference fit
B. Passenger/Cargo Compartment Door between door seal and bumper. Where strip
Installation (369D/E/FF − 500N) can be withdrawn with a light pull, fit of
door against frame is not sufficiently tight
(1). Slide door hinges into slots on side of to provide an adequate seal. This condition
airframe. may be due to deterioration of weatherstrip
compression seal, deformation of door
(2). Insert pins, from inside the aircraft, frame, worn hinges or improper latching.
into airframe holes and though hinges.
(5). Repeat this procedure at approximately
(3). Turn hinge pins to lock tabs into slots 1 foot (30 cm) increments along length
in airframe. of door seal.
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FUSELAGE
DOOR FRAME
SNAPVENT
PASSENGER/CARGO DOOR
(369D/E/FF - 500N)
PILOT'S DOOR
(369D/E/FF - 500/600N)
CLEVIS PIN
FUSELAGE STRUCTURE
HINGE PIN
PRELOAD SPRING
DOOR SPRING
RUBBER STOP
BUSHING DOOR STRUCTURE

DOOR HINGE HALF
G52-1001-1
Figure 201. Crew and Passenger/Cargo Door Installation (Sheet 1 of 2)
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BOLT
WASHER
SNAPVENT
WASHER WASHER
BOLT NUT
DOOR/HINGE ATTACHMENT
(TYP) AFT DOOR
MID DOOR
MID DOOR (600N)

AFT DOOR (600N)
G52-1001-2
Figure 201. Crew and Passenger/Cargo Door Installation (Sheet 2 of 2)
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7. Mid and Aft Door Strut Replacement (2). Slip snapvent flange into window hole
(600N) at an angle of about 30° degrees to
window surface.
(Ref. Figure 201)
(3). Be sure that ends of wire stiffener are
A. Mid and Aft Door Strut Removal (600N) inside window hole.
(1). Remove nut and washer that secures 9. Outside Handle or Spindle Replacement
gas strut pivot post ball to door fitting.
(Ref. Figure 202)
(2). Remove nut and washer that secures
A. Outside Handle or Spindle Removal
gas strut pivot post ball to airframe
fitting. (1). Remove three screws and washers
securing escutcheon to door exterior.
(3). With door in open position, pull gas
strut up away from fittings to remove. (2). Drive spring pin from handle and slide
handle from spindle.
B. Mid and Aft Door Strut Installation (600N)
B. Outside Handle or Spindle Installation
(1). Insert pivot post ball fitting, at shaft
end of strut, into outboard hole in (1). Attach replacement handle to escutch
airframe fitting and install washer and eon with handle washers. Use maxi
nut. mum number of handle washers
possible without impeding free move
(2). Insert pivot post ball fitting, at tube ment between handle and escutcheon.
end of strut, into hole in door fitting (2). Slide handle on spindle and secure
and install washer and nut. escutcheon to door with washers and
(3). While holding pivot post ball fitting to screws.
prevent rotation, torque nuts to 60—85 10. Automatic Latch Block Assembly
inch-pounds (6.78—9.60 Nm). Replacement
(4). Adjust strut pressure after installation (Ref. Figure 202)
by carefully loosening screw at end of
strut and releasing pressure until door A. Automatic Latch Block Removal
opens fully and operates smoothly
(1). Perform this procedure with door in
through full range of travel.
open position and handles at latched
rest position.
8. Snapvent Replacement
(2). Remove screws securing latch cover.
(Ref. Figure 201)
(3). Mark lockplate/nutplate so that
A. Snapvent Removal replacement latch block can be installed
at approximately same position as latch
(1). Push snapvent outward in window that is to be removed.
(open position).
(4). Remove four screws and washers
(2). Grasp open side of snapvent and gently securing latch block to lockplate/nut
squeeze it into an elliptical shape. plate. Note any washers found between
latch block and lockplate/nutplate.
(3). Slip snapvent out of window hole at These are adjustment shims and should
about a 30° degree angle to surface of be reinstalled at same location and
window. position at reinstallation of latch block.
B. Snapvent Installation (5). Remove cotter pin, washer and pin
securing rod end clevis to latch block.
(1). Grasp open end of snapvent and gently
squeeze it into an elliptical shape. (6). Remove latch block from door.
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MAINTENANCE MANUAL
(7). Lubricate moving parts of latch block B. Cam Lock Installation

(Ref. Automatic Latch Block Assembly
Repair). NOTE: Currently available cam lock is longer
than early cam lock and requires a spacer
B. Automatic Latch Block Installation between lock flange and outside surface of
door skin.
(1). Reconnect link and connector rod end to
handle arm with cotter pin and washer. (1). Position lock boss, torsion spring,
washer and replacement handle into
NOTE: Cotter pin and washer are to be in position and insert spindle.
stalled on outboard side of connector rod end
to eliminate possibility of interference. To (2). Install spindle washers and screw to
eliminate excess play, use extra washers for secure spindle in lock plate.
shimming.
(3). Attach one spring hook in hole of lock
boss and attach other spring hook at
(2). Secure latch block to lock plate with
notch in lock plate. Use wire to pull
four screws and washers.
spring hook into place.
(3). Check door latching and safelocking (4). Install outside handle.
operation and make any necessary
adjustment. (5). Check door latching and safelocking
operation and make any necessary
11. Cam Lock Replacement adjustment.
(Ref. Figure 202) 12. Latch Assembly or Striker Adjustment
A. Cam Lock Removal (Ref. Figure 203)
(1). Remove outside handle.

(2). Remove latch block. Item Nomenclature
(3). Note position of lock boss and handle CM425 Sealing compound
torsion spring to aid at reinstallation.
(1). Adjust latch assemblies and strike as
(4). Hold handle, lock boss and torsion necessary to ensure proper door
spring in position and withdraw latching, safelocking and keylocking
spindle. Then slide handle lock boss functions.
and torsion spring out of lock plate.
(2). After adjustments are made, perform a
(5). Remove handle grip from handle arm final inspection of all latching and
by loosening setscrew and sliding grip locking functions, then install latch
from arm. covers.
NOTE: When lock is set to locked position, be (3). Fill in gaps and fair-in area between
sure that cam actuates hinged lock bar. strikes and bumper stripes at each
When lock is in correct position, secure it in position with sealant (CM425).
place by center-punching surface of lock
plate assembly close to flat on hexagonal A. Door Seal Compression Adjustment
locking nut.
To adjust door seal compression, remove latch
(6). Replace key-operated cam lock by covers. Move strikes as necessary in their
unscrewing hexagonal nut. slotted mounting holes.
Page 207
MAINTENANCE MANUAL
SNAPVENT SNAPVENT
LATCH COVER
DOUBLER (TYP)
DOUBLER
STOP
AUTOMATIC
DOOR LATCH
WINDOW
MECHANISM
STOP
DOOR SEAL
LATCH COVER
(TYP) (4 PLCS)
AUTOMATIC
DOOR SEAL PASSENGER/CARGO DOOR
DOOR LATCH (369D/E/FF - 500N)
MECHANISM
CONNECTOR
CLEVIS ROD
DOOR PANEL
PILOT'S DOOR LATCH SLIDER

(369D/E/FF - 500/600N)
ROD MOUNTING LATCH BLOCK

BRACKET
STRIKER
ASSEMBLY
LATCH BLOCK
NOTE 2 SPACER
MOUNTING
BRACKET
SPRING
SHIM WASHER
(NOTE 3) CLEVIS
DOOR PANEL (NOTE 1)
(NOTE 2) DOOR
LATCH SLIDER
FRAME
LOCKPLATE ASSEMBLY
LATCH BLOCK ASSEMBLY
(NOTE 4)
SPRING HOOK NOTCH CONNECTOR ROD
CLEVIS
SPINDLE LINK PIN
SHIM LINK
ARM LATCH BLOCK ASSEMBLY
GRIP
ESCUTCHEON NOTES:
SET SCREW 1. FOR ADJUSTMENT INFORMATION, REFER TO
SPRING PIN LOCK BOSS ADJUSTING LATCH COMPRESSION.
2. INSTALL OUTBOARD TO ELIMINATE POSSIBILITY
OF INTERFERENCE.
SPACER CONNECTOR 3. AS REQUIRED, FOR LATCH ADJUSTMENT, NOT
CAM LOCK
(NOTE 5) ROD END ON ALL WINDOWS.
(KEY OPERATED)
4. IDENTIFIED AS NUTPLATE AT OTHER LOCATIONS.
LATCH ASSEMBLY - EXPLODED VIEW
EARLY SYSTEM 5. SPACER REQUIRED ON NEW LOCKS WHICH ARE
LONGER THAN EARLY MODEL CAM LOCKS.
G52-1002-1
Figure 202. Door Latching System Installation (Sheet 1 of 2)
Page 208
MAINTENANCE MANUAL
CORNER CRANK
ASSEMBLY
PUSH/PULLROD ATTACHMENT
(TYP)
LATCH COVERS
(6 PL)
NOTE 6
LATCH COVERS
(8 PL)
LATCH BLOCK ATTACHMENT

(TYP)
NOTES: (CONT.)
6. SHIM AS REQUIRED (MAX. 2 WASHERS AT EACH RIVET
LOCATION) BETWEEN DOOR STRUCTURE AND CORNER
CRANK ASSY. MAXIMUM GAP AT RIVET NOT TO EXCEED. G52-1002-2
Figure 202. Door Latching System Installation (Sheet 2 of 2)
Page 209
MAINTENANCE MANUAL
B. Engagement Depth of Latch Bolts with modifying as required to compress

Striker Adjustment spring 0.060—0.080 inch
(1.524—2.032 mm) when mechanism is
Adjust engagement depth of latch bolts with at safelocked position.
strikes by removing latch covers and moving
latch assemblies as necessary in their slotted (2). Fill gaps and fair-in area between latch
mounting holes or by adding shims under strikes and bumper strips at each
strikes. position, using sealant (CM425).
NOTE: Complete safelocking exists when latch 13. Latching Mechanism Operational Check
bolt extension is at maximum and roller on (Early System)
safelock trigger is engaged in safelock slot in
latch slider. At this condition, safelock trig (1). Check inside and outside door handle at
ger retracts when latch slider is moved all positions for function.
slightly in unlatch direction.
(2). Close door from inside. Entire beveled
C. Connector Rod Adjustment face of each bolt must make contact
(1). Open door or remove from helicopter. with strike and must hold door firmly
against door seals. Bolts must be
(2). Remove latch cover. positioned on strike such that there is
sufficient space for bolt to extend an
(3). Press all safelock triggers and rotate additional minimum 0.125 inch (3.175
handle to safelock position. Remove mm) into strike for safelocking latches
clevis pin from connector rod or latch (Ref. Figure 203).
being adjusted.
(3). Check that each latch bolt makes
(4). Move latch slider manually to complete
contact with mating strike. Unequal
safelock position. Adjust connector rod striking and latching indicates latch
length so that clevis pin can be in assembly or strike require adjustment
stalled easily. or shimming.
NOTE: Position of fourth and first latches can
be individually adjusted without disturbing (4). Safelock door and observe that door is
adjustment of other latches. If position of forced inward for seal compression at
second or third latches is adjusted, then all each latch position. Unequal safelock
should be checked. When adjusting all four, ing may indicate that connector rods
start with third latch, and proceed to sec are not properly adjusted for complete
ond, first and then fourth. extension of latch bolts.
D. Latch Compression Adjustment (Early 14. Hook−Latch Door Latching System

System) Operational Check
Latch compression spring adjustment may be (Ref. Figure 203)
necessary and should be checked if part
replacement, particularly in stack-up between Perform following operational check of
upper clevis on third latch and first mounting hook-latch door-latching system. If malfunc
bracket or change in position of clevis has been tion is noted, refer to Table 201 for trouble
made. shooting and repair information.
(1). Check inside and outside door handle at
Consumable Materials all positions for function. From open
(Ref. Section 91−00−00) and lock positions door handle should
Item Nomenclature spring back to rest position when
CM425 Sealing compound released.
(2). Move handle to open position. Ensure
(1). Readjust spring load using shorter or all four latch hooks are fully extended
longer spring compressor spacer and by from their latch blocks.
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MAINTENANCE MANUAL
INSIDE HANDLE UNLATCH

ACTION POSITION
OUTSIDE HANDLE SAFELOCK
ACTION POSITION
INSIDE HANDLE TUBING
OUTSIDE HANDLE SAFE

LOCKED POSITION
INSIDE HANDLE LATCHED OUTSIDE HANDLE

REST POSITION (NOTE 2) DOOR FRAME STRUCTURE
CHANNEL STRIP LATCH COVER
OUTSIDE HANDLE LATCHED

INSIDE HANDLE REST POSITION (NOTE 2)
SAFELOCKED POSITION
DOOR PANEL
OUTSIDE HANDLE UNLATCH AC

TION POSITION
HANDLE POSITIONS
SAFELOCK ACTION (RIGHT DOOR INSIDE VIEW)
LATCH SLIDER DOOR FRAME

CLEVIS
BUMPER
SAFELOCK SLOT
SHIM
SAFELOCK TRIGGER
LATCH BOLT
LATCH BOLT
ROLLER STRIKER PLATE
INSIDE
HANDLE 0.88 INCH (22.35 MM)
UNLATCH ACTION
NOTE 1 NOTES:
1. WHEN LATCH IS COMPLETELY SAFELOCKED,
MINIMUM OF 0.125 INCH (3.175 MM) OF FLAT
SURFACE (BEYOND ANGLED LEADING EDGE )
OF LATCH BOLT MUST BE ENGAGED WITH
LATCH ENGAGEMENT STRIKER PLATE.
(THIRD LATCH INTERIOR 2. LATCHED REST POSITION APPLIES WITH DOOR
SHOWN FOR CLARITY) OPEN OR CLOSED.
G52-1003-1
Figure 203. Door Handle Positions and Latch Engagement (Sheet 1 of 3)
Page 211
MAINTENANCE MANUAL
AFT DOOR ASSY

MID DOOR ASSY
WINDOW SEAL
VIEW LOOKING DOWN
DOOR
DOOR FRAME
LATCH BLOCK ENGAGEMENT

(TYP)
G52-1003-2
Page 212
MAINTENANCE MANUAL
WITNESS HOLE
PIN
LATCH LATCH
SLIDER HOUSING
LATCH BLOCK
ASSEMBLY
0.050 INCH (1.27 MM) MAX
GAP BETWEEN DOOR
STRIKER PIN AND HOOK
LATCH WHEN DOOR
LATCH CLOSED AND LATCH IN
SLIDER DEAD BOLT POSITION.
G52-1000-203-3

(3). Check latch blocks, latch sliders, door that semi-circle cutout on latch slider is
waffle and striker pin assemblies for fully seated around pin on latch block.
any nicks, dents, scratches, chipped
paint or other evidence of contact (7). Move handle to open. Note that all four
caused by misalignment of door latches latch hooks extend fully from their
or striker pin assemblies. latch blocks and fully disengage their
striker pins, allowing the door to open.
Handle should spring back to rest
NOTE: Extreme temperatures may cause door
position when released.
seal to swell or door seal-to-door frame
bonding failure. Door seal protrusions 15. Autolatching Pilot and Cargo Doors
caused by swelling or bonding failure may Operational Check
interfere with latching function.
NOTE: When opening door, apply light inward
(4). Check door seal and repair as required. force on door. This reduces wear of latching
mechanism by overcoming door seal pres
(5). Close door firmly from inside helicopter. sure.
Check that all four latch hooks engage
(1). Open and close door to check for smooth
their striker pins and that there is not
operation of handles and latch mecha
more than 0.050 inch (1.27 mm)
nism. Check operation of door stop.
between each hook and striker pin.
(2). Close door from inside. Check all inside
(6). Move handle to lock (full down). With latches for correct engagement at latch
door locked, use flashlight to check and safelock positions of interior and
witness hole on each latch block. Note exterior handle. (Ref. Figure 203).
Page 213
MAINTENANCE MANUAL
(3). Check that setting interior and exterior

handles to safelock position pulls door Consumable Materials
inward for proper closure and sealing. (Ref. Section 91−00−00)
Item Nomenclature
(4). Check that key locks and unlocks door CM219 Methyl−propyl−ketone (MPK)
handle.
16. Door−Latching Mechanism Inspection (All
Systems) 18. Window Replacement
(Ref. Figure 202 and Figure 203) A. Early Style Window Replacement
Make following checks with magnification (Ref. Figure 205) For repair of plastics refer to
glass and strong light: FAA AC 43.13-1B. Replace window as follows:
(1). All parts for excessive wear, nicks,
cracks and corrosion. Consumable Materials
(2). Threaded parts for worn, crossed or Item Nomenclature
otherwise damaged threads. CM415 Cement
(3). Early latch block assemblies for broken CM418 Cement, epoxy
springs and wear on strike contact CM425 Sealing compound
surfaces of latching bolts; and for undue CM432 Dichloromethane
wear of latch sliders, bolts and bolt CM433 Ethylene chloride
rollers. Current latch block assemblies CM717 Tape, pressure sensitive
for wear, damage or distortion of latch
sliders and latch hook.
(1). Remove snapvent from window (Ref.
(4). Cam lock for jamming when key is Snapvent Replacement).
operated.
(2). Drill out rivets attaching window
(5). Link for wear or distortion. retainers to door structure and remove
window. Remove two screws, washers
(6). Handles for distortion, worn pivot holes
and nuts from door hinge doubler.
and worn finish.
(3). If door frame or window is to be reused,
(7). Escutcheon and handle for looseness, carefully scrape off sealant around edge
distortion, thread damage and break of door or window frame using a
age. wooden, plastic or other suitable
(8). Lockplate assembly for wear, distortion, nonmetallic scraper.
thread damage and breakage. (4). Repair retainer-to-window bond, if
applicable, with dichloromethane
(9). Latch block nutplates for thread
(CM432) or ethylene chloride (CM433);
damage and loose rivets.
or use PS-18 or S147 cement (CM415).
(10). Rods and clevis for wear in clevis pin (5). Trim retainer as required to provide
holes, thread damage, and distortion. clearance for door handle and end butt
joint.
17. Anti−Chafing Tape on Door Frame Repair
(6). Place window in position and check for
(Ref. Figure 208) Inspect condition of anti- 0.380 inch (9.652 mm) minimum
chafing tape installed on pilot's and cargo engagement and flush fit with window
compartment door frames. For minor repair, frame. Trim excess if required.
remove defective tape where necessary. Clean
frame surface with MPK (CM219). Replace (7). Use 1/2 inch (12.70 mm) pressure-sen
with polyurethane pressure-sensitive tape sitive tape (CM717) on edge of window.
(CM717). Bond seals to retainer and to door
Page 214
MAINTENANCE MANUAL
frame using cement, epoxy (CM418); (6). Apply 0.250 inch (6.35 mm) tape
bond inside of seals to window using around outside of drawn line.
sealant (CM425). Do not stretch seals
when bonding. (7). Trim glass to the outside of applied
0.250 inch (6.35 mm) tape.
(8). With retainer and window in position
on door frame, press down firmly and (8). Remove tape and gently smooth the
evenly on retainer so that seals are edges.
compressed tightly against window NOTE:
around full circumference of door
D It is best to have ends of seal on aft side of
frame.
window to help keep moisture out while
(9). Locate existing holes in door-reinforc in flight.
ing frame. Mark and drill holes in D Ensure seal is firmly worked onto door to
retainer. It is permissible to install new prevent seal from being cut too short.
rivets between existing holes in rivet
pattern. (9). Install window seal around periphery of
window opening with groove for glass to
(10). Rivet window to door using rivets of the inside. Cut seal to size if new.
correct length. Blind rivets are used for
retainers riveted to door reinforcing (10). Gently trim seal, where needed, around
frame. top door hinges.
Do not use any tools with sharp
(11). Install doubler over retainer at hinge CAUTION edges to aid in installing glass
area with two screws, washers and
nuts. Drill (No. 21 drill) and ream to into seal, glass is easily damaged.
0.166 inch (4.216 mm) diameter NOTE: To aid in installation of glass into seal,
window panel for screws, using slow use a mild mixture of soapy water liberally
speed drill (700-800 rpm). applied to the edge of the glass and into
groove in seal. Do not use any lubricants.
(12). Install snapvent (Ref. Snapvent
Replacement). (11). Install glass from inside by sliding up
into the seal.
(13). Remove protective covering and clean
window (Ref. Section 20-20-00). (12). With hands on either side of glass, work
glass firmly into seal.
B. Current Style Window Replacement
(13). Using a blunt plastic spatula or probe,
(Ref. Figure 206) gradually work edge of window into
(1). Using a blunt plastic spatula or probe, groove of window seal.
pull back edge of window seal and (14). If there is a gap at the seal ends, use
gradually work window out from groove commercially available clear silicone
in seal. seal to fill gap.
(2). Remove seal and clean for re-installa 19. Hinge Replacement
tion of window, discard if not pliable.
(Ref. Figure 204)
(3). Mask around new glass for marking.
(1). Remove door and drill out hinge-at
(4). Place new glass against door and center taching rivets.
over the window opening.
(2). Install replacement hinges at body
(5). Trace line on glass from window attach points with door hinge pins.
opening in door.
(3). With damaged hinges removed, install
NOTE: The following step is to ensure the glass doors in closed position. Have an
is larger than the door opening so glass will assistant retain door in place by
not blow out in flight. actuating door handle locking levers.
Page 215
MAINTENANCE MANUAL
(4). If required for door fit, use one-piece (3). Replace preload spring; with longest
solid aluminum alloy shim, up to 0.040 flat area outboard and aft in hinge body
inch (1.016 mm) maximum thick recess.
ness trimmed flush with hinge outer
edges, under upper or lower hinge (4). Replace door spring; with longest flat
(between hinge and door exterior). area also outboard and aft in body
hinge recess.
(5). Mark hinge rivet attach locations
through existing holes in door. Locate NOTE: Forward curved area of door hinge pres
and mark blind rivet attach points ses against preload spring inboard curved
(cargo door only). area, at installed position.
(6). Remove door hinges and check for (5). Install hinge pins and cotter pins. Pins
proper edge distance. may be installed upward if interference
(7). Drill holes with a No. 28 drill at pilot's does not permit installation with cotter
door upper and lower hinge aft attach pin hole down.
points. Use a No. 21 drill at all other
pilot and cargo door attach points. (6). Cover exposed sharp edges of cotter
pins and pins with sealer (CM424).
(8). On pilot's door upper hinge, install
rivets with washers under bucked (7). Install doors and perform operational
heads. check (Ref. Automatic Latching Mecha
nism (Early System) Operational
(9). Install rivets at remaining pilot's door Check.
attach points.
SHIM AS REQUIRED
(10). Install two mechanically-expanding (NOTE)
rivets at aft cargo door hinge attach
points.
(11). Install four rivets at remaining attach
points.
(12). Paint as required.
(13). Install doors and perform an operation
al check (Ref. Automatic Latching
Mechanism (Early System) Operational DOOR STRUCTURE
Check). DOOR HINGE HALF
SHIM AS REQUIRED
A. Preload Spring Replacement (NOTE)
(Ref. Figure 205)
Item Nomenclature
NOTE: The following procedures apply to both

upper and lower hinges.
NOTE: SHIM AS REQUIRED UNDER HINGE WITH ONE PIECE
OF 2024-T3 ALUMINUM, 0.050 IN. (1.270 MM) MAXIMUM. TRIM
(1). Remove two cotter pins and clevis pins. TO OUTER PERIPHERY OF HINGE.
G52-1004
(2). Remove door spring first; then remove
preload spring. Figure 204. Door Hinge Replacement
Page 216
MAINTENANCE MANUAL
WINDOW LATCH COVER

(TYPICAL)
FUSELAGE
DOOR FRAME
DOOR SEAL
DOOR SEAL
DOOR PANEL
PILOT'S DOOR CARGO DOOR
(369D/E/FF - 500/600N) (369D/E/FF - 500N)
CLEVIS PIN
FUSELAGE STRUCTURE
SHIM DOOR HINGE RETAINER
HINGE PIN (AS REQUIRED) DOUBLER
(NOTE) RIVET
PRELOAD PRESSURE
SPRING SENSITIVE TAPE
DOOR
SPRING HINGE
WINDOW
DOOR PANEL
WINDOW ENGAGEMENT
0.380 INCH (9.652 MM) MINIMUM
RUBBER
STOP WINDOW REPAIR
BUSHING DOOR STRUCTURE
DOOR HINGE HALF
HINGE REPAIR
NOTE:
FILL GAP WITH SEALANT.
G52-1001-3A
Figure 205. Window and Hinge Repair
Page 217
MAINTENANCE MANUAL
SEAL SEAL
0.25 IN.
(6.35 MM)
I
WINDOW N
B
R
D
O
U
T
DOOR FRAME
B
R
D
SEAL
NOTE:
600N SHOWN, TYPICAL OF ALL HELICOPTERS. G52-1001-4
Figure 206. Current Style Window Installation

B. Rubber Stop Replacement
(Ref. Figure 205) Replace rubber door stop if (Ref. Section 91−00−00)
damaged or partially separated. Remove door Item Nomenclature
stops by carefully prying bonded rubber out of
hinge recess. Bond new stop to forward end of CM411 Adhesive, epoxy
hinge recess with adhesive (CM411).
Page 218
MAINTENANCE MANUAL
20. Automatic Latch Block Assembly Repair (2). Replace anti‐chafing tape if damaged.
(Ref. Figure 201 and Figure 207, Sheet 1 of 2) (3). Install washer (if applicable), shims,
Replace worn or damaged parts as necessary. dam (if applicable), strike pin and
Disassemble only to extent required for secure with screws.
replacement of parts. Perform following steps
as required: 22. Litter Door Inspection (50 Hour)
The following is a procedure for inspecting the
Consumable Materials litter door installation for proper condition and
(Ref. Section 91−00−00) security of the quick-release fastener assem
Item Nomenclature blies and the rubber seal (gasket) installed
CM108 Graphite, powdered between the window glass and door frame. The
CM118 Grease
visual inspection is applicable to the PN
369H92733-1 / -2 bubble window assemblies
CM234 Solvent, dry-cleaning (or PN 369H92731-1 / -2 flat window assem
CM307 Lacquer, acrylic semi-gloss blies, if installed) in the PN 369H90085 litter
door installation.
(1). Lubricate all moving parts except lock, (1). Remove quick-release fasteners
with grease (CM118) to prevent securing bubble (or flat) windows to
binding. litter doors.
(2). Lubricate lock with powdered graphite (2). Visually inspect each fastener for
(CM108). condition, and each anchor receptacle in
door structure for condition and
(3). At time of disassembly clean reusable
security of attachment.
parts except locks, using soft bristle
brush dipped in solvent (CM234). (a). Replace each fastener if stud is loose
or worn.
(4). Dry parts using clean, lint-free cloth or
dry compressed air at 20 psi maximum. (b). Replace anchor receptacle and/or
rivets as required.
(5). Clean key-operated cam locks, using
dry compressed air at 20 psi maximum. (3). Visually inspect rubber seal (gasket) on
window assemblies for condition. Seal
(6). Touchup handles with semigloss black must be fully intact; rebond seal to door
acrylic lacquer (CM307). structure as required.
(7). Eliminate binding by lubricating (a). Replace seal if worn, cracked or hard.
moving parts.
(4). Reinstall window assemblies to litter
21. Strike Pin Repair doors using quick-release fasteners.
(Ref. Figure 207) (5). Check for gaps between window glass,
rubber seal and door structure.
NOTE: The 369 model has three different con
figurations. Select the configuration that (6). Replace seal and/or use shorter length
pertains to your specific application. studs if any gap is noted.
(1). Remove screws, strike pin, dam (if (7). If seal is extruded, use longer length
applicable), shim and washers (if studs; replace seal if extrusion still
applicable) from door frame. exists.
Page 219
MAINTENANCE MANUAL
LATCH HOOK
CONNECTOR ROD
LATCH
BLOCK
CONNECTOR ROD
CLEVIS CONNECTOR ROD
LATCH SLIDE
NOTE
LATCH BLOCK
MOUNTING LATCH BLOCK
BRACKET
STRIKER ASSEMBLY
LATCH
BLOCK
LATCH
HOOK
HANDLE
DOOR FRAME ASSEMBLY
LATCH
BLOCK CONNECTOR
CONNECTOR ROD
ROD
CLEVIS LATCH LATCH
HOOK BLOCK
LATCH BLOCK ASSEMBLY HANDLE LATCH

ASSEMBLY HOOK
NOTE:
1. SPRING USED WITH EARLY SYSTEMS ONLY.
CURRENT SYSTEM
SOLID ROD USED ON CURRENT SYSTEM. CONFIGURATION
G52-1005-1A
Figure 207. Automatic Latch Block and Striker Repairs (Sheet 1 of 2)
Page 220
MAINTENANCE MANUAL
DOOR FRAME
(CARGO DOOR
FRAME SHOWN)
RIVNUT
ANTI-CHAFING TAPE
SHIM
WASHER
SCREW
SCREW
SHIM
STRIKER
SCREW DOOR FRAME
STRIKER PIN
SCREW
SHIM
SCREW
DOOR FRAME RIVNUT
WASHER
STRIKER PIN
NUTPLATE
RIVET
WASHER
RIVET
NUTPLATE
G52-1005-2A
Figure 207. Automatic Latch Block and Striker Repairs (Sheet 2 of 2)
Page 221
MAINTENANCE MANUAL
UPPER LATCHES
3.50 INCH 3.50 INCH (8.89 CM)

(8.89 CM) 8.00 INCH (20.32 CM) BLENDED FROM 0.12 INCH (3.05 MM)
DIMENSION TO EDGE OF DOOR (2 PLACES)
8.00 INCH 0.12 INCH (3.05 MM)

(20.32 CM)
SEAL
A
0.12 INCH (3.05 MM)
A 0.25 INCH (6.35 MM)
8.00 INCH (20.32 CM)

SEAL
(FLUSH WITH B 0.12 INCH (3.05 MM)
EDGE OF DOOR
AT BOTTOM) A
B 0.35 INCH A
0.12 INCH
(3.05 MM) (8.89 MM)
PILOT'S DOOR
(LEFT DOOR SHOWN)
(NOTE 1)
FINGER TYPE SEAL
(NOTE 2, 3)
SEAL
SECTION A-A
A
DOOR REINFORCING 0.12 INCH
FRAME (3.05 MM) A 0.025 INCH
(NOTE 1) SEAL (FLUSH WITH CARGO DOOR
(6.35 MM)
EDGE OF DOOR AT (LEFT DOOR SHOWN)
BOTTOM)
(NOTE 2, 3)
SECTION B-B
(BOTTOM SEAL FINGERS DOWNWARD;

PILOT'S DOOR ONLY) NOTES:
1. SEAL NOT TO BE LOCATED ON RADIUS OF
REINFORCED FRAME.
2. SEAL INSTALLED USING ADHESIVE ACCORDING
TO CONTAINER INSTRUCTIONS.
3. SHIM AS REQUIRED UNDER SEAL USING TAPE
BONDED WITH ADHESIVE. G52-1000A
Figure 208. Door Seal Repair
Page 222
MAINTENANCE MANUAL
23. Pilot and Cargo Door Repair 24. Improved Door Seal Installation
A. Seal Repair
installation of QGR2178 door seals on the
cargo/passenger doors.
(Ref. Figure 208)
Consumable Materials (Ref. Section 91−00−00)
(Ref. Section 91−00−00) Item Nomenclature
Item Nomenclature CM220 Naphtha aliphatic
CM418 Cement, epoxy CM235 Cleaner
CM322 Primer, Silicone, Red
CM414 Adhesive, cyanoacrylic / Accelerator
(1). Carefully pull or scrape away damaged
CM439 Adhesive
seal.
(2). Restore chemical film protection to any (1). Remove existing door seals using
base metal exposed during cleaning Desoclean 45 (CM235) or naphtha
process (Ref. Section 20-20-00). aliphatic (CM220). Ensure that all
surfaces are clean to allow proper
(3). Clean seal contact area on metal and adhesion of new seal material. Allow
rubber seal. surface to air-dry a minimum of 15
minutes.
(4). Carefully align and bond seal to
mounting surface with cement, epoxy
NOTE:
(CM418) according to container instruc D On the 369D/E/FF - 500N helicopters,
tions. seals are to be installed around the entire
circumference of the aft doors.
NOTE: Correct seal mounting position results D On the 600N helicopters, seals are to be
in an approximately 0.060 inch (1.52 mm) installed around the entire circumference
interference fit between door seal and bum of the mid doors. Seals are to the applied
per. to the top, bottom and aft edges of the
aft-cabin doors.
B. Partially−Separated Seal Repair
(2). Prime seal faying surface with red
silicone primer (CM321) and allow to
(Ref. Figure 208)
air-dry a minimum of 15 minutes.
(3). Apply a thin uniform coat of adhesive
Consumable Materials (CM439) to faying surface of door and
(Ref. Section 91−00−00) seal. Allow to air-dry a minimum of
Item Nomenclature five minutes.
(4). Apply a second thin uniform coat of
CM418 Cement, epoxy adhesive to faying surface of door and
seal. Allow to air-dry a minimum of
five minutes.
(1). Clean separated area with naphtha
(CM220) and allow to dry for minimum (5). Test glue with clean knuckle. If adhe
of 20 minutes. sive does not transfer to knuckle, press
the seal into place.
(2). Apply one uniform brush coat of (6). Butt joints at forward and aft lower
cement, epoxy (CM418) to rubber seal locations.
and mating surface contact area. Allow
to dry for 5 minutes and press mating (7). Maximum gap of 0.030 inch (0.762
surfaces together. mm) at butt joints.
Page 223
MAINTENANCE MANUAL
(8). Miter joints at upper locations. NOTE: Use glue very sparingly to achieve best
bond.
(9). Bond mitered joints with adhesive
(CM414). (10). Trim seal flush with edge of door.
QGR2178 SEAL
SEAL MAY BE LOCATED FROM

EDGE TO INCLINE AS SHOWN
TRIM SEAL FLUSH WITH AND AS REQUIRED TO ENSURE
EDGE OF DOOR. PROPER SEAL OPERATION.
POSITION OF SEAL ALONG HINGE SIDE
TYPICAL SEAL POSITION;

SEAL MAY BE RELOCATED AS REQUIRED TO ACHIEVE
PROPER SEAL BETWEEN DOOR AND JAMB.
88-759
Figure 209. Improved Door Seal Installation
Page 224
MAINTENANCE MANUAL
Section
52−40−00
Engine Access
Doors
MAINTENANCE MANUAL
ENGINE ACCESS DOORS

1. Engine Access Door − General 3. Engine Access Door Inspection
(Ref. Figure 201) Engine access doors have (1). Check door hinges, door-attaching
upper and lower door hinges that allow door fit hardware and latches for looseness,
adjustment. Fore and aft adjustment and fit of cracks and damage.
doors is made possible by slotted holes in
hinges and serrated mating surfaces between (2). Check outside edge of door for security
hinges and doors. Lateral adjustment is of bonding between outer and inner
obtained with laminated shims under door skin. Any separation requires repair.
hinges. Closed-door alignment is provided by (3). Inspect doors for corrosion, distortion,
spring-type retainers on door frames at the breaks or cracks and condition of
lower latch, and two locating pins that engage abrasion strip tape along upper inside
holes in lower fuselage structure. door edge and under retainers.
2. Engine Access Door Replacement (4). For repairs (Ref. Engine Access Doors
Repairs).
A. Engine Access Door Removal
4. Engine Access Door Repair
(1). Release three latches to open access
doors. Index mark hinge, shim and A. Sheet Metal Repair
serrated plate to door structure.
(Ref. CSP-SRM-6, Structural Repair Manual)
Remove three engine access door hinge
Abrasion strip tape along upper inside door edge
attachment screws with washers.
and on area that mates with retainers must be
Forward screws are attached with nuts
replaced when worn.
and aft screws attach to rivnuts.
B. Abrasion Strip Replacement
(2). For inspection (Ref. Engine Access Door
Inspection).
B. Engine Access Door Installation (Ref. Section 91-00-00)
Item Nomenclature
Consumable Materials CM220 Naphtha aliphatic
(Ref. Section 91-00-00) CM710 Tape, high temperature
Item Nomenclature CM717 Tape, pressure sensitive
(1). Replace worn abrasion strip tape along
upper inside door edge by cleaning
(1). Position door and temporarily install contact area with naphtha (CM220);
shim, serrated plate and attachment allow to air-dry a minimum of 30
hardware. minutes. Install 0.50 x 40.0 inch (1.27 x
(2). Align indexing marks on shim, serrated 101.60 cm) strip of polyurethane tape
plate and hinge with those on door and (CM717) to clean, dry surface. Apply
then tighten screws. hand pressure to ensure firm contact
and trim as required.
(3). Close and latch doors and check for
(2). Replace worn abrasion strip on area
firm fit with no deflections.
that mates with retainers by cleaning
(4). Apply sealing compound (CM425) to all retainers with naphtha (CM220).
cotter pins. Install high temperature tape (CM710)
to clean, dry surface. Apply hand
(5). For adjustment (Ref. Engine Access pressure to ensure firm contact. Trim as
Door Adjustment). required.
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MAINTENANCE MANUAL
C. Hinge Replacement (1). Carefully drill out rivets and remove

defective latch hook or catch from
Replace door hinges as follows: engine access door or fuselage structure
Replace defective stops or serrated
Consumable Materials adjustment plates, if required, by
(Ref. Section 91-00-00) drilling out attaching rivets.
Item Nomenclature
(2). Locate existing rivet holes and install
CM318 Primer replacement latch, catch, door stop or
adjustment plate. Secure with replace
(1). Remove door from fuselage structure ment rivets.
(Ref. Engine Access Door Removal).
(3). Adjust latches as required for proper
(2). Remove nut, washers and hinge pivot tension of latch lever to catch without
screw. deflecting door (Ref. Engine Access
Door Adjustment).
(3). Carefully press out hinge pivot point
spacer and separate hinge halves. (4). Refinish area (except latch lever
Retain two nylon washers. assembly) as required (Ref. Section
20-30-00).
(4). Carefully drill out rivets that secure
defective hinge half to fuselage struc 5. Engine Access Door Adjustment
ture.
(5). Transfer existing hole pattern in Door alignment is provided by means of
fuselage structure to replacement spring-type retainers riveted in door frames
fuselage hinge half and drill out holes. adjacent to lower latch.
Install hinge and shim on fuselage
structure and secure with replacement Consumable Materials
rivets. (Ref. Section 91-00-00)
Item Nomenclature
(6). Assemble hinge halves with nylon
washers as shown. Press steel pivot CM702 Lockwire CRES
spacer coated with primer (CM318)
through mating holes. Install pivot (1). Remove lockwire from threaded
screw with washer and nut. (adjustment) end of hooks.
NOTE: Install shims under door hinge to obtain (2). Loosen all hooks until spring type
firm fit without binding at door-to-fuselage retainers engage in light contact with
contact surfaces when door is closed. Use no door deflection when hooks are
slotted holes in hinge and serrated surfaces latched.
to obtain forward and aft adjustment. When
adjustments are complete, tighten screws (3). Unlatch doors and tighten all hooks
that secure hinge to access door. four to five turns. Check door latching
(7). Refinish repaired area (Ref. Section and make additional minor adjust
20-30-00). ments as required.
D. Catch/Latch Hook Replacement (4). Install lockwire (CM702) in hook

threaded end in a manner to allow
Replace defective catches or latch hooks as latching and unlatching without
follows: interference.
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MAINTENANCE MANUAL
ABRASION
STRIP TAPE
PLATE
CATCH
ABRASION
STRIP
STOP
HOOK
LEVER
AFT LATCHING
BRACKET
PIN
HOOK
PIN
BRACKET
BRACKET
LOWER BRACKET
INSTALLATION DOOR HOLD-UP HOOK
G52-4000-1
Figure 201. Engine Access Doors (Sheet 1 of 3)
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MAINTENANCE MANUAL
CATCH
HOOK
LEVER
C30/C47 FAIRING
RETAINER
ABRASION
STRIP
RETAINER
CATCH
LEVER
C20/C20R2 FAIRING
AFT LOWER LOCKING ASSEMBLY
G52−4000−2A
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MAINTENANCE MANUAL
FUSELAGE STRUCTURE
FORWARD HALF
RIVNUT
STEEL SPACER PLATE SHIM
NYLON WASHERS AFT HALF
LOWER HINGE
FUSELAGE STRUCTURE
SHIM
STEEL SPACER
FORWARD HALF
SHIM
PLATE
AFT HALF
NYLON WASHERS
UPPER HINGE
G52-4000-3
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MAINTENANCE MANUAL
Page 206
MAINTENANCE MANUAL
Section
52−50−00
Miscellaneous
Access Doors
MAINTENANCE MANUAL
MISCELLANEOUS ACCESS DOORS

1. Access and Inspection Provisions (3). Inspect doors for corrosion, distortion,
breaks and cracks.
Any time maintenance work is
CAUTION to be done near engine air and 3. Pilot Compartment Floor Access Doors
engine cooling air inlets, use care to prevent
entry of foreign objects that might later be Each of the two pilot's compartment floor
sucked into compressor or cooling air blow access doors are formed by two hinged panels,
er. Tape covers of cardboard or other suit hinged at the forward edge to the pilot's
able material in place over engine cooling compartment floor.
air screens. Covers should not be removed
until work is completed and debris is thor A latch at the rear, secures each door in place.
oughly cleaned out of the area. Two stainless steel heel strips are hinged and
held in place over each door by a spring.
Removable access doors and covers are
provided in the helicopter for servicing, NOTE: Remove heel strips for better access.
inspection, removal, installation and adjust Detach springs from clips on underside of
ment of components. strips. Remove hinge pins attaching forward
ends of strips to natatorium pedal mounting
Locations of access and inspections provisions bracket.
are shown in Figure 201 for 369D/E/FF,
Figure 202 for 500N and Figure 203 for 600N 4. Pilot Compartment Floor Access Door
helicopters. Replacement
Areas, components and items accessible A. Pilot Compartment Floor Access Door
through locations shown in the figures are in Removal
Table 201. Screws are used to secure access
doors in stress areas. (1). Remove floor access doors by releasing
Liquid level sight gages allow inspection of latch at rear of door.
lubricant levels for main transmission, engine (2). Raise and hold up rear of heel strips for
oil tank and tail rotor transmission (369 access to hinge pins at forward end of
D/E/FF) or fan transmission (500/600N). door.
Methods for removal and installation are
(3). Remove hinge pin securing forward
obvious for most doors and covers.
edge of door to pilot's compartment floor
For information on access doors and covers and remove door.
that are also used for interior trim, Refer to
Sections 25-30-00 and 25-40-00. B. Pilot Compartment Floor Access Door
Installation
2. General Access Doors Inspection
(1). Position door and secure forward edge
(1). Check door hinges, door-attaching to floor using hinge pin.
hardware and latches for looseness,
cracks and damage. (2). If removed, heel strips are reinstalled
by inserting hinge pins through
(2). Check outside edge of door for security brackets on forward end of strip and
of bonding between outer and inner anti-torque pedal mounting bracket
skin. Any separation requires repair, and connecting springs to clips on
refer to Structural Repair Manual. underside of heel strips.
Page 201
MAINTENANCE MANUAL
Table 201. Access and Inspection Provisions Information

Door, Cover or Access Provision Provides Access To
Air inlet forward fairings Main rotor mixer controls, main rotor mast base and supporting
structure.
Collective stick cover Aft end of collective stick and associated electrical wiring.
Wiring cover Electrical wiring at seat structure and auxiliary power receptacle.
Pilot’s seat cover or inboard collective Underseat controls for engine and flight control systems.
pitch stick cover
Plenum chamber access door (air inlet Interior of engine air inlet aft fairing.
bypass door)
Tail rotor drive shaft access door Tail rotor drive shaft and interior of air inlet forward fairing.
Pilot’s compartment floor access door Left door − battery.

Right door − optional avionics equipment and controls linkage.
Aft bulkhead access covers Right side − oil tank, oil cooler and oil system drain valve.
Left side − components of optional cabin heating installation and main
transmission oil cooler.
Footwell fairing Forward landing gear struts and dampers, controls of engine and flight
control systems and electrical wiring. Outboard windows allow
inspections of forward landing gear dampers.
Control access door (1) Lower end of tunnel−routed flight control rods and other control
components in underseat area.
Fuel vent cover Fuel cells vent system crossover fitting.
Tail rotor control bellcrank access Bellcrank connecting tail rotor control rod to tailboom control rod.
fitting
Boom bolts access covers Bolts that secure tailboom to fuselage aft section, tail rotor drive shaft,
tailboom control rod, and damper for tail rotor drive shaft.
Engine access doors Engine, transmission oil cooler, and components in engine
compartment.
Fuel cell access covers (1) Left door − fuel quantity transmitter, fuel shutoff valve, fuel cell cover
(for access to engine starting pump), and left fuel cell.
Right door − right fuel cell.
Tail rotor drive access hole (below Forward end of tail rotor drive shaft and limited access to aft end of
engine cooling air inlet screen) main transmission.
Instrument panel lower section front Electrical and avionics wiring at lower forward area of instrument panel.
panel
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MAINTENANCE MANUAL
Table 201. Access and Inspection Provisions Information

Door, Cover or Access Provision Provides Access To
Instrument panel lower section side Wiring, tubing, fuel shutoff control cable, and anti−torque control torque
panels tube.
Right side cover is mounting surface for landing light relay.
Left side cover mounting running time meter.
Cargo hook access cover Mount fitting and electrical connectors for optional cargo hook
installation.
Convenience trim panel and main Sight gage to check main transmission oil level. Chip detectors and
transmission trim panel (Ref. Sec. main transmission drain valve.
25−00)
Blower access door Main transmission, air cooler blower, and engine−to transmission drive
shaft.
Instrument panel fairings Avionics, gages and electrical wiring.
Engine oil filter access panel Gain access for replacement of engine oil filter. (369FF − 600N)
Access Provisions Unique to 500/600N

Air inlet forward fairings Main rotor mixer controls, main rotor mast base and supporting
structure.
Anti−torque splitter assembly, forward, intermediate and aft control
tube.
Engine plenum access fairing Inner area of air inlet aft fairing.
Fan inlet screen Fan blades and fan/gearbox access cover.
Fan gearbox access cover Fan gearbox and forward driveshaft.
Driveshaft door Forward driveshaft rear coupling.
Pressure relief screens Fan gearbox oil level sight gauge (L/H side).
Tailboom fairing (1) Tailboom attach bolts.

Anti−torque control cable quick disconnect and electrical connectors.
Horizontal stabilizer end plates (1) Vertical stabilator controls and YSAS actuator (R/H side).
Horizontal stabilizer access panel (1) Vertical stabilator controls.
Thruster fairing Rotating thruster attachment.
Access Provisions Unique to 600N

Forward floor access covers Fuel cell components.
Engine air bypass door Interior of engine.
NOTE:
(1) Items are stressed and must be installed prior to helicopter flight.
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MAINTENANCE MANUAL
# $ TAILBOOM MOUNTING
BOLTS ACCESS DOORS
PLENUM ACCESS
COVER
# AIR INLET FORWARD

FAIRING
# TAIL ROTOR CONTROL
BELLCRANK ACCESS COVER
# * ENGINE OIL FILTER

CONTROLS TUNNEL ACCESS DOOR
COVER
# $ TAIL ROTOR DRIVE ACCESS

HOLE (UNDER ENGINE COOLING
AIR INLET SCREEN)
# $ BLOWER ACCESS DOOR
# COLLECTIVE STICK COVER
INSTRUMENT PANEL # WIRING COVER

FAIRING-LEFT SIDE # TRIM MOTOR ACCESS
PANELS
# INSTRUMENT PANEL LOWER

SECTION SIDE PANEL
PILOT'S SEAT COVER
CAUTION:
ITEMS PREFIXED WITH AN ASTERISK ( * ) ARE STRESSED AND MUST BE
INSTALLED PRIOR TO HELICOPTER FLIGHT.
NOTES:
# ITEMS TO BE REMOVED FOR 100-HOUR OR ANNUAL INSPECTIONS.
$ ITEMS TO BE REMOVED FOR 300-HOUR INSPECTIONS. G52-5000-1B
Figure 201. Access and Inspection Provisions and Locations (369D/E/FF) (Sheet 1 of 3)
Page 204
MAINTENANCE MANUAL
# FOOTWELL # $ * CONTROLS
FAIRING ACCESS DOOR
INSTRUMENT PANEL
TAIL ROTOR DRIVE FAIRING-RIGHT SIDE
SHAFT ACCESS DOOR
PLENUM CHAMBER
ACCESS DOOR
# TAIL ROTOR CONTROL
BELLCRANK ACCESS COVER
# INSTRUMENT PANEL
LOWER SECTION SIDE
PANEL

SECTION FRONT PANEL
PILOT'S COMPARTMENT
FLOOR ACCESS DOOR
# * FUEL CELL
ACCESS DOOR
ENGINE ACCESS
DOORS # * FUEL CELL
ACCESS DOOR
# FOOTWELL FAIRING
# AFT BULKHEAD # AFT BULKHEAD
ACCESS COVER ACCESS COVER # FUEL VENT COVER
CARGO HOOK COVER

(FUSELAGE UNDERSIDE)
INSTRUMENT
PANEL FAIRING

SECTION SIDE PANEL

SECTION FRONT PANEL
G52-5000-2A
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MAINTENANCE MANUAL
500MD CIRCUIT
BREAKER PANEL
# 500MD ELECTRICAL
CONSOLE
# PILOT'S COLLECTIVE PITCH

STICK COVER ASSEMBLY 500MD ASH RECEIVER AND
CIGARETTE LIGHTER PANEL
FLEXIBLE CLOSURE
ASSEMBLY
INBOARD COLLECTIVE PITCH

SUPPORT TUBE STICK COVER (500MD)
CLAMP
SUPPORT TUBE
ASSEMBLY
LOWER CURTAIN
UPPER CURTAIN STOP
CURTAIN
COTTER PIN
SLIDER
FASTENER FASTENER STUD

BUTTON
EXPLODED VIEW (ROTATED)

G52-5000-3A
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MAINTENANCE MANUAL
# $ HORIZONTAL STABILIZER
ACCESS PANEL
# $ FAN INLET
SCREEN
# ENGINE PLENUM
ACCESS FAIRING
END PLATE (2 PL)
# AIR INLET
FORWARD FAIRINGS
# $ TAILBOOM FAIRING
PRESSURE RELIEF SCREEN

(2 PL)
# CONTROL
ACCESS
COVER # $ BLOWER ACCESS COVER
# COLLECTIVE STICK COVER
# WIRING COVER
INSTRUMENT PANEL
FAIRING - LEFT SIDE
# TRIM MOTOR
ACCESS PANEL

SECTION SIDE PANEL
CAUTION:
ITEMS PREFIXED WITH AN ASTERISK ( * ) ARE STRESSED AND MUST BE
INSTALLED PRIOR TO HELICOPTER FLIGHT.
NOTES:
$ ITEMS TO BE REMOVED FOR 300-HOUR INSPECTIONS. G52-5001-1B
Figure 202. Access and Inspection Provisions and Locations (500N) (Sheet 1 of 2)
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MAINTENANCE MANUAL
# FOOTWELL
FAIRING # $ CONTROLS
ACCESS DOOR
INSTRUMENT PANEL
INLET ACCESS PANEL FAIRING - RIGHT SIDE
ENGINE PLENUM
BYPASS DOOR
# FAN GEARBOX
ACCESS COVER
PRESSURE SECTION SIDE PANEL
RELIEF SCREEN

SECTION FRONT PANEL
# $ TAILBOOM
FAIRING
PILOT'S COMPARTMENT
ENGINE ACCESS FLOOR ACCESS DOOR
DOORS
# * FUEL CELL
ACCESS COVER
# FOOTWELL FAIRING
# AFT BULKHEAD
ACCESS COVER # * FUEL CELL # FUEL VENT COVER
# AFT BULKHEAD ACCESS COVER
ACCESS COVER
CARGO HOOK COVER
(FUSELAGE UNDERSIDE) G52-5001-2A
Figure 202. Access and Inspection Provisions and Locations (500N) (Sheet 2 of 2)
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MAINTENANCE MANUAL
# CONTROL
ACCESS COVER
# COLLECTIVE
STICK COVER
# WIRING COVER
ACCESS PANEL
INSTRUMENT PANEL
FAIRING-LEFT SIDE
# INSTRUMENT
PANEL LOWER # $ TRIM MOTOR # $ FAN INLET SCREEN
SECTION SIDE PANEL ACCESS PANEL
# ENGINE PLENUM
ACCESS FAIRING
BYPASS DOOR ASSY END PLATE (2 PL)
# $ TAILBOOM FAIRING
# $ CONTROLS FAIRING PRESSURE RELIEF

SCREEN (2 PL)
# * ENGINE OIL FILTER
ACCESS DOOR
# $ BLOWER ACCESS COVER
* FUEL CELL
ACCESS COVER INSTRUMENT PANEL
FAIRING-RIGHT SIDE
# $ CONTROLS
# FOOTWELL ACCESS DOOR
PILOT'S COMPARTMENT FAIRING
FLOOR ACCESS DOOR
# FAN GEARBOX
ACCESS COVER
# FOOTWELL
FAIRING
# FUEL VENT
COVER
CAUTION:
ITEMS PREFIXED WITH AN ASTERISK ( * ) ARE STRESSED AND MUST BE # AFT BULKHEAD
INSTALLED PRIOR TO HELICOPTER FLIGHT. ACCESS COVER
NOTES:
$ ITEMS TO BE REMOVED FOR 300-HOUR INSPECTIONS. 6G52-096
Figure 203. Access and Inspection Provisions and Locations (600N)
Page 209
MAINTENANCE MANUAL
FLOOR ACCESS COVERS

(4 PL)
BYPASS DOOR ASSY
6G52-089A
Figure 204. Floor Access Covers and Engine Bypass Door (600N)
Page 210
MAINTENANCE MANUAL
Chapter
53
Fuselage
MAINTENANCE MANUAL
TABLE OF CONTENTS
53-00-00 Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Fuselage - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Stressed Sheet Metal Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Stressed Sheet Metal Panel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Non-Stressed Sheet Metal Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Negligible Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Negligible Damage Inspection - Fuselage . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Fuselage - Major Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Fuselage - Model 600N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
53-10-00 Windshields and Aft Section Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Windshields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Aft Section Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Aft Section Windows Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Aft Section Windows Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Aft Section Windows Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Windshield Frame Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. New-Style Windshield Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Windshield Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6. Windshield Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7. Water Leak Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8. Geon Strips Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Negligible Damage of Canopy/Windshield . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. (Round Nose) Windshields and Aft Section Windows . . . . . . . . . . . . . 203
Figure 202. (Extended Nose) Windshield and Aft Section Windows . . . . . . . . . . . 204
Figure 203. Windshield Installation (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 204. (Extended Nose) Windshields and
Aft Section Windows (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
53-15-00 Lower Forward Fuselage (530F and 600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Nose Shelf Assembly Replacement (530F and 600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Nose Shelf Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Nose Shelf Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Nose Shelf Assembly (530F and 600) . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
2. Seat Pan Shelf Assembly Replacement (530F and 600) . . . . . . . . . . . . . . . . . . . . . . . . 404
Page i
MAINTENANCE MANUAL

A. Seat Pan Shelf Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

B. Seat Pan Shelf Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 402. Seat Pan Shelf Assembly (530F and 600) . . . . . . . . . . . . . . . . . . . . . . . 405
3. Right-Hand Footlocker (Large Shelf Avionics)
Replacement (530F and 600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. Right-Hand Footlocker (Large Shelf Avionics)
Removal and Installation (530F and 600) . . . . . . . . . . . . . . . . . . . . . . . 407
4. Right-Hand Footlocker (Small Shelf Avionics)
Replacement (530F and 600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Right-Hand Footlocker (Small Shelf Avionics) Removal . . . . . . . . . . . . . . . . . . . . . 408
B. Right-Hand Footlocker (Small Shelf Avionics) Installation . . . . . . . . . . . . . . . . . . 408
Figure 404. Right-Hand Footlocker (Small Shelf Avionics)
Removal and Installation (530F and 600) . . . . . . . . . . . . . . . . . . . . . . . 409
1. Forward Lower Fuselage Inspection (530F and 600) . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Lower Center Fuselage Inspection (530F and 600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Forward Center Fuselage Repair (530F and 600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Forward Center Fuselage Section Structure Rework (530F and 600) . . . . . . . . . . . 801
53-20-00 Lower Center Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Lower Center Fuselage - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Lower Center Fuselage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Fuel Tank Support Skin Inspection (Fuel Cells Removed) . . . . . . . . . . . . . . . . . . . . . 201
4. Fuel Tank Support Skins Repair (Fuel Cells Removed) . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Lower Center Fuselage (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Lower Center Fuselage (Model 600N) . . . . . . . . . . . . . . . . . . . . . . . . . . 203
53-30-00 Upper Aft Section Fuselage (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Upper Firewall Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Firewall and Plenum Chamber Panels Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Soundproofing Insulation - Firewall and
Plenum Chamber (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Mast Support Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3. Mast Support Structure Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Firewalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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4. Firewalls Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Figure 202. Firewall and Aft Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Firewall, Station 124.00 Insulation and Soundproofing . . . . . . . . . . . . . . . . . . . . . 205
5. Firewall and Plenum Chamber Soundproofing Panel Inspection . . . . . . . . . . . . . . . 205
A. Engine Air Inlet Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Engine Air Inlet (Plenum Chamber) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Upper Aft Section General Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Aft Fuselage Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
C. Aft Fuselage Fittings General Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7. Aft Section Strut Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8. Silver Brazing Procedure - Upper Firewall Shell Patch . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Major Bulkheads and Structural Members - Aft Fuselage . . . . . . . 207
9. Plenum Chamber Hole Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
10. Forward Fuselage Section Structure Rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
11. Transmission Compartment Air Baffle,
Seal and Cover Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 204. Forward Fuselage Section Structure Rework . . . . . . . . . . . . . . . . . . . 211
Figure 205. Installation of Air Baffle, Seal and
Cover Assemblies (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
12. Engine Exhaust Pipe Support Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
A. Remove Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
B. Install Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Figure 207. Engine Exhaust Pipe Support Fitting Replacement . . . . . . . . . . . . . . 214
53-30-30 Upper Aft Section Fuselage (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Engine/Anti-Torque Air Inlet Fan Fairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Engine Air and Fan Inlet (Plenum Chamber Area) Inspection . . . . . . . . . . . . . . . . . 201
Figure 201. Upper Aft Section (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Upper Aft Section Fuselage (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Upper Aft Section General Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3. Upper Fuselage Controls Fairing (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Upper Fuselage Controls Fairing Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Upper Fuselage Controls Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Upper Fuselage Controls Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Engine Inlet Fairings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Engine Inlet Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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B. Engine Inlet Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

6. Anti-Torque Fan Air Inlet Screen Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Fan Air Inlet Screen Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Fan Air Inlet Screen Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
7. Fan Hub and Transmission Cover Fairing Replacement . . . . . . . . . . . . . . . . . . . . . . . 204
A. Fan Hub and Transmission Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Fan Hub and Transmission Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8. Engine Plenum Access Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Engine Plenum Access Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Engine Plenum Access Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9. Tailboom Attach Fitting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 203. Tailboom Attach Fitting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10. Lower Longeron Inspection (L158, R158) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
11. Upper Longeron Inspection (L153, R153) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
12. Forward Upper Longeron Inspection (L137, R137) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 204. Inspection Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
13. Control Tunnel (FS 78.50) Beam Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 205. Control Tunnel (FS 78.50) Beam Inspection . . . . . . . . . . . . . . . . . . . . 209
53-40-00 Tailboom (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Tailboom - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Tailboom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Tailboom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Tailboom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Tailboom Assembly and Tailboom Extension . . . . . . . . . . . . . . . . . . . . 202
3. Tailboom Extension Replacement (369FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Tailboom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5. Tailboom Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Tailboom Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
53-40-30 Tailboom (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Tailboom Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Tailboom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Tailboom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Tailboom Assembly (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Tailboom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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3. Tailboom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Figure 202. Tailboom Flap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4. Tailboom Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5. Stator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Stator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Stator Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
7. Rotating Thruster Cone Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Rotating Thruster Cone Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Rotating Thruster Cone Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8. Rotating Thruster Cone Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9. Stationary Thruster Cone Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
A. Stationary Thruster Cone Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
B. Stationary Thruster Cone Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
10. Stationary Thruster Cone Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
11. Conduit and Support Strap Rebonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 203. Conduit and Support Strap Rebonding . . . . . . . . . . . . . . . . . . . . . . . . . 209
12. Horizontal Stabilizer Mount Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
13. 500N3500-5 Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 204. 500N3500-5 Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
14. Tail Skid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
A. Tail Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
B. Tail Skid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Figure 205. Tail Skid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Rotating Thruster Cone Strap Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Rotating Thruster Cone Strap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Rotating Thruster Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
B. Rotating Thruster Cone Strap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
53-50-10 Stabilizer (T-Tail) (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Horizontal Stabilizer and Tip Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201. Troubleshooting Tailboom and Tail Surfaces . . . . . . . . . . . . . . . . . . . . . 201
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Figure 201. Stabilizer T-Tail Removal and Installation . . . . . . . . . . . . . . . . . . . . . 202

Figure 202. Sealing — Vertical Stabilizer (SNs 0003D thru 0286D) . . . . . . . . . . 203
B. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Vertical Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Adjustment / Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Angle of Incidence Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Horizontal Stabilizer Tab Weight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Inspection / Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Horizontal Stabilizer and Tip Plate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Vertical Stabilizer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
C. Angle of Incidence Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Horizontal Stabilizer Incidence Angle Measuring Tool . . . . . . . . . . . 207
Figure 204. Establishing Horizontal Stabilizer Angle of Incidence . . . . . . . . . . . . 207
Table 202. Horizontal Stabilizer Angle of Incidence . . . . . . . . . . . . . . . . . . . . . . . . . 208
7. Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
A. Horizontal Stabilizer and Tip Plate Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
B. Vertical Stabilizer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
53-50-30 Stabilizer (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Stabilizers Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Horizontal Stabilizer Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Vertical Stabilizers Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Vertical Stabilizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Vertical Upper and Lower Stabilizer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Vertical Upper and Lower Stabilizer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Horizontal Stabilizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Horizontal Stabilizer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Horizontal Stabilizer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Stabilizer Installation with YSAS (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 203
4. Horizontal Stabilizer Eye Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Horizontal Stabilizer Eye Bolt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Horizontal Stabilizer Eye Bolt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Horizontal/Vertical Stabilizer Control Tube and Bellcrank Replacement . . . . . . . . 205
A. Horizontal/Vertical Stabilizer Control Tube and Bellcrank Removal . . . . . . . . . . 205
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B. Horizontal/Vertical Stabilizer Control Tube and Bellcrank Installation . . . . . . . 205

6. Vertical Stabilizer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7. Vertical Stabilizer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8. Horizontal Stabilizer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9. Vertical Stabilizer Torque Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Vertical Stabilizer Torque Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Vertical Stabilizer Torque Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 202. Stabilizer Installation without YSAS . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203. Vertical Stabilizer Installation with Expandable Bolts . . . . . . . . . . . 208
10. Horizontal Stabilizer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
11. Vertical Stabilizer Torque Tube and/or Bushing
Replacement (Non-Bonded Bushings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
12. Vertical Stabilizer Torque Tube and/or Bushing
Replacement (Bonded Bushings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
13. Vertical Stabilizer Torque Tube Bushing Rework
(Non-Bonded Bushings to Bonded Bushings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
14. Vertical Stabilizer Torque Tube Bearing Race Replacement . . . . . . . . . . . . . . . . . . . . 211
15. Stabilizer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Table 201. Troubleshooting Tailboom and Tail Surfaces . . . . . . . . . . . . . . . . . . . . . 212
Page vii
MAINTENANCE MANUAL

Page viii
MAINTENANCE MANUAL
Section
53−00−00
Fuselage
MAINTENANCE MANUAL
FUSELAGE
1. Fuselage − General are those that form the cylindrically-tapered
tailboom assembly (Ref. Section 53-40-00).
(Ref. Figure 201) The helicopter fuselage
consists of three major structural sections; the NOTE: No damage can be considered negligi
forward, lower and aft fuselage sections. For ble. All damage shall be repaired upon de
classification and definition of types of tection.
negligible damage, and for guidelines defining
extent of damage requiring repair or replace 3. Stressed Sheet Metal Panel Inspection
ment, (Ref. Stressed Sheet Metal Panels,
Cracks, tears or punctures in stressed sheet
Non-Stressed Sheet Metal Panels and
metal panels that are not more than 0.20
Table 201).
inch (5.08 mm) diameter and can be
(Ref. Figure 202) The fuselage of the 600N removed by drilling out with 1/4 inch (6.35
helicopter is a stretched version of the 500N mm) or smaller diameter drill do not require
Series helicopter with numerous upgrades and structural doublers. If cracks, tears or punc
improvements. (shaded areas indicate new tures are more than 0.20 inch (5.08 mm)
sections to fuselage) The longer cabin area of diameter, they are to be repaired or the panel
the 600N greatly increases passenger and/or must be replaced per instructions in FAA AC
cargo carrying capacity. Upper deck area 43.13-1B and FAA AC 43.13-2B Inspection
fairings and covers were added or modified to and Repair for Standard Sheet Metal Repair
accommodate control surfaces or air inlet and Alterations and Structural Repair
passages. Manual.
The tailboom on the 600N helicopter is 4. Non−Stressed Sheet Metal Panels
essentially the same as the 500N Series, only
longer. The vertical stabilizers or endplates are Non-stressed sheet metal members consist
longer than on the 500N model, providing an primarily of hinged covers and doors, except
increased control surface area. fuel cell access and controls access doors,
which are stressed (Ref. Stressed Sheet Metal
An extended passenger step alongside the Panels).
passenger/cargo compartment allows for easy
entrance and exit through either mid or aft 5. Negligible Damage Inspection
cabin doors.
(Ref. Table 201) Panels damaged in excess of
2. Stressed Sheet Metal Panels negligible damage limits (Ref. Table 201)
should be repaired, or damaged panel should
Stressed sheet metal panels consist primarily be replaced per instructions in FAA AC
of helicopter fuselage skins and bulkhead 43.13-1A & 2A and CSP-SRM-6 (Structural
webs. The most-highly-stressed skin sections Repair Manual).
Page 201
MAINTENANCE MANUAL
Table 201. Negligible Damage Inspection − Fuselage

Maximum Maximum Length
Area *Damage Depth or Surface Remarks
Stressed sheet No unrepaired damage
metal panels. allowed.
(For tailboom, Ref. Section
53−40−00).
Non−stressed sheet Dents. Small dents allowed.**

metal panels.
Scratches/nicks. Minor scratches/nicks

allowed.**
Cracks. Smaller of 0.250 Must be one inch or more

inch (6.35 mm) or from any attachment fitting
one−fourth panel and/or panel edge.
width.
Main rotor mast. No unrepaired damage

allowed (Ref. Figure 201)
Firewalls. No unrepaired damage

allowed.
Fuselage fittings. Longitudinal 0.010 inch 15% of fitting After polishing or repair.
scratches, dents, and (0.254 mm) length.
nicks.
Transverse scratches, 0.010 inch 10% of fitting After polishing or repair.
dents, and nicks. (0.254 mm) thickness.
NOTES:
* All damage to fuselage exceeding limits given requires repair or replacement of effected panel or
component.
** Dents, scratches and nicks that penetrate aluminum protective coating (4% of panel thickness with paint or
other surface finishes removed) will allow corrosion of aluminum panel, and should be repaired.
Page 202
MAINTENANCE MANUAL
LOWER FUSELAGE
FORWARD FUSELAGE
AFT FUSELAGE
G53-0000
Figure 201. Fuselage − Major Sections
Page 203
MAINTENANCE MANUAL
VERTICAL STABILIZER-
ENDPLATES
FAIRINGS AND COVERS
EXTENDED FUSELAGE
TAILBOOM
EXTENDED PASSENGER STEP
STA
78.50
P. STA P. STA
0.00 30.00
6G53 052B
Figure 202. Fuselage − Model 600N
Page 204
MAINTENANCE MANUAL
Section
53−10−00
Windshields and Aft
Section Windows
MAINTENANCE MANUAL
WINDSHIELDS AND AFT SECTION WINDOWS

1. Windshields (2). Using a blunt plastic spatula or probe,
gradually work edge of window under
Center and lower windshield panels are flap surface of window seal.
clearest acrylic (Ref. Figure 201 and
Figure 202). Upper windshield panels are (3). Maintain pressure on window until
smoke-grey-tinted cast acrylic. The center entire perimeter of window is under
windshield panels are approximately 0.100 seal.
inch (2.540 mm) thick.
(4). Apply an even amount of sealing
2. Aft Section Windows compound (CM425) to form a water
tight seal around window seal to
For repair of plastics, Ref. FAA AC 43.13-1B. fuselage and from window seal to
Replace aft section window if it is damaged window.
beyond practical repair, according to applicable
instructions in Structural Repair Manual. 4. Windshield Frame Replacement
(Ref. Figure 204) On the 600N helicopter the
”Aft Section Windows” refer to the upper mid Consumable Materials
section windows located above the mid (Ref. Section 91−00−00)
passenger/cargo doors. On the 500 Series Item Nomenclature
helicopters this area was referred to as the CM305 Lacquer, acrylic
”Aft Section”.
3. Aft Section Windows Replacement
For older model helicopters with riveted-in
(Ref. Figure 204) windshields, remove or replace windshield
A. Aft Section Windows Removal according to applicable instructions in the
Structural Repair Manual.
(1). Remove old sealing compound from
around edge of window and window A. New−Style Windshield Installation
seal.
(1). Install windshields in place and install
(2). Using a blunt plastic spatula or probe, hardware (Ref. Figure 203 and
pull back flap of window seal and Figure 204).
gradually work window out from under
flap of seal. (2). After normal installation of windshield,
grind two screws flush with nuts (Ref.
(3). Remove seal and clean for re-installa Figure 203).
tion of window.
(3). Touch-up with lacquer (CM305).
Consumable Materials (4). Seal all windshield seams with sealing

(Ref. Section 91−00−00) compound (CM425).
Item Nomenclature
CM425 Sealing compound 5. Windshield Inspection
Minor defects or imperfections that do not

B. Aft Section Windows Installation impair pilot's critical visibility, or that obvious
ly are not signs of impending structural failure
(1). Install window seal around periphery of can be considered as negligible. (For allowable
window opening in fuselage. damage limits, Refer to Table 201.)
Page 201
MAINTENANCE MANUAL
6. Windshield Repair Fill voids between geon strips and transparen

cies as follows:
(1). Measure the insertion depth of acrylic
windshield into geon slot, reject parts
Item Nomenclature
having less than 0.125 inch (3.175
CM806 Plastic restoration kit mm) insertion. Replace parts with
debonding areas over 8 inches (20.32
For repair of plastics, use the plastic restora cm) in length.
tion kit (CM806) and Ref. FAA AC 43.13-1B.
Replace windshields if damage beyond (2). Mask the geon weatherstrip and
practical repair, according to applicable windshield on both sides with tape
instructions in Structural Repair Manual. (CM722).
7. Water Leak Prevention (3). Wipe all faying surfaces with aliphatic
naphtha (CM220) and dry for a mini
mum of 15 minutes.
(Ref. Section 91−00−00) (4). For small voids:
Item Nomenclature
CM425 Sealing compound (a). Apply adhesive (CM414) to all faying
surfaces using syringe if necessary.
If water leakage through geon strips of the (b). Use light pressure to hold the joint
forward canopy occurs, remove any existing closed for a minimum of 2 minutes.
sealant using a plastic or other non-metallic
scraper which will not scratch the canopy (5). For large voids:
glass. Apply 0.060 inch (1.524 mm) bead of
sealant (CM425) along gaps between geon (a). Apply accelerator to the acrylic
strips. Apply sealant as directed by sealant transparency and air dry for a
manufacturer. minimum of 2 minutes.
8. Geon Strips Repair (b). Apply adhesive to the geon weather
strip only.
(Ref. Section 91−00−00) (c). Apply local pressure to insure
Item Nomenclature complete contact between adherents
and maintain pressure for a mini
mum of 30 seconds.
CM414 Adhesive, cyanoacrylic / Accelerator
CM722 Tape, polyethylene (d). Remove tape and remove excess
residue with aliphatic naphtha.
Table 201. Negligible Damage of Canopy/Windshield
Maximum
Maximum Length or
Depth Surface Area
Area Damage in (mm) in (mm) Remarks
Canopy and Windshield. Nicks 0.010 (0.254) 0.250 (6.35) One per square foot
only.
Scratches 0.010 (0.254) 5.000 (12.7 cm)

Spots or stains If removable by light
polishing.
Page 202
MAINTENANCE MANUAL
Table 201. Negligible Damage of Canopy/Windshield (Cont.)

Maximum
Maximum Length or
Depth Surface Area
Area Damage in (mm) in (mm) Remarks
Panels (not windshields or Punctures 0.200 (5.08) dia
windows).
Windshield. Polarization faults Small area near edges.

(distortion)
Doublers or stiffeners. Delamination No more than one area

within each square foot
of windshield.
Grazing around 0.010 (0.254)
delamination
UPPER CANOPY WINDSHIELD

(TWO SECTIONS)
OUTSIDE AIR TEMPERATURE

INDICATOR
CENTER CANOPY WINDSHIELD

(TWO SECTIONS)
FUSELAGE AFT SECTION
WINDOWS (BOTH SIDES)
(NOTE)
CABIN VENTILATION PANEL

(FIBERGLASS)
LOWER CANOPY WINDSHIELD

(TWO SECTIONS)
NOTE:
FUSELAGE AFT SECTION WINDOWS ARE UNIQUE TO G53−1000
ROUND-NOSE HELICOPTERS ONLY.
Figure 201. (Round Nose) Windshields and Aft Section Windows
Page 203
MAINTENANCE MANUAL
UPPER CANOPY WINDSHIELD

(TWO SECTIONS)
CENTER CANOPY WINDSHIELD

(TWO SECTIONS)
OUTSIDE AIR TEMPERATURE

INDICATOR
LOWER CANOPY WINDSHIELD

(TWO SECTIONS)
CABIN VENTILATION PANEL

(FIBERGLASS)
G53-1001A
Figure 202. (Extended Nose) Windshield and Aft Section Windows
Page 204
MAINTENANCE MANUAL
SCREW SCREW
WINDSHIELD WINDSHIELD
NUT NUT
BEFORE AFTER
CL FUSELAGE 2X ONLY
BL 0.0 (SEE NOTE)
STA 75.24
NOTE:
SCREW LENGTH INTERFERES WITH INSTALLATION 600n6501--010101
OF AIR DUCT INSIDE COCKPIT. 6G53-087
Figure 203. Windshield Installation (New Style)
Page 205
MAINTENANCE MANUAL
AFT SECTION WINDOW

(RH SIDE IS TYPICAL) WINDOW
WINDSHIELDS
(EXTENDED NOSE) SEALANT
WINDOW SEAL
SEALANT
MID DOOR
FUSELAGE
LOOKING AFT
SCREW
RETAINER WASHER
SCREW WINDSHIELD
WASHER RETAINER FUSELAGE
RETAINER
WASHER
NUT
WINDSHIELD
WINDOW‐TO‐STRUCTURE INSTALLATION
WINDSHIELD LOOKING INBD
WASHER
NUT
WINDOW‐TO‐WINDOW INSTALLATION
LOOKING AFT
600n6501--010101
6G53-053
Figure 204. (Extended Nose) Windshields and Aft Section Windows (New Style)
Page 206
MAINTENANCE MANUAL
Section
53−15−00
Lower Forward
Fuselage
(530F and 600)
MAINTENANCE MANUAL
FORWARD LOWER FUSELAGE

1. Nose Shelf Assembly Replacement (530F (a). Remove left—hand bracket (11).
and 600)
(b). Remove right—hand bracket (12).
(Ref. Figure 401)
B. Nose Shelf Assembly Installation
A. Nose Shelf Assembly Removal
Power Off
Power Off

Use caution when you install
(2). Do the Instrument Rack Removal CAUTION the nose shelf. Damage to the
procedure (Ref. CSP-HMI-3, 95-00-30, windshield canopy can occur.
Instrument Rack Removal).
(2). Connect right—hand bracket (12) to
Do not damage the windshield console.
CAUTION canopy when you remove the
nose shelf . (a). Install one screw (14) and washer
(15).
(3). Remove six screws (3), washers (4), and
nuts (5) from the upper end of the left (b). If electrical bond is suspect or fault
and right-hand angle bracket support develops with equipment, do a
(8). electrical bond test (Ref. Section
20-50-00, Electrical Bonding Main
(4). Remove four screws (6) and washers (7) tenance Practices).
from the lower end each angle bracket
support (8) to release them from the (3). Connect left—hand bracket (11) to
forward, left and right-hand side of the console.
nose shelf (13).
(a). Install one screw (14) and washer
(5). Remove the two angle bracket supports (15).
(8).
(b). If electrical bond is suspect or fault
(6). Remove the screws (1) and washers (2) develops with equipment, do a
to release the nose shelf (13) from the electrical bond test (Ref. Section
console. 20-50-00, Electrical Bonding Main
tenance Practices).
(7). Remove the screw (9) and washer (10)
from the upper end of the left-hand (or Support the nose shelf during
CAUTION installation. Damage to console
right-hand) bracket (11, 12).
support can occur.
(a). Remove the screw (14) and washer
(15) from the lower end of the left- (4). Put the nose shelf (13) into position.
hand (or right-hand) bracket (11, 12). (a). Install three screws (1) and washers
(b). Remove the bracket (11, 12) from (2).
nose shelf (13). (b). If electrical bond is suspect or fault
(8). Remove nose shelf (13). develops with equipment, do a
electrical bond test (Ref. Section
(9). Remove two screws (14) and washers 20-50-00, Electrical Bonding Main
(15). tenance Practices).
Page 401
MAINTENANCE MANUAL
(5). Connect left—hand bracket (11) and (9). Install GTX-330 Transponder unit rack
right—hand bracket (12) to the nose (Ref. CSP-HMI-3, Section 97-50-00).
shelf (13).
(10). Install GMA 350H Audio unit (Ref.
(a). Install two screws (9) and washers CSP-HMI-3, Section 97-10-10).
(10).
(11). Install GTX-330 Transponder unit (Ref.
(6). Install two angle bracket supports (8) to
CSP-HMI-3, Section 97-50-00).
the nose shelf (13).
(a). Install four screws (6) and washers (12). Install the slant panel access covers
(7). (Ref. CSP-HMI-3, Section 95-00-30).
(7). Connect two angle bracket supports (8) (13). Do applicable operational checks:
to forward fuselage.
D Ref. the GTX-330 Transponder
(a). Install six screws (3), washers (4) and Installation Manual Document
nuts (5). 190-00207-02.
(8). Do the GMA 350H Audio Panel rack D Ref. the GMA 350/350H Installation
(Ref. CSP-HMI-3, Section 97-10-10). Manual 190-01134-11.
Page 402
MAINTENANCE MANUAL
4 (REF)
5 (REF) 3 (REF)
5 (REF)
4 (REF) 8 (REF)
3 (REF) 13
8 (2 PL)
6 (4 PL)
7 (4 PL)
10 (4 PL)
9 (4 PL)
11
12 OPP
CONSOLE (REF)
15 (2 PL)
14 (2 PL)
2 (3 PL) 1 (3 PL)
BOTTOM VIEW
G53-1500-401-1
1. SCREW 9. SCREW
2. WASHER 10. WASHER
3. SCREW 11. LH BRACKET
4. WASHER 12. RH BRACKET
5. NUT 13. NOSE SHELF
6. SCREW 14. SCREW
8. ANGLE BRACKET SUPPORT
Figure 401. Nose Shelf Assembly (530F and 600)
Page 403
MAINTENANCE MANUAL
2. Seat Pan Shelf Assembly Replacement B. Seat Pan Shelf Assembly Installation
(530F and 600)
(Ref. Figure 402) Power Off
NOTE: The left-hand seat pan shelf removal
and installation is given. The right-hand
seat pan shelf removal and installation is
the same.
A. Seat Pan Shelf Assembly Removal (1). Disconnect electrical power.

Power Off
(2). Put seat pan shelf (1) on brackets.
(3). (YSAS on 600N only) Make sure the

YSAS Gyro rack mounting hole is
aligned with the YSAS mounting hole
(2). Lift the seat cushion from the left-hand on the seat pan shelf (1).
crew seat (Ref. CSP-HMI-2-25-10-00,
Upholstered Crew Seat Replacement). (4). Attach seat pan shelf on brackets with
(3). Remove four screws (2) and washers four screws (2) and washers (3).
(3).
(4). (YSAS on 600N only) Remove the YSAS (5). Attach the seat cushion in the left-
Gyro rack. hand crew seat (Ref. CSP-
HMI-2-25-10-00, Upholstered Crew
(5). Remove seat pan shelf (1). Seat Replacement).
Page 404
MAINTENANCE MANUAL
1 2 (REF)
3 (REF)
BRACKET (REF)
2 (4 PL)
3 (4 PL)
BRACKET (REF)
YSAS MOUNTING
HOLE (600 ONLY)
GP53-1500-402-1
1. SCREW 3. SCREW
2. WASHER
Figure 402. Seat Pan Shelf Assembly (530F and 600)
Page 405
MAINTENANCE MANUAL
3. Right−Hand Footlocker (Large Shelf (6). Remove right-hand footlocker large

Avionics) Replacement (530F and 600) shelf (1).
(Ref. Figure 403) B. Installation
A. Removal Power Off
Power Off

(2). Put right-hand footlocker shelf (1) on
(1). Disconnect electrical power. brackets.
(2). Lift the seat cushion out of the right- (3). Attach right-hand footlocker large shelf
hand crew seat. (Ref. CSP- (1) on brackets with six screws (2).
(4). Remove Artex ME406 Series Emergen
Seat Replacement)
cy Locator Transmitter (Ref. CSP-
(3). Open right-hand footlocker. HMI-3,97-40-00, Emergency Locator
Transmitter (ELT) Component Replace
(4). Remove Artex ME406 Series Emergen ment).
cy Locator Transmitter (Ref. CSP- (5). Close right-hand footlocker.
HMI-3,97-40-00, Emergency Locator
Transmitter (ELT) Component Replace (6). Attach the seat cushion in the right-
ment). hand crew seat. (Ref. CSP-
(5). Remove six screws (2). Seat Replacement)
Page 406
MAINTENANCE MANUAL
2 (REF) 1
2 (6 PL)
2 (REF)
BRACKET (REF)
BRACKET (REF)
BRACKET (REF)
ROTATED G53-1500-403-1
1. SCREW 3. SCREW
2. WASHER
Figure 403. Right−Hand Footlocker (Large Shelf Avionics)
Removal and Installation (530F and 600)
Page 407
MAINTENANCE MANUAL
4. Right−Hand Footlocker (Small Shelf (6). Remove right-hand footlocker shelf (1).
Avionics) Replacement (530F and 600)
B. Right−Hand Footlocker (Small Shelf
(Ref. Figure 404) Avionics) Installation
A. Right−Hand Footlocker (Small Shelf Power Off
Avionics) Removal
Power Off

(2). Put right-hand footlocker shelf (1) on
(1). Disconnect electrical power. brackets.
(2). Lift the seat cushion from the right- (3). Attach right-hand footlocker shelf (1)
hand crew seat to get access to the on brackets with six screws (2).
right-hand footlocker (Ref. CSP-
HMI-2-25-10-00, Upholstered Crew (4). Install RA-4500 Radar Altimeter (Ref.
Seat Replacement) CSP-HMI-3-97-30-00, Radar Altime
ter Component Replacement).
(3). Open right-hand footlocker.
(5). Close right-hand footlocker.
(4). Remove RA-4500 Radar Altimeter (Ref.
CSP-HMI-3-97-30-00, Radar Altime (6). Attach the seat cushion in the right-
ter Component Replacement). hand crew seat (Ref. CSP-
(5). Remove six screws (2). Seat Replacement)
Page 408
MAINTENANCE MANUAL
2 (2 PL)
BRACKET (REF)
BRACKET (REF)
ROTATED
G53-1500-404-1
1. RIGHT−HAND FOOTLOCKER SHELF 2. SCREW

Figure 404. Right−Hand Footlocker (Small Shelf Avionics)
Removal and Installation (530F and 600)
Page 409
MAINTENANCE MANUAL
Page 410
MAINTENANCE MANUAL
FORWARD LOWER FUSELAGE

INSPECTION/CHECK
1. Forward Lower Fuselage Inspection tion and Repair for Standard Sheet
(530F and 600) Metal Repair and Structural Repair
Manual for standard sheet metal
Lower center fuselage is made up of those repair.
areas below fuselage floor level (WL 13.10) on
both sides of the center beam and between Sta. (2). Inspect electrical harnesses and wiring
00.00 and Sta. 78.50. for frayed insulation and grounding
terminals for corrosion.
The Forward Lower Fuselage for the Model
600N helicopter is similar to that of the 500 (3). Inspect nutplates and nuts for stripped
Series (Ref. Section 06-00-00). Additional floor or damaged threads and corrosion.
access covers are also contained within this Make sure floating nutplates float.
section of fuselage. (Ref. Section 53-00-00). (4). Inspect rivets for loose attachments and
corrosion.
2. Lower Center Fuselage Inspection (530F
and 600) (5). If cargo floor is bent or punctured,
remove appropriate access covers and
(1). Ref. FAA AC 43.13-1B Aircraft Inspec inspect.
Page 601
MAINTENANCE MANUAL
Page 602
MAINTENANCE MANUAL
FORWARD CENTER FUSELAGE

REPAIRS
1. Forward Center Fuselage Repair (530F (2). Inspect upper fuselage skin for cracks
and 600) or damage at area of forward nutplate
attachment holes. Also inspect repair
Ref. FAA AC 43.13-1B and FAA AC 43.13-2B doublers if, previously installed, on
Inspection and Repair for Standard Sheet upper fuselage skin.
Metal Repair and Alterations and Structural
Repair Manual for additional repair proce (3). If you see cracking or damage to
dures. fuselage skin or repair doublers, do the
Repair of cast and forged fittings should only following:
be temporary and be done only when replace
ment components are not immediately (a). Stop-drill all cracks or remove
available. Replacement of bushings or inserts damaged skin area or damaged
that become part of assembly are considered repair doublers before maintenance.
insertion repairs. (Insertion repairs are Do all work in accordance with FAA
described in FAA AC 43.13-1B and FAA AC AC 43.13-1B and FAA AC 43.13-2B
43.13-2B Inspection and Repair for Standard Inspection and Repair for Standard
Sheet Metal Repair and Alterations and Sheet Metal Repair and Alterations
Structural Repair Manual.) and Structural Repair Manual.
(1). For access, open doors and compart (b). Field fabricate and install doublers
ment access doors, if necessary. on outer fuselage skin.
(2). Make sure that removable forward (c). Apply primer (CM318) and paint
panels are secure. doublers to match finish color of
(3). Negligible Damage (Ref. Table 201, helicopter.
Section 53-00-00).
(4). If cracking or damage to fuselage frame
(4). Replacement. Replace fittings according is noted, do the following:
to Structural Repair Manual.
(a). Stop drill all cracks or remove
2. Forward Center Fuselage Section damaged area prior to installation of
Structure Rework (530F and 600) repair angles and support assem
blies. Do all work in accordance with
Consumable Materials FAA AC 43.13-1B and FAA AC
(Ref. Section 91−00−00) 43.13-2B Inspection and Repair for
Item Nomenclature Standard Sheet Metal Repair and
Alterations and Structural Repair
CM206 Chemical coating Manual.
CM234 Solvent, dry-cleaning (b). Drill holes in support assemblies and
CM304 Enamel, epoxy repair angles for nutplates and for
CM318 Primer conduit clearance as required. Install
nutplate rivets through support,
frame, angle, upper skin and doubler,
(1). Remove interior trim panels and wire if installed.
harnesses, as applicable, to gain access
to work forward areas. (5). Reinstall removed components.
Page 801
MAINTENANCE MANUAL
Page 802
MAINTENANCE MANUAL
Section
53−20−00
Lower Center
Fuselage
MAINTENANCE MANUAL
LOWER CENTER FUSELAGE

1. Lower Center Fuselage − General (4). Do the repair (Ref. Fuel Tank Support
Skins Repair (Fuel Cells Removed)).
(Ref. Figure 201) Lower center fuselage is
those areas below fuselage floor level (WL 3. Fuel Tank Support Skin Inspection (Fuel
13.10) on both sides of the center beam and Cells Removed)
between Sta. 78.50 and Sta. 124.00.
(1). Check security of fiberglass skin
(Ref. Figure 202) The Lower Center Fuselage attachment to support angles and
for the Model 600N helicopter is similar to that brackets.
of the 500 Series helicopters except for the (2). Inspect anti-abrasion tape for security
additional stretched or extended fuselage of adhesion over rivet heads, all sharp
IplugI station. The extended lower center edges and lap joints.
fuselage section is located at Sta. 78.50
(designated P. Sta. 0.00 thru 30.00) (Ref. (3). Negligible damage (Ref. Section
Section 06-00-00). Additional floor access 53-00-00, Table 201, ).
covers for the fuel cell are also contained
within this section of fuselage. 4. Fuel Tank Support Skins Repair (Fuel
Cells Removed)
2. Lower Center Fuselage Inspection
(1). Ref. FAA AC 43.13-1B Aircraft Inspec (Ref. Section 91−00−00)
tion and Repair for Standard Sheet Item Nomenclature
Metal Repair and Structural Repair
Manual for standard sheet metal
repair.
(1). Repair fuel tank support skins accord
(2). Inspect electrical harnesses and wiring ing to applicable instructions in FAA
for frayed insulation and grounding AC 43.13-1A & 2A or Structural Repair
terminals for corrosion. Manual.
(3). If cargo floor is bent or punctured, (2). Cover exposed rivet heads with 10 mil
remove appropriate fuel cell access by 1 inch (2.54 cm) tape (CM711) to
cover and inspect fuel cell. prevent chafing fuel cell fabric.
Page 201
MAINTENANCE MANUAL
FLOOR WEB
(0.016 IN. (0.4064 MM) CENTER BEAM
2024-T3 AL ALY) STIFFENER
(0.020 IN. (0.508 MM)
STIFFENERS
7075-T6 AL ALY)
(0.032 IN. (0.8128 MM) WEB
(TYPICAL 8 PLCS)
7075-T6 AL ALY) (0.016 IN. (0.4064 MM)
(TYPICAL 7 PLCS) 7075-T6 AL ALY)
DOUBLER
STIFFENER (0.032 IN. (0.8128 MM)
(0.032 IN. (0.8128 MM) 7075-T6 AL ALY)
7075-T6 AL ALY)
STA 119.67 RIB
(0.025 IN. (0.635 MM)
7075-T6 AL ALY)
WL 13.10
124.00 LOWER FRAME

(0.020 IN. (0.508 MM)
15-7 CRES)
STA 113.85 RIB
STIFFENERS (0.025 IN. (0.635 MM)
(0.020 IN. (0.508 MM) 7075-T6 AL ALY)
2024-T3 AL ALY)
STA 108.04 RIB
DOUBLER (0.025 IN. (0.635 MM)
(0.025 IN. (0.635 MM) 7075-T6 AL ALY)
2024-T3 AL ALY) STA 102.23 RIB
WEB (0.025 IN. (0.635 MM)
(0.016 IN. (0.4064 MM) STA 90.61 RIB 7075-T6 AL ALY)
2024-T3 AL ALY) (0.040 IN. (1.016 MM)
7075-T6 AL ALY) JACK FITTING
DOUBLER (PART OF STA 96.42 RIB)
(0.050 IN. (1.270 MM)
7075-T6 AL ALY)
DOUBLER STA 96.42 RIB ASSY
STIFFENER CARGO HOOK FITTING
(0.050 IN. (1.270 MM) (0.050 IN. (1.270 MM)
(0.032 IN. (0.8128 MM) (IF APPLICABLE)
7075-T6 AL ALY) 7075-T6 AL ALY)
7075-T6 AL ALY) STA 84.70 RIB
CANT STA 78.50
(0.032 IN. (0.8128 MM)
LOWER FRAME
7075-T6 AL ALY)
(0.040 IN. (1.016 MM)
2024-T3 AL ALY)
G53-2002A
Figure 201. Lower Center Fuselage (369D/E/FF − 500N)
Page 202
MAINTENANCE MANUAL
FLOOR ACCESS
COVER, FUEL CELL
CENTER BEAM
P STA
30.00
P STA
0.00 STA 124.00
LOWER FRAME
FLOOR ACCESS
COVER, FUEL CELL
(2 PL)
CANTED STA 78.50

BULKHEAD
600N2500--011010
6G53-054
Figure 202. Lower Center Fuselage (Model 600N)
Page 203
MAINTENANCE MANUAL
Page 204
MAINTENANCE MANUAL
Section
53−30−00
Upper Aft Section
Fuselage
(369D/E/FF)
MAINTENANCE MANUAL
UPPER AFT SECTION FUSELAGE (369D/E/FF)

1. Upper Firewall Replacement (9). Using solvent (CM234), clean forward
flanges, lower flanges and surface
where tape routing covers fasteners;
Consumable Materials then apply tape (CM721).
Item Nomenclature (10). Install compressor cooling air duct
CM234 Solvent, dry-cleaning support bracket.
CM721 Tape, aluminum foil (11). Install tailpipes.
2. Firewall and Plenum Chamber Panels

Use care when working on or Replacement
CAUTION around firewall shell because of
its light-weight construction.
(1). Remove tailpipes (Ref. Chapter 78, (Ref. Section 91−00−00)
Exhaust System Replacement). Item Nomenclature
(2). Remove tape covering fasteners and CM419 Sealer
firewall edges.
(3). Detach compressor cooling air duct Replace all defective, torn or fraying sound
support bracket (Ref. Chapter 71, proofing panels. Loose panels can be pressed
Engine Cooling System Repair and back in place. (For part number identification
Replacement). Remove firewall shell by of individual panels, refer to CSP-IPC-4.)
pulling out button head fasteners (Ref.
Figure 202). (1). Open engine compartment access doors.
(2). Remove individual panels (Ref.
(4). If burn marks are detected on firewall Figure 201, Sheet 1 of 2) by pulling
shell or button head fasteners, inspect away from structure.
airframe above burn marks for damage.
(3). (If applicable) Remove individual
(5). Replace damaged or corroded fasteners. panels (Ref. Figure 201, Sheet 2 of 2) by
removing fasteners.
(6). Replace aft firewall shell if damaged
beyond practical repair. Trim replace NOTE: Panels have pressure-sensitive tape
ment shell to fit installation. Allow backing.
sufficient trim excess for folding back to
provide double thickness at attach (4). Prior to installing replacement panel,
points. clean surfaces with solvent (1, Table
201, Section 91-00-00).
(7). Pierce fastener holes in new firewall
(5). Install replacement panel in place and
shell to align holes in surrounding
trim edges as necessary. Press panel in
fuselage rings and waterline 34.96 rib.
place to secure.
(8). Place firewall shell in position and (6). Seal edges of replacement panel with
secure in place by pressing fasteners sealer (130).
into holes. Attach compressor cooling
air duct support bracket to hoist fitting (7). Reinstall trim (Ref. Section 25-30-00,
(Ref. Chapter 75, Engine Cooling Interior Trim Replacement) and close
System Repair and Replacement). engine access doors.
Page 201
MAINTENANCE MANUAL
-3 PANEL
-5 PANEL
-7 PANEL
-39 PANEL
SOUNDPROOFING PANELS
(FIREWALL AND PLENUM
CHAMBER) AFT SECTION AND CANTED
FORWARD FIREWALL
-37
-29
-11
-45 -35
-33 -31
-9
-43
-15 -17 -18 -16

-21 -23 -22
SOUNDPROOFING PANELS
(ON AFT SIDE OF ACCESS
-13 -19 -14
DOORS) (NOTE 1)
-20
-27 -25 -28
NOTES:
1. RIGHT PANEL SHOWN. OPPOSITE
SIDE LEFT PANEL (-41) IS SAME;
EXCEPT MIRROR IMAGE AND A SOUNDPROOFING PANELS
SOLID PANEL. (ENGINE COMPARTMENT
2. ALL DASH NUMBERS SHOWN SIDE OF FIREWALL)
APPLY TO BASIC PART NO.
369H2008. (EXAMPLE: -25 G53-3003-1
Figure 201. Soundproofing Insulation − Firewall and Plenum Chamber (Sheet 1 of 2)
Page 202
MAINTENANCE MANUAL
TRANSMISSION
PANEL
QUARTER
PANEL
TRANSMISSION
PANEL
EARLY CONFIGURATION
QUARTER
PANEL
G53-3003-2
Figure 201. Soundproofing/Insulation − Firewall and Plenum Chamber (Sheet 2 of 2)
Page 203
MAINTENANCE MANUAL
A. Mast Support Structure (7). Clean and inspect any suspected area;
use dye penetrant to determine if a
The mast support structure is part of the crack does exist. If a crack is found,
fuselage structure and is composed of two part must be replaced.
longitudinal forged fittings, a lower pan and
an aft pan. The mast support structure (8). Inspect mast support structure for
supports and mounts the main rotor mast. corrosion, loose bolts and rivets and
general condition of finish.
NOTE: The main rotor static mast has been re
moved, in it's entirety, from this section be (9). Check that mast support structure pan
cause of duplicate information in Section drain hole is open.
63-30-00. Refer to Section 63-30-00 for all
information concerning the main rotor stat (10). Reinstall controls tunnel cover.
ic mast.
(11). Reinstall left and right forward sections
3. Mast Support Structure Inspection of air inlet fairing (Ref. Engine Inlet
Fairing Replacement).
Accomplish the following inspection at
specified intervals (Ref. Chapter 05). (12). Reinstall main gearbox access cover
and trim.
When working near or around
CAUTION engine air and cooling inlets, A. Firewalls
use care to prevent entry of foreign objects
(Ref. Section 71). (Ref. Figure 202) A shell-like aft section upper
firewall surrounds the upper portion of engine
(1). Remove left and right sections of air combustion chamber and exhaust pipe
inlet forward fairing (Ref. Engine Inlet assembly. The design contains engine heat as
Fairing Replacement). well as any fire that might develop within the
engine compartment. Upper firewall is thin,
(2). Remove interior trim (Ref. Section 0.0015 inch (0.0381 mm) thick sheet, rigidized
25-30-00, Interior Trim Replacement) CRES sheet covered with double thickness of
and main gearbox access cover (same nonflammable ceramic fiber blanket.
section).
(3). Detach control tunnel cover from 4. Firewalls Inspection
structure and slide out of way.
No unrepaired damage is permissible. (For
NOTE: Use bright light and 5X magnifying repairs to forward firewall, Ref. FAA AC
glass to carefully inspect areas described in 43-13-1A & 2A or Structural Repair Manual.)
steps below for evidence of cracks. For repairs of the upper firewall (Ref. Silver
Brazing Upper Firewall Shelf Patch).
(4). Inspect visible areas of mast support
fitting, mast base and mast tube, with (1). Inspect forward firewall for punctures
particular attention to base attachment and corrosion.
areas and shaded areas.
(2). Inspect upper firewall for punctures,
(5). Inspect both side of channels on aft corrosion and evidence of contact with
canted bulkhead from mast support discoloration. If contact with discol
fitting down to waterline 34.00 with oration is observed on the firewall
particular attention to points of attachment button heads, remove the
attachment. upper firewall and inspect the attach
frames for discoloration or damage;
(6). Inspect side channels and fore and aft contact MDHI for further directions.
webs of controls tunnel, from mast
support fitting down to top of pilot's (3). Inspect for complete seal around
seatback (canted bulkhead waterline openings for overrunning clutch, engine
45.36). compressor air inlet and oil cooler.
Page 204
MAINTENANCE MANUAL
TAIL ROTOR DRIVE SHAFT FAIRING
REMOVABLE PANEL
CANTED STA. 124.00

CHANNEL
ENGINE AIR INLET WATERLINE 34.96 RIB

INSTALLATION
(PLENUM CHAMBER)
AFT SECTION UPPER FIREWALL
(NOTE)
FORWARD ENGINE
AIR INLET PANEL
ENGINE AIR INLET SIDE PAN
DRAIN FITTING
ENGINE AIR AFT SECTION FORWARD FIREWALL

INLET PAN (NOTE)
369D/E/FF SHOWN
NOTE:
AFT SECTION FIREWALL IS A REMOVABLE ASSEMBLY. BOTTONHEAD FASTENERS
ARE WITHDRAWN FROM INSIDE SURFACE OF FIREWALL SHELL TO REMOVE.
G53-3008A
Figure 202. Firewall and Aft Section
A. Firewall, Station 124.00 Insulation and (4). Check that all individual panels are
Soundproofing securely attached to firewall and
plenum areas with no loose edges.
(Ref. Figure 201, Sheet 1 of 2) Engine compart
ment forward firewall is insulated and
soundproofed for heat and noise reduction in (5). Check panels in passenger compart
passenger/cargo compartment. ment of defects, tears, looseness, or
missing panels.
5. Firewall and Plenum Chamber
Soundproofing Panel Inspection (6). For applicable repairs refer to Plenum
Chamber Hole Sealing reference.
(Ref. Figure 201, Sheet 1 of 2 and Figure 202)
(1). Remove trim (Ref. Section 25-30-00, A. Engine Air Inlet Fairing
Interior Trim Replacement) for access
to passenger/cargo compartment
firewall areas. Open engine access The engine air inlet fairing on top of the
doors to inspect engine compartment fuselage structure directs ambient outside air
panels. to the engine air inlet and oil cooler blower.
The fairing installation consists of a forward
(2). Check for defective, torn, loose or fairing section and an aft fairing section. Right
missing panels. and left halves of forward fairing are remov
able. The aft fairing is riveted to fuselage
(3). Inspect aft firewall for security, punc structure. A UHF/VHF antenna is bonded to
tures and corrosion. the aft vertical face and is part of aft fairing.
Page 205
MAINTENANCE MANUAL
6. Engine Air Inlet (Plenum Chamber) (1). Negligible Damage (Ref. Section
Inspection 53-00-00, Table 201).
(1). For access, open bypass door on right (2). Replacement. Replace fittings according
side of engine air inlet and engine to Structural Repair Manual.
compartment access doors for view of
rear side of plenum (Ref. Figure 202). 7. Aft Section Strut Repair
(2). Inspect all panels for evidence of Repair of strut is limited to smoothing out
corrosion, security of rivets and punc minor dents, scratches or nicks. Replace strut
tures. if it is badly damaged according to Structural
Repair Manual.
(3). Inspect engine air shield mounting clips
for secure attachment. 8. Silver Brazing Procedure − Upper Firewall
Shell Patch
(4). Inspect aft section strut for rivet
corrosion and edge clearance where it (Ref. Figure 203)
passes through cutout in forward panel.
For applicable repairs (Ref. Aft Section Consumable Materials
Strut Repair). (Ref. Section 91−00−00)
(5). Ensure that removable forward panels Item Nomenclature
are secure. Inspect rubber seals for CM234 Solvent, dry-cleaning
security and partial compression. CM721 Tape, aluminum foil
(6). Inspect drive shaft tube fairing for CM817 Brazing flux
dents, buckled or wrinkled areas and CM818 Brazing alloy
signs of corrosion.
(7). Close engine compartment access doors (1). Remove aft section upper firewall (Ref.
and two air inlet access doors. Upper Firewall Replacement).
A. Upper Aft Section General Repair (2). Remove tape and ceramic fiber blankets
Ref. FAA AC 43.13-1B and FAA AC 43.13-2B from firewall shell.
Inspection and Repair for Standard Sheet (3). Clean firewall shell with stiff bristle
Metal Repair and Alterations and Structural brush moistened with solvent (CM234)
Repair Manual for additional repair proce and wipe dry with clean, dry cloth.
dures.
B. Aft Fuselage Fittings (4). Smooth out rigidized pattern in area on
which patch will be brazed.
Mast support structure fitting and fuselage
boom fairing frame fitting are critical fatigue- (5). Cut suitable repair patch for Type 321
loaded parts. Any damage in excess of negligi stainless steel sheet in thickness range
ble limits specified in (Ref. Aft Section Strut of 0.0015—0.0018 inch
Repair) requires replacement of part. (0.0381—0.04572 mm).
C. Aft Fuselage Fittings General Repair (6). Contour patch to match contour of
firewall shell repair area.
Repair of cast and forged fittings should only
be temporary and be done only when replace Use only stainless steel wire
ment components are not immediately CAUTION brush in next step. Particles
available. Replacement of bushings or inserts from bristles of other metals can contami
that become part of fitting assembly are nate the patch area and cause brazing to
considered insertion repairs. (Insertion repairs fail.
are described in FAA AC 43.13-1B and FAA
AC 43.13-2B Inspection and Repair for (7). Use stainless steel wire brush to clean
Standard Sheet Metal Repair and Alterations and abrade inner and outer surfaces of
and Structural Repair Manual.) stainless steel patch and firewall.
Page 206
MAINTENANCE MANUAL
STA. 197.78 BOOM FAIRING

CANTED FRAME FITTING
BOOM FAIRING RING
AFT SECTION STRUT
AFT SECTION
UPPER FIREWALL
ENGINE AIR INLET

INSTALLATION
(PLENUM CHAMBER)
G53-3006
Figure 203. Major Bulkheads and Structural Members − Aft Fuselage
(8). Rinse patch and firewall shell thor Use extreme care not to over
oughly with clean water and allow to CAUTION heat and burn through firewall
air dry. shell.
(11). Braze patch in place with Class 8 silver

(9). Coat surfaces to be joined with a thin brazing alloy (CM818), using suitable
even coating of silver alloy brazing flux torch to heat patch area to temperature
(CM817). moderately above 12955F (7075C) flow
point of brazing alloy.
(10). Use clamp or other suitable device to (12). Allow joint to cool for at least 60
hold patch in place during brazing seconds before removing clamping
operation. device.
Page 207
MAINTENANCE MANUAL
(13). Remove flux by immersing repaired reinforcement at the forward attach points for
area in water at 160—2125F the engine inlet fairing assemblies.
(72—1015C) for 40 minutes.
(14). Thoroughly rinse in clear, running
water; air dry, or wipe dry with clean,
Item Nomenclature
dry cloth.
CM318 Primer
(15). Install ceramic blanket on outer surface
of firewall shell.
(1). Remove engine inlet forward fairing
(16). Install aft section upper firewall shell assemblies from helicopter (Ref. Engine
(Ref. Upper Firewall Replacement). Inlet Fairing Replacement).
(2). Remove interior trim panels and wire
(17). Install tape (CM721) on flanges of harnesses, as applicable, to gain access
firewall shell. to work area at forward area at forward
attach nutplate assembly for L/H and
9. Plenum Chamber Hole Sealing R/H engine inlet forward fairings.
(Ref. Figure 203) (3). Remove existing forward nutplate (for
both L/H and R/H fairing assemblies)
from fuselage frame structure.
(Ref. Section 91−00−00) (4). Inspect upper fuselage skin for cracks
Item Nomenclature or damage at area of forward nutplate
CM418 Cement, epoxy attachment holes. Also inspect repair
doublers if, previously installed, on
upper fuselage skin.
NOTE: If cracking or damage to fuselage skin
or repair doublers is noted, do the following:
All tape must be applied to out
CAUTION side of inlet surfaces, so that (a). Stop drill all cracks or remove
any subsequently loosened tape cannot en damaged skin area or damaged
ter plenum chamber to cause engine dam repair doublers prior to rework. Do
age. all work in accordance with FAA AC
43.13-1B and FAA AC 43.13-2B
(1). Using 10 mil by 1 inch (2.54 cm) Inspection and Repair for Standard
pressure-sensitive tape (CM713), tape Sheet Metal Repair and Alterations
all 0.130 inch (3.302 mm) diameter or and Structural Repair Manual.
larger holes.
(b). Field fabricate and install doublers
(2). Using sealant (CM424), seal all holes on outer fuselage skin. Drill
less than 0.130 inch (3.302 mm) 0.196—0.204 inch (4.978—5.182
diameter. mm) diameter hole in each doubler
to match existing hole in fuselage
(3). Rebond loose rubber seals with adhe skin for fairing attach screw. Use
sive (CM418) according to container existing rivet pattern as shown;
instructions. install MS20470AD3 rivets with
primer (CM318).
10. Forward Fuselage Section Structure (c). Prime and paint double to match
Rework finish color of helicopter.
(Ref. Figure 204) The following information is (5). Inspect fuselage frame structure
a procedure for installing support assemblies (channel) for cracks or damage at
to the fuselage frame structure to provide forward nutplate attach areas.
Page 208
MAINTENANCE MANUAL
NOTE: If no cracking or damage to fuselage 11. Transmission Compartment Air Baffle,

frame is noted, install 80-369D22400-3 and Seal and Cover Initial Installation
-4 support assemblies at FWD side of frame (Ref. Figure 205) (Serial No. 0003D thru
structure using rivets. Drill holes in support 0333D only)
assemblies for nutplates and for conduit
clearances as required. Install nutplate riv Consumable Materials
ets (MS20470AD3) through support, frame, (Ref. Section 91−00−00)
upper skin and doubler, if installed. Item Nomenclature
N/A Calking compound
(6). If cracking or damage to fuselage frame
is noted, do the following:
(1). Remove engine air inlet forward

(a). Stop drill all cracks or remove fairings.
damaged area prior to installation of
(2). Remove cooling fan inlet screen.
repair angles and support assem
blies. Do all work in accordance with (3). Remove aft compartment interior trim
FAA AC 43.13-1B and FAA AC panels and blower access door.
43.13-2B Inspection and Repair for (4). Install PN 369D26541-19 upper baffle
Standard Sheet Metal Repair and assembly as follows;
Alterations and Structural Repair
Manual. (a). Position baffle between main trans
mission and mast support structure.
Align four attach holes in baffle with
existing holes in structure.
(b). Field fabricate and install repair
angles at AFT side of fuselage frame (b). Install baffle with screws, washers
structure (channel) and install and nuts. Seal screw heads with
80-369D22400-3 and -4 support sealant (CM425).
assemblies at FORWARD side of (5). Install PN 369D26542 lower baffle to
frame structure using MS20470AD3 upper baffle with two screws and
rivets. Drill 0.096 inch (2.4384 mm) washers at matching nutplates in upper
diameter holes in angles to match baffle.
support assemblies. (6). Disconnect 5/8 inch (15.875 mm)
diameter drain tube at mast support
base and insert tube though hole in
(c). Drill holes in support assemblies and baffle. Safetywire drain tube to struc
repair angles for nutplates and for ture.
conduit clearance as required. Install
nutplate rivets through support, (7). Reinstall blower access door.
frame, angle, upper skin and doubler, (8). Position and install PN 369D26543-11
if installed. and -12 seal assemblies at lower baffle
and blower access door as shown.
Install seal assemblies with screws and
(7). Check installation of 80-369D22400-3 washers at matching clipnuts on lower
and -4 assemblies and repair angles baffle and on blower.
and doublers, if installed, for discrepan NOTE: If excessive gap, 0.060 inch (1.524
cies. mm) or more, exists between structure
and rubber extrusion on seals, fill gap by
bonding strip of adhesive-backed gasket to
(8). Reinstall removed components. structure.
Page 209
MAINTENANCE MANUAL
(9). Position PN 369D26545-11 and -21 NOTE: Not applicable if modified rotor brake
cover assemblies as shown; align cover handle trim cover panel has already been in
attach holes with existing fairing attach stalled.
nutplates. Temporarily secure cover
assemblies with screws and washers, 5 (a). Carefully trim modified trim cover
places each. panel assembly (for LH or RH rotor
brake handle assembly). Locate and
drill screw attach holes in modified
(10). Using caulking compound, seal all gaps panel.
between fuselage structure and baffle;
seal and cover assemblies. (b). Slide modified trim panel boot over
brake handle. Align screw holes and
check panel for fit. Remove panel and
(11). Remove screws securing cover assem
make minor trim adjustments as
blies. Reinstall engine air inlet forward
required.
fairings.
(c). Install panel if removed and secure
(12). Reinstall aft compartment trim. panel with attaching hardware.
(d). Push panel boot aft on brake handle
(13). For helicopters equipped with Rotor approximately two inches and secure
Brake Kit, do the following; with fastener tape.
Weight Arm Moment
lbs (kg) inches (cm) in−lbs (kg−mm)
+1.5 (+0.681) 110.2 (279.908) +169 (+1947.0828)
Page 210
MAINTENANCE MANUAL
DOUBLER (NOTE 1)
0.030 INCH (0.762 MM)
2024-T3 AL ALY SHEET
BL
6.00
LH CANTED
STA 78.50
0.196-0.204 INCH
(4.978-5.182 MM) HOLE
OUTER SKIN
TO MATCH EXISTING
SCREW HOLE
369A2400-5 ANGLE
STA.
89.39 DOUBLER
VIEW A 369H2508 FRAME

3 RIVETS EACH SIDE
OF DAMAGE (AD3)
SKIN
80-369D22400-3, -4
SUPPORT FORWARD
SIDE OF FRAME
NUTPLATE (NOTE 3) ANGLE 0.020 INCH
(NOTE 5) (0.508 MM) AFT
SIDE OF FRAME
FRAME
(NOTES 2, 3)
SUPPORT
(LH SHOWN)
DOUBLER
UP
ANGLE
(NOTES 2, 3) VIEW B
INBOARD
SKIN
80-369D22400-3, -4
SUPPORT FORWARD
SIDE OF FRAME
NOTES: (NOTE 3)
1. DOUBLER ON OUTER SKIN TO PICK UP EXISTING RIVETS.
2. REPAIR ANGLE INSTALLED ONLY IF FRAME DAMAGE IS NOTED. FRAME
3. DRILL HOLES IN SUPPORT/ANGLE AS REQUIRED FOR CONDUIT
CLEARANCES.
4. STOP DRILL ALL CRACKS OR REMOVE DAMAGED AREA.
5. INSTALL NUTPLATE RIVETS THRU SUPPORT, FRAME, ANGLE VIEW C
(IF INSTALLED), SKIN AND DOUBLER. G53-3007A
6. INSTALL RIVETS WITH PRIMER.
Figure 204. Forward Fuselage Section Structure Rework
Page 211
G53-3009-1
369D26543-15 GASKET ACCESS DOOR 369D26543-9 GASET
-15 GASKET
Figure 205. Installation of Air Baffle, Seal and Cover Assemblies (Sheet 1 of 2)
NOTE 1
MAST SUPPORT STRUCTURE
369D23009 FRAME
369D26541-19 BAFFLE -9 GASKET
-15 GASKET INSTL.
-19 BAFFLE NOTE 6 NOTE 9 -19 BAFFLE
CANTED STATION
124.0
NOTE 5 NOTE 2
-5 COVER NOTE 4
MAINTENANCE MANUAL
HEATER DUCT
NOTE 2 369D26542 BAFFLE

NOTE 7
-15 GASKET
NOTE 4 -7 SEAL
-3 COVER NOTE 8
-13 SEAL
53-30-00
NOTE 9 ACCESS
DOOR
NOTE 3
-19 GASKET
NOTE 8
NOTE 3
-9 GASKET
369D26542 BAFFLE
369D26542 BAFFLE NOTE 8
CL SHIP ACCESS DOOR
-21 SEAL ASSEMBLY CANTED
VIEW LOOKING FORWARD -11 SEAL ASSEMBLY
STATION
124.0
NOTES:
1. MOLD ALONG STRUCTURE AND JOGGLE ON 369D22070 ACCESS DOOR. 4. INSIDE CONTOUR TO MATCH 369D26542 BAFFLE.
2. TRIM REAR END ALONG CANTED STA. 124.0 TO CLEAR STRUCTURAL 5. FORWARD FLANGE TO MATCH 369D26542 BAFFLE.
Revision 38
6. JOGGLE TO CLEAR 369D26542 BAFFLE.
CSP-HMI-2
COMPONENTS. CLEARANCE TO STRUCTURE BEFORE BONDING SEAL

IS 0.16 INCH. 7. OPTIONAL 0.50 INCH WIDTH CUTOUT FOR ROTOR BRAKE (RH CONTROL)
Page 212
3. MOLD BOTTOM END ALONG UPPER OUTSIDE CONTOUR OF 369D22070 8. HOLE(S) MATCH CLIP NUTS IN 369D22070 ACCESS DOOR.
ACCESS DOOR. TRIM BOTTOM END TO SECURE MINIMUM OVERLAP 9. HOLE(S) MATCH CLIP NUTS IN 369D26542 BAFFLE.
OF 0.50 INCH.
MAINTENANCE MANUAL
369D26541-19 BAFFLE SHIP STRUCTURE
B RUBBER
EXTRUSION
GASKET
369D26543 SEAL
C C 369D26541-19
369D26543-11 SEAL GAP (NOTE 3) BAFFLE
(LH SHOWN) NOTE 1
369D26543-21 SEAL
NAS603-8 SCREW (4)
AN960PD10L WASHER (4)
(LH SHOWN)
B NOTE 2
369D26542
BAFFLE
369D22070
ACCESS DOOR 369D22070
369D26545-21 COVER
ACCESS DOOR
NAS608-3 SCREW (-11 OPPOSITE)
AN960PD10L WASHER
369D26542 BAFFLE
369D26543-11 SEAL NAS602-8 SCREW (2)
369D22025-3 FAIRING PLATE AN960PD10L WASHER (2)
(NOTE 5)
NOTE 4
VIEW B-B
D
369D22025 FAIRING
VIEW D-D
(TYP BOTH SIDES) 369D26541-19 BAFFLE
D
NAS603-8 SCREW (4)
VIEW C-C AN960PD10L WASHER (4)
MS21043L3 NUT (4)
NOTES:
1. DURING INSTALLATION OF 369D26542 BAFFLE, DISCONNECT
AND INSERT HEATER DUCT THRU HOLE IN BAFFLE.
2. AFTER 369D26542 BAFFLE IS INSTALLED, DISCONNECT AND
ROUTE DRAIN TUBE THRU HOLE IN BAFFLE.
3. IF EXCESSIVE GAP (0.06 X 1.00 OR MORE)EXISTS BETWEEN
STRUCTURE AND RUBBER EXTENSION ON SEALS, FILL GAP BY
BONDING STRIP OF ADHESIVE-BACKED GASKET TO STRUCTURE.
4. NO. 10 SCREW HOLE IN FAIRING ON SHIPS. DO NOT USE THIS G53-3009-2
HOLE TO INSTALL COVER OR FAIRING.
5. TRIM PLATE, AS REQUIRED, TO CLEAR SCREW HEAD.
Figure 205. Installation of Air Baffle, Seal and Cover Assemblies (Sheet 2 of 2)
Page 213
MAINTENANCE MANUAL
12. Engine Exhaust Pipe Support Fitting B. Install Fitting

Replacement
Misalignment of fitting can
(Ref. Figure 206) CAUTION cause too much force on exhaust
pipe hanger.
A. Remove Fitting
(1). Open engine compartment access doors. (1). Position fitting on upper firewall
with hanger flange to the left side
(2). Remove two screws and two washers (ref. Detail A, View Looking For
that attach fitting to firewall. ward).
(3). Remove fitting. (2). Install two washers and two screws.
NOTE:
VERTICAL FLANGE OF SUPPORT FITTING
IS LOCATED TO THE LEFT WHEN LOOKING
FORWARD. (AS SHOWN)
BL 0.00
ENGINE EXHAUST PIPE

SUPPORT FITTING WASHER (REF)
WASHER (2 PL) ENGINE SCREW (REF)

EXHAUST PIPE
SUPPORT FITTING
SCREW (2 PL) (REF)
CL SHIP
VIEW LOOKING FWD
M53-3000-2061
Figure 207. Engine Exhaust Pipe Support Fitting Replacement
Page 214
MAINTENANCE MANUAL
Section
53−30−30
Upper Aft Section
Fuselage (500/600N)
MAINTENANCE MANUAL
UPPER AFT SECTION FUSELAGE (500/600N)

NOTE: For all the following items, refer to Sec the engine plenum chamber area. With the
tion 53-30-00. installation of a particle separator, ejector
Upper Firewall outlets are positioned on each side of the
Firewall and Plenum Chamber Panels plenum cover.
General Inspection
Mast Support Structure On the 500N, the R/H side of the aft fairing is
Main Rotor Mast the inlet bypass door which remains on the
Firewalls fuselage when the aft fairing is removed.
Firewall Insulation and Soundproofing On the 600N, the inlet bypass door is just aft
of the mast assembly and just forward of the
1. Engine/Anti−Torque Air Inlet Fan Fairings engine plenum access cover.
When working near or around
CAUTION engine air and cooling inlets,
A removable fan hub and transmission gear
box fairing is also located in the fan plenum
use care to prevent entry of foreign objects. chamber.
(Ref. Figure 201) On the 500N, the engine air For general maintenance practices for the
inlet fairing on top of the fuselage structure upper aft section (Ref. Section 53-30-00).
directs ambient outside air to the engine air
inlet and the oil cooler blower. The fairing 2. Engine Air and Fan Inlet (Plenum
installation consists of a forward fairing Chamber Area) Inspection
section and an aft fairing section. Right and
left halves of forward fairing are removable. (Ref. Figure 201 and Figure 202)
(Ref. Figure 202) On the 600N, the engine air Avoid FOD, Cover compressor
CAUTION inlet prior to working in plenum
inlet fairing on top of the fuselage structure
directs ambient outside air to the engine air chamber area. Vacuum all FOD debris out
inlet bypass door and the oil cooler blower. The of the plenum chamber before removing the
fairing installation consists of a forward inlet protective cover from the inlet bell. Severe
fairing sections and an aft fairing section. The damage to the engine can result from entry
controls cover and right and left halves of of foreign objects.
forward fairing are removable.
(1). Open the plenum chamber bypass door
On the 600N, the engine inlet or particle by pulling the handle located in the
separator is mounted aft of the inlet fairings cockpit. Open the engine access doors to
and wraps around the engine plenum for inspect the rear side of the plenum
increased air flow due to the larger engine panels.
installation. (2). For access, remove the fan air inlet
The aft section consists of an air inlet screen screen and engine plenum fairing
on top of the fuselage structure which directs assemblies.
ambient air to the anti-torque fan assembly. (3). Inspect all panels for evidence of
The engine plenum access cover bolted to the corrosion, punctures and security of
fuselage and is removable to provide access to rivets and fasteners.
the engine plenum, particle separator and mist
eliminator (optional equipment) if installed. (4). Inspect the engine air inlet bypass door
attaching hardware and installation
The engine plenum access cover on the 600N (Ref. Section 71-10-10, Engine Air
helicopter mounts to the aft end of the particle Intake System).
separator/bypass door frame. The plenum
cover directs air downward for the engine air (5). Inspect engine air shield mounting for
intake and when removed provides access to secure attachment.
Page 201
MAINTENANCE MANUAL
FAN AIR INLET

SCREEN
ENGINE PLENUM
ACCESS COVER
INTAKE FAIRING
ACCESS DOOR
BYPASS DOOR
PIN
INTAKE
FAIRINGS
COTTER
PIN BYPASS DOOR
LATCH ASSEMBLY
FAN HUB FAIRING AND
TRANSMISSION COVER
G53-3005A
Figure 201. Upper Aft Section (500N)
Page 202
MAINTENANCE MANUAL
ENGINE PLENUM
ACCESS COVER
ENGINE INLET SCREEN OR

PARTICLE SEPARATOR
FORWARD INLET
FAIRINGS
CONTROLS FAIRING
PARTICLE SEPARATOR/
BYPASS DOOR FRAME
MID UPPER
STRUCTURE
EXTENDED FUSELAGE
ROOF BEAMS OF 600N
MAST SUPPORT STRUCTURE
3040--010101
3011--010303
6G53-055
Figure 202. Upper Aft Section Fuselage (600N)
Page 203
MAINTENANCE MANUAL
(6). Inspect aft section strut for rivets B. Upper Fuselage Controls Fairing
corrosion and edge clearance where it Installation
passes though cutout in forward panel.
(1). Inspect upper fuselage controls fairing
(7). Inspect engine air cooling inlet screen for cracks, delaminations and overall
for damage, seal deterioration and general condition.
security.
(2). Position controls fairing to align with
(8). Inspect fan transmission driveshaft holes in mounting surfaces.
tube fairing and access panel for dents,
(3). Install attaching hardware.
buckled or wrinkled areas and signs of
corrosion. 5. Engine Inlet Fairings Replacement
(9). Inspect the fan inlet screen mesh for The R/H and L/H engine inlet fairings are
condition and security. made of a lightweight Kevlar fabric and are
used on the 500/600N installation only.
(10). If fan inlet screen needs repair, re
welded using 0.063 inch (1.600 mm) A. Engine Inlet Fairing Removal
annealed cres 302 or 304 wire per
AMS5336 or AMS5639. (1). Remove hardware from left-hand inlet
fairing and remove fairing.
(11). Visually inspect through the fan inlet
(2). Remove hardware from right-hand
screen for security of the transmission
inlet fairing and remove fairing.
fairing and FOD.
B. Engine Inlet Fairing Installation
(12). Ensure that forward removable inlet
fairings and engine access doors are (1). Inspect fairings for cracks, delamina
secure. tions and condition of pressure sensitive
tape.
A. Upper Aft Section General Repair
(2). Install right-hand inlet fairing and
(Ref. FAA AC 43.13-1B and FAA AC 43.13-2B attaching hardware.
Inspection and Repair for Standard Sheet
Metal Repair and Alterations and Structural (3). Install left-hand inlet fairing and
Repair Manual for additional repair proce attaching hardware.
dures.
(4). Ensure that 1-1/2 threads protrude
3. Upper Fuselage Controls Fairing (600N) through nutplates.
The Upper Fuselage Controls Fairing covers 6. Anti−Torque Fan Air Inlet Screen
the flight control rods that travel longitudinal Replacement
ly aft along the roof of the fuselage for the A. Fan Air Inlet Screen Removal
rotor collective and cyclic controls.
(1). Remove attaching hardware and
4. Upper Fuselage Controls Fairing remove air inlet screen.
Replacement (600N)
B. Fan Air Inlet Screen Installation
The Upper Fuselage Controls Fairing is made
of a lightweight Kevlar fabric and is used on (1). Install air screen and attaching
the 600N installation only. hardware.
A. Upper Fuselage Controls Fairing 7. Fan Hub and Transmission Cover Fairing
Removal Replacement
(1). Remove hardware that attaches upper A. Fan Hub and Transmission Cover
fuselage controls fairing to mounting Removal
surfaces.
(1). Remove attaching hardware on the fan
(2). Remove controls fairing. hub transmission fairing.
Page 204
MAINTENANCE MANUAL
B. Fan Hub and Transmission Cover (2). Install hardware attaching plenum
Installation cover to structure.
(1). Inspect fairing for cracks and general
condition. 9. Tailboom Attach Fitting Inspection
(2). Install attaching hardware. (Ref. Figure 203) Inspect the upper left-hand
and right-hand tailboom attach fittings,
(3). Check for minimum run-on torque of angles and nutplates as follows:
attaching screws, 2 inch-pounds
(0.226 Nm) minimum. (1). Remove button plug from attach fitting
access cover.
8. Engine Plenum Access Cover
Replacement
(2). Using a bright light, inspect fitting and
Avoid FOD, Cover compressor angle:
CAUTION inlet prior to working in plenum
chamber area. Vacuum all FOD debris out (a). Inspect attach fittings for cracks.
of the plenum chamber before removing the
protective cover from the inlet bell. Severe NOTE: Pay particular attention to area around
damage to the engine can result from entry aft rivet holes. No cracks are allowed.
of foreign objects.
(b). Inspect angle for cracks.
A. Engine Plenum Access Cover Removal
NOTE: If particle separator is installed, ejector (c). If any cracks are found in attach
ducting is not removed with plenum access fitting or angle, contact MDHI Field
cover. Service Dept. for replacement
instructions.
(1). Remove hardware that attaches engine
plenum access cover to supporting (3). Inspect nutplate for thread damage and
structure. cracks.
(2). Remove plenum cover. NOTE: Cracks would appear from top of self-
B. Engine Plenum Access Cover Installation locking nut split to base of nut.
(1). Position engine plenum access cover to (a). Replace nutplate if threads are
align with mounting holes in fuselage. damaged or cracked.
Page 205
MAINTENANCE MANUAL
50N3422 TAILBOOM ATTACH FITTING

(RIGHT SIDE SHOWN)
500N3429-6 ANGLE
(RIGHT SIDE SHOWN)
6G53−103
Figure 203. Tailboom Attach Fitting Inspection
Page 206
MAINTENANCE MANUAL
10. Lower Longeron Inspection (L158, R158) (2). Using bright light and mirror, or
borescope, inspect the longeron, Sta.
(Ref. Figure 204) Inspect the lower left-hand 155.75 frame and Cant. Sta. 159.97
and right-hand longerons as follows: frame for cracks.
Consumable Materials (3). If any cracks are found, contact MDHI

(Ref. Section 91−00−00) Field Service Department for repair
Item Nomenclature instructions.
(4). Install button plugs in inspection hole
and seal with sealing compound
(1). Remove button plugs (L158, R158) from (CM425).
side of helicopter.
12. Forward Upper Longeron Inspection
(2). Using bright light and mirror, or (L137, R137)
borescope, inspect the longeron, Sta.
155.75 frame and Cant. Sta. 159.97 (Ref. Figure 204) Inspect the foreword upper
frame for cracks. left-hand and right-hand longerons as follows:
(3). If any cracks are found, contact MDHI
Field Service Dept. for repair instruc Consumable Materials
tions. (Ref. Section 91−00−00)
(4). Install button plugs in inspection hole Item Nomenclature
and seal with sealing compound CM425 Sealing compound
(CM425).
11. Upper Longeron Inspection (L153, R153) (1). Remove button plugs (L137, R137) from
side of helicopter.
(Ref. Figure 204) Inspect the foreword upper
left-hand and right-hand longerons as follows: (2). Using a borescope, inspect the longeron
and Sta. 137.50 frame for cracks.
(Ref. Section 91−00−00) (3). If any cracks are found, contact MDHI
Item Nomenclature Field Service Dept. for repair instruc
CM425 Sealing compound tions.
(4). Install button plugs in inspection hole

(1). Remove button plugs (L153, R153) from and seal with sealing compound
side of helicopter. (CM425).
Page 207
MAINTENANCE MANUAL
UPPER LONGERON, FWD

UPPER LONGERON
(L137, R137)
(L153, R153)
LOWER LONGERON
(L158, R158)
HOLE IN 0.75 IN. (19.05 MM)

CANT. STA. HOLE IN SKIN
159.97
NOTE
NOTE
LOWER LONGERON (VIEW UPPER LONGERON

LOOKING DOWN) (VIEW LOOKING UP)
NOTE:
AREAS WHERE CRACKS ARE MOST LIKELY TO APPEAR. G53-3013A
Figure 204. Inspection Hole Locations
Page 208
MAINTENANCE MANUAL
13. Control Tunnel (FS 78.50) Beam (3). Using a mirror and bright light, inspect
Inspection tunnel beams, both sides, for cracks in
the rivet area; no cracks allowed.
(Ref. Figure 205) If cracks are found, contact MDHI field
service department for repair instruc
(1). Remove Ty-Raps securing boots to tions.
control tubes and shelf assembly. (4). Slide boots down over shelf assembly
and secure top and bottom of boots with
(2). Slide boots up to top of tubes. Ty-Raps.
NOTE 2
369D 22508-7 WEB
NOTE 1
369H2564 TUNNEL BEAM
369D22508-5 WEB
NOTE:
1. INSPECT THESE AREAS FOR CRACKS (BOTH SIDES OF TUNNEL).
2. REMOVE CONTROL TUBE BOOTS TO GAIN ACCESS FOR INSPECTION. G53-3014
Figure 205. Control Tunnel (FS 78.50) Beam Inspection
Page 209
MAINTENANCE MANUAL
Page 210
MAINTENANCE MANUAL
Section
53−40−00
Tailboom
(369D/E/FF)
MAINTENANCE MANUAL
TAILBOOM
1. Tailboom − General (8). Remove nuts and washers from bolts
that attach boom to fuselage. Remove
(Ref. Figure 201) The tailboom assembly, a lower bolts first and top bolt last; then
monocoque structure of aluminum skin over remove boom.
forged aluminum frames, houses the tail rotor
drive shaft and tail rotor control rod, and B. Tailboom Installation
supports the horizontal and vertical stabiliz
ers. Consumable Materials
2. Tailboom Replacement Item Nomenclature
A. Tailboom Removal CM103 Solid film lubricant
Special Tools
Special Tools
Item Nomenclature
Item Nomenclature
ST2010 Adapter, torque wrench
ST1005 Insertion/extraction tool
ST1006 Insertion/extraction tool
(1). Support tailboom so that mating
bulkheads are flush.
(1). Remove vertical stabilizer (Ref. Section
53-50-10). NOTE: Prior to tailboom installation, coat
threads of external wrenching bolts and at
(2). Remove tail rotor transmission and tail taching nuts with lubricant (CM103).
rotor drive shaft as a unit (Ref. Section
(2). Slide countersunk washers on external
63-15-00).
wrenching bolts with countersunk side
(3). Remove tail rotor control rod (Ref. facing bolt heads.
Section 67-20-10). If washers are installed back
CAUTION wards, structural failure may
(4). (369FF Model Only) Remove tailboom
extension (Ref. Tailboom Extension result due to insufficient surface in bearing
Replacement). that can cause spreading or cracking of
washers and result in loss of clamp-up
(5). Position suitable cradles under tail torque.
boom at Cant. Sta. 209.78 frame fitting
(3). Install bolts through aft section
and the forward stabilizer boom
fuselage frame into boom frame and
mounting frame (Cant. Sta. 273.00)
place flat washer(s) on each bolt as
(Ref. Figure 202).
required for correct bolt grip. Use no
To avoid damage, ensure that more than three flat washers under
CAUTION boom is properly supported be each nut. Install nuts and torque only
fore removing boom attach bolts. the nuts to 380—410 inch-pounds
(42.93—46.32 Nm).
(6). Open boom bolts access doors and
remove bond jumper from boom. NOTE: Bolts may be reversed for access to
torque nuts. Torque wrench adapter
(7). Disconnect connector of chip detector (ST2010) or a thin-walled deep socket is
wiring and night lighting system used for torquing.
wiring. Disconnect knife splice by hand (4). Install vertical stabilizer.
or use appropriate connector insertion/
extraction tool (ST1005 or ST1006) for (5). (369FF Model Only) Install tailboom
wire mate type connector. extension.
Page 201
MAINTENANCE MANUAL
STABILIZER MOUNTING
FITTINGS
GROMMET
GEARBOX AND STABILIZER
WIRING CONDUIT MOUNT FRAME
GROMMET
FORWARD STABILIZER BOOM
RIGHT SKIN PANEL MOUNTING FRAME
GROMMET STA. 264.32

STA. 209.78 CANT. FRAME
CANT. FRAME
STA. 242.14
CANT. FRAME NUT
WASHER
LEFT SKIN PANEL
STA. 219.96
CANT. FRAME
TAILBOOM
EXTENSION
STA. 197.78 CANT. FORWARD STABILIZER
GEARBOX AND STABILIZER
FRAME FITTING BOOM MOUNTING FRAME
MOUNT FRAME
369FF ONLY
G53-4000
Figure 201. Tailboom Assembly and Tailboom Extension

(6). Install tail rotor transmission and tail (3). Remove tailboom extension from
rotor drive shaft as a unit. tailboom assembly.
(7). Install control rod. (4). Apply primer (CM318) in holes, on
faying surfaces and on the grip area of
(8). Perform tail rotor control rigging (Ref. the mounting studs and install tail
Section 67-20-10). boom extension while primer is still
wet.
(9). Install bond jumper to boom and
connect chip detector wiring. Connect NOTE:
night lighting wiring.
D Note the drag torque for each nut and it's
3. Tailboom Extension Replacement (369FF) location on the extension, in the helicop
ter for later use.
(Ref. Figure 201) D Torque nuts while primer is still wet.
(5). Install tailboom extension on tailboom
assembly and secure with four washers
and four nuts.
Item Nomenclature
CM318 Primer (6). Torque nuts to 75—95 inch-pounds
(8.47—10.73 Nm) plus drag torque.
(1). Remove tail rotor transmission and tail (7). Apply torque stripe paint.
rotor drive shaft as a unit (Ref. Section
63-15-00). (8). Between 2 and 10 hours of helicopter
operation (to allow parts to seat), check
(2). Remove four nuts and four washers the torque of each mounting nut as
from tailboom assembly. follows:
Page 202
MAINTENANCE MANUAL
(a). Using the drag torque previously (4). Inspect bond jumper for security and
measured and noted, apply a torque corrosion.
load of 92—97 inch-pounds
(10.39—11.07 Nm) plus the noted (5). Inspect boom exterior for loose or
drag torque (noted at each individu missing rivets.
al nut) to each mounting nut of the
extension. (6). Inspect boom and gearbox stabilizer
mounting frames for cracks, security of
(b). Re-apply torque stripe paint. attachment, elongated holes or condi
tion of mounting studs.
(9). Install tail rotor driveshaft and tail
rotor transmission as a unit.
(7). Replace damaged or deformed studs
4. Tailboom Inspection (Ref. CSP-SRM-6, Structural Repair
Manual).
(Ref. Figure 201)
5. Tailboom Repair
(1). Inspect boom interior skin and frames
for corrosion and cracks. There is no damage that can be
CAUTION considered negligible. All dam
(2). Check attaching nuts and bolts in boom
Cant. Sta. 197.78 frame fitting for age must be repaired upon detection (Ref.
security. CSP-SRM-6, Structural Repair Manual).
(3). Inspect tail rotor control rod grommets NOTE: The skins forming the monocoque boom
in boom frames for evidence of deterio assembly are highly stressed (Ref.
ration. Figure 201).
Page 203
MAINTENANCE MANUAL
FORWARD STABILIZER
BOOM MOUNTING FRAME
(CANT. STA 273.00)
CANT. STA 209.78
SELF-LOCKING NUT
FLAT WASHER (CRES)
NUT
PLAIN HEX NUT
(NOTE 4)
FLAT WASHER
(AL-ALY UNTREATED)
SPRING LOCKWASHER
BOND JUMPER NOTE 1 FLAT WASHER(S)
SPRING LOCKWASHER (NOTE 2)
FLAT WASHER
FLAT WASHER (AL-ALY UNTREATE
(NOTE 2)
COUNTERSUNK WASHER
ACCESS HOLE
EXTERNAL WRENCHING BOLT
(NOTE 4)
CHIP DETECTOR WIRING
TAIL LIGHT WIRING

BOOM FITTING
BRACKET
JUMPER CONNECTION
ACCESS HOLE
BOND JUMPER TAILBOOM ATTACHMENT

SPRING LOCKWASHER
FLAT
WASHER
NOTES:
1. ENSURE THAT GROUND CONTACT SURFACE IS CLEAN
FLAT WASHER (CRES)
BEFORE BOND JUMPER INSTALLATION. AFTER
FLAT WASHER INSTALLATION, COAT EXPOSED BARE METAL GROUNDED
(NOTE 1) AREA WITH LACQUER (CM306).
(AL-ALY UNTREATED)
2. THREE FLAT WASHERS MAXIMUM UNDER NUT. WASHERS
ADDED UNDER BOLT HEAD. COUNTERSUNK WASHER IS
BOOM FITTING BRACKET AND
JUMPER-INSTALLATION REQUIRED.
3. CRES-CORROSION RESISTANT STAINLESS STEEL.
4. PRIOR TO INSTALLATION, COAT THREADS
WITH LUBRICANT (CM103). G53-4001A
Figure 202. Tailboom Installation and Removal
Page 204
MAINTENANCE MANUAL
Section
53−40−30
Tailboom (500/600N)
MAINTENANCE MANUAL
TAILBOOM (500/600N)
1. Tailboom Description blade pitch angle for engine power
changes.
(Ref. Figure 201) The tailboom assembly is a
fully monocoque construction of graphite (8). A Strake, a composite strip bonded to
composites, it provides directional control for the left side of the tailboom, breaks up
the helicopter. airflow on the left side of the boom for
hovering stability.
The tailboom for the Model 600N helicopter is (9). A Stator located directly behind the fan
a similar version to that on the Model 500N and mounted inside the tailboom
helicopter. One of the obvious differences is the straightens low pressure air flowing
length, approximately 28 inches (71.12 cm) through the boom. The stator has
longer on the 600N. Also, two of the four eleven composite removable blades, and
mounting bolts that hold the boom to the is accessible by removing the tailboom.
fuselage are a larger diameter. These two
points have been reinforced both on the boom (10). A tail skid mounted bottom aft on the
and on the fuselage for added strength. tailboom is constructed of aluminum
tubing.
(1). The tailboom converts energy from the (11). A jack pad is located on the tailboom
main rotor downwash to an anti-torque underside. The jackpad can be accessed
force. In order to accomplish this, a by removing the tail skid.
variable pitch fan pushes low pressure
air through two longitudinal slots on (12). The tailboom provides for the mounting
the right side of the tailboom and two of the horizontal stabilizer and a
thrusters ports at the end of the control cable conduit for the flight
tailboom. These slots located at 130° controls.
and 76° degrees, direct low pressure air 2. Tailboom Replacement
downward over the tailboom surface.
(Ref. Figure 201)
(2). Slot air flow mixes with main rotor NOTE: When removing tailboom as an assem
downwash air, delaying its separation bly with the horizontal and vertical stabiliz
at the bottom of the tailboom and ers installed, precaution should be taken to
effectively creating a lifting force. adequately support and balance the tail
(3). Air from the main rotor passing over boom assembly equally due to the mass of
the boom provides directional control to the stabilizers.
neutralize the main rotor torque. A. Tailboom Removal
(4). Approximately 60% of the anti-torque (1). Remove tailboom fairing.
force required in a hover, is provided by (2). Disconnect the forward end of the
the tailboom lift, the remaining 40% is anti-torque control cable by turning
by metered air flowing out the end of outside collar sleeve counter-clockwise
the tailboom rotating thruster cone. and back to expose the inner cable.
Apply sufficient right pedal to expose
(5). A stationary thruster cone port directs engagement pin and pull collar sleeve
air flow to the left or to the right. outward.
(6). The rotating thruster cone (a can- (3). Disconnect electrical connector.
shaped structure) meters exit air for (4). Have assistants support tailboom.
left or right directional control.
(5). Remove four mounting bolts and
(7). Pedal movement opens and closes the washers and remove tailboom. Inspect
thruster cone ports and changes fan bolts for corrosion.
Page 201
MAINTENANCE MANUAL
500N TAILBOOM SHOWN G53-4002-1A
Figure 201. Tailboom Assembly (Sheet 1 of 3)
Page 202
MAINTENANCE MANUAL
FITTING PIN
COLLAR
LARGER DIAMETER
MOUNTING HOLE
600N TAILBOOM SHOWN
LARGER DIAMETER
MOUNTING HOLE
G53-4002-2C
Figure 201 Tailboom Assembly (Sheet 2 of 3)
Page 203
MAINTENANCE MANUAL
500N THRUSTER SHOWN
G53 4002 3
Figure 201 Tailboom Assembly (Sheet 3 of 3)
Page 204
MAINTENANCE MANUAL
B. Tailboom Installation bolts to 180—220 inch-pounds

(20.33—24.85 Nm) plus drag
Before tailboom installation, in torque. Safety bolts.
CAUTION spect radius blocks for brinnel
ing, corrosion, cracks and indication of in RN003 - RN059 with TB600N-007
dent on face; none allowed. complied with and RN060 & subs;
torque bolts to 180—220 inch-
NOTE: If installing a new tailboom, the pounds (20.33—24.85 Nm) plus
500N3500-5 cover will have to be installed drag torque. Safety bolts.
after internal tailboom components are
installed (Ref. 500N3500-5 Cover Installa (5). Check for a minimum of two threads
tion). protruding from nutplates.
(6). Using a 0.002 inch (0.051 mm) feeler
(1). Support tailboom so that the mating
gauge, check for gap between tailboom
bulkhead surfaces are flush.
and fuselage flange within 0.60 inch
(2). Slide countersunk/chamfered washers (15.3 mm) of centerline of each of the
on external wrenching bolts with four attach bolts; no gap allowed.
countersunk side facing bolt head.
(7). Re-connect electrical connectors.
If washers are installed back
CAUTION wards, structural failure can re (8). Re-connect control cable assembly.
sult due to insufficient surface in load bear (9). Install tailboom fairing.
ing area that can cause spreading or
3. Tailboom Inspection
cracking of washers and result in loss of
clamp-up torque. (Ref. Figure 201)
(3). 600N: (1). Inspect tailboom exterior as follows:
Install washer on bolt after the counter (a). Inspect tailboom fairing for cracks
sunk washer. and delaminations.
(a). Install either an AN960C516 or (b). Inspect tailboom flange and mount
NAS1149C0563R washer on -5 bolts. ing bolt holes attachment area for
cracks at Sta. 168.20.
(b). Install either an AN960C616 or
NAS1149C0663R washer on -6 bolts. (c). Inspect radius blocks for brinneling,
corrosion and indication of indent on
Do not lubricate tailboom at
CAUTION tach bolts or nutplates, this will
face; none allowed. If found, scrap
radius block and install new radius
cause a false torque reading and lead to bolt
block.
loosening.
(d). Inspect strake for cracks, delamina
(4). With the tailboom supported in place,
tions, debonding, dents, nicks and
install four bolts with washers. separation.
(a). 500N:
NOTE: Damage to slots can cause significant
Torque bolts to 130—150 inch- degradation of aircraft performance in a
pounds (14.69—16.95 Nm) plus hover.
drag torque. Verify minimum run (e). Inspect tailboom surface area and
on torque of 6.5 inch-pounds tailboom circulation control slots
(0.73 Nm). surface area for cracks, voids, dents,
(b). 600N: holes, scratches, separation, delami
nations at tailboom and security.
RN003 - RN059 without
TB600N-007 complied with; torque 1). Using a bright light, inspect fore
the two smaller diameter bolts to and aft radii of the lower portion of
130—150 inch-pounds the three upper slot bridges for
(14.68—16.94 Nm) plus drag cracks, illuminate area under the
torque and the two larger diameter flap.
Page 205
MAINTENANCE MANUAL
1.25 IN. (3.175 CM) CRACK

LENGTH PERMISSIBLE
1.25 IN. (3.175 CM) CRACK

LENGTH PERMISSIBLE
6G53-102A
Figure 202. Tailboom Flap Inspection

NOTE: The flap can be raised slightly, using to the forward inboard legs) and
finger pressure only, to aid in checking this attachment fittings for cracks, voids,
area. separation and delamination.
(f). Inspect flaps for cracking and de (h). Inspect stabilizers (Ref. Section
bonding (Ref. Figure 202): 53-50-30).
(i). Inspect (tail-skid) for cracks, dents,
1). A crack of any length, in line with
holes and delamination.
aft edge of flap, is permissible at
interface between flap and tail (j). Inspect rotating thruster cone for
boom. freedom of operation, cracks, holes,
separation and delamination.
2). A crack of 1.25 inch (3.175 cm)
maximum length, in line with the (k). Inspect tailboom grommets (2) places
forward edge of flap, is permissible for cracks and proper fit.
at interface between flap and
(2). Inspect tailboom interior as follows:
tailboom.
(a). Check stator vanes and stator
NOTE: If crack in forward edge of flap is long diffuser cone for cracks, delamina
er than 1.25 inch (3.175 cm), contact your tions and separation.
local MDHI Field Service Representative for
disposition. 1). Maximum allowable cracks found
emanating from stator vane
(g). Inspect horizontal stabilizer mount inserts should not exceed 0.10 inch
ing brackets (pay particular attention (2.54 mm) span-wise.
Page 206
MAINTENANCE MANUAL
2). No cracks allowed running cord- 6. Stator Blade Replacement

wise towards leading or trailing
edge (Ref. Figure 201, View E)
(1). Stator Blade Removal: Remove two
(b). Inspect slot air foils for cracks, self-locking screws and two surface
delamination and separation from washers.
boom.
(2). Stator Blade Installation: Install two
(c). Inspect control cable assembly surface washers and two self-locking
attachment points for looseness, screws. Torque screws to 3—6 inch-
cracks and condition. pounds (0.34—0.68 Nm) plus drag
torque. Total torque should not exceed
(d). Inspect cable conduit for cracks, 15 inch-pounds (1069 Nm) total
separation and delamination. torque.
(e). Inspect air circulation area for FOD 7. Rotating Thruster Cone Replacement
and cleanliness. If necessary, clean
with mild soap and water. (Ref. Figure 201, View H)
(3). Inspect rotating thruster cone collar A. Rotating Thruster Cone Removal
strap ring rivets for looseness, strap for (1). Remove cone tip cap by removing eight
cracks and condition. screws and washers.
4. Tailboom Repair (2). Support rotating thruster cone and
remove three bolts and washers that
Minor repair procedures for the tailboom are attach the rotating thruster cone,
in the Repair section (Ref. Section 53-40-30). carefully slide rotating cone aft to clear
stationary cone, bearings and followers
5. Stator Replacement and the cable and drum assembly.
(Ref. Figure 201, View D) B. Rotating Thruster Cone Installation
A. Stator Removal (1). Carefully slide rotating thruster cone
over stationary cone, bearings, rollers
(1). Remove tailboom. and followers.
(2). Note or index top of stator for reas (2). With the thruster supported in place,
semble. Support stator and remove install three bolts with washers
seven exterior screws and washers attaching the rotating thruster to
mounted around the forward part of the thruster gear box. Torque bolts 70—90
tailboom. inch-pounds (7.91—10.17 Nm).
Safety wire bolts.
B. Stator Installation
(3). Install cone tip cap with eight screws
(1). Support stator and align stator vanes and washers, torque screws per general
in tailboom, install seven screws and aircraft practices.
washers, torque screws to 3—6 inch-
pounds (0.34—0.68 Nm) plus drag 8. Rotating Thruster Cone Inspection
torque. Total torque should not exceed (1). Inspect for cracks and separation of
15 inch-pounds (1069 Nm) total composite laminates.
torque.
(2). Check for freedom of rotational move
(2). Install tailboom. ment within the control range of
thruster.
(3). Verify that stator does not rub against
the fan and for clearance of (3). When the thruster is removed from
0.020—0.080 inch (0.508—2.032 mm) helicopter, check roller surface area
between stator and fan. (strap) for cracks and condition.
Page 207
MAINTENANCE MANUAL
NOTE: Refer to MD Helicopters Inc. Represen washer and bolt, torque bolt per
tative for structural repairs, cracks, etc. standard aircraft torque values and
safety wire.
9. Stationary Thruster Cone Replacement
(4). Install thruster cone fairings.
(Ref. Figure 201)
(5). Install rotating thruster (Ref. Rotating
A. Stationary Thruster Cone Removal Thruster Cone Installation).
(1). Remove rotating thruster cone (Ref. 10. Stationary Thruster Cone Inspection
Rotating Thruster Cone Removal).
(1). Inspect for cracks and delamination of
(2). Remove eight off wing screws from pan composites structure for the following:
cover, remove cotter pin, nut and Internal ducts, air foil supports, pan
washer from sector input shaft and cover and pan (hat section).
remove pan cover. Remove washer and
bushing from sector bellcrank input (2). Inspect rollers and bearings for condi
shaft. tion and freedom of rotation. Inspect for
cleanliness.
(3). Remove bolt, washer and bushing from
thruster input sector bellcrank clevis (3). Inspect sector bellcrank, cable assem
(Ref. View J). blies, pulleys and support brackets for
condition, inspect of cleanliness.
(4). Remove thruster cone fairings.
(4). Inspect upper input shaft for damage
(5). Support stationary thruster cone and and wear. Check for play in mounting
remove eight bolts and washers, with pins. If mounting pins are found to
cable assembly attached to cone, have play, replace with new pins and
carefully lift cone off tailboom so that collars.
the control rod passes through the
thruster cone cutout. (5). Inspect thruster aft support shaft for
damage and wear. Check for play in
B. Stationary Thruster Cone Installation mounting hardware. If top bolt is found
to be loose, retorque to 10—15 inch-
(1). Support stationary thruster cone to pounds (1.13—1.69 Nm). If bottom
tailboom so that the control rod passes mounting pins are found to be loose,
through the cutout of the stationary replace with new pins and collars.
cone, and that the mating surfaces are
flush to the tailboom. Slide counter 11. Conduit and Support Strap Rebonding
sunk/chamber washers on external
wrenching bolts with countersunk side (Ref. Figure 203) The following procedure is for
facing bolt head. rebonding of the conduit supports.
If washers are installed back

CAUTION wards, structural failure can re Consumable Materials
sult due to insufficient surface clamp-up in (Ref. Section 91−00−00)
load bearing areas that can cause spreading Item Nomenclature
or cracking, resulting in loss of clamp-up CM217 Isopropyl alcohol
torque. CM402 Adhesive
(2). With the stationary thruster cone
support in place, install eight bolts and (1). Lightly abrade faying surfaces with
washers. Torque bolts 30—40 inch- Scotchbrite until surface gloss of the
pounds (3.39—4.52 Nm) plus drag laminate is gone.
torque.
(2). Solvent-wipe parts using a clean
(3). Connect control rod to input sector lint-free cloth dampened with isopropyl
bellcrank clevis and install bushing, alcohol (CM217).
Page 208
MAINTENANCE MANUAL
(3). Wipe dry using a clean, lint-free, dry NOTE: Adhesive must be applied within 2
cloth and allow to air dry for 15 hours of preparation. If more than 2 hours
minutes at ambient temperature. elapse before adhesive application, re-pre
pare surfaces.
Do not heat conduit to more
CAUTION than 1705F (775C). Conduit and (5). Mix adhesive (CM402) according to
tailboom can be damaged from too much manufacturer's instructions and apply
heat. to faying surfaces.
(4). If conduit is bent away from tailboom, (6). Secure parts together with light
heat conduit to make more flexible for pressure and allow to cure for 24 hours
re-bonding. at ambient temperature.
FS 263.916
CANT
A C
A B
FS 168.200 C
CANT
BL BL
0.000 0.000
38° 28′ APPLY ADHESIVE HERE

28° 20′
TAILBOOM
SUPPORT
APPLY
ADHESIVE APPLY
HERE ADHESIVE
HERE
CONDUIT
APPLY
ADHESIVE
HERE
SECTION B-B
SECTION A-A
LOOKING AFT SECTION C-C
LOOKING FORWARD
500N TAILBOOM SHOWN G53-4004A
Figure 203. Conduit and Support Strap Rebonding
Page 209
MAINTENANCE MANUAL
12. Horizontal Stabilizer Mount Fitting (8). Locate new fitting on tailboom.
Replacement
(9). Back-drill fittings to 0.186—0.188
(Ref. Figure 201) inch (4.724—4.775 mm).
(10). Remove fitting and deburr rivet holes.
Empennage Fitting Part No.
L/H, Aluminum 500N3530−3, −7 (11). Touch up rivet holes with solid film
lubricant (CM101) for steel fittings or
R/H, Aluminum 500N3530−4, −8
chemical coating (CM206) for alumi
L/H, CRES 500N3530−9 num fittings.
R/H, CRES 500N3530−10
(12). Steel fittings only:
Consumable Materials (a). Using abrasive paper (CM801),

(Ref. Section 91−00−00) lightly abrade tailboom where fitting
Item Nomenclature is to be mounted.
CM101 Solid film lubricant (b). Clean fitting and tailboom abraded
CM206 Chemical coating area with isopropyl alcohol (CM217).
CM217 Isopropyl alcohol (c). Prime fitting with adhesive primer
CM304 Enamel, epoxy (CM315).
CM315 Adhesive primer
(d). Apply a thin layer of cement (CM418)
CM318 Primer
between fitting and tailboom.
CM418 Cement, epoxy
CM425 Sealing compound NOTE:
CM801 Abrasive paper, silicon carbide D Use HTS12-6-4/-5 pin rivets with
HTS1176DU-6AWU collars or alternate
HTS48-6-4/-5 pin rivets with
(1). Remove horizontal stabilizer (Ref. HST2000-6AW collars.
Section 53-50-30, Horizontal Stabilizer
Replacement). D Gage rivet holes to ensure proper length
pin rivets.
(2). Remove rotating thruster cone (Ref.
(13). Relocate fitting on tailboom and install
Rotating Thruster Cone Replacement).
with pin rivets wet with primer
(3). Remove stationary thruster cone (Ref. (CM318).
Stationary Thruster Cone (14). Seal edges around fittings with sealing
Replacement). compound (CM425).
(4). Remove collars from pins in mount (15). If installing steel fittings, prime with
fittings. adhesive primer (CM315).
(5). Drive pins out of fittings. (16). Touch up with paint (CM304).
Do not allow fittings to reach (17). Reinstall stationary thruster cone (Ref.
CAUTION 2005F (945C), damage to tail Stationary Thruster Cone
boom composite material will occur. Replacement).
NOTE: Heating the fitting to 1505F (665C) can (18). Reinstall rotating thruster cone (Ref.
assist in removing them from tailboom. Rotating Thruster Cone Replacement).
(6). Carefully pop fittings loose from (19). Reinstall horizontal stabilizer (Ref.
tailboom while not damaging fiberglass Section 53-50-30, Horizontal Stabilizer
sheets under fitting. Replacement).
(7). Clean area with isopropyl alcohol (20). Check rigging of thruster (Ref. Section
(CM217). 67-20-30).
Page 210
MAINTENANCE MANUAL
(21). Check rigging of vertical stabilizers (a). If tailboom is not previously marked,
(Ref. Section 67-20-30). place a mark every 2.0 inches (50.8
mm) around cover and tailboom.
13. 500N3500−5 Cover Installation
(b). Do not bond the bottom 8.0 inches
(Ref. Figure 204) New tailbooms come with the (203.2 mm) on aft end of cover.
500N3500-5 cover separate. This cover must
be bonded in place after the wiring and cables (4). Abrade around the cover mating
are installed. surface with 240 grit abrasive cloth
(CM802) to remove gloss.
(Ref. Section 91−00−00) NOTE:
Item Nomenclature D Use care to avoid damage to the fiber re
CM217 Isopropyl alcohol inforcement.
CM410 Adhesive, epoxy (parts A & B) D Metallic faying surfaces do not require
CM802 Abrasive cloth, aluminum oxide abrading.
CM819 Kimwipe
(5). Using 240 grit abrasive cloth (CM802),
lightly abrade spots, where marked,
(1). With cutout facing down and forward, around the tailboom until the surface
gently role cover to shape of tailboom gloss is removed.
and position inside aft end of tailboom.
Slide cover in until aft end is flush with (6). Wipe abraded surfaces with kimwipes
tailboom. (CM819) dampened with isopropyl
alcohol (CM217). Allow to air dry for 15
NOTE: Right edge of cover should be just to the minutes.
right of the torque tube housing (8° to the
right of centerline). Left edge should be un (7). Mix adhesive according to manufactur
der the left horizontal stabilizer empennage er's instructions.
fitting.
(2). Check holes in cover to ensure they line
NOTE: Adhesive must be applied within two
hours of cleaning. Repeat solvent prep if
up with electrical connectors on
more than two hours elapses before bond
tailboom.
ing.
(3). If holes do not line up with electrical
connectors, remove cover, role 180° and (8). Apply adhesive to abraded areas and
reposition in tailboom. position cover in tailboom. Clean up
excessive adhesive.
NOTE: Tailboom is manufactured with 1.0 x
1.0 inch (25.4 x 25.4 mm) spots marked for (9). Allow to cure per manufacturer's
abrasion. instructions.
Page 211
MAINTENANCE MANUAL
R/H HORIZONTAL CL
EMPENNAGE FITTING RIGHT EDGE OF
-5 COVER
LEFT EDGE OF
-5 COVER
8°
TORQUE TUBE
HOUSING
RIGHT EDGE OF
-5 COVER
U -5 COVER
P
TAILBOOM
LEFT EDGE OF
-5 COVER
8.0 IN. (203.2 MM)

L/H HORIZONTAL DO NOT BOND
EMPENNAGE FITTING THIS AREA
VIEW LOOKING DOWN
G53-4005
Figure 204. 500N3500−5 Cover Installation

14. Tail Skid Replacement (a). Insert removed shims and install two
bolts and washers.
(Ref. Figure 205)
(b). Torque bolts to 36—40 Inch-
A. Tail Skid Removal pounds (3.95—4.52 Nm) plus drag
(1). Remove two bolts with washers from torque.
aft tail skid brace. (4). If installing a new tail skid:
(2). Retain shims between base and brace if (a). Install bolts finger tight, ensure gap
same tail skid is to be reinstalled. is even on both sides.
(3). Slide tail skid from forward bracket (b). Measure gap between brace and
assembly. base.
B. Tail Skid Installation (c). Subtract 0.010 in. (0.254 mm) and
(1). Slide tail skid into forward bracket peel shims to that thickness.
assembly. (d). Insert shims between brace and base
(2). Install aft brace onto aft base. and torque bolts to 36—40 Inch-
pounds (3.95—4.52 Nm) plus drag
(3). If reinstalling the same tail skid: torque.
Page 212
MAINTENANCE MANUAL
FORWARD BRACKET
ASSEMBLY AFT BASE
SHIM AFT BRACE

BOLT
WASHER
TAIL SKID
G53-4006
Figure 205. Tail Skid Installation
Page 213
MAINTENANCE MANUAL
Page 214
MAINTENANCE MANUAL
TAILBOOM (500/600N)
REPAIRS
1. Rotating Thruster Cone Strap Repair A. Rotating Thruster Cone Strap Removal
For minor repairs not described in this section, (1). Remove the rotating thruster cone
refer to MDHI Field Service Representative. assembly. (Ref. Section 53-40-30).
(Ref. Figure 801) (2). Remove rivets (2) from rotating
thruster cone (1).
Consumable Materials (3). Remove strap (3) from rotating thruster
(Ref. Section 91−00−00) cone.
Item Nomenclature
CM235 Cleaner (4). Remove any adhesive residue from
CM214 Releasing agent rotating thruster cone strap bonding
area.
CM441 Sealing compound, corrosion-inhibiting (5). Clean the bonding area with cleaner
(CM235).
3
2 (24 PL)
G53-4007
Figure 801. Rotating Thruster Cone

1. ROTATING THRUSTER CONE 3. STRAP
2. RIVET
Page 801
MAINTENANCE MANUAL
B. Rotating Thruster Cone Strap Installation (9). Install the strap in the rotating
thruster cone.
NOTE: The rotating thruster cone strap bond
ing area must be smooth. Small surface de (10). Apply releasing agent (CM214) to cleco
fects in the bonding area can be filled with fasteners.
adhesive (CM409) before bonding. Do not let
excess adhesive change the contour of the (11). Use cleco fasteners to align the rotating
bonding area. thruster cone and strap rivet holes.
(1). Put the rotating thruster cone strap (3)
in position on the rotating thruster cone (12). Remove excess adhesive from rotating
(1) bonding area. thruster cone strap and bonding area.
(2). Transfer the 24 rivet hole locations in Make sure the strap is not de
the rotating thruster cone to the strap. CAUTION formed or out-of-round when
installed in the rotating thruster cone. An
(3). Match drill the strap for the rivets (2). out-of-round contour can cause the rotat
(4). Remove the strap from the rotating ing thruster cone to bind during operation.
thruster cone.
(13). Cure adhesive for 24 hours at ambient
(5). Clean and deburr the rivet holes in the temperature or heat to 170—1905 F
strap. (76.7—87.75 C) for 90 minutes.
(6). Inspect the rotating thruster cone strap (14). Remove cleco fasteners from rivet holes.
bonding area for any surface defects.
(7). If necessary, fill bonding area surface (15). Wet install rivets with sealing com
defects with adhesive (CM409). pound (CM441).
(8). Apply adhesive (CM409) to the rotating (16). Paint exterior of rotating thruster cone
thruster cone strap bonding area. as required (Ref. Section 20-30-00).
Page 802
MAINTENANCE MANUAL
Section
53−50−10
Stabilizer (T−Tail)
(369D/E/FF)
MAINTENANCE MANUAL
STABILIZER (T−TAIL) (369D/E/FF)

1. Description and Operation 2. Fault Isolation
(Ref. Figure 201) (Ref. Table 201)
The tail surfaces (empennage) stabilize the 3. Horizontal Stabilizer and Tip Plate
helicopter and maintain it in a relatively level Replacement
attitude during high speed forward flight. The
tail surfaces consist of a vertical and horizon (Ref. Figure 201)
tal stabilizer attached to the aft end of the
tailboom. A. Removal
The horizontal stabilizer mounts atop of the NOTE: Tip weights are installed at the factory
vertical stabilizer in a T-shaped arrangement. and are only required to reduce T-tail vibra
Tip plates are attached to ends of the horizon tion.
tal stabilizer with a steel tip weight between (1). Remove the four screws from the tip
each tip plate and the stabilizer. The horizon plate and tip weight (if applicable, right
tal stabilizer is constructed of aluminum alloy and left tip plates and/or tip weights
skins riveted to formed ribs and spars. are interchangeable) and horizontal
stabilizer.
The vertical stabilizer is constructed of
aluminum alloy skins bonded to formed spars. (2). Remove the nuts and washers from the
horizontal stabilizer and vertical
The vertical stabilizer includes fittings, stabilizer fitting.
honeycomb core, and non-structural leading
and trailing edges. The tip plates are con (3). Disconnect the position light electrical
structed of aluminum alloy skins bonded over connection and bond jumper.
a honeycomb core. The vertical stabilizer is
mounted aft right of the tailboom and is bolted NOTE: MDHI Notice DN-63 has information
to the gearbox and stabilizer mount frame and for the addition of drain holes and to seal the
a upper and lower mount fitting. The vertical doubler edges on some 369D helicopters.
stabilizer fitting supports the horizontal MDHI Notice DN-44.1 has information for
stabilizer. The lower end of the vertical the replacement of the trailing edge tabs, re
stabilizer incorporates a tail skid assembly. location of the static pressure tube, and the
addition of doublers on some 369D heli
Lighting provisions are provided on both copters.
vertical and horizontal stabilizers. (Ref.
CSP-HMI-3, Section 96-40-00 for informa (4). Examine the horizontal tip plates and
tion on exterior lights.) stabilizer (Ref. Procedure 6.A.).
Table 201. Troubleshooting Tailboom and Tail Surfaces

High frequency vibration. Loose vertical stabilizer. Torque bolts 190—220 inch−pound
(21.47—24.86 Nm).
NOTE: High frequency vibrations in Loose horizontal stabilizer. Torque nuts 90—110 inch−pound
helicopter can be caused by (10.17—12.43 Nm).
components in other systems (Ref.
Chapters 63, 64, and 71). Do a check of the angle of incidence
(Ref. Procedure 6.C.).
Page 201
MAINTENANCE MANUAL
POSITION LIGHT
BRACKET
GROMMET
HORIZONTAL
STABILIZER
TIP WEIGHT
(NOTE 1)
HORIZONTAL
STABILIZER
VERTICAL ELECTRICAL
STABILIZER LEAD
POSITION LIGHT
BRACKET - ATTACHMENT
TIP PLATE
ANTI-COLLISION
LIGHT SUPPORT
SEAL
0.1 X 0.75 X 2.0 INCH

(2.54 X 19.05 X 50.8 MM)
1 OZ (28.35 G) MS20470AD4 RIVET

LEAD WEIGHT (2 REQD)
(NOTES 2, 3, 4) HS306-318 WASHER
(2 REQD) (NOTE 3)
GROMMET
FORWARD
SEAL SEAL
VERTICAL
HORIZONTAL STABILIZER TAB STABILIZER
WEIGHT INSTALLATION FITTING
(421-087-505 STABILIZER ONLY)
NOTE:
1. TIP WEIGHTS ARE INSTALLED AT MANUFACTURING AND
ARE ONLY REQUIRED TO REDUCE T-TAIL VIBRATION.
2. COMMERCIAL 1 OZ (28.35 G). LEAD AUTOMOBILE
ALLOY WHEEL BALANCE WEIGHT.
3. INSTALL WEIGHT, RIVETS AND WASHERS WITH PRIMER
4. SEAL EDGES WITH SEALANT AFTER INSTALLATION. HORIZONTAL STABILIZER/VERTICAL
STABILIZER - ATTACHMENT
G53−5000B
Figure 201. Stabilizer T−Tail Removal and Installation
Page 202
MAINTENANCE MANUAL
TOP OF RIB 0.250 INCH

369D23608 (6.35 MM)
-0.000
0.030 INCH +0.010
(-0.000)
(0.762 MM) (+0.254)
VIEW B-B
TOP OF RIB
369D23609 CL
-0.000
0.030 INCH +0.010
(-0.000)
(0.762 MM) (+0.254)
VIEW C-C
SEALANT TO BE APPLIED
AROUND ELECTRICAL
SEALANT (NON-HARDENING), EDGES AND CONDUIT
TOOLING HOLES, EXCEPT DRAIN HOLES RTV
DRAIN HOLE 0.60 INCH

C (1.524 MM) DIAMETER
THRU SEALANT SHOULD
B B NOT COVER DRAIN HOLE
C
TOOLING HOLES
DRAIN HOLE 0.60 INCH (1.524 MM)
DIAMETER THRU SEALANT SHOULD 369D23600 VERTICAL
NOT COVER DRAIN HOLE STABILIZER ASSEMBLY
VIEW A-A
A A
Figure 202. Sealing — Vertical Stabilizer (SNs 0003D thru 0286D)
Page 203
MAINTENANCE MANUAL
B. Installation (8). Check the angle of incidence (Ref.

Procedure 6.C.).
Consumable Materials (9). Install the tip plates with the tip
(Ref. Section 91−00−00) weight between the tip plate and
Item Nomenclature horizontal stabilizer with four screws.
CM103 Solid film lubricant
(10). Remove the support from the rear
jack-point.
(1). Support the helicopter at the rear 4. Vertical Stabilizer

jack-point (Ref. Section 07-00-00) (Ref. Figure 201)
during installation of the horizontal
stabilizer to make sure that the A. Removal
helicopter angle of incidence does not
change during measurements. (1). Remove the horizontal stabilizer (Ref.
Procedure 3.A.).
(2). Measure the inclination angle of the
horizontal stabilizer at BL 10.66 inch (2). Disconnect the anti-collision light
(27.076 cm) to right (S RIGHT) and left electrical connection.
(S LEFT) of horizontal stabilizer (3). Remove the bolts and washers from the
centerline (Ref. Figure 203). stabilizer and tailboom.
(a). If angles S RIGHT and S LEFT differ (4). Examine the vertical stabilizer (Ref.
by more than one degree, replace the Procedure 6.B.).
horizontal stabilizer.
B. Installation
(3). For 369D aircraft SNs 0003D thru
0286D (Ref. Figure 202):
(a). Apply a 0.030 to 0.040 inch (0.76 to (Ref. Section 91−00−00)
1.02 mm) bead of sealant (CM425) Item Nomenclature
around the perimeter of the top rib CM109 Molybdenum disulfide powder lubricant
assemblies and at the attach fitting.
NOTE: Do not seal the drain holes. (1). Align the stabilizer with the mounting
holes on the tailboom fitting.
(b). Apply sealant around the electrical
conduit and seal over tooling holes. (2). Spray lubricant (CM109) on the threads
of the bolts.
(4). Position the horizontal stabilizer on the
vertical stabilizer fitting (ref. (3). Install the bolts:
Figure 201).
(a). Torque the bolts 190—220 inch-
(5). Connect the position light electrical pound (21.47—24.86 Nm).
connection and bond jumper.
(b). Safety the bolts in pairs with lock
(6). Spray solid-film lubricant (CM103) on wire.
the threads of the nuts.
(4). Connect the anti-collision light electri
(7). Install the nuts and washers. cal connection.
(a). Torque the nuts 90—110 inch- (5). Install the horizontal stabilizer (ref.
pound (10.17—12.43 Nm). Procedure 3.B.).
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MAINTENANCE MANUAL
5. Adjustment / Test NOTE: The tab weight can be made from a com
mercial automobile alloy wheel balance
A. Angle of Incidence Adjustment weight (0.100 x 0.750 x 2.000 inch (2.54 x
(1). Remove the bolts and washers from the 19.05 x 50.80 mm)).
horizontal stabilizer and vertical (2). Locate the weight span-wise to the
stabilizer fitting. point of the observed maximum
Do not add more than two wash amplitude vibration.
CAUTION ers under each boss. (3). Run the engine at 102% to 105% N2 :
(2). Lift the horizontal stabilizer to add an (a). Observe the horizontal stabilizer tab.
equal number of AN960PD416L
washers under each of the two front or (b). Move the weight inboard or outboard
each of the two rear bosses. on the tab depending on response.
(3). Install the horizontal stabilizer with (c). If necessary, a one-ounce (28g) tab
washers and bolts. weight can be installed on left tab.
(4). Torque the bolts 90—110 inch-pound (d). A maximum of two one-ounce (28g)
(10.17—12.43 Nm). tab weights can be installed on each
tab.
(5). Do the angle of incidence measurement
again (Ref. Procedure 6.C.). (4). Once the correct position and amount of
weight has been found, install the tab
B. Horizontal Stabilizer Tab Weight weight(s) as follows:
Installation
(a). Cleco the tab weight in place on the
(Ref. Figure 201) stabilizer.
Consumable Materials (b). Drill two #31 holes through each tab
(Ref. Section 91−00−00) weight and stabilizer.
Item Nomenclature (c). Remove the tab weight.
CM318 Primer
CM425 Sealing compound (d). Deburr the holes.
(e). Touch up the stabilizer holes with
Installation of tab weight is optional on the primer (CM318).
421-087 -505 horizontal stabilizer if difficulty (f). Wet install the tab weight, washers,
in tail rotor balance and horizontal stabilizer and rivets with primer (CM318).
tab resonance vibration is found (Ref. Section
18-20-00, Horizontal Stabilizer Tuning). (g). Seal the mating edges of the tab
weight with sealing compound
(1). Temporarily apply a one-ounce (28g) (CM425).
tab weight to the upper right trailing
edge of the right tab with tape. (5). Touch up with paint to match.
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MAINTENANCE MANUAL
6. Inspection / Check (5). Examine the condition of grommets.

A. Horizontal Stabilizer and Tip Plate (6). Examine the mount holes for elonga
Inspection tion.
(1). Examine the metal skin for holes, (7). For repair (Ref. Vertical Stabilizer
cracks, loose rivets, or corrosion. Repair).
(a). Stop-drill or patch a crack. C. Angle of Incidence Measurement
(2). Examine the attach fittings and light (Ref. Table 202, Figure 203, and Figure 204)
mounting bracket for cracks, loose
rivets, or corrosion.
Special Tools
(3). Examine the attach studs and mating (Ref. Section 91-00-00)
holes for evidence of wear caused by Item Nomenclature
looseness in service.
ST2014 Angle measuring tool
(a). If there are questionable studs, do a
dye-penetrant or magnetic particle
inspection, as applicable. NOTE: It is not necessary to level the helicopter
to find the horizontal stabilizer angle of inci
(4). Examine the drain holes on the lower dence.
surface. D If the mast is tilted forward of 0°, add “H”
(a). Make sure they are not blocked or to “S”.
clogged with debris. D If the mast is tilted aft of 0°, subtract “H”
from “S”.
(5). Examine the seal around the upper and
lower doublers. (1). Remove the hub fairing from the main
rotor hub assembly.
(a). Make sure all gaps/edges between
the doublers and stabilizer skin are (2). Measure the incidence angle of the
sealed. horizontal stabilizer (Ref. Figure 203)
with the angle measurement tool
(6). Repair the horizontal stabilizer and tip
(ST2014) at BL 10.66 inch (27.076 cm)
plates (Ref. Procedure 7.A.).
to right (S RIGHT) and left (S LEFT) of
B. Vertical Stabilizer Inspection horizontal stabilizer centerline.
(1). Examine the skin for holes, cracks, (a). If angles S RIGHT and S LEFT differ
bonding separation, or corrosion. by more than one degree, replace the
(2). Examine the attach fitting for cracks,
loose rivets, or corrosion. (3). Measure the inclination of the top of
main rotor hub (Ref. Figure 204).
(3). Examine the tail skid for cracks,
deformation, and loose or missing (a). Record as Angle H.
rivets.
(4). Compute average of angles S RIGHT
(4). Examine the anti-collision light and S LEFT.
bracket for cracks, loose rivets or
screws, and corrosion. (a). Record result as Angle S.
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MAINTENANCE MANUAL
S LEFT S RIGHT HORIZONTAL

STABILIZER
B.L. 10.66 INCH B.L. 10.66 INCH

(27.076 CM) (27.076 CM)
NOTE 2.030 INCH
13.850 INCH (5.1562 CM)
(35.179 CM)
0.50 INCH (12.7 MM) 0.50 INCH

RADIUS (3 PLACES) (12.7 MM)
1.090 INCH (2.769 CM)
1.575 INCH (4.0005 CM)

CHORD PLANE
OML SKIN AT
STABILIZER STA. 10.66
14.015 INCH
(35.598 CM)
NOTE:
TOOL FUNCTION - TO CHECK STABILIZER INCIDENCE. G53-5001B
Figure 203. Horizontal Stabilizer Incidence Angle Measuring Tool
HORIZONTAL STAB.
STAB. INCIDENCE CHORD PLANE
TOP OF M/R ANGLE `Ì''
HUB PLANE AVERAGE STAB. INCLINATION
ANGLE ``S'' AVERAGE
HUB INCLINATION ANGLE ``H''
CL
GROUND LEVEL PLANE

MAST
G53-5002
Figure 204. Establishing Horizontal Stabilizer Angle of Incidence
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MAINTENANCE MANUAL
(5). Add angles H and S to find the angle of (a). Remove excess sealant with naphtha
incidence of the horizontal stabilizer. (CM220).
(a). Models D/E Only — If H plus S is (2). Repaint the sealed areas.
between 8 degrees 55 minutes and 9
degrees 25 minutes, the angle of (3). Do other horizontal stabilizer repairs
incidence is correct (Ref. Table 202). with the applicable instructions in
(b). Model FF Only — If H plus S is CSP-SRM-6, Structural Repair
between 7 degrees 30 minutes and 8 Manual.
degrees 00 minutes, the angle of
incidence is correct (Ref. Table 202). NOTE: Support the helicopter at the rear jack-
point during installation of the horizontal
Table 202. Horizontal Stabilizer Angle of stabilizer.
Incidence
(4). Install the horizontal stabilizer (Ref.
Angle Model Procedure 3.B.).
8° 55’ to 9° 25’ 369D
8° 55’ to 9° 25’ 369E B. Vertical Stabilizer Repair
7° 30’ to 8° 00’ 369FF
(6). If angle of incidence is not acceptable,
do Procedure 5.A.
Item Nomenclature
(7). Install the hub fairing on the main CM418 Cement, epoxy
rotor hub assembly.
7. Repairs (1). For allowable repairs and additional
A. Horizontal Stabilizer and Tip Plate Repair inspection criteria, Ref. CSP-SRM-6,
Structural Repair Manual.
Consumable Materials (2). Replace damaged or worn seals.

Item Nomenclature (a). Bond the replacement seal with
CM220 Naphtha aliphatic cement (CM418).
(3). Replace damaged, worn, or missing
grommets.
(1). Seal gaps/edges between the doublers
and stabilizer skin with sealant (4). Install the vertical stabilizer (Ref.
(CM425). Procedure 4.B.).
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MAINTENANCE MANUAL
Section
53−50−30
Stabilizer (500/600N)
MAINTENANCE MANUAL
STABILIZER
1. Stabilizers Description a hollow core spar, retainer fittings and
nonstructural leading and trailing edges.
The tail surfaces consist of two verticals and a
horizontal stabilizer. The tail surfaces (empen The differences on the 600N are that the
nage) stabilize the helicopter and maintain it vertical stabilizers are slightly longer, the skin
in a relatively contain level attitude and is thicker and on standard 600N helicopters,
heading during autorotation and forward are both controlled by the directional control
flight. pedals. The lower vertical stabilizer angle of
attack is eight degrees clockwise relative to the
A. Horizontal Stabilizer Description upper vertical stabilizer. Refer to Section
67-20-30 for flight controls linkage details.
The horizontal stabilizer is constructed of
laminated fiber glass composite ribs and skin, The left vertical stabilizer is mounted to the
bonded to a formed graphite composite spar. horizontal on a torque tube fitting assembly
The horizontal stabilizer includes a non-struc and has approximately 6.5 inches (16.51 cm) of
tural leading and trailing edges. hollow core travel.
spar, sparbox fittings, access panels, torque
tubes, bellcranks and control rods. On the 500N and S.A.S. equipped 600N, the
right vertical stabilizer, also mounted on a
On the 500N and optional on the 600N, a torque tube, is controlled by the stability
stability augmentation system (S.A.S.) is augmentation system. From the fully extended
attached to the right-hand vertical stabilizer, to the fully retracted position on the S.A.S.
the early 600N does not have a S.A.S system. actuator, the tip of the right vertical stabilizer
trailing edge will travel a minimum of 2.70
The horizontal stabilizer mounts atop the inches (6.86 cm). The amount of travel is
tailboom. Four eye bolts from the horizontal determine by the S.A.S. computer and gyro.
attach to clevis attachment points on the
tailboom. Access plates are attached to the NOTE: The anti-torque control system must be
ends caps of the horizontal stabilizer and at re-rigged immediately after removal or re
center line for access to the control rods, S.A.S. placement of control rods, linkages, and
and bellcranks. Two control rods, S.A.S. and components or if helicopter operation re
bellcranks are routed in the center aft of the veals a rigging deficiency.
sparbox. The angle of incidence of the horizon
2. Vertical Stabilizer Replacement
tal stabilizer is preset at -2°. An anti-collision
light is mounted in the top center of the (Ref. Figure 201, Figure 202)
stabilizer. Position lighting provisions are
provided on both ends of the stabilizers. A. Vertical Upper and Lower Stabilizer
Removal
On the 600N without S.A.S., gurney flaps were
added to the trailing edge of the horizontal for (1). Remove nuts, washers, and bolts.
the purpose of increasing lift without increas Remove by lifting vertical stabilizer off
ing the stabilizer area or weight. torque tube.
Refer to CSP-HMI-3, Section 96-40-00 for B. Vertical Upper and Lower Stabilizer
information on exterior lights and Section Installation
67-20-30 for rigging requirements. (1). Installation with Standard Hardware:
B. Vertical Stabilizers Description Do not over-torque nut. Over-
CAUTION torquing nut can crack vertical
The vertical stabilizers (upper and lower) are stabilizer fitting.
constructed of laminated fiber glass composite
ribs and skin, bonded to a formed fiberglass (a). Install stabilizer onto torque tube
composite spar. The vertical stabilizers include fittings.
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MAINTENANCE MANUAL
(b). Install bolts, washers and nuts. NOTE: Horizontal stabilizer can be removed
Torque to 30—40 inch-pounds with vertical stabilizers installed. Support
(3.39—4.52 Nm) plus drag torque. stabilizer during removal.
(2). Installation with Expandable Bolts: A. Horizontal Stabilizer Removal
Do not over-torque nut. Over- (1). Remove seven screws securing center
CAUTION torquing nut can crack vertical access plate to horizontal stabilizer.
stabilizer fitting. (2). Disconnect position light electrical
(a). Install bolt with washer under bolt interconnect.
head and thick washer under nut. (3). On 500N, disconnect S.A.S. electrical
interconnect.
NOTE:
D Do not remove any expanding elements (4). Remove cotter pin, nut, washer and bolt
from bolt. from center bellcrank shaft. Index mark
bellcrank with grease pencil in relation
D If 600N2012-5 spacers are not present, ship to shaft. Disconnect bellcrank.
up to two spacers can be added to achieve
proper installation. (5). Remove nuts, washers and expandable
bolts securing horizontal stabilizer to
(b). Remove one (1) or two (2) tailboom attachment clevis fittings.
600N2012-5 spacers, as required) to Remove horizontal stabilizer.
obtain 0.005—0.035 inch
(0.127—0.889 mm) gap between the B. Horizontal Stabilizer Installation
washers and the vertical stabilizer,
equal on each side.
NOTE: When installing horizontal stabilizer it
can be necessary to loosen eye bolts and
(c). Install nut and note drag torque. nuts to align with clevises, if so, install
mounting expandable bolts first and torque
(d). Do a break in cycle by torquing the per step (2). below, then torque clevis nuts to
nut to 20—25 inch-pounds 80—120 inch-pounds (9.04—13.56 Nm).
(1). Position horizontal stabilizer on
(e). Back off nut until bolt moves freely tailboom attach fittings.
in hole. (2). Install expandable bolts, washers and
(f). Torque nut to 20 inch-pounds (2.26 nut. Torque to 30—40 inch-pounds
Nm) plus drag torque. (3.39—4.52 Nm). Install cotter pin.
(3). Connect position light/strobe light
(g). Check for equal gap of 0.005—0.035
electrical connector.
inch (0.127—0.889 mm) between
the washers and the vertical stabiliz (4). On 500N, connect S.A.S. electrical
er. interconnect.
NOTE: NAS1149C0332R or NAS1149C0363R When installing bellcrank on
washers can be added under the nut for ade CAUTION center bellcrank shaft it is possi
quate cotter pin engagement. ble to be one spline tooth off in either direc
tion, install bellcrank centered on shaft
(h). If necessary, tighten nut until cotter (Ref. Section 67-20 -30).
pin hole aligns with castillation in
nut. (5). Connect bellcrank to center bellcrank
shaft and install bolt, washers and nut.
(i). Install cotter pin. Torque nut to 30—40 inch-pounds
(3.39—4.52 Nm) and install cotter pin.
3. Horizontal Stabilizer Replacement
(6). Install center access plate with seven
(Ref. Figure 201 and Figure 202) screws and washers.
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MAINTENANCE MANUAL
VERTICAL
STABILIZER
(UPPER)
NUT
(NOTE 2)
TRIM TAB
(NOTE 1)
500N TAILBOOM
SHOWN
NUT
(NOTE 2)
VERTICAL
STABILIZER
(LOWER)
WASHER
WASHER
BOLT
CENTER
BELLCRANK
SHAFT
TORQUE TUBE
HOUSING
NOTE 4
BELLCRANK CENTER BELLCRANK SHAFT
G53-5003-1B
Figure 201. Stabilizer Installation with YSAS (Sheet 1 of 2)
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MAINTENANCE MANUAL
YSAS ACTUATOR
(500N, AND 600N WITH YSAS)
CENTER ACCESS
PLATE
HORIZONTAL
STABILIZER
EYEBOLT END TIP

ACCESS
COVER TORQUE
TUBE
WASHER
SPACER
(NOTE 3)
TAILBOOM BEARING RACE

ATTACH
FITTING
BELLCRANK
BUSHING NOTE 4
COTTER PIN
NUT
NOTES:
1. TYPICAL LEFT AND RIGHT STABILIZERS (500/600N).
2. TORQUE 30 - 40 INCH-POUNDS (3.39 - 4.52 NM) PLUS DRAG TORQUE.
3. SPACERS INSTALLED ON AFT BOSS ONLY.
4. OPENING IN BELLCRANK ALWAYS FACES OUTBOARD (LH AND RH SIDES).
G53−5003−2F
Figure 201. Stabilizer Installation with YSAS (Sheet 2 of 2)
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MAINTENANCE MANUAL
4. Horizontal Stabilizer Eye Bolt (2). Install control tubes and bellcranks as
Replacement required, safety wire or cotter pin.
A. Horizontal Stabilizer Eye Bolt Removal (3). Install center access plate with seven
screws and washers.
(1). Remove horizontal stabilizer.
6. Vertical Stabilizer Inspection
(2). Remove eye bolts by holding the flat
surface of eye bolt with a wrench and (Ref. Figure 201 and Figure 202)
removing nut. (1). Inspect skin for cracks, bonding
separation, delamanation and obvious
B. Horizontal Stabilizer Eye Bolt Installation damage.
(1). Install eye bolts in horizontal stabilizer, (2). Inspect stabilizer for freedom of
the short eye bolts in the forward holes movement through pedal travel range,
and the longer eye bolts with spacer to check for clearance between vertical to
the aft holes of horizontal stabilizer. horizontal.
(2). Torque eye bolts to 80—120 inch- (3). Check mounting fitting holes for
pounds (9.04—13.56 Nm) plus drag elongation.
torque.
NOTE: Internal stabilizer fitting can display
(3). Install horizontal stabilizer. cracking after installation of expandable
bolts. This cracking, internal fitting only, is
5. Horizontal/Vertical Stabilizer Control Tube acceptable for continued service. Cracking
and Bellcrank Replacement of the external skin from the mounting bolt
holes is unacceptable and stabilizer must be
(Ref. Figure 201 and Figure 202) removed from service and scrapped.
A. Horizontal/Vertical Stabilizer Control Tube 7. Vertical Stabilizer Repair

and Bellcrank Removal Refer to MDHI Field Service Representative.
(1). Remove horizontal stabilizer end tip 8. Horizontal Stabilizer Inspection
covers and center access cover for
access to bellcranks and control tubes. (1). Inspect skin for cracks, bonding
separation, delamination and obvious
(2). Remove cotter pin, nut, washer and bolt damage.
from center bellcrank shaft. Index mark
bellcrank with grease pencil in relation (2). Inspect mounting fitting and attach
ship to shaft. Disconnect bellcrank. ment hardware for condition.
(3). Disconnect control tube from vertical (3). Inspect center access panel and nut
stabilizer torque tube bellcrank. plate fasteners for condition, end tip
Remove controls from horizontal plate access covers and position lights
stabilizer as required for maintenance. for condition.
(4). Inspect vertical stabilizer torques tubes
B. Horizontal/Vertical Stabilizer Control Tube for excessive axial and radial move
and Bellcrank Installation ment, 0.010 inch (0.254 mm) axial end
play maximum allowable.
Refer to adjustment and test control rigging
during installation. (5). Inspect torque tube bushings for wear
and security.
(1). Connect bellcrank to center bellcrank
shaft and install bolt, washers and nut. (6). If the bushings are not bonded to the
Torque bolt to standard aircraft torque horizontal stabilizer, rework Vertical
values and install cotter pin. Stabilizer Torque Tube Bushings.
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MAINTENANCE MANUAL
9. Vertical Stabilizer Torque Tube (2). Apply one layer of teflon tape (CM726)
Replacement to threads of torque tube prior to
installing locknut.
A. Vertical Stabilizer Torque Tube Removal
(3). Install locknut, hand tighten and adjust
(1). Remove vertical stabilizers (Ref. to a 0.005—0.010 inch (0.127—0.254
Vertical Stabilizer Replacement). mm) gap; Install cotter pin.
(2). Remove horizontal tip plate access NOTE: When installing the bellcrank, opening
cover and disconnect YSAS torque tube in bellcrank must face outboard.
(if installed) from vertical stabilizer (4). Install bellcrank, with opening facing
bellcrank. outboard, on torque tube and install
(3). Remove bellcrank from torque tube by expandable bolt; Torque to 30—40
removing expandable bolt. inch-pounds (3.39—4.52 Nm) plus
drag torque; Install cotter pin.
(4). Remove cotter pin, locknut and bushing (5). Connect YSAS actuator to vertical
from torque tube. Remove torque tube stabilizer torque tube bellcrank. Torque
by lifting upward. nut to 30—40 inch-pounds
B. Vertical Stabilizer Torque Tube
Installation (6). Install end plate access covers.
(1). Slide torque tube from the top thru the (7). Install vertical stabilizer (Ref. Vertical
horizontal stabilizer. Stabilizer Replacement).
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MAINTENANCE MANUAL
GURNEY FLAPS
RIGHT
CONTROL ROD
AFT
CONTROL ROD
NOTE 1
NOTE:
1. EXTRA WASHER BETWEEN RADIUS BLOCK
LEFT AND SPACER.
CONTROL ROD NOTE 2 2. OPENING IN BELLCRANK ALWAYS FACES
OUTBOARD (LH AND RH SIDES).
EARLY 600N SHOWN G53-5003-3B
Figure 202. Stabilizer Installation without YSAS
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MAINTENANCE MANUAL
VERTICAL STABILIZER TORQUE TUBE
EXPANDABLE
ELEMENTS NON EXPANDABLE
ELEMENT
THIN WASHER
THIN WASHER
THICK EXPANDABLE
WASHER SPACERS (2) ELEMENTS
EXPANDABLE DIAMETER
BOLT INSTALLATION
WASHER
(OPTIONAL)
NUT
COTTER PIN
THICK WASHER
WASHER
SPACERS BOLT
WASHER
(OPTIONAL)
COTTER NUT
PIN
THICK WASHER
WASHER
SPACERS BOLT MAX. DIA. O.254 IN. (6.4516 MM)
(8 PLCS) EACH TORQUE TUBE
TORQUE TUBE
NOTE:
THE BOLT, WASHER, THICK WASHER, SPACERS AND NUT ARE
COMPONENTS OF THE EXPANDABLE DIAMETER BOLT ASSEMBLY. 53-5007
Figure 203. Vertical Stabilizer Installation with Expandable Bolts
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MAINTENANCE MANUAL
10. Horizontal Stabilizer Repair (10). Connect YSAS actuator to vertical

stabilizer torque tube bellcrank. Torque
Refer to MDHI Field Service Representative. nut to 30—40 inch-pounds
11. Vertical Stabilizer Torque Tube and/or
Bushing Replacement (Non−Bonded (11). Install end plate access covers.
Bushings)
(12). Install vertical stabilizer (Ref. Vertical
(Ref. Figure 201) The following procedure is for Stabilizer Replacement).
replacing the early style (non-bonded) torque
tube bushings. 12. Vertical Stabilizer Torque Tube and/or
Bushing Replacement (Bonded Bushings)
Consumable Materials (Ref. Figure 201) The following procedure is for
(Ref. Section 91−00−00) replacing the current style (bonded) torque
Item Nomenclature tube bushings.
CM726 Tape, teflon
(1). Remove vertical stabilizers (Ref. Item Nomenclature
Vertical Stabilizer Replacement).
(2). Remove horizontal tip plate access CM402 Adhesive
cover and disconnect YSAS torque tube CM726 Tape, teflon
(if installed) from vertical stabilizer CM802 Abrasive cloth, aluminum oxide
bellcrank.
(3). Remove bellcrank from torque tube by (1). Remove vertical stabilizers (Ref.
removing expandable bolt. Vertical Stabilizer Replacement).
(4). Remove cotter pin, locknut and bushing (2). Remove horizontal tip plate access
from torque tube. Remove torque tube cover and disconnect YSAS torque tube
by lifting upward. (if installed) from vertical stabilizer
bellcrank.
(5). Remove bushing from bearing race of
torque tube. (3). Remove bellcrank from torque tube by
removing expandable bolt.
(6). Install one bushing on bearing race of
torque tube and insert torque tube (4). Remove cotter pin, locknut and bushing
through fitting of horizontal stabilizer from torque tube. Remove torque tube
from the top downward. by lifting upward.
(7). Apply one layer of teflon tape (CM726) In the following steps, care must
CAUTION be taken to not damage the fi
to threads of torque tube prior to
installing locknut. bers of the horizontal stabilizer.
(8). Install bushing and locknut, hand (5). Remove bushing(s) from horizontal
tighten locknut and adjust to a stabilizer by gently working a sharp
0.005—0.010 inch (0.127—0.254 mm) scraper between bushing and stabilizer.
gap; Install cotter pin. (6). Sand excess sealant from horizontal
stabilizer taking care not to disturb the
NOTE: Ensure shouldered bushings are
composite fibers of the stabilizer.
installed in bellcrank.
(7). Clean faying surfaces of horizontal
(9). Install bellcrank on torque tube and stabilizer, where bushings are to be
install expandable bolt and washers; bonded, with isopropyl alcohol (CM217).
Torque to 30—40 inch-pounds
(3.39—4.52 Nm) plus drag torque; (8). Wipe dry using a clean dry rag and
Install cotter pin. then allow to air dry for 15 minutes.
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MAINTENANCE MANUAL
(9). Lightly abrade the faying surface of the 13. Vertical Stabilizer Torque Tube Bushing
new bushings with abrasive cloth Rework (Non−Bonded Bushings to
(CM802) until all gloss is removed. Bonded Bushings)
Wipe clean with isopropyl alcohol
(CM217). (Ref. Figure 201) The following procedure is for
converting the vertical stabilizer torque tube to
(10). Wipe dry using a clean dry rag and the current 500N3980-3 bushings,
then allow to air dry for 15 minutes. 500N3970-3 locknuts and MS24665-361
cotter pins.
(11). Mix adhesive (CM402) according to
manufacturers instructions. Apply Consumable Materials
adhesive within 2 hours of cleaning. (Ref. Section 91−00−00)
Item Nomenclature
(12). Apply a thin uniform layer of adhesive CM217 Isopropyl alcohol
(CM402) to faying surfaces.
CM402 Adhesive
Do not apply too much pressure, CM726 Tape, teflon
CAUTION damage to horizontal stabilizer CM802 Abrasive cloth, aluminum oxide
can occur.
(13). Press the faying surfaces firmly (1). Remove vertical stabilizers (Ref.
together and maintain contact pressure Vertical Stabilizer Replacement).
or apply 50 psi (3.45 kPa) maximum for (2). Remove cotter pins, locknuts and
24 hours at ambient temperature. bushings, and scrap. Remove torque
tube by lifting upward. Remove bushing
(14). Using isopropyl alcohol (CM217), clean and scrap.
excess adhesive from parts before
adhesive has had time to cure. (3). Clean faying surfaces of horizontal
stabilizer, where bushings are to be
(15). Slide torque tube from the top thru the bonded, with isopropyl alcohol (CM217).
(4). Wipe dry using a clean dry rag and
(16). Apply one layer of teflon tape (CM726) then allow to air dry for 15 minutes.
to threads of torque tube prior to (5). Lightly abrade the faying surface of the
installing locknut. new bushings with abrasive cloth
(CM802) until all gloss is removed.
(17). Install locknut, hand tighten and adjust Wipe clean with isopropyl alcohol
to a 0.005—0.010 inch (0.127—0.254 (CM217).
mm) gap; Install cotter pin.
(6). Wipe dry using a clean dry rag and
(18). Install bellcrank on torque tube and then allow to air dry for 15 minutes.
install expandable bolt; Torque to
30—40 inch-pounds (3.39—4.52 Nm) (7). Mix adhesive (CM402) according to
plus drag torque; Install cotter pin. manufacturers instructions. Apply
adhesive within 2 hours of cleaning.
(19). Connect YSAS actuator to vertical
stabilizer torque tube bellcrank. Torque (8). Apply a thin uniform layer of adhesive
nut to 30—40 inch-pounds (CM402) to faying surfaces.
(3.39—4.52 Nm) and install cotter pin. Do not apply too much pressure,
CAUTION damage to horizontal stabilizer
(20). Install end plate access covers. can occur.
(21). Install vertical stabilizer (Ref. Vertical (9). Press the faying surfaces firmly
Stabilizer Replacement). together and maintain contact pressure
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MAINTENANCE MANUAL
or apply 50 psi (3.45 kPa) maximum for (2). Remove vertical stabilizer torque tubes
24 hours at ambient temperature. (Ref. Vertical Stabilizer Torque Tube
Replacement).
(10). Using isopropyl alcohol, clean excess
adhesive from parts before adhesive has (3). Fabricate the following tool for bearing
had time to cure. race removal.
(a). Locate a steel plate of approximately
(11). Slide torque tube from the top thru the 0.250 inch (6.35 mm) thickness.
(b). Drill a 1.510 inch (38.3540 mm) hole
(12). Apply one layer of teflon tape (CM726) in the plate.
to new 500N3970-3 locknut.
(c). Deburr edges of hole to prevent
damage to torque tube.
(13). Install locknut, hand tighten and adjust
to a 0.005—0.010 inch (0.127—0.254 (d). Apply tape (CM730) to tool to prevent
mm) gap; Install MS24665-361 cotter damage to bearing race.
pin.
(4). Insert torque tube through the removal
(14). Install bellcrank on torque tube and tool and install on arbor press.
install expandable bolt; Torque to In the following steps, care must
30—40 inch-pounds (3.39—4.52 Nm) CAUTION be taken to not damage the hori
plus drag torque; Install cotter pin. zontal stabilizer torque tube.
(15). Install end plate access covers. (5). Place suitable device over torque tube
end to protect tube from damage from
(16). Install vertical stabilizer (Ref. Vertical arbor press.
Stabilizer Replacement).
(6). Remove bearing from the torque tube
by gently pressing torque tube through
14. Vertical Stabilizer Torque Tube Bearing the removal tool.
Race Replacement
(7). Using solvent (CM234), clean primer
(Ref. Figure 201) The following procedure is for residue from torque tube.
removal of the bearing race from the vertical
stabilizer torque tube. Some special tools will (8). Inspect torque tube for damage to
need to be manufactured for this procedure. bearing race contact surface.
(9). Fabricate the following tool for bearing
race installation.
(Ref. Section 91−00−00) (a). Locate a steel plate of approximately
Item Nomenclature 0.250 inch (6.35 mm) thickness.
(b). Drill a 1.390 inch (35.306 mm) hole
CM318 Primer in the plate.
CM730 Tape, duct
(c). Deburr edges of hole to prevent
damage to torque tube.
Special Tools
(Ref. Section 91-00-00) (d). Apply tape (CM730) to tool to prevent
Item Nomenclature damage to bearing race.
N/A Arbor press (10). Insert bearing race into tool and mount
on arbor press.
(1). Remove vertical stabilizers (Ref. (11). Coat torque tube bearing race mating
Vertical Stabilizer Replacement). surface with primer (CM318).
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MAINTENANCE MANUAL
In the following steps, care must bearing race is tight against flange on
CAUTION be taken to not damage the the torque tube.
horizontal stabilizer torque tube.
(14). Inspect bearing race flanged surface to
ensure no warpage occurred during
(12). Place suitable device over torque tube
installation.
end to protect tube from damage from
arbor press. (15). Reinstall vertical stabilizer torque
tubes (Ref. Vertical Stabilizer Torque
In the following step, ensure Tube Replacement).
CAUTION bearing race is not cocked on
torque tube, this will cause non-repairable (16). Reinstall vertical stabilizers (Ref.
damage to bearing race and torque tube. Vertical Stabilizer Replacement).
15. Stabilizer Troubleshooting
(13). While primer is wet, press torque tube
down through the bearing race until (Ref. Table 201)
Table 201. Troubleshooting Tailboom and Tail Surfaces
High frequency vibration Fan assembly out of balance Re−balance fan assembly.
Loose fan blades Replace and re−balance fan assy.
Loose bolts/nuts on Horizontal or Inspect mounting hardware; adjust or
Vertical stabilizer replace as necessary.
NOTE: High frequency vibrations in helicopter can be caused by components in other systems (Ref. Section
64−00−00, 63−25−10, 63−25−30 and 71−00−00).
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MAINTENANCE MANUAL
Chapter
62
Main Rotor
MAINTENANCE MANUAL
TABLE OF CONTENTS
62-00-00 Main Rotor (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Main Rotor System - General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Main Rotor System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Troubleshooting Main Rotor Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . 102
62-10-00 Main Rotor Blade (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Blade - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Rotor Blade Leading Edge Erosion Protection - General . . . . . . . . . . . . . . . 401
2. Main Rotor Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Rotor Blade Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Rotor Blade Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Main Rotor Blade and Damper Attach Pin Installation and Adjustment . . . . . . . . 401
Figure 401. Main Rotor Blade - Attachment and Outboard End . . . . . . . . . . . . . 403
1. Main Rotor Blade Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Main Rotor Blade Damage and Repair Limits -
Nicks, Scratches, Gouges and Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
2. Main Rotor Blade and Damper Attach Pin
Inspection and Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Disassembly and Special Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
4. Main Rotor Blade Forward Tip Cap
Inspection and Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
5. Main Rotor Blade Upper and Lower Root Fitting Attach
Lug and Lead-Lag Link Attach Lug Inspection (25 Hour) . . . . . . . . . . . . . . . . . . . . . 605
Figure 602. Main Rotor Blade Damage
Limits for Dents and Depressions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Figure 603. Main Rotor Blade Attach Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
6. Main Rotor Blade Upper and Lower Root Fitting, Attach Lug
and Lead-Lag Link Attach Lug Inspection (100 Hour) . . . . . . . . . . . . . . . . . . . . . . . . 608
7. Main Rotor Blade Leading Edge Abrasion Strip Check . . . . . . . . . . . . . . . . . . . . . . . . 610
8. Main Rotor Blade Torque Event Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
Figure 604. Main Rotor Blade Root Fitting,
Attach Lugs and Lead-Lag Link
Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
Figure 605. Application of Slippage Mark to Main
Rotor Blade Bushings and Root Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 612
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MAINTENANCE MANUAL

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Main Rotor Blade Repair (Nicks, Scratches and Wear Spots) . . . . . . . . . . . . . . . . . . . 801
2. Main Rotor Blade Repair (Dents, Depressions and Erosion) . . . . . . . . . . . . . . . . . . . . 801
3. Trim Tab Damage Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
4. Forward Tip Cap Threaded Insert Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 801. Main Rotor Blade Trailing Edge Weight Rework. . . . . . . . . . . . . . . . . 803
5. Loose Balance Weight Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
6. Loose Trailing Edge Weight Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
7. Loose or Missing Rivets or Aft Tip Cap Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Figure 802. Repair and Removal of Trim Tab, Main Rotor Blade . . . . . . . . . . . . . 805
Figure 803. Bearing Replacement -
Main Rotor Blade Damper Attach Fitting . . . . . . . . . . . . . . . . . . . . . . . 805
8. Damper Attach Blade Fitting Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 806
9. Outboard Leading Edge Abrasion Tape Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 806
A. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
B. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
Figure 804. Installation/Replacement of Abrasion Tape
(Main Rotor Blade Leading Edge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
Figure 805. Installation/Replacement of Double Layer Abrasion Tape
(369D21100-505, -509 and -511 Rotor Blades) . . . . . . . . . . . . . . . . . . 808
10. Leading Edge Abrasion Strip Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
11. Tip Cap Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
Figure 806. Main Rotor Blade Abrasion Strip and Tip Cap Sealing . . . . . . . . . . . 810
12. Main Rotor Blade Protective Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
A. Stainless Steel Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
62-20-00 Main Rotor Hub (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Hub - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Main Rotor Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Rotor Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Rotor Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Pulling Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Main Rotor Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4. Main Rotor Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Main Rotor Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Main Rotor Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5. Main Rotor Damper Nominal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
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MAINTENANCE MANUAL

Figure 402. Main Rotor Hub - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

1. Main Rotor Hub Balancing - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Main Rotor Blade Phasing Check and/or Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Main Rotor Hub Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Strap Pack Lamination - Exploded View . . . . . . . . . . . . . . . . . . . . . . . 602
4. Lead-Lag Bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
5. Main Rotor Strap Pack Lamination Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Figure 602. Strap Pack Lamination Inspection (Sheet 1 of 2) . . . . . . . . . . . . . . . . 606
Table 601. Strap Pack Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
6. Main Rotor Hub Droop Angle Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
7. Main Rotor Damper and Attachments Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
8. Main Rotor Damper Weight Loading and Extension Check . . . . . . . . . . . . . . . . . . . . 610
Figure 603. Periodic Check of Main Rotor Damper Assembly . . . . . . . . . . . . . . . . 611
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Main Rotor Retention Strap Pack Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Pitch Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Unbushed Outboard Clevis Lug Hole Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Field Repair of Main Rotor
Hub Pitch Control Lugs (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
4. Pitch Control Bearing Housing Assembly,
Spacer or Striker Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
5. Pitch Control Bearing Housing Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
6. Pitch Control Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Figure 802. Main Rotor Hub Components -
Repair and Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
7. Lead-Lag Link Blade Stop Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Figure 803. Striker Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
8. Damper Attach Lug Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
9. Lead-Lag Bolt Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
10. Pitch Control Bearing Pivot Pin Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . 810
11. Droop Stop Roller Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
12. Droop Stop Ring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
13. Droop Stop Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
14. Droop Stop Follower (T-Head) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
15. Droop Stop Plunger Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . 812
16. Main Rotor Hub Droop Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
Figure 804. Main Rotor Hub Assembly - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
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MAINTENANCE MANUAL

17. Main Rotor Hub Tapered Bearing Grease

Repack, Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
18. Main Rotor Hub Scissors Attach Lug Bearing Replacement . . . . . . . . . . . . . . . . . . . . 815
Figure 805. Main Rotor Hub - Cross Section (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . 817
Figure 806. Tapered Bearing Tools - Main Rotor Hub (Sheet 1 of 2) . . . . . . . . . . 819
62-20-60 Main Rotor Hub (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Hub - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Main Rotor Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Rotor Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Rotor Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Pulling Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Main Rotor Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4. Main Rotor Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Main Rotor Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Main Rotor Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5. Main Rotor Damper Nominal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 402. Main Rotor Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
1. Main Rotor System Balancing - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Main Rotor Hub Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Strap Pack Lamination - Exploded View . . . . . . . . . . . . . . . . . . . . . . . 602
3. Lead-Lag Bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4. Main Rotor Strap Pack Lamination Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 602. Strap Pack Lamination Inspection (Sheet 1 of 2) . . . . . . . . . . . . . . . . 604
Table 601. Strap Pack Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
5. Main Rotor Hub Droop Angle Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
6. Main Rotor Damper and Attachments Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
7. Main Rotor Damper Weight Loading and Extension Check . . . . . . . . . . . . . . . . . . . . 609
Figure 603. Periodic Check of Main Rotor Damper Assembly . . . . . . . . . . . . . . . . 610
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Main Rotor Retention Strap Pack Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Pitch Control Bearing Housing Assembly,
Spacer or Striker Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Striker Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
3. Lead-Lag Link Blade Stop Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 802. Main Rotor Hub Components Repair and Installation . . . . . . . . . . . 803
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MAINTENANCE MANUAL

4. Lead-Lag Bolt Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804

5. Pitch Control Bearing Pivot Pin Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . 804
6. Droop Stop Roller Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
7. Droop Stop Ring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8. Droop Stop Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
9. Droop Stop Follower (T-Head) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 803. Droop Stop Ring Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . 807
10. Droop Stop Plunger Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . 808
11. Main Rotor Hub Droop Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
12. Main Rotor Hub Tapered Bearing Grease
Figure 804. Tapered Bearing Tools - Main Rotor Hub (Sheet 1 of 2) . . . . . . . . . . 810
13. Main Rotor Hub Upper Bearing Grease
14. Main Rotor Hub Scissors Attach Lug Bearing Replacement . . . . . . . . . . . . . . . . . . . . 814
Figure 805. Main Rotor Hub - Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815
62-30-00 Swashplate and Mixer (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Swashplate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Swashplate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Swashplate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Mixer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4. Mixer Controls Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Mixer Controls Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Pitch Control Rods and
Swashplate Scissors - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Mixer Controls Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Mixer Controls - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5. Scissors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
6. Scissors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Scissors Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Scissors Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
7. Scissors Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
8. Pitch Control Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9. Pitch Control Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Pitch Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Page v
MAINTENANCE MANUAL

B. Pitch Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

10. Counterweight and Interrupter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
1. Swashplate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Mixer Controls Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
3. Scissors Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
4. Pitch Control Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Swashplate Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Mixer Controls Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Scissors Bushing and Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
4. Scissors Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 801. Field Modification - 369D21002-11 Crank
Assembly to 369D21002-21 Configuration . . . . . . . . . . . . . . . . . . . . . . 803
Figure 802. Installation of 369D21002-21 Crank to Hub Lower Shoes . . . . . . . 804
5. Mixer Controls Rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Figure 803. Rework of Main Rotor and Mixer Controls (Sheet 1 of 2) . . . . . . . . . 806
62-30-60 Swashplate and Mixer (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Swashplate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Swashplate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Swashplate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Pitch Control Rods and Swashplate Scissors - Installation . . . . . . . 402
3. Controls Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4. Controls Mixer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Controls Mixer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Mixer Controls Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Controls Mixer - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5. Scissors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
6. Scissors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Scissors Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Scissors Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
7. Scissors Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
8. Pitch Control Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9. Pitch Control Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Page vi
MAINTENANCE MANUAL

A. Pitch Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

B. Pitch Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
1. Swashplate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Mixer Controls Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
3. Scissors Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
4. Pitch Control Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Swashplate Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Mixer Controls Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Scissors Bushing and Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Page vii
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Page viii
MAINTENANCE MANUAL
Section
62−00−00
Main Rotor
(369D/E/FF −
500/600N)
MAINTENANCE MANUAL
MAIN ROTOR
FAULT ISOLATION
1. Main Rotor System − General Information NOTE: Unless specifically indicated in the text
and illustrations, information applies to all
NOTE: Auto-Rotation RPM charts are found in model helicopters. Where information is
Chapter 18. limited to a specific model helicopter or con
The main rotor located over the helicopter figuration, the text or effectivity block will
center-of-gravity provides lift, lateral and indicate.
longitudinal control. The fundamental
components of the rotor are five or six remov 2. Main Rotor System Troubleshooting
able blades, pitch housings and a hub. Each
articulated blade is controlled through a pitch Sudden onset of excessive
housing and link arrangement which transfers WARNING and/or unusual main rotor
flight control inputs into the rotor blades. vibration should be investigated imme
Rotor blades, pitch housings and links are diately as to the cause, prior to contin
secured to the hub by five sets of laminated ued flight. Under no circumstance
steel straps. The collective, stick working should main rotor tracking be at
through linkages, increases or decreases rotor tempted to correct the problem until a
blade angle affecting helicopter ascent and thorough inspection of the main rotor
descent (collective pitch). Helicopter pitch and blades, hub assembly and strap pack
roll angles are controlled by the cyclic stick. assembly has been performed.
Mixed collective and cyclic control inputs are
simultaneously transferred into the main rotor (1). First determine which major installa
for coordinated flight control. The four main tion is defective.
equipment groups of the main rotor and
control system are the rotor blades, hub, upper (2). Isolate each linkage installation from
exterior controls, and cyclic and collective others until area of malfunction is
controls in the pilot's compartment. located.
(1). Main rotor blades (3). Investigate and determine exact

(Ref. Section 62-10-00). location of malfunction.
(2). Main rotor hub (4). Repair or replace defective components.
(Ref. Section 62-20-00 and 62-20-60).
(3). Main rotor swashplate and mixer NOTE: First indications of trouble are usually
(Ref. Section 62-30-00 and 62-30-60). felt through cyclic or collective controls. Iso
lation procedures (Ref. Section 67-10-00,
(4). Main rotor flight controls Table 101) indicate symptoms detected
(Ref. Chapter 67). through these controls.
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MAINTENANCE MANUAL
Table 101. Troubleshooting Main Rotor Vibrations

Unusual or excessive vibration. Main rotor blades damaged. Inspect blades
(Ref. Section 62−10−00).
Vertical or Lateral vibration. Main rotor hub or hub components Inspect main rotor hub assembly
damaged. (Ref. Section 62−20−00/62−20−60).
Inspect strap pack assemblies.
One−per revolution lateral beat in Defective damper or blade phasing. Check damper nominal adjustment
hover and cruise. Can also occur (Ref. Section 62−20−00/62−20−60)
on ground during warmup or Replace defective damper.
shutdown.
Five−per−revolution or Worn pitch control bearings. Replace pitch control bearings

medium−frequency beat. (Ref. Chapter 67).
One−per revolution vertical beat. Main rotor blades out of track. Track main rotor blades
Beat can appear throughout (Ref. Section 18−10−00/18−10−60).
entire flight regime, becoming
more pronounced at higher
airspeeds.
Lateral feedback (beat) in cyclic Rotor blades out of track. Track main rotor blades
control stick with no longitudinal (Ref. Section 18−10−00/18−10−60).
feedback detected.
One−per−revolution lateral beat, Main rotor blade tip balance weights Check balance weights for security;
continuous. not secure. repair as necessary:
(Ref. Section 62−10−00).
Incorrect blade phasing. Check main rotor track and balance

(Ref. Section 18−10−00/18−10−60).
High frequency vibrations. Loose or defective component in (Ref. Chapters 18, 62, 64 and 67)
another system.
Main rotor track and/or balance Play between longitudinal pitch mixer Re−bond collective pitch mixer
inconsistent. bellcrank and collective pitch mixer bearings and install shims between
bellcrank. longitudinal pitch mixer bellcrank and
bearings (Ref. Section 62−30−00 or
62−30−60).
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MAINTENANCE MANUAL
Section
62−10−00
Main Rotor Blade
(369D/E/FF −
500/600N)
MAINTENANCE MANUAL
MAIN ROTOR BLADE

1. Main Rotor Blade − General etc). Detach damper clevis from blade.
Remove two blade fitting attaching
Each of the main rotor blades are a balanced pins.
airfoil consisting primarily of a wraparound,
aluminum alloy skin bonded to an extruded (3). If rotor system is not already color
aluminum alloy spar, an upper root fitting and coded, use masking tape and/or grease
a lower root fitting (Ref. Figure 401). Two pencil, to mark each blade and its
pre-set balance weights are installed in the tip respective pitch housing links so that
end of each blade. A removable forward tip blades can be reinstalled in same
cap, at the outboard end of each blade, is relative positions.
replaced with a tracking cap when tracking.
Blade trailing edge tab can be bent up or down (4). Slide blade from lead-lag links.
to compensate for differences in diving or
B. Main Rotor Blade Installation
climbing characteristics between individual
blades during forward flight. (Ref. Figure 401)
A. Main Rotor Blade Leading Edge Erosion (1). Position main rotor blade in its
Protection − General (marked) pitch housing links. Install
blade attaching pins.
Rotor blades produced since 1980 have an 18
inch or 36 inch leading edge abrasion strip to If new blade is to be installed, or
reduce wear. Earlier model blades without the CAUTION if blades are not reinstalled in
abrasion strip that are used in a highly same positions from which removed or are
abrasive environment should have outer 24 installed on new rotor hub, blade attach
inches of each blade (PN 369D21100-503 or pins must be adjusted. It is also necessary to
-507, Ref. Figure 804) or outer 18 inches of track blades.
each blade (PN 369D21100-505 or -509, Ref.
Figure 805) leading edge covered equally by (2). Align damper clevis on fitting of main
protective tape so blade life is not reduced by rotor blade; install damper attach bolt
excessive erosion. to attach clevis to blade.
(3). Remove blade-to-pitch housing link

2. Main Rotor Blade Replacement
match-markings.
A. Main Rotor Blade Removal
Installation and Adjustment
When main rotor blades are re
CAUTION moved, the weight of the blades Whenever new attach pin is in
is not there to balance the force of the col CAUTION stalled, main rotor blade is re
lective bungee spring. The collective can placed, or rotor hub assembly is replaced,
move quickly when the collective stick is adjustment is required to ensure that pins
moved past the over-center position. properly fit in mating holes.
(Ref. Figure 401) (1). Check main rotor blade and damper
arm attach pins for cracks, wear and
(1). Relieve load on blade attachment corrosion.
points by supporting main rotor blade
from below. (2). Support blade tip to establish align
ment of holes in blade root fittings and
(2). Identify blade attaching hardware and pitch housing lead-lag links; install
pins for location (grease pencil, tape, pin.
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MAINTENANCE MANUAL
NOTE: After final adjustment of main rotor NOTE: After adjustment, measure installed
blade and damper attach pins, thread pro length of pins from face of thrust washer to
trusion from adjuster nut of 1/2 to 1 thread outer edge of last bushing, dimension
is acceptable if adjuster nut run-on torque should be 0.99—1.04 inch (2.515—2.642
is a minimum of 4 inch-pounds (0.45 cm) for damper pins and 2.84—2.89 inches
Nm) and attach pin safety latch is securely (7.214—7.341 cm) for main rotor blade
latched over adjuster nut. pins.
(3). Adjust pin for correct fit by rotating
small hex nut at end of pin until 25—35 (4). At final installation, locking levers of
pounds force (111.2—155.68 N) is both blade root fitting pins should be
required to snap safety latch into place located inboard of (behind) stop springs
over nut. of pitch housing lead-lag links.
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MAINTENANCE MANUAL
TURNBUCKLE JAMNUT
MINIMUM 2-THREAD
PROTRUSION AFTER
FINAL ADJUSTMENT
BOLT
WASHER
WASHER
NUT
COTTER PIN JAMNUT
ALTERNATE DAMPER
CLEVIS ATTACH PIN
JAMNUTS SAFETY WIRED TO
TURNBUCKLE AFTER FINAL
ADJUSTMENT
DAMPER CLEVIS ATTACHMENT
BLADE ATTACHING
PIN
DAMPER
UPPER ROOT
FITTING
369D21102 BLADE
BUSHING
(NOTE 2)
BLADE TAB
LOWER ROOT
FITTING
VENT HOLE
TIP CAP
BLIND RIVET
(NOTE 1)
AFT TIP CAP
0.130-0.160 IN.
SPAR AND WEIGHT RIVETS

2.62 INCH
(6.655 CM) FORWARD BALANCE WEIGHT
AFT BALANCE WEIGHT
SCREW
THREADED
FORWARD INSERT
TIP CAP
369D21100 BLADE
NOTES:
1. BLIND RIVETS TO BE INSTALLED THRU EACH SIDE OF
ALL BLADES. IF ONE TIP CAP REPLACED OR REPAIRED,
ASSEMBLY BALANCE IS NOT AFFECTED.
2. BUSHING INSTALLED IN EACH OF UPPER AND LOWER
ATTACHMENT LUGS.
G62-1000A
Figure 401. Main Rotor Blade − Attachment and Outboard End
Page 403
MAINTENANCE MANUAL
Page 404
MAINTENANCE MANUAL
MAIN ROTOR BLADE

INSPECTION/CHECK
1. Main Rotor Blade Inspection 90 degrees from spanline are acceptable
without repair. Nicks and gouges not
Special Tools
exceeding 0.003 inch (0.076 mm) depth
are acceptable without repair and to
Item Nomenclature
0.005 inch (0.127 mm) with repair.
N/A Plastic inspection tool (Fabricate from AREA 3: Scratches to 0.005 inch (0.127
0.001-0.002 inch (0.025-0.051 mm) thick mm) depth if oriented 0-30 degrees
plastic material) from spanline and to 0.003 inch (0.076
mm) deep if oriented between 30-40
degrees from spanline must be re
(1). Inspect skin for evidence of cracks and moved. No sharp nicks or gouges
holes. Cracks or holes in blade skin requiring more than 0.005 inch (0.127
surface, regardless of location, are mm) removal of skin surface are
cause for rejection of blade. Scratches, permissible.
dents, nicks and other surface defects
in blade skin are limited according to AREA 4: Scratches to 0.003 inch (0.076
(3). below. Use suitable dial indicator to mm) depth if oriented 0-30 degrees and
check depth of blade dents and to 0.003 inch (0.076 mm) depth if
scratches. oriented between 30-90 degrees from
spanline must be removed. No sharp
Repairable limit dimensions in nicks or gouges requiring more than
CAUTION following procedures apply to 0.003 inch (0.076 mm) removal of skin
surfaces that have not been repaired before. surface are permissible.
Be sure that material has not been removed
AREA 5: Scratches exceeding a depth
from damaged areas before determining
of 0.001 inch (0.025 mm) are cause for
that damage depth limit has not been ex
rejection. Remove scratches to a depth
ceeded. Refer all questionable surface dam
of 0.001 inch (0.025 mm). Area inside
age not covered by following information to
outboard two root fitting bolt holes
MDHI.
(both upper and lower surfaces) and
(2). (Ref. Figure 601) Limitations for including skin surface adjacent to these
surface scratches, nicks, gouges and bolt holes within radius of 1.00 inch
erosion in seven areas of blade skin are (2.54 cm) from each hole must be free of
described below. Scratches that do not scratches, nicks, or gouges as would be
penetrate clad surface are acceptable detected under 5X magnification
without reword in all areas except (minimum).
AREAS 5 and 8. AREA 6: Scratches to 0.005 inch (0.127
AREA 1: Minor scratches, nicks and mm) depth and oriented 0-15 degrees
gouges without skin penetrations are from spanline are acceptable without
acceptable without repair. Skin defor repair. Scratches to 0.005 inch (0.127
mation with holes is cause for replace mm) depth and oriented from 15-30
ment. Blade leading edge erosion can be degrees from spanline must be re
repaired if skin is not eroded through. moved. Scratches 0.003 inch (0.076
If leading edge skin is eroded through, mm) deep and oriented from 15-30
no matter how slightly, blade must be degrees from spanline are acceptable
replaced immediately. without repair. Scratches to 0.003 inch
(0.076 mm) depth and oriented from
AREA 2: Scratches to 0.005 inch (0.127 30-90 degrees from spanline must be
mm) depth if oriented 0-30 degrees repaired. Nicks and gouges not exceed
from spanline and to 0.003 inch (0.076 ing 0.005 inch (0.127 mm) depth must
mm) depth if oriented between 30 and be repaired. All gouges, nicks, scratches
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MAINTENANCE MANUAL
and cracks on trailing edge not exceed acceptable without repair. No repairs
ing 0.030 inch (0.076 mm) depth must are permitted in this area.
be smoothed and radiused out over
0.120 inch (3.048 mm) area on each side AREA C: No repairs permitted.
of damage. Defects beyond 0.030 inch
(0.762 mm) depth are cause for rejec AREA D: Dents and depressions
tion. exceeding 0.005 inch (0.127 mm)
without sharp change in section to a
AREA 7: Scratches, nicks, or gouges up maximum of 0.030 inch (0.762 mm)
to 0.005 inch (0.127 mm) deep and must be repaired.
detectable with 5X magnification are
not acceptable without repair. Defects AREA E: Dents and depressions
beyond 0.005 inch (0.127 mm) depth are exceeding 0.010 inch (0.254 mm)
cause for rejection. Gouges, nicks, without sharp change in section to a
scratches and cracks not exceeding maximum of 0.040 inch (1.016 mm)
0.250 inch (6.35 mm) depth on trailing must be repaired.
edge, except for AREA 8, must be
smoothed and radiused out to 0.250 AREA F: Dents and depressions
inch (6.35 mm) area on each side of exceeding 0.010 inch (0.254 mm)
damage center. Defects beyond 0.250 without sharp change in section to
inch (6.35 mm) depth require blade maximum of 0.040 inch (1.016 mm)
replacement. must be repaired.
AREA 8: Check for gouges, nicks, AREA G: No repairs permitted.

scratches and cracks detected by using
a bright light and 5X magnification at AREA H: Dents and depressions
trailing edge corners where blade and exceeding 0.010 inch (0.254 mm)
tabs join. View area from different without sharp change in section to
angles during inspection. Damage at maximum of 0.040 inch (1.016 mm)
this point not exceeding 0.030 inch must be repaired.
(0.762 mm) depth must be smoothed
and radiused out over a 0.120 inch AREA J: Dents and depressions
(3.048 mm) area on each side of exceeding 0.010 inch (0.254 mm)
damage. Defects beyond 0.030 inch without sharp change in section to
(0.762 mm) depth (Ref. Trim Tab maximum of 0.040 inch (1.016 mm)
Damage Repair). must be repaired. Dents and depres
sions exceeding these limitations, refer
(3). (Ref. Figure 602) Depth limitations for to trim tab damage repair.
surface dents or depressions in eight
areas of blade skin are described below. (4). Inspect surface areas of upper and
A dent or depression is defined as a lower root fittings (other than AREA 5)
smooth depression or discontinuity with for evidence of nicks, scratches, and
no sharp changes in section. wear spots. Nicks, scratches, and wear
spots deeper than 0.010 inch (0.254
mm) in attachment lug area, and bolt
AREA A: Dents and depressions hole area are not repairable. Damage
exceeding 0.015 inch (0.381 mm) 0.010 inch (0.254 mm) deep or less
without sharp changes in section to a must be repaired.
maximum of 0.062 inch (1.575 mm)
must be repaired.
(5). Inspect four attachment lug bushings
in root fittings (Ref. Figure 401) for
AREA B: Dents and depressions to a security, and evidence of cracks or
maximum of 0.010 inch (0.254 mm) are severe scoring.
Page 602
MAINTENANCE MANUAL
DAMAGE 0.010 INCH (0.25 MM)

IN DEPTH OR LESS IS
REPAIRABLE IN THESE AREAS CHORD LINE
(NOTE 1) 1.00 INCH (25.4 MM) RADIUS AROUND LAST
2 BOLT HOLES 0.001 INCH (0.03 MM) SPAN LINE 1
5 MAXIMUM DEPTH 0.380 INCH
(9.65 MM)
3.00 INCH 90°

120°
(7.62 CM)
4 2
30° 30°
1.25 INCH
(31.8 MM) 120°
120° 1.00 INCH
3
(25.4 MM)
30° 30° 120° 30° 30°
15°
DAMAGE LESS THAN 6

0.030 INCH (0.76 MM)
DEPTH REPAIRABLE IN
THIS AREA (NOTE 1) 15°
30° 7 8
8 23.00 INCH
(584.2 MM)
GOUGES, NICKS AND CRACKS

SCRATCHES GOUGES AND NICKS TRAILING EDGE ONLY
ORIENTATION MAXIMUM DEPTH MAXIMUM DEPTH MAXIMUM DEPTH MAXIMUM DEPTH MAXIMUM DEPTH MAXIMUM DEPTH WITH
AREA WITHOUT REPAIR WITH REPAIR REPAIR
FROM SPANLINE WITHOUT REPAIR WITH REPAIR WITHOUT REPAIR
1 0°-90° MINOR WITHOUT MINOR WITHOUT MINOR WITHOUT MINOR WITHOUT

SKIN PENETRATION SKIN PENETRATION SKIN PENETRATION SKIN PENETRATION
2 0°-30° 0.005 INCH (0.13 MM) 0.005 INCH (0.13 MM) 0.003 INCH (0.08 MM) 0.005 INCH (0.13 MM)
30°-90° 0.003 INCH (0.08 MM) 0.003 INCH (0.08 MM) 0.003 INCH (0.08 MM) 0.005 INCH (0.13 MM)
3 0°-30° NONE 0.005 INCH (0.13 MM) NONE 0.005 INCH (0.13 MM) N/A N/A
30°-90° NONE 0.003 INCH (0.08 MM) NONE 0.005 INCH (0.13 MM)
4 0°-30° NONE 0.003 INCH (0.08 MM) NONE 0.003 INCH (0.08 MM)
5 0°-90° NONE 0.001 INCH (0.03 MM) NONE 0.001 INCH (0.025 MM)
(NOTE 2) (NOTE 2)
(NOTE 2)
0°-15° 0.005 INCH (0.13 MM) 0.005 INCH (0.13 MM) NONE 0.005 INCH (0.13 MM)
0.030 INCH (0.76 MM)
6 15°-30° 0.003 INCH (0.08 MM) 0.005 INCH (0.13 MM) NONE 0.005 INCH (0.13 MM) NONE (NOTES 2, 4)
7 0.005 INCH (0.13 MM) 0.005 INCH (0.13 MM) 0.250 INCH (6.35 MM)
0°-90° NONE NONE NONE
(NOTE 2) (NOTES 2, 5) (NOTES 2, 3, 5)
8 NOT APPLICABLE NONE 0.030 INCH (0.76 MM)

(NOTES 2, 4, 5)
TAB END
NOTES:
1. DAMAGE LIMITS APPLY TO BOTH UPPER AND LOWER ROOT FITTING 4. SMOOTHED AND RADIUSED CLEANOUT OVER 0.120 INCH (3.05 MM)
SURFACES. AREA ON EACH SIDE OF DAMAGE.
2. INSPECTION UNDER 5X MAGNIFICATION (MINIMUM) REQUIRED. 5. REFER TO TRIM TAB DAMAGE REPAIR.
3. AREAS NOTED: 0.250 INCH (6.35 MM) SMOTHERED AND RADIUSED
CLEANOUT ALLOWED. G62-1000-601-1
Figure 601. Main Rotor Blade Damage and Repair Limits −

Nicks, Scratches, Gouges and Cracks
Page 603
MAINTENANCE MANUAL
(6). Inspect damper-attachment bearing for and aft balance weights (Ref.
binding, evidence of galling or scoring Figure 401) for security. Weights are
in bore and wear. No radial play is normally recessed 0.050 inch (1.270
permissible. Maximum axial play is mm) inside end surface of tip. Security
0.015 inch (0.381 mm). of weights can be checked by using
torque wrench with screwdriver socket
(7). Inspect all bonded areas for evidence of in slot of weight to detect if weight can
separation. If there appears to be be rotated by less than 20 inch-
separation of trailing edge bond, lightly pounds (2.26 Nm). If torque wrench is
probe joint with a 0.001-0.002 inch not available, check weight security by
(0.025-0.051 mm) plastic inspection fitting small coin in weight slots and
tool. If plastic inspection tool can be applying maximum force that can be
inserted to a depth of 1/2 inch (12.70 exerted by only index finger and thumb.
mm) or more, either above or below V If weights are found to be loose,
insert, separation is excessive. retighten (Ref. Loose Balance Weight
Repair).
NOTE: Trailing edge structural bond line to V
insert starts 1/4 inch (6.35 mm) in (chord 2. Main Rotor Blade and Damper Attach Pin
wise) from trailing edge joint: therefore Inspection and Corrosion Protection
above tolerance allows 1/4 inch (6.35 mm)
separation. Be sure measurement is taken (Ref. Figure 603)
from trailing edge joint, not tab trailing
edge. Maximum trailing edge joint gap al Consumable Materials
lowed during fabrication is 0.080 inch (2.032 (Ref. Section 91−00−00)
mm). Item Nomenclature
(8). Inspect doubler shown in AREA G CM120 Oil, corrosion preventive
(Ref. Figure 602) for bonding voids
between doubler and blade skin top and (1). Inspect pin cam handle lobe for cracks
bottom. Use a heavy coin and lightly and excessive wear. Remove pin from
tap doubler surface. A void is detected service if cracking or excessive wear is
by a distinct change in sound. Note that noted.
tapping sounds differ slightly due to
blade structure in leading and trailing NOTE: If hard anodizing surface of cam lobes is
edge, internal channel and doubler worn, cam lobes can be re-anodized or
areas. Allowable voids or debonds on treated with corrosion preventive oil
main rotor blade ribs are as follows: (CM120).
(a). 50% void or debond. (2). Inspect attach pin for evidence of
corrosion, or wear, and for straightness.
(b). Maximum four (4) ribs, no more than Pay particular attention to area along
two (2) adjacent for the 369D21100 edges of barrel nut and bore in cam
and 369D21102 blades. handle. Remove pin from service if
corrosion or wear is noted or if pin is
(9). Ensure that vent holes are open (Ref. bent.
Figure 401).
NOTE: If subject to salt laden atmosphere, fol
(10). Inspect fasteners that secure upper and lowing corrosion prevention treatment is to
lower root fittings, and six rivets that be applied at each periodic inspection to en
secure skin to spar near tip, for securi sure continued serviceability of attach pin;
ty. Inspect forward tip cap screw insert and at each pin removal.
for security and thread damage. Inspect
trailing edge upper and lower weights (3). With attach pin removed, lubricate
for debonding and loose rivets. mating surfaces of barrel nut and cam
handle, using corrosion preventive oil
(11). When continuous one-per-revolution (CM120). Rotate cam handle back and
lateral vibration occurs, inspect forward forth on barrel nut several times to
Page 604
MAINTENANCE MANUAL
ensure that oil penetrates all sections of (1). Inspect tip caps for evidence of corro
pin operating mechanism. Wipe excess sion, with particular attention at
oil from pin surfaces. mating area of blade skin to tip weight
interface. Verify integrity of sealant
3. Main Rotor Blade and Damper Attach Pin coating.
Disassembly and Special Inspection
(Ref. Figure 603) This inspection is to be (2). If damage is evident, remove tip caps
preformed in event of a main rotor blade and apply penetrating oil to blade tip
strike. weight area. Oil arrests any corrosion
between blade skin and weight assem
bly.
(Ref. Section 91−00−00) (3). Using brush and clean cloth, clean area
Item Nomenclature with isopropyl alcohol (CM217). Dry
CM217 Isopropyl alcohol with clean cloth.
Do not intermix bushings, (4). Spray area with light film of rust
CAUTION spacers and thrust washers be inhibitor (CM232); then apply thin film
tween bolts. Component parts make up a of primer and paint lightly as required
single bolt assembly. (Ref. Sec. 20-40-00).
(1). Remove adjusting nut and remove 5. Main Rotor Blade Upper and Lower Root
adjusting bushings, spacers and thrust Fitting Attach Lug and Lead−Lag Link
washers from pin. Attach Lug Inspection (25 Hour)
(2). Using brush and clean cloth, clean
parts with isopropyl alcohol (CM217). (Ref. Figure 604 and Figure 605) The following
Dry with clean cloth. procedure pertains to helicopters equipped
with 369D21100-BSC thru -515 and
(3). Inspect pin as follows: 369D21102-BSC and -501 main rotor blades
and/or 369H1203-BSC, -11, -21 and -31
(a). Fluorescent inspect pin per MIL- lead-lag link assemblies.
STD-6866.
(b). Magnetic particle inspect thrust
washers, bushings and spacer per
MIL-STD-1949.
Item Nomenclature
(4). Reassemble pin in sequence as follows; CM805 Dye penetrant kit
install thrust washer, three (3) adjust
able bushings, spacer, three (3) adjust
able bushings and secure with adjust NOTE: Main rotor blades and hub assemblies
ing nut. installed on helicopters operating in a salt
water or corrosive environment should be
4. Main Rotor Blade Forward Tip Cap
cleaned and washed on a daily basis as a
Inspection and Corrosion Protection
preventative measure to arrest corrosion
(Ref. Figure 603) (Ref. Main Rotor Hub Corrosion Prevention
(Tri-Flow Wash Procedures)).
(1). Visually inspect exposed portion of all
installed main rotor blade upper and
Item Nomenclature
lower root fitting attach lugs, and main
CM217 Isopropyl alcohol rotor hub lead-lag link attach lugs, for
CM232 Rust inhibitor spray broken or cracked lugs, corrosion or
other damage to the lug areas.
Page 605
MAINTENANCE MANUAL
2.12 INCH 0.38 INCH

(53.8 MM) (9.7 MM)
1.58 INCH
(3.8 MM)
2.00 INCH
(50.8 MM) 0.58 INCH
(14.7 MM) 2.17 INCH 23.00 INCH
0.96 INCH (55.1 MM) (584.2 MM)
(24.384 MM)
DENTS AND DEPRESSIONS
MAXIMUM MINIMUM DISTANCE

MAXIMUM DEPTH MAXIMUM DEPTH MAXIMUM NUMBER BETWEEN DEFECT
AREA WITHOUT REPAIR ALLOWED
WITH REPAIR OF DEFECTS CENTERS
AREA
1.50 INCH (3.8 MM)

0.015 INCH 0.062 INCH
X 1 N/A
(0.38 MM) (1.58 MM)
1.50 INCH (3.8 MM)
0.250 INCH (6.35 MM)

0.010 INCH
0.000 X 2 18
(0.25 MM)
0.250 INCH (6.35 MM)
0.000 0.000 NONE

0.000 ALLOWED N/A
1.50 INCH (3.8 MM)

0.005 INCH 0.030 INCH X 2 18
(0.13 MM) (0.76 MM) 1.50 INCH (3.8 MM)
0.010 INCH 1.50 INCH (3.8 MM)

0.040 INCH 2
(0.25 MM) X 18
(1.02 MM)
1.50 INCH (3.8 MM)
1.50 INCH (3.8 MM)

0.010 INCH 0.040 INCH 3
X 18
(0.25 MM) (1.02 MM)
1.50 INCH (3.8 MM)
0.000 0.000 0.000 NONE N/A

ALLOWED
0.010 INCH 1.50 INCH (3.8 MM)

0.040 INCH
(0.25 MM) X 1 N/A
(1.02 MM)
1.50 INCH (3.8 MM)
0.350 INCH 1.50 INCH (3.8 MM)

0.010 INCH (8.89 MM) X N/A N/A
(0.25 MM) (NOTE 2) 1.50 INCH (3.8 MM)
NOTES:
1. N/A - NOT APPLICABLE.
2. REFER TO TRIM TAB DAMAGE REPAIR. G62-1000-602-1
Figure 602. Main Rotor Blade Damage Limits for Dents and Depressions
Page 606
MAINTENANCE MANUAL
OIL
BARREL NUT
OIL
CAM HANDLE
THRUST WASHER
BUSHING SEGMENTS
SPACER
SAFETY LATCH
G62-1008
Figure 603. Main Rotor Blade Attach Pin
Page 607
MAINTENANCE MANUAL
NOTE: If movement is suspected but cannot be

verified with the blades installed, remove Consumable Materials
those blades and examine bushings for (Ref. Section 91−00−00)
movement. Item Nomenclature
(2). Using a bright light, examine slippage CM318 Primer
marks on the root fitting bushings to
CM420 Sealant
make sure there has been no movement
of the bushings. If bushings have CM805 Dye penetrant kit
moved, replace main rotor blade before
next flight. Return those main rotor (1). Remove affected main rotor blades (Ref.
blades where bushing movement has Main Rotor Blade Removal).
occurred to MDHI for possible rework.
CAUTION
CAUTION
D If cracked or broken lug is noted in main
D If broken or cracked lugs are noted in rotor blade upper and lower root fittings,
main rotor blade upper and lower root fit replace main rotor blade (ref. Main Rotor
tings, replace main rotor blade before fur Blade Removal) before further flight.
ther flight (Ref. Main Rotor Blade Remov D If cracked or broken lug is noted in main
al). rotor lead-lag links, replace or repair
D If broken or cracked lugs are noted in main rotor hub before further flight (ref.
main rotor lead-lag links, replace main Section 62-20-00) (Ref. NOTE: below).
rotor hub (Ref. Section 62-20-00) (Ref. D If a crack is suspected in either the rotor
NOTE: below). blade or lead-lag link attach lug, do the
D If cracking is suspected in either the rotor dye penetrant (CM805) inspection on the
blade or hub lead-lag link attach lugs, do lugs per MIL-I-25135. If a crack in noted,
the dye penetrant (CM805) inspection on replace main rotor blade (ref. Main Rotor
the lugs per MIL-I-25135. If cracking is Blade Removal) or replace or repair main
noted, replace main rotor blade (Ref. rotor hub assembly (ref. Section
Main Rotor Blade Removal) or replace or 62-20-00) (Ref. NOTE: below).
repair main rotor hub assembly (Ref. Sec NOTE: Do not remove bushings or corrosion in
tion 62-20-00), before further flight (Ref. hibiting sealer.
NOTE: below).
(2). Use a bright light and 5X magnification
NOTE: Lead-Lag link assemblies can only be glass to visually examine the attach
replaced by MDHI authorized personnel or lugs of all main rotor blade upper and
under MDHI supervision. Contact your local lower root fitting and main rotor
MDHI Field Service Representative for fur lead-lag links for broken or cracked
ther information. lugs, corrosion or other damage to the
lug areas.
6. Main Rotor Blade Upper and Lower Root
Fitting, Attach Lug and Lead−Lag Link NOTE:
Attach Lug Inspection (100 Hour) D Pay particular attention to area around
attach pin hole bushings in the lugs.
(Ref. Figure 604 and Figure 605) The following D Pay particular attention to the cross-
procedure pertains to helicopters equipped hatched areas.
with 369D21100-BSC thru -523,
369D21120-501, -503, and -505, (3). If slippage marks have already been
369D21102-BSC thru -523, and applied, examine the root fitting for any
369D21121-501, -503, and -505 main rotor indication of movement of the bushings;
blades and/or 369H1203-BSC, -11, -21 and no movement is allowed. Return main
-31 lead-lag link assemblies. rotor blades that have root fitting
Page 608
MAINTENANCE MANUAL
bushing movement to MDHI for (5). Inspect lead-lag link blade attach pin
possible rework. If slippage mark is hole bushings for any indication of
degraded, reapply. movement of the bushings in the links.
If any of the bushings have movement,
(4). Do the main rotor blade upper and replace the links.
lower root fitting inspection as follows:
If required, apply a light but
(a). Inspect main rotor blade root fitting CAUTION thorough coat of sealer (CM420)
for missing (no squeeze-out) or or primer (CM318) around bushings. Note
cracked adhesive/paint around the that excessive amounts of sealant or primer
periphery of the root fitting. If this around the bushings are not desirable and
condition exists, proceed as follows: can unbalance the main rotor system.
1). Loosen, but do not remove the
(6). If sealing compound is not already
extreme outboard bolt.
installed or becomes loose, clean and
2). Insert a 0.004 inch (0.10 mm) then seal all junctions between all the
thick piece of mylar/viewfoil steel bushings and the main rotor blade
between the fitting and the dou root fitting attach lugs with a film of
bler. sealing compound or zinc-chromate
primer without removing the bushings.
3). If the mylar can be inserted,
contact Field Service Representa (7). For the main rotor blade root fitting
tive for disposition of blade. attach lugs, carefully remove sufficient
amount of sealant and paint from only
4). If the insertion is 0.10 inch (2.54
the bushing in the area where the
mm) or more, remove blade from
slippage mark is to be applied (if not
service.
already done). Using isopropyl alcohol
NOTE: Measurement of the insertion is from (CM217), clean the area where the
the edge of the root fitting. slippage mark is going to be applied to
allow adequate adherence of epoxy
5). Retorque root fitting outboard bolt paint.
to 60 to 65 inch-pound (6.78 to
7.34 Nm) plus drag torque. NOTE:
CAUTION
In the following step, a crack D Locate slippage mark in a position that
might be difficult to detect if can be viewed at subsequent inspections
bright light is not used. with main rotor blade installed in the
NOTE: The bottom side of the blade is more hub. Slippage marks should not be ap
susceptible to cracks. plied to cross-hatched areas to preclude
masking possible cracks.
(b). Using a bright light, inspect doubler
and root fitting, paying particular D Make sure that slippage mark is applied
attention to the lower side, for to bushing at upper and lower root fitting
cracks. If crack is found, blade is to inside surfaces.
be scrapped. D Do not use torque seal.
NOTE: Lead-Lag link assemblies can only be (8). Apply epoxy paint slippage marks to
replaced by MDHI authorized personnel or four locations as shown.
under MDHI supervision. Contact your local
Field Service Representative for further in (9). Install main rotor blades (Ref. Main
formation. Rotor Blade Installation).
Page 609
MAINTENANCE MANUAL
7. Main Rotor Blade Leading Edge Abrasion (2). Examine the bottom side of the blade as
Strip Check follows:
The leading edge abrasion strip should be (a). Use a bright light and 10x magnify
checked prior to each flight or on every daily ing glass, examine for chordwise
check. The following is a comprehensive cracks protruding from under root
checklist: fitting, doubler, and skin. (View C
NOTE: If void is noted towards end of blade, re and Note 6 and 7).
move tip cap and check for presence of bal (b). Examine lower root fitting for
ance weights. If weights are not installed, a missing or cracked adhesive/paint
false indication of a void is possible. around the periphery of the root
(1). Check for any blistering, bubbling or fitting. (Figure 604, Note 5)
lifting of the abrasion strip; this
(c). If adhesive or paint is missing from
indicates a void.
the lower root fitting, do the inspec
(a). Voids cannot be closer than 0.50 inch tion. (Ref. Main Rotor Blade Upper
(12.70 mm) to any outside edge of and Lower Root Fitting, Attach Lug
abrasion strip. and Lead-Lag Link Attach Lug
(b). Voids exceeding 1.5 square inch Inspection (100 Hour)).
(9.677 square cm) are unacceptable. (d). Examine the attach lugs at the
(c). Voids cannot be closer than one inch bushings for cracks.
(2.54 cm) to any other void. (e). Examine the entire length of the
(2). Number of acceptable voids depends blade for cracks.
upon length of abrasion strip.
(f). Lower blade back onto droop stop.
(a). There cannot be more than three
voids on either the top or bottom of (3). Put the blade on the droop stop,
the 36 inch (91.44 cm) long abrasion examine the top side of the blade as
strip surface. follows:
(b). There cannot be more than two voids (a). Use a bright light and 10x magnify
on either the top or bottom of the 18 ing glass, examine for chordwise
inch (45.72 cm) long abrasion strip cracks protruding from under the
surface. root fitting, doubler, and skin.
(Figure 604, Note 8)
(3). Record all voids in regards to size and
location in the helicopter log book and (b). Examine the upper root fitting for
check each void prior to each flight for missing or cracked adhesive/paint
growth and acceptable criteria. around the periphery of the root
8. Main Rotor Blade Torque Event Inspection fitting. (Figure 604, Note 5)
(Ref. Figure 604) (c). If adhesive or paint is missing from

the upper root fitting, do the inspec
In the following steps, a crack
CAUTION might be difficult to detect if
tion. (Ref. Main Rotor Blade Upper
and Lower Root Fitting, Attach Lug
bright light is not used. and Lead-Lag Link Attach Lug
NOTE: It is recommended to only paint the in Inspection (100 Hour)).
board 24 inches (60.96 cm) gloss white to aid
(d). Examine the lugs at the bushings for
in crack detection. All blades must be paint
cracks.
ed alike. (Ref. Section 20-30-00)
NOTE: The bottom side of the blade is more (e). Examine the entire length of the
susceptible to cracks. blade for cracks.
(1). Lift blade off the droop stop from the (4). If cracks are found, reject and discard
outboard end of the blade. the main rotor blade.
Page 610
MAINTENANCE MANUAL
NOTES 2, 3 AND 4
NOTE 1, 2 AND 3
NOTE 5
DOUBLER
NOTE 6, 7
ROOT FITTING
ROTATED
NOTE 5
LOOSEN BUT DO NOT REMOVE BOLT.
18.0”
RETORQUE BOLT TO 60 - 65 INCH-POUNDS
(6.78 - 7.34NM) PLUS DRAG TORQUE.
VIEW LOOKING UP
UPPER ROOT FITTING ATTACH LUG

(TYP 2 PLS) (NOTE 1)
NOTE 5
LEAD-LAG LINK ATTACH

MAIN ROTOR BLADE (TYP 8 PLS) (NOTE 1)
LOWER ROOT FITTING

NOTE 8 ATTACH LUG (TYP 2 PLS) (NOTE 1)
NOTES:
1. VISUALLY EXAMINE AREAS OF ALL ROOT FITTINGS AND LEAD-LAG ATTACH LUGS FOR CRACKS OR BREAKS. EXAMINE BLADE
ATTACH BUSHINGS FOR LOOSENESS. IF LOOSE, REPLACE LEAD-LAG LINKS.
2. CAREFULLY EXAMINE THE AREA AROUND ATTACH PIN HOLES IN LUGS.
3. SEAL ALL JUNCTIONS BETWEEN BUSHINGS AND ATTACH LUGS WITH SEALER OR PRIMER (CM318).
4. LEAD-LAG LINK ASSEMBLIES ARE SUB-ASSEMBLIES OF THE MAIN ROTOR HUB ASSEMBLY.
5. EXAMINE THE MAIN ROTOR BLADE UPPER AND LOWER ROOT FITTINGS FOR MISSING OR CRACKED ADHESIVE.
6. USE A BRIGHT LIGHT AND 10X MAGNIFYING GLASS TO EXAMINE THE BLADE WITH IT RAISED OFF THE DROOP STOP.
7. THE BOTTOM SIDE OF THE BLADE IS MORE SUSCEPTIBLE TO CRACKS. LIFT THE BLADE TO AID IN DETECTION OF CRACKS.
8. USE A BRIGHT LIGHT AND 10X MAGNIFYING GLASS TO INSPECT THE BLADE WITH IT ON THE DROOP STOP.
G62-1009D
Figure 604. Main Rotor Blade Root Fitting, Attach Lugs and Lead−Lag Link
Assembly Inspection
Page 611
MAINTENANCE MANUAL
ÇÇÇÇÇÇ
ÇÇÇÇÇÇ
* ONLY REMOVE 1/2 DEPTH OF
CORROSION INHIBITING SEALER
ÇÇÇÇÇÇ
AT LOCATION WHERE SLIPPAGE
ÇÇÇÇÇÇ
MARK IS TO BE APPLIED.
ÇÇÇÇÇÇ
UPPER ROOT FITTING
SLIPPAGE MARK LOCATIONS
ÎÎ
ÎÎ
(INSIDE SURFACES)
ÎÎ
ÎÎ
ÎÎÎÎ
ÎÎÎÎ
ÎÎ DO NOT APPLY SLIPPAGE MARK
TO CROSS-HATCH AREAS LOWER ROOT FITTING
ÎÎÎ
ÎÎÎ
ÎÎÎÎÎ
ÎÎ VIEW LOOKING UP
ÎÎ
(LAG SIDE SHOWN)
(LEAD SIDE OPPOSITE)
UPPER AND LOWER
88−675
Figure 605. Application of Slippage Mark to Main Rotor Blade Bushings and Root Fittings
Page 612
MAINTENANCE MANUAL
MAIN ROTOR BLADE

REPAIRS
1. Main Rotor Blade Repair (Nicks,
Scratches and Wear Spots) CAUTION
D Repair only those damaged areas that are
Consumable Materials within repairable limits specified.
Item Nomenclature
D Do not use chemical paint remover to re
move paint from abrasion strip. Chemi
CM206 Chemical coating cals can attack the abrasion strip to blade
CM801 Abrasive paper, silicon carbide bonding agent.
(Ref. Figure 601) (1). Using abrasive paper (CM801), not

coarser than grade 320, remove paint
Do not use chemical paint re from surface area to be repaired.
CAUTION mover to remove paint from
abrasion strip. Chemicals can attack the (2). Clean abraded area with clean cloth
abrasion strip to blade bonding agent. dampened by solvent (CM234). Allow to
dry for minimum of 15 minutes.
(1). Using abrasive paper (CM801), not
coarser than grade 320, remove nicks, (3). Mask edges of repair areas with one
scratches and wear spots from upper layer of tape (CM708).
and lower root fittings, and from blade
skin. Do not cut tape after it is
CAUTION applied to blade.
(2). Use finer grade of paper, as necessary
to restore surface roughness to original
(4). Mix filler (CM507), three parts ”A” and
finish.
two parts ”B” by weight. Mix thorough
(3). Remove material in such a manner that ly until mixture is dark red in color. An
no abrupt changes occur in surface alternate filler (CM508) can be used if
contours. equal parts ”A” and ”B” by weight are
mixed.
(4). Apply chemical film surface treatment
(CM206) to repaired surface(s) (Ref. (5). Allow filler to cure for minimum of 24
Section 20-30-00). hours at room temperature.
2. Main Rotor Blade Repair (Dents,
(6). Smooth filler area with grade 400
Depressions and Erosion)
abrasive paper (CM801). Limit smooth
(Ref. Figure 602) ing to masked area.
(7). Remove the tape and inspect alclad

coating of area around repair. Penetra
tion of coating is cause for blade
Item Nomenclature
replacement.
CM229 Paint remover (8). Clean repaired area with a cloth
CM234 Solvent, dry-cleaning dampened by solvent (CM220).
CM304 Enamel, epoxy
CM507 Resin, filler
(9). Apply chemical film treatment to
repaired surface (Ref. Section
CM508 Resin, filler 20-30-00).
CM708 Tape
CM801 Abrasive paper, silicon carbide (10). Touch-up reworked area with paint
(CM304) as required.
Page 801
MAINTENANCE MANUAL
3. Trim Tab Damage Repair (6). If excessive damage requires full or

partial removal of trim tab from blade,
(Ref. Figure 802) do the following (no minimum length of
trim tab is required):
Consumable Materials (a). Position blade on workbench so that
(Ref. Section 91−00−00) a straight edge is provided for cutting
Item Nomenclature or filing off trim tab.
CM220 Naphtha aliphatic Cutting, grinding or filing to re
CAUTION move trim tab, and deburring of
reworked blade trailing edge, are to be done
CM304 Enamel, epoxy in a SPANWISE direction only. Do NOT
CM318 Primer use shears or clippers to remove trim tab.
(b). Use metal cutting saw or equivalent

Provide protective surface and/ to remove the 0.38 inch (9.65 mm)
CAUTION or covering to prevent scratch
wide trim tab per dimensions shown
ing, nicking or other damage to blade during Ref. Figure 802, View A-A). Deburr
rework. Position blade on work bench or edges in a SPANWISE direction only.
equivalent.
(7). Peel and remove tape from blade and
NOTE: No minimum length of trim tab is re inspect area around repair; clean
quired. In addition, the entire trim tab, or repaired area with cloth dampened in
portion of the trim tab, can be removed if re naptha (CM220).
quired. Removal of entire trim tab elimi
nates adjustment of blade tracking capabili (8). Apply chemical film treatment (CM206)
ty for that blade. Main rotor blades with and to reworked area of blade trailing edge
without trim tabs are 100% interchange or trim tab; apply a thin film of primer
able, individually and in ship sets. (CM318) and paint (CM304) lightly.
(1). Remove main rotor blade with damaged (9). Reinstall main rotor blade and do the
trim tab. track and balance (Ref. Section
18-10-00).
(2). Wipe away dirt on and around trim tab
area with clean cloth dampened with
NOTE: Removal of entire trim tab eliminates
dry cleaning solvent (CM234).
adjustment of blade tracking capability for
that blade.
(3). Mask edges of blade area around trim
tab area with tape; do NOT cut tape
after it has been applied to blade. 4. Forward Tip Cap Threaded Insert Repair
(4). Remove damaged area of trim tab by

making V-type cut with 45° sides
joined by a 0.25 inch (6.35 mm) radius
Item Nomenclature
at the bottom of the V. Maximum V-cut
depth is 0.35 inch (8.89 mm); do not cut CM318 Primer
past trim tab area into main portion of
blade.
Replace a loose or stripped insert. Use
(5). If damage occurs within 1 inch (2.54 self-locking insert of correct size and install
cm) of either or both ends of trim tab, with wet primer (CM318). Comply with
remove tab end(s) and restore contour replacement requirements of applicable NAS
as shown. standard.
Page 802
MAINTENANCE MANUAL
MS2070AD3
RIVETS (2 PLS) 6.312 INCH
(16.033 CM)
(REF)
EXISTING EXISTING
EXISTING
BLADE RIVET BLADE RIVET
BLADE RIVET
A
1.58 INCH
A (4.013 CM)
(REF)
0.75 INCH
9.25 INCH (19.05 MM)
(23.495 CM)
369D21106 UPPER EXTERNAL

TRAILING EDGE WEIGHT
(369D21100 ONLY)
369D21106 LOWER EXTERNAL

TRAILING EDGE WEIGHT
(369D21100 ONLY)
VIEW A-A
(ROTATED 90°)
NOTES: POSITION WEIGHT ONTO BLADE (ONE

EACH ON UPPER AND LOWER SURFACES) BY ALIGNING
CENTERS OF HOLES IN WEIGHT TO EXISTING RIVETS ON BLADE. G62-1003A
Figure 801. Main Rotor Blade Trailing Edge Weight Rework.
Page 803
MAINTENANCE MANUAL
5. Loose Balance Weight Repair (4). Mix epoxy adhesive (CM409) per
manufacturer`s instructions and apply
(Ref. Figure 401) Reinstall loose forward and aft to bonding surfaces.
balance weights as follows:
(5). Position weights on blade by aligning
holes in weights to existing rivet holes
Consumable Materials on blade and apply light pressure to
(Ref. Section 91−00−00) weights until epoxy sets.
Item Nomenclature
CM431 Sealing, locking and retaining compound (6). Install (3 ea.) rivets in existing holes.
(7). If not already installed, install two
more rivets as follows.
(1). Unscrew loose weight until it projects
approximately 0.5 inch (12.7 mm) and (a). Mark location of rivets to be in
remove old accumulation of powdered stalled.
compound. (b). Drill holes at marked locations.
(2). Apply grade A locking compound (c). Deburr and clean debris from holes.
(CM431) and screw weight back into
blade until slotted end of weight is (d). Coat all exposed surfaces with primer
recessed 0.050 inch (1.27 mm) below tip (CM318).
surface. Wipe off excess compound. (e). Install rivets.
Allow to cure for a minimum of (f). Allow epoxy adhesive to cure per
CAUTION 12 hours. If faster cure is de manufacturer's instructions before
sired, complete cure can be obtained by al flying aircraft.
lowing part to set for 30 minutes at room
temperature and then heating for 30 min 7. Loose or Missing Rivets or Aft Tip Cap
utes at approximately 2125F (1015C). Repair
(Ref. Figure 401) Replace all loose or missing
(3). If locking compound is not available, rivets. Reinstall or replace loose or missing aft tip
screw weight into normal position and cap as follows:
centerpunch end of weight into mating
threads at three evenly spaced points to
prevent rotation. Consumable Materials
6. Loose Trailing Edge Weight Repair Item Nomenclature
(Ref. Figure 801)
CM318 Primer
Consumable Materials CM801 Abrasive paper, silicon carbide
Item Nomenclature
NOTE: Spare tip caps are supplied with bond
ing surface coated with nylon primer to fa
CM318 Primer cilitate installation. Main rotor balance is
CM409 Adhesive, epoxy not affected by following repair.
(1). Lightly abrade primed surfaces of tip
cap with grade 180 abrasive paper
(1). Carefully remove loose or partially (CM801). Wipe away residue with cloth
debonded weights. dampened in solvent (CM234) and
allow tip cap to dry at room tempera
(2). Abrade debonded surface using ture for 30 minutes.
#200-300 grit emery cloth (CM804).
(2). Mix two-part bonding adhesive
(3). Clean bonding surfaces with naptha (CM411) in equal proportions by
aliphatic (CM220). weight.
Page 804
MAINTENANCE MANUAL
NOTE 2
NOTE 2
TOP NOTES 2, 3
6.80 INCH (17.272 CM)
SURFACE
0.38 INCH
NOTE 1
(9.652 MM) NOTE 3
0.00 - 0.10 INCH
A
(0.00 - 2.54 MM)
NOTE 4
0.38 INCH
(9.652 MM)
A 1.00 INCH
1.00 INCH (2.54 CM)
(2.54 CM)
VIEW A-A
NOTES:
1. REMOVE DAMAGED END(S) IF THEY OCCUR WITHIN 1 INCH (2.54 CM) OF TAB ENDS.
2. 0.25 INCH (6.35 MM) RADIUS CLEANUP. FINISH PER BASIC HMI.
3. MAXIMUM DEPTH OF REPAIR 0.35 INCH (8.89 MM).
4. NO MINIMUM LENGTH OF TAB REQUIRED. IF DAMAGE OCCURS AT BOTH ENDS, IT IS
PERMISSIBLE TO REMOVE AT BOTH ENDS. G62-1004A
5. ENTIRE TAB MAY BE REMOVED IF REQUIRED.
Figure 802. Repair and Removal of Trim Tab, Main Rotor Blade
0.002 INCH
(0.0508 MM)
MAXIMUM
EDGE OF
STAKING TOOL
FLUSH TO
ARM +0.010 INCH
(+0.254 MM)
BEARING WITH STAKING
GROOVE IN OUTER RACE
PRESSING STAKING
BEARING IN ARM BEARING IN ARM
G62-1005A
Figure 803. Bearing Replacement − Main Rotor Blade Damper Attach Fitting
Page 805
MAINTENANCE MANUAL
(3). Apply bonding adhesive to abraded tip (5). Measure fitting bore diameter. Accept
cap and mating surfaces at rotor blade able limits are 0.7488—0.7493 inch
tip. To extent possible, be sure that (19.01952—19.03222 mm).
there are no adhesive voids.
(6). Apply thin coat of primer (CM318) to
(4). Install tip cap in blade tip, apply fitting bore.
uniform clamping pressure to joint, and (7). Press bearing into fitting with arbor
wipe away excessive adhesive. Allow to press and fixture (ST709). Wipe away
cure for eight hours at room tempera excess primer.
ture or two hours at 1505F (665C).
(8). Stake bearing at both sides of fitting
(5). Install two MS20604AD3C2 blind with staking tool (ST710) in hydraulic
rivets, one though each side of blade tip press with 6000—8000 pounds
and tip cap. (2722—3629 Kg) of force. When
staked, outer race of bearing shall be
flush to not more than 0.010 inch (0.254
8. Damper Attach Blade Fitting Bearing
mm) above fitting surface (both sides).
Replacement
Gap between staked lip of bearing race
and chamfered surface of fitting bore
(Ref. Figure 803) shall not exceed 0.002 inch (0.0508 mm)
as checked with feeler gage. Staking
Consumable Materials operation shall produce no cracks in
(Ref. Section 91−00−00) fitting or bearing.
Item Nomenclature (9). Fill staking gap, if any, with primer
CM216 Loctite remover (CM318).
9. Outboard Leading Edge Abrasion Tape
CM318 Primer Replacement
(Ref. Figure 804 and Figure 805) Replace
Special Tools abrasion tape when it is worn or eroded. Operation
(Ref. Section 91-00-00) in rain or dust reduces tape life and more frequent
Item Nomenclature replacement is necessary.
ST709 Arbor press fixture
ST710 Staking tool Consumable Materials
Item Nomenclature
(1). Use fly or circle cutter with 5/16 inch CM220 Naphtha aliphatic
(7.9375 mm) pilot to remove staked lip
from one side of bearing without
removing any material from fitting. If CM801 Abrasive paper, silicon carbide
fitting is damaged by cutter, blade must
be replaced. A. Removal
(2). Use an arbor press to press bearing NOTE: A second abrasion tape can be applied
from fitting. on top of the first tape to help replacement
when top tape becomes eroded.
(3). Clean primer residue from fitting bore (1). When only the top tape is replaced, peel
with MPK (CM219). Remove locking off top tape. Do not damage bottom tape
compound residue, if any, with locking bond to main rotor blade.
compound remover (CM216).
(2). Wipe surface of bottom tape with a
(4). Using 10X magnifying glass, inspect clean cloth dampened with naptha
fitting bore for cracks. No cracks are aliphatic (CM220) to remove any
permitted. adhesive.
Page 806
MAINTENANCE MANUAL
(3). Do not allow naptha aliphatic (CM220) B. Installation

to touch the bond line between the
bottom tape and the main rotor blade (1). Lightly abrade faying surface of main
surface. rotor blade with 400 grit abrasive paper
(CM801).
(4). If necessary, remove bottom tape from (2). Wipe faying surface of blade with
main rotor blade. naptha aliphatic (CM220) to eliminate
grease or dirt film.
(5). Wipe main rotor blade surface with a
clean cloth dampened with naptha (3). Use heat gun or equivalent to warm
aliphatic (CM220) to remove any blade faying surface. Temperature must
adhesive. not be more than 1205F (495C).
24.00 INCH
(60.96 CM) A
(NOTE 1)
A
MAIN ROTOR BLADE
ABRASION STRIP
ABRASION STRIP TIP
(369A1105)
BLADE PROFILE (NOTE 2) EROSION 0.40 INCH
(369D21105)
(10.16 MM) MAXIMUM
ABRASION TAPE
(369D21104 OR CM717)
SKIN TIP EROSION

0.30 INCH (7.62 MM)
CHORDWISE MAXIMUM
BALL. WEIGHT
VIEW A-A
(NOTE 3)
NOTES:
1. END OF TAPE TO BE FLUSH WITH OUTBOARD END OF BLADE SKIN. TAPE
TO BE SYMMETRICAL ABOUT LEADING EDGE.
2. ABRASION TAPE MUST BE ALIGNED AT TOP PART OF BLADE.
3. VIEW IS TYPICAL FOR 369D21100 BLADES EXCEPT -505, -509, -511
(SEE ALSO DN-39). G62-1006B
Figure 804. Installation/Replacement of Abrasion Tape

(Main Rotor Blade Leading Edge)
Page 807
MAINTENANCE MANUAL
30.00 INCH
(76.2 CM)
(REF)
12.00 INCH
(30.48 CM) M50459-7
M50459-1 ABRASION TAPE
ABRASION TAPE 0.50 INCH
(12.7 MM)
(BOTTOM LAYER) A
1.00 INCH
(2.54 CM)
A 1.00 INCH
(2.54 CM)
369D21100-505 OR 369D21105
369D21100-509 MAIN M50459-1 ABRASION OR
ROTOR BLADE ASSY TAPE (BOTTOM LAYER) 369D21105-3
ABRASION STRIP
-7 ABRASION TAPE
-1 ABRASION TAPE
NOTE
VIEW A-A
NOTE: ABRASION TAPE MUST

BE ALIGNED AT TOP SURFACE OF BLADE. G62-1007A
Figure 805. Installation/Replacement of Double Layer Abrasion Tape

(369D21100−505, −509 and −511 Rotor Blades)
Page 808
MAINTENANCE MANUAL
(4). Remove backing and apply (CM717 MPK is flammable. Use in

preferred over 369D21104) abrasion WARNING well ventilated area and
tape to outboard leading edge of main away from open flame.
rotor blade as follows:
(3). Clean areas to be sealed with clean
(a). Trim corners of abrasion tape to a cloth moistened with solvent (CM228).
0.25 inch (6.35 mm) radius to reduce For hard to clean problem areas, MPK
peeling. (CM219) can be used.
(b). Apply 6.50 inch (16.5 cm) wide and (4). Prepare adhesive (CM404) per
24 inch (61 cm) long abrasion tape manufacturer's instructions.
along blade leading edge (Ref.
Figure 804) so tape overlaps bottom (5). Apply bead of adhesive to interface of
and top of blade edge equally or (Ref. abrasion strip and blade skin. Ensure
Figure 805) for 369D21100-505, -509 there are no gaps or bridges in bead.
and -511 blades.
(6). Cure adhesive per manufacturer's
(c). Smooth and press abrasion tape into instructions.
place by hand. Use heat gun or
equivalent to maintain temperature. 11. Tip Cap Sealing
(d). Re-apply pressure by hand following (Ref. Figure 805)
initial installation to make sure of
proper bonding. Abrasion tape must
be free of surface wrinkles or air Consumable Materials
bubbles. (Ref. Section 91−00−00)
Item Nomenclature
NOTE: A second abrasion tape can be applied CM212 Releasing agent
on top of the first tape to facilitate replace
CM213 Releasing agent
ment when top tape becomes eroded. To ap
ply second tape, wipe surface of installed CM318 Primer
strip clean with naptha aliphatic (CM220) CM420 Sealant
and repeat steps (3). and (4). above. Second CM427 Sealing compound
abrasion tape must be evenly aligned with CM428 Sealing compound
first at top surface of blade (Ref. Figure 804
or Figure 805).
(1). Apply release agent (CM212 or CM213)
10. Leading Edge Abrasion Strip Sealing to inside of tip cap per manufacturer's
instructions.
(Ref. Figure 805)
(2). Prepare and apply a 0.010—0.020 inch
Consumable Materials (0.254—0.508 mm) coating of sealant
(Ref. Section 91−00−00) (CM420, CM427 or CM428) to faying
Item Nomenclature surfaces per manufacturer's instruc
tions.
CM228 Surface cleaner (3). Attach tip cap to blade and install
CM404 Adhesive, epoxy screw with primer (CM318).
(4). Wipe off squeezed out sealant flush

(1). Remove screw and tip cap from main with surface.
rotor blade.
NOTE: To inhibit moisture entering bond joint
(2). Remove any loose or cracked sealant or of abrasion strip after initial application,
adhesive from areas of main rotor reapply sealant, when sealant is worn away
blade. or becomes cracked.
Page 809
MAINTENANCE MANUAL
C C A A
369A1116 TIP CAP

C SEAL WITH
PR1436G, CLASS B-2
OR
SEAL WITH EC2216 B/A FROM L.E. TO PR1422G, CLASS B
0.75 INCH (19.05 MM) DIM. ON T.E.
RADIUS (UPPER AND LOWER SURFACE) C
0.75 INCH
(19.05 MM) 0.75 INCH
(19.05 MM)
369D21100 MAIN ROTOR BLADE ASSEMBLY
369D21105 ABRASION STRIP REF.

0.003-0.005 INCH
369A1103 SKIN REF. TYP.
(0.0762-0.127 MM)
SEAL WITH
EC2216 B/A
369A1109-501, 269A1186 0.010 INCH SEAL SKIN / BAL. WT.

BAL. WT. REF. (0.254 MM) ASSY INTERFACE
SEAL WITH TYP
EC2216 B/A WITH EC2216 B/A
A-A TIP CAP OMITTED FOR CLARITY

0.12 INCH
(3.048 MM)
TYP
369D21105 ABRASION STRIP

C-C TYP 2 PLCS 369A1103 SKIN SEAL SCREW BY INSTALLING
WITH WET PRIMER
NAS517-3-0
G62-1013A
Figure 806. Main Rotor Blade Abrasion Strip and Tip Cap Sealing
Page 810
MAINTENANCE MANUAL
12. Main Rotor Blade Protective Tape NOTE: Tape must be of equal length on all
Installation blades to ensure proper balance.
In an effort to reduce the amount of erosion in (2). Cut tape long enough to cover erosion
the area inboard of the abrasion strip, MDHI plus approximately 0.5 inch (12.7 mm)
has approved the installation of stainless steel overlap on leading edge abrasion strip.
or Mylar tape to the blade leading edge.
Installation of the tape is optional. (3). Round off square corners of tape to
reduce peeling.
The approved 3M Mylar tape, P/N 8671-1, is 1
inch (2.54 cm) wide and the 304 stainless steel (4). Lightly abrade faying surface of main
tape, P/N 87-369D21104, is 0.027 inch (0.6858 rotor blade in area where tape is to be
mm) thick and 2 inch (5.08 cm) wide. installed with 400-grit abrasive paper
(CM801).
The length of the tape can vary, up to 8.0
inches (20.32 cm) in length, but must be equal (5). Wipe abraded area with naphtha
on all blades. aliphatic (CM220) to eliminate grease
and dirt film.
It is recommended to start with 2.5 inch (6.35
cm) length and increase the length as erosion (6). Treat any bare metal with epoxy-type
occurs by replacing the tape. paint.
NOTE: NOTE: Do not allow temperature to be more
D This installation is only approved on than 1205F (495C).
main rotor blades equipped with the 36
inch (91.44 cm) abrasion strips. (7). Using a heat gun, or equivalent, heat
abraded area.
D For installation of the Mylar tape, refer to
manufacturer's instructions. Use of aero (8). Apply aerosol primer to bonding area
sol primer Promoter 86 can be used to and allow to dry.
speed cure time of the tapes adhesive.
Mylar tape comes in rolls one inch (2.54 (9). Remove backing and apply tape to
cm) wide by 36 yards (329184 m) in length leading edge of blade.
and the promoter comes in 36 ounce
(1.065 L) cans. Mylar tape can be pur (a). Apply tape so it overlaps each side of
chased from RS Hughes Company blade equally.
(1-800-453-8116). (b). Tape should overlap the inboard end
A. Stainless Steel Tape Installation of abrasion strip 0.5 ±0.03 inch (12.7
±0.762 mm) at the leading edge of
blade.
(Ref. Section 91−00−00) NOTE: Tape must be free of surface wrinkles or
Item Nomenclature air bubbles.
CM801 Abrasive paper, silicon carbide (10). Smooth and press tape into place by
hand.
Do not cut or trim tape after (11). Re-apply pressure by hand following
CAUTION installation on blade, damage to initial installation to ensure proper
blade will occur. bonding.
(1). Measure length of eroded area on blade (12). Do the main rotor balance (Ref. Section
with the most erosion. 18-10-00 or 18-10-60).
Page 811
MAINTENANCE MANUAL
Page 812
MAINTENANCE MANUAL
Section
62−20−00
Main Rotor Hub
(369D/E/FF − 500N)
MAINTENANCE MANUAL
MAIN ROTOR HUB

1. Main Rotor Hub − General (3). Remove lockwire and disconnect
flexible boot from lower end of hub
The main rotor hub consists of a central hub, liner.
five identical pitch housings spaced 72 degrees
apart horizontally around the hub with (4). Disconnect each pitch control rod from
associated mechanisms and linkages. pitch housing.
Lead-lag links, a lead-lag damper, a droop (5). Disconnect scissors crank from main
stop striker strip and spacer, and a pitch rotor hub or scissors link.
control bearing with each pitch housing
produce the pivoting axis, blade flapping stop NOTE: To facilitate assembly, color code each
contact surfaces and lead-lag hinge function pitch control rod to match pitch housing to
for the rotor blades. which it is attached.
(6). Remove two screws securing retainer to

Five laminated retention strap assemblies that
main rotor hub nut.
are flexible both vertically and torsionally
extend through the pitch housings and connect (7). Remove nut retainer.
to the lead-lag links.
(8). Using main rotor mast nut wrench
A lower shoe, attached to the central hub, (ST701), remove nut from mast.
contains a droop stop ring and droop restrain
ers that support the blades at rest and (9). Using hub puller (ST702), break loose
distribute droop loads at low blade rpm. main rotor hub (Ref. Figure 401).
Remove hub puller.
The following instructions provide field
maintenance and repair procedures for the (10). Attach hoisting adapter, to eyebolts and
main rotor hub. hoist hub from mast.
2. Main Rotor Hub Replacement B. Main Rotor Hub Installation
(Ref. Figure 402)

A. Main Rotor Hub Removal

Item Nomenclature
Special Tools
(Ref. Section 91-00-00) CM111 Grease, aircraft
Item Nomenclature CM115 Grease, oscillating bearing
ST201 Hoisting adapter CM128 Grease
ST701 Main rotor wrench assembly CM204 Compound, corrosion preventative
ST702 Hub puller CM702 Lockwire CRES
Special Tools
(1). Remove all main rotor blades. (Ref. Section 91-00-00)
Item Nomenclature
(2). Remove main rotor drive shaft; then
ST201 Hoisting adapter
reinstall hoisting eyebolts, washers and
nuts in rotor hub. Locate them to ST701 Main rotor wrench assembly
correspond with lugs of hoisting ST703 Main rotor hub driver
adapter (ST201).
Page 401
MAINTENANCE MANUAL
Main rotor hub is a highly (5). Hand-pack hub cavity, between sleeve
CAUTION stressed component. Use ex bushing and hub, with grease (CM111).
treme care to prevent it from striking any
object. Any impact damage can require re (6). Place recessed spacer, recess down, on
placement of hub. top of sleeve bushing.
NOTE: (7). Hand-pack upper bearing cup and cone

with grease; then install cone on mast
D Removal of recessed spacer, upper bear and use hub drive tool (ST703), to fully
ing cone, upper seal and seal retainer is seat cone.
not mandatory for installation of the
main rotor hub. If these items are in (8). Fill remaining cavity to upper seal with
stalled, do steps (1). thru (4). and (11). grease.
thru (22). Caution should be used when
(9). Position upper seal in seal retainer
installing hub to prevent damage to these
with lip up; then press seal and retain
parts.
er in hub counterbore.
D If recessed spacer, upper bearing cone,
upper seal and seal retainer have been re (10). Using a soft drift, carefully tap seal
moved, these parts should not be as outer ring to seat in counterbore. Wipe
sembled in hub before installation of hub away any excess grease.
on helicopter. These items are reas
(11). Apply grease (CM128) to exposed
sembled in hub after seating hub on mast.
threads on mast.
Prior to installing main rotor hub, insure
that all bearings are adequately serviced Be sure that seal is properly po
with grease (CM111). CAUTION sitioned against seal retainer
D Replacement main rotor hubs do not come and that seal retainer does not pinch seal.
balanced from MDHI. If installing a re Check by inserting a loop of approximately
placement hub, do a main rotor hub bal 0.050 inch (1.27 mm) diameter lockwire,
ance (Ref. Section 18-10-00, Main Rotor round feeler gage or other suitable tool with
Hub Balance Procedure). out sharp edges between seal lip and retain
er.
(1). Attach hoisting adapter (ST201) to
eyebolts in main rotor hub and connect NOTE: To insure that hub is seated onto mast
suitable hoist. properly before torquing, 2—4 threads
should be showing above the mast nut with
If hub assembly (with sleeve nut installed finger tight.
CAUTION bushing, spacer, upper bearing
(12). Install mast nut, using wrench (ST701);
and seal retainer installed) does not seat
torque nut to 200 foot-pounds (271
properly onto mast, do not attempt to force
Nm). Apply coat of corrosion preventive
it into position. Remove hub assembly from
compound (CM204) to screw holes in
mast and determine cause of hub not seat
mast nut.
ing, correct the problem and follow the pro
cedures for reinstallation. (13). Place retainer on nut and check
retainer-to-nut screw hole alignment.
(2). Check that rotor mast is clean. Hoist
main rotor hub and position over mast; (14). Increase nut torque to not more than
then lower hub onto mast. 250 foot-pounds (339 Nm) to align
holes in retainer and nut.
NOTE: To inhibit mast corrosion when operat
ing in salt water environment, lightly coat NOTE: If holes cannot be aligned in 200—250
bearing journals of mast with grease foot-pound (271—339 Nm) torque range,
(CM115). remove and invert nut and repeat proce
dures in (12). thru (14). to align holes.
(3). Remove adapter, hoist and eyebolts.
(15). Secure retainer to nut with two screws;
(4). Check that hub is fully seated on mast. lockwire screws.
Page 402
MAINTENANCE MANUAL
SLEEVE BUSHING
ROTOR HUB
OUTER LINER
SEAL JAW CONTACT

POINT
MAIN ROTOR PULLER

(ST702) LIFT POINT
(TYPICAL 3 PLCS)
THRUST PAD
ROTOR MAST
ROTOR MAST
G62-2004A
Figure 401. Pulling Hub Assembly
Page 403
MAINTENANCE MANUAL
Make sure that no washers are Excessive lead-lag load applied

CAUTION used under screwheads and that CAUTION to the main rotor blades during
screwheads are free of burrs. ground handling can result in damage to the
elastomeric damper buns and failure of the
(16). Make sure that screwheads do not damper assembly. Operators and mainte
protrude more than 0.025 inch nance personnel should use extra caution to
(0.64 mm) above hub upper surface for avoid lead-lag loads in excess of 35 pounds
adequate clearance between scre (155.68 N) at the tip of the main rotor
wheads and driveshaft flange. blades.
NOTE:
(17). Connect scissors crank to main rotor D Refer to MDHI Notice DN-45.2 for infor
hub lower shoe and/or to scissors link. mation concerning required modification
of dampers produced prior to October
NOTE: Make sure pitch control rods are in 1979. If lead-lag dampers, P/N
stalled at same locations from which re 369D21400-501 are installed, they must
moved. be modified to M50452 or be replaced
with P/N 369D21400-503 dampers.
(18). Install five pitch control rods to pitch D If one or more main rotor blades strike an
housings (Ref. Section 62-30-00, Pitch object while rotating or the drive system
Control Rod Replacement). has been subjected to sudden stop, in
spect damper.
(19). Connect flexible boot to lower end of
rotor hub liner and secure with lock 4. Main Rotor Damper Replacement
wire (CM702). A. Main Rotor Damper Removal
(20). Install main rotor drive shaft (Ref. (1). Note and record location from which
Section 63-10-00). damper is to be removed from main
rotor hub.
(21). Install five main rotor blades. NOTE: At reinstallation, if damper is not rein
stalled at same location, a check of and/or
(22). Do the main rotor blade droop angle blade phasing is required.
check if hub is new or replacement. (2). Support blade parallel to ground.
(23). Do the main rotor hub balance (Ref. (3). Remove damper.
Section 18-10-00, Main Rotor Hub NOTE: If damper is to be reinstalled at same lo
Balance Procedure) if a new or rebuilt cation, do not disturb damper clevis, jam
hub is installed. nuts or turnbuckle setting. Otherwise,
blade phasing is required at reinstallation
3. Main Rotor Damper of damper.
(4). If damper is not to be reinstalled,
(Ref. Figure 603) A main rotor damper is remove bushing from damper ear and
attached to each pitch housing of the rotor retain with hub.
hub. The damper is connected to the inboard
trailing edge of the associated main rotor blade B. Main Rotor Damper Installation
by an adjustable clevis to prevent lateral (1). Check, and if necessary, preset main
vibrations from occurring in main rotor blades. rotor damper length (Ref. Nominal
Neither damper travel nor stiffness is adjust Damper Adjustment Procedure). Leave
able on the helicopter. Phasing of rotor blades jamnuts fingertight.
is affected by turnbuckle adjustment. Any
phasing problem caused by a defective damper NOTE: Make sure that bushing is installed in
should be corrected by replacing damper. large hole of damper ears.
Page 404
MAINTENANCE MANUAL
(2). With damper rotational direction decal hours. Preferred ambient temperature
facing outboard so it can be read, during storage is 55—855F (13—305C).
attach damper ears to pitch housing lug
with bolt (head up), washers, and nut. (3). Set damper length, centerline-to-cent
Torque nut to 30—60 inch-pounds erline of bolt attach holes, for initial
(3.39—6.78 Nm) and install cotter pin. installation.
369D/E
(3). Adjust main rotor blade phasing for 8.224—8.234 inches
associated main rotor blade. (208.890—209.144 mm)
(4). After final phasing adjustments, torque 369F/FF
jamnuts to 95—110 inch-pounds 8.127—8.137 inches
(10.73—12.43 Nm). Safety jamnuts to (206.426—206.680 mm)
turnbuckle with new lockwire. Lock 500N
wire must be located out-board, away 8.127—8.137 inches
from pitch housing. (206.426—206.680 mm).
NOTE: Threaded end of damper turnbuckle (4). Install dampers on helicopter.

shaft must protrude through clevis base a
minimum of two full threads and must clear NOTE: If ground rock or stick shake is noted,
blade damper attach fitting. complete following step.
(5). Connect damper to blade.
(5). Length of damper can be adjusted after
(6). Remove blade support. initial setting by checking main rotor
system balance (Ref. Section 18-10-00,
5. Main Rotor Damper Nominal Adjustment Main Rotor Balancing Procedure).
Check of main rotor system balance
(1). Remove all five main rotor blade should be accomplished only after main
dampers from helicopter if installed. rotor blades have been tracked.
NOTE: If dampers are being replaced, do not
If more than four flats turn of
mix part numbers. CAUTION turnbuckle adjustment is neces
(2). Store all five dampers together in sary to correct balance, return to step (1).
horizontal position for minimum of six and repeat procedure.
Page 405
MAINTENANCE MANUAL
SCREW (2 PLCS)
(NOTE 2)
MAST
LOCKNUT
RETAINER
LOCKWIRE 0.020 INCH (0.508 MM)

RETAINER
MAXIMUM SCREW HEAD
HEIGHT ABOVE HUB
SCREW LOCKNUT
DRIVE SHAFT MAST SEAL

RETAINER SEAL RETAINER
SAFETYING
LOCKNUT AND SEAL
INSTALLATION
LOCKNUT MAIN ROTOR

HUB
PITCH HOUSING
ASSEMBLY
SHIMS / SHIM WASHERS

(NOTE 4)
LOWER
SHOE
SHOULDERED BUSHING
MAIN ROTOR MAST

PITCH
FLEXIBLE BOOT CONTROL
ROD
NOTE 1 NOTES:
1. EDGE OF BUSHING MUST PROTRUDE A
ROTATING SWASHPLATE MINIMUM OF 0.010 INCH (0.254 MM) TO A
MAXIMUM OF 0.060 INCH (1.524 MM) ABOVE
OUTSIDE SURFACE OF PART AFTER NUT IS
NOTE 3 TIGHTENED.
2. IF LOCKNUT AND RETAINER SCREWHOLES
DO NOT MATCH WITHIN CORRECT TORQUE
RANGE, LOCKNUT IS TO BE INVERTED.
3. WASHER(S) AS REQUIRED FOR BOLT END
TO SWASHPLATE BOOT CLEARANCE.
SCISSORS CRANK 4. SHIMS / SHIM WASHERS USED TO FILL GAP
ON SHOULDERED BUSHING SIDE.
G62-2005A
Figure 402. Main Rotor Hub − Installation
Page 406
MAINTENANCE MANUAL
MAIN ROTOR HUB

INSPECTION/CHECK
1. Main Rotor Hub Balancing − General form of crescent-shaped grooves. If
chafing wear exists, repair or replace.
(Ref. Section 18-20-00) Main rotor hub Chafed area must be cleaned up before
balancing is accomplished by adding or measuring depth of damage to deter
removing weight (flat washers) as required at mine housing serviceability.
the lead-lag bolts. Analysis of main rotor hub
balance is accomplished using instrumentation (3). Inspect droop stop ring for corrosion,
that measures and localizes vibrations due to dents and scratches. If defects are
main rotor hub imbalance. Data provided by found, repair or replace.
the instrumentation is plotted on a chart
designed to indicate how much weight must be NOTE: To inhibit corrosion, spray droop stop
added or removed from the lead-lag bolt. No ring, rollers and pitch bearings with rust in
other means of balancing is to be used. hibitor (CM232).
(4). Inspect droop stop roller for flat spots,
2. Main Rotor Blade Phasing Check and/or
pit marks and looseness on roller shaft.
Adjustment
(5). Inspect striker plate for dents and pit
Main rotor blade phasing (alignment) is
marks that exceed 0.030 inch (0.762
necessary at damper installation or replace
mm) depth. Damage exceeding this
ment, and can be necessary if there is ground
limit requires replacement of striker
rocking, or if one-to-one lateral (main rotor)
plate.
vibration occurs during flight (Ref. Main Rotor
Damper Nominal Adjustment). (6). Press each pitch housing downward
several times and check for evidence of
3. Main Rotor Hub Inspection binding pitch bearing or droop restrain
er follower. Inspect visible portion of
Consumable Materials droop restrainer for cracks and follower
(Ref. Section 91−00−00) spring for breaks.
NOTE: Do not remove tetrafluoroethylene
Item Nomenclature
CM232 Rust inhibitor spray (TFE) debris which works out of pitch bear
ing edge. Debris is normal and helps lubri
cate bearing. Removal of debris increases
(1). Inspect pitch housing for scratches,
bearing wear rate.
nicks and cracks. No cracks are permis
sible. Scratches and nicks must be (7). Use bright light and 5X magnifying
cleaned up before measuring depth of glass to inspect all main rotor hub
damage to determine housing service lead-lag links (Ref. Figure 802) for
ability. discoloration, pitting, intergranular
cracks or stress corrosion cracks. Any
(2). Inspect sleeve bushing for snug fit in
discoloration or pitting is evidence of
pitch housing arm clevis lug (Ref.
more than superficial corrosion and
Figure 805); lug must not show evi
main rotor hub must be removed for
dence of wear caused by bushing
replacement of lead-lag links.
movement. Maximum allowable
diameter for hole in bushed lug is NOTE: Normal or premature overhaul requires
0.5004 inch (12.71016 mm); for un visual inspection plus dye-penetrant in
bushed lug, not more than 0.3135 inch spection of links for same conditions.
(7.9629 mm). Inspect inner surfaces of
all pitch housing arm clevis lugs for (8). Inspection lead-lag link stop for broken
chafing caused by misaligned pitch spring, cracks, breaks or visible bond
control rod end bearings. Chafing is in line cracks.
Page 601
MAINTENANCE MANUAL
DAMAGE AREA
369D21271-5
LAMINATE
369D21271-3
LAMINATE
369D21271-7
LAMINATE
G62-2006
Figure 601. Strap Pack Lamination − Exploded View
Page 602
MAINTENANCE MANUAL
(9). Inspect interiors of lead-lag bolts using (1). Inspect interiors of lead-lag bolts using
bright light and 5X glass for cracks or bright light and 5X glass for cracks or
corrosion per Lead-Lag Bolt Inspection. corrosion.
(10). Inspect each striker strip for cracks, (a). Remove cotter pin securing nut to
deformation and badly worn contact lower end of lead-lag bolt. Do not
surfaces. disturb torque on nut or remove nut.
(11). Inspect all parts of main rotor hub for (b). Remove screw, nut, washers and
cracks, breaks, scratches and nicks. balance hardware, if installed, from
(Refer all questionable damage to lead-lag bolt.
MDHI for disposition.)
(c). Inspect bolt interior. Treat minor
(12). Inspect lower shoe scissors attach surface corrosion if noted. If corrosion
bearings for binding, looseness in bore pitting or cracks are noted remove
and wear. Maximum wear limits are and replace hub.
0.010 inch (0.254 mm) radial and 0.020
inch (0.508 mm) axial. (d). Swab entire ID of bolt with primer
(CM318).
(13). Inspect each of five main rotor reten
(e). Reinstall screw, nut, washers and
tion strap packs (Ref. Main Rotor Strap
balance hardware removed in step 2.
Pack Lamination Inspection) at
Ensure hardware is installed exactly
specified intervals (Ref. Section
as removed. Torque MS21042L08
05-10-00). (Ref. MDHI Notices DN-154
locknut on screw to 20—35 inch-
/ EN-44 / FN-33 for specific inspection
pounds (2.26—3.95 Nm). Torque
requirements.)
MS21042L3 locknut on screw to
(14). Inspect hub outer liner for rotational 30—60 inch-pounds (3.39—6.78
play. Maximum limits are 0.750 inch Nm). Coat exposed screw threads,
(19.05 mm). No vertical play is allowed. washers and nut with sealant
Inspect for additional movement at (CM420).
100-hour inspection. If additional play
is noticed or the rotational play has
NOTE: Excessive amount of sealant can unbal
ance rotor system. Apply light but thorough
reached the 0.750 inch limit notify
coat of sealant.
MDHI field service department.
(f). Install new cotter pin to secure nut to
4. Lead−Lag Bolt Inspection lead-lag bolt.
NOTE: There are prebalanced rotor hubs in
service. Lead-lag bolts of prebalanced hubs
can contain balancing hardware. If so, re
Item Nomenclature
move balancing hardware to do the inspec
CM318 Primer tion. Each set of removed hardware should
CM420 Sealant be tagged or color-coded to make sure cor
rect reinstallation.
Page 603
MAINTENANCE MANUAL
5. Main Rotor Strap Pack Lamination the rotor system. Any time a vibration de
Inspection velops or there is an increase in vibration
level over a short period of time, the main
CAUTION rotor strap pack assembly should be in
spected for cracked or failed laminates.
D Figure 601 and Figure 602 depict the
main rotor hub and strap pack assembly NOTE: Conduct inspection indoors, if possible,
disassembled for clarity of location and or in a shaded area to eliminate glare of sun
area to be inspected for cracks. Under no or bright outdoor light. To facilitate inspec
circumstances should the strap pack or tion, field fabricate and use plastic inspec
main rotor hub assembly ever be disas tion tool and wooden probe (Ref Figure 602).
sembled in the field. MDHI and MDHI
(1). Remove main rotor blades.
Approved Licensees are the only ap
proved repair stations for main rotor hub (2). If required, trim teflon from edges of
assembly overhaul. laminates using a aluminum chisel.
D If a hub assembly or strap pack assembly Fabricate from stock 0.250 x 6.00 x
(other than new parts in storage) are sub 0.100 inch (6.35 x 152.4 x 2.54 mm).
jected to extended periods of non-use, Carefully scrape excess interlaminate
whether installed on the helicopter or not, teflon sheets from both sides of strap
the strap assembly should be inspected pack between top and bottom shoes at
critically for corrosion and pitting before outboard attachment bolt of all five
return to service. If corrosion is found on strap packs.
the strap pack assemblies, contact MDHI
for disposition. NOTE:
D It is acceptable to operate a helicopter D Do not pry at strap pack assemblies with
with a hub assembly having a strap pack sharp or hard edged tools. If edges become
with up to two failed laminates in any one nicked or laminates get scratched, addi
leg of the strap assembly. When a lami tional cracking can occur thus causing
nate in the strap assembly fails, the re hub replacement.
maining laminates pick up and carry the D Where accessible, ends of acceptable
load. This increased load causes slightly cracked or broken laminates should be
more elongation in the remaining lami taped to prevent scratching and damag
nates of that leg thus shifting the mass of ing of adjacent laminates.
Page 604
MAINTENANCE MANUAL
(3). (Ref. Figure 602) Field fabricate plastic 2). Three or more laminates in a
tool. Run plastic inspection tool in both single strap pack are cracked in
directions along each laminate, feeling the same lead or lag leg.
for a ”catch” from a crack on a single
laminate. Use the wooden or phenolic 3). One laminate is cracked at the
probe and probe at upper and lower end outboard end in the area between
of pack. Failed laminate in lead or lag outboard shoes (Ref. Figure 602).
will move away from the other lami
nates. 4). There are two or more gaps in the
same strap pack. A single gap in
(4). Using a light and mirror, visually any one strap pack assembly is
inspect each of the main rotor strap allowed.
pack assemblies for evidence of cracks
or breaks in strap pack laminates in the (7). Visually inspect strap pack assemblies
areas of the outboard shoes and pitch for evidence of corrosion. If corrosion is
housing assemblies. found on strap pack laminates contact
(5). Using a 10X magnifying glass, visually MDHI service department for disposi
inspect the edge of strap pack lami tion.
nates on both sides at outboard end of
blade pitch housing (area between (8). Using a blunt-nosed wooden or pheno
outboard shoes). lic pin, pencil size with 1/16 inch
(1.5875 mm) radius point, probe at the
(6). Use the following as acceptance/rejec upper and lower strap laminations at
tion criteria for laminate inspection: the outboard ends of the blade pitch
housings for evidence of laminate
(a). A laminate has failed if cracked in failure. A failed laminate, either at the
tongue area or in lead and lag legs of lead or lag end of the strap pack, will
the same laminate. move away from the other laminates. If
(b). Reject strap pack and return hub the adjacent upper and lower laminates
for overhaul when: remain in tension under the probing
operation, no laminate failures have
1). Three or more laminates in a occurred. Refer to Step (5). Caution for
single strap pack have failed. gap limitations.
Page 605
MAINTENANCE MANUAL
ALL LAMINATES STRAIGHT,

NO GAPS.
DETAIL 1: ACCEPTABLE
ALL LAMINATES STRAIGHT. SINGLE GAP

EXISTING ADJACENT TO EITHER SHOE.
NOTE:
WHITE TEFLON MAY APPEAR WRINKLED AND EXTEND PAST END OF LAMINATES,
PREVENTING CLEAR VIEW OF LAMINATES. WHEN THIS OCCURS, LOOK ALONG
EITHER SIDE IN AREA A-A OR B-B (DETAIL 3).
A A

EXISTING ANYPLACE WITHIN LAMINATES.
B B
REMOVE EXCESS TEFLON IN THIS AREA
G62-2007-1
Figure 602. Strap Pack Lamination Inspection (Sheet 1 of 2)
Page 606
MAINTENANCE MANUAL
PLASTIC 0.125 INCH WOODEN OR

1 INSPECTION (3.175 MM) PHENOLIC
TOOL PROBE
LEAD LEG
LAMINATE HAS FAILED IF CRACK OCCURS

ON BOTH LEAD AND LAG LEGS OF SAME
LAMINATE. 0.250 INCH
(6.35 MM)
LAG LEG
2
TONGUE IN TONGUE OF LAMINATE (SHADED AREA
SHOWN BEYOND JOINT OF STRAP PACK
LEGS). 6.00 INCH
(15.24 CM)
4.00 INCH
10.16 CM)
1.5 INCH
(3.81 CM)
(REF)
3
TWO LAMINATE FAILURES AS DEFINED IN 1 1.00 INCH

AND/OR 2 ARE ALLOWED IN EACH STRAP (2.54 CM) 0.50 INCH
PACK ASSEMBLY. (TOTAL OF TEN LAMINATE (12.7 MM)
FAILURES PER HUB ASSEMBLY.)
FIELD FABRICATION INSPECTION TOOLS 0.050-0.125 INCH
ALUMINUM CHISEL NOT SHOWN (1.27-3.175 MM)
(REF. TABLE 601, NOTE 2)
STRAP PACK IS REJECTED IF THREE OR MORE 5

4 LAMINATES IN SAME PACK HAVE FAILED AS
DEFINED IN 1 AND/OR 2 ABOVE.
STRAP PACK IS REJECTED IF THREE OR MORE

LAMINATES IN SAME PACK ARE CRACKED IN
THE LEG (LEAD OR LAG).
FAILED LAMINATE IF CRACK IS

FOUND ON EITHER EDGE OF
LAMINATE. IF ONE LAMINATE
CAUTION: HAS FAILED IN THIS AREA,
DO NOT DISASSEMBLE STRAP PACK ASSEMBLY, REPLACE HUB.
LAMINATIONS ARE SHOWN SEPARATED ONLY TO
DEPICT POSSIBLE CRACK LOCATIONS.
NOTE:
ANY CRACK IN LAMINATE IS CONSIDERED A BREAK. 1.50 INCH
THE LAMINATE HAS NOT FAILED HOWEVER, UNLESS (3.81 CM)
BOTH LEAD AND LAG LEGS ARE CRACKED, CRACK
IS LOCATED IN TONGUE AREA OF LAMINATE OR IS
UNDER SHOES (SEE DETAIL 6). G62-2007-2B
Page 607
MAINTENANCE MANUAL
Table 601. Strap Pack Inspection

Replace or Return
Inspect Procedure (1) For Acceptable Hub for Overhaul
Outboard end. Visually. Use blunt nosed Failed laminates Two or less per Three or more laminate
wooden or phenolic probe (3). pack. failures in one pack.
(Figure 602). Probe at
upper and lower end of
pack. Failed laminate in
lead or lag leg will move
away from other
laminates.
Visually. Gaps between Single straight More than one gap

laminates. gap not exceed- found; gap exceeds
ing 0.030 inch acceptable limit.
(0.762 mm) within
pack or next to
either upper or
lower outer shoe.
Visually using light and Cracks or breaks. None. Cracks or breaks are
mirror (2). noted.
In area of and Visually with light and Cracks or breaks. Two or less Three or more laminate
within pitch mirror (2). laminate failures failures (2) in a pack;
housing assem- per strap pack (2). three or more laminates
blies. in pack with crack in
same leg (lead or lag).
Shims at each of Visually with light and Crack or break. Inspect top Top laminate is cracked
two attach mirror. laminate around in area of cracked or
points. shim (4). broken shim.
NOTES:
(1) Conduct visual inspections indoors or in shaded area to eliminate glare of sun or bright outdoor light.
(2) Removal of teflon covering is required for visual inspection of laminate edges. Use aluminum chisel,
fabricated from stock 0.025 x 6.00 x 0.100 inch (0.635 x 152.4 x 25.4 mm) to carefully scrape excess
interlaminate teflon sheets from both sides of strap pack between top and bottom shoes at outboard
attachment bolt of all five strap packs. Remove excess teflon from a point 1/2 inch (12.70 mm) outboard of
bolt centerline to 1−1/2 inches (38.1 mm) inboard of bolt centerline. Field fabricate and use plastic tool
(Ref. Figure 602). Run plastic tool in both directions along each laminate feeling for cracked laminate. Use
of plastic tool will ensure that shreds of teflon still hanging free does not obscure small cracks.
(3) Laminate has failed if crack is found in tongue area or if crack is found in both legs (lead and lag).
(4) Pay particular attention to shim installed at upper side of lead leg of each strap pack assembly. Maximum
of two shims can have been installed on top side of lead leg of strap pack to accommodate tolerance
buildup during strap pack assembly. If more than one shim is installed, pay particular attention to lower
shim when checking for cracks or breaks.
Page 608
MAINTENANCE MANUAL
NOTE: Laminate failures are defined in step (1). Install cyclic lateral rigging fixture
(6). (ST506 or ST507), cyclic longitudinal
rigging fixture (ST504 or ST505), and
(9). Inspect upper, lower and center lami collective rigging fixture (ST501 or
nates for cracks and breaks (Ref. ST502).
Figure 601).
(2). Rotate main rotor to position one blade
NOTE: Cracks, breaks or other noticeable dam over tailboom.
age to the laminate/shims require main ro
tor hub overhaul/replacement. (3). Raise and support other four blades
until four corresponding droop stop
(10). Install main rotor blades. rollers no longer contact their striker
plates.
(11). Do the tracking of main rotor blades
(Ref. Section 18-20-00). (4). Place accurate propeller protractor on
top of main rotor drive shaft. Adjust
The maximum allowable bal protractor to zero setting.
CAUTION ance weight per pitch case hous
(5). Place protractor on machined surface of
ing on the main rotor hub assembly is 150
outboard end of blade pitch housing,
grams.
alongside lead-lag bolthead. Measure
(12). Record location of all cracked/broken and record static droop angle.
laminates in helicopter Log Book (6). Repeat (2). thru (5). above for remain
including strap serial number, blade ing blades.
color, leg, lead or lag, and laminate
position, if possible numbering from the (7). Maximum allowable static droop angle
top down. is six degrees. If measured droop angle
exceeds six degrees, inspect striker
6. Main Rotor Hub Droop Angle Check plate and roller for excessive wear and
adjust droop angle (Ref. Main Rotor
(Ref. Figure 805) Whenever new or replacement Hub Droop Angle Adjustment).
main rotor hub is installed or whenever excessive
droop angle is suspected, measure static droop 7. Main Rotor Damper and Attachments
angle of all five rotor blades. Droop angle must be Inspection
5.5 ±0.5 degrees.
CAUTION to the main rotor blades during
Special Tools ground handling can result in damage to the
(Ref. Section 91-00-00) elastomeric damper buns and failure of the
Item Nomenclature damper assembly. Operators and mainte
Left−Hand Command: nance personnel should use extra caution to
avoid lead-lag loads in excess of 35 pounds
ST501 Collective rigging fixture
(155.68 N) at the tip of the main rotor
(LH command)
blades.
ST504 Longitudinal rigging fixture
(LH command) (1). Inspect bearing in rotor blade and
ST506 Lateral rigging fixture bearing in the pitch housing for
(LH command) looseness around outer race. No degree
of radial or axial play is permitted.
Right−Hand Command
ST502 Collective rigging fixture (2). Inspect pitch housing and blade
(RH command) bearings for binding, galling, or scoring
ST505 Longitudinal rigging fixture in bore and for wear. No radial play is
(RH command) permitted. Maximum allowable axial
play is 0.015 inch (0.381 mm).
ST507 Lateral rigging fixture
(RH command) (3). Inspect clevis bushings for wear and
looseness.
Page 609
MAINTENANCE MANUAL
(4). Inspect damper flange bushing for wear (2). Attach dial indicator or equivalent to
and play. outer case of damper; position indicator
arm on center aluminum disc as shown.
(5). Inspect lower bolt hole in damper
flange for wear. NOTE: Fabricate holding bar or fixture capable
of sustaining 100 pound (45.359 kg) static
(6). Inspect damper housing (including load (Ref. Figure 603).
flanges) for damage.
(3). Attach damper end cap to holding bar
(7). Inspect damper turnbuckle, jamnuts or fixture.
and safetywire for security. No end play
is permitted when manually tested. NOTE: Do the weight loading and extension
check at ambient temperature of 70° ±l0°F
NOTE: When doing the lead-lag of main rotor (21° ±5°C). Apply total 100 pound (45.359
blades, apply rotor brake (if installed) or kg) weight load to damper at one time, not in
have assistant hold main rotor hub from weight increments.
moving. A second assistant is recommended
to measure approximate damper extension (4). Using hydraulic jack or equivalent,
and compression. raise and attach 100 pound (45.359 kg)
weight load at damper clevis end.
(8). Lead-lag each main rotor blade in turn Slowly lower jack to avoid shock
to provide approximately 0.10 inch loading. After period of two minutes
(2.54 mm) extension and compression of under load, measure damper extension
the damper elastomer. on dial indicator.
(9). Visually check each damper in turn for (5). If extension is more than 0.056 inch
cracks in elastomer or in elastomer-to- (1.4224 mm) for M50452 damper, or
metal bond at end face of damper: If 0.063 inch (1.6002 mm) for
bonding or elastomer cracks are noted, 369D21400-503 damper, replace the
measure depths of cracks, using depth damper assembly.
gage fabricated of shim stock or
equivalent having a 0.20 inch (5.08 (6). Reinstall existing damper; or as
mm) indication. If depth of crack required; install replacement damper of
exceeds 0.20 inch (5.08 mm), remove same type and part number (Ref. Main
and check damper. Rotor Damper Installation). Do not
intermix PN 369D21400-503 damper
8. Main Rotor Damper Weight Loading and with any other part number damper
Extension Check assemblies.
(Ref. Figure 603) NOTE: If replacement damper is installed, re

cord part number, serial number, and other
(1). Remove damper assembly (Ref. Main pertinent information in Components Re
Rotor Damper Removal). cord of helicopters Log Book.
Page 610
MAINTENANCE MANUAL
ELASTOMER
(NOTE)
MAIN ROTOR
DAMPER
ELASTOMER-TO-METAL
ALUMINUM BOND (NOTE)
DISC
END FACE - MAIN ROTOR DAMPER
HOLDING BAR
OR FIXTURE
END CAP
DAMPER
CLAMP
INDICATOR
INDICATOR ARM
THREADED SHAFT
CLEVIS
100 POUND (45.359 KG) WEIGHT
NOTE:
CHECK ELASTOMER AND
ELASTOMER-TO-METAL BOND
FOR CRACKS.
G62-2000-603-1
Figure 603. Periodic Check of Main Rotor Damper Assembly
Page 611
MAINTENANCE MANUAL
Page 612
MAINTENANCE MANUAL
MAIN ROTOR HUB

REPAIRS
1. Main Rotor Retention Strap Pack Repair (2). After smoothing (removal of all sharp or
raised edges) repair depth must not
exceed 0.010 inch (0.254 mm) in any
Consumable Materials area of housing except inner surfaces of
(Ref. Section 91−00−00) arm clevis lugs.
Item Nomenclature
(3). Maximum repair depth of 0.050 inch
CM725 Tape, electrical, plastic (1.27 mm) is acceptable in clevis lug
with sleeve bushing.
(Ref. Table 601) Where accessible, ends of
permissible cracks or broken laminates should (4). On opposite clevis lug repair depth of
be taped to prevent scratching and damaging 0.030 inch (0.762 mm) is permissible in
adjacent laminates. area of spot faces and maximum of
0.050 inch (1.27 mm) in area outside
Do not bend broken ends exces spot faces.
CAUTION sively and scratch adjacent
straps. (5). Touch up repaired areas with chemical
film (CM206) followed by primer
(1). Carefully wipe ends of broken strap (CM318) and remove main rotor hub for
with a clean soft cloth moistened with pitch housing replacement.
solvent (CM234).
(2). Use mild blast of filtered air to dislodge 3. Unbushed Outboard Clevis Lug Hole
any foreign particles between broken Repair
strap ends and adjacent strap.
(3). Carefully tape broken ends of strap (Ref. Figure 801) Repair elongated outboard hole
with plastic electrical tape (CM725). in unbushed side of clevis lug if inside diameter of
hole is more than 0.3135 inch (7.9629 mm).
2. Pitch Housing Repair

Item Nomenclature
(Ref. Section 91−00−00) CM118 Grease
Item Nomenclature CM318 Primer
CM206 Chemical coating CM431 Sealing, locking and retaining compound
CM318 Primer
CM802 Abrasive cloth, aluminum oxide
(1). Remove existing bushing from inboard
lug.
During repair of pitch housing,
CAUTION comply with precautions for cov
(2). Drill elongated hole in outboard lug to
ering engine air inlet fairing opening to pre
0.3680 inch (9.3472 mm). Use drill
vent entry of foreign objects into air intake.
bushing as guide.
(1). Use grade 320 abrasive cloth (CM802)
to smooth scratches, nicks and chafing (3). Line ream hole to 0.3760-0.3770 inch
wear in pitch housing. (9.5504-9.5758 mm) diameter.
Page 801
MAINTENANCE MANUAL
0.360 IN. (9.144 MM)

MINIMUM WALL WIDTH
AROUND LUG (NOTE 1)
OUTBOARD LUG
PITCH HOUSING
0.250 IN. (6.35 MM) OUTBOARD LUG

MINIMUM LUG WIDTH
(NOTE 1)
INBOARD LUG
A
A
0.220 IN.
(5.588 MM)
INBOARD LUG MINIMUM LUG
THICKNESS
(NOTE 1) 0.146 IN. (3.7084 MM)
MINIMUM LUG THICKNESS
0.20 IN. (5.08 MM) AT SPOTFACE
LUG THICKNESS (NOTE 1)
(NOTE 1)
NOTES:
1. MAINTAIN MINIMUM WALL THICKNESS AROUND LUG AND MINIMUM
LUG THICKNESS FOR FIELD REPAIR OF CLEVIS LUG.
2. NO PAINT OR PRIMER PERMISSIBLE IN THIS AREA.
3. BRUSH CADMIUM PLATE GROUND SURFACE BEFORE INSTALLATION
IF POSSIBLE. IF NOT, COAT GROUND SURFACE THOROUGHLY WITH
PRIMER (CM318) AND INSTALL WHILE WET.
G62-2000-801-1
Figure 801. Field Repair of Main Rotor Hub Pitch Control Lugs (Sheet 1 of 2)
Page 802
MAINTENANCE MANUAL
BUSHING 0.44 IN. (11.176 MM) O.D. X 0.25 IN. (6.35 MM) I.D. X 0.31 IN. (7.874 MM) LONG
BUSHING 0.75 IN. (19.05 MM) O.D. X 0.56 IN. (14.224 MM) I.D. X 0.31 IN. (7.874 MM) LONG
BOLT 0.25 IN. (6.35 MM) DIA X 1.38 IN. (3.5052 CM) LONG
WASHER 0.25 IN. (6.35 MM) I.D. X 0.75 IN. (19.05 MM) O.D. X 0.06 IN. (1.524 MM) THICK (2 EA.)
SECTION A-A
1 REMOVAL OF HS610 SP 5010 R 313 X 290 SOLID BUSHING
DRILL BUSHING
0.4990-0.4995 INCH 0.3775-0.3780 INCH 1.13 INCH LONG
O.D. X I.D. X
(12.6746-12.6873 MM) (9.5885-9.6012 MM) (2.8702 CM)
0.3760-0.3770 INCH
REAMER DIA
(9.5504-9.5758 MM)
DRILL NO. U 0.3689 INCH DIA
(9.37006 MM)
DRILL BUSHING
DRILL THEN REAM
0.875 INCH DRILL BUSHING
(22.225 MM) 0.375 X 0.250 X 0.31 IN.
(9.525 X6.35 X 7.874 MM) LONG 2 DRILL AND REAM OUTBOARD LUG
NOTE 2
BACK SPOTFACE TREAT SPOTFACE SURFACE AND REAMED

0.875 IN. (22.225 MM) DIA X HOLE WITH SEALING COMPOUND (CM431)
0.250 IN. (6.35 MM) DIA SHAFT
0.020-0.030 INCH 0.010-0.030 INCH
(0.508-0.762 MM) FILLET RADIUS
(0.254-0.762 MM)
0.146 INCH (3.7084 MM) MIN.
0.20 INCH (5.08 MM) MIN.
3 BACK SPOTFACE OUTBOARD LUG
AFTER INSTALLATION OF BUSHING,

SEAL EDGES WITH PRIMER (CM318).
FLANGE TO BE FLUSH WITH SURFACE. 369D21309-3 BUSHING
GRIND OFF TO 0.000-0.015 IN. (0.000-0.381 MM)
BELOW 0.75 IN. (19.05 MM) DIA. SPOTFACE
SURFACE (NOTE 3)
INSTALL WITH LOCTITE.
0.015-0.025 INCH
X 455 CHAMFER (TYP)
369D21306 SPLIT BUSHING, COAT WITH (0.381-0.635 MM)
LUBRIPLATE (CM118) AT INSTALLATION. 0.360 IN. 0.000-0.015 INCH
(9.144 MM) MIN. (0.000-0.381 MM)
4 INSTALLATION OF 369D21306 AND 369D21309-3 BUSHINGS
G62-2012-2B
Figure 801. Field Repair of Main Rotor Hub Pitch Control Lugs (Sheet 2 of 2)
Page 803
MAINTENANCE MANUAL
NOTE: Check outboard lug two places for mini 4. Pitch Control Bearing Housing Assembly,
mum wall thickness of 0.146 inch (3.7084 Spacer or Striker Strip Replacement
mm) and 0.20 inch (5.08 mm).
(Ref. Figure 802)
(4). Back spotface inside surface of outboard Consumable Materials

lug to 0.875 inch (22.225 mm) diameter (Ref. Section 91−00−00)
and 0.020-0.030 inch (0.508-0.762 mm) Item Nomenclature
depth. Use drill bushing as guide for
CM222 1,1,1-Trichloroethane
spotface pilot. Add chamfer to clear
bushing two places. CM217 Isopropyl alcohol
NOTE: Measure height of bushing and thick

ness of lug prior to installation. Grind off (1). Support blade and pitch housing from
end surface of bushing as required to secure beneath. Remove nuts. washers, and
0.000-0.015 inch (0.000-0.381 mm) clear bolts that secure bearing housing.
ance. Brush cadmium plate ground end of If droop shim washers are in
bushing before installation. If equipment is CAUTION stalled between spacer and
not available coat ground end thoroughly striker strip, they must be retained for rein
with primer (CM318) and install while wet. stallation to establish correct static droop
If primer is used check for corrosion around angle between pitch housing and hub.
lug hole and bushing.
(2). Carefully remove spacer by sliding it
downward past striker strip. Retain
(5). Install flanged bushing using loctite exact number of droop shim washers, if
(CM431). Use attach bolt or assembly installed.
pin as guide to ensure proper align
ment. Seal edges with loctite. (3). Slide bearing housing assembly off
pivot pin. Inspect pivot pin for grooving
or excessive wear.
(6). Install slotted bushing with grease
(CM118) in inboard lug. NOTE: Do not remove tetrafluoroethylene
(TFE) debris which works out of pitch bear
NOTE: Check outboard and inboard lugs of cate bearing. Removal of debris increases
pitch control horn for interference with up bearing wear rate.
per jamnut on pitch control rod. Use file or
portable grinder to carefully trim off interf (4). Remove and discard pitch bearing if
ering corner of pitch housing lugs to provide defective, total radial looseness of
sufficient pitch control rod clearance. It is assembled ball and pivot pin must not
not necessary to trim to minimum wall exceed 0.010 inch (0.254 mm).
thickness. Do not exceed rework limitations.
(5). Replace striker strip if it is cracked or
Touch up reworked area with chemical film
lead-lag contact areas are worn
and primer. Paint with matching color.
through hard anodized surface.
(6). Remove sealant between pitch housing
(7). Reconnect pitch control rod assembly. and striker strip. use care not to scratch
Check for proper clearance between pitch housing. Remove striker strip
outboard lug and upper jamnut on pitch from pitch housing.
control rod.
(7). Cut old striker strip to facilitate
removal from retention strap assembly.
Use care during removal of
CAUTION parts from around strap pack.
Do not scratch strap assembly.
Any nicks or scratches on straps require (8). Clean old sealant from pitch housing
scrapping of strap pack. using isopropyl alcohol (CM217).
Page 804
MAINTENANCE MANUAL
(9). Cut out area of new striker strip (Ref. (1). Remove housing, striker plate and pitch
Figure 803). Deburr, smooth and radius control bearing.
cut edges.
(2). Place housing on drill press, striker
(10). Apply sealant (CM425) to faying surface down.
surfaces of the striker strip and pitch
housing. (3). Drill rivet hole out to 0.192—0.198
inch (4.8768—5.0292 mm) dia.
(11). Position pitch control bearing housing
on pivot pin (Ref. Figure 802). (4). Using a 0.453 inch (11.5062 mm) dia.
counterbore, counterbore rivet hole
If droop shim washers were re 0.396 inch (10.0584 mm) deep.
CAUTION moved from between spacer and
striker strip, same exact thickness removed NOTE: The screw-held striker plate is dimen
must be reinstalled. There must be an equal sionally thicker.
number of washers on each of all three bolts.
These washers establish correct static droop (5). Counterbore should have a 0.030 inch
between pitch housing and hub. (0.762 mm) radius. Deburr counterbore.
(12). Slide spacer into position between (6). Clean drilled and counterbored surfaces
bearing housing assembly and striker with solvent (CM234) and treat with
strip on pitch housing. Install exact chemical film (CM206).
thickness of droop shim washers
removed at time of disassembly. Align (7). Prime and paint counterbored surface
holes for all three bolts. with primer (CM318) and black paint
(CM305).
(13). Install bolts, washers and nuts; torque
(8). Reinstall pitch control bearing and
to 50—70 inch-pounds (5.65—7.91
striker plate and reinstall housing.
Nm) and install safety wire.
(14). Seal all parting lines (joints) of the 6. Pitch Control Bearing Replacement
assembly with bead of sealing com
pound (CM425). (Ref. Figure 802)
(15). Do a droop angle check (Ref. Main Consumable Materials

Rotor Hub Droop Angle Adjustment). (Ref. Section 91−00−00)
Item Nomenclature
5. Pitch Control Bearing Housing CM206 Chemical coating
Modification
(Ref. Figure 802) To replace riveted striker plate CM318 Primer
with screw held striker plate, refer to following CM425 Sealing compound
instructions. CM803 Crocus cloth
Consumable Materials (1). To remove striker plate, remove screw,

(Ref. Section 91−00−00) nut and washer or drill out rivets as
Item Nomenclature required. Discard striker plate if
CM206 Chemical coating brinnelling or pits exceed 0.030 inch
CM234 Solvent, dry-cleaning (0.762 mm) depth.
CM305 Lacquer, acrylic (2). Press bearing from housing bore. Clean
CM318 Primer any residual primer from housing bore
with MPK solvent (CM219).
Page 805
MAINTENANCE MANUAL
CAUTION: WASHERS ARE INSTALLED BETWEEN SPACERS AND STRIKER

STRIP TO ESTABLISH CORRECT STATIC DROOP ANGLE BETWEEN HOUSING
AND HUB. EXACT NUMBER REMOVED MUST BE REINSTALLED. THREE PITCH
BEARING HOUSING BOLTS MUST EACH HAVE SAME NUMBER (THICKNESS) OF
WASHERS WHEN SHIMMING IS NECESSARY.
HUB
LEAD-LAG
LEAD-LAG
LINKS
BOLT
DROOP SHIM WASHERS
(SEE CAUTION)
SLEEVE
BUSHING
SPACER
PIVOT PIN
STRIKER STRIP
MAIN ROTOR
PITCH CONTROL
STRAP PACK
BEARING HOUSING
ASSEMBLY PITCH BEARING HOUSING AND
SPACER - INSTALLATION
(CURRENT CONFIGURATION)
NOTE 2 ELONGATED HOLE LINE REAMED (USING

NOTE 1 SLEEVE BUSHING AS GUIDE) TO PROVIDE 0.001
LEAD-LAG -0.0015 IN. (0.0254-0.0381 MM) INTERFERENCE
STOP FIT FOR 0.3675-0.3685 IN. (9.3345-9.3599 MM)
LEAD-LAG LINK AND STOP OUTSIDE DIAMETER REPAIR BUSHING
PITCH HOUSING ARM
REPAIR BUSHING (2024-T3 OR 7075-T6
(CLEVIS LUG)
ALUMINUM PRESS FIT
PRESS-FITTED REPAIR BUSHING LINE

SLEEVE DRILLED AND LINE REAMED USING SLEEVE
BUSHING BUSHING AS GUIDE:
FINAL ID; 0.3125-0.3135 IN. (7.9375-7.9629 MM)
PITCH HOUSING BUSHINGS - REPAIR
NOTES: NOTES: (CONT)

1. FOR REMOVAL, WOOD DOWEL PLACED HERE AND 7. COUNTERSUNK RIVET HEAD OR SCREW HEAD MUST BE
STRUCK SHARPLY WITH HAMMER TO BREAK STOP BOND. FLUSH WITH HOUSING. UPSET END MUST BE FLUSH
2. ALL STOP-TO-LINK SHADED CONTACT SURFACES WITH PLATE.
BONDED WITH ADHESIVE (CM405 OR CM410). 8. UPSET END MUST BE FLUSH WITH PLATE.
3. INSTALL WITH WET PRIMER (CM318). 9. MANUFACTURED RIVET HEAD MUST BE FLUSH WITH
4. WET PRIMER (CM318) ON WASHER AND MATING SURFACES PLATE IN ALTERNATE RIVET INSTALLATION.
BEFORE INSTALLATION. 10. REPLACEMENT HOUSING FOR BOTH VERSIONS
5. NUT RETAINING BRACKET IS BONDED TO HUB. ATTACHED TO STRIKER PLATE WITH SCREW, WASHER
6. EARLY CONFIGURATION MODIFIED BY HUGHES SERVICE AND NUT FOR EASE OF REMOVAL.
NOTICE DN-3.
Figure 802. Main Rotor Hub Components − Repair and Installation (Sheet 1 of 2)
Page 806
MAINTENANCE MANUAL
NOTE 7
NOTE 10
SCREW
HOUSING
NUT
PITCH BEARING WASHER
STRIKER NUT
PLATE
WASHER
THREADED
(2 PLCS)
COUNTERSUNK
HEAD SCREW
PITCH BEARING -
INSTALLATION MODIFIED CONFIGURATION
(ROTATED) (NOTE 6)
SUPPORT NUT
MAXIMUM ALLOWABLE WEAR IS 90%

CIRCUMFERENCE OF 0.4328 INCH
(10.99312 MM) MINIMUM DIAMETER 0.4328 INCH
(10.99312 MM)
SPECIAL WASHER MINIMUM DIA.
NOTE 7 (NOTE 4)
HOUSING
0.125 INCH (3.175 MM)
MAXIMUM WEAR
NUT RETAINING
BRACKET (NOTE 5)
STRIKER CURRENT CONFIGURATION PITCH PIVOT PIN
PLATE (CURRENT CONFIGURATION)
HUB (NOTE 3)
RETAINING NUT
ROUND HEAD CAPTIVE NUT BRACKET (NOTE 5)
RIVET (NOTE 8) EARLY CONFIGURATION
MAXIMUM ALLOWABLE WEAR IS 90%

CIRCUMFERENCE OF 0.4328 INCH
(10.99312 MM) MINIMUM DIAMETER 0.4328 INCH
PITCH (10.99312 MM)
BEARING MINIMUM DIA.
PITCH PIVOT PIN 0.125 INCH (3.175 MM)
COUNTERSUNK HEAD RIVET (EARLY CONFIGURATION) MAXIMUM WEAR
(ALTERNATE) (NOTE 9) (NOTE 3)
EARLY CONFIGURATION
PIVOT PITCH PIN - INSTALLATION
62−2013−2A
Figure 802. Main Rotor Hub Components − Repair and Installation (Sheet 2 of 2)
Page 807
MAINTENANCE MANUAL
NOTE: Diameter of bearing bore, after cleanup, (1). Provide a backup support for link
should not be more than 1.1880 inch assembly. Use 0.5 inch (12.7 mm) wood
(3.01752 cm). Localized areas of clean up dowel and hammer to drive stop from
should not be more than 0.003 inch (0.0762 link. Strike dowel sharply to break
mm) within an area of 25% of the circumfer adhesive bond.
ence.
(3). Rework minor surface abrasion in (2). Using sharp-edge metal scraper,
housing bore by polishing with crocus carefully scrape any adhesive residue
cloth (CM803). Restore chemical film from link. If scraper penetrates through
(CM206), where removed. paint and chemical surface film, surface
must be refinished. Depth of gouges or
(4). Press bearing into bore using wet nicks is limited to 0.010 inch (0.254
primer (CM318). Wipe away any excess mm) maximum after rework. Rework
primer using care to keep it out of by smooth blending into surrounding
bearing. Check teflon linings of bearing
area with grade 320 abrasive cloth
after installation to determine that no
(CM802). Final polish with crocus cloth
damage occurred from pressing opera
tion. (CM803). Restore chemical film protec
tion (CM206).
NOTE: Ensure bearing is seated completely in
bore of housing and striker plate fits flush
on housing. (3). Clean bond area of all contact surfaces
by wiping with cleaner (CM228).
(5). Apply sealant (CM425) to faying Flush-wipe cleaned surface four times
surfaces and install striker plate with with mixture of equal parts of distilled
screw, washer and nut or rivets. Head water and isopropyl alcohol (CM217) to
of countersunk screw or rivet must be remove all traces of phosphoric acid.
completely flush. Rinse cleaned surface with tap water,
followed by a rinse of distilled water
7. Lead−Lag Link Blade Stop Replacement until surface is ”water break” free. Dry
for 30 minutes minimum at 150°F
(Ref. Figure 802) Replace blade stop if it is (66°C).
broken, cracked, has broken spring, or if there
are visible bond line cracks.
(4). Check fit of stop in link. Flange and
radius contact surfaces of stop must
Consumable Materials mate with link within 0.010 inch (0.254
(Ref. Section 91−00−00) mm). Maximum clearance between stop
Item Nomenclature and inside surfaces of link ears is
CM206 Chemical coating limited to 0.020 inch (0.508 mm). This
CM217 Isopropyl alcohol tolerance applies to both sides of stop.
CM411 Adhesive, epoxy (5). Prepare mixture of epoxy adhesive
CM802 Abrasive cloth, aluminum oxide (CM411). Apply uniform coating of
CM803 Crocus cloth mixed adhesive to all contact surfaces.
Hand press stop into place between link
ears until all mating surfaces are in
Lead-lag link assembly must firm contact. Apply a clamping device
CAUTION not be removed from pitch con so that contact is maintained. Cure for
trol housing for this repair, since retention minimum of eight hours at room
bolt cannot be retorqued without special temperature, or two hours at 150°F
adapter. (66°C).
Page 808
MAINTENANCE MANUAL
2.50 INCH
(6.35 CM)
CAUTION:
DO NOT SCRATCH STRAP PACK WHEN INSTALLING
THROUGH STRAP ASSY.
0.25-0.50 IN.
(6.35-12.70 MM)
NOTE:
(NOTE)
CUT OUT 0.25-0.50 IN. (6.35-12.70 MM) PIECE OF THE
STRIKER STRIP BETWEEN LOWER BOLT HOLES G62-2009A
Figure 803. Striker Strip Replacement

8. Damper Attach Lug Bearing Replacement (4). Using 10X magnifying glass, inspect
fitting bore for cracks. No cracks are
permitted.
Item Nomenclature
(5). Measure fitting bore diameter. Accept
able limits are 0.6548—0.6552 inch
CM216 Loctite remover (16.63192—16.64208 mm).
CM318 Primer (6). Apply thin coat of primer (CM318) to
fitting bore.
Special Tools
(Ref. Section 91-00-00) (7). Press bearing into fitting with arbor
Item Nomenclature press and fixture (ST706). Wipe away
excess primer.
ST706 Arbor press fixture
ST707 Staking tool (8). Stake bearing at both sides of fitting
with staking tool (ST707) in hydraulic
press with 6000—8000 pounds
(1). Use fly or circle cutter with 0.25 inch
(26688—35584 N) of force. When
(6.35 mm) pilot to remove staked lip
staked, outer race of bearing shall be
from one side of bearing without
flush to not more than 0.010 inch (0.254
removing any material from fitting. If
mm) above fitting surface (both sides).
fitting is damaged by cutter, blade must
Gap between staked lip of bearing race
be replaced.
and chamfered surface of fitting bore
(2). Use an arbor press to press bearing shall not be more than 0.002 inch
from fitting. (0.0508 mm) as checked with feeler
gage. Staking operation shall produce
(3). Clean primer residue from fitting bore no cracks in fitting or bearing.
with MPK (CM219). Remove locking
compound residue (if any) with locking (9). Fill staking gap (if any) with primer
compound remover (CM216). (CM318).
Page 809
MAINTENANCE MANUAL
9. Lead−Lag Bolt Corrosion Control NOTE: Torque pivot pin to 70—80 inch-
pounds (7.91—9.04 Nm), then use 0.002
inch (0.0508 mm) feeler gage and check for
gap between pin flange and washer on
Item Nomenclature
mounting lug surface. No gap is allowed.
CM219 Methyl−propyl−ketone (MPK) (3). Install pivot pin in mounting lug with
CM318 Primer washer (Ref. Figure 802). Torque pivot
CM425 Sealing compound pin to 250—280 inch-pounds
(28.25—31.64 Nm). Apply sealant
(CM420) at junctures of pivot pin
flange, washer and hub.
Do not disturb torque on lead-
CAUTION lag bolts. Special adapter is 11. Droop Stop Roller Repair or Replacement
needed to retorque lead-lag bolts. (Ref. Figure 804) Replace defective droop stop
(1). Remove and tag or color-code each set roller if clearance between roller bearing liner
of balance hardware that is installed. and shaft is more than 0.015 inch (0.381
mm). Roller shaft outside diameter must not
(2). Remove corrosion with grade 180 be less than 0.4370 inch (11.0998 mm).
abrasive cloth (CM802) and finish with
grade 400 abrasive cloth. Consumable Materials
(3). Swab cleaned surface with MPK (Ref. Section 91−00−00)
(CM219) and apply unthinned zinc Item Nomenclature
chromate primer (CM318). CM217 Isopropyl alcohol
(4). Reinstall original balance hardware

that was removed. Using sealant (1). Remove pitch control bearing housing
(CM425), reseal balance hardware. that contacts lower shoe roller to be
removed.
10. Pitch Control Bearing Pivot Pin Repair or
Replacement NOTE: Only one roller can be removed at one
time. Two opposing droop stop followers
(Ref. Figure 802) Minimum allowable pin must be pressed against droop stop ring to
diameter is 0.4328 inch (10.99312 mm). Pivot force opposite follower out and expose roller
pin grooving or excessive side wear can be shaft for removal. Same condition exists at
polished to original finish as long as minimum installation.
allowable pin diameter, 0.4328 inch (10.99312
mm), remains after rework. Replace any pin (2). Press down on pitch housing that is
requiring more rework as follows. opposite roller that is to be removed.
Remove cotter pin and shaft.
Consumable Materials (3). Remove droop stop roller.

(4). Wet down and clean plunger and
Item Nomenclature
mating shoe bushing with isopropyl
CM318 Primer alcohol (CM217).
CM420 Sealant
(5). To install replacement roller, press
down on pitch housings at opposite
(1). Remove pivot pin. sides of hub from roller to be installed.
Install roller, shaft and new cotter pin.
(2). Install replacement pivot pin wet with
primer (CM318). (6). Install pitch control bearing housing.
Page 810
MAINTENANCE MANUAL
12. Droop Stop Ring Repair When T-head is free of ring channel,
turn it perpendicular (vertical) to
(Ref. Figure 804) channel.
NOTE: Followers can be easily rotated by use of
Consumable Materials nonmetallic drift in hole for droop stop roller
(Ref. Section 91−00−00) shaft.
Item Nomenclature
CM103 Solid film lubricant
(6). Push droop stop ring toward number 4
and 5 followers. Pull number 2 follower
T-head from droop stop ring channel.
(1). Repair depth limit for corrosion, nicks When T-head is free of channel, turn it
or scratches in droop stop ring is 0.007 perpendicular to channel.
inch (0.1778 mm) for all surfaces except (7). Push droop stop ring toward number 1
outer edges of ring outer flanges. Depth and 5 followers. Pull number 3 follower
limit is 0.030 inch (0.762 mm). All T-head from droop stop ring channel.
reworked areas must be blended When T-head is free of channel, turn in
smoothly with 15 to 1 ratio into sur perpendicular to channel.
rounding area.
(8). Tilt ring up on number 1, 2, and 3
(2). Spray repaired areas of rings with solid T-heads as far as possible.
film lubricant (CM103).
(9). While pulling upward on ring, rotate (in
(3). Replace droop stop ring if repair limits succession) number 1, 2, and 3 T-heads
are exceeded. so that they are out of, and below, droop
stop ring.
13. Droop Stop Ring Replacement
(10). Withdraw number 4 and 5 T-heads
(Ref. Figure 804) from droop stop ring channel and
remove ring.
(1). With hub upside down, support hub so
When installing droop stop ring,
that pitch housings unload cam follow CAUTION droop stop followers T-Heads
ers and provide maximum clearance
between striker plates and droop stop must be offset away from lower shoe to pre
rollers. vent damage to lower shoe.
(11). Install replacement droop stop ring by
(2). Release retaining (snap) ring of each reversing removal procedure, steps (1).
droop stop restrainer from its groove. through (10)., making certain to
Move retaining ring flush against droop reinstall followers according to mark
stop follower (T-head) to provide ings placed thereon prior to removal.
additional clearance and reduce spring
tension. (12). Compress follower spring and install
retaining (snap) ring in its groove on
(3). Remove five droop stop rollers. each follower.
(4). Starting from either scissors crank (13). Reinstall droop stop rollers.
attach lug, number all five droop stop
follower assemblies in clockwise 14. Droop Stop Follower (T−Head)
direction for location identification at Replacement
replacement. This number code should (Ref. Figure 804) Replace the droop stop
be placed on outer, upper end of plunger follower (T-head) if it is worn, scored or is
and on adjacent area of lower shoe. causing damage to the droop stop ring. After
Make sure codes are not accidentally the droop stop ring has been removed, the
removed during remaining steps. droop stop follower assemblies can be removed
from hub.
(5). Push droop stop ring toward number 3
and 4 followers. Pull number 1 follower (1). Remove droop stop follower assembly
T-head from droop stop ring channel. from hub.
Page 811
MAINTENANCE MANUAL
(2). Remove pins that secure follower to (c). The maximum wear condition can
plunger. exist in one spot or in several spots
totaling 2.1 square inches (13.55
Droop stop followers T-Heads cm2).
CAUTION must be offset away from lower
shoe to prevent droop stop ring from damag (6). Wet down and clean plunger and
ing lower shoe. mating shoe bushing with isopropyl
alcohol (CM217).
(3). Insert new follower. T-head must be at
right angle to roller shaft in plunger. (7). Install droop stop plunger into lower
shoe.
(4). Drill two 0.156—0.158 inch
(8). Install roller, shaft and new cotter pin.
(3.9624—4.0132 mm) diameter holes
through follower in line with holes in (9). Complete droop stop ring installation.
plunger.
16. Main Rotor Hub Droop Angle Adjustment
(5). Insert pins and stake ends. No burrs or
roughness permissible after staking. (Ref. Figure 802) If static droop angle exceeds
six degrees, adjust as follows.
(6). Install follower assembly in hub.
(1). Remove main rotor blade.
(7). Reinstall droop stop ring. (2). Use flat washers of thickness required
to adjust spacing between spacer and
15. Droop Stop Plunger Removal, Inspection striker strip. Any one type, or combina
and Installation tion, of correct part number washers
(Ref. Figure 804) (IPC) can be used; however, an identical
washer selection must be installed on
each of three bolts that secure pitch
Consumable Materials control bearing assembly to pitch
(Ref. Section 91−00−00) housing.
Item Nomenclature
(3). Remove nuts and washers and separate
CM217 Isopropyl alcohol spacer from striker strip. The use of one
0.016 inch washer raises static droop
(1). Remove droop stop ring. angle approximately one-half degree.
Add sufficient washers to adjust droop
(2). Remove pitch control bearing housing angle within range of 5.5 ±0.5 degrees.
assembly that contacts the lower shoe Reinstall nuts and washers.
roller.
(4). If more than 0.063 inch (1.6002 mm)
(3). Remove cotter pin and shaft from droop spacing is required (above factory
stop follower assembly. spacing), inspect striker plate and
droop stop roller or follower and droop
(4). Remove droop stop roller. stop ring for excessive wear. Replace as
required.
(5). Check droop stop plunger for wear by
using the following criteria: NOTE: The average factory spacing on new and
rebuilt hubs is 0.063 inch (1.6002 mm).
(a). The minimum acceptable diameter
after wearing in service should be (5). Reinstall blade. Repeat measurement of
0.996 inch (25.2984 mm). static droop angle.
(6). As required, repeat above procedures
(b). The acceptable amount of wear for remaining blades.
though the anodized coating shall not
exceed 40% or 2.1 square inches (7). Following reinstallation or replacement
(13.55 cm2) of the total sliding of parts, check track of main rotor
surface area of the cylinder. blades.
Page 812
MAINTENANCE MANUAL
LOWER
SHOE
PINS
DROOP STOP
PLUNGER DROOP STOP
0.007 INCH (0.1778 MM)
FOLLOWER
MAX. DEPTH (15 TO 1
DROOP STOP (T-HEAD) (NOTE)
RADIUS) AFTER REWORK
ROLLER
COTTER
15 TO 1 SNAP RING
PIN
RADIUS SHAFT
SPRING
DROOP STOP FOLLOWER - INSTALLATION
0.007 INCH (0.1778 MM)

MAX. DEPTH (15 TO 1
0.030 IN. MAX. RADIUS) AFTER DROOP STOP RING
AFTER REWORK REWORK
DROOP STOP RING - REPAIR LIMITS
DROOP STOP FOLLOWER

ASSEMBLY (5 PLCS)
BEARING ROTATIONAL DRAG

SCISSORS CRANK
1.0 - 2.0 IN-LBS
ATTACH LUG
(0.113 - 0.226 NM)
LOWER SHOE - INVERTED
NOTE: DROOP STOP FOLLOWER T-HEADS TO

BE OFFSET AWAY FROM LOWER SHOE. G62-2011C
Figure 804. Main Rotor Hub Assembly − Repair
Page 813
MAINTENANCE MANUAL
17. Main Rotor Hub Tapered Bearing Grease (4). Check bearing cup hub bore for scoring.
Repack, Inspection and Replacement Smooth out any roughness with grade
400-600 abrasive cloth (CM802).
(Ref. Figure 805) Replace tapered roller Restore chemical film protection where
bearing cup or cone if it has any flat spots, removed. Maximum diameter of hub
scoring, pitting, grooving, discoloration (blue) bore for upper bearing cup (Ref.
or if it feels rough when rotated. Figure 805) is 4.4335 inch (11.26109
cm), measured in any direction.
Consumable Materials Maximum diameter of hub bore for
(Ref. Section 91−00−00) lower bearing cup is 4.3095 inch
Item Nomenclature (10.94613 cm), measured in any
direction.
CM121 Preservation oil (5). Check upper seal retainer. No cracks,
sharp nicks or burrs are allowed. Minor
corrosion or other surface defects can be
CM802 Abrasive cloth, aluminum oxide polished out using crocus cloth
CM803 Crocus cloth (CM803). Grooving on seal contact
surfaces must not exceed 0.004 inch
Special Tools (0.1016 mm) depth after polishing.
Bearing cups are installed in
Item Nomenclature WARNING hub by differential tempera
ST701 Main rotor wrench assembly ture (shrink-fit) method. Take appro
priate precautions to prevent burns
when handling parts that are cooled to
Do not intermix Timken or NTN
CAUTION bearing cups and cones at upper
sub-zero temperatures.
and lower tapered roller bearing locations of (6). Place bearing cups in closed container
main rotor hub. of dry ice and cool for not less than 20
minutes to -40°F (-40°C).
NOTE:
(7). Coat bore of hub with grease (CM111).
D Roller bearing cones and cups should al Use care to maintain cup-to-hub bore
ways be replaced as a set. alignment and press cup into bore,
D Replace tapered roller bearing cup and using tools D and E (Ref. Figure 806),
cone if it has any flat spots, scoring, pit until cup is seated.
ting, grooving, discoloration (blue) or if it
feels rough when rotated. (8). Apply film of grease to sleeve bushing.
Use pressing tool equivalent to tool C,
(1). Use pressing tools equivalent to items and press bearing cone onto sleeve
A and B (Ref. Figure 806) to press bushing.
upper and lower bearing cups from hub.
(9). With lip on center seal up, hand press it
A press ram of one to two tons is
into hub (Ref. Figure 805).
sufficient for removal.
(10). Apply film of grease on mast. Install
(2). Press lower bearing cone from sleeve preassembled sleeve bearing and
bushing. bearing cone on mast. Do not apply any
additional lubricant to roller bearing
In next step, do not spin reus
CAUTION able bearings while cleaning.
set. Wipe any excess preservative oil
from bearing cone and cup.
Coat bearings lightly with oil (CM121) after
cleaning. (11). Place assembled hub over mast and
seat on lower roller bearing cone.
(3). Clean hub bore, sleeve bushing, seal
retainer and reusable bearings using (12). Install lead spacer 369A1224-5 (thick
filtered solvent (CM234) spray. ness gage substitute for recessed
Page 814
MAINTENANCE MANUAL
spacer) over mast. Rest spacer on top of (1.13—1.69 Nm). This will be 1.5—3
sleeve bushing. pounds (0.681—1.362 kg) on spring
scale used as in step (15). above.
NOTE: If lead spacer is not available, fabricate
its equivalent from lead sheet. Spacer di (18). Remove hub and sleeve bushing with
mensions are; 2.96 inch (7.5184 cm) outside lower bearing cone from mast.
diameter; 2.68 inch (608072 cm) ID; (19). Position hub upside-down. Hand-pack
0.075-0.085 inch (1.905-2.159 mm) thick. lower hub cavity (Ref. Figure 805) and
(13). Install upper bearing cone into hub and bearing cone on sleeve bushing with
on top of lead spacer. grease.
(20). Install sleeve bushing with bearing
(14). Install steel ring washer, equivalent to cone in hub. Hand-pack cavity between
tool F (Ref. Figure 806), as substitute bearing and hub liner with grease; then
for seal retainer (Ref. Figure 805). press in lower seal with seal lip toward
NOTE: Step (14). is not required. However, use top of hub. Wipe off excess grease.
of substitute washer for retainer prevents (21). Turn hub assembly right side up.
unnecessary scoring of retainer. Several
tightening and loosening actions can be re (22). Complete reassembly of hub by install
quired to get correct rotational drag on hub ing recessed spacer, upper bearing cone,
bearings. upper seal and seal retainer in hub at
installation of hub on mast.
(15). Install mast nut on mast using mast
nut wrench (ST701), tighten until 18. Main Rotor Hub Scissors Attach Lug
bearings are preloaded to 10—12 Bearing Replacement
inch-pounds (1.13—1.36 Nm) of
rotational drag. Measure rotational Consumable Materials
drag using 0—10 pound (0—4.536 kg) (Ref. Section 91−00−00)
spring scale hooked over one of hub Item Nomenclature
support web bosses, 6.5 inch (16.51 cm) CM206 Chemical coating
from hub centerline). A 1.50—1.75 CM216 Loctite remover
pound (0.681—0.7945 kg) pull with
CM304 Enamel, epoxy
hub in motion indicates correct rota
tional drag. CM321 Surface primer locking compound
CM431 Sealing, locking and retaining compound
(16). Remove mast nut, tool F (Ref.
Figure 806), (or seal retainer), and
upper bearing cone. Remove lead spacer (1). Remove main rotor hub (Ref. Main
and measure compressed thickness. Rotor Hub Replacement).
Obtain serviceable recessed spacer of (2). Invert hub and place on work bench.
same thickness, or grind new recessed
spacer to required dimension. Discard (3). Remove droop stop ring (Ref. Droop
lead spacer after recessed spacer is Stop Ring Replacement).
correctly ground. (4). Press bearing from hub lug.
NOTE: To insure that hub is seated onto mast (5). Clean bearing bore with Loctite
properly before torquing, 2—4 threads remover (CM216).
nut installed finger tight. (6). Inspect bearing bore for nicks,
scratches and grooves.
(17). Install recessed spacer, recess down, on (7). Inspect bore for diameter of
top of sleeve bushing. Reinstall upper 0.6551—0.6556 inch
bearing cone, seal retainer and mast (16.63954—16.65224 mm).
nut. Torque nut to 200—250 foot-
pounds (271—339 Nm) and check for (8). Touch up bearing bore with chemical
rotational drag of 10—15 inch-pounds coating (CM206).
Page 815
MAINTENANCE MANUAL
(9). Apply surface primer (CM321) to room temperature or heat to 140° -

mating surfaces of bearing and bores 160°F (60° - 72°C) for one hour.
per manufacturer's instructions.
(13). As required, touch up bearing lug with
NOTE: Do not allow primer to enter bearing. paint (CM304).
(10). Apply locking compound (CM431) to
(14). Check bearing for a no-load rotational
faying surfaces of bearing and bore,
drag of 1.0—2.0 inch-pounds
press bearing into bore while locking
(0.113—0.226 Nm).
compound is wet.
(11). Remove excess sealant, do not allow (15). Reinstall droop stop ring (Ref. Droop
sealant to enter bearing. Stop Ring Replacement).
(12). Apply a small fillet of sealant around (16). Reinstall main rotor hub (Ref. Main
bearing and allow to dry for 24 hours at Rotor Hub Replacement).
Page 816
MAINTENANCE MANUAL
STRIKER
STRIP
SEALANT
(NOTE 2)
PITCH BEARING
(NOTE 1)
PITCH (NOTE 1)
HOUSING
DROOP SHIM
WASHER (NOTE 9)
LAMINATED SPACER
STRAP PACK SEALANT STRIKER
(NOTE 2) PLATE
PITCH CONTROL DROOP RESTRAINER
BEARING HOUSING AND ROLLER
UPPER BEARING CUP
SEAL (NOTE 10)
(NOTE 4) UPPER BEARING CONE
HUB (NOTE 10) SEAL RECESSED SPACER
RETAINER (NOTE 3)
SEALANT
(NOTE 2) SEAL
(NOTE 4)
PIVOT PIN
SEALANT
(NOTE 2)
HUB OUTER
LINER
ROTATED
LOWER
SHOE
NOTE 1 NOTE 11
NOTES: DROOP STOP
1. HEAVY LINES INDICATE REINFORCED NOTE 5 RING
SEAL
TEFLON BEARINGS (TYPICAL) (NOTE 4)
2. SEALANT (CM420) APPLIED TO LOCATIONS SHOWN. HUB OUTER LOWER BEARING CUP
3. RECESSED SPACER SPECIALLY GROUND TO ESTABLISH CORRECT LINER (NOTE 10)
ROTATIONAL DRAG ON TAPERED BEARINGS, INSTALLED RECESS
DOWN ON TOP OF SLEEVE BUSHING.
4. SEAL TO BE UPWARD.
5. BEARING AND CAVITY TO BE FILLED WITH GREASE (CM111).
6. EARLY CONFIGURATION MODIFIED BY HUGHES SERVICE NOTICE DN-3.
7. ON CURRENT CONFIGURATION, RIVET IS REPLACED BY SCREW, WASHER, AND NUT.
8. SEALANT (CM420) APPLIED TO SURFACES SHOWN.
9. DROOP SHIM WASHERS ARE INSTALLED AS REQUIRED TO OBTAIN PROPER ROTOR
DROOP ANGLE.
10. DO NOT INTERMIX TIMKEN AND NTN BEARING CUPS AND CONES AT UPPER AND LOWER
TAPERED BEARING LOCATIONS.
11. DROOP STOP FOLLOWER T-HEAD TO BE OFFSET AWAY FROM LOWER SHOE. G62-2014-1B
Figure 805. Main Rotor Hub − Cross Section (Sheet 1 of 2)
Page 817
MAINTENANCE MANUAL
LEAD-LAG
PIVOT BOLT
LEAD-LAG SEALANT
LINKS (NOTE 2)
NOTE 2 NOTE 2
NOTE 1
COTTER PIN NOTE 7
RIVET
(NOTE 7)
EARLY CONFIGURATION
NOTE 8 MS21042L08
LOCKNUT MS21042L3 SUPPORT
LOCKNUT NOTE 8 NUT
WASHERS FOR
BALANCE AS
REQUIRED
STEP WASHER
WASHER
WASHER WASHER
LEAD LAG
PIVOT BOLT
SCREW SCREW
CURRENT CONFIGURATION CURRENT CONFIGURATION

SERIAL NO. 0260D AND SUBS SERIAL NO. 003D THRU 0259D
G62-2014-2A
Figure 805. Main Rotor Hub − Cross Section (Sheet 2 of 2)
Page 818
MAINTENANCE MANUAL
2.875 IN. (7.3025 CM)

OUTSIDE DIAMETER
CUT OUT AFTER 0.50 IN.
BEVELING (12.7 MM)
3.50 IN. (8.89 CM)

OUTSIDE DIAMETER
3.875 IN.
(9.8425 CM) 11.0 IN.
53 (27.94 CM)
°
5.75 IN.
3.375 IN. (14.605 CM)
0.375 IN. (8.5725 CM)
(9.525 MM)
0.1875 IN. (4.7625 MM) 0.203125 IN. (5.159375 MM)

4130 STEEL PLATE WALL STEEL PIPE WALL STEEL PIPE
A B C
4.40 IN. 4.30 IN.

(11.176 CM) (10.922 CM)
2.58 IN. 0.30 IN.
(6.5532 CM) (7.62 MM)
3.50 IN.
(8.89 CM)
2.0 IN. 2.0 IN.
(5.08 CM) (5.08 CM)
ALUMINUM ALLOY ALUMINUM ALLOY STEEL RING WASHER
D E F
TOOL USE:
A & B - PRESS BEARING CUPS OUT OF HUB

C - PRESS LOWER BEARING CONE ON SLEEVE BUSHING
D - PRESS UPPER BEARING CUP INTO HUB
E - PRESS LOWER BEARING CUP ONTO HUB
F - IN PLACE OF UPPER SEAL RETAINER WHILE ADJUSTING ROTATIONAL DRAG
G - HUB BEARING REMOVAL - FABRICATION
G62-2010-1
Figure 806. Tapered Bearing Tools − Main Rotor Hub (Sheet 1 of 2)
Page 819
MAINTENANCE MANUAL
7.0 INCH (17.78 CM)

SQUARED
4.75 INCH
(12.065 CM)
10.0 INCH (25.40 CM)

0.75 INCH SQUARED
MATERIAL: WOOD (19.05 MM) H62-2010-2A
Page 820
MAINTENANCE MANUAL
Section
62−20−60
Main Rotor Hub
(600N)
MAINTENANCE MANUAL
MAIN ROTOR HUB

1. Main Rotor Hub − General (3). Remove lockwire and disconnect
flexible boot from lower end of hub
(Ref. Figure 402) The main rotor hub consists liner.
of a central hub, six identical pitch housings
spaced 60 degrees apart horizontally around (4). Disconnect each pitch control rod from
the hub with associated mechanisms and pitch housing.
linkages. Lead-lag links, a lead-lag damper, a (5). Disconnect scissors crank from main
droop stop striker strip and spacer, and a pitch rotor hub or scissors link.
control bearing with each pitch housing
produce the pivoting axis, blade flapping stop NOTE: To facilitate assembly, color code each
contact surfaces and lead-lag hinge function pitch control rod to match pitch housing to
for the rotor blades. Six laminated retention which it is attached.
strap assemblies that are flexible both (6). Remove two screws securing retainer to
vertically and torsionally extend through the main rotor hub nut.
pitch housings and connect to the lead-lag
links. A lower shoe, attached to the central (7). Remove nut retainer.
hub, contains a droop stop ring and droop (8). Using main rotor mast nut wrench
restrainers that support the blades at rest and (ST701), remove nut from mast.
distribute droop loads at low blade rpm. The
following instructions provide field mainte (9). Using hub puller (ST702), break loose
nance and repair procedures for the main rotor main rotor hub. Remove hub puller.
hub.
(10). Attach hoisting adapter (ST201), to
eyebolts and hoist hub from mast.
2. Main Rotor Hub Replacement
B. Main Rotor Hub Installation
A. Main Rotor Hub Removal
(Ref. Figure 402)
(Ref. Figure 401)
Special Tools Item Nomenclature
(Ref. Section 91-00-00) CM111 Grease, aircraft
Item Nomenclature
CM115 Grease, oscillating bearing
ST201 Hoisting adapter CM128 Grease
ST701 Main rotor wrench assembly CM204 Compound, corrosion preventative
ST702 Hub puller CM702 Lockwire CRES
Special Tools
(1). Remove main rotor blades. (Ref. Section 91-00-00)
Item Nomenclature
(2). Remove main rotor drive shaft; then
reinstall hoisting eyebolts, washers and ST201 Hoisting adapter
nuts in rotor hub. Locate them to ST701 Main rotor wrench assembly
correspond with lugs of hoisting ST703 Main rotor hub driver
adapter (ST201).
Page 401
MAINTENANCE MANUAL
Main rotor hub is a highly (5). Hand-pack hub cavity, between sleeve
CAUTION stressed component. Use ex bushing and hub, with grease (CM111).
treme care to prevent it from striking any
object. Any impact damage can require re (6). Place recessed spacer, recess down, on
placement of hub. top of sleeve bushing.
NOTE: (7). Hand-pack upper bearing cup and cone

with grease; then install cone on mast
D Removal of recessed spacer, upper bear and use hub driver (ST703), to fully
ing cone, upper seal and seal retainer is seat cone.
not mandatory for installation of the
main rotor hub. If these items are in (8). Fill remaining cavity to upper seal with
stalled, do steps (1). thru (4). and (11). grease.
thru (22). Caution should be used when
(9). Position upper seal in seal retainer
installing hub to prevent damage to these
with lip up; then press seal and retain
parts.
er in hub counterbore.
D If recessed spacer, upper bearing cone,
upper seal and seal retainer have been re (10). Using a soft drift, carefully tap seal
moved, these parts should not be as outer ring to seat in counterbore. Wipe
sembled in hub before installation of hub away any excess grease.
on helicopter. These items are reas
(11). Apply grease (CM128) to exposed
sembled in hub after seating hub on mast.
threads on mast.
Prior to installing main rotor hub, insure
that all bearings are adequately serviced Ensure that seal is properly po
with grease (CM111). CAUTION sitioned against seal retainer
D Replacement main rotor hubs do not come and that seal retainer does not pinch seal.
balanced from MDHI. If installing a re Check by inserting a loop of approximately
placement hub, do a main rotor system 0.050 inch (1.27 mm) diameter lockwire,
balance (Ref. Section 18-10-60, Main Ro round feeler gage or other suitable tool with
tor System Balance Procedure). out sharp edges between seal lip and retain
er.
(1). Attach hoisting adapter (ST201) to
eyebolts in main rotor hub and connect NOTE: To insure that hub is seated onto mast
suitable hoist. properly before torquing, two to four threads
If hub assembly (with sleeve nut installed finger tight.
CAUTION bushing, spacer, upper bearing
(12). Install mast nut, using wrench (ST701);
and seal retainer installed) does not seat
torque nut to 200 foot-pounds (271
properly onto mast, do not attempt to force it
Nm). Apply coat of corrosion preventive
into position. Remove hub assembly from
compound (CM204) to screw holes in
mast and determine cause of hub not seat
mast nut.
ing, correct the problem and follow the pro
cedures for reinstallation. (13). Place retainer on nut and check
retainer-to-nut screw hole alignment.
(2). Check that rotor mast is clean. Hoist
main rotor hub and position over mast; (14). Increase nut torque to not more than
then lower hub onto mast. 250 foot-pounds (339 Nm) to align
holes in retainer and nut.
NOTE: To inhibit mast corrosion when operat
ing in salt water environment, lightly coat NOTE: If holes cannot be aligned in 200—250
bearing journals of mast with grease foot-pound (271—339 Nm) torque range,
(CM115). remove and invert nut and repeat proce
dures in (12). thru (14). to align holes.
(3). Remove adapter, hoist and eyebolts.
(15). Secure retainer to nut with two screws;
(4). Check that hub is fully seated on mast. safety screws with lockwire (CM702).
Page 402
MAINTENANCE MANUAL
MAIN ROTOR
PULLER
ROTOR HUB
6G62-009A
Figure 401. Pulling Hub Assembly
Ensure that no washers are (21). Install main rotor blades.

CAUTION used under screw heads and
that screw heads are free of burrs.
(22). Do the main rotor blade droop angle
(16). Verify that screwheads do not project check if hub is new or replacement.
more than 0.020 inch (0.508 mm) above
hub upper surface, for adequate (23). Do the main rotor system balance (Ref.
clearance between screw heads and Section 18-10-60, Main Rotor System
driveshaft flange. Balance Procedure) if a new or rebuilt
hub is installed.
(17). Connect scissors crank to main rotor
hub lower shoe and/or to scissors link.
3. Main Rotor Damper
NOTE: Ensure pitch control rods are installed
at same locations from which removed.
(Ref. Figure 603) A main rotor damper is
(18). Install pitch control rods to pitch attached to each pitch housing of the rotor
housings (Ref. Section 62-30-60, Pitch hub. The damper is connected to the inboard
Control Rod Replacement). trailing edge of the associated main rotor blade
by an adjustable clevis to prevent lateral
(19). Connect flexible boot to lower end of vibrations from occurring in main rotor blades.
rotor hub liner and secure with lock Neither damper travel nor stiffness is adjust
wire (CM702). able on the helicopter. Phasing of rotor blades
is affected by turnbuckle adjustment. Any
(20). Install main rotor drive shaft (Ref. phasing problem caused by a defective damper
Section 63-10-00). should be corrected by replacing damper.
Page 403
MAINTENANCE MANUAL
Excessive lead-lag load applied NOTE: Ensure that bushing is installed in

CAUTION to the main rotor blades during large hole of damper ears.
elastomeric damper buns and failure of the (2). With damper rotational direction decal
damper assembly. Operators and mainte facing outboard so it can be read, attach
nance personnel should use extra caution to damper ears to pitch housing lug with
avoid lead-lag loads in excess of 35 pounds bolt (head up), washers, and nut.
(155.68 N) at the tip of the main rotor Torque nut to 30—60 inch-pounds
blades. (3.39—6.78 Nm) and install cotter pin.
NOTE: If one or more main rotor blades strike (3). Adjust main rotor blade phasing for
an object while rotating or the drive system associated main rotor blade.
has been subjected to sudden stop, inspect (4). After final phasing adjustments, torque
damper. jamnuts to 95—110 inch-pounds
(10.73—12.43 Nm). Safety jamnuts to
4. Main Rotor Damper Replacement
turnbuckle with new lockwire. Lock
A. Main Rotor Damper Removal wire must be located out-board, away
from pitch housing.
(1). Note and record location from which
damper is to be removed from main NOTE: Threaded end of damper turnbuckle
rotor hub. shaft must protrude through clevis base a
minimum of two full threads and must clear
NOTE: At reinstallation, if damper is not rein blade damper attach fitting.
stalled at same location, a check of and/or
blade phasing is required. (5). Connect damper to blade.
(2). Support blade parallel to ground. (6). Remove blade support.
(3). Remove damper. 5. Main Rotor Damper Nominal Adjustment
NOTE: If damper is to be reinstalled at same lo (1). Remove main rotor blade dampers from
cation, do not disturb damper clevis, jam helicopter if installed.
nuts or turnbuckle setting. Otherwise, blade
phasing is required at reinstallation of (2). Store all dampers together in horizontal
damper. position for minimum of six hours.
Preferred ambient temperature during
(4). If damper is not to be reinstalled, storage is 55—855F (13—305C).
remove bushing from damper ear and
retain with hub. (3). Set damper length, centerline-to-cent
erline of bolt attach holes, for initial
B. Main Rotor Damper Installation installation.
600N
(1). Check, and if necessary, preset main 8.127—8.137 inches
rotor damper length (Ref. Nominal (206.426—206.680 mm).
Damper Adjustment Procedure). Leave
jamnuts fingertight. (4). Install dampers on helicopter.
Page 404
MAINTENANCE MANUAL
DRIVE SHAFT
SCREW AND
LOCKWIRE
RETAINER
RETAINER
LOCKNUT
LOCKNUT
MAIN ROTOR
HUB
LOCKNUT AND SEAL
INSTALLATION
LOCKWIRE
SHIMS/ SCREW
SHIM WASHERS LOCKNUT RETAINER
(NOTE 2)
SHOULDERED LOWER SHOE DRIVE

BUSHING SHAFT
MAIN ROTOR MAST

MAST
FLEXIBLE SAFETYING
BOOT
PITCH CONTROL NOTE 1

ROD
NOTES: SCISSORS
1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM CRANK
OF 0.010 INCH (0.254 MM) TO A MAXIMUM OF
0.060 INCH (1.524 MM) ABOVE OUTSIDE SURFACE ROTATING
OF PART AFTER NUT IS TIGHTENED. SWASHPLATE
2. SHIMS/SHIM WASHERS USED TO FILL GAP ON 6G62-026
Figure 402. Main Rotor Hub Installation
Page 405
MAINTENANCE MANUAL
Page 406
MAINTENANCE MANUAL
MAIN ROTOR HUB

INSPECTION/CHECK
1. Main Rotor System Balancing − General (3). Inspect droop stop ring for corrosion,
dents and scratches. If defects are
Main rotor system balancing is accomplished found, repair or replace.
by adding or removing weight (flat washers) as NOTE: To inhibit corrosion, spray droop stop
required at the lead-lag bolts. Analysis of ring, rollers and pitch bearings with spray
main rotor system balance is accomplished lubricant (CM104).
using instrumentation that measures and
localizes vibrations due to main rotor system (4). Inspect droop stop roller for flat spots,
imbalance. Data provided by the instrumenta pit marks and looseness on roller shaft.
tion is plotted on a chart designed to indicate
how much weight must be added or removed (5). Inspect striker plate for dents and pit
from the lead-lag bolt. No other means of marks that exceed 0.030 inch (0.762
balancing is to be used. If there is ground mm) depth. Damage exceeding this
rocking, or if one-per-rev lateral (main rotor) limit requires replacement of striker
vibration occurs during flight refer to Section plate.
18-10-60, Main Rotor System Balance (6). Press each pitch housing downward
Procedure. several times and check for evidence of
binding pitch bearing or droop restrain
2. Main Rotor Hub Inspection er follower. Inspect visible portion of
droop restrainer for cracks and follower
spring for breaks.
(Ref. Section 91−00−00) NOTE: Do not remove tetrafluoroethylene
Item Nomenclature (TFE) debris which works out of pitch bear
CM104 Lubricant, spray cate bearing. Removal of debris increases
bearing wear rate.
(1). Inspect pitch housing for scratches, (7). Use bright light and 5-power magnify
nicks and cracks. No cracks are permis ing glass to inspect all main rotor hub
sible. Scratches and nicks must be lead-lag links (Ref. Figure 805) for
cleaned up before measuring depth of discoloration, pitting, intergranular
damage to determine housing service cracks or stress corrosion cracks. Any
ability. discoloration or pitting is evidence of
more than superficial corrosion and
(2). Inspect sleeve bushing (Ref. Figure 805) main rotor hub must be removed for
for snug fit in pitch housing arm clevis replacement of lead-lag links.
lug; if bushings are loose, remove and NOTE: Normal or premature overhaul requires
inspect. Inspect lug for evidence of wear visual inspection plus dye-penetrant in
caused by bushing movement. Maxi spection of links for same conditions.
mum allowable diameter for hole in
each lug is 0.4380 inch (11.13 mm). (8). Inspect lead-lag link stop for broken
Inspect inner surfaces of all pitch spring, cracks, breaks or visible bond
housing arm clevis lugs for chafing line cracks.
caused by misaligned pitch control rod (9). Inspect interiors of lead-lag bolts using
end bearings. Chafing is in form of bright light and 5X glass for cracks or
crescent-shaped grooves. If chafing corrosion per Lead-Lag Bolt Inspection.
wear exists, repair or replace. Chafed
area must be cleaned up before measur (10). Inspect each striker strip for cracks,
ing depth of damage to determine deformation and badly worn contact
housing serviceability. surfaces.
Page 601
MAINTENANCE MANUAL
DAMAGED AREA
CUSHIONING
LAMINATE
CUSHIONING
LAMINATE
CUSHIONING
LAMINATE
6G62−027
Figure 601. Strap Pack Lamination − Exploded View
Page 602
MAINTENANCE MANUAL
(11). Inspect all parts of main rotor hub for NOTE: Excessive amount of sealant can unbal
cracks, breaks, scratches and nicks. ance rotor system. Apply light but thorough
(Refer all questionable damage to coat of sealant.
MDHI for disposition.)
(f). Install new cotter pin to secure nut to
(12). Inspect lower shoe scissors attach lead-lag bolt.
bearings for binding, looseness in bore
and wear. Maximum wear limits are
0.010 inch (0.254 mm) radial and 4. Main Rotor Strap Pack Lamination
0.020 inch (0.508 mm) axial. Inspection
(13). Inspect each of six main rotor retention
strap packs (Ref. Main Rotor Strap CAUTION
Pack Lamination Inspection) at
specified intervals (Ref. Section D Figure 601 and Figure 602 depict the
05-10-00). main rotor hub and strap pack assembly
disassembled for clarity of location and
3. Lead−Lag Bolt Inspection area to be inspected for cracks. Under no
circumstances should the strap pack or
Consumable Materials main rotor hub assembly ever be disas
(Ref. Section 91−00−00) sembled in the field. MDHI and MDHI
Item Nomenclature Approved Licensees are the only ap
proved repair stations for main rotor hub
CM318 Primer
assembly overhaul.
D If a hub assembly or strap pack assembly
(other than new parts in storage) are sub
(1). Inspect interiors of lead-lag bolts using jected to extended periods of non-use,
bright light and 5X glass for cracks or whether installed on the helicopter or not,
corrosion. the strap assembly should be inspected
(a). Remove cotter pin securing nut to critically for corrosion and pitting before
lower end of lead-lag bolt. Do not return to service. If corrosion is found on
disturb torque on nut or remove nut. the strap pack assemblies, contact MDHI
for disposition.
(b). Remove screw, nut, washers and
balance hardware, if installed, from D It is acceptable to operate a helicopter
lead-lag bolt. with a hub assembly having a strap pack
with one failed laminate in any one leg of
(c). Inspect bolt interior. Treat minor the strap assembly. When a laminate in
surface corrosion if noted (Ref. the strap assembly fails, the remaining
Lead-Lag Bolt Corrosion Control). If laminates pick up and carry the load. This
corrosion pitting or cracks are noted increased load causes slightly more elon
remove and replace hub. gation in the remaining laminates of that
leg thus shifting the mass of the rotor sys
(d). Swab entire ID of bolt with primer
tem. Any time a vibration develops or
(CM318).
there is an increase in vibration level over
(e). Reinstall screw, nut, washers and a short period of time, the main rotor
balance hardware removed in step 2. strap pack assembly should be inspected
Ensure hardware is installed exactly for cracked or failed laminates.
as removed. Torque MS21042L08
locknut on screw to 20—35 inch- NOTE: Conduct inspection indoors, if possible,
pounds (2.26—2.82 Nm). Torque or in a shaded area to eliminate glare of sun
MS21042L3 locknut on screw to or bright outdoor light. To facilitate inspec
30—60 inch-pounds (3.39—6.78 tion, field fabricate and use plastic inspec
Nm). Coat exposed screw threads, tion tool and wooden probe (Ref Figure 602).
washers and nut with sealant
(CM425). (1). Remove main rotor blades.
Page 603
MAINTENANCE MANUAL
ALL LAMINATES STRAIGHT,

NO GAPS.
DETAIL 1 ACCEPTABLE

DETAIL 2 ACCEPTABLE EXISTING ADJACENT TO EITHER SHOE.
NOTE:
WHILE TEFLON MAY APPEAR WRINKLED AND EXTEND PAST END OF LAMINATES,
PREVENTING CLEAR VIEW OF LAMINATES. WHEN THIS OCCURS, LOOK ALONG
EITHER SIDE IN AREA A-A OR B-B (DETAIL 3).
A A
B B
EXISTING ANYPLACE WITHIN LAMINATES.
DETAIL 3 ACCEPTABLE
REMOVE EXCESS TEFLON IN THIS AREA
6G62-078-1
Page 604
MAINTENANCE MANUAL
0.125 INCH WOODEN OR

1 (3.175 MM) PHENOLIC
PROBE
LEAD LEG

ON BOTH LEAD AND LAG LEGS OF SAME
LAMINATE. 0.250 INCH
(6.35 MM)
LAG LEG
2
TONGUE IN TONGUE OF LAMINATE (SHADED AREA
SHOWN BEYOND JOINT OF STRAP PACK
LEGS). 6.00 INCH
(15.24 CM)
4.00 INCH
10.16 CM)
1.5 INCH
(3.81 CM)
(REF)
3
TWO LAMINATE FAILURES AS DEFINED IN 1 1.00 INCH

AND/OR 2 ARE ALLOWED IN EACH STRAP (2.54 CM) 0.50 INCH
PACK ASSEMBLY. (TOTAL OF TEN LAMINATE (12.7 MM)
FAILURES PER HUB ASSEMBLY.)
FIELD FABRICATION INSPECTION TOOLS 0.050-0.125 INCH
ALUMINUM CHISEL NOT SHOWN (1.27-3.175 MM)
(REF. TABLE 601, NOTE 2)
STRAP PACK IS REJECTED IF THREE OR MORE 5

4 LAMINATES IN SAME PACK HAVE FAILED AS
DEFINED IN 1 AND/OR 2 ABOVE.
STRAP PACK IS REJECTED IF THREE OR MORE

LAMINATES IN SAME PACK ARE CRACKED IN
THE LEG (LEAD OR LAG).
FAILED LAMINATE IF CRACK IS

FOUND ON EITHER EDGE OF
LAMINATE. IF ONE LAMINATE
CAUTION: HAS FAILED IN THIS AREA,
DO NOT DISASSEMBLE STRAP PACK ASSEMBLY, REPLACE HUB.
LAMINATIONS ARE SHOWN SEPARATED ONLY TO
DEPICT POSSIBLE CRACK LOCATIONS.
NOTE:
ANY CRACK IN LAMINATE IS CONSIDERED A BREAK. 1.50 INCH
THE LAMINATE HAS NOT FAILED HOWEVER, UNLESS (3.81 CM)
BOTH LEAD AND LAG LEGS ARE CRACKED, CRACK
IS LOCATED IN TONGUE AREA OF LAMINATE OR IS
UNDER SHOES (SEE DETAIL 6).
6G62−078−2B
Page 605
MAINTENANCE MANUAL
Table 601. Strap Pack Inspection

Replace or Return
Inspect Procedure (1) For Acceptable Hub for Overhaul
Outboard end. Visually. Use blunt nosed Failed laminates One or less per Two or more laminate
wooden or phenolic probe (3). pack. failures in one pack.
(Figure 602). Probe at
upper and lower end of
pack. Failed laminate in
lead or lag leg will move
away from other
laminates.
Visually. Gaps between Single straight More than one gap

laminates. gap not exceed- found; gap exceeds
ing 0.03 inch acceptable limit.
(0.762 mm) within
pack or next to
either upper or
lower outer shoe.
Visually using light and Cracks or breaks. None. Cracks or breaks are
mirror (2). noted.
In area of and Visually with light and Cracks or breaks. One or less Two or more laminate
within pitch mirror (2). laminate failures failures (2) in a pack;
housing assem- per strap pack (2). two or more laminates
blies. in pack with crack in
same leg (lead or lag).
Cushioning Visually with light and Crack or break. None Cracks or breaks are
laminates at mirror. noted.
each of two
attach points.
NOTES:
(1) Conduct visual inspections indoors or in shaded area to eliminate glare of sun or bright outdoor light.
(2) Removal of teflon covering is required for visual inspection of laminate edges. Use aluminum chisel,
fabricated from stock 0.025 x 6.00 x 0.100 (6.35 x 152.4 x 25.4 mm) to carefully scrape excess
interlaminate teflon sheets from both sides of strap pack between top and bottom shoes at outboard
attachment bolt of all six strap packs. Remove excess teflon from a point 0.50 inch (12.7 mm) outboard of
bolt centerline to 1.50 inches (38.1 mm) inboard of bolt centerline. Field fabricate and use plastic tool (Ref.
Figure 602). Run plastic tool in both directions along each laminate feeling for cracked laminate. Use of
plastic tool will ensure that shreds of teflon still hanging free does not obscure small cracks.
(3) Laminate has failed if crack is found in tongue area or if crack is found in both legs (lead and lag).
Page 606
MAINTENANCE MANUAL
(2). If required, trim teflon from edges of (a). A laminate has failed if cracked in
laminates using a aluminum chisel. tongue area or in lead and lag legs of
Fabricate chisel from stock, 0.250 x 6.00 the same laminate.
x 0.100 inch (6.35 x 152.4 x 25.4 mm).
Carefully scrape excess interlaminate (b). Reject strap pack and return hub
teflon sheets from both sides of strap for overhaul when:
pack between top and bottom shoes at
outboard attachment bolt of all six 1). Two or more laminates in a single
strap packs. strap pack have failed.
2). Two or more laminates in a single

NOTE: strap pack are cracked in the same
lead or lag leg.
D Do not pry at strap pack assemblies with
sharp or hard edged tools. If edges be
3). One laminate is cracked at the
come nicked or laminates get scratched,
outboard end in the area between
additional cracking can occur thus caus
outboard shoes (Ref. Figure 602).
ing hub replacement.
D Where accessible, ends of acceptable 4). There are two or more gaps in the
cracked or broken laminates should be same strap pack. A single gap in
taped to prevent scratching and damag any one strap pack assembly is
ing of adjacent laminates. allowed.
(7). Visually inspect strap pack assemblies

(3). (Ref. Figure 602 for field fabricate for evidence of corrosion. If corrosion is
plastic tool) Run plastic inspection tool found on strap pack laminates contact
in both directions along each laminate, MDHI service department for disposi
feeling for a ``catch'' from a crack on a tion.
single laminate. Use the wooden or
phenolic probe and probe at upper and (8). Inspect upper, lower and center cush
lower end of pack. Failed laminate in ioning laminates for cracks and breaks
lead or lag will move away from the (Ref. Figure 601).
other laminates. If the adjacent upper
and lower laminates remain in tension NOTE: Cracks, breaks or other noticeable
under the probing operation, no damage to the cushioning laminates re
laminate failures have occurred. quire main rotor hub overhaul/replace
ment.
(4). Using a light and mirror, visually (9). Record location of all cracked/broken
inspect each of the main rotor strap laminates in Helicopter Log Book
pack assemblies for evidence of cracks including strap serial number, blade
or breaks in strap pack laminates in the color, leg (lead or lag) and laminate
areas of the outboard shoes and pitch position, if possible, numbering from
housing assemblies. the top down.
(10). Install main rotor blades.

(5). Using a 10X magnifying glass, visually
inspect the edge of strap pack lami
nates on both sides at outboard end of 5. Main Rotor Hub Droop Angle Check
blade pitch housing (area between
outboard shoes). (Ref. Figure 805) Whenever new or replace
ment main rotor hub is installed or whenever
excessive droop angle is suspected, measure
(6). Use the following as acceptance/rejec static droop angle of all six rotor blades.
tion criteria for laminate inspection: Droop angle must be 5.0—6.0 degrees.
Page 607
MAINTENANCE MANUAL
6. Main Rotor Damper and Attachments

Special Tools Inspection
Item Nomenclature CAUTION to the main rotor blades during
ST206 Prop protractor ground handling can result in damage to
Left−Hand Command: the elastomeric damper buns and failure of
ST501 Collective rigging fixture the damper assembly. Operators and main
(LH command) tenance personnel should use extra caution
ST504 Longitudinal rigging fixture to avoid lead-lag loads in excess of 35
(LH command) pounds (155.68 N) at the tip of the main
rotor blades.
(LH command) (1). Inspect bearing in rotor blade and
Right−Hand Command bearing in the pitch housing for
looseness around outer race. No degree
of radial or axial play is permitted.
(RH command)
ST505 Longitudinal rigging fixture (2). Inspect pitch housing and blade
(RH command) bearings for binding, galling, or scoring
ST507 Lateral rigging fixture in bore and for wear. No radial play is
(RH command) permitted. Maximum allowable axial
play is 0.015 inch (0.381 mm).
(3). Inspect clevis bushings for wear and
(1). Install cyclic lateral rigging fixture looseness.
(ST506 or ST507), cyclic longitudinal
rigging fixture (ST504 or ST505), and (4). Inspect damper flange bushing for wear
collective rigging fixture (ST501 or and play.
ST502).
(5). Inspect lower bolt hole in damper
(2). Rotate main rotor to position one blade flange for wear.
over tailboom. (6). Inspect damper housing (including
flanges) for damage.
(3). Raise and support other five blades
until five corresponding droop stop (7). Inspect damper turnbuckle, jamnuts
rollers no longer contact their striker and safetywire for security. No end play
plates. is permitted when manually tested.
(4). Place accurate prop protractor (ST206) NOTE: When doing the lead-lag of main rotor
on top of main rotor drive shaft. Adjust blades, apply rotor brake (if installed) or
protractor to zero setting. have assistant hold main rotor hub from
moving. A second assistant is recom
(5). Place protractor on machined surface of mended to measure approximate damper
outboard end of blade pitch housing, extension and compression.
alongside lead-lag bolthead. Measure (8). Lead-lag each main rotor blade in turn
and record static droop angle. to provide approximately 0.10 inch
(2.54 mm) extension and compres
(6). Repeat (2). thru (5). above for remain sion of the damper elastomer.
ing blades.
(9). Visually check each damper in turn for
(7). Maximum allowable static droop angle cracks in elastomer or in elastomer-to-
is six degrees. If measured droop angle metal bond at end face of damper: If
exceeds six degrees, inspect striker bonding or elastomer cracks are noted,
plate and roller for excessive wear and measure depths of cracks, using depth
adjust droop angle (Ref. Main Rotor gage fabricated of shim stock or
Hub Droop Angle Adjustment). equivalent having a 0.20 inch (5.08
Page 608
MAINTENANCE MANUAL
mm) indication. If depth of crack is NOTE: Do the weight loading and extension
more than 0.20 inch (5.08 mm), check at ambient temperature of 60—80F
remove and check damper. (16—26C). Apply total 100 pound (45.359
kg) weight load to damper at one time, not
in weight increments.
7. Main Rotor Damper Weight Loading and
Extension Check (4). Using hydraulic jack or equivalent,
raise and attach 100 pound (45.359
(Ref. Figure 603) kg) weight load at damper clevis end.
Slowly lower jack to avoid shock
(1). Remove damper assembly (Ref. Main loading. After period of two minutes
Rotor Damper Removal). under load, measure damper extension
on dial indicator.
(2). Attach dial indicator or equivalent to (5). If extension is more than 0.063 inch
outer case of damper; position indicator (1.6002 mm), replace the damper
arm on center aluminum disc as shown. assembly.
NOTE: Fabricate holding bar or fixture capable (6). Reinstall existing damper; or as
of sustaining 100 pound (45.359 kg) static required; install replacement damper.
load (Ref. Figure 603). NOTE: If replacement damper is installed, re
cord part number, serial number, and other
(3). Attach damper end cap to holding bar pertinent information in Components Re
or fixture. cord of helicopters Log Book.
Page 609
MAINTENANCE MANUAL
ELASTOMER
(NOTE)
MAIN ROTOR
DAMPER
ELASTOMER-TO-METAL
ALUMINUM BOND (NOTE)
DISC
END FACE - MAIN ROTOR DAMPER
HOLDING BAR
OR FIXTURE
END CAP
DAMPER
CLAMP
INDICATOR
INDICATOR ARM
THREADED
SHAFT
CLEVIS
100 POUND (45.359 KG)

WEIGHT
NOTE:
CHECK ELASTOMER AND
ELASTOMER-TO-METAL
BOND FOR CRACKS.
G62-2008A
Figure 603. Periodic Check of Main Rotor Damper Assembly
Page 610
MAINTENANCE MANUAL
MAIN ROTOR HUB

REPAIRS
1. Main Rotor Retention Strap Pack Repair If droop shim washers are in
CAUTION stalled between spacer and
Where accessible, ends of permissible cracks or striker strip, they must be retained for rein
broken laminates (Ref. Table 601) should be stallation to establish correct static droop
taped to prevent scratching and damaging angle between pitch housing and hub.
adjacent laminates.
(2). Carefully remove spacer by sliding it
downward past striker strip. Retain
Consumable Materials exact number of droop shim washers, if
(Ref. Section 91−00−00) installed.
Item Nomenclature
(3). Slide bearing housing assembly off
pivot pin. Inspect pivot pin for grooving
CM725 Tape, electrical, plastic or excessive wear.
NOTE: Do not remove tetrafluoroethylene
Do not bend broken ends exces (TFE) debris which works out of pitch bear
CAUTION sively and scratch adjacent ing edge. Debris is normal and helps lubri
straps. cate bearing. Removal of debris increases
bearing wear rate.
(1). Carefully wipe ends of broken strap
with a clean soft cloth moistened with (4). Remove and discard pitch bearing if
solvent (CM234). defective, total radial looseness of
assembled ball and pivot pin must not
(2). Use mild blast of filtered air to dislodge exceed 0.010 inch (0.254 mm).
any foreign particles between broken
strap ends and adjacent strap. (5). Replace striker strip if it is cracked or
lead-lag contact areas are worn
(3). Carefully tape broken ends of strap through hard anodized surface.
with plastic electrical tape (CM725). (6). Remove sealant between pitch housing
and striker strip. use care not to scratch
2. Pitch Control Bearing Housing Assembly, pitch housing. Remove striker strip
Spacer or Striker Strip Replacement from pitch housing.
(Ref. Figure 801)
(7). Cut old striker strip to facilitate
removal from retention strap assembly.
Consumable Materials Do not scratch strap assembly.
Item Nomenclature (8). Clean old sealant from pitch housing
CM217 Isopropyl alcohol using isopropyl alcohol (CM217).
CM425 Sealing compound (9). Cut out area of new striker strip.
Deburr, smooth and radius cut edges.
(1). Support blade and pitch housing from (10). Apply sealant (CM425) to faying
beneath. Remove nuts. washers, and surfaces of the striker strip and pitch
bolts that secure bearing housing. housing.
Page 801
MAINTENANCE MANUAL
2.50 INCH
(6.35 CM)
CAUTION:
DO NOT SCRATCH STRAP PACK WHEN INSTALLING
THROUGH STRAP ASSY.
0.25-0.50 IN.
(6.35-12.70 MM)
NOTE:
(NOTE)
CUT OUT 0.25-0.50 IN. (6.35-12.70 MM) PIECE OF THE
STRIKER STRIP BETWEEN LOWER BOLT HOLES. G62-2009A
DEBURR AND RADIUS‐CUT EDGES.
Figure 801. Striker Strip Replacement
(11). Position pitch control bearing housing 3. Lead−Lag Link Blade Stop Replacement
on pivot pin (Ref. Figure 802). Replace blade stop if it is broken, cracked, has bro
ken spring, or if there are visible bond line cracks
If droop shim washers were re (Ref. Figure 802).
CAUTION moved from between spacer and
striker strip, same exact thickness removed Consumable Materials
must be reinstalled. There must be an equal (Ref. Section 91−00−00)
number of washers on each of all three bolts. Item Nomenclature
These washers establish correct static droop
between pitch housing and hub. CM206 Chemical coating
(12). Slide spacer into position between CM228 Surface cleaner
bearing housing assembly and striker CM411 Adhesive, epoxy
strip on pitch housing. Install exact
thickness of droop shim washers
removed at time of disassembly. Align CM803 Crocus cloth
holes for all three bolts.
Lead-lag link assembly must
(13). Install bolts, washers and nuts; torque CAUTION not be removed from pitch con
to 50—70 inch-pounds (5.65—7.91
trol housing for this repair, since retention
Nm) and install safety wire.
bolt cannot be retorqued without special
adapter.
(14). Seal all parting lines (joints) of the
assembly with bead of sealing com (1). Provide a backup support for link
pound (CM425). assembly. Use 1/2 inch (12.7 mm) wood
dowel and hammer to drive stop from
(15). Do a droop angle check (Ref. Main link. Strike dowel sharply to break
Rotor Hub Droop Angle Adjustment). adhesive bond.
Page 802
MAINTENANCE MANUAL
LEAD-LAG
BOLT
LEAD-LAG LINKS
MAIN ROTOR
STRAP PACK
STRIKER STRIP
PITCH CONTROL BEARING

HOUSING ASSEMBLY
PITCH PIVOT PIN

SLEEVE (NOTE 3)
BUSHING
SPECIAL WASHER
(NOTE 4)
DROOP SHIM WASHERS
(CAUTION)
HUB
SPACER NUT RETAINING

PITCH BRACKET
BEARING (NOTE 5)
STRIKER NUT
COUNTERSUNK
PLATE HEAD SCREW
NOTE 2
PITCH BEARING HOUSING AND

NOTE 1 SPACER - INSTALLATION
0.4328 IN.
LEAD-LAG STOP (1.03872 MM)
DIA. MIN.
LEAD-LAG LINK AND STOP
CAUTION:
WASHERS ARE INSTALLED BETWEEN SPACERS AND STRIKER STRIP TO ESTABLISH
CORRECT STATIC DROOP ANGLE BETWEEN HOUSING AND HUB. EXACT NUMBER
REMOVED MUST BE REINSTALLED. THREE PITCH BEARING HOUSING BOLTS MUST EACH
HAVE SAME NUMBER (THICKNESS) OF WASHERS WHEN SHIMMING IS NECESSARY.
NOTES:
1. FOR REMOVAL, WOOD DOWEL PLACED HERE AND STRUCK SHARPLY WITH
HAMMER TO BREAK STOP BOND.
2. ALL STOP-TO-LINK SHADED CONTACT SURFACES BONDED WITH ADHESIVE.
3. THREADED SHANK LIGHTLY LUBRICATED WITH GREASE BEFORE INSTALLATION.
4. WET PRIMER ON WASHER AND MATING SURFACES BEFORE INSTALLATION.
5. NUT RETAINING BRACKET IS BONDED TO HUB.
G62-2060-802-1
Figure 802. Main Rotor Hub Components Repair and Installation
Page 803
MAINTENANCE MANUAL
(2). Using sharp-edge metal scraper, Do not disturb torque on lead-

carefully scrape any adhesive residue CAUTION lag bolts. Special adapter is
from link. If scraper penetrates through needed to retorque lead-lag bolts.
paint and chemical surface film, surface
must be refinished. Depth of gouges or (1). Remove and tag or color-code each set
nicks is limited to 0.010 inch (0.254 of balance hardware that is installed.
mm) maximum after rework. Rework
by smooth blending into surrounding (2). Remove corrosion with grade 180
area with grade 320 abrasive cloth abrasive cloth (CM802) and finish with
(CM802). Final polish with crocus cloth grade 400 abrasive cloth.
(CM803). Restore chemical film protec
tion (CM206). (3). Swab cleaned surface with MPK
(CM219) and apply unthinned primer
(3). Clean bond area of all contact surfaces
(CM318).
by wiping with cleaner (CM228).
Flush-wipe cleaned surface four times
with mixture of equal parts of distilled (4). Reinstall original balance hardware
water and isopropyl alcohol (CM217) to that was removed. Using sealant
remove all traces of phosphoric acid. (CM425), reseal balance hardware.
Rinse cleaned surface with tap water,
followed by a rinse of distilled water 5. Pitch Control Bearing Pivot Pin Repair or
until surface is ``water break'' free. Dry Replacement
for 30 minutes minimum at 150°F
(Ref. Figure 802) Minimum allowable pin di
(66°C).
ameter is 0.4328 inch (10.993 mm). Pivot pin
(4). Check fit of stop in link. Flange and grooving or excessive side wear can be pol
radius contact surfaces of stop must ished to original finish as long as minimum
mate with link within 0.010 inch (0.254 allowable pin diameter remains after rework.
mm). Maximum clearance between stop Replace any pin requiring more rework as fol
and inside surfaces of link ears is lows.
limited to 0.020 inch (0.508 mm). This
tolerance applies to both sides of stop. Consumable Materials
(5). Prepare mixture of epoxy adhesive
Item Nomenclature
(CM411). Apply uniform coating of
mixed adhesive to all contact surfaces. CM115 Grease, oscillating bearing
Hand press stop into place between link CM420 Sealant
ears until all mating surfaces are in
firm contact. Apply a clamping device
so that contact is maintained. Cure for (1). Remove pivot pin.
minimum of eight hours at room
temperature, or two hours at 150°F (2). Lightly lubricate shank of replacement
(66°C). pivot pin with grease (CM115).
4. Lead−Lag Bolt Corrosion Control NOTE: Torque pivot pin to 70—80 inch-
pounds (7.91—9.04 Nm), then use 0.002
Consumable Materials inch (0.0508 mm) feeler gage and check for
(Ref. Section 91−00−00) gap between pin flange and washer on
Item Nomenclature mounting lug surface. No gap is allowed.
(3). Install pivot pin in mounting lug with
CM318 Primer
washer. Torque pivot pin to 250—280
CM425 Sealing compound inch-pounds (28.25—31.64 Nm).
CM802 Abrasive cloth, aluminum oxide Apply sealant (CM420) at junctures of
pivot pin flange, washer and hub.
Page 804
MAINTENANCE MANUAL
6. Droop Stop Roller Repair or Replacement (3). Replace droop stop ring if repair limits
are exceeded.
(Ref. Figure 803)
Replace defective droop stop roller if clearance 8. Droop Stop Ring Replacement
between roller bearing liner and shaft is more
than 0.015 inch (0.381 mm). Roller shaft (Ref. Figure 803)
outside diameter must not be less than 0.4370 (1). With hub upside down, support hub so
inch (11.0998). that pitch housings unload droop stop
followers and provide maximum
Consumable Materials clearance between striker plates and
(Ref. Section 91−00−00) droop stop rollers.
Item Nomenclature
(2). If necessary, release retaining (snap)
ring of each droop stop restrainer from
its groove. Move retaining ring flush
(1). Move pitch control bearing housing out against droop stop follower (T-head) to
of the way that contacts lower shoe provide additional clearance and reduce
roller to be removed. spring tension.
NOTE: It can be easier if only one roller is re (3). Remove six droop stop rollers.
moved at one time. The opposing pitch hous
ing can be pressed against it's follower to (4). Starting from either scissors crank
force opposite follower out and expose roller attach lug, number, or color code, all six
shaft for removal. Same condition exists at droop stop follower assemblies in
installation. clockwise direction for location identifi
cation at replacement. This number
(2). Remove droop stop roller. code should be placed on outer, upper
(3). Wet down and clean plunger and end of plunger and on adjacent area of
mating shoe bushing with isopropyl lower shoe. Ensure codes are not
alcohol (CM217). accidentally removed during remaining
steps.
(4). Install roller, shaft and new cotter pin.
(5). Compress each droop stop follower and
(5). Install pitch control bearing housing. insert a small wedge from the back side
to hold follower away from droop ring.
7. Droop Stop Ring Repair
(Ref. Figure 803) (6). After all followers are compressed,
remove droop stop ring.
Consumable Materials When installing droop stop ring,
(Ref. Section 91−00−00) CAUTION droop stop followers T-Heads
Item Nomenclature must be offset away from lower shoe to pre
CM103 Solid film lubricant vent damage to lower shoe.
(7). Install replacement droop stop ring by
(1). Repair depth limit for corrosion, nicks reversing removal procedure, steps (1).
or scratches in droop stop ring is 0.007 thru (6)., making certain to reinstall
inch (0.1778 mm) for all surfaces except followers according to markings placed
outer edges of ring outer flanges where thereon prior to removal.
the depth limit is 0.030 inch (0.762
mm). All reworked areas must be (8). Compress follower spring and install
blended smoothly with 15 to 1 ratio into retaining (snap) ring, if removed, in its
surrounding area. groove on each follower.
(2). Spray repaired areas of rings with solid (9). Reinstall droop stop rollers, shafts and
film lubricant (CM103). cotter pins.
Page 805
MAINTENANCE MANUAL
LOWER SHOE
DROOP STOP
PINS FOLLOWER
(T-HEAD) (NOTE)
SNAP RING
COTTER PIN SPRING
DROOP STOP
ROLLER
DROOP STOP PLUNGER
SCISSORS CRANK
ATTACH LUG SHAFT
BEARING ROTATIONAL DRAG
1.0 - 2.0 IN-LBS
(0.113 - 0.226 NM) DROOP STOP FOLLOWER - INSTALLATION
DROOP STOP
RING 0.007 IN. (0.178 MM) MAX. DEPTH
(15 TO 1 RADIUS) AFTER REWORK
DROOP STOP FOLLOWER

ASSEMBLY (6 PLACES)
LOWER SHOE - INVERTED
0.030 IN. (0.762 MM)

MAX. AFTER REWORK
15 TO 1 RADIUS
DROOP STOP RING - REPAIR LIMITS
NOTE: DROOP STOP FOLLOWER T-HEADS TO

BE OFFSET AWAY FROM LOWER SHOE. 6G62-028C
Figure 803. Droop Stop Ring Replacement and Repair
Page 806
MAINTENANCE MANUAL
9. Droop Stop Follower Replacement (b). Wet install the pins.

(Ref. Figure 803) A pin that protrudes from the
CAUTION plunger will damage the sleeves
Replace a droop stop follower (T-head) if it is in the lower shoe and prevent plunger actu
worn, scored, or causes damage to the droop ation.
stop ring. After droop stop ring removal, the
droop stop follower assemblies can be removed (c). The pins must not protrude from
from hub. either side of the plunger.
(4). Install the stake ends.
Consumable Materials (a). No burrs or roughness are permitted
(Ref. Section 91−00−00) after staking.
Item Nomenclature
(5). Install the droop stop follower assembly
CM318 Primer in the hub.
(6). Install the droop stop ring (ref. Proce
dure 8. Droop Stop Ring Replacement).
A. Disassembly
10. Droop Stop Plunger Removal, Inspection
(1). Remove the droop stoop ring (ref. and Installation
Procedure 8. Droop Stop Ring Replace (Ref. Figure 803)
ment).
(2). Remove the droop stop follower assem Consumable Materials
bly from the hub. (Ref. Section 91−00−00)
Item Nomenclature
(3). Remove the pins that attach the
plunger to the follower (ref. View A). CM217 Isopropyl alcohol
B. Assembly
(1). Remove the droop stop ring (ref.
The follower must be offset
CAUTION away from the lower shoe to pre Procedure 8. Droop Stop Ring Replace
ment).
vent damage to the lower shoe from the
droop stop ring. (2). Examine the plunger for wear:
(1). Insert a new follower: (a). The minimum acceptable diameter
after wear-in service is 0.996 inch
(a). Apply CM318 primer to the mating (25.30 mm).
surfaces of the follower with the
plunger. (b). The acceptable wear through the
anodized coating cannot be more
(b). Wet install the follower in the than 2.1 inch2 (13.55 cm2) of the
plunger. total sliding surface area of the
cylinder.
(c). The follower must be at a right angle
to the roller shaft in the plunger. (c). The maximum wear condition can
exist in one spot or in several spots
(2). Drill two 0.156 to 0.158 inch (3.96 to over 2.1 inch2 (13.55 cm2) total.
4.01 mm) diameter holes through the (3). Clean the plunger and mating shoe
follower in line with the holes in the bushing with CM217 isopropyl alcohol.
plunger.
(4). Install droop stop plunger in the lower
(3). Insert the pins: shoe.
(a). Apply CM318 primer to the mating (5). Complete the droop stop ring installa
surfaces of the pins with the plunger tion (ref. Procedure 8. Droop Stop Ring
and follower. Replacement).
Page 807
62-20-60 TR18-002
MAINTENANCE MANUAL
(6). Install roller, shaft, and new cotter pin. 12. Main Rotor Hub Tapered Bearing Grease
Repack, Inspection and Replacement
11. Main Rotor Hub Droop Angle Adjustment
(Ref. Figure 805)
(Ref. Figure 802)
If static droop angle is more than six degrees, Consumable Materials
do this adjustment: (Ref. Section 91−00−00)
(1). Remove the main rotor blade (ref. Item Nomenclature
62-10-00, Removal and Installation, CM111 Grease, aircraft
Procedure 2.A. Main Rotor Blade CM121 Preservation oil
Removal).
(2). Use flat washers of the necessary CM802 Abrasive cloth, aluminum oxide
thickness to adjust the spacing between
CM803 Crocus cloth
the spacer and striker strip.
NOTE: One type, or a combination of, correct Special Tools
part number washers (ref. CSP-IPC-4) can (Ref. Section 91-00-00)
be used. However, an identical washer selec Item Nomenclature
tion must be installed on each of the three
ST701 Main rotor wrench assembly
bolts that attach the pitch control bearing
assembly to the pitch housing.
(3). Remove nuts, washers, and bolts. Do not intermix Timken or NTN
CAUTION bearing cups and cones at the
(4). Separate the spacer from the striker upper and lower tapered roller bearing loca
strip. tions of the main rotor hub.
NOTE: The use of one 0.016 inch (0.41 mm) NOTE:
washer raises the static droop angle approx
imately one-half degree. D Always replace roller bearing cones and
cups as a set.
(5). Add sufficient washers to adjust the
droop angle 5.0 to 6.05. D Replace a tapered roller bearing cup and
cone if there are flat spots, scoring, pit
(6). Install nuts, washers, and bolts. ting, grooving, discoloration (blue), or if it
feels rough when turned.
(7). If more than 0.063 inch (1.60 mm)
spacing is necessary (above factory (1). Use press tools equivalent to items A
spacing), examine the striker plate and and B (ref. Figure 804) to press the
droop stop roller or follower and droop upper and lower bearing cups from hub.
stop ring for too much wear.
(a). Replace worn parts. NOTE: A press ram of one to two tons is suffi
cient for removal.
(8). Install the main rotor blade (ref.
62-10-00, Removal and Installation, (2). Press lower bearing cone from sleeve
Procedure 2.B. Main Rotor Blade bushing.
Installation).
In next step, do not spin reus
(9). Measure the static droop angle again. CAUTION able bearings while cleaning.
(10). As necessary, repeat steps (1). thru (8). Coat bearings lightly with CM121 preserva
for the remaining blades. tion oil after cleaning.
(11). After installation of parts, track the (3). Clean hub bore, sleeve bushing, seal
main rotor blades (ref. 18-10-00, retainer, and reusable bearings with
Adjustment and Test, Procedure 1. filtered CM234 dry-cleaning solvent
Blade Tracking Procedure). spray.
Page 808
TR18-002 62-20-60
MAINTENANCE MANUAL
2.875 IN. (7.3025 CM)

OUTSIDE DIAMETER
CUT OUT AFTER 0.50 IN.
BEVELING (12.7 MM)
3.50 IN. (8.89 CM)

OUTSIDE DIAMETER
3.875 IN.
(9.8425 CM) 11.0 IN.
53 (27.94 CM)
°
5.75 IN.
3.375 IN. (14.605 CM)
0.375 IN. (8.5725 CM)
(9.525 MM)
0.1875 IN. (4.7625 MM) 0.203125 IN. (5.159375 MM)

4130 STEEL PLATE WALL STEEL PIPE WALL STEEL PIPE
A B C
4.40 IN. 4.30 IN.

(11.176 CM) (10.922 CM)
2.58 IN. 0.30 IN.
(6.5532 CM) (7.62 MM)
3.50 IN.
(8.89 CM)
2.0 IN. 2.0 IN.
(5.08 CM) (5.08 CM)
ALUMINUM ALLOY ALUMINUM ALLOY STEEL RING WASHER
D E F
TOOL USE:
A & B - PRESS BEARING CUPS OUT OF HUB

C - PRESS LOWER BEARING CONE ON SLEEVE BUSHING
D - PRESS UPPER BEARING CUP INTO HUB
E - PRESS LOWER BEARING CUP ONTO HUB
F - IN PLACE OF UPPER SEAL RETAINER WHILE ADJUSTING ROTATIONAL DRAG
G - HUB BEARING REMOVAL - FABRICATION
G62-2010-1
Page 809
MAINTENANCE MANUAL
7.0 INCH (17.78 CM)

SQUARED
4.75 INCH
(12.065 CM)
10.0 INCH (25.40 CM)

0.75 INCH SQUARED
MATERIAL: WOOD (19.05 MM) H62-2010-2A
(4). Examine the bearing cup hub bore for Bearing cups are installed in
scoring: WARNING hub by differential tempera
ture (shrink-fit) method. Take the ap
plicable precautions to prevent burns
(a). Smooth out roughness with grade handling parts that are cooled to sub-
400-600 CM802 abrasive cloth. zero temperatures.
(6). Put the bearing cups in a container of

(b). Restore chemical film protection dry ice.
where removed.
(a). Close the container.
(c). The hub bore for the upper bearing (b). Let the bearing cups cool to -40F
cup (ref. Figure 805) must have a (-40C) for 20 minutes minimum.
4.4335 inch (112.611 mm) maxi
mum diameter. (7). Coat the bores of the hub with CM111
grease.
(d). The hub bore for the lower bearing (8). Carefully keep the cup-to-hub bore
cup must have a 4.3095 inch alignment as the cup is pressed into the
(109.461 mm) maximum diameter. bore with tools D and E until cup is
installed (ref. Figure 804).
(5). Examine the upper seal retainer:
(9). Apply a film of CM111 grease to the
sleeve bushing.
(a). No cracks, sharp nicks, or burrs are
permitted. (a). Press the bearing cone on the sleeve
bushing with a press tool equivalent
to Tool C.
(b). Polish out minor corrosion or other
surface defects with CM803 crocus (10). With the lip on the center seal up, hand
cloth. press it in the hub (ref. Figure 805).
(11). Apply a film of CM111 grease on mast.

(c). The seal contact surfaces cannot have
a groove deeper than 0.004 inch (12). Install the assembled sleeve bearing
(0.10 mm) after the polish. and bearing cone on mast.
Page 810
TR18-002 62-20-60
MAINTENANCE MANUAL
SEAL DROOP SHIM WASHER

(NOTE 4) (NOTE 6)
SEAL RETAINER HUB STRIKER
STRIP
PIVOT PIN SEALANT PITCH
UPPER BEARING CONE (NOTE 2) HOUSING
(NOTE 7)
NOTE 1
UPPER BEARING CUP
(NOTE 7)
(NOTE 5)
SEAL PITCH
(NOTE 4) BEARING
SLEEVE
RECESSED BUSHING
SPACER
(NOTE 3) SEALANT STRAP
(NOTE 2) PACKS
LOWER SHOE
NOTE 5
DROOP STOP RING STRAP

NOTE 8 ASSEMBLY
SPRING NOTE 1
HUB OUTER LINER ROLLER SPACER
LOWER BEARING CONE RETAINING ASSEMBLY
SEAL
(NOTE 4) (NOTE 7) CLIP FOLLOWER PITCH CONTROL
ASSEMBLY BEARING HOUSING
LOWER BEARING CUP
(NOTE 7)
BUSHING LEAD-LAG PIVOT BOLT
PITCH HOUSING SEALANT

BEARING (NOTE 2)
(NOTE 1)
LEAD-LAG LINKS
SHIM
STRAP ASSEMBLY BUSHING

COTTER PIN
NUT
NOTES:
1. HEAVY LINES INDICATE REINFORCED TEFLON BEARING LININGS (TYPICAL).
2. SEALANT APPLIED TO LOCATIONS SHOWN.
3. RECESSED SPACER SPECIALLY GROUND TO ESTABLISH CORRECT ROTATIONAL
DRAG ON TAPERED BEARINGS. INSTALL RECESS DOWN ON TOP OF SLEEVE BUSHING.
4. SEAL TO BE UPWARD.
5. BEARING AND CAVITY TO BE FILLED WITH GREASE.
6. DROOP SHIM WASHERS ARE INSTALLED, AS REQUIRED, TO OBTAIN PROPER
ROTOR DROOP ANGLE.
7. DO NOT INTERMIX TIMKEN AND NTN BEARING CUPS AND CONES AT UPPER AND
LOWER TAPERED BEARING LOCATIONS.
8. DROOP STOP FOLLOWER T-HEAD TO BE OFFSET AWAY FROM LOWER SHOE.
G62-2060-805-1
Figure 805. Cross Section of the Main Rotor Hub Assembly
Page 811
62-20-60 TR18-002
MAINTENANCE MANUAL
(a). Do not apply additional lubricant to (a). Install subsequently thinner spacers,
roller bearing set. from kit K-600N-1200A, starting
with a thick spacer, along with cone,
(b). Clean the unwanted preservative oil substitute washer for retainer and
from the bearing cone and cup. locknut.
(b). Torque nut 200 to 250 foot-pound
If hub assembly does not install
CAUTION correctly on the mast, do not to (271 to 339 Nm) until there is 10 to
15 inch-pound (1.13 to 1.69 Nm)
force it in position. Remove the hub assem of rotational drag (not break-
bly from the mast, find the cause, correct the away torque) on the hub.
problem, and do the installation procedures.
(19). When the correct torque has been
(13). Place assembled hub over mast and gotten, disassemble, and remove the
seat on lower roller bearing cone. steel ring washer.
(20). Alternative method to find the neces
(14). Install upper bearing cone into hub. sary thickness for the spacer:
NOTE: Use of a substitute steel ring washer for (a). Install 369A1224-5 lead spacer in
the retainer prevents unnecessary scoring place of the 369A1224-3 spacer.
of the retainer. Tighten and loosen several
(b). Place a steel ring washer for the
times as necessary to get the rotational drag
retainer and locknut on the mast.
on the hub bearings.
(c). Gradually tighten the retainer nut
(15). Install steel ring washer, equivalent to until there is a rolling torque of 10 to
Tool F (ref. Figure 804), as a substitute 15 inch-pound (1.13 to 1.69 Nm)
for the seal retainer (ref. Figure 805). of rotational drag (not break-
away torque) on hub.
(16). Install the mast nut on mast with
(d). If the rotational drag is more than 10
ST701 mast nut wrench.
to 15 inch-pound (1.13 to 1.69
Nm), discard the lead washer and
(a). Tighten the mast nut until the
install a new washer and continue.
bearings are preloaded to 10 to 12
inch-pound (1.13 to 1.36 Nm) of (e). When correct torque has been
rotational drag. reached, disassemble, and measure
thickness of the lead washer in the
(b). Measure the rotational drag with 0 bearing seat area.
to 10 pound (0 to 4.5 kg) spring
scale hooked over one of hub support 1). Grind the 369A1224-3 spacer to
web bosses, 6.5 inch (16.51 cm) the same thickness as measured on
from hub centerline). the lead washer.
2). Make sure the thickness of the
(c). A 1.50 to 1.75 pound (0.681 to ground washers at six locations do
0.795 kg) pull with the hub in not change by more than 0.0005
motion is an indication of correct inch (0.013 mm).
rotational drag.
(f). Assemble with the ground steel
(17). Remove the locknut, washer, and cone. washer, steel ring washer, and
locknut.
(18). To find the thickness necessary for (g). Torque the locknut 200 to 250
spacer: foot-pound (271 to 339 Nm) until
there is 10 to 15 inch-pound (1.13
NOTE: To find the correct spacer thickness, to 1.69 Nm) of rotational drag
start with a thick spacer and work down to a (not break-away torque) on the
thinner spacer. hub.
Page 812
TR18-002 62-20-60
MAINTENANCE MANUAL
(21). Remove hub and sleeve bushing with (2). Put the main rotor hub assembly on a
lower bearing cone from mast. workbench.
(22). Position the hub upside-down. (3). Remove upper bearing cone.
(a). Hand-pack the lower hub cavity (ref. Do not intermix Timken or NTN
CAUTION bearing cups and cones at upper
Figure 805) and bearing cone on
sleeve bushing with CM111 grease. and lower tapered roller bearing locations of
main rotor hub.
(23). Install the sleeve bushing with the
bearing cone in the hub. NOTE:
D Roller bearing cones and cups should al
(a). Hand-pack the cavity between the ways be replaced as a set.
bearing and hub liner with CM111
grease. D Replace tapered roller bearing cup and
cone if it has any flat spots, scoring, pit
(b). Then press in the lower seal with the ting, grooving, discoloration (blue) or if it
seal lip toward the top of hub. feels rough when rotated.
(c). Clean off unwanted grease. (4). Use pressing tools equivalent to items
A and B (ref. Figure 804) to press upper
(24). Turn the hub assembly right side up. bearing cup from hub. A press ram of
one to two tons is sufficient for removal.
(25). Install the recessed spacer, upper
bearing cone, upper seal, and seal In next step, do not spin reus
retainer in the hub during installation CAUTION able bearing while cleaning.
of the hub on the mast. Coat bearings lightly with CM121 oil after
cleaning.
13. Main Rotor Hub Upper Bearing Grease
Repack, Inspection and Replacement (5). Clean hub bore, sleeve bushing, seal
retainer and reusable bearing with
This procedure is for greasing, inspection, filtered CM234 solvent spray.
and replacement of the main rotor hub upper
bearing only. (6). Examine the bearing cup hub bore for
scoring:
(a). Smooth out roughness with 400 to
600 grade CM802 abrasive cloth.
Item Nomenclature
CM111 Grease, aircraft (b). Restore the chemical film protection
CM204 Compound, corrosion preventative where removed.
CM121 Preservation oil (c). The maximum diameter of the hub
CM234 Solvent, dry-cleaning bore for the upper bearing cup is
CM702 Lockwire CRES 4.4335 inch (112.611 mm) (ref.
CM802 Abrasive cloth, aluminum oxide Figure 805).
(7). Examine the upper seal retainer:
Special Tools
(Ref. Section 91-00-00) (a). No cracks, sharp nicks, or burrs are
Item Nomenclature permitted.
ST701 Main rotor wrench assembly (b). Minor corrosion or other surface
ST703 Main rotor hub driver defects can be polished out with
CM803 crocus cloth.
(1). Remove the main rotor hub assembly (c). Grooves on the seal contact surfaces
(ref. 62-20-60, Procedure 2.A. Main cannot be more than 0.004 inch
Rotor Hub Removal). (0.10 mm) deep after polishing.
Page 813
62-20-60 TR18-002
MAINTENANCE MANUAL
Bearing cups are installed in NOTE: Use of substitute steel ring washer for
WARNING hub by differential tempera retainer prevents unnecessary scoring of
ture (shrink-fit) method. Take appro the retainer. Tighten and loosen actions as
priate precautions to prevent burns necessary to get rotational drag on hub
when handling parts that are cooled to bearings.
sub-zero temperatures.
(19). Install a steel ring washer, equivalent
(8). Put the bearing cup in a container of to Tool F (ref. Figure 804), as substitute
dry ice. for seal retainer (ref. Figure 805)
(20). Install mast nut on mast with ST701
(a). Close the container. mast nut wrench.
(b). Let the bearing cups cool to -40F (a). Tighten until the bearings are
(-40C) for 20 minutes minimum. preloaded to 10 to 12 inch-pound
(1.13 to 1.36 Nm) of rotational
(9). Coat the bore of the hub with CM111 drag.
grease.
(b). Measure rotational drag with 0 to
(10). Carefully keep the cup-to-hub bore 10 pound (0 to 4.536 kg) spring
alignment as the cup is pressed into the scale hooked over one of hub support
bore with tools D and E until cup is web bosses, 6.5 inch (16.5 cm) from
installed (ref. Figure 804). hub centerline).
If hub assembly does not cor (c). A 1.50 to 1.75 pound (0.681 to
CAUTION rectly install on the mast, do not 0.795 kg) pull with the hub in
attempt to force it into position. Remove the motion is an indication of correct
hub assembly from mast and find the cause rotational drag.
of interference, correct the problem, and fol (21). Remove the locknut, washer, and cone.
low the installation procedures.
(22). To find the thickness necessary for the
(11). Make sure that the rotor mast is clean. spacer:
(12). Hoist the main rotor hub in position NOTE: During the procedure to find the spacer
over the mast. thickness, start with a thick spacer and
work down to thinner spacer.
(13). Lower the hub on the mast. (a). Install thinner and thinner spacers,
from kit K-600N-1200A.
NOTE: To inhibit mast corrosion during opera
tion in a salt water environment, lightly 1). Start with a thick spacer, along
coat the bearing journals of the mast with with cone, steel ring washer for
CM111 grease. retainer and locknut.
(14). Remove the adapter, hoist, and eye- (b). Torque nut 200 to 250 foot-pound
bolts. (271 to 339 Nm) until there is 10 to
15 inch-pound (1.13 to 1.69 Nm)
(15). Make sure that the hub is fully in of rotational drag (not break-
stalled on the mast. away torque) on the hub.
(16). Hand-pack the hub cavity, between the (23). When the correct torque has been
sleeve bushing and hub, with CM111 reached, disassemble, and remove steel
grease. ring washer.
(24). Alternative method to find the neces
(17). Apply a thin layer of CM111 grease on sary spacer thickness:
the upper bearing cone.
(a). Install 369A1224-5 lead spacer in
(18). Put the upper bearing cone in hub. place of the 369A1224-3 spacer.
Page 814
TR18-002 62-20-60
MAINTENANCE MANUAL
(b). Place a steel ring washer, instead of a 2). Make sure the thickness of the
retainer, and a locknut on the mast. ground washers at six locations do
not change by more than 0.0005
1). Gradually tighten the retainer nut inch (0.013 mm).
until you get a rolling torque of 10
to 15 inch-pound (1.13 to 1.69
Nm) of rotational drag (not (d). Assemble with the ground steel
break-away torque) on hub. washer, steel ring washer, and
locknut.
2). If the rotational drag is more than
10 to 15 inch-pound (1.13 to
1.69 Nm), discard the lead washer, (e). Torque the locknut 200 to 250
install a new washer, and continue. foot-pound (271 to 339 Nm) until
there is 10 to 15 inch-pound (1.13
(c). When you get the correct torque, to 1.69 Nm) of rotational drag
disassemble, and measure thickness (not break-away torque) on the
of the lead washer in the bearing seat hub.
area.
1). Grind the 369A1224-3 spacer to (25). Install the main rotor hub assembly
the same thickness as measured on (ref. 62-20-60, Procedure 2.B. Main
the lead washer. Rotor Hub Installation).
Page 815
62-20-60 TR18-002
MAINTENANCE MANUAL
14. Main Rotor Hub Scissors Attach Lug Do no let the surface primer get
Bearing Replacement CAUTION in the bearing. Damage to the
bearing will occur.
(9). Apply CM321 surface primer to the
mating surfaces of the bearing and bore
Item Nomenclature
(ref. manufacturer instructions).
CM216 Loctite remover (10). Apply CM431 locking compound to the
CM304 Enamel, epoxy mating surfaces of the bearing and
CM321 Surface primer locking compound bore.
(11). Wet install the bearing in the bore with
a press.
(1). Remove the main rotor hub assembly
(ref. 62-20-60, Procedure 2.A. Main (12). Remove unwanted sealant, do not allow
Rotor Hub Removal). sealant to enter the bearing.
(2). Invert the hub and place it on a (13). Apply a small fillet of sealant around
workbench. bearing.
(3). Remove the droop stop ring (ref. (a). Dry for 24 hours at room tempera
Procedure 8. Droop Stop Ring Replace ture or heat to 140 to 160F (60 to
ment). 72C) for one hour.
(4). Press the bearing from the hub lug.
(14). As necessary, touch up the bearing lug
(5). Clean the bearing bore with CM216 with CM304 paint.
Loctite remover.
(15). Do a check of the bearing for a no-load
(6). Examine the bearing bore for nicks, rotational drag of 1.0 of 2.0 inch-
scratches, and grooves. pound (0.11 to 0.23 Nm).
(7). Measure the bore diameter. (16). Install the droop stop ring (ref. Proce
(a). The diameter must be 0.6551 to dure 8. Droop Stop Ring Replacement).
0.6556 inch (16.64 to 16.65 mm).
(17). Install the main rotor hub assembly
(8). Touch up the bearing bore with CM206 (ref. 62-20-60, Procedure 2.B. Main
chemical coating. Rotor Hub Installation).
Page 816
TR18-002 62-20-60
MAINTENANCE MANUAL
Section
62−30−00
Swashplate and
Mixer (369D/E/FF −
500N)
MAINTENANCE MANUAL
SWASHPLATE AND MIXER

1. Main Rotor Swashplate B. Swashplate Installation
(Ref. Figure 403) The main rotor swashplate (1). If swashplate lower boot was removed,
includes a rotating swashplate, stationary install boot on mast (Ref. Figure 403).
swashplate, bearing and retainer and two
counterweights. (2). Position swashplate over main rotor
mast and carefully lower into place.
2. Swashplate Replacement (3). Engage upper end of boot in groove at
A. Swashplate Removal lower side of stationary swashplate.
Secure boot with self-clinching nylon
(1). Tag or color-identify five pitch control strap (Ref. Figure 403).
rods (Ref. Figure 401) to simplify
(4). Align longitudinal link with stationary
replacement at same locations.
swashplate (Ref. Figure 402).
Failure to reinstall pitch control
CAUTION rods at correct locations prob
(5). Install flanged bushing, if removed,
bolt, two washers, nut and cotter pin to
ably will result in main rotor blades exces
secure upper end of longitudinal link.
sively out of track.
(6). Align upper ends of mixer links with
(2). Disconnect pitch control rods from stationary swashplate. Install slotted
rotating swashplate. bushing (if removed), bolt, two washers,
(3). Remove scissors. nut and cotter pin to secure each link to
swashplate.
(4). Remove main rotor hub.
(7). Install scissors.
(5). Disconnect longitudinal link (Ref. (8). Using color code, reinstall pitch control
Figure 402) from stationary swash rods at same locations from which
plate. removed.
(6). Disconnect right and left side mixer (9). Check track of main rotor blades (Ref.
links (Ref. Figure 402) from stationary Chapter 18) following any maintenance
swashplate. activity that could result in a dimen
(7). Remove protective boot from groove in sional variation affecting rigging or
lower side of stationary swashplate tracking.
(Ref. Figure 403).
3. Mixer Controls
Do not strike rotating swash
CAUTION plate or bearing assembly (Ref.
Mixer controls consist of various links,
bellcranks, idlers, support bracket and
Figure 403) with tools or in any way deface associated fasteners that secure these compo
these components. Rotating swashplate is a nents in place and to the control rods and main
stressed part; all surfaces are shot peened. rotor swashplate.
Use particular care to protect teflon liner in
bearing bore. A damaged swashplate bear 4. Mixer Controls Replacement
ing must not be retained in service.
A. Mixer Controls Removal
(8). Lift swashplate carefully up and off of
mast. (Ref. Figure 402)
(9). To remove boot from mast, remove (1). Remove air intake forward fairing for
self-clinching nylon strap. access.
Page 401
MAINTENANCE MANUAL
ROTOR HUB CLOSE TOLERANCE 6.25 IN.

LOWER SHOE BOLT (15.875 CM)
WASHERS SCISSORS CRANK

(NOTE 4) PITCH CONTROL ROD - LENGTH
SLOTTED BUSHING
(NOTE 3)
(NOTE 1) MAXIMUM ALLOWABLE LOOSENESS
0.040 IN. (1.016 MM)
AT INSTALLATION, ROD ENDS
TO BE PARALLEL WITH
MATING CLEVIS
BEARING 1.30 IN. (3.302 CM) TYPICAL

(UPPER BEARING ONLY)
WASHERS
(NOTE 4)
BUSHING ELASTOMER RING
ELASTOMER RING (NOTE 6)
(NOTE 6)
SCISSORS LINK
BEARING PITCH CONTROL ROD

(NOTE 2)
ELASTOMER RING
SLOTTED BUSHING (NOTE 6)
(NOTE 1)
ELASTOMER RING
(NOTE 5)
ROTATING
SWASHPLATE
INTERRUPTER
SLOTTED BUSHING
COLLECTIVE PITCH (NOTE 1)
CONTROL ROD
LONGITUDINAL PITCH
CONTROL ROD
SLOTTED BUSHING
(NOTE 1)
LATERAL PITCH
CONTROL ROD NOTES:
1. END OF SLOTTED BUSHING MUST PROTRUDE MINIMUM OF
0.010 IN. (0.254 MM) TO MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE
OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.
2. COLOR CODED TO MATCH BLADE.
3. OPTIMUM INITIAL SETTING (FIVE PLACES).
4. AS REQUIRED TO FILL GAP.
5. THIS SIDE ONLY ON EARLY CONFIGURATION.
6. BOTH SIDES ON CURRENT CONFIGURATION.
G62-3000D
Figure 401. Pitch Control Rods and Swashplate Scissors − Installation
Page 402
MAINTENANCE MANUAL
(2). Disconnect upper ends of collective support bracket and bore in mast base
mixer, lateral mixer and longitudinal lug is 0.015 inch (0.381 mm) or less.
mixer control rods (Ref. Figure 401).
NOTE: If necessary, loosen aft two bracket-to-
NOTE: Control rods are attached by slightly fitting nuts, position support bracket to
different length bolts. Reinstall each bolt in minimize misalignment and retighten nuts.
its bellcrank following control rod removal
to simplify reinstallation at correct loca (4). Install mixer support attaching bushing
tions. in bracket and mast base lug.
(3). Remove mixer links. (Mixer link (5). Check that sleeve bushing is in place;
bearings are not replaceable.) then install bolt, two washers and nut.
Torque nut to 80—100 inch-pounds
(4). Disconnect longitudinal link from (9.04—11.30 Nm).
stationary swashplate.
(6). Position longitudinal pitch idler and
(5). Remove longitudinal control mixer link. collective pitch mixer bellcrank on
support bracket. Position washer
(6). Disconnect lateral bellcrank from between right side of longitudinal pitch
collective pitch mixer bellcrank. idler bearing and center bearing of
mixer support bracket. Install left-
(7). Remove connecting hardware (includ hand bearing, with attaching hardware.
ing flanged bushing) from each side of
longitudinal pitch mixer bellcrank. (7). Position lateral bellcrank between
Carefully remove bellcrank. Retain any collective pitch mixer bellcrank bear
shims that can be installed. ings and install attaching hardware.
(8). Remove bolt from hingeline of support (8). Position longitudinal pitch mixer
bracket, longitudinal pitch idler and bellcrank with collective pitch mixer
collective pitch mixer bellcrank. bellcrank; insert two flanged bushings.
Separate the three parts. Install two bolts.
(9). Remove mixer support bracket from (9). Push longitudinal bellcrank to one side
mast base. and measure gap between bellcrank
and bearings in collective pitch bell
To prevent washing dirt into crank.
CAUTION bearings, or washing grease out
of bearings, do not permit solvent to enter (10). Using HS5079-2646 laminated wash
bearings when cleaning mixer control com er(s), shim evenly to take up gap.
ponents.
(11). Insert flanged bushings, bolts, six
B. Mixer Controls Installation washers (two under each nut) shims
and nuts. Torque nut to 30—40 inch-
(Ref. Figure 402) pounds (3.39—4.52 Nm) and install
cotter pin.
(1). Position support bracket over forward
lug on mast base. (12). Position longitudinal control mixer link
between longitudinal pitch idler and
(2). Install two aft bolts and washers in longitudinal pitch mixer bellcrank;
support bracket and mast base. Install check that two slotted bushings are in
two thin washers and nuts; torque nuts place. Install bolt, three washers (two
to 80—100 inch-pounds (9.04—11.30 under each nut), nut and cotter pin at
Nm) above drag torque. each end of link.
(3). Using ball hole gage and standard (13). Position longitudinal link between
micrometer, check that misalignment longitudinal pitch mixer bellcrank
between forward bolt hole bore in bearings. Install attaching hardware.
Page 403
MAINTENANCE MANUAL
LONGITUDINAL LONGITUDINAL
BUSHING PITCH IDLER CONTROL MIXER LINK
(NOTE 2)
MIXER LINK
*LATERAL MIXER STATIONARY
BELLCRANK SWASHPLATE BUSHING
(NOTE 2) STATIONARY
SWASHPLATE
BEARING BUSHING FLANGED

(NOTE 2) BUSHING
WASHER
MIXER BEARING
LINK
MIXER LONGITUDINAL
SUPPORT LINK (NOTE 3)
ATTACHING BEARING
MIXER
BUSHING SUPPORT
(NOTE 6) BRACKET BUSHING
FLANGED NOTE 1
BUSHING (NOTE 2)
(NOTE 4)
NOTE 1
BEARING
*COLLECTIVE
PITCH MIXER
BEARING BELLCRANK
BEARING
NOTE 7
BEARING
SLEEVE FLANGED
BUSHING BUSHING *LONGITUDINAL
(NOTE 4) PITCH MIXER
NOTE 1
BELLCRANK
2 PL
MAST
BASE
NOTES:
1. DIRECTION OF BOLT OPTIONAL.
2. EDGE OF BUSHING MUST PROTRUDE MINIMUM OF 0.010 IN. (0.254 MM) TO MAXIMUM OF
0.060 IN. (1.524 MM) ABOVE OUTSIDE OF PART AFTER NUT IS TIGHTENED.
3. LONGITUDINAL LINK DETAILS ROTATED FOR CLARITY.
4. MUST BE PULLED OUT FIRST TO REMOVE BELLCRANK.
5. ASTERISK ( * ) INDICATES PART THAT MAY BE EITHER MAGNESIUM OR ALUMINUM ALLOY.
(FOR ALLOY IDENTIFICATION AND CORROSION CONTROL, REF. SEC. 20-40-00).
6. INSTALL BUSHING AFTER THE TWO AFT ATTACHING BOLTS WITHOUT EXCESSIVE
MISALIGNMENT, 0.015 IN. (0.381 MM).
7. USING HS5079-2646 SHIMS, SHIM EQUALLY TO REMOVE GAP.
G62−3003C
Figure 402. Mixer Controls − Assembly
Page 404
MAINTENANCE MANUAL
(14). Position mixer links in stationary Scissors crank must be posi

swashplate and lateral bellcrank; check CAUTION tioned (Ref. Figure 401) with de
that slotted bushings are in place. cal up and proper direction towards lower
Install attaching hardware. side lugs.
(15). Place collective mixer, lateral mixer NOTE: Ensure crank-to-hub lower shoe lugs
longitudinal mixer control rods (Ref. are not preloaded.
Figure 401) in mounting position; check
that slotted bushing in place. Install (3). Position scissors crank on hub lower
attaching hardware. shoe lugs; install connecting hardware
(Ref. Figure 401). Torque nuts to
(16). Install air intake forward fairing. 30—60 inch-pounds (3.39—6.78
Nm); install cotter pin.
(17). Check rigging of collective and cyclic
controls. NOTE: Shim washers can be required on shoul
dered bushing side of clevis.
5. Scissors
(4). Position elastomer rings and lower end
The scissors provide a movable connection of pitch control rod in swashplate lug
between the rotating swashplate and main and install attaching hardware. (Nut is
rotor hub. to be adjacent to bushing in swash
plate.) Torque nut to 30—60 inch-
6. Scissors Replacement pounds (3.39—6.78 Nm).
A. Scissors Removal 7. Scissors Link Replacement
(Ref. Figure 401)
Removal of all pitch control rods (Ref. Section 91−00−00)
CAUTION is recommended prior to scissors
Item Nomenclature
removal. Failure to observe this precaution
could result in damage to pitch control rods, CM103 Solid film lubricant
swashplate and/or hub.
(1). Disconnect lower end of pitch control (1). Remove cotter pin, nut, washer and bolt
rod that is in line with scissors link in that join link and crank.
rotating swashplate. (2). Remove two bushings from link only if
(2). Remove cotter pin, nut, washer, and replacement is necessary.
bolt from each leg of scissors crank.
(3). Do not remove bearing from link,
Disconnect crank from hub lower shoe.
replace complete link if bearing is
(3). Remove cotter pin, nut, washer, and defective.
bolt connecting scissors link to swash
plate; remove scissors.
NOTE: Install new bushings using solid film lu
bricant (CM103); do not use zinc chro
B. Scissors Installation mate.
(Ref. Figure 401) (4). If bushings were removed at disassem

bly, install new bushings. After installa
(1). Place scissors link in mounting posi tion, dimension between outer faces of
tion, chamfered edge of link must face bushings should be 1.579—1.586
outboard. inches (4.0107—4.0284 cm).
(2). Check that slotted bushing is in (5). Align bore of link with bore of crank;
swashplate web and install attaching install bolt, washer and nut. Torque nut
hardware. Torque nut to 15—20 to 30—40 inch-pounds (3.39—4.52
inch-pounds (1.69—2.26 Nm). Nm), install cotter pin.
Page 405
MAINTENANCE MANUAL
8. Pitch Control Rods NOTE: Bushing must project 0.010-0.060 inch

(0.254-1.524 mm) after nut is torqued.
Five pitch control rods transfer pitch control
from the rotating swashplate to the main rotor (4). Torque lower nut to 30—60 inch-
blades. pounds (3.39—6.78 Nm).
(5). Secure nuts with cotter pins.
9. Pitch Control Rod Replacement
(6). Rotate pitch change rod assembly fore
A. Pitch Control Rod Removal and aft to ensure clearance exists
between rod end bearing and pitch
(Ref. Figure 401) housing clevis at both ends.
NOTE: (7). If installation is final and tracking is
D If rod is not to be reinstalled, but is to be not required, safetywire rod ends to rod;
replaced, measure and record length of ensure rod ends are centered.
removed rod. Optimum length can have (8). As necessary, repeat above procedures
been changed at previous rigging; pre-ad for remaining pitch control rods.
just replacement rod to length of rod re
moved. 10. Counterweight and Interrupter Installation
D Rods are color coded for reinstallation at
correct locations. If more than one rod is Consumable Materials
being removed and color coding is not vis (Ref. Section 91−00−00)
ible, identify each by color or similar Item Nomenclature
means to points of connection to simplify CM111 Grease, aircraft
reinstallation. CM409 Adhesive, epoxy
(1). Remove cotter pin, nut, washer and bolt

from each end of pitch control rod. NOTE: If counterweights are to be added, one
thick and one thin (any position) is recom
(2). Remove pitch control rod and O-ring. mended for ease of balancing; Hub must be
re-balanced.
B. Pitch Control Rod Installation
(1). Apply coat of adhesive (CM409) to
(Ref. Figure 401) counterweight OD. Reinstall weight
with smaller hole outboard, using
At installation, install rod at dummy bolt to align weight to rotating
CAUTION correct color code location. Cen swashplate. Remove bolt and allow
ter bearing rodends between attach clevis. If adhesive to cure according to container
rod length is changed, blades must be instructions.
tracked.
NOTE: Ensure interrupters are installed with
(1). If actual rod length is incorrect or same type and number of washers removed
either actual or required rod length is at disassembly, and that correct part num
unknown, preset rod length to optimum ber interrupter is installed in each swash
length of 6.25 inches (15.875 cm). plate arm. (Ref. CSP-IPC-4 for correct part
numbers and corresponding locations).
NOTE: Install both pitch change rod bolts in
direction of rotation. (2). Install interrupters, beveled edges
inboard, with bolts, washers, nuts and
(2). Install rod with elastomeric rings on new cotter pins. Coat bolts with grease
both sides of upper bearing and lower (CM111) prior to installation. Torque
bearing. nuts to 30—60 inch-pounds
(3.39—6.79 Nm).
NOTE: Add washers as required to align nut
with cotter pin hole. (3). Install interrupters using bolts,
washers and nuts; torque nuts to
(3). Torque upper nut to 100—130 inch- 15—20 inch-pounds (1.69—2.26
pounds (11.30—14.69 Nm). Nm).
Page 406
MAINTENANCE MANUAL
COUNTERWEIGHT
NOTE 2 BEARING
ASSEMBLY
INTERRUPTER
(NOTE 3) DOUBLE
INTERRUPTER
COUNTERWEIGHT (NOTE 4)
ROTATING
SWASHPLATE
NOTE 2
INTERRUPTER SPACER INTERRUPTER

(NOTE 3) (NOTE 4)
INTERRUPTER
(NOTE 4)
STATIONARY
SWASHPLATE
DRAIN HOLES
(HIDDEN)
INDEX
PROTRUSIONS
STATIONARY
SWASHPLATE
GROOVE
DRAIN HOLES
(2 PL)
BOOT
NYLON STRAP
NOTES:
1. COLOR CODED TO MATCH BLADES.
MAST 2. IF COUNTERWEIGHTS ARE USED, COAT BOLT WITH
GREASE (CM116) BEFORE INSTALLATION.
BOOT INSTALLATION 4. TORQUE NUT TO 15-20 IN. LBS (1.69-2.26 NM).
G62−3001B
Figure 403. Main Rotor Swashplate
Page 407
MAINTENANCE MANUAL
Page 408
MAINTENANCE MANUAL

INSPECTION/CHECK
1. Swashplate Inspection (a). Maximum radial play between
sliding surface liner and stationary
mast is 0.020 inch (0.508 mm).
(Ref. Section 91−00−00) (b). Maximum axial play between spheri
Item Nomenclature cal ball and teflon liner is 0.010 inch
(0.254 mm).
(c). If play is suspected in double row ball
bearing, turn rotating swashplate
When cleaning swashplate for until arms line up with those of
CAUTION inspection, prevent solvent from stationary swashplate and check
entering either spherical ball bearing or motion between arms at control bolt
double row ball bearing. Use cloth moist in stationary swashplate.
ened in alcohol (CM217) to wipe clean
spherical ball, ball bore liner and exterior of (d). Maximum total vertical movement of
double row ball bearing. 0.015 inch (0.381 mm) is allowable.
(e). If movement limit is exceeded replace
NOTE: double row ball bearing (Ref. COM).
D Stationary swashplate can be constructed (5). Inspect swashplate spherical and
of either magnesium or aluminum alloy. double row ball bearings for condition.
For corrosion control and identification of
magnesium and aluminum alloys (Ref. (a). Nicks and dents that do not deform
Section 20-40-00). ID chamfered edge of hard anodized
ball, and not more than 0.10 inch
D In the following inspection, the rotating
(0.254 mm) deep along spherical ball
and stationary swashplates must be dis
surface from edge are allowed.
connected (Ref. Swashplate and Mixer
Removal/Installation). (b). Scratches, any length, on OD of
spherical ball are allowed if they are
(1). Inspect swashplate bearing assembly no deeper than 0.010 inch (0.254
(Ref. Figure 403 for evidence of binding mm) or wider than 0.060 inch (1.524
in either radial or axial movement. mm).
(2). Inspect teflon liners for condition. (c). Not more than two scratches are
permitted in a one inch wide area.
(3). Ensure that all flexible rubber seals (6). Check existing preload on spherical
enclosing ball bearing races are in bearing.
place; inspect for deterioration and
indication of grease leakage. (For (a). Hook spring scale over one of the
bearing maintenance information bolts securing stationary swashplate
(including lubrication), Ref. CSP- to the bearing flange.
COM-5). (b). With stationary swashplate in
motion, drag should be no more than
NOTE: New swashplate bearing assembly nor 30 pounds (13.61 kg). (Use average
mally shows some signs of grease leakage of four readings taken 90 degrees
for first 10-15 hours of operation after in apart).
stallation.
(c). If readings are more than 30 pounds
(4). Inspect swashplate spherical ball and (13.61 kg), clean spherical bearing
double row ball bearing for radial or with isopropyl alcohol and recheck
axial play. drag.
Page 601
MAINTENANCE MANUAL
(d). Repair damage or replace bearings mixer link for binding, play in link bore
(Ref. CSP-COM-5). and wear. Wear limit is 0.008 inch
(0.203 mm) radially and 0.040 inch
(7). Check double row ball bearing for (1.016 mm) axially. Replace complete
serviceability, with seals in place and mixer link if bearings are faulty.
unbroken. Inspect bearings in other linkage for
(a). Check for correct operation and binding and looseness in mating bores.
lubrication.
3. Scissors Inspection
(b). Bearing must rotate smoothly,
(Ref. Figure 401)
without roughness. Binding or
catching should not exist when Any evidence of failure,
bearings are rotated 360°. WARNING damage, or deformation of
(c). Replace defective double row ball crank or link is justification for re
bearings (Ref. CSP-COM-5). placement of either crank, link, or com
plete scissors assembly. Failure of any
(8). Do a careful visual inspection of of these components in flight can result
stationary and rotating swashplate for in failure of movable flight controls,
cracks, wear in bolt and bushing bores, loss of helicopter, and possible injury
and fork inner surfaces; and for or loss of life.
corrosion, nicks and dents.
(1). Inspect crank and link for evidence of
(9). Do a dye penetrant check on question impact damage and deformation. If
able areas. condition is questionable, do a fluores
cent dye penetrant inspection.
(10). Check that counterweights are securely
bonded in rotating swashplate. (2). Inspect bearings for binding, looseness
in bore and wear. Maximum wear limits
2. Mixer Controls Inspection are 0.010 inch (0.254 mm) radial and
0.020 inch (0.508 mm) axial.
(Ref. Figure 402)
(1). Inspect all bushings for security of fit. 4. Pitch Control Rod Inspection
(2). Inspect longitudinal link, support (Ref. Figure 401)

bracket, longitudinal control mixer link, Ensure that rod end bearings
mixer links, longitudinal pitch idler, CAUTION are centered and do not contact
longitudinal pitch mixer bellcrank, attach clevis.
lateral bellcrank and collective pitch
mixer bellcrank for scratches, cracks, (1). Visually inspect upper and lower rod
corrosion and similar surface defects. end bearings for evidence of excessive
For components that are questionable, axial play, 0.040 inch (1.016 mm)
do a fluorescent dye penetrant inspec maximum; and for any extrusion,
tion. displacement or damage to the bearing
teflon liner.
(3). Inspect spherical, teflon (or equivalent)
lined, bearings in longitudinal link, (2). Replace rod end bearing if discrepan
mixer link, and longitudinal control cies are noted.
Page 602
MAINTENANCE MANUAL

REPAIRS
1. Swashplate Repairs be restored on magnesium and alumi
num parts.
(Ref. Figure 403) Disassembly other than as
illustrated is considered a part of swashplate (7). Replace defective bearings and bush
overhaul (Ref. CSP-COM-5). If tracking ings, except swaged spherical bearings
interrupters are to be removed, mark them for in mixer links which require link
reinstallation at original locations. replacement. Remove bearings or
bushings by pressing them out. Install
2. Mixer Controls Repair new bearing with surface primer and
grade A locking compound (CM321 and
(Ref. Figure 402) CM431).
NOTE: Left-hand bearing in support bracket is
Consumable Materials not supplied as part of bracket. This bearing
(Ref. Section 91−00−00) is installed at time support bracket and lon
Item Nomenclature gitudinal pitch idler are assembled. Install
CM321 Surface primer locking compound new bearing by seating flush with inner face
CM431 Sealing, locking and retaining compound of support bracket flange.
3. Scissors Bushing and Bearing
Replacement
NOTE: Following depth limits are total limits, (Ref. Figure 401)
including effects of all previous repairs to
any given area.
(1). Repair minor surface defects such as (Ref. Section 91−00−00)
scratches, nicks and corrosion using Item Nomenclature
abrasive cloth, grade 400 - 600 CM103 Solid film lubricant
(CM802) to smooth out and blend in CM217 Isopropyl alcohol
such defects.
CM318 Primer
(2). Cast and forged surfaces can be CM321 Surface primer locking compound
reworked to depth of 0.020 inch (0.508 CM431 Sealing, locking and retaining compound
mm).
(3). Flat machined surfaces, except clevis (1). Remove cotter pin, nut, washer, and
inner ears, will be reworked to depth of bolt that join link and crank.
0.015 inch (0.381 mm). Clevis inner ear
surfaces will be reworked to depth of (2). Remove two bushings from link only if
0.020 inch (0.508 mm). replacement is necessary.
(4). Machined holes can have 0.003 inch (3). Do not remove bearing from link.
(0.076 mm) removed from bore wall in Replace complete link if bearing is
an area no greater than 15 percent of defective.
circumference and 50 percent of depth. (4). Remove slotted bushings and bearings
from crank, only if replacement is
(5). All edges can have 0.030 inch (0.762 necessary.
mm) removed except around machined
holes which are limited to 0.010 inch During cleaning, do not allow
(0.254 mm) chamfer. CAUTION solvent to enter bearings.
(6). All rework must be smoothly blended (5). Install new bushings using solid film
into adjacent surfaces and finish must lubricant (CM103); do not use zinc
Page 801
MAINTENANCE MANUAL
chromate. Press in bushing until end 4. Scissors Modification

is flush with inside surface of crank
inboard ears. (Ref. Figure 801) The following procedure is for
modification of 369D21002 main rotor hub
(6). If bearings were removed from crank at scissors to 369D21002-21 configuration to
disassembly, reinstall using the preclude shimming problems experienced with
following procedure: the early crank configuration. Field rework
consists primarily of relocating existing
NOTE: Do not allow sealant to enter bearing bushings in the crank outboard attach lugs to
race. the inboard lugs, and installing new flange
type bushings in the outboard lugs. The wall
thickness of the crank outboard attach lugs
(a). Clean bearing outer face, counterbore must be reduced to accommodate installation
and faying surfaces with isopropyl of the flange bushings.
alcohol (CM217). Do not allow
isopropyl alcohol (CM217) to enter
bearing. Instructions are also provided for replacement
of existing hardware for the crank assembly.
Existing attach bolts can have insufficient
(b). Coat the faying surfaces with surface thread length which, in some cases, can cause
primer (CM321) as per manufactur loosening of the bolt in service.
er's instructions.
It is to be noted that the field modification and
(c). Apply locking compound (CM431) to installation of the PN 369D21002-21 crank
faying surfaces. assembly with new attach hardware also
upgrades the PN 369D21001 scissors assembly
(d). Press bearing until outer face is to PN 369D2101-501 configuration.
seated firmly against shoulder of
counterbore.
(e). Remove excess sealant. Do not allow Item Nomenclature
sealant to enter bearing race.
(f). Apply a small fillet of sealant to the CM318 Primer
faying edges of bearing housing. Use
cellophane or masking tape to
exclude air and allow sealant to cure (1). Disconnect scissors crank from hub
for 24 hours at ambient temperature lower shoe and scissors link.
or force cure by heating to
140—1605F (60—725C) for one hour (2). Remove existing HS626-S-4-500
prior to use of assembly. bushings from outboard lugs of scissors
crank.
(7). If bushings were removed from link at
disassembly, install new bushings. (3). Using grinder or file, remove minimum
After installation, dimension between 0.063 inch (1.6002 mm) material from
outside faces of bushings should be inner side of both outboard attach lugs,
1.579—1.586 inches (4.0107—4.0284 to obtain distance of 9.735 inches
cm). (24.7295 cm) between lugs. After
removal of material, wall thickness of
(8). Align bore of link with bore of crank; lugs should not be less than 0.230 inch
install bolt, washer and nut. Torque nut (5.842 mm). Coat reworked area of lug
to 30—40 inch-pounds (3.39—4.52 with iridite (CM206) or equivalent
Nm). corrosion protective chemical film.
Page 802
MAINTENANCE MANUAL
9.736 IN.
(24.7295 CM)
MINIMUM WALL 0.230 IN. (5.8420 MM) TYP.
NOTE 5 NOTE 5 MAXIMUM WALL 0.249 IN. (6.3246 MM) TYP.
HS626-S-4-500
BUSHING (2 REQ'D)
NAS77-4-23 BUSHING
(TYP. 2 PL)
369D21002-21 CRANK 0.020 IN. (0.508 MM) X 45°

ASSEMBLY CHAMFER (4 PL) 0.3750 IN. (9.5250 MM) DIA.
0.3755 IN. (9.5377 MM)
6.421 IN. (NOTE 3)
16.3093 CM)
NAS6204-38D BOLT
AN960C416 WASHER PLATE
2 REQ'D (NOTE 2)
MS17826-4 NUT (NOTE 1)
INSTALL THIS SIDE

TOWARD BLADES
NOTE 4
NOTES:
1. TORQUE NUT 30 - 40 INCH-POUNDS (3.39 - 4.52 NM).
2. ONE WASHER EACH UNDER BOLT HEAD AND NUT. SCISSORS LINK
3. TWO HOLES IN LINE (TYP. 2 PLACES) ASSEMBLY
4. FILL GAP WITH HS5079-2646 WASHERS. SHIM WASHERS
SHOULD BE EQUALLY SPACED.
5. REMOVE MATERIAL EVENLY FROM INNER SIDE OF OUTBOARD
ATTACH LUG TO OBTAIN 9.736 IN. (24.7295 CM) DIMENSION. G62-3004B
Figure 801. Field Modification − 369D21002−11 Crank Assembly to 369D21002−21 Configuration
NOTE: Remove material only from inner side of (a). Install scissors crank to hub lower
existing crank outboard attach lugs. shoe with NAS6204-18D bolts,
AN960PD416L washers, MS17826-4
(4). Using existing hole in outboard lug as nuts and cotter pins (Ref.
guide, drill and ream 0.252 inch (6.4008 Figure 802).
mm) dia. hole in outboard lugs to
0.3750—0.3755 inch (9.5250—9.5377 (b). Install scissors link to scissors crank
mm) dia. for press fit of assembly with NAS6204-38D bolt,
HS626-S-4-500 bushings. AN960C416 washers, MS17826-4
nut and cotter pins (Ref. Figure 801).
(5). Install HS626-S-4-500 bushings in Torque nut to 30—40 inch-pounds
inboard lugs of scissors crank with (3.39—4.52 Nm).
primer (CM318).
(6). Install new NAS77-4-23 flanged (10). Record upgrade of PN 369D21002 main
bushings with primer (CM318) in rotor hub scissors crank assembly to
outboard lugs. PN 369D21002-21 configuration per
DN-46.1 in Component Record of
(7). Re-identify crank assembly as PN Helicopter Log Book.
369D21002-21 on ID plate.
(11). Record upgrade of PN 369D21001 main
(8). zinc chromate rotor hub scissors assembly to PN
369D21001-501 configuration per
(9). Reinstall scissors crank assembly using DN-46.1 in Component Record of
new attach hardware as follows: Helicopter Log Book.
Page 803
MAINTENANCE MANUAL
369D21204 LOWER SHOES
369H1001 BOOT
NAS6204-18D BOLT (2 REQD)

AN960PD416L WASHER (4 REQD)
MS17826-4 NUT (2 REQD) (NOTE)
MS24665-153 COTTER PIN (2 REQD)
369D21002-21 CRANK ASSEMBLY
NOTE:
TORQUE NUT 30 - 60 INCH-POUNDS (3.39 - 6.78 NM). G63-3005A
Figure 802. Installation of 369D21002−21 Crank to Hub Lower Shoes

5. Mixer Controls Rework (a). Chamfer 369D21002-3 scissors crank
and 369A1003 link assembly per
dimensions shown (Ref. Figure 803).
(Ref. Figure 803) The following lists
instructions and criteria for rework of the (b). Touch up reworked area with chemi
mixer controls to preclude interference cal film (CM206) and refinish with
between mixer components. Rework is primer (CM318) and black paint
applicable to 369D helicopter, Serial No. (CM305).
0001D thru 0129D only, unless already
(c). Using permanent ink stamp
accomplished, and is to be done prior to rigging
(CM312), reidentify scissors link part
the main rotor controls.
number as 369A1003-501.
(d). Apply a coat of varnish (CM314) over
Consumable Materials ink stamp.
(2). Rework installed 369D27611 rotating
Item Nomenclature
swashplate as follows:
CM206 Chemical coating (a). Chamfer 369D27611 swashplate per
CM305 Lacquer, acrylic dimensions shown (Ref. Figure 803).
CM312 Ink stamp, permanent (b). Touch up reworked area with chemi
CM314 Varnish, moisture resistant cal film and refinish with primer and
black paint.
CM318 Primer
(c). Using permanent ink stamp, reiden
tify rotating swashplate assembly
part number as 369A27611-501.
(1). Remove and rework the 369D21002-3
scissors crank assembly and scissors (d). Apply a coat of varnish over ink
link assembly as follows: stamp.
Page 804
MAINTENANCE MANUAL
(3). Remove and rework 369N2664 collec (d). Apply a coat of varnish over ink
tive mixer bellcrank and 369N2670 stamp.
lateral mixer bellcrank as follows:
(a). Chamfer collective and lateral NOTE: The 369N2666-503 longitudinal mixer
bellcrank assemblies per dimensions idler is compatible installed with the
shown (Ref. Figure 803). 369N2668 basic longitudinal mixer bell
crank only. If the 369N2666-505 idler is in
(b). Touch up reworked area with chemi stalled, the 369N2668-503 bellcrank must
cal film and refinish with primer and be used.
black paint.
(c). Using permanent ink stamp, re-iden (4). Reinstall removed components.
tify collective bellcrank part number
as 369N2664-501; reidentify lateral
bellcrank part number as (5). Do the rigging of main rotor controls
369N2670-501. (Ref. Section 67-10-00).
Page 805
MAINTENANCE MANUAL
0.38 IN.
0.080 IN. (2.032 MM) X 45° A A (9.652 MM)
ROTOR CHAMFER AND BLEND
BOTH ENDS SMOOTHLY CHAMFERED ZONE
HUB (4 PL)
LOWER
SHOE 369D21002 0.38 IN. (9.652 MM)
SCISSORS
CRANK
SECTION A-A 0.20 IN. (5.08 MM)
0.25 IN. (6.35 MM)
(4 PL)
(TYP BOTH SIDES)

0.25 IN. 0.040 IN. (1.016 MM)
(6.35 MM) 0.060 IN. (1.524 MM) CHAMFER
BLEND BOTH ENDS
369A1003 AT 0.25 IN. (6.35 MM) B
SCISSORS WIDTH SMOOTHLY
LINK
0.25 IN.
(6.35 MM)
SECTION B-B (TYP BOTH SIDES) B

0.040 IN. (1.016 MM) CL OF 0.625 IN.
0.060 IN. (1.524 MM) X 45° CHAMFER (15.875 MM)
BLEND BOTH ENDS SLOT
SMOOTHLY
LONGITUDINAL
CONTROL
MIXER LINK
LONGITUDINAL
PITCH IDLER
COLLECTIVE PITCH
MIXER BELLCRANK 369D27611 ROTATING
SWASHPLATE
COLLECTIVE PITCH
CONTROL ROD
0.10 IN. (2.54 MM) X 30°

CHAMFER, BLEND
2.25 IN. (5.715 CM) BOTH ENDS WITH
(TYP) SMOOTH RADIUS TO
LONGITUDINAL PITCH 2.25 IN. (5.715 CM) DIM.
CONTROL ROD
LATERAL MIXER
C
0.10 IN. (2.54 MM)
BELLCRANK (TYP BOTH SIDES)
C
1.50 IN. (3.81 CM)
(TYP FAR SIDE) SECTION C-C
G62−3006−1A
Figure 803. Rework of Main Rotor and Mixer Controls (Sheet 1 of 2)
Page 806
MAINTENANCE MANUAL
369N2666 LONGITUDINAL
PITCH IDLER 369A7607 LONGITUDINAL
CONTROL MIXER
MIXER BELLCRANK
369N2670
LATERAL MIXER STATIONARY
BELLCRANK SWASHPLATE
CHAMFER 0.15 IN. (3.81 MM)

0.040 IN. (1.016 MM) X 0.20 IN. (5.08 MM)
BLEND BOTH ENDS
SMOOTHLY
MIXER LINK
1.50 IN. (3.81 CM)

1.68 IN. (4.2672 CM)
MIXER
SUPPORT
BRACKET
369N2664 COLLECTIVE
PITCH MIXER BELLCRANK
CHAMFER 0.080 IN. (2.032 MM)

MAX X 0.180 IN. (4.57 MM)
BLEND BOTH ENDS SMOOTHLY
0.25 IN. (6.35 MM)

(TYP) 1.62 IN. (4.1148 CM)
1.50 IN. (3.81 CM) 1.75 IN. (4.445 CM)
MAST BASE 1.75 IN. (4.445 CM)
0.180 IN.
(4.57 MM)
0.425 IN. (10.795 MM)

32° 0.440 IN. (11.176 MM)
6°
0.45 IN. (11.43 MM) (4 PL)

4.375 IN.
(11.1125 CM) 0.48 IN. (12.19 MM) R
(TYP) 0.48 IN. (12.19 MM) R (4 PL)
30°(4 PL)
0.50 IN. (12.70 MM) R
G62−3006−2A
Figure 803. Rework of Main Rotor and Mixer Controls (Sheet 2 of 2)
Page 807
MAINTENANCE MANUAL
Page 808
MAINTENANCE MANUAL
Section
62−30−60
Swashplate and
Mixer (600N)
MAINTENANCE MANUAL

1. Main Rotor Swashplate Do not strike rotating swash
CAUTION plate or bearing assembly (Ref.
Figure 403) with tools or in any way deface
(Ref. Figure 403) The main rotor swashplate these components, the rotating swashplate
includes a rotating swashplate, stationary is a stressed part. Use particular care to pro
swashplate, bearing and retainer and one tect teflon liner in bearing bore. A damaged
counterweight. The rotating swashplate swashplate bearing must not be retained in
converts movement from the stationary service.
swashplate into rotating motion and transfers
it to the main rotor hub assembly for lift, and (8). Lift swashplate carefully up and off of
longitudinal and lateral control of the helicop mast.
ter.
(9). To remove boot from mast, remove
self-clinching nylon strap.
2. Swashplate Replacement
B. Swashplate Installation
A. Swashplate Removal (1). If swashplate lower boot was removed,
install boot on mast (Ref. Figure 403).
(1). Tag or color-identify six pitch control (2). Position swashplate over main rotor
rods (Ref. Figure 401) to simplify mast and carefully lower into place.
replacement at same locations.
(3). Engage upper end of boot in groove at
Failure to reinstall pitch control lower side of stationary swashplate.
CAUTION rods at correct locations can re Secure boot with self-clinching nylon
sult in main rotor blades excessively out of strap (Ref. Figure 403).
track.
(4). Align longitudinal link with stationary
swashplate (Ref. Figure 402).
(2). Disconnect pitch control rods from
rotating swashplate. (5). Install flanged bushing, if removed,
bolt, two washers, nut and cotter pin to
secure upper end of longitudinal link.
(3). Remove scissors.
(6). Align upper ends of mixer links with
stationary swashplate. Install slotted
(4). Remove main rotor hub. bushing (if removed), bolt, two washers,
nut and cotter pin to secure each link to
(5). Disconnect longitudinal link (Ref. swashplate.
Figure 402) from stationary swash
(7). Install scissors.
plate.
(8). Using color code, reinstall pitch control
(6). Disconnect right and left side mixer rods at same locations from which
links (Ref. Figure 402) from stationary removed.
swashplate.
(9). Check track of main rotor blades (Ref.
Section 18-10-60) following any
(7). Remove protective boot from groove in maintenance activity that could result
lower side of stationary swashplate in a dimensional variation affecting
(Ref. Figure 403). rigging or tracking.
Page 401
MAINTENANCE MANUAL
ROTOR HUB
LOWER SHOE
WASHERS
(NOTE 4) BEARING
SLOTTED BUSHING
(NOTE 1) SCISSORS CRANK WASHERS
(NOTE 4)
BUSHING
CLOSE TOLERANCE SCISSORS LINK

BOLT (NOTE 5)
BEARING
PITCH CONTROL
ROD (NOTE 2)
SLOTTED BUSHING
(NOTE 1) ELASTOMER RING
ROTATING ELASTOMER RING

SWASHPLATE
INTERRUPTER
SLOTTED BUSHING
(NOTE 1)
COLLECTIVE LINK
ASSEMBLY
LONGITUDINAL
LINK ASSEMBLY 6.25 IN.
(15.875 CM)
(NOTE 3)
0.040 IN. (1.016 MM) MAX

ALLOWABLE LOOSENESS
AT INSTALLATION, ROD
SLOTTED BUSHING ENDS TO BE PARALLEL
(NOTE 1) WITH MATING CLEVIS
LATERAL CONTROL 1.30 IN. (3.302 CM)

LINK ASSEMBLY (TYP UPPER BEARING ONLY)
NOTES:
1. END OF SLOTTED BUSHING MUST PROTRUDE MINIMUM OF
0.010 IN. (0.254 MM) TO MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE
OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.
2. COLOR CODED TO MATCH BLADE.
3. OPTIMUM INITIAL SETTING (SIX PLACES).
4. AS REQUIRED TO FILL GAP.
5. BOLT HEADS TO FACE INWARD. 6G62-031B
Figure 401. Pitch Control Rods and Swashplate Scissors − Installation
Page 402
MAINTENANCE MANUAL
3. Controls Mixer B. Mixer Controls Installation
Controls mixer includes links, bellcranks, (Ref. Figure 402)

idlers, support bracket and fasteners to secure
these components in place and to the control (1). Position support bracket over forward
rods and main rotor swashplate. lug on mast base.
4. Controls Mixer Replacement (2). Install two aft bolts and washers in
support bracket and mast base. Install
A. Controls Mixer Removal two thin washers and nuts; torque nuts
to 80—100 inch-pounds (9.04—11.30
(Ref. Figure 402) Nm) plus drag torque.
(1). Remove air intake forward fairing for (3). Using ball hole gage and standard
access. micrometer, check that misalignment
between forward bolt hole bore in
(2). Disconnect upper ends of collective, support bracket and bore in mast base
lateral and longitudinal control links lug is 0.015 inch (0.381 mm) or less.
(Ref. Figure 401).
NOTE: If necessary, loosen aft two bracket-to-
NOTE: Control links are attached by slightly fitting nuts, position support bracket to
different length bolts. Reinstall each bolt in minimize misalignment and retighten nuts.
its bellcrank following control rod removal
to simplify reinstallation at correct loca (4). Install mixer support attaching bushing
tions. in bracket and mast base lug.
(3). Remove mixer links. (Mixer link (5). Check that sleeve bushing is in place;
bearings are not replaceable.) then install bolt, two washers and nut.
(4). Disconnect longitudinal link from
(9.04—11.30 Nm).
stationary swashplate.
(5). Remove longitudinal control mixer link. (6). Position longitudinal pitch idler and
collective pitch mixer bellcrank on
(6). Disconnect lateral mixer bellcrank from support bracket. Position washer
collective pitch mixer bellcrank. between right side of longitudinal pitch
idler bearing and center bearing of
(7). Remove connecting hardware (includ mixer support bracket. Install left-
ing flanged bushing) from each side of hand bearing, with attaching hardware.
longitudinal pitch mixer bellcrank.
Carefully remove bellcrank. Retain any (7). Position lateral bellcrank between
shims that can be installed. collective pitch mixer bellcrank bear
ings and install attaching hardware.
(8). Remove bolt from hingeline of support
bracket, longitudinal pitch idler and (8). Position longitudinal pitch mixer
collective pitch mixer bellcrank. bellcrank with collective pitch mixer
Separate the three parts. bellcrank; insert two flanged bushings.
Install two bolts.
(9). Remove mixer support bracket from
mast base. (9). Push longitudinal bellcrank to one side
and measure gap between bellcrank
To prevent washing dirt into and bearings in collective pitch bell
CAUTION bearings, or washing grease out crank.
of bearings, do not permit solvent to enter
bearings when cleaning mixer control com (10). Using HS5079-2646 laminated wash
ponents. er(s), shim evenly to take up gap.
Page 403
MAINTENANCE MANUAL
BUSHING LONGITUDINAL CONTROL

(NOTE 2) MIXER LINK STATIONARY BUSHING
LONGITUDINAL SWASHPLATE
MIXER LINK (NOTE 2) STATIONARY
PITCH IDLER
SWASHPLATE LONGITUDINAL
FLANGED LINK
BUSHING (NOTE 3)
LATERAL MIXER BEARING
BELLCRANK
(NOTE 5)
NOTE 1
MIXER
LINK
WASHER
BEARING
NOTE 1
NOTE 1 BUSHING BUSHING
(NOTE 2) (NOTE 2)
BEARING FLANGED
BUSHING
(NOTE 4) BEARING
MIXER
BEARING
SUPPORT
ATTACHING
BUSHING
(NOTE 6)
MIXER
SUPPORT NOTE 7
BRACKET
BEARING
LONGITUDINAL
COLLECTIVE PITCH PITCH MIXER
SLEEVE MIXER BELLCRANK BELLCRANK
BEARING
BUSHING
FLANGED BUSHING
(NOTE 4)
MAST BASE
TWO IDENTIFYING LOCATORS

ONE IDENTIFYING LOCATOR (FACING UP AND OUT)
(FACING OUT) L/H SIDE ONLY R/H SIDE ONLY
NOTES: LEFT-HAND RIGHT-HAND

1. DIRECTION OF BOLT OPTIONAL. MIXER LINK MIXER LINK
2. EDGE OF BUSHING MUST PROTRUDE MINIMUM OF 0.010 IN. (600N7636-1/-9) (600N7636-3/-11)
(0.254 MM) TO MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE
OUTSIDE OF PART AFTER NUT IS TIGHTENED.
3. LONGITUDINAL LINK DETAILS ROTATED FOR CLARITY. LONGITUDINAL LINK
4. MUST BE PULLED OUT FIRST TO REMOVE BELLCRANK.
5. PART MAY BE EITHER MAGNESIUM OR ALUMINUM ALLOY.
(FOR ALLOY IDENTIFICATION AND CORROSION CONTROL, MAST CL
REFER TO SECTION 20-40-00). MIXER LINK IDENTIFICATION
6. INSTALL BUSHING AFTER THE TWO AFT ATTACHING BOLTS FOR PROPER INSTALLATION 6G62-032C
Figure 402. Controls Mixer − Assembly
Page 404
MAINTENANCE MANUAL
(11). Insert flanged bushings, bolts, six Removal of all pitch control rods
washers (two under each nut) shims CAUTION is recommended prior to scissors
and nuts. Torque nut to 30—40 inch- removal. Failure to observe this precaution
pounds (3.39—4.52 Nm) and install could result in damage to pitch control rods,
cotter pin. swashplate and/or hub. Ensure all rods are
color-coded or marked so they will be rein
(12). Position longitudinal control mixer link stalled in the correct location.
between longitudinal pitch idler and
(1). Disconnect lower end of pitch control
longitudinal pitch mixer bellcrank;
rod that is in line with scissors link in
check that two slotted bushings are in
rotating swashplate.
place. Install bolt, three washers (two
under each nut), nut and cotter pin at (2). Remove cotter pin, nut, washer, and
each end of link. bolt from each leg of scissors crank.
Disconnect crank from hub lower shoe.
(13). Position longitudinal link between
longitudinal pitch mixer bellcrank (3). Remove cotter pin, nut, washer, and
bearings. Install attaching hardware. bolt connecting scissors link to swash
plate; remove scissors.
NOTE: In the following step, ensure mixer B. Scissors Installation
links are not installed inverted and are
installed in the correct position (Ref. (Ref. Figure 401)
Figure 402, View A).
(1). Place scissors link in mounting posi
(14). Position mixer links in stationary tion, chamfered edge of link must face
swashplate and lateral mixer bellcrank; outboard.
check that slotted bushings are in (2). Check that slotted bushing is in
place. Install attaching hardware. swashplate web and install attaching
hardware. Torque nut to 15—20
(15). Place collective, lateral longitudinal inch-pounds (1.69—2.26 Nm).
control links (Ref. Figure 401) in
mounting position; check that slotted Scissors crank must be posi
CAUTION tioned (Ref. Figure 401) with de
bushing is in place. Install attaching
hardware. cal up and proper direction towards lower
side lugs.
(16). Install air intake forward fairing. NOTE: Ensure crank-to-hub lower shoe lugs
are not preloaded.
(17). Check rigging of collective and cyclic
controls. (3). Position scissors crank on hub lower
shoe lugs; install connecting hardware.
Install bolts with bolt heads facing
5. Scissors inward and a washer under head of bolt
(Ref. Figure 401). Torque nuts to 30 -
The scissors provide a movable connection 60 inch-pounds (3.39—6.78 Nm).
between the rotating swashplate and main
rotor hub. NOTE: Shim washers can be required on shoul
dered bushing side of clevis.
6. Scissors Replacement (4). Position elastomer rings and lower end

of pitch control rod in swashplate lug
and install attaching hardware. (Nut is
A. Scissors Removal to be adjacent to bushing in swash
plate.) Torque nut to 30—60 inch-
(Ref. Figure 401) pounds (3.39—6.78 Nm).
Page 405
MAINTENANCE MANUAL
7. Scissors Link Replacement (1). Remove cotter pin, nut, washer and bolt
from each end of pitch control rod.
(Ref. Section 91−00−00) (2). Remove pitch control rod and O-ring.
Item Nomenclature
CM103 Solid film lubricant B. Pitch Control Rod Installation
(Ref. Figure 401)

(1). Remove cotter pin, nut, washer and bolt
that join link and crank. At installation, install rod at
CAUTION correct color code location. Cen
(2). Remove two bushings from link only if
replacement is necessary. ter bearing rodends between attach clevis. If
rod length is changed, blades must be
(3). Do not remove bearing from link, tracked.
replace complete link if bearing is
defective. (1). If actual rod length is incorrect or
NOTE: Install new bushings using solid film lu either actual or required rod length is
bricant (CM103); do not use zinc chro unknown, preset link length to opti
mate. mum length of 6.25 inches (15.88 cm).
(4). If bushings were removed at disassem NOTE: Install both pitch change rod bolts in
bly, install new bushings. After installa direction of rotation.
tion, dimension between outer faces of
bushings should be 1.579-1.586 inches (2). Install rod with elastomeric rings on
(4.011-4.028 cm). both sides of upper bearing and lower
(5). Align bore of link with bore of crank; bearing.
install bolt, washer and nut. Torque nut
to 30—40 inch-pounds (3.39—4.52 NOTE: Add washers as required to align nut
Nm); install cotter pin. with cotter pin hole.
8. Pitch Control Rods (3). Torque upper nut to 100—130 inch-

pounds (11.30—14.69 Nm).
Six pitch control rods transfer pitch control
from the rotating swashplate to the main rotor
blades. NOTE: Bushing must project 0.010—0.060
inch (0.254—1.524 mm) after nut is
9. Pitch Control Rod Replacement torqued.
A. Pitch Control Rod Removal (4). Torque lower nut to 30—60 inch-
(Ref. Figure 401) pounds (3.39—6.78 Nm).
NOTE: (5). Secure nuts with cotter pins.

D If rod is not to be reinstalled, but is to be
replaced, measure and record length of (6). Rotate pitch control rod assembly fore
removed link. Optimum length possibly and aft to ensure clearance exists
changed at previous rigging; pre-adjust between rod end bearing and pitch
replacement link to length of link re housing clevis at both ends.
moved.
D Rods are color coded for reinstallation at (7). If installation is final and tracking is
correct locations. If more than one rod is not required, safetywire rod ends to rod;
being removed and color coding is not vis ensure rod ends are centered.
ible, identify each by color or similar
means to points of connection to simplify (8). As necessary, repeat above procedures
reinstallation. for remaining pitch control rods.
Page 406
MAINTENANCE MANUAL
BEARING
ASSEMBLY
ROTATING BALANCE
SWASHPLATE WEIGHT
INTERRUPTER INTERRUPTER
(NOTE 1) (NOTE 2)
STATIONARY
SWASHPLATE
DRAIN HOLES
(HIDDEN)
INDEX
PROTRUSIONS
DRAIN HOLES
(2 PLCS)
STATIONARY
SWASHPLATE
GROOVE
BOOT
NYLON STRAP
MAST
NOTES:
6G62-033A
Figure 403. Main Rotor Swashplate
Page 407
MAINTENANCE MANUAL
Page 408
MAINTENANCE MANUAL

INSPECTION/CHECK
1. Swashplate Inspection (a). Maximum radial play between
sliding surface liner and stationary
mast is 0.020 inch (0.508 mm).
(Ref. Section 91−00−00) (b). Maximum axial play between spheri
Item Nomenclature cal ball and teflon liner is 0.010 inch
(0.254 mm).
(c). If play is suspected in double row ball
bearing, turn rotating swashplate
When cleaning swashplate for until arms line up with those of
CAUTION inspection, prevent solvent from stationary swashplate and check
entering either spherical ball bearing or motion between arms at control bolt
double row ball bearing. Use cloth moist in stationary swashplate.
ened in alcohol (CM217) to wipe clean
spherical ball, ball bore liner and exterior of (d). Maximum total vertical movement of
double row ball bearing. 0.015 inch (0.381 mm) is allowable.
(e). If movement limit is exceeded replace
NOTE: double row ball bearing (Ref. COM).
D Stationary swashplate can be constructed (5). Inspect swashplate spherical and
of either magnesium or aluminum alloy. double row ball bearings for condition.
For corrosion control and identification of
magnesium and aluminum alloys (Ref. (a). Nicks and dents that do not deform
Sectioin 20-40-00). ID chamfered edge of hard anodized
ball, and not more than 0.10 inch
D In the following inspection, the rotating
(0.254 mm) deep along spherical ball
and stationary swashplates must be dis
surface from edge are allowed.
connected (Ref. Swashplate and Mixer
Removal/Installation). (b). Scratches, any length, on OD of
spherical ball are allowed if they are
(1). Inspect swashplate bearing assembly no deeper than 0.010 inch (0.254
(Ref. Figure 403 for evidence of binding mm) or wider than 0.060 inch (1.524
in either radial or axial movement. mm).
(2). Inspect teflon liners for condition. (c). Not more than two scratches are
permitted in a one inch wide area.
(3). Ensure that all flexible rubber seals (6). Check existing preload on spherical
enclosing ball bearing races are in bearing.
place; inspect for deterioration and
indication of grease leakage. (For (a). Hook spring scale over one of the
bearing maintenance information bolts securing stationary swashplate
(including lubrication), Ref. CSP- to the bearing flange.
COM-5). (b). With stationary swashplate in
motion, drag should be no more than
NOTE: New swashplate bearing assembly nor 30 pounds (13.61 kg). (Use average
mally shows some signs of grease leakage of four readings taken 90 degrees
for first 10-15 hours of operation after in apart).
stallation.
(c). If readings are more than 30 pounds
(4). Inspect swashplate spherical ball and (13.61 kg), clean spherical bearing
double row ball bearing for radial or with isopropyl alcohol and recheck
axial play. drag.
Page 601
MAINTENANCE MANUAL
(d). Repair damage or replace bearings mixer link for binding, play in link bore
(Ref. CSP-COM-5). and wear. Wear limit is 0.008 inch
(0.203 mm) radially and 0.040 inch
(7). Check double row ball bearing for (1.016 mm) axially. Replace complete
serviceability, with seals in place and mixer link if bearings are faulty.
unbroken. Inspect bearings in other linkage for
(a). Check for correct operation and binding and looseness in mating bores.
lubrication.
3. Scissors Inspection
(b). Bearing must rotate smoothly,
(Ref. Figure 401)
without roughness. Binding or
catching should not exist when Any evidence of failure,
bearings are rotated 360°. WARNING damage, or deformation of
(c). Replace defective double row ball crank or link is justification for re
bearings (Ref. CSP-COM-5). placement of either crank, link, or com
plete scissors assembly. Failure of any
(8). Do a careful visual inspection of of these components in flight can result
stationary and rotating swashplate for in failure of movable flight controls,
cracks, wear in bolt and bushing bores, loss of helicopter, and possible injury
and fork inner surfaces; and for or loss of life.
corrosion, nicks and dents.
(1). Inspect crank and link for evidence of
(9). Do the dye penetrant check on ques impact damage and deformation. If
tionable areas. condition is questionable, do the
fluorescent dye penetrant inspection.
(10). Check that counterweights are securely
bonded in rotating swashplate. (2). Inspect bearings for binding, looseness
in bore and wear. Maximum wear limits
2. Mixer Controls Inspection are 0.010 inch (0.254 mm) radial and
0.020 inch (0.508 mm) axial.
(Ref. Figure 402)
(1). Inspect all bushings for security of fit. 4. Pitch Control Rod Inspection
(2). Inspect longitudinal link, support (Ref. Figure 401)

bracket, longitudinal control mixer link, Ensure that rod end bearings
mixer links, longitudinal pitch idler, CAUTION are centered and do not contact
longitudinal pitch mixer bellcrank, attach clevis.
lateral bellcrank and collective pitch
mixer bellcrank for scratches, cracks, (1). Visually inspect upper and lower rod
corrosion and similar surface defects. end bearings for evidence of excessive
For components that are questionable, axial play, 0.040 inch (1.016 mm)
do the fluorescent dye penetrant maximum; and for any extrusion,
inspection. displacement or damage to the bearing
teflon liner.
(3). Inspect spherical, teflon (or equivalent)
lined, bearings in longitudinal link, (2). Replace rod end bearing if discrepan
mixer link, and longitudinal control cies are noted.
Page 602
MAINTENANCE MANUAL

REPAIRS
1. Swashplate Repairs be restored on magnesium and alumi
num parts.
(Ref. Figure 403) Disassembly other than as
illustrated is considered a part of swashplate (7). Replace defective bearings and bush
overhaul (Ref. CSP-COM-5). If tracking ings, except swaged spherical bearings
interrupters are to be removed, mark them for in mixer links which require link
reinstallation at original locations. replacement. Remove bearings or
bushings by pressing them out. Install
2. Mixer Controls Repair new bearing with surface primer and
grade A locking compound (CM321 and
(Ref. Figure 402) CM431).
NOTE: Left-hand bearing in support bracket is
Consumable Materials not supplied as part of bracket. This bearing
(Ref. Section 91−00−00) is installed at time support bracket and lon
Item Nomenclature gitudinal pitch idler are assembled. Install
CM321 Surface primer locking compound new bearing by seating flush with inner face
CM431 Sealing, locking and retaining compound of support bracket flange.
3. Scissors Bushing and Bearing
Replacement
NOTE: Following depth limits are total limits, (Ref. Figure 401)
including effects of all previous repairs to
any given area.
(1). Repair minor surface defects such as (Ref. Section 91−00−00)
scratches, nicks and corrosion using Item Nomenclature
abrasive cloth (CM802), grade 400 - CM103 Solid film lubricant
600 to smooth out and blend in such CM217 Isopropyl alcohol
defects.
CM318 Primer
(2). Cast and forged surfaces can be CM321 Surface primer locking compound
reworked to depth of 0.020 inch (0.508 CM431 Sealing, locking and retaining compound
mm).
(3). Flat machined surfaces, except clevis (1). Remove cotter pin, nut, washer, and
inner ears, can be reworked to depth of bolt that join link and crank.
0.015 inch (0.381 mm). Clevis inner ear
surfaces can be reworked to depth of (2). Remove two bushings from link only if
0.020 inch (0.508 mm). replacement is necessary.
(4). Machined holes can have 0.003 inch (3). Do not remove bearing from link.
(0.076 mm) removed from bore wall in Replace complete link if bearing is
an area no greater than 15 percent of defective.
circumference and 50 percent of depth. (4). Remove slotted bushings and bearings
from crank, only if replacement is
(5). All edges can have 0.030 inch (0.762 necessary.
holes which are limited to 0.010 inch During cleaning, do not allow
(0.254 mm) chamfer. CAUTION solvent to enter bearings.
(6). All rework must be smoothly blended (5). Install new bushings using solid film
into adjacent surfaces and finish must lubricant (CM103); do not use zinc
Page 801
MAINTENANCE MANUAL
chromate. Press in bushing until end (d). Press bearing until outer face is
is flush with inside surface of crank seated firmly against shoulder of
inboard ears. counterbore.
(e). Remove excess sealant. Do not allow
(6). If bearings were removed from crank at sealant to enter bearing race.
disassembly, reinstall using the
following procedure: (f). Apply a small fillet of sealant to the
faying edges of bearing housing. Use
NOTE: Do not allow sealant to enter bearing cellophane or masking tape to
race. exclude air and allow sealant to cure
for 24 hours at ambient temperature
or force cure by heating to
(a). Clean bearing outer face, counterbore 140—1605F (60—725C) for one hour
and faying surfaces with isopropyl prior to use of assembly.
alcohol (CM217). Do not allow
isopropyl alcohol (CM217) to enter (7). If bushings were removed from link at
bearing. disassembly, install new bushings.
After installation, dimension between
(b). Coat the faying surfaces with surface outside faces of bushings should be
primer (CM321) as per manufactur 1.579-1.586 inches (4.0107-4.0284 cm).
er's instructions. (8). Align bore of link with bore of crank;
install bolt, washer and nut. Torque nut
(c). Apply locking compound (CM431) to to 30—40 inch-pounds (3.39—4.52
faying surfaces. Nm).
Page 802
MAINTENANCE MANUAL
Chapter
63
Transmission and
Drive System
MAINTENANCE MANUAL
TABLE OF CONTENTS
63-00-00 Transmission and Drive System (369D/E/FF - 500/600N) . . . . . . . . . . . . . . A

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Power Train System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Power Train System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Troubleshooting Power Train System . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101. Power Train System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
63-10-00 Drive Shafts / Clutches / Couplings (369D/E/FF - 500/600N) . . . . . . . . . . . A
1. Main Rotor Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Main Rotor Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Rotor Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Rotor Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Main Rotor Drive Shaft Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . 402
3. Main Transmission Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4. Main Transmission Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Main Transmission Drive Shaft Removal (Bendix and Kamatics) . . . . . . . . . . . . 404
B. Main Transmission Drive Shaft Installation (Bendix and Kamatics) . . . . . . . . . . 404
Figure 402. Main Transmission Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . 405
5. Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
6. Overrunning Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Overrunning Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Overrunning Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. 369A5350 Overrunning Clutch Installation . . . . . . . . . . . . . . . . . . . . . 407
Figure 404. 369F5450 Overrunning Clutch Installation . . . . . . . . . . . . . . . . . . . . . 408
7. Overrunning Clutch Subassembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Overrunning Clutch Subassembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Overrunning Clutch Subassembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
8. Overrunning Clutch-to-Firewall Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
9. Overrunning Clutch-to-Firewall Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 411
10. Main Transmission Drive Shaft Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
11. Main Transmission Drive Shaft Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . 411
A. Main Transmission Drive Shaft Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Main Transmission Drive Shaft Coupling Installation . . . . . . . . . . . . . . . . . . . . . . 411
12. Tail Rotor Drive Shaft Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Tail Rotor Drive Shaft Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Tail Rotor Drive Shaft Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
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Figure 405. 369F5468/5469 Bolt Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413

1. 369D25510 Main Rotor Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. 600N5510 and 369F5510 Main Rotor Drive Shaft Inspection . . . . . . . . . . . . . . . . . . 601
Figure 601. Main Rotor Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 602. Main Rotor Drive Shaft Overtorque Verification Stripe . . . . . . . . . . 603
3. Main Transmission Drive Shaft Inspection (Bendix) . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4. Main Transmission Drive Shaft Inspection (Kamatics) . . . . . . . . . . . . . . . . . . . . . . . . 604
5. Overrunning Clutch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
6. Overrunning Clutch-to-Firewall Seal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
7. Bendix Tail Rotor Drive Shaft Coupling Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
8. Kamatics Coupling Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Figure 603. Typical Clutch Subassembly Lock Washer Crimp . . . . . . . . . . . . . . . . 606
9. Main Rotor Drive Shaft Inspection (300 Hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Main Rotor Drive Shaft Exterior Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Main Rotor Drive Shaft Corrosion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
3. Main Transmission Drive Shaft Repair (Bendix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
4. Main Transmission Drive Shaft Repair (Kamatics) . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
5. Overrunning Clutch Repair/Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
6. Overrunning Clutch-to-Firewall Seal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
7. Main Transmission Drive Shaft Coupling Corrosion Removal . . . . . . . . . . . . . . . . . . 803
8. Bendix Coupling Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
9. Kamatics Coupling Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
63-15-10 Tail Rotor Drive Shaft (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Tail Rotor Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Tail Rotor Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Tail Rotor Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Tail Rotor Drive Shaft Installation with Bendix Couplings . . . . . . . . . . . . . . . . . . 401
Figure 401. Tail Rotor Drive Shaft Installation
(369D/E/FF) (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 402. Tail Rotor Drive Shaft Installation (369FF) . . . . . . . . . . . . . . . . . . . . . 407
C. Tail Rotor Drive Shaft Installation with Kamatic Couplings . . . . . . . . . . . . . . . . . 408
3. Tail Rotor Drive Shaft Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
4. Tail Rotor Drive Shaft Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
1. Tail Rotor Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
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2. Tail Rotor Drive Shaft Twist Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

Figure 601. Tail Rotor Drive Shaft - Inspection Markings . . . . . . . . . . . . . . . . . . . 602
Figure 602. Tail Rotor Drive Shaft -
Inspection Markings (Extended Tailboom) . . . . . . . . . . . . . . . . . . . . . . . 603
3. Tail Rotor Drive Shaft Damper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Figure 603. Tail Rotor Drive Shaft Damper - Inspection . . . . . . . . . . . . . . . . . . . . 605
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Tail Rotor Drive Shaft Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Tail Rotor Drive Shaft Index Stripe Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
63-15-30 NOTAR) Anti-Torque System Drive Shafts (500/600N) . . . . . . . . . . . . . . . . A
1. Anti-Torque System Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fan Gearbox Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Fan Gearbox Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Fan Gearbox Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Fan Gearbox Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Fan Gearbox Drive Shaft Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Fan Gearbox and Inter-Connecting Drive Shafts . . . . . . . . . . . . . . . 204
5. Fan Inter-Connect Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Fan Inter-Connect Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Fan Inter-Connect Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Inter-Connect Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7. Inter-Connect Drive Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8. Transmission and Fan Coupling Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
9. Gearbox and Fan Coupling Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10. Transmission Coupling / Fan Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Transmission Coupling / Fan Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Transmission Coupling / Fan Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 202. Fan Interconnect Drive Shaft Coupling Installation . . . . . . . . . . . . . 207
63-20-00 369D25100 Main Transmission (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . A
1. Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Main Transmission Buildup and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Main Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Main Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Main Transmission Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
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4. Main Transmission Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Figure 201. 369D25100 Main Transmission Installation . . . . . . . . . . . . . . . . . . . . 204
5. Lubrication Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Lubrication Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Lubrication Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 202. Main Transmission Lubrication
Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Input Drive Assembly - Oil Leakage Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . 206
7. Input Drive Pinion Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203. Input Drive Assembly O-Ring Replacement . . . . . . . . . . . . . . . . . . . . 210
Figure 204. Assembly Aid Tool for Input Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
63-20-25 369F5100 Main Transmission (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . . A
1. Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Main Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Main Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Main Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Main Transmission Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Main Transmission Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. 369F5100 Main Transmission Installation . . . . . . . . . . . . . . . . . . . . . . 204
5. Main Transmission Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Main Transmission Build-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7. Main Transmission Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8. Main Transmission Break-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
9. Lubrication Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Lubrication Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Lubrication Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10. Scavenge Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Scavenge Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Scavenge Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 202. 369F5100 Main Transmission Build-Up . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203. Main Transmission Scavenge
Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
11. Input Drive Assembly - Oil Leakage Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . 208
A. Input Pinion O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
B. Input Pinion Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
12. Gearshaft Repair Using Speedi-Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
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A. Speedi-Sleeve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

B. Speedi-Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 204. Drive Assembly O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 211
63-21-00 Main Transmission Lubrication and
Cooling System (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Transmission Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Main Transmission Lubrication Pump
Replacement (369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Transmission Lubrication Pump
Removal (369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Transmission Lubrication Pump
Installation (369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Replacement (369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Removal (369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Installation (369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Pump (369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Pump (369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4. Main Transmission Filter Replacement (369D25100 Transmission) . . . . . . . . . . . . 404
5. Main Transmission Filter Replacement (369F5100 Transmission) . . . . . . . . . . . . . . 404
6. Main Transmission Scavenge Pump
A. Main Transmission Scavenge Pump
B. Main Transmission Scavenge Pump
Installation (369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
7. Main Transmission Oil Cooler Bypass Valve Replacement . . . . . . . . . . . . . . . . . . . . . 405
A. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 403. Main Transmission Oil Cooler - Removal/Installation . . . . . . . . . . . 407
8. Main Transmission Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Main Transmission Oil Cooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Main Transmission Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
9. Main Transmission Oil Temperature Sender Replacement . . . . . . . . . . . . . . . . . . . . . 408
10. Main Transmission Oil Pressure Sender Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 409
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11. Liquid Level Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

Figure 404. Main Transmission - Cross-Section View . . . . . . . . . . . . . . . . . . . . . . 410
12. Chip Detector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
13. Cooling Blower Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Cooling Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Cooling Blower Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
C. Cooling Blower Installation (369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . 411
Figure 405. Cooling Blower Installation (369D25100 Transmission) . . . . . . . . . . 412
D. Cooling Blower Installation (369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . 413
Figure 406. Oil Cooler Blower Installation (369F5100 Transmission) . . . . . . . . . 414
E. 369D, E, F, and 500N - Cooling Blower Belt Tracking . . . . . . . . . . . . . . . . . . . . . . 415
Figure 407. Cooling Blower Belt Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
1. Lubrication System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Cooling Blower Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Cooling Blower Inspection (Disassembled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Main Transmission Cooling Blower and Duct . . . . . . . . . . . . . . . . . . . 602
4. Cooling Blower Belt Tension Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. 369D25630 Cooling Blower Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. 369D25630 Cooling Blower - Cross-Section View . . . . . . . . . . . . . . . 802
2. 369D25630 Cooling Blower Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
3. 600N5630 Cooling Blower Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Figure 802. 600N5630 Cooling Blower - Cross-Section View . . . . . . . . . . . . . . . . 805
4. 600N5630 Cooling Blower Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
5. Cooling Blower Cleaning (Disassembled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
6. Transmission and Cooling Blower Drain Tube Repair and Replacement . . . . . . . . . 808
7. Installation of Heating System and Oil Cooling
Line Standoff Clamps (0003D - 0539D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Figure 803. Installation of Standoff Clamps -
Heating and Oil Cooling Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
63-22-00 Rotor Brake (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Rotor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Rotor Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Rotor Brake Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Master Cylinder Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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MAINTENANCE MANUAL

5. Rotor Brake Hydraulic System Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

6. Rotor Brake Component Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
7. Master Cylinder Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
8. Caliper Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Table 201. Troubleshooting Rotor Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . 204
1. Rotor Brake Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Master Cylinder Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Master Cylinder Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Airframe-Mounted Rotor Brake Components . . . . . . . . . . . . . . . . . . . 402
B. Master Cylinder Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Master Cylinder Linkage Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Master Cylinder Linkage Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Master Cylinder Linkage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Master Cylinder Linkage Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4. Caliper Assembly, Brake Disc, and Drive
Coupling Replacement (369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Caliper Assembly, Brake Disc, and Drive
Coupling Removal (369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 403. Transmission-Mounted Rotor Brake Components . . . . . . . . . . . . . . . 406
B. Caliper Assembly, Brake Disc and Drive
Coupling Installation (369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 404. Caliper Assembly and Brake Disc
Interface (369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 405. Lockwire Installation (369D25100 Transmission) . . . . . . . . . . . . . . . 408
5. Caliper Mounting Bracket Replacement (369D25100 Transmission) . . . . . . . . . . . . 409
A. Caliper Mounting Bracket Removal (369D25100 Transmission) . . . . . . . . . . . . . . 409
B. Caliper Mounting Bracket Installation (369D25100 Transmission) . . . . . . . . . . . 409
6. Caliper Assembly, Brake Disc, and Drive Coupling
A. Caliper Assembly, Brake Disc, and Drive Coupling
Figure 406. Rotor Brake Caliper Installation (369F5100 Transmission) . . . . . . 411
B. Caliper Assembly, Brake Disc and Drive
Coupling Installation (369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
7. Hydraulic Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Hydraulic Relief Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Hydraulic Relief Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
8. Hydraulic Tube Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
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MAINTENANCE MANUAL

A. Hydraulic Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413

B. Hydraulic Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
9. Rotor Brake Forward Cover Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
1. Rotor Brake Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Rotor Brake Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
1. Rotor Brake Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Aircraft Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Installation Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Removing Components to be Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Angle Assembly Installation (500D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
E. Master Cylinder Linkage Assembly and Mount Bracket Installation . . . . . . . . . 902
Figure 901. Locating Permanently Installed Components (Sheet 1 of 2) . . . . . . 903
F. Handle Retainer Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
G. Rivnut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Figure 902. Rotor Brake Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 906
H. Window Support Channel Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
I. Caliper Mounting Bracket Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
J. Caliper Assembly, Brake Disc and Drive Coupling Installation . . . . . . . . . . . . . . . 908
Figure 903. Modifying Window Support Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . 909
Figure 904. Hydraulic Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910
K. Master Cylinder Assembly Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 911
Figure 905. Positioning Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 911
L. Hydraulic Relief Valve Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
M. Hydraulic Tube Assemblies Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
N. Rotor Brake Installation Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
Figure 906. Reworking Master Cylinder Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
O. Installing Interior Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 913
P. Map Case Assembly Modification and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 913
Q. Convenience Panel Cover Assembly Modification and Installation . . . . . . . . . . . 913
R. Rotor Brake Forward Cover Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 913
Figure 907. Modifying Map Case Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 914
Figure 908. Modifying Rotor Brake Cover
Panel Assemblies (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 915
S. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917
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MAINTENANCE MANUAL

63-25-10 Tail Rotor Transmission (Two and Four Blade) (369D/E/FF) . . . . . . . . . . A

1. Tail Rotor Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Tail Rotor Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Tail Rotor Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Tail Rotor Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Tail Rotor Transmission Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. General Inspection -
Transmission Housing and Shaft Covers . . . . . . . . . . . . . . . . . . . . . . . . 203
Table 202. Detailed Inspection -
Associated Transmission Housing Parts . . . . . . . . . . . . . . . . . . . . . . . . . 204
Table 203. Detailed Inspection -
Components of Output Gearshaft Assembly . . . . . . . . . . . . . . . . . . . . . 204
Figure 201. Serviceability Criteria - Gear Teeth of Output Shaft . . . . . . . . . . . . 205
4. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Exterior Paint Touchup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
C. Complete Exterior Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Tail Rotor Transmission Parts Repair/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Chip Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Liquid Level Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
C. Oil Breather-Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
D. Damaged Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 202. Replacement of Liquid Level Plug
and Breather-Filler (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7. Input Gearshaft Cover Oil Leak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8. Output Gearshaft Cover Oil Leak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
A. Protective Sleeve (Speedi-Sleeve) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
B. Output Gearshaft Seal Installation Thimble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
C. Output Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 203. Output Gearshaft Seal
Installation Thimble - Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 204. 369D25400 Tail Rotor Transmission Assembly . . . . . . . . . . . . . . . . . . 212
9. Tail Rotor Transmission Housing
Assembly Repair/Rework (PN 369D25401) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Figure 205. Tail Rotor Transmission Mount Stud Limits . . . . . . . . . . . . . . . . . . . . 213
Figure 206. Rework of Tail Rotor Transmission Housing Assembly . . . . . . . . . . . 214
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MAINTENANCE MANUAL

10. Tail Rotor Transmission Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

11. Tail Rotor Transmission Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Figure 207. Tail Rotor Transmission - Stripping/Buildup . . . . . . . . . . . . . . . . . . . . 215
63-25-30 NOTAR) Anti-Torque System Fan Transmission (500/600N) . . . . . . . . . . A
Maintenance practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Fan Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fan Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Fan Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Fan Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Fan Transmission Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Fan Transmission Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Tube Support Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5. Fan Transmission Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Fan Transmission Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 204
63-30-00 Main Rotor Static Mast (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Static Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Main Rotor Static Mast Replacement
(369D25100 Transmission Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Main Rotor Static Mast Removal
(369D25100 Transmission Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Main Rotor Static Mast Installation
(369D25100 Transmission Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Main Rotor Mast and Support Structure
(369D25100 Transmission Installation) . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Main Rotor Static Mast Replacement
(369F5100 Transmission Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Main Rotor Static Mast Removal
(369F5100 Transmission Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
(369F5100 Transmission Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4. Main Rotor Static Mast Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Main Rotor Mast and Support Structure
(369F5100 Transmission Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 203. Main Rotor Mast - Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . 206
Page x
MAINTENANCE MANUAL
Section
63−00−00
Transmission and
Drive System
(369D/E/FF −
500/600N)
MAINTENANCE MANUAL
TRANSMISSION AND DRIVE SYSTEM

FAULT ISOLATION
1. Power Train System 2. Power Train System Troubleshooting
(Ref. Figure 101) The power train system,
starting at the engine power takeoff pad, (Ref. Table 101) Diagnose and repair power
consists primarily of the overrunning clutch, train system malfunctions using procedures as
drive shafts, and transmissions. follows.
Table 101. Troubleshooting Power Train System
Main drive shaft vibrates Coupling flange bolts on main drive Torque bolts to 50 − 70
excessively. (For serviceability shaft are loose. inch−pounds (5.65 − 7.91 Nm).
limits, refer to Section 63−10−00).
Excessive noise or vibration in Defective impeller or damaged Replace impeller or scroll (Ref. Sec.
cooling blower. scroll. 63−21−00).
Main drive shaft turns erratically or Defective overrunning clutch. Replace overrunning clutch (Ref.
not at all. Sec. 63−10−00).
Main transmission requires Leakage at main transmission input If leakage is found at input shaft or
frequent addition of oil. or output seals. tail rotor shaft, replace seal
according to instructions (Ref. COM).
If leakage is at main rotor drive shaft,
replace transmission (Ref. Sec.
63−20−00).
Oil leak around accessory drive Tighten cover or replace

cover. transmission (Ref. Sec. 63−20−00).
Oil temperature warning light Defective oil temperature sender. Replace oil temperature sender (Ref.
comes on when oil temperature is Sec. 63−21−00).
normal.
Oil temperature warning light Defective cooling blower. Repair or replace cooling blower
comes on when oil temperature is (Ref. Sec. 63−21−00).
abnormally high.
Low or high oil level in Establish correct oil level (Ref. Sec.
transmission. 12−00−00).
Defective lubrication pump. Replace pump (Ref. COM).
Defective oil cooler bypass valve. Replace valve. (Ref. Sec.

63−21−00).
Defective bearings or gears. Replace transmission (Ref. Sec.

63−20−00).
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MAINTENANCE MANUAL
Table 101. Troubleshooting Power Train System (Cont.)

NOTE: Noise that indicates a defective transmission should not be confused with normal gear backlash noise at
rundown or low rpm and power conditions.
Excessive noise in main Inadequate oil supply. Service main transmission (Ref. Sec.
Defective bearings or gears. Replace transmission (Ref. Sec.

63−20−00).
Oil pressure warning light (low oil Low oil in main transmission. Service main transmission (Ref. Sec.
pressure) remains lighted at above 12−00−00).
55% N2.
Defective oil pressure switch. Replace oil pressure switch (Ref.
Sec. 63−21−00).
Defective lube pump. Replace lube pump (Sec.

63−20−00).
Filter clogged. Replace filter (Ref. Sec. 63−21−00).
369F5100 Transmission impending Filter clogged. Reset indicator. On second pop−up,

bypass indicator popped. replace filter (Ref. Sec. 63−21−00).
Defective differential pressure Replace differential pressure

indicator. indicator (Ref. COM).
369F5100 Transmission impending Defective differential pressure Replace differential pressure

bypass indicator popped in less indicator. indicator (Ref. COM).
than 100 hours since filter change.
Tail rotor drive shaft damper Damper out of adjustment. Adjust damper (Ref. Sec. 63−15−00).
vibrates.
Damper defective. Replace damper (Ref. Sec.
63−15−00).
Tail rotor drive shaft bent or dented. Replace defective drive shaft (Ref.
Sec. 63−15−00).
Tail rotor out of balance. Adjust tail rotor balance (Ref. Sec.
18−10−00).
Tail rotor transmission output shaft Worn or damaged bearing or gear Replace tail rotor transmission (Ref.
vibrates. in tail rotor transmission. Sec. 63−25−10).
Excessive shaft wobble or end play Replace tail rotor transmission (Ref.
(Ref. Sec. 63−15−10). Sec. 63−25−10).
Excessive noise in tail rotor Inadequate oil supply. Service tail rotor transmission (Ref.
transmission. Sec. 12−00−00).
Defective bearings or gears in tail Replace tail rotor transmission (Ref.

rotor transmission. Sec. 63−25−10).
Page 102
MAINTENANCE MANUAL
Table 101. Troubleshooting Power Train System (Cont.)

Chip detector caution light on. Metallic chips in either main Inspect and clean chip detector
transmission, fan transmission or magnetic plugs. If there are heavy
tail rotor transmission. chip deposits (chips larger than 1/8
inch in any direction), replace
transmission. If chips are smaller,
drain and refill transmission with new
oil. Reinstall chip detector and check
after four hours of flight. If more
chips are found, replace
transmission (main − Sec. 63−20−00
or 63−20−25; tail rotor − Sec.
63−25−10; fan − 63−25−30).
Chip detector caution light is on, Defective chip detector circuit Troubleshoot chip detector circuit
but no chips are on detector. components. (Ref. CSP−HMI−3).
NOTE: High frequency vibrations in helicopter can also be caused by components in other systems.
High frequency vibrations. Loose tail rotor drive shaft Tighten coupling bolts (Ref. Sec.
coupling(s). 63−15−00).
Tail rotor drive shaft coupling Shim correctly (Ref. Sec. 63−15−00).
shimmed improperly.
Loose, mismatched or bottomed Tighten or install correct hardware

hardware retaining tail rotor drive and be sure hardware is installed
shaft coupling to main correctly (Ref. Sec. 63−15−00).
transmission.
Cooling blower impeller has cracks, Replace impeller (Ref. Sec.

loose rivets, defective blades or 63−21−00).
other damage.
Tail rotor drive shaft damper out of Adjust damper friction (Ref. Sec.
adjustment. 63−15−00).
Defective overrunning clutch. Replace overrunning clutch (Ref.

Sec. 63−10−00).
Tail rotor drive shaft damaged. Replace shaft (Ref. Sec. 63−15−00).
Abnormal drag in drive system. Excessive drag in main Replace transmission (Ref. Sec.
NOTE: Drag is excessive when force required to rotate transmission input shaft exceeds 25 inch−pounds (2.82
Nm) with all shafting disconnected and transmission temperature between 50°F (10°C) and 100°F (38°C).
Page 103
MAINTENANCE MANUAL
TAIL ROTOR TRANSMISSION
TAIL ROTOR DRIVE

MAIN ROTOR DRIVE SHAFT DAMPER
SHAFT
MAIN TRANSMISSION
TAIL ROTOR DRIVE SHAFT
COOLING BLOWER
MAIN TRANSMISSION
DRIVE SHAFT
DRAIN LINE
FAN TRANSMISSION
FAN GEARBOX
DRIVE SHAFT
ANTI-TORQUE FAN
FAN INTER-CONNECT
DRIVE SHAFT
G63-0000A
Figure 101. Power Train System
Page 104
MAINTENANCE MANUAL
Section
63−10−00
Drive Shafts /
Clutches / Couplings
(369D/E/FF −
500/600N)
MAINTENANCE MANUAL
DRIVE SHAFTS / CLUTCHES / COUPLINGS

1. Main Rotor Drive Shaft B. Main Rotor Drive Shaft Installation
The main rotor drive shaft is a shot-peened,

steel alloy forging having a nitrided spline at Special Tools
one end that mates with the transmission (Ref. Section 91-00-00)
output shaft, and a flanged opposite end that Item Nomenclature
attaches to the rotor hub with seven bolts and ST704 Adapter, torque wrench
three eyebolts.
2. Main Rotor Drive Shaft Replacement Damage to main rotor drive

CAUTION shaft or transmission splines
can occur during installation. Care should
(Ref. Figure 401)
be taken while meshing driveshaft splines
into transmission output splines to prevent
When removing or installing the
CAUTION main rotor drive shaft external-
damage.
wrenching bolts or eyebolts, always hold (1). Slowly and carefully lower drive shaft
bolts stationary while installing or remov through main rotor hub and mast until
ing nuts. Never turn external-wrenching rotor shaft splines and transmission
bolts or eyebolts while inserting or removing shaft splines engage.
from drive shaft holes.
(2). Rotate hub to align holes in flange with
A. Main Rotor Drive Shaft Removal holes in drive shaft.
Main rotor drive shaft is a high
CAUTION ly stressed part. Do not allow
(3). Install three eyebolts, washers, and
nuts. Using torque wrench adapter
tools to strike shaft, or shaft to strike any (ST704), torque nuts to 120—140
object. Any impact damage can require re inch-pounds (13.56—15.82 Nm).
placement of drive shaft.
(4). With fairing support spacers and
(1). Remove main rotor fairing. special washers in place, position main
rotor fairing support so that eyebolt
(2). Remove seven external-wrenching shoulders are inserted in large holes in
bolts; and associated hardware. Lift off fairing support. Make certain that
main rotor fairing support and remove support extensions are between pitch
seven spacers. housings.
Any time drive shaft is removed, (5). Install seven external-wrench bolts,
CAUTION cover opening in top of main ro seven washers and nuts as in step (3).
tor hub to prevent possible entry of foreign above.
matter into hub, mast and transmission.
NOTE: Phillips screws, used to attach main ro
NOTE: If special washers between fairing sup tor hub fairing, can be replaced with hex
port and drive shaft dome are not bonded to head Phillips screws (PN NAS1096-3-10)
the underside of fairing support, remove and washers (PN HS306-223). The hex
washers before proceeding. head will make torquing the screws easier.
(3). Remove three eyebolts and associated (6). Install main rotor fairing with five
hardware and lift drive shaft clear of screws. Torque screws to 20—25
main rotor hub. inch-pounds (2.26—2.82 Nm).
Page 401
MAINTENANCE MANUAL
HUB FAIRING
EYEBOLT (3 PL)
AS SHOWN (NOTE 4) SCREW (5 PL)
NOTE 1 WASHER (5 PL)
EXTERNAL
WRENCHING BOLT (7 PL)
NOTE 1
FAIRING SUPPORT
(NOTE 5)
NOTE 3
SPACER (7 PL)
CORK
(NOTE 2)
HUB DRIVE SHAFT
THIN WASHERS (10 PL)
TORQUE WRENCH
ADAPTER
369D/E/FF - 500N INSTALLATION
NOTES:
1. INSTALLED WITH COUNTERSINK NEXT TO BOLT HEAD, WASHERS UNDER NUT ARE FLAT.
2. INSTALLED WITH SEALING COMPOUND.
3. MAY BE BONDED TO FAIRING SUPPORT.
4. WHEN INSTALLING EYEBOLTS, ENSURE FAIRING SUPPORT ARMS ARE NOT POSITIONED OVER
PITCH HOUSINGS.
5. THREE HOLES IN FAIRING SUPPORT ARE LARGER TO GO OVER EYEBOLTS AND TO AID IN FAIRING
SUPPORT ALIGNMENT.
G63-1001B
Figure 401. Main Rotor Drive Shaft Installation (Sheet 1 of 2)
Page 402
MAINTENANCE MANUAL
MAIN ROTOR BOLT (9 PL)

DRIVE SHAFT
EYEBOLT (3 PL) COUNTERSUNK WASHER

(NOTE 1) (NOTE 2)
COUNTERSUNK WASHER FLAT WASHER

(NOTE 2)
FLAT WASHER MAIN ROTOR HUB
WASHER
WASHER
NUT
NUT
600N INSTALLATION
NOTES:
1. ALIGN HOLES IN EYE BOLTS TO MATCH HOISTING ADAPTER.
2. COUNTERSINK IN WASHER TO FACE BOLT HEAD. 6G63-008
Figure 401. Main Rotor Drive Shaft Installation (Sheet 2 of 2)
Page 403
MAINTENANCE MANUAL
3. Main Transmission Drive Shaft less than 25 inch-pounds (2.82

Nm) before torquing bolt.
The main transmission drive shaft is equipped
with a flexible joint (diaphragm) and drive (b). For 36F5450 clutch, actual drag
shaft coupling at each end. The shaft connects torque plus 315—365 inch-
the overrunning clutch and the transmission pounds (35.59—41.24 Nm). If bolt
input shaft. is not seated and/or existing torque is
found to be less than 315—365
4. Main Transmission Drive Shaft inch-pounds (35.59—41.24 Nm),
Replacement ensure self-locking drag torque is not
less than 25 inch-pounds (2.82
(Ref. Figure 402) Nm) before torquing bolt.
Compression of drive shaft dia
A. Main Transmission Drive Shaft Removal CAUTION phragms (static state) is limited
(Bendix and Kamatics)
to 0.020 inch (0.508 mm). Do not stress dia
(1). Remove sound insulation and main phragms by forcing drive shaft into position
transmission access cover over main for installation in step (2). below.
transmission drive shaft in cargo NOTE: If original shaft and couplings are being
compartment. reinstalled, a check of shimming as de
scribed below is not necessary. Install drive
(2). Remove eight bolts and washers that shaft to clutch and transmission couplings
secure shaft to couplings. as described in steps (1). above and (4). be
low.
(3). Remove drive shaft; use care to keep it
from striking any object. (2). Position drive shaft alongside transmis
sion input and clutch couplings. If
NOTE: Clutch oil level should be checked any compression is required to fit shaft
time engine or main drive shaft is removed between couplings, continue with step
(Ref. Sec. 12-00-00). (3). below. If there is a gap between
drive shaft flanges and coupling
B. Main Transmission Drive Shaft flanges, continue with step (6). below.
Installation (Bendix and Kamatics)
NOTE: Removal or addition of shims should be
accomplished at transmission input cou
pling only. Shims at overrunning clutch cou
pling are of predetermined thickness to pre
Item Nomenclature
vent O-ring damage and oil leakage.
CM112 Anti-seize compound high temperature (3). Remove coupling bolt that secures
transmission input coupling; remove
coupling and shims.
(1). Check overrunning clutch for correct oil
level, indications of oil seepage, drive CAUTION
shaft couplings for corrosion and that
coupling bolt securing clutch coupling is D The 0.010 inch (0.254 mm) minimum
torqued to: measurement between the bolt seating
surface and the input shaft must be ob
(a). For 369A5350 clutch, actual drag tained to ensure proper clamp up. Warped
torque plus 250—300 inch- shims or foreign material could provide a
pounds (28.25—33.90 Nm). If bolt false 0.010 inch (0.254 mm) minimum
is not seated and/or existing torque is measurement and improper clamp up
found to be less than 250—300 could result during normal operation
inch-pounds (28.25—33.90 Nm), which can damage the main transmission
ensure self-locking drag torque is not input shaft.
Page 404
MAINTENANCE MANUAL
D Do not use clutch coupling shims under bolts to 50—70 inch-pounds

transmission input coupling. Inside diam (5.65—7.91 Nm).
eter of clutch coupling shims, 1.260-1.270
inches (3.2004-3.2258 cm), is approxi (7). Manually align drive shaft and trans
mately 0.070 inch (1.778 mm) larger than mission input coupling flanges:
inside diameter of shims used at trans (8). Using feeler gage, measure gap be
mission coupling. Incorrect diameters can tween flanges. Gap should be 0.010
cause an improperly seated shim, mis inch (0.254 mm) gap to 0.020 inch
alignment and cocked coupling. (0.508 mm) compression.
NOTE: Transmission input coupling shims are (a). If gap is 0.010 inch (0.254 mm) or
laminated stock. Each lamination is 0.002 less, attach upper end of drive shaft
inch (0.051 mm) thick. Peel to thickness re to transmission input coupling with
quired. four bolts and washers. Torque bolts
to 50—70 inch-pounds (5.65—7.91
(4). Add sufficient shims to get a measure Nm).
ment of 0.010 inch (0.254 mm) mini
mum between bolt seating surface on (b). If gap exceeds 0.010 inch (0.254 mm),
coupling and transmission input shaft. repeat step (3). thru (5). above,
except install thickness of shims
equal to measured gap, plus thick
(5). Lubricate input shaft splines with ness that results in not more than
grease (CM111). Coat bolt threads with 0.010 inch (0.254 mm) gap between
anti-seize compound (CM112). Rein coupling and drive shaft nor more
stall coupling and bolt. Check coupling than 0.020 inch (0.508 mm) compres
bolt for minimum drag of 25 inch- sion of flexible couplings. Install four
pounds (2.82 Nm). Torque bolt to bolts and washers and torque bolts to
250—300 inch-pounds (28.25—33.90 50—70 inch-pounds (5.65—7.91
Nm) plus drag torque. Nm).
(6). Attach drive shaft to clutch coupling (9). Install access door and sound insulation
with four bolts and washers. Torque over main transmission drive shaft.
TRANSMISSION INPUT COUPLING

INTERNAL-WRENCHING BOLT
DRIVE SHAFT COUPLING (2 PL)
MAIN TRANSMISSION DRIVE SHAFT
(EARLY CONFIGURATION) (BENDIX)
DRIVE SHAFT COUPLING (2 PL) FLEXIBLE JOINT
(DIAPHRAGM 2 PL)
0.010 IN. (0.254 MM)

MAXIMUM GAP
0.020 IN. (0.508 MM)
MAXIMUM COMPRESSION CLUTCH COUPLING
MAIN TRANSMISSION DRIVE SHAFT

DRIVE (CURRENT CONFIGURATION) (KAMATICS)
PULLEY
TRANSMISSION INPUT COUPLING-TO-DRIVE
SHAFT COUPLING ATTACHMENT
G63-1002C
Figure 402. Main Transmission Drive Shaft Installation
Page 405
MAINTENANCE MANUAL
5. Overrunning Clutch (b). Insert a long 3/8 inch (9.525 mm) hex
wrench, approximately 10 inches
The overrunning clutch transmits power from (25.4 cm) long, through tool and into
the engine to the main transmission drive back of clutch assembly.
shaft. The clutch disengages the engine from
the remainder of the drive system in case of (c). While holding internal hex wrench
engine failure and during autorotations. [3/8 inch (9.525 mm)], turn external
hex wrench [1.00 inch (2.54 cm)]
The clutch contains a sprag unit that disen counter-clockwise to remove bolt
gages automatically when N2 rpm is less than from back of clutch.
corresponding main rotor rpm.
(5). Remove nuts and washers that secure
Repair and overhaul information for the overrunning clutch; remove clutch.
overrunning clutch can be found in COM.
(6). If clutch is being replaced, install spare
6. Overrunning Clutch Replacement coupling bolt and O-ring or suitable
plug in output shaft (clutch inner race
(Ref. Figure 403 or Figure 404) bore) to prevent contamination during
clutch handling, shipping or storage.
A. Overrunning Clutch Removal
NOTE: Operating lubricant is an approved pre
servative for shipping or storage.
(Ref. Section 91−00−00) (7). Inspect overrunning clutch splines (Ref.
Item Nomenclature Overrunning Clutch Inspection).
CM208 Barrier material
(8). Wrap clutch in barrier material
(CM208) to protect splined areas of
NOTE: For removal of only the internal clutch shafts.
subassembly as an alternative to complete
clutch removal, refer to Overrunning Clutch B. Overrunning Clutch Installation
Subassembly Removal.
(1). Remove engine. Consumable Materials

(2). Remove bolts, washers, nuts and engine Item Nomenclature
shaft firewall seal from clutch. CM111 Grease, aircraft
CM112 Anti-seize compound high temperature
NOTE: Removal of clutch coupling from clutch
is unnecessary unless clutch is replaced. CM125 Oil
CM126 Oil, turbine
(3). Remove coupling bolt, packing, clutch
coupling and coupling shim(s). Keep
shim(s) with coupling for reuse. (1). If clutch is new, (369A5350 clutch only)
Reinstall bolt and packing to prevent drain preservative oil. Trapped oil can
spillage of lubricating oil from clutch be removed by inverting clutch a
housing during final steps of removal. minimum of three times. Add lubricat
ing oil (CM125 or CM126) (Ref. Sec.
(4). On 369F5450 clutch, remove output 12-00-00). Temporarily install coupling
shaft cover plate from back of engine bolt and packing.
accessory drive to gain access to clutch
bolt. NOTE: Relubricate splines on clutch input
shaft and splines inside engine power and
(a). Insert tool (Ref. Figure 405) to accessory gearbox with grease (CM111)
engage bolt in back of clutch. prior to reinstalling overrunning clutch.
Page 406
MAINTENANCE MANUAL
CLUTCH
LAMINATED SHIM
GAP
0.035 IN. (0.889 MM)
0.055 IN. (1.397 MM)
MAIN DRIVE SHAFT

COUPLING OVERRUNNING
CLUTCH SHAFT
COUPLING
BOLT CLUTCH
COUPLING
COUPLING-TO-CLUTCH SHIMMING
LAMINATED
COUPLING SHIM
ENGINE SHAFT
FIREWALL SEAL
O-RING
OVERRUNNING
CLUTCH
REPLACEMENT OF COMPLETE CLUTCH
CLUTCH SUBASSEMBLY
RETAINING RING
(BEVELED SIDE OUTWARD) ENGINE POWER AND
ACCESSORY GEARBOX
ENGINE SHAFT
FIREWALL SEAL
REPAIR BY REPLACEMENT CLUTCH HOUSING

OF CLUTCH SUBASSEMBLY
G63-1003A
Figure 403. 369A5350 Overrunning Clutch Installation
Page 407
MAINTENANCE MANUAL
369F5160
COUPLING BOLT 369F5133
COUPLING
369F5467-1 SEAL ASSEMBLY

3X MS51957-42 SCREW
3X NAS620A8L WASHER
369F5450-501
CLUTCH ASSEMBLY
369F5468-1 BOLT (C20 SERIES ENGINE)

369F5469-1 BOLT (C30/C47 ENGINE)
M83248/1-019 PACKING
NOTE
M83248/2-026 PACKING
0.010-0.030 IN.
(0.254-0.762 MM)
COUPLING SHIMMING
ROTATED
NOTE: LUBRICATE SPLINES BEFORE ASSEMBLY WITH GREASE

(CM111). PACK ALL VOIDS AND GAPS BETWEEN THE OUTSIDE
OF BOLT AND INSIDE OF ENGINE POWER OUTPUT SHAFT. CSP102-013C
Figure 404. 369F5450 Overrunning Clutch Installation
Page 408
MAINTENANCE MANUAL
(2). Coat clutch splines and internal splines (5). Shim coupling on 369A5350 clutch
of engine power accessory gearbox with assembly as follows:
lubricant (CM111). Insert overrunning
(a). Remove output coupling bolt and
clutch outer-race spline into engine and
coupling.
install six washers and nuts.
Deleted. (b). Shim coupling to achieve 0.035-0.055
inch (0.889-1.397 mm) step above
(3). For 369F5450 clutch installation: clutch output shaft.
(a). Remove power output shaft cover When installing clutch coupling
CAUTION bolt, installation torque on the
plate from back of engine (Ref. Sec.
01-00-00, Rolls-Royce Operation bolt must be 250—300 inch-pounds
and Maintenance Manual). (28.25—33.90 Nm) plus drag torque for
the 369A5350 clutch or 315—365 inch-
(b). Install O-rings on 369F5469 pounds (35.59—41.24 Nm) plus drag
(C30/C47 engine) or 369F5468 (C20 torque for the 369F5450 clutch. Torquing to
series engines) bolt (Ref. Figure 404). lower value reduces clutch bearing clamp-
up and can result in bearing race spinning.
NOTE: Fill all voids and gaps between the out
side of bolt and inside of engine shaft with (6). Coat clutch-to-coupling splines with
grease. grease (CM111); install shim(s) and
clutch coupling. Coat coupling bolt
(c). Lubricate internal spline area of threads with anti-seize compound
engine output shaft with grease (CM112); install bolt with new O-ring.
(CM111). Check for bolt self-locking drag torque
of 25 inch-pounds (2.82 Nm) mini
(d). Lubricate bolt threads with anti- mum to 200 inch-pounds (22.60
seize compound (CM112) and insert Nm) maximum. Replace bolt if torque
through engine into overrunning values are exceeded.
clutch assembly.
(a). For 369A5350 clutch, torque coupling
(e). Using bolt removal tool (Ref. bolt to actual drag torque plus
Figure 405) either hold output 250—300 inch-pounds
coupling to prevent overrunning (28.25—33.90 Nm).
clutch from turning or insert hex (b). For 36F5450 clutch, torque coupling
wrench through bolt to engage and bolt to actual drag torque plus
hold clutch. 315—365 inch-pounds
(35.59—41.24 Nm).
(f). Torque bolt to 250—300 inch-
pounds (28.25—33.90 Nm) plus (7). Install engine shaft firewall seal, bolts,
drag torque. washers, and nuts.
(8). Reinstall engine.
(g). Using existing hardware, reinstall
power output shaft cover plate on 7. Overrunning Clutch Subassembly
back of engine (Ref. Sec. 01-00-00, Replacement
Rolls-Royce Operation and Mainte
(Ref. Figure 403 or Figure 404)
nance Manual).
A. Overrunning Clutch Subassembly
(4). Shim coupling on 369F5450 clutch Removal
assembly as follows:
(1). Remove main transmission drive shaft.
(a). Remove output coupling bolt and (2). For 369F5450 clutch installation:
coupling.
(a). Remove power output shaft cover
(b). Shim coupling to achieve 0.010-0.030 plate from back of engine (Ref. Sec.
inch (0.254-0.762 mm) step above 01-00-00, Rolls-Royce Operation
clutch output shaft. and Maintenance Manual).
Page 409
MAINTENANCE MANUAL
(b). Insert tool (Ref. Figure 405) to (6). For 369F5450 clutch installation:
engage bolt in back of clutch.
(a). Remove power output shaft cover
(c). Insert a long 3/8 inch (9.525 mm) hex plate from back of engine (Ref. Sec.
wrench, approximately 10 inches 01-00-00, Rolls-Royce Operation
(25.4 cm) long, through tool and into and Maintenance Manual).
back of clutch assembly.
(b). Install O-rings on 369F5469
(d). While holding internal hex wrench
(C30/C47 engine) or 369F5468 (C20
[3/8 inch (9.525 mm)], turn external
series engines) bolt (Ref. Figure 404).
hex wrench [1.00 inch (2.54 cm)]
counter-clockwise to remove bolt
from back of clutch. NOTE: Fill all voids and gaps between the out
side of bolt and inside of engine shaft with
(3). Remove coupling bolt, clutch coupling grease.
and shims.
(c). Lubricate internal spline area of
(4). Remove retaining ring from clutch engine output shaft with grease
housing. Then pull complete clutch (CM111).
subassembly out of housing.
(d). Lubricate bolt threads with anti-
(5). Inspect lock spacer crimp for cracks seize compound (CM112) and insert
using a 10x magnifying lens (Ref. through engine into overrunning
Overrunning Clutch Inspection) clutch assembly.
B. Overrunning Clutch Subassembly
Installation (e). Using bolt removal tool (Ref.
Figure 405) either hold output
coupling to prevent overrunning
Consumable Materials clutch from turning or insert hex
(Ref. Section 91−00−00) wrench through bolt to engage and
Item Nomenclature hold clutch.
CM125 Oil
(f). Torque bolt to 250—300 inch-
pounds (28.25—33.90 Nm) plus
CM126 Oil, turbine drag torque.
(1). Remove shipping plug and O-ring from (g). Using existing hardware, reinstall
end of shaft in replacement clutch power output shaft cover plate on
subassembly. back of engine (Ref. Sec. 01-00-00,
Rolls-Royce Operation and Mainte
(2). Drain preservative oil from clutch nance Manual).
subassembly by inverting it several
times. Add lubricating oil (CM125 or (h). Lubricate coupling bolt threads with
CM126) (Ref. Sec. 12-00-00). anti-seize compound (CM112).
(3). Coat clutch splines with grease (7). Install clutch coupling, shims and
(CM111). coupling bolt.
(4). Using care to avoid oil spillage, insert (8). Install main transmission drive shaft.
clutch subassembly into clutch housing
and install retaining ring with beveled
side outward. 8. Overrunning Clutch−to−Firewall Seal
(5). Check fluid level of clutch assembly The overrunning clutch-to-firewall seal
before installing clutch coupling (Ref. consists of a stamped steel backing and a seal
Sec. 12-00-00). bonded to the cupped diameter of the backing.
Page 410
MAINTENANCE MANUAL
9. Overrunning Clutch−to−Firewall Seal

Replacement CAUTION
(Ref. Figure 403) D The 0.010 inch to 0.060 inch (0.254 mm -

1.524 mm) measurement between the bolt
(1). Remove engine. seating surface and the input shaft must
be obtained to make sure proper clamp
(2). Remove three bolts, six washers and up. Warped shims or foreign material
three nuts that attach firewall seal to could provide a false 0.010 inch (0.254
overrunning clutch. mm) minimum measurement and im
proper clamp up could result during nor
(3). Position replacement clutch-to-firewall mal operation which can damage the
seal assembly on flange of clutch with main transmission input shaft.
seam orientated at the 6 o'clock position
and secure with attaching hardware. D Do not use clutch coupling shims under
transmission input coupling. Inside diam
10. Main Transmission Drive Shaft Couplings eter of clutch coupling shims, 1.260-1.270
inches (3.2004-3.2258 cm), is approxi
The main transmission drive shaft couplings mately 0.070 inch (1.778 mm) larger than
connect the overrunning clutch to the drive inside diameter of shims used at trans
shaft and the drive shaft to the main transmis mission coupling. Incorrect diameters can
sion. cause an improperly seated shim, mis
alignment and cocked coupling.
11. Main Transmission Drive Shaft Coupling
Replacement NOTE: Transmission input coupling shims are
laminated stock. Each lamination is 0.002
(Ref. Figure 402) inch (0.051 mm) thick. Peel to thickness re
quired.
A. Main Transmission Drive Shaft Coupling
Removal (1). Install previously removed shims or
refer to Main Transmission Drive Shaft
(1). Remove drive shaft; use care to keep it Installation for shim thickness calcula
from striking any object. tion.
(2). Remove coupling bolt from main (2). Lubricate drive shaft splines with
transmission and overrunning clutch. grease (CM111) and install in place.
Retain shim(s) with couplings for Coat bolt threads with anti-seize
reinstallation. compound (CM112) and install.
B. Main Transmission Drive Shaft Coupling (a). For 369D25100 transmission instal
Installation lation, torque coupling bolt to actual
drag torque plus 250—300 inch-
pounds (28.25—33.90 Nm). If bolt
is not seated and/or existing torque is
Item Nomenclature
found to be less than 250—300
inch-pounds (28.25—33.90 Nm),
CM111 Grease, aircraft ensure self-locking drag torque is not
CM112 Anti-seize compound high temperature less than 25 inch-pounds (2.82
Page 411
MAINTENANCE MANUAL
(b). For 369F5100 transmission installa (2). Remove couplings from main and tail
tion, torque coupling bolt to actual rotor transmissions. Retain shims with
drag torque plus 315—365 inch- couplings for reinstallation.
pounds (35.59—41.24 Nm). If bolt
is not seated and/or existing torque is
found to be less than 315—365 Do not immerse Bendix flexible
inch-pounds (35.59—41.24 Nm), CAUTION couplings in fluid or cleansers
ensure self-locking drag torque is not such as magnetic particle, fluorescent pene
less than 25 inch-pounds (2.82 trant, visible dye etc. Do not apply corrosion
protection fluids unless coupling has been
(3). Reinstall main transmission drive cleaned with solvent or detergent. Apply
shaft, main transmission access cover any corrosion protection very sparingly to
and sound insulation. outside only.
12. Tail Rotor Drive Shaft Coupling
Replacement B. Tail Rotor Drive Shaft Coupling
A. Tail Rotor Drive Shaft Coupling Removal Installation
(1). Remove tail rotor drive shaft (Ref. Sec. According to type of coupling installed, instal
63-15-10). lation of tail rotor shaft requires shimming of
NOTE: With Bendix coupling installed, remove couplings, and in some instances, tail rotor
socket from main transmission coupling gearbox-to-tailboom shimming (Ref. Sec.
only if visual inspection reveals signs of con 63-15-10, Tail Rotor Drive Shaft Installa
tact between coupling bolt and socket. tion).
Page 412
MAINTENANCE MANUAL
0.375 IN. (9.53 MM HEX BAR TO PICK UP 0.375 IN.

(9.53 MM) HEX SOCKET IN CLUTCH OUTER RACE
(NOTE 1)
OUTER RACE ENGINE BOLT TORQUED TO

250 - 300 INCH-POUNDS (28.25 - 33.90 NM)
1.00 IN. (2.54 CM) HEX BAR TO PICK UP

1.00 IN. (2.54 CM) HEX SOCKET IN
ENGINE BOLT (THRU HOLE IN CENTER)
ÎÎÎÎÎÎ ÎÎÎ
0.72 IN.
(18.29 MM)
ÎÎÎ
ÎÎÎÎÎÎ 1.23 IN.
ÎÎÎ
(3.124 CM) TOOL REQUIRED
(NOTE 3) FOR BOLT REMOVAL
0.68 IN.
(17.27 MM)
ENGINE PTO SHAFT 2.50 IN.
(6.35 CM)
(NOTE 3)
9.00 IN.
(22.86 CM)
(NOTE 3)
369F5450 CLUTCH ASSEMBLY
0.375 IN. (9.53 MM) HEX 0.375 IN. (9.53 MM) SQUARE
ÎÎÎÎÎÎÎ
DRIVE EXTENSION
ÎÎÎÎÎÎÎ
STANDARD 3/8” SOCKET 1.00 IN. (2.54 CM) HEX
(NOTES 2, 3)
369F5468/5469 BOLT REMOVAL TOOL
NOTES:
1. HOLD HEX BAR STAEDY WHEN TORQUING BOLT.
2. TOOL TO BE A MINIMUM OF 2.5 INCHES IN LENGTH
TO CLEAR STUDS ON ENGINE.
3. THIS IS MINIMUM LENGTH, TOOL MAY BE MADE
LONGER FOR EASE OF MAINTENANCE.
G63-1024A
Figure 405. 369F5468/5469 Bolt Removal Tool
Page 413
MAINTENANCE MANUAL
Page 414
MAINTENANCE MANUAL

INSPECTION/CHECK
1. 369D25510 Main Rotor Drive Shaft (a). Thoroughly clean shaft spline with
Inspection dry cleaning solvent (CM234) to
remove oil, dirt and grease.
(Ref. Figure 601)
(b). Using magnifying glass and light,
inspect spline for cracks. Pay particu
Consumable Materials lar attention to side of each tooth
(Ref. Section 91−00−00) with large wear pattern (hairline
Item Nomenclature cracks appear crescent-shaped
CM234 Solvent, dry-cleaning usually at center bottom of tooth in
root area).
(c). Inspect neck of spline (area where
spline and shaft meet) for cracks.
(1). Inspect all surfaces of drive shaft for
dents, nicks, scratches and evidence of (7). Check shaft straightness. When rotated
deformation. No damage of any kind is between centers, run-out must not
permissible in the area within two exceed 0.040 inch (1.016 mm) TIR
inches of the spline. Dents less than (allowable dents excluded).
0.050 inch (1.270 mm) deep and 0.050
inch (1.270 mm) diameter are permissi 2. 600N5510 and 369F5510 Main Rotor Drive
ble in other areas. A dent is defined as Shaft Inspection
a smooth depression of surface with no
sharp edges or abrupt changes in (Ref. Figure 601 and Figure 602)
contour. No nicks or scratches are
permitted. Consumable Materials
(2). If shaft condition is questionable, do a Item Nomenclature
magnetic particle inspection according
to Specification MIL-I-6868. No CM234 Solvent, dry-cleaning
surface or subsurface defects are
permissible. Anytime main rotor drive shaft
CAUTION is removed, cover opening at top
(3). Inspect all external surfaces of shaft for of main rotor hub to prevent entry of any
corrosion. foreign material into hub, mast and trans
mission.
(4). Remove cork plug and inspect shaft
interior for corrosion. Remove light (1). Inspect overtorque verification stripe
surface corrosion and pitting which can for straightness.
be removed without causing shaft ID to
exceed 1.655 inches (4.2037 cm). (2). Inspect all surfaces of drive shaft for
dents, nicks, scratches and evidence of
(5). Inspect splines on end of drive shaft for deformation. No damage of any kind is
excessive wear by measuring distance permissible in the area within two
across two 0.108 inch (2.7432 mm) inches of the spline. Dents less than
diameter pins placed in opposite spline 0.050 inch (1.270 mm) deep and 0.050
grooves. Dimension should be 2.2625 inch (1.270 mm) diameter are permissi
inches (5.74675 cm) minimum. ble in other areas. A dent is defined as
a smooth depression of surface with no
(6). Inspect shaft spline for cracks-using sharp edges or abrupt changes in
bright light and 5X to 10X magnifying contour. No nicks or scratches are
glass. permitted.
Page 601
MAINTENANCE MANUAL
1.70 IN.
(4.318 CM)
8.0 IN.
(20.32 CM)
TOOTH
CONTACT
0.010 IN. 0.050 IN. (1.270 MM) AREA
(0.254 MM) MAX
MAX. DEPTH 5.40 IN.
13.716 CM)
0.050 IN.
(1.270 MM)
MAX
AREA 4
AREA 4
ROOT AREA
(TYP)
SPLINE
NECK
NOTE: LARGER WEAR

PAY PARTICULAR ATTENTION TO ROOT AREA AT EACH PATTERN (TYP)
SPLINE TOOTH. SIMULATED CRACKS SHOWN. ALSO SIMULATED CRACKS
CHECK SPLINE NECK (SHADED AREA) FOR CRACKS. SHOWN
G63-1011A
Figure 601. Main Rotor Drive Shaft Inspection
Page 602
MAINTENANCE MANUAL
(3). If shaft condition is questionable, do a

magnetic particle inspection according
to Specification MIL-I-6868. No
surface or subsurface defects are
permissible.
(4). Inspect all external surfaces of shaft for

corrosion.
OVERTORQUE
VERIFICATION STRIPE
(5). Remove cork plug and inspect shaft
interior for corrosion. Remove light
surface corrosion and pitting which can
be removed without causing shaft ID to
exceed 1.655 inches (4.2037 cm).
(6). Inspect splines on end of drive shaft for

excessive wear by measuring distance
across two 0.108 inch (2.7432 mm)
diameter pins placed in opposite spline
grooves. Dimension should be 2.2625
inches (5.74675 cm) minimum.
(7). Inspect shaft spline for cracks-using

bright light and 5X to 10X magnifying
glass.
(a). Thoroughly clean shaft spline with 6G63-003

dry cleaning solvent (CM234) to
remove oil, dirt and grease. Figure 602. Main Rotor Drive Shaft
Overtorque Verification Stripe
(b). Using magnifying glass and light,
inspect spline for cracks. Pay particu
lar attention to side of each tooth 3. Main Transmission Drive Shaft Inspection
with large wear pattern (hairline (Bendix)
cracks appear crescent-shaped
usually at center bottom of tooth in (Ref. Figure 402)
root area).
(c). Inspect neck of spline (area where Consumable Materials

spline and shaft meet) for cracks. (Ref. Section 91−00−00)
Item Nomenclature
(8). Check shaft straightness. When rotated
between centers, run-out must not CM318 Primer
exceed 0.040 inch (1.016 mm) TIR
(allowable dents excluded).
(1). Inspect drive shaft diaphragms for
(9). Apply thin coat of sealing compound dents, cracks, scratches, nicks, rust
(CM425), mixed according to container spots and evidence of joint separation
instructions, to all cork plug surfaces; from shaft or outside edges. Evidence of
press cork into drive shaft until top of any such defects on either diaphragm
cork is flush with top of drive shaft. requires removal of shaft from service.
Allow sealing compound to cure
according to container instructions. (2). Inspect drive shaft tube between
Apply second coat of sealing compound diaphragms for dents, scratches, cracks
to exposed surfaces of cork; allow to dry. or corrosion pits.
Page 603
MAINTENANCE MANUAL
(a). Measure depth and diameter of 4. Main Transmission Drive Shaft Inspection
dents. Dents that blend smoothly into (Kamatics)
surrounding surface area with no
(Ref. Figure 402)
sharp change in contour and do not
exceed 0.015 inch (0.381 mm) depth
are acceptable. Dents not within Consumable Materials
these limits require removal of shaft (Ref. Section 91−00−00)
from service. Item Nomenclature
CM318 Primer
(b). Measure depth of cracks, nicks,

corrosion pits, or scratches; length (1). Inspect drive shaft for dents, cracks,
and direction are not limited. Maxi scratches, nicks, rust spots and evi
mum depth allowed before rework is dence of joint separation from shaft or
0.003 inch (0.076 mm). outside edges.
(2). Inspect drive shaft tube between
couplings for dents, scratches, cracks or
(c). Check suspected cracks using dye
corrosion pits.
penetrant. If crack indication ap
pears, remove black (phenolic com (a). Measure depth and diameter of
pound) coating from area. dents. Dents that blend smoothly into
surrounding surface area with no
NOTE: Drive shaft is coated with special phe exceed 0.010 inch (0.254 mm) in
nolic thermosetting compound. It is a brittle depth are acceptable. Dents not
coating that can indicate a crack that does within these limits require removal
not penetrate tube. of shaft from service.
(b). Measure depth of cracks, nicks,
(d). Re-inspect suspected area using corrosion pits or scratches; length
magnetic-particle or dye-penetrant and direction are not limited. Maxi
methods. If crack does not reappear, mum depth allowed before rework is
touch up cleaned area with primer 0.005 inch (0.127 mm).
coating (CM318) and return part to
(c). Check suspected cracks using dye
service.
penetrant. If crack indication ap
pears, remove coating from surface.
NOTE: Do inspection steps (3). and (4). only if (d). Re-inspect suspected area using
shaft damage is suspected. magnetic particle or dye penetrant
methods. If crack does not reappear,
touch up cleaned area with primer
(3). Inspect shaft tube for out-of-round
coating (CM318) and return part to
condition, which shall not exceed 0.060
service. If shaft is found to be
inch (1.524 mm).
cracked, remove shaft from service.
Kamatics parts cannot be inter
(4). Inspect shaft for straightness. Shaft CAUTION changed between drive shafts.
shall be straight within 0.030 inch
(0.762 mm) at all locations relative to (3). Inspect all attaching hardware for
centerlines of two flange mounting bolt serviceable condition. Discard and
patterns. replace defective hardware.
NOTE: Do the following inspections if shaft
damage is suspected.
(5). Inspect all attaching hardware for
serviceable condition. Check nut plates (4). Inspect shaft tube for out-of-round
for drag torque. Discard and replace condition not to exceed 0.060 inch
defective hardware. (1.524 mm).
Page 604
MAINTENANCE MANUAL
(5). Inspect shaft for straightness. Shaft NOTE: Reference the Component Overhaul
shall be straight within 0.030 inch Manual for inspection information specific
(0.762 mm) at all locations relative to to helicopters equipped with cargo hooks.
centerlines of two flange mounting bolt
patterns. 6. Overrunning Clutch−to−Firewall Seal
Inspection
5. Overrunning Clutch Inspection Inspect firewall seal and backing for cracks,
breaks, corrosion or other damage that can
Consumable Materials prevent complete sealing of firewall opening.
7. Bendix Tail Rotor Drive Shaft Coupling
Inspection
Item Nomenclature
(1). Inspect coupling diaphragms for dents,
cracks, nicks, rust spots and joint
(Ref. Figure 403 and Figure 404) Do the separation at weld junction.
following inspections any time the helicopter
engine or overrunning clutch assembly is (2). Inspect coupling splined section and
removed from the helicopter. For further flange for scratches, nicks, dents,
inspection requirements, refer to Chapter 05 cracks and corrosion pits. No cracks are
and Component Overhaul Manual. allowed. Maximum depth of other
defects allowed before rework is 0.005
NOTE: Overrunning clutch subassembly can inch (0.127 mm).
be replaced with engine installed.
(3). Measure overall length of couplings at
NOTE: Do an inspection of the mating engine three different points. If average of
output splines every time the overrunning readings exceed 2.541 inches (6.45414
clutch is removed from the helicopter. Wear cm), coupling must be replaced.
on the engine output splines can be felt as a (4). Inspect socket and main transmission
“step” inside the splines (ref. the applicable coupling bolt for signs of contact. If
engine maintenance manual). signs of contact are noted, remove and
(1). Check clutch oil level (ref. Sec. reinstall coupling bolt and socket (Ref.
12-00-00). Sec. 63-15-00). Reposition socket and
or bolt so maximum clearance between
(2). Clean clutch input shaft splines with bolt key and socket is obtained.
isopropyl alcohol (CM217), removing
any oil, grease and dirt. 8. Kamatics Coupling Inspection
(1). Inspect coupling springs for dents,
(3). Visually check clutch input shaft
cracks, nicks and rust spots.
splines for excessive wear (ref. Compo
nent Overhaul Manual for acceptable (2). Inspect coupling splined section and
wear tolerances of the clutch input flange for scratches, nicks, dents,
shaft splines). cracks and corrosion pits. No cracks are
allowed. Maximum depth of other
NOTE: If only the overrunning clutch sub defects allowed before rework is 0.005
assembly is removed do the following steps 4 inch (0.127 mm).
and 5.
(3). Measure overall length of coupling at
(4). Using a 10X magnifying glass inspect three different points. If average of
lock washer crimped areas for cracks readings exceed 2.630 inch (6.6802 cm),
(ref. Figure 603) coupling must be replaced.
(5). If any cracks are found replace the lock (4). Inspect drive shaft flange for signs of
washer securing the retaining nut of contact. If signs of contact are noted,
the overrunning clutch assembly. Refer remove coupling bolt, re-shim coupling
to the Component Overhaul Manual for and reinstall coupling bolt (Ref. Sec.
replacement instructions. 63-15-00).
Page 605
MAINTENANCE MANUAL
INNER
CLUTCH
RACE
RETAINING
NUT
SPRAG
ASSEMBLY
LOCK
WASHER
NOTCHES
(5 PL)
LOCK WASHER
SHOWN FLAT
CRIMP
(NOTE)
NOTE: INSPECT CRIMP (5 PL) FOR CRACKS. LOCK WASHER

SHOWN CRIMPED
G63-1000-6031
Figure 603. Typical Clutch Subassembly Lock Washer Crimp
Page 606
MAINTENANCE MANUAL
9. Main Rotor Drive Shaft Inspection (300 (c). Pay particular attention to side of
Hour) (each) tooth with larger wear pattern.
Hairline cracks appear crescent-
(Ref. Figure 601) shaped and at the center and bottom
of tooth in the root area. Also, inspect
neck (shaded area) of spline for
Consumable Materials cracks.
Item Nomenclature
NOTE:
D If cracking is suspected, do a magnetic
particle inspection of shaft spline and
teeth.
Anytime main rotor drive shaft D If cracking or damage is found, the shaft
CAUTION is removed, cover opening at top is no longer airworthy. Contact MDHI
of main rotor hub to prevent entry of any Warranty Department for further in
foreign material into hub, mast and trans structions.
mission. D Inspect replacement drive shaft per steps
(a). thru (c). prior to installation of shaft
(1). Remove main rotor drive shaft (ref. on helicopter.
Main Rotor Drive Shaft Removal). (3). Inspect all other surfaces of the drive
shaft (ref. Main Rotor Drive Shaft
(2). Do a visual inspection of the shaft Inspection).
spline as follows:
NOTE: If surface corrosion or pitting of the
(a). Thoroughly clean with cleaning shaft surface is noted, do a field repair of
solvent (CM234) to remove oil, dirt, drive shaft (Ref. Main Rotor Drive Shaft -
etc. Exterior Repair and Main rotor Drive Shaft
- Corrosion Removal).
(b). Use 5X to 10X magnifying glass and (4). Remove protective cover and install
bright side light (45° or less; down main rotor drive shaft (ref. Main Rotor
ward lighting can not define cracks). Drive Shaft Installation).
Page 607
MAINTENANCE MANUAL
Page 608
MAINTENANCE MANUAL

REPAIRS
1. Main Rotor Drive Shaft Exterior Repair Exercise care when removing
CAUTION pits to ensure that shot peening
is not completely penetrated. Remove only
(Ref. Figure 601) No repair of drive shaft is minimum material necessary to remove
permitted except for removal of light surface pits. Minimum wall thickness of 0.1775 inch
corrosion and polishing of minor nicks and (4.5085 mm) must be maintained.
chips in noncritical spline areas indicated
below. (d). Lightly abrade corroded surface with
crocus cloth (CM803) to remove pits.
If pit removal exceeds depth of
Consumable Materials 0.0012 inch (0.03048 mm) in Area 1
(Ref. Section 91−00−00) or 0.0008 inch (0.02032 mm) in Area
Item Nomenclature 2, shaft is unserviceable and must be
replaced.
CM121 Preservation oil
CM217 Isopropyl alcohol (e). Repeat steps (a). thru (c). above.
CM228 Surface cleaner (f). Spray two coats of epoxy primer and
CM302 Epoxy primer / Catalyst reducer catalyst reducer (CM302), mixed per
manufacturers instructions, on shaft
CM803 Crocus cloth exterior. Do not prime spline teeth or
mounting surface.
(2). Polish out minor nicks and chips on

(1). Remove corrosion as follows:
shaft spline teeth as follows:
(a). Degrease corroded area of drive shaft (a). Using 320—400 grit abrasive stone,
with clean cloth saturated with carefully grind, blend and polish out
isopropyl alcohol (CM217). nicks and chips which are outside the
critical (active) spline tooth contact
areas (Area 4 profile and end views
Surface cleaner, used in step for permissible repair areas).
WARNING below, irritates hands on re
peated exposure. Rubber gloves should (b). If the repair (grind and polish)
be worn. operation extends beyond limits
shown, or if any tooth damage exists
within the critical tooth contact area,
(b). Swab shaft exterior with diluted shaft is unserviceable and must be
solution of surface cleaner (CM228). replaced.
(Mix one part surface cleaner with
four parts water.) Keep wet with (c). Do a magnetic particle inspection
solution for 10 minutes or until according to Specification MIL-
corrosion appears to be removed. I-6868. No surface or subsurface
Wipe clean and inspect. Repeat as defects are permissible.
necessary until there is no further
evidence of corrosion. (3). Apply preservation oil (CM121) to
spline teeth.
(c). Rinse with water and dry with (4). Immediately reinstall main rotor drive
compressed air. shaft.
Page 801
MAINTENANCE MANUAL
2. Main Rotor Drive Shaft Corrosion Do not allow epoxy primer or

Removal CAUTION epoxy enamel to contact drive
shaft splines or mounting surfaces.
(Ref. Figure 601) (7). Fill shaft with epoxy primer (CM302)
mixed according to manufacturer's
instructions. Drain primer from shaft.
Ensure that shaft ID is completely
coated. Allow primer to dry one hour at
Item Nomenclature
room temperature.
(8). Apply one coat of black epoxy enamel
CM228 Surface cleaner (CM304) to driveshaft by filling and
CM302 Epoxy primer / Catalyst reducer draining shaft. Allow enamel to dry 48
CM303 Wash primer hours at room temperature or let dry 30
minutes at room temperature, then
CM304 Enamel, epoxy cure for three hours in oven at 250° -
CM425 Sealing compound 275°F (122° - 136°C).
(9). Apply thin coat of sealing compound
(1). Degrease entire shaft inner diameter (CM425), mixed according to container
(ID), using isopropyl alcohol (CM217). instructions, to all cork plug surfaces;
press cork into drive shafts until top of
cork is flush with top of drive shaft.
(2). Using a fine wire rotary brush or wire Allow sealing compound to cure
brush, remove corrosion and contami according to container instructions.
nants from drive shaft ID. Apply second coat of sealing compound
to exposed surfaces of cork; allow to dry.
Turco WO-1 will irritate the
WARNING skin; always use rubber 3. Main Transmission Drive Shaft Repair
gloves when handling this material. (Bendix)
Wash skin exposed to Turco WO-1,
(Ref. Figure 402)
thoroughly with water.
(3). Using swab and extension rod, swab ID Consumable Materials

of driveshaft with Turco WO-1 (Ref. Section 91−00−00)
(CM228), diluted one part to four parts Item Nomenclature
water. CM318 Primer
(4). Thoroughly rinse drive shaft ID with CM803 Crocus cloth
clear water; dry with compressed air.
(1). Repair of drive shaft diaphragms
(5). Using suitable light or borescope, (Bendix) is not permissible.
inspect shaft ID for corrosion pitting.
Remove pitting by honing locally. Shaft (2). Repair all damage that is no deeper
ID can not exceed 1.655 inches (4.2037 than 0.003 inch (0.076 mm).
cm) after honing. Blend honed area
with existing surrounding area. If (a). Completely remove defect. Maintain
pitting removal causes or would cause smooth transition into surrounding
shaft ID to exceed 1.655 inches (4.2037 surface.
cm), replace shaft. (b). Use grade 400 wet or dry abrasive
paper (CM801) for preliminary
(6). Apply one coat of wash primer (CM303) finishing, and then polish with crocus
to shaft ID according to primer man cloth (CM803). Restore surface until
ufacturer's instructions. it equals original finish of shaft.
Page 802
MAINTENANCE MANUAL
(c). After rework, check shaft tube wall Care should be taken when re
thickness in repair area. Wall thick CAUTION moving or installing nutplates
ness shall not be less than 0.025 inch in Kamatics drive shafts. Damage to flex
(0.635 mm). frames could cause drive shaft replacement.
(d). Apply primer coating (CM318) for (a). Carefully drill out rivets securing
corrosion protection. nutplate.
(b). Using two MS20605-MP3W3 rivets,

4. Main Transmission Drive Shaft Repair install a new MS21075-L4 nutplate
(Kamatics) in place.
5. Overrunning Clutch Repair/Overhaul

(Ref. Section 91−00−00) Accomplish repair/overhaul of overrunning
Item Nomenclature clutch according to instructions in COM.
CM318 Primer
6. Overrunning Clutch−to−Firewall Seal
CM801 Abrasive paper, silicon carbide Repair
CM803 Crocus cloth
(1). Repairs of Kamatics drive shaft flexible
Item Nomenclature
couplings are limited. Repairs to spring
area are not allowed. No cracks are CM411 Adhesive, epoxy
allowed.
Re-bond loose engine firewall seal to backing
(2). Repair drive shaft tube area damage with adhesive (CM411).
that is no deeper than 0.005 inch (0.127
mm). Maximum depth after repair is
7. Main Transmission Drive Shaft Coupling
0.010 inch (0.254 mm). The maximum
Corrosion Removal
thickness of material removed shall not
be more than 10 percent of the original
material thickness. Consumable Materials
(a). Completely remove defect. Maintain Item Nomenclature
smooth transition into surrounding CM801 Abrasive paper, silicon carbide
surface. CM804 Emery cloth, fine
(b). Use grade 400 wet or dry abrasive

paper (CM801) for preliminary (1). Prior to installing original drive shaft
finishing, then polish with crocus coupling (369A5512 or 369H5560 only),
cloth (CM803). Restore surface until inspect flange face of coupling for
it equals original finish of shaft. corrosion. Evidence of corrosion can be
removed by hand lapping the affected
(c). After rework, check shaft tube wall parts by using a sheet of #440 (or finer)
thickness in repair area. emery cloth (CM804) or wet or dry
abrasive paper (CM801) placed on a
surface table with a figure eight motion,
(d). Apply primer coating (CM318) for using care not to let the part rock.
corrosion protection.
NOTE: Couplings can be reused if flange is not
(3). Replace nutplates on Kamatics drive less than 0.100 inch (2.540 mm) after clean
shafts as follows: up. Recheck shimming.
Page 803
MAINTENANCE MANUAL
8. Bendix Coupling Repair 9. Kamatics Coupling Repair
Consumable Materials Consumable Materials

(Ref. Section 91−00−00) (Ref. Section 91−00−00)
Item Nomenclature Item Nomenclature
CM202 Metal protector, aerosol CM318 Primer
CM318 Primer CM801 Abrasive paper, silicon carbide
CM801 Abrasive paper, silicon carbide CM803 Crocus cloth
CM803 Crocus cloth CM804 Emery cloth, fine
NOTE: If coupling is cleaned with solvent or de (1). Repairs to coupling spring areas are not
tergent, spray a light coating of metal pro allowed.
tector (CM202) on interior and exterior of
coupling diaphragm. Dip flange of coupling (2). Repair damage to splined section and
in liquid or spray with aerosol metal protec flange of coupling that is no deeper
tor. Wipe away excess liquid. Metal protec than 0.005 inch (0.127 mm). Use
tor cures in eight hours at room tempera abrasive paper grade 320 grit or finer
ture or 15 minutes at 150°F (66°C). (CM801) and crocus cloth (CM803) to
completely remove and polish out
Metal protector (CM202) defect. Maximum depth after rework is
WARNING must only be used in a well
0.007 inch (0.178 mm). Apply primer
ventilated area. Persons using the met (CM318) to repaired area.
al protector must follow all safety pre
cautions normally used with a chlori NOTE: Flange can be hand-lapped using a
nated solvent and all safety sheet of #440 emery cloth (CM804), placed
precautions on the product label. on a surface table. A figure ``8'' motion
should be used while lapping the coupling,
(1). Repairs to flexible web areas of dia
using care not to let part ``rock''.
phragms are not allowed.
(2). Repair damage to splined section and (3). Minimum flange thickness after
flange of coupling that is no deeper cleanup is 0.100 inch (2.540 mm).
than 0.005 inch (0.127 mm). Use (4). Replace nutplates on Kamatics cou
abrasive paper (CM801) grade 400 - plings as follows:
600 and crocus cloth (CM803) to
completely remove and polish out Care should be taken when re
defect. Maximum depth after rework is CAUTION moving or installing nutplates
0.010 inch (0.254 mm). Apply primer in Kamatics couplings. Damage to flex
(CM318) to repaired area. frames could cause coupling replacement.
(3). Repair damage to outer welded portion (a). Carefully drill out rivets securing
of diaphragm halves as in step (2). nutplate.
above, except that maximum thickness
of material removed shall be not more (b). Using two MS20605-MP3W3 rivets,
than 10 percent of original material install a new MS21075-L4 nutplate
thickness. in place.
Page 804
MAINTENANCE MANUAL
Section
63−15−10
Tail Rotor Drive
Shaft (369D/E/FF)
MAINTENANCE MANUAL

1. Tail Rotor Drive Shaft washers, and remove drive shaft from
tail rotor transmission.
The tail rotor drive shaft connects the main
transmission and the tail rotor transmission.
The total drive shaft length is approximately B. Tail Rotor Drive Shaft Installation with
13 feet long for 369D/E and approximately 14 Bendix Couplings
feet long for 369FF. Flanges at each end of the
shaft attach to flexible joint couplings on the (Ref. Figure 401) Whenever main transmis
transmission shafts. sion, tail rotor transmission, forward coupling
bolt and/or socket, transmission couplings or
2. Tail Rotor Drive Shaft Replacement coupling shims, tail rotor drive shaft or
tailboom assembly have been replaced, start
A. Tail Rotor Drive Shaft Removal installation with step (1). below. If none of
these components has been replaced, and only
(Ref. Figure 401, and Figure 402) installation is involved, start with step (7).
(1). Remove (or open) tail rotor drive shaft below.
access doors.
(2). Remove three bolts and washers that Consumable Materials
secure tail rotor drive shaft to output (Ref. Section 91−00−00)
shaft coupling on main transmission. Item Nomenclature
(3). Disconnect chip detector wire from tail
rotor transmission. CM112 Anti-seize compound high temperature
(4). Detach Sta. 284.00 bellcrank from tail
rotor transmission. CM311 Coating, logo white / Thinner
CM318 Primer
(5). Remove nuts and washers that attach
tail rotor transmission to tailboom.
To prevent damage to transmis NOTE: If tail rotor drive shaft is replaced for
CAUTION sion input shaft coupling during torsional buckling, replace and discard
and after shaft removal, provide level sup transmission output gear shaft coupling bolt
port for both transmission and tail rotor, as and socket, and tail rotor gearbox coupling
weight of these items might buckle coupling and coupling bolt.
diaphragm.
(1). Remove existing shims. Coat coupling
(6). With assistance in guiding shaft splines with grease (CM111) and
through damper, remove tail rotor, tail coupling failsafe bolt threads with
rotor transmission and tail rotor drive anti-seize compound (CM112) before
shaft as an assembly. Slowly and assembly. Install coupling and tighten
carefully slide assembly aft until drive failsafe coupling bolt to 250—300
shaft clears tailboom. inch-pounds (28.25—33.90 Nm) plus
drag torque. (Check coupling bolt for
Do not carry or otherwise sup
CAUTION port transmission by use of cou
drag torque serviceability of 25 inch-
pounds (2.82 Nm) minimum, 200
pling. Use care with removal tools to pre inch-pounds (22.60 Nm) maximum.)
vent scratching of coupling diaphragms.
(7). Support assembly along its entire (2). Determine shim thickness required at
length, remove three coupling bolts and forward flexible coupling:
Page 401
MAINTENANCE MANUAL
COUPLING
SHIMS
TAIL ROTOR DRIVE

SHAFT DAMPER
MAIN TRANSMISSION
SHAFT DAMPER OUTPUT GEARSHAFT
SLEEVE COUPLING
TAIL ROTOR
DRIVE SHAFT
FAILSAFE
COUPLING
BOLT
FAILSAFE
SOCKET
DRIVE SHAFT INSTALLATION
NOTES:
1. DO NOT LIFT TAIL ROTOR TRANSMISSION OR DRIVE SHAFT BY COUPLING. KEEP THE ASSEMBLY ALIGNED DURING REMOVAL.
2. SHIM AS REQUIRED.
3. ADD 0.005 IN. (0.127 MM) TO MEASURED GAP FOR MINIMUM SHIM THICKNESS.
4. HOLD COUPLING AT 1.370 IN. (34.798 MM) OD ONLY, TO BOTTOM COUPLING.
5. INSTALL BOLT WITH ANTI-SEIZE COMPOUND. MINIMUM DRAG TORQUE FOR COUPLING BOLT, 25 INCH-POUNDS (2.82 NM).
6. MINIMUM 0.010 IN. (0.254 MM) STEP BETWEEN AFT END OF OUTPUT SHAFT AND SHOULDER OF FORWARD COUPLING.
7. INSTALL WITH GAP EITHER SIDE OF FAILSAFE BOLT.
G63−1005−1B
Figure 401. Tail Rotor Drive Shaft Installation (369D/E/FF) (Sheet 1 of 3)
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MAINTENANCE MANUAL
LOCK RING
AND STUD
(4 PL)
TRANSMISSION
COUPLING (NOTE 1)
COUPLING SHIM
(NOTE 2) TAIL BOOM
COUPLING
BOLT
FAILSAFE
SOCKET
FAILSAFE
COUPLING BOLT
INPUT
SHAFT
TAIL ROTOR TRANSMISSION TRANSMISSION

COUPLING SHIM COUPLING (NOTE 1)
(NOTE 2)
MEASURED GAP
0.010-0.020 IN. THIN WASHER
(0.254-0.508 MM) ALIGNMENT (3 PL)
1.370 IN. BOLT OR PIN AFT
(34.798 MM) OD COUPLING TAIL ROTOR
(NOTE 4) GEARSHAFT
INPUT SHAFT
NOTE 3
SHIMS
MAIN TRANSMISSION
OUTPUT PINION COUPLING BOLT
TAIL ROTOR (NOTE 5)
DRIVE SHAFT
COUPLING BOLT AFT KAMATIC COUPLING
FORWARD KAMATIC COUPLING (NOTE 5)
0.010 IN. (0.254 MM)

MINIMUM STEP
(NOTE 6)
KAMATIC COUPLINGS
G63-1005-2A
Page 403
MAINTENANCE MANUAL
MEASURED GAP
0.010-0.020 IN.
(0.254-0.508 MM)
ALIGNMENT THIN
BOLT OR PIN D WASHER
WASHER TAIL ROTOR GEARBOX
(3 PL) OUTPUT SHAFT
(3 PL)
MAIN TRANSMISSION D
OUTPUT PINION
TAIL ROTOR FAILSAFE
DRIVE SHAFT BOLT
AFT
NOTE 3 COUPLING
SHIMS 1.370 IN SHIMS

(34.798 MM) OD
(NOTE 5)
FAILSAFE SOCKET
FAILSAFE BOLT D
(NOTE 5) D
FORWARD BENDIX COUPLING AFT BENDIX COUPLING
COUPLING
0.010 IN. (0.254 MM)

MINIMUM STEP FAILSAFE BOLT
(NOTE 6) FAILSAFE SOCKET (NOTE 7)
D-D FAILSAFE INSTALLATION
G63-1005-3D
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MAINTENANCE MANUAL
(a). Install minimum shim thickness on

main transmission output shaft. CAUTION
D Ensure security of tail rotor gearbox
Bottom the flexible coupling by
CAUTION holding at the 1.370 inch
mount studs. Maximum allowable side
play at end of stud is 0.004 inch (0.102
(3.4798 cm) OD of coupling. Do not bottom
mm), maximum allowable axial play is
coupling by pushing on drive shaft attach
0.005 inch (0.127 mm) (Ref. Sec.
flange; doing so can damage coupling.
63-25-10).
(b). Bottom forward coupling on main D When installing tail rotor transmission
transmission output shaft. and drive shaft, do not compress the for
ward or aft couplings as damage to the
(c). Measure step between aft end of coupling could result.
output shaft and shoulder of flexible
coupling, by bottoming coupling (7). With assistance, support transmission
against shims (refer to CAUTION and shaft in line, for minimum deflec
above). tion of coupling, and guide drive shaft
carefully through tailboom and damper
NOTE: Maintain minimum 0.010 inch (0.254 into position.
mm) step between aft end of output shaft
and coupling shoulder to prevent coupling (8). Secure transmission to four tailboom
bolt from bottoming on output shaft. mounting studs (Ref. Sec. 63-25-10).
Install four washers and nuts, torque
(d). Install additional shims to maintain nuts to 75—95 inch-pounds
0.010 inch (0.254 mm) minimum step (8.47—10.73 Nm) plus drag torque.
as required. (9). Align forward end of drive shaft with
(3). Position failsafe socket on aft face of coupling on main transmission output
forward coupling so that three of the gearshaft. Partially install two bolts as
nine holes are indexed to the three an alignment aid but do not tighten.
nutplates of the coupling in such a way Align drive shaft inspection markings.
that maximum clearance is obtained If any of four white stripes is indistinct
between the bolt key and socket. or does not exist, paint (CM311)
Visually verify proper clearance before replacement stripe:
installing tail rotor drive shaft. (10). Obtain 0.010-0.020 inch (0.254-0.508
mm) gap between forward flange of tail
(4). Repeat previous step to install failsafe rotor drive shaft and aft end of socket,
socket on input coupling of tail rotor using the following procedure:
transmission.
(a). Back off three attach bolts on for
(5). Support entire length of tail rotor drive ward flange of tail rotor drive shaft
shaft and position end stamped AFT to assembly 0.050—0.100 inch
align with tail rotor transmission (1.270—2.540 mm).
coupling.
(b). Pull and hold tail rotor output shaft
(6). Install three bolts and washers to of main rotor transmission aft (out of
connect tail rotor transmission coupling transmission) to remove end play. If
to shaft; torque bolts to 80—100 rotor brake is installed, make certain
inch-pounds (9.04—11.30 Nm) plus that brake pucks do not restrict axial
drag torque. travel of tail rotor output shaft.
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MAINTENANCE MANUAL
(c). Remove end play in tail rotor trans (12). With assistance, support transmission
mission by applying force to tail rotor and shaft in line for minimum deflec
blades in opposite direction of tion of coupling and guide drive shaft
operational rotation (while holding carefully through tailboom and damper
forward coupling of tail rotor drive into position.
shaft on main transmission output
shaft to prevent rotation). Do not (13). Apply primer (CM318) to the four
push tail rotor drive shaft fore or aft. gearbox mounting studs. Install nuts
and washers while the primer is still
(d). Using feeler gage, measure gap wet; torque evenly to 75—95 inch-
between socket and flange of tail pounds (8.47—10.73 Nm) plus drag
rotor drive shaft. Socket flange must torque.
be in full contact with flange of
flexible coupling. Verify that a minimum of (1) one
CAUTION thread protrudes through each
(e). With assistance, remove tail rotor nut from the four tail rotor transmission
transmission and driveshaft in line mounting studs. If less than one thread is
for minimum deflection of coupling. showing, refer to CSP-DEF-6, Structural
Repair Manual, to replace with a longer
(f). Using measured gap from step (d). MS1992A803-14 stud and insert.
above, add or remove required
number of shims at tail rotor trans (14). Install three bolts and washers at
mission input pinion shaft and forward end of tail rotor drive shaft to
coupling to obtain specified gap of connect to forward coupling; torque
0.010—0.020 inch (0.254—0.508 bolts to 80—100 inch-pounds
mm). (9.04—11.30 Nm) plus drag torque.
NOTE: (15). Connect electrical wire to tail rotor

transmission chip detector. Torque nut
D Maintain minimum 0.010 inch (0.254
to 12—15 inch-pounds (1.36—1.69
mm) step between coupling shoulder and
Nm).
output shaft (Ref. step (2).).
D If less than specified gap, 0.010—0.020 (16). Coat pin of Sta. 284.00 bellcrank with
inch (0.254—0.508 mm) exists under grease (CM111) and insert it into
minimum shim requirements, install a bearing in tail rotor pitch control. Pivot
maximum of one HS306-326 or bellcrank to align with mating hole in
HS306-326H washer on each of the four tail rotor transmission and install bolt,
tail rotor transmission mounting studs, washers, nut and cotter pin.
between gearbox housing and boom fit
ting. Apply primer (CM318) to both sides
of washer at installation. After washer in (17). Check transmission oil level and service
stallation, repeat step (10). as required.
(11). Coat forward coupling splines with (18). Slowly rotate drive shaft and visually
grease (CM111) and coupling bolt check to ensure shaft is not bent and for
threads with antiseize compound (36) not less than 0.250 inch (6.35 mm)
before assembly. Install coupling and clearance between shaft and fairing
torque failsafe bolt to 250—300 tube at Sta. 137.5. In addition, check
inch-pounds (28.25—33.90 Nm) plus for minimum clearance of 0.190 inch
drag torque. (Check coupling bolt for (4.83 mm) between shaft and cooling
drag torque serviceability of 25 inch- blower scroll.
pounds minimum (2.82 Nm), 200
inch-pounds (22.60 Nm) maximum.) (19). Install all access doors and covers.
Page 406
MAINTENANCE MANUAL
COUPLING SHIMS
MAIN TRANSMISSION OUTPUT

GEARSHAFT COUPLING
TAIL ROTOR
DRIVE SHAFT
TAIL ROTOR DRIVE

SHAFT DAMPER
TAIL ROTOR DRIVE
SHAFT DAMPER SLEEVE SHAFT DAMPER
(2 PL)
LOCK RING AND STUD

DRIVE SHAFT INSTALLATION (4 PL)
COUPLING SHIM TAILBOOM

(NOTE)
EXTENSION
COUPLING BOLT
TRANSMISSION COUPLING
INPUT SHAFT
NOTE:
SHIM AS REQUIRED. G63-1006
Figure 402. Tail Rotor Drive Shaft Installation (369FF)
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MAINTENANCE MANUAL
C. Tail Rotor Drive Shaft Installation with torque coupling bolt to 250—300
Kamatic Couplings inch-pounds (28.25—33.90 Nm) plus
drag torque. (Check coupling bolt for
(Ref. Figure 401 and Figure 402) Whenever drag torque serviceability of 25 inch-
main transmission, tail rotor transmission, pounds (2.82 Nm) minimum, 200
transmission couplings, coupling shims, tail inch-pounds (22.60 Nm) maximum.)
rotor drive shaft or tailboom assembly have
been replaced, start installation with step (1). (3). Support entire length of tail rotor drive
below. If none of these components have been shaft and position end marked AFT to
replaced, and only installation is involved, align with tail rotor transmission
start with step (5). below. coupling.
(4). Install three bolts and washers to
Consumable Materials connect tail rotor gearbox coupling to
(Ref. Section 91−00−00) shaft; torque bolts to 80—100 inch-
Item Nomenclature pounds (9.04—11.30 Nm) plus drag
CM111 Grease, aircraft torque.
Ensure security of tail rotor
CM115 Grease, oscillating bearing CAUTION gearbox mount studs. Maxi
CM311 Coating, logo white / Thinner mum allowable side play at end of stud is
CM318 Primer 0.004 inch (0.102 mm), maximum allowable
axial play is 0.005 inch (0.127 mm) (Ref. Sec.
NOTE: 63-25-10).
D Kamatic couplings do not require failsafe (5). With assistance, support tail rotor
bolts or sockets. transmission and shaft in line, for
D When installing 369D25501-3 Kamatic minimum deflection of coupling, and
coupling, install SKCP2554-13 coupling guide drive shaft carefully through
bolt supplied with the Kamatic coupling. tailboom and damper into position.
D If tail rotor drive shaft is replaced for tor (6). Secure transmission to four tailboom
sional buckling, replace and discard main mounting studs with washers and nuts;
transmission output gear shaft coupling, torque to 75—95 inch-pounds
tail rotor gearbox coupling and both cou (8.47—10.73 Nm) plus drag torque.
pling bolts.
(7). Align forward end of driveshaft with
(1). Coat coupling splines with grease coupling on main transmission output
(CM111) and coupling bolt threads with gearshaft. Partially install two bolts as
anti-seize compound (CM112) before an alignment aid but do not tighten.
assembly. Install coupling onto tail Align drive shaft inspection markings.
rotor gearbox and torque coupling bolt If any of four white stripes is indistinct
to 250—300 inch-pounds or does not exist, paint replacement
(28.25—33.90 Nm) plus drag torque stripes.
(Check coupling bolt for drag torque
serviceability of 25 inch-pounds (2.82 (8). Obtain 0.010—0.020 inch (0.254—0.508
Nm) minimum, 200 inch-pounds (22.60 mm) gap between forward flange of tail
Nm) maximum.) rotor drive shaft and flange of forward
coupling using the following procedure:
(2). Coat forward coupling splines with
grease (CM111) and coupling bolt (a). Ensure alignment bolts in previous
threads with anti-seize compound step are backed off between
(CM112) before assembly. Install 0.050—0.100 inch (1.270—2.540
coupling onto main transmission; mm).
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MAINTENANCE MANUAL
(b). Pull and hold tail rotor output shaft guide drive shaft carefully through
of main rotor transmission aft (out of tailboom and damper into position.
transmission) to remove end play. If
rotor brake is installed, ensure that (11). Secure transmission to four tailboom
brake pucks do not restrict axial mounting studs with washers and nuts;
travel of tail rotor output shaft. torque to 75—95 inch-pounds
(c). Remove end play in tail rotor trans
mission by applying force to tail rotor (12). Install three bolts and washers at
blades in opposite direction of forward coupling; torque bolts to
operation (while holding forward 80—100 inch-pounds (9.04—11.30
coupling of tail rotor drive shaft on Nm) plus drag torque.
main transmission to prevent rota (13). Connect electrical wire to tail rotor
tion). Do not push tail rotor drive transmission chip detector. Torque nut
shaft fore or aft. to 12—15 inch-pounds (1.36—1.69
Nm).
(d). Using feeler gage, measure gap
between forward coupling flange and (14). Coat pin of Sta. 284.00 bellcrank with
flange of tail rotor drive shaft. Record grease (CM111) and insert into bearing
the gap. in tail rotor pitch control. Pivot bell
crank to align with mating hole in tail
(e). With assistance, remove tail rotor rotor transmission and install bolt,
transmission and driveshaft in line washers, nut and cotter pin.
for minimum deflection of coupling.
(15). Check transmission oil level and service
(f). Using measured gap from step (d). as required (Ref. Sec. 12-10-00).
above, add or remove required
number of shims at tail rotor trans (16). Slowly rotate driveshaft and check for
mission input pinion shaft and not less than 0.25 inch (6.35 mm)
coupling to obtain specified gap of clearance between shaft and fairing
0.010—0.020 inch (0.254—0.508 tube at Sta. 137.50. In addition, check
mm). for minimum clearance of 0.190 inch
(4.83 mm) between shaft and cooling
NOTE: blower scroll.
D Maintain minimum 0.010 inch (0.254 (17). Install all access doors and covers.
mm) step between coupling shoulder and
output shaft (Ref. Figure 401). 3. Tail Rotor Drive Shaft Damper
D If less than specified gap, 0.010—0.020
inch (0.254—0.508 mm) exists under (Ref. Figure 603) The tail rotor drive shaft
minimum shim requirements, install a damper is a graphite-filled teflon plate that
maximum of one HS306-326 or controls and limits deflection of the tail rotor
HS306-326H washer on each of the four drive shaft about its approximate mid-point.
tail rotor transmission mounting studs, The damper is spring-loaded against a
between gearbox housing and boom fit structural support bracket mounted on the aft
ting. Apply primer (CM318) to both sides section tailboom fairing. On 369FF Model
of washer at installation. After washer in helicopters, a second damper is located at Sta.
stallation, repeat step (10). 137.50 (Ref. Figure 602).
(9). Re-install coupling and torque coupling 4. Tail Rotor Drive Shaft Damper
bolt to 250—300 inch-pounds Replacement
(28.25—33.90 Nm) plus drag torque. (Ref. Figure 602)
(10). With assistance, support tail rotor (1). Remove boom-bolts access covers.
transmission and shaft in line for
minimum deflection of coupling and (2). Remove tail rotor drive shaft.
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MAINTENANCE MANUAL
(3). Remove two bolts, washers, springs, (6). Install tail rotor drive shaft.
thin washers, plate and spacers and
damper.
(7). Displace damper so that it touches tail
NOTE: The damper at Sta. 137.50 (369FF only) rotor drive shaft.
has 369DSK152-13 bushings installed in
side the Teflon Graphite Damper in conjunc
tion with the spacers.
(8). Use wire gage to measure damper to
(4). Position new damper over mounting shaft clearance 180° from contact point.
holes in support bracket. Install plate Minimum acceptable clearance is 0.020
and spacers with bolts, washers, inch (0.508 mm).
springs and spacer washers.
Ensure washers under bol
CAUTION theads are seated against
(9). Repeat steps (7). and (8). above at 90°
spacer when tightened. Bolts wear rapidly if intervals from initial check point.
clamp-up is not solid.
(5). Adjust damper friction. (10). Install boom-bolts access covers.
Page 410
MAINTENANCE MANUAL

INSPECTION/CHECK
1. Tail Rotor Drive Shaft Inspection straightness. When rotated between
centers, or with ends plugged and rolled
Inspect shaft as described below. Replace bent over roller, runout of large diameter
shaft. Other damage (scratches, nicks, etc) must not exceed 0.060 inch (1.524 mm)
that exceeds repairable limits also requires (allowable dents excluded).
shaft replacement.
(1). Inspect for scratches in shaft section 2. Tail Rotor Drive Shaft Twist Inspection
that passes through plenum chamber (Ref. Figure 601 and Figure 602) Following
fairing tube. Such scratches indicate inspection determines if drive shaft has been
possible contact with tube edges at torsionally strained to extent that permanent
bulkhead openings. twist exists.
(2). Inspect for evidence of torsional (1). Hand-turn main rotor until two white
buckling or shaft bending as result of stripes (A, Figure 601) are aligned.
blade strike or hard ground contact by
lower stabilizer. (2). Look inboard from tail rotor side of
helicopter and locate two white stripes
(3). Inspect for corrosion. (B, Figure 601). Stripe on input shaft
(4). Inspect for evidence of shaft damper bearing retainer flange of tail rotor
sleeve bond failure (sleeve shifting) transmission is located at approximate
from excessive heat or loads. ly 2 o'clock, looking aft. Stripe on
coupling should be at approximately 10
(5). If there is abnormal shaft vibrations, o'clock, looking forward. Both stripes
check damper friction and shaft should be aligned.
Page 601
MAINTENANCE MANUAL
TAIL ROTOR
DRIVE SHAFT
DOUBLER
TAIL ROTOR
TRANSMISSION
WHITE STRIPES
1/8 IN. (3.175 MM) WIDE STA. 137.50 RING
STA. 137.50
(LOOKING FORWARD)
DAMPER
TAIL ROTOR
DRIVE SHAFT
STA. 137.50
INPUT SHAFT TAIL ROTOR

BEARING RETAINER TRANSMISSION
WHITE STRIPES
1/8 INCH (3.175 MM)
COUPLING
WIDE
WHITE STRIPES
1/8 IN. (3.175 MM) WIDE
(EARLY CONFIGURATION)
COUPLING
AFT COUPLING
(NEW CONFIGURATION)
G63-1007A
Figure 601. Tail Rotor Drive Shaft − Inspection Markings
Page 602
MAINTENANCE MANUAL
TAIL ROTOR
DRIVE SHAFT
DAMPER
WHITE STRIPE
1/8 IN. (3.175 MM) WIDE
TAIL BOOM EXTENSION
INPUT SHAFT
BEARING RETAINER
COUPLING
WHITE STRIPE (1/8
INCH WIDE)
DOUBLER
BUSHING
WHITE STRIPE
1/8 IN. (3.175 MM)
WIDE
(EARLY CONFIGURATION)
WHITE
STRIPE
1/8 IN.
(3.175 MM) TAIL ROTOR
WIDE DRIVE SHAFT
STA. 137.50 RING COUPLING
(CURRENT CONFIGURATION)
STA. 137.50
(LOOKING FORWARD)
AFT COUPLING
G63-1008B
Figure 602. Tail Rotor Drive Shaft − Inspection Markings (Extended Tailboom)
Page 603
MAINTENANCE MANUAL
3. Tail Rotor Drive Shaft Damper Inspection NOTE: Tail rotor drive shaft must be removed
to do the following inspection.
(Ref. Figure 603)
(2). Inspect damper for correct drag friction
NOTE: If there is excessive drive shaft vibra adjustment.
tion as shaft passes through first critical
rpm range, probable cause is defective or (3). Inspect inside diameter of damper for
loose damper. excessive wear. If diameter is more
than 3.035 inches (7.7089 cm), damper
(1). Inspect damper for shaft clearance as must be replaced.
follows:
(4). Adjust friction damper as necessary to
(a). Remove boom-bolts access cover.
achieve the required drag as follows:
(b). Inspect tail rotor drive shaft damper
(a). Fabricate friction-checking tool.
and support structure for broken,
cracked or bent parts. (b). Using 0-10 pound spring scale,
(c). Displace damper so that it touches measure force required to move
tail rotor drive shaft. damper radially on bulkhead. Fric
tion must be adjusted so that pull of
(d). Use wire gage to measure damper to 2 ±0.25 pounds (0.91 ±0.11 kg) is
shaft clearance 180° from contact required to slide damper between
point. Minimum acceptable clearance plate and support bracket.
is 0.020 inch (0.508 mm).
NOTE: Minimum of one washer must always
(e). Repeat steps (c). and (d). above at 90° remain between each spring and plate.
intervals from initial check point.
(c). To increase friction, add thin washers
(f). Dampers not meeting minimum between springs and plate. To
clearance of 0.020 inch (0.508 mm) at decrease friction, remove washers.
four equidistant points are to be (Add or remove same number of
replaced. washers at each spring.)
Page 604
MAINTENANCE MANUAL
STA. 197.78
THIN WASHER
(AS REQUIRED)
WASHER
TEFLON GRAPHITE
DAMPER
BOLT
SPRING
METAL PLATE
1.13 IN.
(2.8702 CM)
BRACKET
SPACER
5.00 IN.
(12.7 CM)
SPRING SCALE
0-10 POUNDS
0-5 KG)
1.75 IN.
(4.445 CM) 2.00 IN.
2.88 IN. (5.08 CM)
(7.3152 CM)
FRICTION CHECKING TOOL

(NOTE)
NOTE:
MANUFACTURED LOCALLY FROM 1/8 IN. (3.175 MM)
CORROSION RESISTANCE SPRING WIRE. G63-1009A
Figure 603. Tail Rotor Drive Shaft Damper − Inspection
Page 605
MAINTENANCE MANUAL
Page 606
MAINTENANCE MANUAL

REPAIRS
1. Tail Rotor Drive Shaft Repair Procedure depth of a dent is 0.040 inch (1.016
mm). Dents that raise material require
that shaft be replaced.
2. Tail Rotor Drive Shaft Index Stripe
Application
Item Nomenclature
CM318 Primer (Ref. Figure 601 and Figure 602)
CM803 Crocus cloth Consumable Materials
Item Nomenclature
Nicks and scratches no deeper than 0.0015
CM311 Coating, logo white / Thinner
inch (0.0381 mm) are allowable without
rework but require finish protection with
chemical film (CM206). Other surface damage If any of the four white index stripes used for
shall be evaluated and repaired according to twist inspection of tail rotor drive shaft are
limits specified below. Use grade 400 abrasive indistinct or do not exist, paint (CM311)
paper (CM801) to smooth out and blend repair replacement aligning index stripes as follows:
area into surrounding material until damage
is completely removed; then polish with crocus To prevent damage to gearbox
cloth (CM803) to equal original finish. Apply CAUTION coupling during and after shaft
finish protection with chemical film and two removal, provide good level support for both
coats of primer (CM318). tail rotor transmission and shaft, as the
weight of these items might buckle the cou
Any section of shaft that ap pling.
CAUTION pears to be scratched, nicked or
corroded in a previously reworked area NOTE: Any time the associated tail rotor drive
must not be repaired a second time. Remove shaft units are removed or replaced, an in
such shaft from further service. Replace any dexing check and re-application of index
shaft that has damage in excess of following marks is required.
limits.
(1). Remove tail rotor transmission and
(1). Scratches 0.007 inch (0.178 mm) deep drive shaft as an assembly.
to maximum length of 1.00 inch (2.54
cm) at any random angle can be (2). Inspect tail rotor drive shaft for
repaired. evidence of torsional twist or buckling.
(2). Scratches 0.010 inch (0.254 mm) deep (3). Remove any old index stripes.
to maximum length of 0.250 inch (6.35
mm) at any random angle can be (4). Apply white index stripe 0.120 inch
repaired. (3.048 mm) wide and 0.250 inch (6.35
mm) long onto tail rotor transmission
(3). Circumferential scratches 0.004 inch input shaft bearing flange, at approxi
(0.102 mm) deep can be repaired. mate 10 o'clock position (viewed looking
forward), so it can be seen when viewed
(4). Smoothly contoured dents are allowable on left side of tailboom.
when ratio of dent diameter to dent
depth is at least 15:1; for example, (5). Apply white index stripe 0.120 inch
when depth is 0.040 inch (1.016 mm) (3.048 mm) wide and any length, on the
minimum acceptable diameter is 0.60 aft coupling in line with index stripe on
inch (15.24 mm). Maximum acceptable tail rotor gearbox retainer.
Page 801
MAINTENANCE MANUAL
(6). Install tail rotor drive shaft. mm) long on boom bulkhead doubler
(Sta. 137.50), at approximately 6 - 8
(7). Align index stripes on tail rotor gearbox o'clock position looking forward.
bearing retainer and aft coupling.
(8). Remove tail rotor bellcrank access door (10). Apply a corresponding joining index
at the forward left side of fuselage boom stripe on the tail rotor drive shaft at
fairing and observe the area where tail Sta. 137.50, approximately 0.120 inch
rotor drive shaft passes through the (3.048 mm) wide and 0.50 inch (12.70
fairing forward bulkhead. mm) long.
(9). Apply white index stripe 0.120 inch
(3.048 mm) wide and 0.50 inch (12.70 (11). Install all access doors and covers.
Page 802
MAINTENANCE MANUAL
Section
63−15−30
NOTAR®
Drive Shafts
(500/600N)
MAINTENANCE MANUAL
NOTAR) ANTI−TORQUE SYSTEM DRIVE SHAFTS

1. Anti−Torque System Drive Shafts coupling and remove three bolts and
washers that secure fan gearbox drive
The Fan Gearbox Drive Shaft connects the shaft to input shaft coupling on fan
main transmission and the fan gearbox. The transmission gearbox. Support drive
total drive shaft length is approximately 14 shaft and output shaft coupling on
inches long. Flanges on each end of the shaft main transmission.
attach to flexible (Kamatic) type joint coupling
on the main transmission output shaft and fan (6). Remove fan gearbox (Ref. Sec.
gearbox input shaft. 63-25-30).
The Fan Inter-Connecting Drive Shaft is (7). Remove fan gearbox drive shaft by
equipped with a kamatic flexible-type joint removing three bolts and washers from
and mounting flange (coupling) at each end. output shaft couping on main transmis
The shaft connects the fan gearbox to the fan sion.
assembly by (two) couplings mounted on the
B. Fan Gearbox Drive Shaft Installation
output shaft of the fan gearbox and input shaft
of the fan assembly. The fan pitch control rod (Ref. Figure 201) Whenever main transmis
is routed through the center of the inter-con sion, fan gearbox, transmission couplings,
nect drive shaft. coupling shims, fan gearbox drive shaft
assembly have been replaced, start installation
2. Fan Gearbox Drive Shaft Replacement with step (1). below. If none of these compo
nents have been replaced, and only installa
A. Fan Gearbox Drive Shaft Removal tion is involved, start with step (3). below.
(Ref. Figure 201)
(1). Remove fan gearbox drive shaft access (Ref. Section 91−00−00)
doors and covers, upper aft section Item Nomenclature
fuselage and interior trim panels as
required. CM111 Grease, aircraft
(2). Remove tailboom fairing and tailboom CM115 Grease, oscillating bearing
(Ref. Sec. 53-40-30). CM318 Primer
(3). Remove fan pitch control rod (Ref. Sec.
67-20-30). NOTE: Kamatic couplings do not require fail
(4). Remove fan inter-connecting drive safe bolts or sockets. When installing
shaft (Ref. Fan Inter-Connect Drive 369D25501-9 Kamatic coupling, install
Shaft Replacement). SKCP2554-15 coupling bolt supplied with
the Kamatic coupling or 369D25503-1 bolt.
If fan gearbox drive shaft is replaced for
WARNING torsional buckling, replace and discard
main transmission output gear shaft
D To prevent damage to the engine in coupling, fan gearbox coupling and both
stall F.O.D. cover over engine air in coupling bolts.
let.
D To prevent damage to shaft provide (1). Coat coupling splines with grease
level support for fan transmission (CM111) and coupling bolt threads with
drive shaft during removal or instal anti-seize compound (CM112) before
lation. assembly. Install coupling onto fan
gearbox input shaft and torque coupling
(5). Gain access thru plenum chamber and bolt to 250—300 inch-pounds
remove drive shaft access panel to aft (28.25—33.90 Nm) plus drag torque.
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MAINTENANCE MANUAL
Check coupling bolt for drag torque (b). Pull and hold fan output pinion shaft
serviceability of 25 inch-pounds (2.82 of main rotor transmission aft (out of
Nm) minimum, 200 inch-pounds (22.60 transmission) to remove end play. If
Nm) maximum. rotor brake is installed, ensure that
brake pucks do not restrict axial
(2). Coat forward coupling splines with travel of fan output shaft.
grease (CM111) and coupling bolt (c). Remove end play in fan transmission
threads with anti-seize compound by applying force to the coupling in
(CM112) before assembly. Install opposite direction of operation while
coupling onto main transmission output still holding forward coupling of drive
shaft and torque coupling bolt to shaft on main transmission. Do not
250—300 inch-pounds (28.25—33.90 push fan drive shaft fwd or aft.
Nm) plus drag torque. Check cou
pling bolt for drag torque serviceability (d). Using feeler gage, measure gap
of 25 inch-pounds (2.82 Nm) minimum, between forward coupling flange and
200 inch-pounds (22.60 Nm) maximum. flange of fan drive shaft using
average of 3 readings. Record the
gap.
(3). Support drive shaft and position to
align with fan transmission coupling on (e). Adjust the number of shims
main transmission. (369A5516-3, -5, -7, or -9). Using
measured gap from step 4 above, add
(4). Install fan gearbox with four mounting or remove required number of shims
bolts and torque to 70—90 inch behind the coupling of main trans
pounds (7.90—10.17 Nm); torque- mission output pinion shaft or
stripe bolts. between fan gearbox forward cou
pling to obtain specified gap of
0.010—0.020 inch (0.254—0.508
NOTE: If re-shimming is required, removal mm).
and installation of the fan gearbox is neces
sary to obtain the specified gap between the NOTE: All shims can be removed from forward
coupling flange and flange of drive shaft. or aft coupling if required.
(f). Coat forward coupling splines with
(5). Install three bolts and washers to grease (CM111) and coupling bolt
connect fan gearbox coupling to drive threads with anti-seize compound
shaft; torque bolts to 80—100 inch- (CM112) before assembly. Install
pounds (9.04—11.30 Nm) plus drag coupling and torque coupling bolt to
torque. 250—300 inch-pounds
(28.25—33.90 Nm) plus drag
(6). Align forward end of drive shaft with torque. Check coupling bolt for drag
coupling on main transmission output torque serviceability of 25 inch-
gearshaft. Partially install three bolts pounds (2.82 Nm) minimum, 200
as an alignment aid but do not tighten. inch-pounds (22.60 Nm) maximum.
(8). Install three bolts and washers at
(7). Obtain 0.010—0.020 inch (0.254—0.508 forward coupling; torque bolts to
mm) gap between forward flange of the 80—100 inch-pounds (9.04—11.30
fan gearbox drive shaft and flange of Nm) plus drag torque.
forward coupling using the following (9). Slowly rotate drive shaft and check for
procedure: not less than 0.25 inch (6.35 mm)
clearance between shaft and fairing
(a). Ensure alignment bolts in previous tube at Sta. 137.50. In addition, check
step are backed off between for minimum clearance of 0.190 inch
0.050—0.100 inch (1.270—2.540 (4.83 mm) between shaft and cooling
mm). blower scroll.
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MAINTENANCE MANUAL
(10). Install fan gearbox (Ref. Sec. (1). Replace bent shaft. Other damage
63-25-30). (scratches, nicks, etc.) that exceeds
repairable limits also requires shaft
(11). Install inter-connecting drive shaft replacement.
(Ref. Fan Inter-Connect Drive Shaft
Replacement) (2). Inspect for scratches in shaft section
that passes through plenum chamber
(12). Install fan pitch control; control rod fairing tube. Such scratches indicate
(Ref. Sec. 67-20-30). possible contact with tube edges at
bulkhead openings.
(13). Install tailboom and fairing (Ref. Sec.
53-40-30). (3). Inspect for evidence of torsional twist,
buckling or shaft bending as result of
(14). Check anti-torque flight control rigging blade strike or hard ground contact.
(Ref. Sec. 67-20-30). (4). Inspect for corrosion.
(15). Install all access doors and covers, and 4. Fan Gearbox Drive Shaft Repair
interior trim panels. Procedure
3. Fan Gearbox Drive Shaft Inspection For information on repair procedures, refer to
Sec 63-15-10, Tail Rotor Drive Shafts Repair
Inspect shaft as described below. Procedure.
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BOLT
(NOTE 3)
SHIM
SHAFT
COUPLING
BOLT
(NOTE 3) WASHER
SPEEDI
SLEEVE
BOLT
SHIM WASHER
LOCKNUT
COUPLING
BOLT
WASHER
COUPLING
SHIM
LOCKNUT (NOTE 1)
SPEEDI SHAFT
SLEEVE
SHIM
(NOTE 1)
NOTE 2
COUPLING
NOTES:
1. DO NOT EXCEED 0.100 IN. (2.54 MM) SHIM THICKNESS
IN EITHER OF THE TWO FLANGE LOCATIONS.
2. 0.010-0.020 IN. (0.254-0.508 MM) GAP.
WASHER 3. TORQUE 250 - 300 INCH-POUNDS (28.25 - 33.90 NM) PLUS
DRAG TORQUE OF 25 INCH-POUNDS (2.82 NM) MINIMUM,
BOLT 200 INCH-POUNDS (22.60 NM) MAXIMUM.
G63-1012B
Figure 201. Fan Gearbox and Inter−Connecting Drive Shafts
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MAINTENANCE MANUAL
5. Fan Inter−Connect Drive Shaft Do not exceed 0.100 inch (2.540

Replacement CAUTION mm) shim thickness in either of
the two flange locations. Shim thickness in
(Ref. Figure 201) both locations to be within 0.020 inch (0.508
mm) of each other.
A. Fan Inter−Connect Drive Shaft Removal
(4). Adjust the shim thickness between the
forward flange and the aft flange of the
(1). Remove fan inlet screen and fan inter-connect drive shaft and the two
transmission cover (Ref. Sec. couplings.
53-30-30).
(5). Install shims to obtain the specified
(2). Remove tailboom fairing and tailboom 0.010—0.020 inch (0.254—0.508 mm)
(Ref. Sec. 53-40-30). gap. Install inter-connect drive shaft
with eight mounting bolts and washers.
(3). Remove fan pitch control rod (Ref. Sec. Torque forward and aft mounting bolts
67-20-30). 50—70 inch-pounds (5.65—7.91 Nm)
plus drag torque.
To prevent damage to the shaft
CAUTION and couplings during and after
(6). Install fan pitch control; control rod
(Ref. Sec. 67-20 -30).
removal, provide level support for inter-
connecting drive shaft. (7). Install tailboom and fairing (Ref. Sec.
53-40-30).
(4). Remove four mounting bolts and
washers (2 places) and remove shims at (8). Check control rigging (Ref. Sec.
both ends of inter-connect drive shaft, 67-20-30).
remove inter-connect drive shaft.
Retain shims for reinstallation. (9). Install access panels and covers (Ref.
Sec. 53-30-30).
B. Fan Inter−Connect Drive Shaft
6. Inter−Connect Drive Shaft Inspection
Installation
Install inter-connect drive shaft to obtain Consumable Materials

0.010-0.020 inch (0.254-0.508 mm) gap (Ref. Section 91−00−00)
between the forward flange of the inter-con Item Nomenclature
nect drive shaft and the coupling aft flange as CM318 Primer
follows:
(1). Install inter-connect drive shaft, install (1). Inspect drive shaft coupling for dents,
8 mounting bolts and washers except cracks, scratches, nicks, rust spots and
leave the 4 mounting bolts on the evidence of joint separation from shaft
forward flange of the inter-connect or outside edges.
drive shaft backed off 0.050-0.100 inch
(2). Inspect drive shaft tube between
(1.270-2.540 mm) and torque the four
coupling for dents, scratches, cracks or
aft mounting bolts 50—70 inch-
corrosion pits.
pounds (5.65—7.91 Nm).
(a). Measure depth and diameter of
(2). Pull and hold the coupling on the fan dents. Dents that blend smoothly into
gearbox Aft to remove end play. surrounding surface area with no
(3). With a feeler gage measure gap (aver exceed 0.010 inch (0.254 mm) depth
age of 4 readings) between the flange of are acceptable. Dents not within
the inter-connect drive shaft and the these limits require removal of shaft
coupling. from service.
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MAINTENANCE MANUAL
(b). Measure depth of cracks, nicks, be more than 10 percent of original

corrosion pits or scratches; length material thickness.
and direction are not limited. Maxi
mum depth allowed before rework is (a). Completely remove defect. Maintain
0.005 inch (0.127 mm). smooth transition into surrounding
surface.
(c). Check suspected cracks using dye (b). Use grade 400 wet or dry abrasive
penetrant. If crack indication ap paper (CM801) for preliminary
pears, remove coating from area. finishing, and then polish with crocus
cloth (CM803).
(d). Re-inspect suspected area using
magnetic-particle or dye-penetrant (c). After rework, check shaft tube wall
methods. If crack does not reappear, thickness in repair area.
touch up cleaned area with primer
coating (CM318) and return part to (d). Apply primer coating (CM318) for
service. corrosion protection.
(3). Inspect all attaching hardware for 8. Transmission and Fan Coupling
serviceable condition. Discard and Inspection
replace defective hardware.
The following procedures is for inspection of
NOTE: Do inspection steps (4). and (5). below fan gearbox and fan input coupling. For
only if shaft damage is suspected. information on Kamatics coupling inspection,
refer to Sec. 63-10-00.
(4). Inspect shaft tube for out-of-round (1). Inspect coupling splined section and
condition, which shall not exceed 0.060 flange for cracks, scratch, nicks, dent
inch (1.524 mm). and corrosion pits. No cracks are
allowed. Maximum depth of other
(5). Inspect shaft for straightness. Shaft defects allowed before rework is 0.005
shall be straight within 0.030 inch inches.
(0.762 mm) at all locations relative to
centerlines of two flange mounting bolt (2). Inspect coupling speedi-sleeve for wear,
patterns. security of attachment to coupling.
7. Inter−Connect Drive Shaft Repair 9. Gearbox and Fan Coupling Repair

The following procedures is for repair of fan
Consumable Materials gearbox and fan input coupling. For informa
(Ref. Section 91−00−00) tion on Kamatic coupling repair, refer to Sec.
Item Nomenclature 63-10-00.
CM318 Primer
CM801 Abrasive paper, silicon carbide Consumable Materials
CM803 Crocus cloth
Item Nomenclature
CM318 Primer
(1). Repair of drive shaft Kamatic flexible CM801 Abrasive paper, silicon carbide
type joint is limited. Repairs to spring CM803 Crocus cloth
area are not allowed. No cracks are
allowed.
(1). Repair damage to splines section and
(2). Repair drive shaft tube area damage flange of coupling that is no deeper
that is no deeper than 0.005 inch (0.127 than 0.005 inch (0.127 mm). Use
mm). Maximum depth after repair is abrasive paper (CM801) grade
0.010 inch (0.254 mm). The maximum 400—600 and crocus cloth (CM803) to
thickness of material removed shall not completely remove and polish out
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MAINTENANCE MANUAL
defect. Maximum depth after rework is

0.010 inch (0.254 mm). Apply primer Special Tools
(CM318) to repaired area. (Ref. Section 91-00-00)
Item Nomenclature
(2). After rework, check coupling wall ST604 Coupling socket

thickness in repair area. The maximum
thickness of material removed shall not A. Transmission Coupling / Fan Coupling
be more than 10 percent of original Removal
material thickness.
(1). Remove nut from shaft using coupling
socket (ST604) and coupling holding
10. Transmission Coupling / Fan Coupling fixture tool; remove coupling.
Replacement
B. Transmission Coupling / Fan Coupling
Installation
(Ref. Figure 202)
(1). Slide coupling onto support shaft.
Consumable Materials (2). Install nut using anti-seize compound

(Ref. Section 91−00−00) (CM113) as required. Torque nut to
Item Nomenclature 800—1000 inch-pounds
CM113 Anti-seize compound low temperature using coupling socket (ST604) and
holding fixture.
G63-1023A
Figure 202. Fan Interconnect Drive Shaft Coupling Installation
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MAINTENANCE MANUAL
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MAINTENANCE MANUAL
Section
63−20−00
369D25100 Main
Transmission
(369D/E/FF − 500N)
MAINTENANCE MANUAL
P/N 369D25100
369D25100 MAIN TRANSMISSION
NOTE: The Overhaul instructions for the 369D25100 Transmission are contained in CSP-
COM-5-1. Please contact MDHI Aftermarket Sales for access to the manual.
1. Main Transmission (7). Drain oil from transmission.
The main transmission is secured to the (8). Disconnect tail rotor output shaft seal
underside of the main rotor mast support drain line, input shaft seal drain line
structure pan by four structure bolts, washers, and two hoses that attach to lubrication
and nuts. The transmission is a two-stage pump.
speed reduction unit. The first reduction stage
is for the tail rotor drive system and accessory (9). With assistance, support transmission;
drive trains. The second stage is for further then remove four nuts and washers
reducing rpm for the main rotor. The transmis from mast support structure studs.
sion housing is magnesium alloy. The accesso
ry gear train drives a rotor tachometer Lower transmission with ex
generator and the transmission oil pump that CAUTION treme care to prevent contact
are mounted on drive pads at the aft end of the between tail rotor drive coupling and sur
transmission. The transmission is cooled by air rounding structure. Any dents, nicks or
drawn through a cooling blower and routed scratches on coupling diaphragm requires
through the transmission oil cooler. Access to that coupling be scrapped. Use care to pro
the main transmission is attained by entrance tect oil pressure sender and chip detector
into the passenger compartment. terminal studs from damage during handl
ing or when placing transmission on any
2. Main Transmission Buildup and surface.
Replacement
A. Main Transmission Removal (10). With assistance, carefully lower
transmission from mounting studs.
(Ref. (Ref. Figure 201)
NOTE: Cover top opening of transmission to
(1). Remove sound insulation and transmis prevent entry of foreign material. Residual
sion access covers (Ref. Sec. 52-40-00). operating lubricant is an approved preser
(2). Remove main transmission drive shaft vative for transmission shipment or storage.
(Ref. Sec. 63-10-00).
(11). Do the following steps as applicable to
(3). Remove cooling blower (Ref. Sec. strip main transmission.
63-21-00).
(a). Remove tachometer generator.
(4). Remove anti-torque drive shaft (Ref.
Sec. 63-15-00). (b). Remove coupling bolt, coupling and
shim from tail rotor output shaft.
NOTE: Removal of main rotor drive shaft (step
e. below) is optional. If help is not available (12). Remove coupling bolt, coupling, shim,
to rotate rotor hub for spline alignment, drive pulley and pulley guard from
shaft removal simplifies reinstallation of main transmission input shaft.
transmission.
(5). Remove main rotor drive shaft (Ref. (a). Remove input shaft seal drain
Sec. 63-10-00). connector (Ref. Figure 203).
(6). Disconnect wires from tachometer (b). Install suitable covers and plugs to
generator, two chip detectors and oil protect all openings, including
pressure sender. threaded holes.
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MAINTENANCE MANUAL
P/N 369D25100
B. Main Transmission Installation especially area contacted by O-ring on
top of transmission.
(Ref. Figure 201)
Damage to main rotor drive
Consumable Materials CAUTION shaft or main transmission
(Ref. Section 91−00−00) splines can occur during installation. Care
Item Nomenclature should be taken while meshing drive shaft
CM111 Grease, aircraft splines into transmission output splines to
CM112 Anti-seize compound high temperature prevent damage.
CM121 Preservation oil
CM125 Oil (3). With assistance, slowly and evenly lift
CM126 Oil, turbine and position transmission in place on
mounting studs.
CM417 Cement
CM425 Sealing compound (4). Install four washers and nuts; torque to
60—80 inch-pounds (6.78—9.04
CM430 Sealant, solvent resistant Nm).
(1). Do the following steps as applicable to (5). If transmission is new, drain any
build up main transmission prior to residual preservative oil. Service
installation. transmission with lubricating oil
(CM125 or CM126) (Ref. Sec.
(a). Install one preliminary 0.010 inch 12-00-00).
(0.250 mm) shim on tail rotor output
shaft to prevent coupling bolt from
bottoming in shaft. (6). Connect wiring to tachometer genera
tor, two chip detectors and oil pressure
(b). Coat coupling splines with grease switch.
(CM111) and coat bolt threads with
anti-seize compound (CM112) before
assembly. Install shaft coupling and (7). Install anti-torque drive shaft (Ref.
temporarily tighten coupling bolt to Sec. 63-15-10/30).
approximately 250 inch-pounds
(28.25 Nm). When reinstalling main rotor
CAUTION drive shaft, check that there is
(c). Install tachometer generator. With no gap between shaft mounting flange and
rotor brake installed, ensure electri rotor hub before tightening installation
cal receptacle is at 11 o'clock position. bolts. Gap indicates that shaft splines are
(d). Install input shaft seal drain connec not correctly meshed in transmission.
tor, bonding it in place with sealing
compound (CM425). (8). If main rotor drive shaft has been
removed, apply coating of lubricating
(e). Bond main rotor output shaft O-ring oil (CM121) on shaft before reinstalla
in place with cement (CM417). tion and install drive shaft (Ref. Sec.
(f). Bond filler seal to transmission with 63-10-00).
cement (CM417).
(9). Connect tail rotor output shaft seal
(g). If filler is safetied to case bolt, cut a drain line and input shaft seal drain
small section from seal and bond in line and two hoses that attach to
place. After bonding, fill gap in seal lubrication pump.
with sealant (CM430).
(2). Use clean, absorbent cloth to clean pan (10). Install cooling blower (Ref. Sec.
beneath main rotor mast support, 63-21-00).
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MAINTENANCE MANUAL
P/N 369D25100
(11). Coat input drive coupling splines with cracks. Check that transmission
grease (CM111) and coat bolt threads mounting studs and nuts are secure.
with anti-seize compound (CM112) This should be accomplished from
before assembly. Install pulley guard, fuselage interior as well as exterior at
drive pulley, shim, coupling and main rotor mast base.
coupling bolt and temporarily tighten
coupling bolt to approximately 250 (4). Check that all safety wiring is intact.
inch-pounds (28.25 Nm).
4. Main Transmission Repair Procedure
NOTE: Refer to Sec. 63-10-00, Main Transmis (Ref. Figure 201) Replace electrical compo
sion Drive Shaft Installation for coupling
nents, breather-filler, filler screen, externally
shimming, coupling torque and drive shaft
accessible O-rings, lubrication pump, filter,
installation.
input shaft oil seal and tail rotor output shaft
(12). Install main transmission drive shaft oil seal if defective. Dents in outer surface of
(Ref. Sec. 63-10-00). transmission housing deeper than 0.10 inch or
covering more than 0.60 square inch (3.87 cm2)
(13). Ground run helicopter (refer to appro area require replacement of transmission. This
priate PFM) and check drive system for procedure is applicable to dents not exceeding
excessive vibration and unusual noise. specified limits.
Verify absence of oil over-temperature
and low pressure indications. Inspect
for oil leakage.
(14). Install access covers and sound insula Item Nomenclature
tion (Ref. Sec. 52-40-00). CM234 Solvent, dry-cleaning
CM318 Primer
3. Main Transmission Inspection Procedure
(Ref. Figure 201) The following procedures CM801 Abrasive paper, silicon carbide
provide information for checking the main
transmission for oil leakage and mechanical
defect. NOTE: Any evidence of lubricating oil leakage
in a repair area requires replacement of
(1). Remove sound insulation and transmis transmission.
sion access covers (Ref. Sec. 52-40-00).
(1). Clean area with solvent (CM234) and
(2). Inspect transmission for oil leaks, remove sharp edges with grade 320
cracks, corrosion, secure electrical abrasive paper (CM801).
connections and correct oil level.
Evaluate oil leakage according to Fluid (2). Apply coat of primer (CM318) on
Leak Analysis. repaired surface.
Inspect all fluid lines for ade (3). If dent is deeper than 0.030 inch (0.76
CAUTION quate clearance between struc mm), fill depression with epoxy adhe
ture and components. Vibration can cause sive (CM411) and blend to surrounding
chafing of lines and subsequent leaking. surfaces.
(3). Inspect four mounting flanges on main (4). Touch up re-worked area with paint
transmission housing for corrosion and (Ref. Sec. 20-30-00).
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MAINTENANCE MANUAL
P/N 369D25100
COUPLING BOLT
COUPLING (KAMATIC)
MAIN ROTOR
DRIVE SHAFT
TAIL ROTOR
MAST BASE DRIVE SHAFT
FAILSAFE SOCKET
(NOTE 2)
COUPLING
(BENDIX)
FAILSAFE COUPLING
DEBRIS
BOLT
OUTPUT SHAFT COVER
LAMINATED SHIM
OUTPUT SHAFT
COOLING BLOWER
FILLER
PLUG
O-RING INPUT SHAFT PULLEY GUARD COUPLING
(NOTE 1) INTERNAL-
PULLEY
SEAL SEAL WRENCHING
(NOTE 3) (NOTE 3) LAMINATED SHIM BOLT
ÇÇÇÇ ÇÇÇÇÇ
SAFETY WIRE
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ
SEALANT
(NOTE 4)
ÇÇÇÇÇ NOTES:
1. O-RING MUST BE CEMENTED IN PLACE BEFORE INSTALLING TRANSMISSION.
2. NOT USED WITH KAMATIC COUPLING.
3. SEAL MUST BE CEMENTED IN PLACE BEFORE INSTALLING TRANSMISSION.
FILLER SEAL INSTALLATION 4. FILL CUT IN SEAL WITH SEALANT (CM430).
G63-2004B
Figure 201. 369D25100 Main Transmission Installation
Page 204
Revsion 51 63-20-00
MAINTENANCE MANUAL
P/N 369D25100
5. Lubrication Pump Removal and B. Lubrication Pump Installation
Installation
(1). Install packings (4, 5) on lubrication
pump assembly (3).
(Ref. Figure 202)
(2). Install lubrication pump assembly (3)
on tail rotor drive assembly studs with
A. Lubrication Pump Removal nuts (1) and washers (2).
Make sure square input shaft of
(1). Remove three nuts (1) and washers (2) CAUTION lubrication pump aligns correct
and lubrication pump (3) from trans ly with oil pump drive shaft in tail rotor
mission. drive assembly as pump is installed.
(3). Install washers (2) and nuts (1) on
(2). Remove three o-rings (4, 5) from transmission mount studs. Torque nuts
lubrication pump assembly (3). 50—70 inch-lbs (5.65—7.91 Nm).
5
4
1
2
G63-2000-202-1
1. NUT 4. O−RING
2. WASHER 5. O−RING
3. LUBRICATION PUMP
Figure 202. Main Transmission Lubrication Pump Removal and Installation
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MAINTENANCE MANUAL
P/N 369D25100
6. Input Drive Assembly − Oil Leakage o-ring (8) between the main housing
Repair Procedure and the input pattern shim.
(Ref. Figure 203) (7). Remove the slide hammer tool from the
input drive assembly pinion.
Use the following repair procedure when oil (8). If necessary, cut defective o-ring (8).
leakage occurs between the main transmission
housing and the pinion bearing sleeve flange. If one or more of the input pat
CAUTION tern shims is removed, record
Replace the o-ring (8) 369D25184-3 as follows. the total thickness of all shims together. The
high-speed gear-set in the main transmis
Consumable Materials sion will be severely damaged if the original
(Ref. Section 91−00−00) thickness is not maintained.
Item Nomenclature D The transmission must be returned to
CM218 Alcohol, denatured MDHI for overhaul for pattern-wipe veri
fication if the original input pattern shim
thickness cannot be determined.
(1). Remove the shaft interconnect, trans (9). Clean and inspect pattern shim for
mission input coupling, drive pulley distortion and ensure no overlap
and guard, and cooling blower assembly condition exists at butt/split line of
(Ref. Sec. 63-21-00). shim.
(2). Drain oil from input drive assembly (10). Clean area between main housing and
through the lower chip detector plug input drive sleeve with alcohol (CM218)
(Ref. Sec. 12-00-00). to remove paint chips or other foreign
matter.
(3). Remove bolts (5) and washers (6) from
the blower mount assembly. (11). Install a new o-ring (8) over the blower
mount. Seat the o-ring (8) in contact
(4). Install four alignment bolts in place of with the main housing.
mount bolts (5) for the blower mount
assembly. (Use any type of 2.00 inch (12). Remove the alignment bolts and install
(5.08 cm) length x 1/4-28 diameter the assembly aid tool halves between
bolt.) the o-ring and the input bearing sleeve
flange. (Ref. Figure 204 for locally
(5). Install a slide hammer tool on the input fabricated assembly aid tool.)
drive assembly pinion. (13). Install the blower mount, the input
pinion bearing sleeve, and the assembly
Use heat resistance gloves to aid tool with the four washers (6) and
WARNING prevent burns to hands if
bolts (5).
the transmission input housing assem
bly has been heated. It can be neces (a). Keep an inward preload of the
sary to heat the main transmission in assembly aid tool halves against the
put housing assembly to 250—300 F input pinion bearing sleeve. Tighten
(123—147 C) when disassembled. the four bolts (5) equally.
Do not remove the input pinion. (b). Tighten bolts (5) until there is a
CAUTION Movement of the input pinion positive clamp-up between the main
more than 0.150 inch (3.81 mm) can cause housing, assembly aid tool halves,
the scavenge pump to disengage. Support and input pinion bearing sleeve
the pinion at all times to prevent it from flange.
sliding out of the transmission. (14). Remove the bolts (5) and slide out the
assembly aid tool halves.
(6). Gently tap input drive assembly away
from main housing no more than 0.150 (15). Make sure the o-ring (8) is seated in
inch (3.81 mm) to gain access to the the main housing groove.
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MAINTENANCE MANUAL
P/N 369D25100
(16). When the o-ring (8) is seated, install Main Transmission Drive Shaft
the input pattern shim between the Replacement).
main housing and input pinion bearing
sleeve flange and install the bolts (5). (a). Keep all shims with the coupling.
(a). Keep an inward preload on the input (3). Remove oil cooler blower (Ref.
pattern shim during the tightening 63-21-00, 13. Cooling Blower Replace
sequence. ment).
(b). Torque bolts (5) to 65—75 inch (4). Drain the oil from the input drive
pounds (7.34—8.47 Nm). assembly through the lower chip
detector plug. (Ref. 12-00-00, 5. Main
(17). Inspect the input pattern shim to make Rotor Transmission Servicing)
sure no overlap condition exists at the
butt/split line. NOTE: The thickness of the blower spacer (1) is
critical for correct blower belt alignment.
(18). Install the shaft interconnect, transmis
sion input coupling, drive pulley and (5). Use a three-leg bearing puller to
guard, and cooling blower assembly remove the blower spacer (1) from the
(Ref. Sec. 63-21-00). input drive pinion.
(19). Add oil to input drive assembly (Ref. (6). Remove lockwasher (2).
Sec. 12-00-00).
NOTE: The following procedure requires two
7. Input Drive Pinion Seal Replacement people.
(Ref. Figure 203) (7). Use the locknut T-Tool 369A9966 to

remove locknut (3).
Use the following repair procedure when oil
leakage occurs at the input pinion seal. (a). Insert T-Tool 369A9966 over locknut
(3) and put a breaker bar over one
ear of the tee.
(Ref. Section 91−00−00) (b). Insert socket through the center of
Item Nomenclature the tee to engage splines on input
CM112 Anti-Seize Compound shaft.
CM218 Isopropyl Alcohol
(c). Insert adapter and breaker bar into
CM425 Sealing Compound the socket.
Special Tools (d). Turn the locknut removal tee coun

(Ref. Section 91-00-00) terclockwise while holding the spline
Item Nomenclature socket.
N/A Arbor Press
(e). Remove the locknut (3) and outer
N/A Drill Press input seal (4).
N/A T-Tool 369A9966
(8). Remove the four bolts (5) and washers
(6) from the blower mount assembly.
(1). Remove the main transmission drive
shaft (Ref. 63-10-00, 4. Main Trans (9). Install the four stop bolts on blower
mission Drive Shaft Replacement). mount assembly (use 2.00 inch (5.08
cm) length x ¼-28 diameter bolt).
(2). Remove the coupling nut from the
transmission input coupling, the drive (10). Install a slide hammer tool on the input
pulley and the guard. (Ref. 63-10-00, 4. drive pinion assembly.
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MAINTENANCE MANUAL
P/N 369D25100
Use heat resistance gloves to (19). Clean the excess sealant.
WARNING prevent burns to hands if
(a). Allow sealant to cure (Ref. Manufac
the transmission input housing assem turer's instructions).
bly has been heated. It can be neces
sary to heat the main transmission in (20). Replace the cooler blower mount
put housing assembly to 250—300 F housing o-ring (8).
(123—147 C) when disassembled. (a). Lubricate the o-ring and input seals
with existing transmission oil.
If one or more of the input pat
CAUTION tern spacers is removed, record (21). Install the new o-ring (8) on the blower
the total thickness of all spacers together. mount assembly.
The high-speed gear-set in the main trans Use heat resistance gloves to
mission will be severely damaged if the orig WARNING prevent burns to hands if
inal thickness is not maintained. the transmission input housing assem
D The transmission must be returned to bly has been heated. It can be neces
MDHI for overhaul for pattern-wipe veri sary to heat the main transmission in
fication if the original input pattern spac put housing assembly to 250—300 F
er thickness cannot be determined. (123—147 C) when disassembled.
Do not remove the input pinion.
(11). Record the position of the input pattern CAUTION Movement of the input pinion
shim(s).
more than 0.150 inch (3.81 mm) can cause
(12). Lightly tap the input drive assembly the scavenge pump to disengage. Support
away from the main housing no more the pinion at all times to prevent it from
than 0.150 inch (3.81 mm) to remove sliding out of the transmission.
the oil cooler blower mount only. If one or more of the input pat
CAUTION tern shims is removed, record
(13). Remove the slide hammer tool from the
input drive assembly pinion. the total thickness of all shims together. The
high-speed gear-set in the main transmis
Do not remove the input pinion. sion will be severely damaged if the original
CAUTION Movement of the input pinion thickness is not maintained.
more than 0.150 inch (3.81 mm) can cause D The transmission must be returned to
the scavenge pump to disengage. Support MDHI for overhaul for pattern-wipe veri
the pinion at all times to prevent it from fication if the original input pattern shim
sliding out of the transmission. thickness cannot be determined.
(14). Remove the four stop bolts from the (22). Install the oil cooler blower mount.
cooler blower mount housing. (a). Make sure that the input pattern
spacer(s) and the input bearing shim
(15). Remove the cooler blower mount are in place.
housing, o-rings (8) and inner input
seal (7). (b). Make sure that the input pattern
spacer has the split at 3 o'clock and 9
(16). Clean the sealant from the seal seat o'clock positions.
surface in the blower mount with (c). Support the cooler blower mount
denatured alcohol (CM218). assembly to keep an inward preload
(a). Allow to air dry. on the input pinion.
(d). Install the cooler blower mount
(17). Apply sealing compound (CM425) to the washers (6) and bolts (5). Torque
seal edge and mating surface in the bolts (5) 65—75 inch-pounds
blower mount. (7.34—8.47 Nm).
(18). Press the inner input seal (7) in to the (e). Make sure there is no overlap of the
blower mount assembly and remove the input pattern spacer(s) at the butt/
spring from the sealing lip. split line.
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MAINTENANCE MANUAL
P/N 369D25100
(f). The maximum gap allowed at the (e). Torque the locknut (3) to 200 foot-
butt/split line of the input pattern pounds (271 Nm) to seat the inner
spacer(s) is 0.000—0.030 inch input seal (7).
(0.00—0.76 mm).
(f). Remove and then reinstall the
(23). Rotate rotor hub 10 full rotations to locknut (3).
circulate the transmission oil through
(g). Torque the locknut (3) 150—175 foot
the scavenge pump.
pounds (203—237 Nm).
(a). Make sure the oil shows FULL on the (26). Install lockwasher (2).
transmission sight gauge (Ref.
Section 12-00-00). NOTE: If necessary, heat the main input blower
spacer (4) to help with installation.
(24). Apply anti-seize compound (CM112) to
non-serrated threads on the pinion. (27). Install the blower spacer (4) firmly on
input drive pinion shaft.
NOTE: Two maintainers are required for Step
(25). (28). Install the cooler blower assembly (Ref.
Section 63-21-00; Ref. Chapter 5 -
(25). Use the locknut T-Tool 369A9966 to Special Inspections, Table 1: 25 HOURS
install locknut (3). AFTER INSTALLATION OF OIL
COOLER BLOWER).
(a). Insert T-Tool 369A9966 over locknut
(3) and put a breaker bar over one NOTE: Install input bearing shim with cou
ear of the tee. pling.
(29). Install coupling bolt with shims from
(b). Insert the socket through the center the transmission input coupling, the
of the tee to engage splines on input drive pulley, and the guard.
shaft.
(30). Keep the correct input coupling inner
(c). Insert an adapter and breaker bar race clamp up gap 0.010—0.060 inch
into the socket. (0.254—1.524 mm).
(d). Turn the locknut removal tee coun (31). Install main transmission drive shaft
terclockwise while holding the spline (Ref. 63-10-00, 4. Main Transmission
socket. Drive Shaft Replacement).
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MAINTENANCE MANUAL
P/N 369D25100
NOTE 1
NOTE 2
INPUT PATTERN
SHIM (NOTE 4)
8
INPUT DRIVE
BEARING ASSEMBLY
(NOTE 3)
INPUT BEARING
SHIM (NOTE 4)
BLOWER MOUNT
ASSEMBLY
6 (4 PL)
5 (4 PL)
NOTES:
1. MOVEMENT IN EXCESS OF 0.15 INCH
(3.81 MM) MAY CAUSE DISENGAGEMENT
OF SCAVENGE PUMP DRIVE. 4
2. INSTALL SLIDE HAMMER ON INPUT DRIVE
ASSEMBLY PINION. 3
3. DO NOT EXPOSE ITEMS DURING
DISASSEMBLY / ASSEMBLY. 2
4. RETURN SHIMS TO ORIGINAL POSITION.
1
G63-2000-203-1
1. INPUT BLOWER SPACER 5. BOLT

2. LOCKWASHER 6. WASHER
3. LOCKNUT 7. INNER INPUT SEAL
4. OUTER INPUT SEAL 8. PACKING
Figure 203. Input Drive Assembly O−Ring Replacement
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MAINTENANCE MANUAL
P/N 369D25100
1.50 (3.81 CM) 1.50 (3.81 CM) 0.257 (0.653 CM) DIA
(TYP) (TYP) (4 PLS)
0.375 (9.53 MM)

(REF)
1.50 (3.81 CM)

(TYP)
3.750 (9.53 CM)
3.350 (8.51 CM) DIA

1.50 (3.81 CM)
(TYP)
1.250 (3.05 CM)

(4 PLS)
0.375 (9.53 MM)
(REF)
1.150 1.850
(2.92 CM) 4.70 CM) SHIM SPLIT
(4 PLS) (4 PLS) (2 PLS)
6.00
(15.24 CM)
NOTES:
1. MATERIAL - 0.070 INCH ( 1.78 MM) CRES STEEL.
2. ALL DIMENSIONS ARE IN INCHES (CM). G63-2028A
Figure 204. Assembly Aid Tool for Input Drive
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MAINTENANCE MANUAL
P/N 369D25100
Page 212
MAINTENANCE MANUAL
Section
63−20−25
369F5100 Main
Transmission
(369D/E/FF −
500/600N)
MAINTENANCE MANUAL
P/N 369F5100
369F5100 MAIN TRANSMISSION
NOTE: The Overhaul instructions for the 369F5100 Transmission are contained in CSP-COM-5-2.
Please contact MDHI Aftermarket Sales for access to the manual.
1. Main Transmission (8). Disconnect anti-torque output shaft
seal drain line, input shaft seal drain
The main transmission is secured to the line and two hoses that attach to
underside of the main rotor mast support lubrication pump.
structure pan by four structure bolts, washers,
and nuts. The transmission is a two-stage NOTE: The following step will require an assis
speed reduction unit. The first reduction stage tant to hold the transmission mount bolts
is for the tail rotor drive system and accessory from the top of the helicopter and an assis
drive trains. The second stage is for further tant to remove the nuts and washers.
reducing rpm for the main rotor. The transmis
sion housing is magnesium alloy. The accesso (9). With assistance, support transmission;
ry gear train drives a rotor tachometer then remove hardware securing
generator and the transmission oil pump that transmission to mast support structure.
are mounted on drive pads at the aft end of the Lower transmission with ex
transmission. The transmission is cooled by air CAUTION treme care to prevent contact
drawn through a cooling blower and routed between anti-torque drive coupling and sur
through the transmission oil cooler. Access to rounding structure. Any dents, nicks or
the main transmission is attained by entrance scratches on coupling requires that coupling
into the passenger compartment. be scrapped. Use care to protect oil pressure
sender and chip detector terminal studs
2. Main Transmission Replacement
from damage during handling or when plac
A. Main Transmission Removal ing transmission on any surface.
(Ref. Figure 201) (10). With assistance, carefully lower

transmission.
(1). Remove sound insulation and transmis
sion access covers. NOTE: Cover top opening of transmission to
prevent entry of foreign material. Residual
(2). Remove main transmission drive shaft operating lubricant is an approved preser
(Ref. Sec. 63-10-00). vative for transmission shipment or storage.
(3). Remove cooling blower (Ref. Sec. B. Main Transmission Installation
63-21-00).
(Ref. Figure 201)
(4). Remove anti-torque drive shaft (Ref.
Sec. 63-15-10/30). Consumable Materials
NOTE: Removal of main rotor drive shaft is op (Ref. Section 91−00−00)
tional. If help is not available to rotate rotor Item Nomenclature
hub for spline alignment, shaft removal sim CM111 Grease, aircraft
plifies reinstallation of transmission. CM112 Anti-seize compound high temperature
(5). Remove main rotor drive shaft (Ref. CM121 Preservation oil
Sec. 63-10-00). CM125 Oil
(6). Disconnect wires from tachometer

generator, two chip detectors and oil (1). Use clean, absorbent cloth to clean pan
pressure sender. beneath main rotor mast support,
especially area contacted by O-ring on
(7). Drain oil from transmission. top of transmission.
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MAINTENANCE MANUAL
P/N 369F5100
Damage to main rotor drive (9). Install cooling blower (Ref. Sec.
CAUTION shaft or main transmission 63-21-00).
splines can occur during installation. Care
should be taken while meshing drive shaft
splines into transmission output splines to (10). Coat input drive coupling splines with
prevent damage. grease (CM111) and coat bolt threads
with anti-seize compound (CM112)
NOTE: The following procedure will require before assembly.
the assistance of another person.
(2). With assistance, slowly and evenly lift
When installing pulley and
and position transmission in place. CAUTION guard, make sure the spring pin
(3). Install four washers and nuts; torque to in pulley is fully engaged inside hole in
900—1100 inch-pounds pulley guard. If the spring pin does not align
(101.69—124.28 Nm) plus drag correctly with hole in pully guard, the
torque. torque will be incorrect.
(4). If transmission is new, drain any
residual preservative oil. Service (11). Install pulley guard, drive pulley, shim,
transmission with lubricating oil coupling and coupling bolt and tempo
(CM125) (Ref. Sec. 12-00-00). rarily tighten coupling bolt to approxi
(5). Connect wiring to tachometer genera mately 250 inch-pounds (28.25 Nm).
tor, two chip detectors and oil pressure
switch.
NOTE: Refer to Sec. 63-10-00, Main Transmis
(6). Install anti-torque drive shaft (Ref. sion Drive Shaft Installation and for cou
Sec. 63-15-10/30). pling shimming, coupling torque and drive
shaft installation.
When reinstalling main rotor
CAUTION drive shaft, check that there is
no gap between shaft mounting flange and (12). Install main transmission drive shaft
rotor hub before tightening installation (Ref. Sec. 63-10-00).
bolts. Gap indicates that shaft splines are
not correctly meshed in transmission.
(7). If main rotor drive shaft has been (13). Ground run helicopter (refer to appro
removed, apply coating of preservative priate PFM) and check drive system for
oil (CM121) on shaft before reinstalla excessive vibration and unusual noise.
tion and install drive shaft (Ref. Sec. Verify absence of oil over-temperature
63-10-00). and low pressure indications. Inspect
for oil leakage.
(8). Connect anti-torque output shaft seal
drain line and input shaft seal drain
line and two hoses that attach to (14). Install access covers and sound insula
lubrication pump. tion.
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MAINTENANCE MANUAL
P/N 369F5100
3. Main Transmission Repair Procedure (3). If dent is deeper than 0.030 inch (0.762
mm), fill depression with epoxy adhe
(Ref. Figure 201) sive (CM411) and blend to surrounding
Replace electrical components, breather-filler, surfaces.
filler extension, filler screen, externally
accessible O-rings, scavenge pump, lubrication (4). Touch up re-worked area with paint
pump, filter, input shaft oil seal and anti- (Ref. Sec. 20-30-00).
torque output shaft oil seal if defective. Dents
in outer surface of transmission housing 4. Main Transmission Inspection Procedure
deeper than 0.10 inch (2.54 mm) or covering
(Ref. Figure 201)
more than 0.60 square inch (3.87 cm2) area
require replacement of transmission. The following procedures provide information
This procedure is applicable to dents not for checking the main transmission for oil
exceeding specified limits. leakage and mechanical defect.

Consumable Materials sion access covers.
Item Nomenclature (2). Inspect transmission for oil leaks,
CM234 Solvent, dry-cleaning cracks, corrosion, secure electrical
CM318 Primer connections and correct oil level.
Evaluate oil leakage according to Fluid
Leak Analysis.
Inspect all fluid lines for ade
CAUTION quate clearance between struc
NOTE: Any evidence of lubricating oil leakage
in a repair area requires replacement of ture and components. Vibration can cause
transmission. chafing of lines and subsequent leaking.
(1). Clean area with solvent (CM234) and (3). Inspect four mounting flanges on main
remove sharp edges with grade 320 transmission housing for corrosion and
abrasive paper (CM801). cracks. Check that transmission
mounting nuts are secure.
(2). Apply coat of primer (CM318) on
repaired surface. (4). Check that all safety wiring is intact.
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MAINTENANCE MANUAL
P/N 369F5100
MAIN ROTOR DRIVE SHAFT
MAST BASE
COUPLING COUPLING
(KAMATIC) BOLT
LAMINATED
SHIM
TAIL ROTOR
OUTPUT DRIVESHAFT
SHAFT
OUTPUT SHAFT
DEBRIS
COVER
COOLING BLOWER
FILLER
INPUT
SHAFT
COUPLING
O-RING
(NOTE) PULLEY
GUARD
PULLEY
INTERNAL
WRENCHING BOLT
NOTE:
O-RING MUST BE CEMENTED IN PLACE
BEFORE INSTALLING TRANSMISSION. G63−2032A
Figure 201. 369F5100 Main Transmission Installation
Page 204
MAINTENANCE MANUAL
P/N 369F5100
5. Main Transmission Stripping (4). Install input shaft seal drain connector,
bonding it in place with sealing com
(Ref. Figure 202) pound (CM425).
(1). Remove tachometer generator. NOTE: On the 369F5100 transmission, the oil
pressure switch is mounted on the bottom,
(2). Remove coupling bolt, coupling and right side, facing down.
shim from anti-torque output shaft. (5). 600N: Using a new O-ring, install
147D-2 snubber and torque to
(3). Remove coupling bolt, coupling, shim, 155—165 inch-pounds (17.51—18.64
drive pulley and pulley guard from Nm).
main transmission input shaft. 369D/E/FF - 500N: Using a new
O-ring, install 369F5195-1 adapter
(4). Remove input shaft seal drain connec
and torque to 155—165 inch-pounds
tor (Ref. Sec. 12-00-00).
(17.51—18.64 Nm).
(5). Install suitable covers and plugs to (6). Using a new O-ring, install oil pressure
protect all openings, including threaded switch and coat threads with electrical
holes. ly conductive sealant (CM442). Safety
with lockwire (CM702).
6. Main Transmission Build−Up
NOTE: Do not apply electrically conductive
(Ref. Figure 202) sealant to the first two threads of pressure
switch.
Consumable Materials (7). Bond main rotor output shaft O-ring in

(Ref. Section 91−00−00) place with cement (CM417).
Item Nomenclature (8). Using two new O-rings, install exten
CM111 Grease, aircraft sion, screen and filler on transmission.
CM112 Anti-seize compound high temperature Use 369A5169 shims to ensure filler is
angled no more than 30° from center
CM417 Cement facing forward.
CM442 Sealant electrically conductive 7. Main Transmission Filter Replacement
CM702 Lockwire CRES (Ref. Figure 202)
(1). Remove interior trim and blower access
(1). Install one preliminary 0.010 inch door.
(0.254 mm) shim on anti-torque output (2). Position container or cloth to catch
shaft to prevent coupling bolt from residual oil. Loosen and remove filter
bottoming in shaft. housing by turning counterclockwise.
(2). Coat coupling splines with grease (3). Remove filter element.
(CM111) and coat bolt threads with
anti-seize compound (CM112) before (4). Inspect filter element for metal par
assembly. Install shaft coupling and ticles. If metal particles are present,
temporarily tighten coupling bolt to remove main transmission chip detec
approximately 250 inch-pounds tors and inspect for other evidence of
(28.25 Nm). internal failure in gearbox.
(5). If filter is excessively clogged, flush
(3). Install tachometer generator. With system and check filter bypass valve for
rotor brake installed, ensure electrical operation.
receptacle is at 11 o'clock position.
Torque nuts to 30—40 inch-pounds (6). Install new filter element and new
(3.39—4.52 Nm) plus drag torque. O-rings.
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MAINTENANCE MANUAL
P/N 369F5100
(7). Install housing and torque to 90—100 9. Lubrication Pump Removal and
inch-pounds (10.17—11.30 Nm). Installation
(8). If necessary, replenish transmission oil (Ref. Figure 203)
supply.
A. Lubrication Pump Removal
(9). Do the ground runup of helicopter and
check for oil leakage. (1). Remove three nuts (3) and washers (4)
and lubrication pump assembly (1) from
(10). Reinstall, in order, blower access door
transmission.
and interior trim.
(2). Remove three o-rings (2, 5) from
8. Main Transmission Break−In Procedure
lubrication pump assembly (1).
New (from the factory) or overhauled trans
missions must have a break-in period to B. Lubrication Pump Installation
remove the corrosion preventative coating
from the coast-side of the drive gears. If not (1). Install three o-rings (2, 5) on lubrica
done at installation, the coating will come off, tion pump assembly (1).
over time, and cause the impending bypass Make sure square input shaft of
button to pop. CAUTION lubrication pump aligns correct
(1). Fly aircraft normally, monitoring the ly with oil pump drive shaft in tail rotor
transmission chip detectors for metal drive assembly as pump is installed.
particles, for the first 10 hours.
(2). Install lubrication pump assembly (1)
NOTE: Ignore the impending bypass indicator on tail rotor drive assembly studs with
in the first 10 hours of flight. three nuts (3) and washers (4). Torque
nuts to 36—46 inch lbs (4.07—5.20
(2). During the first 10 hours of flight time, Nm) plus drag torque.
perform at least three partial autorota
tions (Ref. Pilots Flight Manual) to load 10. Scavenge Pump Removal and Installation
the transmission on the coast side of
the gears. A. Scavenge Pump Removal
NOTE: Each autorotation should be at least 30 (1). Remove three nuts (8) and washers (9)
seconds in duration. and scavenge pump assembly (6) from
(3). After 10 hours flight time has elapsed, transmission.
replace filter element (Ref. Main
(2). Remove three packings (7, 10) from
Transmission Filter Replacement).
scavenge pump assembly (6).
NOTE:
B. Scavenge Pump Installation
D Coating particles are black in color. Some
silver non-magnetic metallic particles (1). Install three packings (7, 10) on
could be in the filter bowl, which are mag scavenge pump assembly (6).
nesium machining debris from manufac
turing. (2). Install scavenge pump assembly (6) on
D Flushing transmission oil is preferred but tail rotor drive assembly studs with
not necessary. three nuts (8) and washers (9). 36—46
inch lbs (4.07—5.20 Nm) plus drag
(4). Reset the impending bypass indicator. torque.
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MAINTENANCE MANUAL
P/N 369F5100
OUTPUT
OUTPUT COUPLING
PINION ROTOR
BRAKE ANTI-TORQUE
OIL FILLER DRIVE SHAFT
A
OIL COOLER
BLOWER
COUPLING BOLT
CHIP
DETECTORS
DRIVE PULLEY
B B INPUT ENGINE-TO-TRANSMISSION
COUPLING DRIVE SHAFT
SNUBBER (600N
TACH GENERATOR
ADAPTER (369D/E/FF - 500N
PACKING
PRESSURE SWITCH LOCK WIRE
TRANSMISSION
OIL FILTER
JUMPER ASSEMBLY
DIFFERENTIAL PRESSURE INDICATOR

(IMPENDING BYPASS INDICATOR)
VIEW A-A
LOOKING FORWARD
VIEW B-B
LOOKING UP
CSP102-009C
Figure 202. 369F5100 Main Transmission Build−Up
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MAINTENANCE MANUAL
P/N 369F5100
3
5
2
5
1
8
10
9
7 10
6
G63-2025-203-1
1. LUBRICATION PUMP 6. SCAVENGE PUMP

2. O−RING 7. O−RING
3. NUT 8. NUT
4. WASHER 9. WASHER
5. O−RING 10. O−RING
Figure 203. Main Transmission Scavenge Pump Removal and Installation
11. Input Drive Assembly − Oil Leakage and guard, and cooling blower assembly
Repair Procedure (Ref. Sec. 63-21-00).
(2). Drain oil from input drive assembly
A. Input Pinion O−Ring Replacement
through the lower chip detector plug
(Ref. Sec. 12-00-00).
(Ref. Figure 204) Use the following repair
procedure when oil leakage occurs between the (3). Remove attaching hardware securing
main transmission housing and the pinion blower mount assembly.
bearing sleeve flange.
(4). Using NAS603-64 jack screws at two
corners of the input quill, begin pulling
Consumable Materials the input quill from the transmission
(Ref. Section 91−00−00) housing. As required, operators can use
Item Nomenclature 0.5-1.0 inch (12.70-25.40 mm) bar
stock or equivalent as spacers to put
CM218 Alcohol, denatured
under the jack screws to assist
removing the input quill.
(1). Remove the shaft interconnect, trans NOTE: It can be necessary to heat main hous
mission input coupling, drive pulley ing to move input drive assembly.
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MAINTENANCE MANUAL
P/N 369F5100
(5). Gently screw input drive assembly (17). Inspect pattern shim to ensure no
away from main housing no more than overlap condition exists at butt/split
necessary to gain access to O-ring line.
between main housing and input
pattern shim. (18). Reinstall the shaft interconnect,
transmission input coupling, drive
(6). Remove jack screws from input drive pulley and guard, and cooling blower
assembly pinion. assembly.
(7). If required, cut defective O-ring for (19). Service the transmission (Ref. Sec.
removal. 12-00-00).
(8). Clean and inspect pattern shim for B. Input Pinion Seal Replacement
distortion and ensure no overlap (Ref. Figure 204)
condition exists at butt/split line of
shim. Use the following repair procedure when oil
leakage occurs at the input pinion seal.
(9). Clean area between main housing and
input drive sleeve with alcohol (CM218) NOTE: If replacing a magnetic seal with a lip
to remove paint chips or other foreign seal, a speedi-sleeve must be installed.
matter.
(10). Install new O-ring by slipping over (Ref. Section 91−00−00)
blower mount. Seat O-ring in contact Item Nomenclature
with the main housing.
(11). Remove alignment bolts and install CM218 Alcohol, denatured
attaching hardware in blower mount
and input pinion bearing sleeve. Special Tools
(12). Tighten attaching hardware as follows: Item Nomenclature
(a). Tightening the four attaching bolts N/A 369F5100ATP-1 Locknut removal tool
equally.
(b). Tighten hardware until attaining a (1). Remove the main transmission drive
positive clamp-up between the main shaft (Ref. Sec. 63-10-00, Main
housing and input pinion bearing Transmission Drive Shaft Replace
sleeve flange. ment).
(13). Remove attaching hardware. (2). Remove nut from transmission input
coupling, drive pulley and guard (Ref.
(14). Ensure the O-ring is seated in main Sec. 63-10-00, Main Transmission
housing groove. Drive Shaft Replacement), keep all
shims with coupling.
(15). When O-ring is seated correctly,
reinstall input pattern shim between (3). Drain oil from input drive assembly
main housing and input pinion bearing through the lower chip detector plug
sleeve flange and reinstall hardware. (Ref. Sec. 12-00-00).
(16). Tighten attaching hardware as follows: (4). Remove lockwasher.
(a). Maintain an inward preload on input (5). Using locknut removal tool, remove
pattern shim during the tightening locknut.
sequence. NOTE: The following procedure requires two
people to accomplish.
(b). Torque attaching hardware 50—70
inch-pounds (5.65—7.91 Nm) plus (a). Insert tee over locknut and put
drag torque. cheater bar over one ear of tee.
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MAINTENANCE MANUAL
P/N 369F5100
(b). Insert socket through center of tee to (14). Service transmission (Ref. Sec.
engage splines on input shaft. 12-00-00).
(c). Insert adapter and breaker bar into 12. Gearshaft Repair Using Speedi−Sleeve
socket.
This procedure covers repair of output
(d). Turn locknut removal tee counter- gearshaft using speedi-sleeve, and input
clockwise, while holding spline socket gearshaft using speedi-sleeve.
stationary, to remove nut.
(6). Using seal removal tool, remove seal (Ref. Section 91−00−00)
from fan mount assembly. Item Nomenclature
(7). Clean sealant from seal seating surface CM216 Retaining Compound
in blower mount with denatured alcohol CM234 Solvent, Dry Cleaning
(CM218). CM321 Primer
CM431 Sealing Compound
(8). Allow to air dry. CM436 Plastic Steel
(9). Insert seal into fan mount assembly.
Special Tools
(10). Apply anti-seize compound (CM112) to (Ref. Section 91-00-00)
non-serrated threads on pinion and Item Nomenclature
install locknut. CM803 Crocus Cloth
NOTE: The following procedure requires two

people to accomplish. A. Speedi−Sleeve Removal
(a). Insert tee over locknut and put (Ref. Figure 204)
cheater bar over one ear of tee. Use care not to cut into or dam
CAUTION age gearshaft when removing
(b). Insert socket through center of tee to damaged sleeve.
engage splines on input shaft.
(1). Use file or other suitable instrument to
(c). Insert adapter and breaker bar into cut through edge of sleeve. Carefully
socket. pry/cut edge away from shaft.
(d). Turn input shaft counter-clockwise, (2). Grasp raised edge with pliers and peel
while holding locknut stationary, to damaged sleeve off shaft.
install nut.
(3). Remove any locking compound (CM216)
(e). Torque nut to 250 foot-pounds (339 or plastic steel (CM436) residue from
Nm). Loosen locknut and re-torque shaft using the following methods:
to 183—225 foot-pounds (248—305 Use care when using stainless
Nm). CAUTION steel brush not to remove plat
ing from shaft.
(11). Install lockwasher.
(a). Remove any residual locking com
(12). Reinstall input coupling with shims pound from shaft with a stainless
previously removed (Ref. Sec. steel bristle brush. Clean shaft with
63-10-00, Main Transmission Drive a lint free cloth dampened in locking
Shaft Replacement). compound remover (CM216).
(13). Reinstall main transmission drive shaft (b). Remove plastic steel residue from
(Ref. Sec. 63-10-00, Main Transmission shaft using lint free cloth dampened
Drive Shaft Replacement). with dry cleaning solvent (CM234).
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MAINTENANCE MANUAL
P/N 369F5100
B. Speedi−Sleeve Installation (a). Mix plastic steel (CM436), in accor
dance with manufacturer's instruc
(Ref. Figure 204) tions.
(1). Clean shaft sleeve mating surface with (b). Apply plastic steel to shaft-sleeve
lint free cloth dampened with dry mating surfaces.
cleaning solvent (CM234).
(4). While locking compound or plastic steel
NOTE: Either locking compound (CM431) or is wet, install new speedi-sleeve on
plastic steel (CM436) may be used for spee shaft flange first.
di-sleeve attachment.
(2). If using locking compound: NOTE: Do not remove installation flange on
speedi-sleeve.
(a). Apply surface primer (CM321) on
shaft-sleeve mating surfaces. Allow (5). Press or tap sleeve into place using a
primer to air dry at ambient temper 1-1/4 inch (3.175 cm) I.D. pipe posi
ature for a minimum of 30 minutes. tioned on flange of sleeve. Refer to
Figure 204 for installation dimensions.
(b). Apply locking compound (CM431) to
shaft-sleeve mating surface. (6). Wipe excess locking compound or
plastic steel from shaft using a clean
(3). If using plastic steel: lint free cloth.
O-RING
SLEEVE INPUT
BEARING SHIM
INPUT SEAL
O-RING FAN MOUNT
BEARING RETAINER
BOLT WASHER
BOLT
INPUT LABYRINTH SEAL

WASHER
INPUT PINION
LOCKNUT
INPUT LOCKWASHER
NOSE BEARING
INPUT PATTERN
SHIM PULLEY SHIM
SPACER
INPUT PATTERN SHIM
O-RINGS O-RING
INPUT SHAFT OUTER SLEEVE
INPUT BEARING
INPUT THRUST BEARING
O-RING G63-2025-204-1
Figure 204. Drive Assembly O−Ring Replacement
Page 211
MAINTENANCE MANUAL
P/N 369F5100
Page 212
MAINTENANCE MANUAL
Section
63−21−00
Main Transmission
Lubrication and
Cooling System
(369D/E/FF −
500/600N)
MAINTENANCE MANUAL
MAIN TRANSMISSION LUBRICATION

AND COOLING SYSTEM
1. Main Transmission Lubrication System (4). Ground run helicopter (Ref. PFM) and
check pump interface for leaks per
The main transmission lubrication system Fluid Leak Analysis (Ref. Section
consists of a lubrication pump driven by the 63-20-00). Verify that pressure
transmission, an oil filter, oil cooler, oil cooler warning light is not on at 55% N2.
bypass valve, oil temperature sender, oil
pressure sender, liquid level plug, two chip (5). Reinstall access covers and sound
detectors, a drain line from the tail rotor insulation.
output shaft seal and a drain line from the
input shaft seal. 3. Main Transmission Lubrication Pump
Replacement (369F5100 Transmission)
Replacement (369D25100 Transmission) (Ref. Figure 402)
(Ref. Figure 401)
A. Main Transmission Lubrication Pump Removal (369F5100 Transmission)
Removal (369D25100 Transmission)
(1). Remove sound insulation and transmis sion access covers (Ref. Section
sion access covers. 52-40-00).
(2). Remove hardware that secure pump (2). Remove hardware that secure pump
housing to mounting pad. housing to mounting pad.
(3). Remove pump and discard three (3). Remove pump and discard O-rings.
O-rings.
B. Main Transmission Lubrication Pump Installation (369F5100 Transmission)
Installation (369D25100 Transmission)
Item Nomenclature
Item Nomenclature
CM114 Petrolatum
CM114 Petrolatum
(1). Install new O-rings in ports and in (1). Install new O-rings in ports and in
groove of pump sleeve. Apply light groove of pump sleeve. Apply light
coating of petrolatum (CM114) to both coating of petrolatum (CM114) to both
O-rings and mating bores in transmis O-rings and mating bores in transmis
sion to prevent damage to O-rings. sion to prevent damage to O-rings.
(2). Align square drive of pump with drive (2). Align square drive of pump with drive
shaft in transmission and carefully shaft in transmission and carefully
press pump into place. press pump into place.
(3). Install attaching hardware; torque to (3). Install attaching hardware; torque to
50—70 inch-pounds (5.65—7.91 40—50 inch-pounds (4.52—5.65 Nm)
Nm). plus drag torque.
Page 401
MAINTENANCE MANUAL
MAIN TRANSMISSION
LUBRICATION PUMP
O-RINGS
ROTATED
63-2008
Figure 401. Main Transmission Lubrication Pump (369D25100 Transmission)
Page 402
MAINTENANCE MANUAL
SCAVENGE
OIL PUMP
LUBRICATION
PUMP
LOOKING FORWARD
LUBRICATION
PUMP
MAIN 0-RINGS
TRANSMISSION
DIFFERENTIAL PRESSURE INDICATOR

(IMPENDING BYPASS INDICATOR)
SCAVENGE OIL PUMP
0-RINGS
6G63-002A
Figure 402. Main Transmission Lubrication Pump (369F5100 Transmission)
Page 403
MAINTENANCE MANUAL
(4). Ground run helicopter (Ref. PFM) and tors and inspect for other evidence of
check pump interface for leaks per internal failure in gearbox.
Fluid Leak Analysis (Ref. Section
63-20-00). Verify that pressure (5). If filter is excessively clogged, flush
warning light is not on at 55% N2. system and check filter bypass valve for
operation (Ref. COM).
(5). Reinstall access covers and sound
insulation (Ref. Section 52-40-00). (6). Install new filter element and new
O-rings.
4. Main Transmission Filter Replacement (7). Install and tighten housing.
(369D25100 Transmission)
(8). If necessary, replenish transmission oil
(1). Remove interior trim and blower access supply; then do ground runup of
door. helicopter and check split line for oil
(2). Position container or cloth to catch leakage.
residual oil. Loosen and remove filter (9). Reinstall blower access door and
housing by turning counterclockwise. interior trim.
(3). Remove filter element. 6. Main Transmission Scavenge Pump
(4). Inspect filter element for metal par Replacement (369F5100 Transmission)
ticles. If metal particles are present, (Ref. Figure 402)
remove main transmission chip detec
tors and inspect for other evidence of A. Main Transmission Scavenge Pump
internal failure in gearbox. Removal (369F5100 Transmission)
(5). If filter is excessively clogged, flush (1). Remove sound insulation and transmis
system and check filter bypass valve for sion access covers (Ref. Section
operation (Ref. COM). 52-40-00).
(6). Install new filter element and new (2). Remove hardware that secure pump
O-rings. housing to mounting pad.
(7). Install housing and torque to 70—100 (3). Remove pump and discard O-rings.
B. Main Transmission Scavenge Pump
(8). If necessary, replenish transmission oil Installation (369F5100 Transmission)
supply; then do a ground runup of
helicopter and check for oil leakage. Consumable Materials
(9). Reinstall, in order, blower access door
Item Nomenclature
and interior trim.
CM114 Petrolatum
5. Main Transmission Filter Replacement
(369F5100 Transmission)
(1). Install new O-rings in ports and in
(1). Remove interior trim and blower access groove of pump sleeve. Apply light
door. coating of petrolatum (CM114) to both
O-rings and mating bores in transmis
(2). Position container or cloth to catch sion to prevent damage to O-rings.
residual oil. Loosen and remove filter
housing by turning counterclockwise. (2). Align square drive of pump with drive
shaft in transmission and carefully
(3). Remove filter element. press pump into place.
(4). Inspect filter element for metal par (3). Install attaching hardware; torque to
ticles. If metal particles are present, 40—50 inch-pounds (4.52—5.65 Nm)
remove main transmission chip detec plus drag torque.
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MAINTENANCE MANUAL
(4). Ground run helicopter (Ref. PFM) and (4). Loosen the jamnut (6), on the union tee
check pump interface for leaks per (7), and remove the transmission hose
Fluid Leak Analysis (Ref. Section assembly (1) from the bypass valve
63-20-00). housing (2).
(a). Separate and store the the transmis
7. Main Transmission Oil Cooler Bypass
sion hose assembly (1), and collect
Valve Replacement
draining oil in to the container.
The oil cooler bypass valve causes main NOTE: It is recommended to secure all
transmission lubrication oil to bypass the oil attached hardware for later installation.
cooler when oil temperature is 178.6 to
180.65F (81 to 835C) or less, or the following (5). Loosen two jamnuts (6), on the union
conditions exist: pressure differential of 25 psi tees (7) against the firewall, and
(172 kPa) or higher across oil cooler with oil remove the four washers (8) and two
temperature of 1905F (885C) or higher. transmission hose assemblies (9) from
the bypass valve housing (2).
Excessive transmission oil temperature can be
caused by failure of oil cooler bypass valve to (a). Separate and store the the transmis
seat in housing. Before installing new valve, sion hose assemblies(9), and collect
inspect seat within housing. If housing seat is draining oil in to the container.
damaged, housing must also be replaced. NOTE: It is recommended to secure all
attached hardware for later installation.
A. Removal
(6). Remove bypass valve housing (2).
(Ref. Figure 403)
(a). Remove thermostatic control valve
assembly (3), and packing (10), from
Consumable Materials the bypass valve housing (2).
Item Nomenclature (b). Drain remaining oil from bypass
valve housing (2) in container.
(c). Remove union tee (4), and the three
other union tees (7) and the six
(1). Prepare container for draining oil from packings (11), from the bypass valve
the two transmission hose assemblies housing (2).
(1) upstream of bypass valve housing
(2) through the bypass valve port. B. Installation
(2). Cut and remove lockwire from the (Ref. Figure 403)
thermostatic control valve assembly (3), (1). Assembly the bypass valve housing (2).
and the union tee (4), between the
bypass valve housing (2) and the (a). Apply light coat of antiseize com
temperature sender housing (5). pound (CM112) to the union tee (4),
and the three other union tees (7)
(3). Loosen jamnut (6), on the union tee (4), threads.
between the temperature sender
(b). Install six packings (11) to the union
housing (5) and the bypass valve
tee (4), and the three other union tees
housing (2).
(7).
(a). Separate and store the temperature (c). Install the union tee (4), and the
sender housing (5), with the trans three other union tees (7), to the
mission hose assembly (1), and collect bypass valve housing (2).
draining oil in to the container.
(d). Install packing (10) to the thermo
NOTE: It is recommended to secure all static control valve assembly (3), and
attached hardware for later installation. to the bypass valve housing (2).
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MAINTENANCE MANUAL
(2). Install two washers (8) to bypass valve (b). Torque the jamnut (6) to 50 to 60
housing (8). inch-pounds (5.65 to 6.78 Nm).
(a). Secure bypass valve housing (8) to (5). Install jamnut (6), to the union tee (4),
the firewall. between the temperature sender
(3). Install two washers (8), and two housing (5) and the bypass valve
jamnuts (6), to the two union tees (7) housing (2).
threads on opposite side of the firewall.
(a). Torque the jamnut (6) to 50 to 60
(a). Install two transmission hose assem inch-pounds (5.65 to 6.78 Nm).
blies (9) to the bypass valve housing
(2). (6). Use lockwire and safety the thermostat
ic control valve assembly (3) to the
(b). Torque the two jamnuts (6) to 50 to union tee (4), between the bypass valve
60 inch-pounds (5.65 to 6.78 Nm). housing (2) and the temperature sender
(4). Install the jamnut (6), to the union tee housing (5).
(7).
(7). Replenish transmission oil lost during
(a). Install the transmission hose assem bypass valve housing (2) removal (Ref.
bly (1) to the bypass valve housing Section 12-00-00, Main Rotor Trans
(2). mission Filling).
Page 406
MAINTENANCE MANUAL
1 (REF)
10
6
7
10
6 10
2 (REF)
sp118-B (REF) 10
7
FIREWALL (REF)
sp119-B (REF) 4
10
8
11
10
3 7 8
8
6
8
6 9
G63−2100−403−1
1. TRANSMISSION HOSE ASSEBMLY 7. UNION TEE

2. BYPASS VALVE HOUSING 8. WASHER
3. THERMOSTATIC CONTROL VALVE ASSEMBLY 9. TRANSMISSION HOSE ASSEMBLY
4. UNION TEE 10. PACKING
5. TEMPERATURE SENDER HOUSING 11. PACKING
6. JAMNUT
Figure 403. Main Transmission Oil Cooler − Removal/Installation
Page 407
MAINTENANCE MANUAL
8. Main Transmission Oil Cooler wide, from pressure-sensitive tape

Replacement (CM715).
A. Main Transmission Oil Cooler Removal (3). Apply seals, fabricated in previous step,
on oil cooler and oil cooler covers. Cut
(1). Drain main transmission lubrication holes in seals to accommodate bolts
system (Ref. Section 12-00-00). (eight places).
(2). Remove two tubes that connect oil (4). Secure oil cooler and oil cooler inlet
cooler to oil cooler bypass valve hous duct to firewall with four bolts, washers
ing. and nuts.
NOTE: MDHI Notice DN-72.1 provides in (5). Secure oil cooler outlet duct to oil cooler
structions for modifying oil cooler drain sys with four bolts, washers and nuts.
tem on early model helicopters to current
configuration. (6). Install tee (with drain cap), elbow and
tubes that run from oil cooler to oil
(3). Remove oil drain tube and drain fitting. cooler bypass valve housing, applying
light coat of antiseize compound
(4). Detach oil cooler outlet duct. (CM112) to threads.
(5). Remove compressor cooling duct and (7). Install oil drain tube and fitting on tee.
pull oil cooler outlet duct away from oil
cooler. (8). Install compressor cooling duct.
(9). Fill main rotor transmission lubrication
(6). Remove hardware that secures oil
system (Ref. Section 12-00-00, Main
cooler and oil cooler inlet duct to
Rotor Transmission Filling).
firewall; remove oil cooler.
(7). Remove covers from oil cooler by 9. Main Transmission Oil Temperature
breaking lockwire and cutting sealant. Sender Replacement
(Ref. Figure 601) The oil temperature sender
NOTE: MDHI Notice DN-23.2 contains infor for the main transmission lubrication system
mation relative to installation of oil cooling is installed in a housing inserted in the 0.5
lines. inch (12.7 mm) oil line to the IN port of the
B. Main Transmission Oil Cooler Installation lubrication pump. The switch closes when the
oil temperature is between 230 to 250F (110
to 121C).
Item Nomenclature Consumable Materials
CM112 Anti-seize compound high temperature Item Nomenclature
CM408 Adhesive, silicone rubber CM112 Anti-seize compound high temperature
CM702 Lockwire CRES CM726 Tape, teflon
(1). Remove lockwire and detach electrical

(1). Scrape old sealant and remnants of wire from sender terminal post.
pressure-sensitive tape seals from oil Position container for draining trans
cooler covers and reinstall covers with mission oil cooler line. Remove two set
(CM702) lockwire and sealant (CM408). screws securing sender within sender
Use sealant to fill gaps (four places) at housing. Unscrew sender and drain oil
ends of covers. in container. Plug housing to prevent oil
drainage.
(2). Make up four 0.125 inch (3.18 mm)
thick and four 0.250 inch (6.35 mm) (2). Apply a light coat of antiseize com
thick seals, all 0.750 inch (19.05 mm) pound (CM112) or tightly wrap two or
Page 408
MAINTENANCE MANUAL
three turns of Teflon tape (CM726) on (1). Detach electrical wire or wires and
tapered threads of sender. Screw using absorbent cloth, unscrew sender
temperature sender into housing; from transmission.
torque 30 to 40 inch-pound (3.39 to
4.52 Nm). Install set screws until light (2). Apply light coat of antiseize compound
contact is made with sender. Lockwire (CM112) or wrap two or three turns of
hex of sender to drilled head of ground Teflon tape (CM726) on tapered threads
wire screw in sender housing. Connect of sender. Screw in sender; torque 30 to
electrical wire to sender terminal and 40 inch-pound (3.39 to 4.52 Nm).
replenish transmission with oil lost Connect wire; make sure that connec
(Ref. Section 12-00-00, Main Rotor tion is clean and tight. If three wires
Transmission Filling). are present, for information on connec
tion of third wire refer to wiring
10. Main Transmission Oil Pressure Sender diagram for running time meter.
Replacement
11. Liquid Level Plug Replacement
(Ref. Figure 404) The main transmission oil
pressure sender provides a ground to cause the (1). Drain oil from transmission until oil
XMSN OIL PRESS warning light to illumi level is well below edge of plug port
nate when oil Pressure is low. It also provides (Ref. Section 12-00-00, Main Rotor
a ground to the running-time meter. Sender's Transmission Draining).
normally-closed contacts open when oil
pressure increases to 13 to 17 psi (89.6 to (2). Remove lockwire from plug.
117.2 kPa); simultaneously the sender's
normally-open contacts close. (3). Remove plug by unscrewing counter
clockwise.
(Ref. Section 91−00−00) (4). Remove and discard O-ring. Install
Item Nomenclature new O-ring on plug.
CM112 Anti-seize compound high temperature (5). Install plug by screwing clockwise.
CM726 Tape, teflon Torque plug 80 to 90 inch-pound
(9.04 to 10.17 Nm); install lockwire.
Page 409
MAINTENANCE MANUAL
BREATHER-FILLER
SPLINES FOR O-RING
MAIN ROTOR (NOTE)
DRIVE SHAFT
OUTPUT SHAFT
(TAIL ROTOR)
OIL SEAL
OIL PRESSURE
SENDER
COOLING BLOWER
MOUNTING BRACKET
CHIP DETECTOR
AND SELF-CLOSING
DRAIN VALVE
COOLING BLOWER
PULLEY SPACER
CHIP DETECTOR
SELF-CLOSING INPUT SHAFT

DRAIN VALVE
NOTE:
INPUT SHAFT SEAL
O-RING MUST BE CEMENTED IN PLACE
DRAIN CONNECTOR
BEFORE INSTALLING TRANSMISSION. 63-2001
Figure 404. Main Transmission − Cross−Section View
12. Chip Detector Replacement engine oil cooler and the main transmission oil
cooler. Exhaust air from transmission and
(Ref. Figure 404) For removal and installation engine oil coolers is directed at various
instructions, refer to Draining Main Transmis external portions of the engine and engine
sion (Ref. Section 12-00-00). For functional accessories.
test information for detector circuit, refer to
Section 95-30-00. B. Cooling Blower Removal
13. Cooling Blower Replacement
(Ref. Figure 405)
A. Cooling Blower
(1). Remove main transmission drive shaft
(Ref. Figure 405) The cooling blower is and blower access door.
mounted to a bracket on the aft underside of
the main transmission and coupled to the (2). Remove coupling bolt, coupling, shim(s)
transmission input shaft by a pulley-driven and pulley from transmission input
belt. The blower exhausts air through the shaft.
Page 410
MAINTENANCE MANUAL
(3). Disconnect cooling blower drain tube. In the following step do not use
Loosen tie-down straps on blower duct CAUTION levers or other tools on belt, or
rubber connectors and roll back in any way force belt onto pulley.
connectors to disconnect ducts from
cooling blower. (5). Slide pulley onto transmission input
(4). Cut lockwire and remove four bolts shaft to engage belt in teeth of both
attaching mounting bracket to trans pulleys.
mission. Remove two shims inserted
between bracket and transmission pad. (6). Adjust belt tension.
(5). Remove mounting bracket (with blower,
pulley and belt) from helicopter. NOTE: Instructions in step (7). below, apply
only when original shim(s) (same shim
NOTE: For 369D25100 transmission installa thickness) are installed and drive shaft,
tion only; If equipped with 369D25626-11 overrunning clutch and couplings remain
mount bracket, examine bolts securing unchanged. A distance of 0.010 inch
mount bracket to cooling blower assembly. If (0.254 mm) between bolt seating surface
safety wired, remove and discard bolts. Re on coupling and transmission input shaft is
place with NAS1224-1L self-locking bolts. required to ensure coupling bolt will not
bottom out shaft and to provide proper as
(6). Disassemble cooling blower if required. sembly clamp up. (Ref. Section 63-10-00).
C. Cooling Blower Installation (369D25100
Transmission) The 0.010 inch (0.254 mm)
CAUTION minimum measurement be
(Ref. Figure 405) tween the bolt seating surface and the in
(1). Install pulley guard on main transmis put shaft must be obtained to ensure prop
sion input shaft. er clamp up. Warped shims or foreign
material could provide a false 0.010 inch
(2). With belt looped around transmission (0.254 mm) minimum measurement and
input shaft, position mounting bracket improper clamp up could result during nor
on main transmission pad and loosely mal operation which can damage the main
install four bolts and washers. Before transmission input shaft.
tightening bolts, insert two shims
between bracket and transmission pad. (7). Install laminated shim and coupling on
Verify that blower scroll clears tail rotor transmission input shaft. Secure
drive shaft by at least 0.190 inch (4.83 coupling with coupling bolt; torque to
mm). Torque bolts to 65—75 inch- 250—300 inch-pounds (28.25—33.90
pounds (7.34—8.47 Nm). Lockwire Nm) plus drag torque.
bolt heads after belt tension is checked.
(3). Connect drain tube to cooling blower (8). Make sure belt tracks correctly (Ref.
scroll fitting. Clamp tube to fitting with Cooling Blower Belt Tracking).
two turns of lockwire.
(4). Roll exhaust duct rubber connectors (9). Install main transmission drive shaft
onto scroll outlets and secure with (.Ref Section 63-10-00).
tie-down straps (Transmission oil
cooler duct and engine oil cooler duct). (10). Install access panels.
Page 411
MAINTENANCE MANUAL
TRANSMISSION
INPUT COUPLING INTERNAL
WRENCHING BOLT
MOUNTING
BRACKET
0.010 IN. (0.254 MM) MINIMUM

(BETWEEN END OF SHAFT AND
BOLT SEATING ON SURFACE
ON COUPLING)
SHIM
(2 PL)
MAIN
TRANSMISSION
WASHER
DRIVEN
PULLEY FAN
MOUNTING ENGINE OIL RUBBER
BRACKET COOLER DUCT CONNECTOR
TIE WRAP STRAP

INPUT SHAFT (TYP)
COOLING
WASHER BLOWER
COOLING
BLOWER SPACER
PULLEY
SPACER
DRIVER PULLEY
LAMINATED
COUPLING SHIM
PULLEY GUARD
INTERNAL
WRENCHING BOLT
RUBBER
CONNECTOR
BELT
TRANSMISSION
INPUT COUPLING
G63-2000
Figure 405. Cooling Blower Installation (369D25100 Transmission)
Page 412
MAINTENANCE MANUAL
D. Cooling Blower Installation (369F5100 In the following step, do not use

Transmission) CAUTION levers or other tools on belt, or
(Ref. Figure 406) in any way force belt onto pulley.
(6). Slide driver pulley onto transmission
Consumable Materials input shaft to engage belt in teeth of
(Ref. Section 91−00−00) both pulleys.
Item Nomenclature The minimum of 0.010 inch
CM111 Grease, aircraft CAUTION (0.254 mm) measurement be
CM112 Anti-seize compound high temperature tween the bolt seating surface and the in
CM425 Sealing compound put shaft must be obtained to ensure prop
CM702 Lockwire CRES er clamp-up.
D Warped shims or foreign material could
(1). With belt looped around driven pulley, provide a false 0.010 inch (0.254 mm)
install oil cooler fan bracket. minimum measurement and improper
clamp-up could result, which during nor
NOTE: NAS1304 series bolts can be used in mal operation, can damage the main
place of NAS6604 series bolts. transmission input shaft.
(a). Install four bolts with washers D Do not use clutch coupling shims under
through oil cooler mounting bracket transmission input coupling. Inside di
into fan bracket. ameter of clutch coupling shim is differ
ent than shim used on transmission in
(b). Before tightening bolts, displace put coupling. Incorrect diameters can
cooler toward the transmission flange cause an improperly seated shim, mis
to eliminate slack in that direction. alignment and cocked coupling.
(c). Torque bolts to 70—90 inch-pounds (7). Torque bolts to 70—90 inch-pounds
(7.91—10.17 Nm) and safety with (7.91—10.17 Nm).
lockwire (CM702). (8). Coat threads of coupling bolt with
(d). After bolts are torqued, seal around anti-seize compound (CM112).
bolt heads with sealant (CM425). (9). Lubricate input shaft splines and
coupling splines with grease (CM111).
When installing pulley and
CAUTION guard, make sure the spring (10). Install input coupling shim and
pin in pulley is fully engaged inside hole in coupling on transmission input shaft
pulley guard. If the spring pin does not with coupling bolt.
align correctly with hole in pully guard, the (11). Adjust belt tension (Ref. Cooling Blower
torque will be incorrect. Belt Tension Check and Adjustment).
(2). Install pulley guard on main transmis NOTE: Check coupling bolt for a minimum of
sion input shaft. 25 inch-pounds (2.82 Nm) drag torque.
(12). Torque coupling bolt to 315—365
(3). With belt looped around transmission inch-pounds (35.59—41.24 Nm) plus
input shaft, position mounting bracket drag torque.
on main transmission pad and loosely
install two bolts with washers from the (13). 369D, E, F, and 500N - Make sure belt
bottom of bracket and two bolts with tracks correctly (Ref. Cooling Blower
washers from top of bracket. Belt Tracking).
(14). Connect drain tube to cooling blower
(4). Before tightening bolts, insert two scroll fitting. Clamp tube to fitting with
shims between bracket and transmis two turns of lockwire (CM702).
sion pad.
(15). Roll exhaust duct rubber connectors
(5). Verify that blower scroll clears anti- onto scroll outlets (transmission oil
torque drive shaft by a minimum of cooler duct and engine oil cooler duct)
0.190 inch (4.826 mm). and secure with tie straps.
Page 413
MAINTENANCE MANUAL
BOLT
BOLT
OIL COOLER FAN

BRACKET FAN BRACKET
BOLT
SHIM
BOLT
PULLEY GUARD
TRANSMISSION INTERNAL
INPUT COUPLING WRENCHING BOLT
INPUT COUPLING
DRIVER PULLEY
BOLT
INPUT COUPLING SHIM

0.010 IN. (0.254 MM) MINIMUM
(BETWEEN END OF SHAFT AND BOLT
SEATING ON SURFACE ON COUPLING)
CSP102-012D
Figure 406. Oil Cooler Blower Installation (369F5100 Transmission)
Page 414
MAINTENANCE MANUAL
E. 369D, E, F, and 500N − Cooling Blower (3). Rotate the lower driver pulley by hand
Belt Tracking in a counter-clockwise direction. Make
(Ref. Figure 407) sure the belt tracks axially towards the
blower on the upper driven pulley.
(1). Make sure the oil cooler belt tracks
correctly. (4). If the oil cooler belt does not track
(2). Rotate the lower driver pulley with correctly, replace with a serviceable
your hand in a clockwise direction (as belt.
you look at the main rotor transmission
input). Make sure the belt tracks
axially away from the blower on the
upper driven pulley.
BLOWER
DRIVEN PULLEY
NOTE 1
DRIVEN PULLEY
NOTE 2
DRIVER PULLEY
(NOTES 1,2)
MAIN TRANSMISSION
DRIVE SHAFT
NOTES:
1. TURN DRIVER PULLEY CLOCKWISE.
VERIFY BELT TRACKS AWAY FROM BLOWER.
2. TURN DRIVER PULLEY COUNTER-CLOCKWISE.
63-2034
VERIFY BELT TRACKS TOWARDS BLOWER.
Figure 407. Cooling Blower Belt Tracking
Page 415
MAINTENANCE MANUAL
Page 416
MAINTENANCE MANUAL

AND COOLING SYSTEM
INSPECTION/CHECK
1. Lubrication System Inspection (4). Examine scroll for cracks or breaks,
and for secure attachment to hub.
(Ref. Figure 601)
(5). Examine rubber connectors at engine
(1). Inspect plumbing and system compo oil cooler duct and transmission oil
nents from oil cooler to lubrication cooler duct where they attach to scroll.
pump for leaks, secure attachment and Examine ducts for damage.
damage.
(6). Look through hub support legs and, to
(2). Inspect oil cooler, lubrication pump, oil extent possible, inspect impeller for
filter, oil pressure switch, liquid level damage. A crack, loose rivet or dis
plug, and chip detectors for leaks, torted vane is cause for impeller
secure attachment and damage. replacement. Inspect mount screws and
bolts for evidence of broken slippage
(3). Inspect electrical connections at oil mark paint.
temperature switch, oil pressure
switch, and chip detectors for absence (7). Examine scroll drain tube for damage,
of corrosion, secure attachment and secure attachment and clear passage.
damage.
(8). Examine mounting bracket and fan
2. Cooling Blower Inspection mounting bracket for secure attach
ment. Check for broken lockwire at bolt
(Ref. Figure 405) heads securing mounting bracket
cooling blower assembly.
(1). Remove blower access door and inspect
belt for damage or excessive wear. Belt 3. Cooling Blower Inspection
should be fully seated in pulley grooves. (Disassembled)
Limited cracking or separation of belt.
(a). Belt should be fully seated in pulley
grooves.
Item Nomenclature
(b). Limited cracking or separation of belt CM206 Chemical coating
between pulley grooves is acceptable. CM318 Primer
Visually monitor any propagation. CM801 Abrasive paper, silicon carbide
Belt should be replaced if any one
separation exceeds three inches in
length or if total separation exceeds (1). Examine belt for damage or excessive
50 percent of peripheral length of wear (Ref. Figure 405).
belt. (For belt replacement schedule,
refer to Section 05-10-00). (2). Examine driver pulley, spring pin,
pulley guard and driven pulley for
(2). Check belt tension. damage or excessive wear.
(3). Hand-rotate main rotor to examine all (3). Check driven pulley retaining nut for a
visible areas of driven pulley and driver minimum of 160 inch-pounds (18.08
pulley for damage or excessive wear. Nm) plus drag torque. If loss of
Listen for sounds of defective bearings torque is indicated, remove pulley nut
or of impeller touching scroll while and inspect washer for evidence of
rotor is turned. elongation and wear.
Page 601
MAINTENANCE MANUAL
OIL PRESSURE
SENDER
LUBRICATION PUMP
MAIN TRANSMISSION AND OIL FILTER
OIL TEMPERATURE
SENDER
GROUND WIRE
OIL COOLER
BYPASS VALVE
CHIP DETECTORS
OIL COOLER BLOWER
TRANSMISSION OIL
COOLER DUCTS
OIL COOLER
OIL LEVEL PLUG
VIEWED FROM RH SIDE OF

MAIN TRANSMISSION
NOTE 1
NOTE: DRAIN CAP

DRAIN CAP INSTALLED AT THIS LOCATION
(EARLY CONFIGURATION ONLY) G63-2007A
Figure 601. Main Transmission Cooling Blower and Duct

(4). Check pulley shaft and splines for (7). Examine scroll (Ref. Figure 801) for
condition. Replace damaged flat washer cracks, breaks and distortion.
or ring washer with flat washer. Install
and torque nut to 160 - 190 inch- Handle impeller carefully to
CAUTION prevent damage that could
pounds (18.08 - 21.47 Nm) plus drag
torque. cause imbalance and require replacement of
impeller.
(5). Examine mounting bracket and fan
mounting bracket for cracks and (8). Visually (minimum 10X magnification)
breaks. examine impeller (Ref. Figure 801) for
cracks, deformation and separation.
(6). Examine web of mounting bracket for
(a). Look for foreign material attached to
wear.
impeller. None is permitted.
(a). Remove nicks, scratches or grooves (b). Check for loose rivets at hub.
leaving sharp impressions in web.
Minimum acceptable web thickness: (c). Use electroprobe or gage of equiva
0.125 inch (3.175 mm). lent accuracy to measure depth of
scratches or nicks.
(b). Replace mounting bracket if web does
not meet 0.125 inch (3.175 mm) (d). Use penetrating dye to examine
minimum after repair. suspected cracks.
Page 602
MAINTENANCE MANUAL
(e). Scratches and nicks not exceeding Kg). This load is to be applied at a right
0.006 inch (0.152 mm) depth are angle to the outside face of the belt.
repairable by sanding with grade 320 Measure belt deflection without turning
abrasive paper (CM801) to blend driven pulley, then turn driven pulley
defect into surrounding area. 1/2 turn and repeat belt deflection
measurement. Turn driven pulley an
1). Treat blended areas with chemical additional 1/4 turn and measure belt
coating (CM206) and touch-up deflection again.
with primer (CM318).
(a). If the tension is too high, greater
2). All other defects require replace than 2.00 pounds (0.9072 Kg),
ment of impeller. tension can be reduced by peeling off
(9). Examine shaft for damage or excessive a layer of the laminated shim, one at
wear. Discard seal (Ref. Figure 801). a time equally from both shims, until
tension falls into proper range.
4. Cooling Blower Belt Tension Check and (b). If the tension is too low: Add layers
Adjustment from a spare shim in the same
(1). Check that laminated shims are in manner as removed in step (2).(a).
position between mounting bracket and above, until tension falls into proper
transmission fan mount assembly. range.
Tighten the four mounting bolts. Rotate (3). Make a final check of bolt torque:
pulley by hand a few turns to even out
belt tension. For 369D25100 transmission installa
tion, 65 - 75 inch-pounds (7.34 - 8.47
(2). Measure belt deflection three times at Nm), and then lockwire drilled heads.
approximate center of one of the spans.
The force required to deflect the belt For 369F5100 transmission installa
0.170-0.200 inch (4.32-5.08 mm) must tion, 70 - 90 inch-pounds (7.91 -
be 1.75-2.00 pounds (0.7938-0.9072 10.17 Nm).
Page 603
MAINTENANCE MANUAL
Page 604
MAINTENANCE MANUAL

AND COOLING SYSTEM
REPAIRS
1. 369D25630 Cooling Blower Disassembly holding device meeting requirements of
caution above, and remove impeller
(Ref. Figure 801) retaining nut and washer.
NOTE: Disassemble cooling blower only to ex Be careful to prevent impeller
tent necessary to do inspection, replacement CAUTION damage. Slight impeller defor
or repair of specific items. Replace cooling mation or damage can cause imbalance.
blower bearings and belt per replacement Protect shaft threads and use nonmetallic
schedule (Ref. Sec. 05-10-00). Bolts used to mallet when doing step (8). below.
secure mount bracket to cooling blower
must be self-locking type only. Discard bolts (8). Manually support impeller and sepa
if safety wired and replace with self-locking rate impeller from shaft by carefully
bolts (Ref. Figure 405). tapping end of shaft. Remove impeller,
scroll, key, spacer and any shimming
(1). Remove mounting bracket (Ref. Sec. present.
63-20-00).
(9). Remove bolt, retaining ring and spring
(2). Remove scroll cover. washer from hub.
(3). Hold impeller retaining nut with socket (10). Use non-metallic mallet on splined end
wrench and remove driven-pulley of shaft to drive impeller-end bearing,
retaining nut and washer. seal, and portion of the shaft from hub.
Do not attempt to remove sleeves from
(4). Remove driven pulley. Do not forcefully hub. Sleeves are line-reamed. If either
tap or pry; if necessary, use pulling sleeve is defective, hub must be re
device. placed. Remove inner retaining ring
from hub. Remove and discard O-ring
(5). Remove spacer from impeller shaft. in upper sleeve if installed.
(6). Remove four screws and washers that (11). If necessary, use pulling device to
attach scroll to hub. extract bearing and seal from shaft.
In following step, do not use (12). If remaining bearing cannot be driven
CAUTION tools or other devices to hold im from hub by tapping outer race from
peller. Tool damage can affect impeller bal inside with nonferrous tube and mallet,
ance. Holding device must not damage shaft re-insert shaft into bearing, drive
splines and must hold shaft with 250—300 bearing out and remove it from shaft as
inch-pounds (28.25—33.90 Nm) of torque described in steps (10). and (11). above.
applied to impeller retaining nut.
(13). Discard bearings. They are not to be
(7). Secure splined end of impeller shaft in re-used.
Page 801
MAINTENANCE MANUAL
SHAFT
SLEEVE
BEARING (NOTE 1)
HUB
O-RING
SHAFT
BEARING SLEEVE
(NOTE 2)
HUB INNER RETAINER
RING
CAVITY FILLED
WITH GREASE
MINIMUM CLEARANCE
TO PREVENT RUBBING SCREWS AND WASHERS
(NOTE 3) (4 PL)
BOLT
SEAL (PART
BEARING OF BEARING) BLOWER
SCROLL
SLEEVE
SEAL
IMPELLER
SCREW AND WASHER
(8 PL)
SPRING WASHER WASHER KEY NUT

SEALANT COVER
OUTER RETAINING LAMINATED (NOTE 1)
RING SHIM
DRAIN TUBE
OUTLET
COVER
(NOTE 2)
NOTES:
1. CURRENT CONFIGURATION.
2. EARLY CONFIGURATION.
3. CLEARANCE SHALL BE 0.020-0.040 IN. (0.508-1.016 MM).
G63-2100-801-1
Figure 801. 369D25630 Cooling Blower − Cross−Section View
Page 802
MAINTENANCE MANUAL
2. 369D25630 Cooling Blower Reassembly (7). Lightly grease (CM116) larger bearing
journal of shaft and bore of remaining
(Ref. Figure 801) bearing.
On current configuration Cool
Consumable Materials CAUTION ing blowers, apply locking com
(Ref. Section 91−00−00) pound (CM431) to outer race of lower bear
Item Nomenclature ing (impeller end) only. Do not apply locking
CM116 Grease, aircraft and instrument compound to upper bearing (pulley end).
(8). Apply primer (CM321) and locking
CM220 Naphtha aliphatic compound (CM431) to faying surfaces of
CM217 Isopropyl alcohol outer bearing race and sleeve according
CM321 Surface primer locking compound to container instructions. Be careful to
CM425 Sealing compound prevent compounds from entering
CM431 Sealing, locking and retaining compound bearing.
NOTE: On newer style bearings, the metal
NOTE: Following procedure covers assembly of shield is replaced by a blue shield.
completely disassembled cooling blower, to (9). Insert bearing so that shield side (metal
gether with those items (belt, brackets, etc) shield or blue disc) faces interior of hub
that form a complete unit. Use only applica and seal side (rubber disc) faces
ble steps of procedure when disassembly is impeller end of shaft.
less than complete. New bearings and new
seal are required; those removed are not to (10). Arbor-press bearing simultaneously
be reused. onto shaft journal and into sleeve.
Exert pressure equally on both races of
(1). Install inner retaining ring in hub and bearing. At same time, exert equal
if removed at disassembly install new pressure on splined end of shaft and
O-ring in upper bearing sleeve. pulley end of hub casting. Bearing is to
firmly contact shaft shoulder and inner
(2). Lightly grease (CM116) smaller bearing retaining ring.
journal of shaft, and bore of correspond
ing bearing. MPK solvent is flammable.
WARNING Use only in well-ventilated
NOTE: This bearing does not have a metal area and away from heat and flame.
shield.
(11). Wipe away excess locking compound.
(3). Place bearing on shaft so that rubber Use MPK (CM219) if hardening begins.
seal of bearing faces splined end of Leave assembled parts undisturbed to
shaft. permit locking compound to cure for
two hours at 75—100°F (24—38°C), or
(4). Using tube that contacts only edge of
for ten minutes at 210—230°F
inner race of bearing, arbor-press
(100—110°C).
bearing onto journal until inner race
contacts shaft shoulder. (12). Temporarily install lubrication fitting.
(5). Clean outer race of both bearings and (13). Install new seal, spring washer and
faying surfaces of both hub sleeves with outer retaining ring.
isopropyl alcohol (CM217) and clean
cloth or paper towel. (14). Fill hub cavity with grease (CM116)
through lubrication fitting until grease
(6). Arbor-press bearing (with shaft seeps out around seal of bearing
installed) into sleeve. Exert pressure nearest splined end of shaft. After
only on bearing outer race and on lubrication, remove lubrication fitting
impeller-end of hub casting (no and install screw and washer. Lockwire
pressure on impeller-end sleeve). screwhead.
Page 803
MAINTENANCE MANUAL
(15). Install hub on scroll with four screws tightening bolts, fully displace bracket
and washers. Torque screws to 12—15 in direction that causes it to be closest
inch-pounds (1.36—1.69 Nm). to main transmission drive shaft when
cooling blower is installed, then torque
(16). Install spacer and impeller on shaft. bolts to 65—75 inch-pounds
(7.34—8.47 Nm). Apply slippage mark
(17). Install washer and locknut on end of
paint.
shaft. Using holding device on splined
end of shaft, tighten locknut sufficiently (23). (Ref. Figure 405) Install spacer, washer,
to remove all end clearance from pulley, washer and nut on shaft. Hold
stack-up of parts. nut on impeller end of shaft with socket
wrench and tighten pulley nut to
(18). Using feeler gage through an air outlet 160—190 inch-pounds (18.08—21.47
port, measure minimum clearance Nm) plus drag torque.
between impeller and scroll lip.
(24). (Ref. Figure 405) Install belt on pulley
NOTE: If minimum clearance is 0.020—0.040 and secure mounting bracket to fan
inch (0.508—1.016 mm), steps (19). and mounting bracket with four bolts and
(20). below can be bypassed. washers. Before tightening bolts, fully
displace bracket in direction that
(19). If clearance is more than 0.040 inch causes it to be closest to main transmis
(1.016 mm), remove impeller and sion drive shaft when cooling blower is
spacer. Replace spacer with 369H5654 installed, then torque bolts to 65—75
shims as required between impeller and inch-pounds (7.34—8.47 Nm) and
seal to obtain 0.020—0.040 inch lockwire drilled heads.
(0.508—1.016 mm) clearance. Reinstall
impeller, washer and locknut. Tighten (25). Clean faying surfaces of scroll and
to remove all end clearance, and then cover with naphtha (CM220); apply
rotate impeller and check for rubbing. If sealant (CM425) according to container
rubbing occurs, do step (20)., otherwise instructions before securing cover to
proceed to step (21).. scroll with eight screws and washers.
3. 600N5630 Cooling Blower Disassembly
(20). If clearance is less than 0.020 inch
(0.508 mm), or if rubbing occurs when (Ref. Figure 802)
doing previous step, disassemble and NOTE: Disassemble cooling blower only to ex
install shim(s) between seal and spacer tent necessary to do inspection, replacement
to ensure 0.020—0.040 inch or repair of specific items. Replace cooling
(0.508—1.016 mm) minimum clearance blower bearings and belt per replacement
and prevent rubbing. schedule (Ref. Sec. 05-10-00).
(21). When clearance is properly adjusted, (1). Remove mounting bracket (Ref. Sec.
remove impeller, install key, impeller, 63-20-25).
washer and locknut. Torque locknut to
250—300 inch-pounds (28.25—33.90 (2). Hold impeller retaining nut with socket
Nm). Use care to avoid placing stress wrench and remove driven-pulley
on impeller or scroll. Hold splined end retaining nut and washer.
of shaft in suitable device. (3). Remove driven pulley. Do not forcefully
tap or pry; if necessary, use pulling
NOTE: Install two self-locking bolts in place of device.
safety-wired bolts if not previously in
stalled. (4). Remove spacer from impeller shaft.
(5). Remove two screws and washers that
(22). (Ref. Figure 405) Secure fan mounting
attach scroll to shroud.
bracket on hub with four bolts and
washers on early configurations, or two (6). Remove four screws six washers, and
self-locking bolts, two screws and four two nuts that attach hub to shroud and
washers on current versions. Before scroll. Retain shim if installed.
Page 804
MAINTENANCE MANUAL
SCREW
WASHER
SHROUD
NUT
WASHER
SHAFT
BEARING
HUB
SCREW
SCREW
WASHER
WASHER
O-RING LOCKWIRE
SCROLL RETAINING RING
SHIM
(NOTE 3) SHIM
(NOTE 3)
BEARING
SPRING
WASHER SEAL
(NOTE 2)
NOTE 3
IMPELLER
RETAINING RING SHIM NUT WASHER

(NOTE 1) WOODRUFF KEY
NOTE:
1. SHIM IMPELLER TO PROVIDE 0.020-0.030 IN. (0.508-0.762 MM) AVERAGE BLADE
TRAILING EDGE TIP CLEARANCE-TO-SHROUD, MEASURED PERPENDICULARLY TO
THE SHROUD FACE. THE BLADE TRAILING EDGE IS AT THE LARGEST BLADE
DIAMETER. SHIM PRIOR TO INSTALLING SCROLL.
2. INSTALL SEAL WITH SMALL DIAMETER GAP IN RINGS FACING OUTSIDE OF HUB.
3. SHIM HUB TO PROVIDE 0.020 IN. (0.508 MM) MINIMUM GAP BETWEEN SCROLL
AND IMPELLER.
G63-2009-2A
Figure 802. 600N5630 Cooling Blower − Cross−Section View
Page 805
MAINTENANCE MANUAL
In following step, do not use 4. 600N5630 Cooling Blower Reassembly

CAUTION tools or other devices to hold im
peller. Tool damage can affect impeller bal (Ref. Figure 802)
ance. Holding device must not damage shaft
splines and must hold shaft with 250—300 Consumable Materials
inch-pounds (28.25—33.90 Nm) of torque (Ref. Section 91−00−00)
applied to impeller retaining nut. Item Nomenclature
(7). Secure splined end of impeller shaft in CM219 Methyl−propyl−ketone (MPK)
holding device meeting requirements of CM220 Naphtha aliphatic
caution above, and remove impeller
retaining nut and washer.
CM321 Surface primer locking compound
Be careful to prevent impeller
CAUTION damage. Slight impeller defor
mation or damage can cause imbalance.
Protect shaft threads and use nonmetallic NOTE: Following procedure covers assembly of
mallet when doing step (8). below. completely disassembled cooling blower, to
gether with those items (belt, brackets, etc)
(8). Manually support impeller and sepa that form a complete unit. Use only applica
rate impeller from shaft by carefully ble steps of procedure when disassembly is
tapping end of shaft. Remove impeller, less than complete. New bearings and new
scroll, key, spacer and any shimming seal are required; those removed are not to
present. be reused.
(1). Install inner retaining ring in hub and
(9). Remove bolt, retaining ring and spring if removed at disassembly install new
washer from hub and shroud. O-ring in upper bearing sleeve.
(2). Lightly grease (CM111) smaller bearing
(10). Use non-metallic mallet on splined end journal of shaft, and bore of correspond
of shaft to drive impeller-end bearing, ing bearing.
seal, and portion of the shaft from hub.
Do not attempt to remove sleeves from NOTE: This bearing does not have a metal
hub. Sleeves are line-reamed. If either shield.
sleeve is defective, hub must be re
(3). Place bearing on shaft so that rubber
placed. Remove inner retaining ring
seal of bearing faces splined end of
from hub. Remove and discard O-ring
shaft.
in upper sleeve if installed.
(4). Using tube that contacts only edge of
(11). If necessary, use pulling device to inner race of bearing, arbor-press
extract bearing and seal from shaft. bearing onto journal until inner race
contacts shaft shoulder.
(12). If remaining bearing cannot be driven (5). Clean outer race of both bearings and
from hub by tapping outer race from faying surfaces of both hub sleeves with
inside with nonferrous tube and mallet, isopropyl alcohol (CM217) and clean
re-insert shaft into bearing, drive cloth or paper towel.
bearing out and remove it from shaft as
described in steps (10). and (11). above. (6). Arbor-press bearing (with shaft
installed) into sleeve. Exert pressure
only on bearing outer race and on
(13). Discard bearings. They are not to be impeller-end of hub casting (no
re-used. pressure on impeller-end sleeve).
Page 806
MAINTENANCE MANUAL
(7). Lightly grease (CM111) larger bearing (15). Install shim on scroll.
journal of shaft and bore of remaining
bearing. (16). Install hub and shroud on scroll with
six screws, eight washers and two nuts.
Apply locking compound Torque screws to 12—15 inch-pounds
CAUTION (CM431) to outer race of lower (1.36—1.69 Nm).
bearing (impeller end) only. Do not apply (17). Using feeler gage through an air outlet
locking compound to upper bearing (pulley port, measure for 0.020 inch (0.508 mm)
end). minimum gap between impeller and
(8). Apply primer (CM321) and locking scroll.
compound (CM431) to faying surfaces of (18). Check for proper thread protrusion of
outer bearing race and sleeve according six screws through nutplates and nuts
to container instructions. Be careful to on inside of scroll.
prevent compounds from entering
bearing. (19). Install spacer and impeller on shaft.
(9). Insert bearing so that shield side (metal (20). Install washer and locknut on end of
disc) faces interior of hub and seal side shaft. Using holding device on splined
(rubber disc) faces impeller end of shaft. end of shaft, tighten locknut sufficiently
to remove all end clearance from
(10). Arbor-press bearing simultaneously stack-up of parts.
onto shaft journal and into sleeve. (21). Using feeler gage through an air outlet
Exert pressure equally on both races of port, measure minimum clearance
bearing. At same time, exert equal between impeller and scroll lip.
pressure on splined end of shaft and
pulley end of hub casting. Bearing is to NOTE: If minimum clearance is 0.020—0.030
firmly contact shaft shoulder and inner inch (0.508—0.762 mm), steps (19). and
retaining ring. (20). below can be bypassed.
MPK solvent is flammable. (22). If clearance is more than 0.030 inch
WARNING Use only in well-ventilated (0.762 mm), remove impeller and
area and away from heat and flame. spacer. Replace spacer with 369H5654
shims as required between impeller and
(11). Wipe away excess locking compound. seal to obtain 0.020—0.030 inch
Use MPK (CM219) if hardening begins. (0.508—0.762 mm) clearance. Reinstall
Leave assembled parts undisturbed to impeller, washer and locknut. Tighten
permit locking compound to cure for to remove all end clearance, and then
two hours at 75—100°F (24—38°C), or rotate impeller and check for rubbing. If
for ten minutes at 210—230°F rubbing occurs, do step (20)., otherwise
(100—110°C). proceed to step (21)..
(12). Temporarily install lubrication fitting. (23). If clearance is less than 0.020 inch
(0.508 mm), or if rubbing occurs when
NOTE: Install seal with small diameter gap in doing previous step, disassemble and
rings facing outside of hub. install shim(s) between seal and spacer
to ensure 0.020—0.030 inch
(13). Install new seal, spring washer and (0.508—0.762 mm) minimum clearance
outer retaining ring. and prevent rubbing.
(14). Fill hub cavity with grease (CM111) (24). When clearance is properly adjusted,
through lubrication fitting until grease remove impeller, install key, impeller,
seeps out around seal of bearing washer and locknut. Torque locknut to
nearest splined end of shaft. After 250—300 inch-pounds (28.25—33.90
lubrication, remove lubrication fitting Nm). Use care to avoid placing stress
and install screw and washer. Lockwire on impeller or scroll. Hold splined end
screwhead. of shaft in suitable device.
Page 807
MAINTENANCE MANUAL
(25). (Ref. Figure 406) Secure fan mounting 6. Transmission and Cooling Blower Drain
bracket on hub with two self-locking Tube Repair and Replacement
bolts, two screws and four washers.
Before tightening bolts, fully displace Consumable Materials
bracket in direction that causes it to be (Ref. Section 91−00−00)
closest to main transmission drive shaft Item Nomenclature
when cooling blower is installed, then
CM702 Lockwire CRES
torque bolts to 50—70 inch-pounds
(5.65—7.91 Nm) and screws to 65—75 CM717 Tape, pressure sensitive
inch-pounds (7.34—8.47 Nm). Apply
slippage mark paint. (1). Disconnect drain tubes from transmis
sion cooling blower, and from drain
fittings and weld assemblies at firewall.
(26). (Ref. Figure 406) Install spacer, washer, Release supporting nylon straps and
pulley, washer and nut on shaft. Hold remove drain tubes (Ref. Figure 601).
nut on impeller end of shaft with socket
wrench and tighten pulley nut to (2). Inspect drain tubes, drain fittings, weld
160—190 inch-pounds (18.08—21.47 assemblies and connectors for damage
Nm) plus drag torque. and clear passage.
(3). Repair damaged flexible drain tubes
with tape (CM716).
(27). (Ref. Figure 406) Install belt on pulley
and secure mounting bracket to fan (4). Install drain tubes as follows:
mounting bracket with four bolts and (a). Attach upper ends of drain tubes to
washers. Before tightening bolts, fully transmission and cooling blower.
displace bracket in direction that Secure with double wraps of lockwire
causes it to be closest to main transmis (CM702).
sion drive shaft when cooling blower is
installed, then torque bolts to 65—75 (b). Route drain tubes and secure with
inch-pounds (7.34—8.47 Nm) and nylon straps. Position tubes so that
lockwire drilled heads. no drainage traps are formed.
(c). Secure lower ends of drain tubes to
fittings and weld assemblies with
(28). Clean faying surfaces of scroll and
double wraps lockwire (CM702).
cover with naphtha (CM220); apply
sealant (CM425) according to container (d). Insert lower end of metal drain tube
instructions before securing cover to through grommet in skin and slip
scroll with eight screws and washers. upper end of tube into weld assembly.
Wrap tube with one layer of 1 inch
(2.54 cm) wide tape (CM717) at
5. Cooling Blower Cleaning (Disassembled) clamp-attach point, and install
clamp.
7. Installation of Heating System and Oil
Consumable Materials Cooling Line Standoff Clamps (0003D −
(Ref. Section 91−00−00) 0539D)
Item Nomenclature
(Ref. Figure 803) The following information
CM234 Solvent, dry-cleaning list a procedure for installing standoff clamps
on the 369D292490 heating system hose and
on the 369D25710 main rotor transmission oil
cooling line to eliminate chafing between the
(1). Clean all usable metal parts with oil cooling lines and chafing of the oil cooling
solvent spray (CM234). Remove lines by the heating system hose. A protective
remnants of locking compound with bushing is also installed to prevent chafing
loctite remover (CM216). between the oil cooling lines.
Page 808
MAINTENANCE MANUAL
(1). Remove aft compartment interior trim (4). Check installation of standoff clamps to
panels and left Sta. 124.00 bulkhead ensure adequate clearance between
access door to gain access to work area. 369D25709 and 369D25710 oil cooling
lines and between oil cooling lines and
NOTE: Inspect the 369D292490 heating sys 369D292490 heating system hose.
tem hose and 369D25709 and 369D25710
main transmission oil cooling lines for evi NOTE:
dence of chafing, kinking or damage at area
of L/H aft section channel assembly. D Later Model 369D helicopters have
369D26544-3 closure plate (with grom
(2). If not already installed, install met) installed on L/H aft section channel.
NAS1713D30N clamp on heating Remove plate from channel, if presently
system hose and NAS1713D8N clamp installed, to preclude interference with oil
on 369D25710 oil cooling line. Connect cooling lines.
clamps with screw, washer and nut.
D Later model 500D helicopters have
(3). If not already installed, install new HS4194-6 standoff bracket installed on
C-SB-16-8 bushing snug against nut channel with MS21919DG30 clamp to se
on 369D25709 oil cooling tube assembly cure heating hose. Install standoff brack
(View A-A). Reposition clamp assembly et and clamp, if not presently installed on
securing 369D25709 (lower) and helicopter.
369D25710 (upper) oil cooling tube
assemblies to accommodate installation (5). Reinstall bulkhead access door and
of bushing. interior trim panels.
Page 809
MAINTENANCE MANUAL
CLAMP ASSY
369D25710 OIL COOLING (RELOCATED)
TUBE ASSY
369D26544-3 CLOSURE PLATE

(REMOVE IF PRESENTLY INSTALLED
ON AFT SECTION CHANNEL)
(ROTATED)
369D25709 OIL COOLING

TUBE ASSY
VIEW A-A C-5B-16-8 BUSHING
(NOTE 3)
369D25710 OIL COOLING A HS4194-6 STANDOFF (NOTE 1)
TUBE ASSY (REF) MS20470AD3 RIVET (2)
C-5B-16-8 BUSHING
369D23024 AFT SECTION
CHANNEL ASSY
(CANT. STA. 124.00)
TUBE ASSY
A
NAS1713D8N CLAMP (NOTE 2)
NAS1096-7 SCREW
MS21919DG30 CLAMP (NOTE 1)
NAS1096-3-7 SCREW
MS21043-3 NUT
AN960PD10L WASHER
TUBE ASSY
NAS1713D8N CLAMP (EXISTING)
AN743-12 BRACKET 369D292490 HEATING HOSE
NAS1096-3-7 SCREW (2)
MS21043-3 NUT (3)
NAS1713D30N CLAMP
NAS1713D30N CLAMP (NOTE 2)
(EXISTING)
NOTES:
1. PRESENTLY INSTALLED ON LATE-MODEL HELICOPTERS.
2. LOCATE NEW CLAMPS APPROXIMATELY AS SHOWN ON
COOLING TUBE AND HEATING HOSE ASSEMBLIES.
3. AFTER INSTALLATION OF BUSHING, ROTATE BUSHING SO
THAT SPLIT IN BUSHING IS FACING DOWN.
G63-2026A
Figure 803. Installation of Standoff Clamps − Heating and Oil Cooling Lines
Page 810
MAINTENANCE MANUAL
Section
63−22−00
Rotor Brake
(369D/E/FF −
500/600N)
MAINTENANCE MANUAL
ROTOR BRAKE
When working with hydrau pressure is produced; this pressure is trans
WARNING lic systems, special care mitted through the tubing to the caliper
must be taken to prevent entrance of assembly where it acts on the pistons. This
dust, moisture or other foreign materi causes the pucks to apply clamping pressure
al. System contamination can cause (braking force) to the brake disc. System
malfunctions which could cause injury pressure is held within safe limits, regardless
to personnel or equipment damage. of the force applied to the brake handle, by
operation of the pressure-relief valve. When
1. Rotor Brake hydraulic pressure exceeds 500 psig (3447
kPa), the pressure-relief valve opens, venting
The rotor brake enables the pilot to manually excess pressure back to the master cylinder.
brake the rotor system to a stop by operating a When application of force is discontinued,
single brake handle. The handle is installed on caliper pistons (and the pucks) are retracted
the upper left (or upper right, depending on by return springs in the caliper assembly.
helicopter seating configuration) side of the Puck-to-disc clearance is maintained by
canted bulkhead 78.50 control tunnel in the action of a self-adjusting mechanism in the
pilot's compartment. Operation of the brake caliper assembly. The original equipment
handle actuates a master cylinder, causing tachometer generator is replaced by a new unit
dual pucks to grip a brake disc installed on the that is included in the rotor brake installation
tail rotor drive shaft. Braking force is trans to provide clearance between the tachometer
mitted through the main transmission to the generator and the brake disc. The original
main rotor. A friction clip secures the handle in equipment electrical connector (P202),
an out-of-the-way position when the brake is installed on the aft fuselage wiring harness
not in use. near the main transmission, is replaced with a
The rotor brake installation includes: new plug which mates with the receptacle on
the new tachometer generator.
(1). A master cylinder with an actuating
handle mechanism (master cylinder 3. Rotor Brake Troubleshooting Procedure
and linkage assembly). (Ref. Table 201)
(2). A caliper assembly with dual opposing 4. Master Cylinder Servicing
pistons to which friction pads (brake
pucks) are attached. (Ref. Figure 401)
(3). A brake disc installed on the tail rotor Consumable Materials

drive shaft coupling at the aft end of (Ref. Section 91−00−00)
the main transmission. Item Nomenclature
(4). A hydraulic pressure relief valve. CM123 Hydraulic fluid
(5). A tachometer generator.

Rotor brake installation servicing includes
(6). Six stainless steel hydraulic tubing adding hydraulic fluid (CM123) to the master
assemblies and associated fittings. cylinder reservoir, and bleeding air from the
system.
(7). Attaching and mounting hardware.
(1). Remove interior trim to gain access to
(8). A trim panel assembly and installation. master cylinder.
2. Rotor Brake Operation (2). Disconnect tube assembly from forward

nipple and move end of tube assembly
When manual force is applied to the brake carefully aside to permit removal of
handle (master cylinder piston), hydraulic master cylinder cap.
Page 201
MAINTENANCE MANUAL
(3). Remove attaching screws, cap with NOTE: Hose material should be resistant to de
assembled hydraulic parts, and gasket terioration from exposure to hydraulic fluid.
from master cylinder. Replace gasket. A glass container should be used to catch
bleed screw outflow so that bubbles of escap
(4). Fill master cylinder reservoir with ing air are clearly visible. The following fill
clean hydraulic fluid (CM123) within ing and bleeding procedure is best done by
1/8 to 1/4 inch (3.175-6.35 mm) of the two persons, one to operate the brake han
top. Install cap with assembled hydrau dle, and one to open and close the bleed
lic parts, new gasket, and attaching screws.
screws. Do not tighten screws if (3). Connect a length of 1/4 inch (6.35 mm)
hydraulic system is to be bled. ID hose on reducer and insert free end
of hose in a container to catch any
(5). If hydraulic system has been opened, hydraulic fluid that can be bypassed by
e.g. as for replacement of components, the relief valve. Connect a second
do procedural steps to bleed the length of 1/4 inch (6.35 mm) ID hose on
hydraulic system. one bleed screw on caliper assembly
and submerge free end of hose in clean
hydraulic fluid (CM123) in a glass
NOTE: It is not necessary to bleed the system if container.
only a small amount of fluid is required to
fill the reservoir, and if the system has not (4). Remove attaching screws and master
been opened. cylinder cap. Fill reservoir with clean
hydraulic fluid (CM123) within 1/8 -
1/4 inch (3.175-6.35 mm) of top of
(6). Tighten attaching screws to secure cap chamber. Replace cap, do not tighten
on master cylinder. Connect tube attaching screws.
assembly to nipple.
NOTE: Verify that master cylinder reservoir is
(7). Reinstall components removed for kept full of fluid throughout the bleeding
access to the master cylinder assembly. process.
(5). Open one bleed screw and operate
brake handle slowly through a full
5. Rotor Brake Hydraulic System Bleeding down stroke to force hydraulic fluid out
of master cylinder reservoir and into all
other parts of the system. Close bleed
Consumable Materials screw and return handle to ”up”
(Ref. Section 91−00−00) position. Remove cap, refill master
Item Nomenclature cylinder reservoir, and replace cap.
CM123 Hydraulic fluid (6). Repeat step (5). several times to ensure
that entire hydraulic system is filled
with fluid, and that no air remains in
The rotor brake hydraulic system must be bled system.
to remove entrapped air whenever the system
has been opened for any reason. NOTE: The presence of bubbles in the bleed
screw outlet flow indicates air is being
forced out of the system and absence of
(1). Remove interior trim for access to the bubbles indicates all air has been bled from
master cylinder assembly and bleed the system.
screws on caliper assembly (if applica
ble). (7). Remove bleeder hose from first bleed
screw and connect it on second bleed
screw.
(2). Disconnect tube assembly from reducer
in relief valve and nipple in master (8). Repeat steps (5). and (6). until bleed
cylinder cap. screw outlet flow is clear of bubbles.
Page 202
MAINTENANCE MANUAL
(9). Remove fluid catch containers and 7. Master Cylinder Assembly Overhaul
hoses. Ensure both bleed screws are
tightly closed. Raise brake handle to (1). Remove defective master cylinder
stowed position and engage in handle assembly.
retainer assembly. Verify that caliper
pistons (and attached brake pucks) are (2). Disassemble unit and replace defective
retracted when handle is raised. parts with components of overhaul kit
(Vendor PN 12-8310), using manufac
(10). Make final check of fluid level in
turer's instructions supplied with kit.
master cylinder reservoir and replen
ish, if necessary. Secure gasket and cap
with attaching screws. (3). Install overhauled master cylinder
assembly.
(11). Connect tube assembly to nipple in cap
and to reducer in relief valve and 8. Caliper Assembly Overhaul
tighten tube nuts.
(1). Remove defective caliper assembly.
6. Rotor Brake Component Repair
The master cylinder assembly or caliper (2). Disassemble unit and replace defective
assembly can be overhauled as necessary. parts with components of overhaul kit
Overhaul kits are available from MD Helicop (Vendor PN 12-11780), using manufac
ters Inc. or an approved MD Helicopter service turer's instructions supplied with kit.
center. Other parts must be replaced when
damaged or otherwise unserviceable. (3). Install overhauled caliper assembly.
Page 203
MAINTENANCE MANUAL
Table 201. Troubleshooting Rotor Brake Installation

Symptom Isolating Step Corrective Action
Brake actuating handle creeps Defective master cylinder assembly. Remove defective master cylinder
downward under sustained force, assembly and replace with new unit,
with hydraulic fluid leakage from or overhaul and reinstall old unit.
master cylinder assembly.
Brake actuating handle creeps Defective caliper assembly. Remove defective caliper assembly
downward under sustained force, and replace with new unit, or
with hydraulic fluid leakage from overhaul and reinstall old unit.
caliper assembly.
‘Spongy‘ feel at brake actuating Air in hydraulic system. Bleed air from hydraulic system.
handle when force is applied.
Hydraulic fluid at low level in master Add fluid to master cylinder

cylinder reservoir. assembly and bleed air from
hydraulic system.
Rotor brake system fails to slow Any of above components or system Follow applicable corrective action
rotor effectively. faults. procedures.
Brake pucks worn excessively. Remove defective caliper assembly,

replace defective pucks and reinstall
repaired unit.
Brake pucks create noises, such Glazed or worn brake pucks. Remove defective caliper assembly,
as squeals or squeaks, when replace defective pucks and reinstall
brakes are applied. repaired unit.
Brake disc creates noises, such Scored or damaged brake disc. Remove defective brake disc and
as squeals or squeaks, when replace with new disc.
brakes are applied.
Page 204
MAINTENANCE MANUAL
ROTOR BRAKE
When working with hydrau nience panel cover assembly from
WARNING lic systems, special care convenience panel assembly.
must be taken to prevent entrance of
dust, moisture or other foreign materi (4). Disconnect electrical wiring and
al. System contamination can cause communications cables from compo
malfunctions which could cause injury nents on back of convenience panel
to personnel or equipment damage. assembly. If cabin heating option is
installed on aircraft, disconnect heated
1. Rotor Brake Component Access air duct from panel-mounted diffuser.
Remove attaching screws and conve
The following items must be removed to gain nience panel assembly from aft side of
access for removal of rotor brake components. canted bulkhead 78.50 structure.
Removal should be limited to damaged or
defective parts for repair, overhaul or replace (5). Remove transmission cover panel
ment, or to remove certain items for access to assembly from fuselage structure.
other components. (6). Cover exposed trim panels to prevent
damage and soiling.
The master cylinder assembly, linkage
assembly and hydraulic relief valve are (7). Remove main transmission from
installed on or attached to the helicopter aircraft (Ref. Sec. 63-20-00/25).
structure. Removal of these components
require access from the crew compartment. (8). Remove tail rotor (Ref. Sec. 64-20-00),
Hydraulic tube assembly is not attached to the tail rotor transmission (Ref. Sec.
helicopter structure. Access from the passen 63-25-10) and tail rotor drive shaft
ger/cargo compartment is required for removal (Ref. Sec. 63-15-10).
of hydraulic tube assembly.
2. Master Cylinder Assembly Replacement
The caliper assembly and related hydraulic
items, caliper mounting bracket, tachometer (Ref. Figure 401 and Figure 402)
generator, brake disc and tail rotor drive A. Master Cylinder Assembly Removal
coupling are installed on the main transmis
sion. Removal of these components require The master cylinder assembly is bolted to the
that certain access provisions be made and bracket of the master cylinder linkage assem
that the main transmission, and attached rotor bly and is connected hydraulically to the
brake components, be removed from the caliper assembly. Remove master cylinder
aircraft. assembly as follows:
NOTE: Component removal can be accom (1). Remove trim panels to gain access to
plished with the doors in place. However, op master cylinder.
erations are facilitated with the doors re
moved. (2). Disconnect tube assembly from nipple,
and tube assembly from elbow, taking
(1). Remove both crew compartment and special care to catch any hydraulic fluid
cargo/passenger compartment doors. that drains or drips from tube assem
blies or fittings when the system is
(2). Remove crew compartment seats. opened.
(3). Remove map case assembly from NOTE: If old master cylinder assembly is to be
forward side of canted bulkhead 78.50 reinstalled, removal of tube assembly, nip
structure. Remove both (LH and RH) ples, and elbow can not be necessary unless
upper forward panel assemblies from the tube assembly or fittings are damaged
bulkhead structure. Remove conve or defective.
Page 401
MAINTENANCE MANUAL
MAST SUPPORT PAN
WINDOW SUPPORT
CHANNEL ASSEMBLY
TEE
PRESSURE RELIEF
VALVE
VENT
MASTER CYLINDER
ACTUATING LINKAGE
LEFT-HAND INSTALLATION SHOWN; RIGHT-HAND OPPOSITE

G63-2003A
Figure 401. Airframe−Mounted Rotor Brake Components
Page 402
MAINTENANCE MANUAL
(3). Remove tube assembly from nipple. threads of nipples and elbow with
Remove nipples from cap, and elbow thread sealant (CM434). Install nipples
from master cylinder. in cap and elbow in master cylinder.
(4). Remove nuts, washers, bolts, stop, and (3). Place one washer and stop on bolts and
master cylinder assembly from bracket. insert bolts through master cylinder.
Drain residual hydraulic fluid from Place two washers on each bolt as
master cylinder assembly. spacers. Position assembled parts on
bracket (ref. Figure 402) and install one
(5). Install protective caps or plugs on open washer on each bolt. Install nuts finger
ends of disconnected tube assemblies, tight to hold master cylinder assembly
and open ports or fittings in master and stop in position.
cylinder assembly to prevent entry of
contaminants. NOTE: Mounting holes in bracket are elon
gated to enable lateral position adjustment
B. Installation of master cylinder assembly.
(4). With actuating handle in stowed

position, adjust position of master
cylinder assembly so that clearance
Item Nomenclature
(measured with a thickness gage)
CM434 Thread sealant between actuating lever (ref.
Figure 905) and master cylinder piston
is 0.020 to 0.040 inch (0.51 to 1.02
(1). For installation of a new master mm).
cylinder assembly only, do steps (a).
through (e).: (5). Install tube assembly on aft nipple.
Connect tube assembly to forward
NOTE: After removal, the dust cover and the nipple and connect tube assembly to
dust cover retainer ring will not be installed elbow.
again.
(6). Fill and bleed the hydraulic system.
(a). Remove the master cylinder dust
cover and the dust cover retainer (7). Install components removed for access
ring. to the master cylinder assembly.
(b). Remove the screws and vendor-
supplied cap from the master cylin 3. Master Cylinder Linkage Assembly
der. Replacement
NOTE: The vendor-supplied cap is not used. (Ref. Figure 402)
(c). Rework the vendor-supplied gasket A. Removal

(ref. Figure 906).
The bracket assembly of the master cylinder
(d). Replace reworked gasket and new linkage assembly is permanently installed on
cap on master cylinder. the canted bulkhead Sta. 78.50 vertical
member by four Jo-bolt blind fasteners. Once
(e). Tighten the screws with your fingers. installed, the Jo-bolts cannot be removed
except by destructive procedures. The master
NOTE: Cap must be installed correctly with re cylinder and linkage assembly can be disas
spect to taper of threaded holes. sembled, leaving the bracket assembly
attached to the structure. Disassembly should
(2). If new master cylinder assembly is be limited to that necessary for removal of
being installed, or if hydraulic fittings damaged or defective parts.
have been removed from a usable unit,
coat all but first two tapered pipe (1). Remove master cylinder.
Page 403
63-22-00 TR18-002
MAINTENANCE MANUAL
STOP
BRACKET
ASSY
NUT
WASHER BOLT ACTUATING LEVER
GRIP SPACER
NUT
WASHER
PIN
COTTER
PIN
HANDLE
ROLL PIN
COTTER PIN
SPRING
NUT
WASHER
FITTING
WASHER
CLEVIS PIN G63-2200-402-1
Figure 402. Master Cylinder Linkage Assembly

When components are as (5). Remove cotter pin, nut, washer, spring,
WARNING sembled, spring force is con and lever with assembled handle parts
stantly exerted to inhibit inadvertent from pin.
brake application. Care must be exer
cised as the spring is disengaged to (6). Remove cotter pin, washers, and clevis
prevent injury to personnel or equip pin, and separate assembled handle
ment damage. parts from lever.
(7). Remove nut, spacer, and bolt from lever.
(2). Manually restrain movement of lever
and attached parts. (8). Drive two spring pins out of fitting and
handle and separate parts.
(3). Carefully disengage end of spring from (9). Remove grip from handle.
under head of clevis pin.
(10). Remove nut and washer from pin.
(4). Release spring force carefully. (11). Remove pin from bracket assembly.
Page 404
TR18-002 63-22-00
MAINTENANCE MANUAL
B. Installation (2). Disconnect tube assembly from caliper

mounted tees. Remove tube assembly
Installation of the master cylinder linkage and interconnect tee as a unit.
assembly will be limited to re-assembly of
components to the bracket assembly. NOTE:
D It is not necessary to disconnect tube as
When the unit is assembled,
WARNING the spring is under restraint semblies from tee except for replacement
of defective and damaged parts.
and, if accidentally or inadvertently re
leased, could cause injury to personnel D New bleed screws are included with the
or equipment damage. new caliper assembly.
(1). Re-assembly procedures are essentially (3). If caliper assembly is to be replaced by

the reverse of disassembly procedures, a new unit, remove two bleed screws
with special care being given to steps from adapters, remove adapters from
involving spring. tees, and remove tees from caliper
assembly.
(2). If cotter pins or spring pins have been
removed, use new parts for reassembly. NOTE: If old caliper assembly is to be rein
stalled, it is not necessary to remove hy
4. Caliper Assembly, Brake Disc, and Drive draulic fittings except for replacement of de
Coupling Replacement (369D25100 fective or damaged parts.
Transmission)
(4). Remove coupling bolt that is used to
(Ref. Figure 403) secure drive coupling on transmission
output shaft so that disc/coupling unit
A. Removal (369D25100 Transmission) is free to slide on shaft splines.
The caliper assembly is bolted to a mounting (5). Note and record, for re-assembly
bracket which is installed on the main reference, placement of 18 washers
transmission tail rotor cover. The brake disc is used as spacers between caliper
bolted on the drive coupling which is installed assembly and mounting bracket, or
on the transmission output shaft. For clarity, under heads of attaching bolts.
the brake disc and drive coupling are consid
ered as a single item (disc/coupling unit). The caliper assembly consists of
CAUTION two identical halves held togeth
Although the caliper assembly and the er by the attaching bolts. Care should be
disc/coupling unit are not mechanically used to avoid dropping parts when bolts are
connected, they are installed on the transmis removed.
sion with the outer portion of the disc posi
tioned between the two halves of the caliper (6). Hold caliper assembly and unscrew
assembly (Ref. Figure 404). This arrangement attaching bolts out of mounting brack
makes it necessary to remove both units et. Slide disc/coupling unit away from
(partially, at least) at the same time. Removal transmission and remove caliper
operations require that the main transmission assembly and attaching hardware.
be removed from the aircraft with the rotor
brake components installed. Proceed as (7). If caliper assembly is to be reused and
follows: some time will elapse before re-assemb
ly, remove disc/coupling unit, position
(1). Remove main transmission and caliper assembly (and assembled parts)
attached rotor brake components from on mounting bracket and screw bolts
aircraft (ref. Sec. 63-20-00 or into bracket to hold parts until time for
63-20-25). re-assembly.
Page 405
63-22-00 TR18-002
MAINTENANCE MANUAL
BLEED-SCREWS PISTON CALIPER

ASSEMBLY
SPECIAL NUT
GASKET SPACER
WASHERS
ROTOR
TACHOMETER
GENERATOR
SHIM WASHERS
MOUNTING BRACKET
FAILSAFE COUPLING BOLT
TAIL ROTOR DRIVE

SHAFT COUPLING
COUPLING
SHIMS
EARLY CONFIGURATION
BRAKE DISC
COUPLING
BOLT
TRANSMISSION
COUPLING
COUPLING
SHIM
G63-2005A
Figure 403. Transmission−Mounted Rotor Brake Components
Page 406
TR18-002 63-22-00
MAINTENANCE MANUAL
DISC
CALIPER
CALIPER
MOUNTING CALIPER
SHIM WASHERS
BRACKET ASSEMBLY
NOTE
BRAKE DISC/BRAKE DRIVE SHAFT COUPLING
PUCK CLEARANCES (KAMATIC)
TAIL ROTOR
DRIVE SHAFT
DRIVE SHAFT COUPLING
(BENDIX)
COUPLING
SHIMS
MAIN TRANSMISSION
NOTE:
CLEARANCE TO BE EQUAL TO WITHIN 0.032 IN. (0.8128 MM). G63-2010B
Figure 404. Caliper Assembly and Brake Disc Interface (369D25100 Transmission)
(8). If disc/coupling unit is to be reinstalled, overall length of old coupling at three
and some time will elapse before separate peripheral locations. Calculate
re-assembly, slide unit back on trans and record the average value.
mission shaft and install coupling bolt
B. Installation (369D25100 Transmission)
finger tight to hold parts until time for
re-assembly.
Axial position of the drive (Ref. Section 91−00−00)
WARNING coupling is critical as it con Item Nomenclature
trols the mechanical interface between CM112 Anti-seize compound high temperature
the coupling and the tail rotor drive CM116 Grease, aircraft and instrument
shaft. Out-of-tolerance axial coupling CM202 Metal protector, aerosol
loads can contribute to coupling fail CM434 Thread sealant
ure which could result in injury to per
CM702 Lockwire CRES
sonnel and equipment damage. Refer
to Sec. 63-10-00 for coupling reinstalla
tion. (1). Position brake disc on drive coupling
with raised center side of disc seated
(9). If either disc or coupling is to be firmly on shoulder of coupling, and with
replaced by a new part, slide disc/coup bolt holes aligned. Insert four bolts
ling unit off shaft, leaving shim wash through disc and coupling flange,
ers in place. Remove nuts, washers, and install washers and nuts on bolts, and
bolts and separate disc and coupling. If torque nuts (in an alternating se
coupling is being replaced, measure quence) to 100 to 140 inch-pound
(and record for re-assembly reference) (11.30 to 15.82 Nm).
Page 407
63-22-00 TR18-002
MAINTENANCE MANUAL
The main transmission must To ensure optimum brake opera

WARNING be installed in the aircraft CAUTION tion and minimize equipment
with special care to avoid damage to damage, caliper-to-disc clearances on both
rotor brake components. Installation sides of disc should be equal, or as nearly
damage could lead to system failure equal as possible. Clearance adjustment is
which could result in injury to person accomplished by varying number of shim
nel and equipment damage. washers, 0.032 inch (0.8128 mm) thick,
placed between the caliper assembly and its
mounting bracket. Nine washers are pro
vided for each attaching bolt; those not used
(2). Install transmission in aircraft (ref.
as shims should be placed under bolt heads.
Section 63-20-00 and 63-20-25). Washer distribution should be the same for
both bolts.
(3). Determine correct shimming for
coupling (ref. Section 63-10-00). (6). Hold assembled parts with caliper
assembly over edge of disc, slide
disc/coupling unit on shaft, and move
Molykote metal protector caliper assembly against mounting
WARNING contains perchloroethylene. bracket at the same time. Screw bolts
It should be used in a well-ventilated into bracket to hold caliper assembly
firmly in position. Screw coupling bolt
area, and the precautions normally fol
into shaft to secure disc/coupling unit.
lowed when working with the chlori
nated solvent should be implemented.
Solvents used to dilute this material, as (7). Measure brake caliper housing-to-disc
well as metal-cleaning or alkali cleans clearances on both sides of disc with a
ers, should only be used with adequate thickness gage. If clearances are equal
ventilation. Follow handling precau within 0.032 inch (0.8128 mm), torque
tions on the solvent container label. attaching bolts to 160 to 190 inch-
pound (18.08 to 21.47 Nm) and secure
with corrosion-resistant lockwire
(CM702) (ref. Figure 405). Torque
NOTE: Couplings should be treated with moly
coupling bolt (ref. Section 63-10-00).
kote metal protector (CM202) after each
washing with any solvent or detergent.
NOTE: Clearance differences greater than
0.032 inch (0.8128 mm) can be reduced by
(4). Spray molykote metal protector rearranging washers on caliper attaching
(CM202) on the interior and exterior bolts.
surfaces of Bendix coupling diaphragm
packs. Spray or dip flange in molykote (8). To adjust clearances, hold caliper
metal protector. Eliminate excess liquid assembly and unscrew bolts from
by gently blowing with compressed air mounting bracket. Transpose washers
(dilute to 10% perchloroethylene). Cure on bolts as required. Reassemble parts,
for 8 hours at room temperature, or 15 and recheck clearances.
minutes at 150F (65C).
(9). If new caliper assembly was installed or
if hydraulic fittings were removed from
(5). Coat, completely but sparingly, splines old unit, coat all but first two threads of
of transmission output shaft with two bleed screws, tees, and plugs with
grease (CM116) and threads of coupling thread sealant (CM434) or equivalent.
bolt with anti-seize compound Install plugs in caliper assembly, install
(CM112), or equivalent. Start disc/coup adapters on tees, and install bleed
ling unit on shaft. screws in adapters.
Page 408
TR18-002 63-22-00
MAINTENANCE MANUAL
MAIN TRANSMISSION
BOLT LOCKWIRE BOLT
LOCKWIRE
SPECIAL NUT
CALIPER MOUNTING
BRACKET
DRIVE COUPLING
G63-2011
Figure 405. Lockwire Installation (369D25100 Transmission)

(10). Install tees (MS20825-2D, 2 ea) in top (2). Remove attaching nuts and washers,
of caliper assembly (ref. Figure 902, and remove mounting bracket from
Sheet 2). Torque each tee to 50 to 55 studs.
inch-pound (5.65 to 6.21 Nm), Apply NOTE: It is not necessary to remove washers
more torque to align tees with tube used as spacers except for replacement.
assemblies (369A8010, 2 each) Nuts can be replaced on studs until time for
re-assembly to prevent loss of parts.
(11). Connect tube assemblies to tees.
B. Installation
The following procedures assume that the
5. Caliper Mounting Bracket Replacement transmission has been removed from the
(369D25100 Transmission) aircraft for removal of the mounting bracket.

A. Removal Item Nomenclature
CM702 Lockwire CRES
The caliper mounting bracket is attached to
the main transmission tail rotor cover by (1). Place three washers on each of the four
special nuts installed on four of the studs used mounting studs (1, 2, 10, and 11 o'clock
for installation of the cover. The caliper positions) as spacers. Position mounting
assembly is bolted to the mounting bracket. bracket on studs, install washers and
Bracket removal requires that the main nuts, and torque nuts to 50 to 75
transmission be removed from the aircraft inch-pound (5.65 to 8.47 Nm).
with the rotor brake components installed.
(2). Secure installation with lockwire
(1). Remove main transmission (and (CM702) (ref. Figure 405).
attached rotor brake components) from (3). Reinstall transmission as required (ref.
aircraft (Ref. Sec. 63-20-00/25). Section 63-20-00 and 63-20-25).
Page 409
63-22-00 TR18-002
MAINTENANCE MANUAL
6. Caliper Assembly, Brake Disc, and Drive (5). Note and record, for re-assembly
Coupling Replacement (369F5100 reference, placement of 18 washers
Transmission) used as spacers between caliper
assembly and mounting bracket, or
(Ref. Figure 406) under heads of attaching bolts.
A. Removal The caliper assembly consists of

CAUTION two identical halves held togeth
er by the attaching bolts. Care should be
The caliper assembly is bolted to the main used to avoid dropping parts when bolts are
transmission anti-torque cover. The brake disc removed.
is bolted on the drive coupling which is
installed on the transmission output shaft. For (6). Hold caliper assembly and unscrew
clarity, the brake disc and drive coupling are attaching bolts. Slide disc/coupling unit
considered as a single item (disc/coupling away from transmission and remove
unit). Although the caliper assembly and the caliper assembly and attaching hard
disc/coupling unit are not mechanically ware.
connected, they are installed on the transmis
sion with the outer portion of the disc posi (7). If caliper assembly is to be reused and
tioned between the two halves of the caliper some time will elapse before re-assemb
assembly. This arrangement makes it neces ly, remove disc/coupling unit, position
sary to remove both units (partially, at least) caliper assembly (and assembled parts)
at the same time. Removal operations require on transmission and insert bolts to hold
that the main transmission be removed from parts until time for re-assembly.
the aircraft with the rotor brake components
installed. NOTE: New bleed screws are included with the
new caliper assembly.
(1). Remove main transmission (and
attached rotor brake components) from (8). If disc/coupling unit is to be reinstalled,
aircraft (ref. Sec. 63-25). and some time will elapse before
re-assembly, slide unit back on trans
(2). Disconnect tube assembly from caliper mission shaft and install coupling bolt
mounted tees. Remove tube assembly finger tight to hold parts until time for
and interconnect tee as a unit. re-assembly.
NOTE: It is not necessary to disconnect tube Axial position of the drive

WARNING coupling is critical as it con
assemblies from tee except for replacement
of defective and damaged parts. trols the mechanical interface between
the coupling and the tail rotor drive
shaft. Out-of-tolerance axial coupling
(3). If caliper assembly is to be replaced by loads can contribute to coupling fail
a new unit, remove two bleed screws ure which could result in injury to per
from adapters, remove adapters from sonnel and equipment damage. Refer
tees, and remove tees from caliper to Sec. 63-15 for coupling reinstalla
assembly. tion.
NOTE: If old caliper assembly is to be rein (9). If either disc or coupling is to be
stalled, it is not necessary to remove hy replaced by a new part, proceed as
draulic fittings except for replacement of de follows:
fective or damaged parts.
(a). Slide disc/coupling unit off shaft,
(4). Remove coupling bolt that is used to leaving shim washers in place.
secure drive coupling on transmission
output shaft so that disc/coupling unit (b). Remove nuts, washers, and bolts and
is free to slide on shaft splines. separate disc and coupling.
Page 410
TR18-002 63-22-00
MAINTENANCE MANUAL
CALIPER MOUNTING BOSS AN960-616LL

ON TRANSMISSION WASHER
MHS4620C19-29 AN960-616L
BUSHING WASHER
(NOTE 1)
NAS6606H52
BOLT
(NOTE 3)
CALIPER
ASSEMBLY
DISC DISC
CALIPER CALIPER
NOTES:
1. CLEARANCE TO BE ADJUSTED BY VARYING WASHERS FROM EITHER SIDE
OF CALIPER ASSEMBLY.
NOTE 2
2. CLEARANCE TO BE EQUAL WITHIN 0.032 IN. (0.8128 MM).
3. TORQUE TO 160 - 190 INCH POUNDS (18.08 - 21.47 NM) AND SAFETY WITH
LOCKWIRE (CM702). G63−2200−406−1
Figure 406. Rotor Brake Caliper Installation (369F5100 Transmission)
Page 411
63-22-00 TR18-002
MAINTENANCE MANUAL
(c). If coupling is being replaced, mea To ensure optimum brake opera

sure (and record for re-assembly CAUTION tion and minimize equipment
reference) overall length of old damage, caliper-to-disc clearances on both
coupling at three separate peripheral sides of disc should be equal, or as nearly
locations. equal as possible. Clearance adjustment is
accomplished by varying number of 0.032
(d). Calculate and record the average inch (0.8128 mm) thick shim washers placed
value. between the caliper assembly and transmis
B. Installation sion.
(3). Measure brake caliper housing-to-disc
NOTE: On the 369F5100 transmission, the clearances on both sides of disc with a
brake caliper attaches directly to the trans
feeler gage. If clearances are equal
mission.
within 0.032 inch (0.8128 mm), torque
The following procedure is for installation of attaching bolts to 160 - 190 inch-
the rotor brake caliper assembly. The caliper pounds (18.08 - 21.47 Nm) and secure
assembly should be installed on the transmis with lockwire (CM702).
sion before the transmission is installed in the NOTE: Clearance differences greater than
helicopter. 0.032 inch (0.8128 mm) can be reduced by
re-arranging washers on caliper attach
Consumable Materials bolts.
Item Nomenclature (4). To adjust clearances, hold caliper
assembly and unscrew bolts from
CM434 Thread sealant mounting bracket. Transpose washers
CM702 Lockwire CRES on bolts as required. Reassemble parts
and recheck clearances.
NOTE: NOTE: If new caliper assembly was installed or
D AN960-616LL (x1 on each side) washers if hydraulic fittings were removed from old
are to be used next to the bushing for ad unit, coat all but first two threads of two
justing caliper-to-disc clearance. bleed screws, tees and plugs with thread
sealant (CM434) or equivalent.
D AN960-616L (x9 on each side) are used
on the attaching bolt for shims. Those not (5). Install tees (MS20825-2D, 2 ea) in top
used as shims should be placed under bolt of caliper assembly (ref. Figure 902,
heads. Washer distribution should be the Sheet 2). Torque each tee to 50 - 55
same for each of the bolts. inch lbs (5.65 - 6.21 Nm). Apply more
torque to align tees with tube assem
(1). Insert two bolts with equal number of blies (369A8010, 2 ea).
washers through the caliper (washers
can be on either side of caliper as (6). Install plugs in caliper assembly, install
needed) and install two bushings. adapters on tees and install bleed
screws in adapters.
(2). Mount the caliper assembly over disc
and thread bolts into transmission. (7). Connect tube assemblies to tees.
Page 412
TR18-002 63-22-00
MAINTENANCE MANUAL
7. Hydraulic Relief Valve Replacement (3). Reinstall components removed for

access to the hydraulic relief valve.
(Ref. Figure 401)
8. Hydraulic Tube Assembly Replacement
A. Removal
(Ref. Figure 904)
The hydraulic relief valve is attached by
means of a clamp to the canted bulkhead 78.50 A. Removal
vertical member, and is connected hydraulical
The hydraulic tube assembly is attached to the
ly between the master cylinder assembly and
main rotor mast pan and to the window
the caliper assembly. Remove the relief valve
channel by four clamps. It is connected
as follows:
between tees. The assembly removal requires
(1). Remove crew compartment hardware access from the cargo/passenger compartment.
and fittings for access to hydraulic (1). Remove attaching screws and both (LH
relief valve assembly. and RH) upper forward trim panel
assemblies. Remove convenience panel
(2). Disconnect tube assembly from reducer
cover assembly. Remove attaching
installed in relief valve. Disconnect
screws and transmission cover panel
tube assembly from relief valve, taking
assembly.
special care to catch any hydraulic fluid
that drains or drips from tube assem (2). Disconnect tube assembly from tees,
blies, reducer, or relief valve when the taking special care to catch any hydrau
system is opened. Remove reducer and lic fluid that drains or drips from tube
O-ring packing from relief valve. assembly or tees when system is
Discard O-ring packing. opened.
NOTE: Because of limited access, it can be (3). Remove (and discard) grommet from
more convenient to disconnect tube assem tube assembly and air baffle.
bly from tee before removing tube assembly
from relief valve. If so, remove tube assem (4). Remove nuts, washers, screws, clamps,
bly from tee; remove relief valve and tube and tube assembly.
assembly from helicopter; and remove tube
(5). If some time is to elapse before re-as
from relief valve. Reinstall tube assembly on
sembly, install protective caps on open
tee finger tight for storage until required for
ends of tees to prevent entrance of
replacement of relief valve.
contaminants.
(3). Remove screw, washer, and clamp, and B. Installation
remove relief valve from canted bulk
head 78.50 structure. Tube assembly installation is essentially the
reverse of removal procedures, with these
(4). Install protective caps or plugs on open specific considerations.
relief valve ports and open ends of
disconnected tube assembly to prevent
entrance of contaminants. Consumable Materials
B. Installation Item Nomenclature
CM418 Cement, epoxy
Installation procedures are essentially the
reverse of removal procedures, with these
special considerations: (1). Make a straight radial cut into center
hole of new grommet and install
(1). Install new O-ring packing on reducer. grommet on tube assembly. Position
parts and bond grommet into slot in air
(2). After relief valve is installed and baffle with epoxy cement (CM418).
connected into the hydraulic system, fill
and bleed the system. (2). Fill and bleed the hydraulic system.
Page 413
63-22-00 TR18-002
MAINTENANCE MANUAL
(3). Reinstall components removed for NOTE: Aft edge of cover must overlap forward
access to the hydraulic tube assembly. edge of convenience panel cover assembly.
(2). Install screw through cover assembly
9. Rotor Brake Forward Cover Assembly and map case panel into isolation
mount on canted bulkhead 78.50
A. Installation structure.
(3). For 369D Model — Attach cover
(Ref. Figure 908)
assembly and doublers to angle assem
bly with screw.
(1). Position cover assembly on map case
assembly with rotor brake handle and For 369E/FF Models — Attach cover
handle retaining clip through cover assembly to convenience panel with
openings. shims and screws.
Page 414
TR18-002 63-22-00
MAINTENANCE MANUAL
ROTOR BRAKE
INSPECTION/CHECK
When working with hydrau (5). Verify that clip (Ref. Figure 901) on
WARNING lic systems, special care handle retainer assembly holds brake
must be taken to prevent entrance of handle securely in the stowed (raised)
dust, moisture. and other foreign mate position.
rial. System contamination can cause
malfunctions that could result in inju (6). Actuate brake handle to check that
ry to personnel and equipment dam components of master cylinder linkage
age. assembly (Ref. Figure 402) operate
freely without binding or excessive play
1. Rotor Brake Assembly Inspection at pivot points. Verify that spring force
holds lever in BRAKE OFF position.
Consumable Materials (7). Visually inspect friction surfaces of

(Ref. Section 91−00−00) brake disc (Ref. Figure 403) for exces
Item Nomenclature sive wear, galling, scoring, cracking,
CM123 Hydraulic fluid distortion, or other evidence of damage.
(8). Rotate the drive system and check that

(1). Visually inspect rotor brake compo caliper brake pucks are not dragging on
nents for general condition, security of the disc.
installation, and evidence of hydraulic (9). Apply sufficient force on brake handle
fluid leakage. to actuate master cylinder assembly to
pressurize hydraulic system.
NOTE: Excessively low fluid level indicates a
system fault that must be isolated and cor NOTE: System pressurization (brake actua
rected. tion) is indicated by the feel of firm resis
tance to handle movement. A cushioned
(2). Disconnect tube assembly (Ref. (spongy) feel indicates that the system con
Figure 902) from nipple installed in tains air which must be removed (bled off)
master cylinder cap. Move end of tube before proceeding with the inspection.
assembly carefully aside, remove
attaching screws and cap with gasket, (10). Maintain force on brake handle and
and check that hydraulic fluid level is verify that pistons in caliper assembly
1/8 - 1/4 inch (3.175-6.35 mm) from top operate to force brake pucks against
of reservoir. If level is low, add hydrau friction surfaces of brake disc. Visually
lic fluid (CM123). Take special care to inspect brake pucks for extent of wear
avoid getting contaminants into the and evidence of damage.
hydraulic system.
Do not apply a side load to brake
(3). Visually inspect gasket for tears, cuts, CAUTION handle as damage to support
or other damage; replace gasket, if bracketry can result.
defective. Visually inspect sealing
surfaces of cap and master cylinder NOTE: Pucks must be extended to the BRAKE
body for nicks, cracks, scratches, or ON position to permit adequate inspection.
other defects; repair minor damage or If parting line between piston face and puck
replace defective parts. is visible, puck is worn excessively and must
be replaced.
(4). Replace cap and gasket on master
cylinder and secure with attaching (11). Monitor feel of resistance and increase
screws. Connect tube assembly to force applied to brake handle until
nipple and tighten tube nut securely. hydraulic relief valve opens.
Page 601
MAINTENANCE MANUAL
NOTE: When working properly, the hydraulic (15). Raise brake handle to stowed position
relief valve opens and routes pressurized and engage it in clip on handle retainer
hydraulic fluid back to the master cylinder assembly.
reservoir when system pressure reaches 500
psig (3447 kPa). Valve opening can be de 2. Rotor Brake Operational Check
tected by a momentary decrease of resis
tance to handle movement. If movement is After rotor brake hydraulic system has been
solidly resisted, regardless of force applied, filled with fluid, an operational checkout of the
the relief valve is defective and must be re rotor brake installation must be done.
placed. (1). Start engine, run up rotor to operating
(12). Maintain steady force (just short of that speed, and then make a normal shut
required to initiate relief valve opening) down (refer to applicable Pilot's Flight
on brake handle and observe handle Manual).
movement. Check that actuating lever Incorrect application of the ro
spacer and master cylinder stop do not CAUTION tor brake can result in sudden
contact. stopping and kick-back of the main rotor, an
Check for installation of master action which can cause damage to the rotor
CAUTION cylinder stop to prevent over blades and strap packs in the rotor hub. Col
travel of piston in master cylinder. If stop is lective pitch must never be applied to slow
not installed, damage to master cylinder rotor rotation as this can cause damage to
components can occur. the rotor blades and strap packs. Applica
tion of a side load to brake handle can dam
NOTE: Continued handle movement indicates age support bracketry.
the presence of an internal leak condition
which must be located and corrected. (2). When rotor slows to approximately 205
or less rpm, disengage brake handle
(13). Release force on brake handle and from retaining clip and pull handle
verify that caliper pistons (and attached down to apply braking force. Make
brake pucks) are retracted. certain that collective pitch stick is in
full down position, and that cyclic
NOTE: Failure of pistons to retract indicates control stick is in neutral position.
that caliper assembly is defective and must
be overhauled or replaced. (3). Release brake pressure during last
revolution of rotor.
(14). Reinstall components that were
removed for access to the rotor brake (4). Raise brake handle to stowed position
system. and engage it in handle retaining clip.
Page 602
MAINTENANCE MANUAL
ROTOR BRAKE
When working with hydrau NOTE: A new design convenience panel cover
WARNING lic systems, special care assembly (Ref. Figure 908) must be in
must be taken to prevent entrance of stalled to cover the aft portion of the brake
dust, moisture, or other foreign materi master cylinder assembly.
al. Hydraulic system contamination
can cause malfunctions that could re (4). Disconnect electrical wiring and
sult in injury to personnel or equip communications cables from compo
ment damage. nents on back of convenience panel
assembly. If cabin heating option is
1. Rotor Brake Initial Installation installed on aircraft, disconnect heated
air duct from panel-mounted diffuser.
This section provides detailed instructions for Remove attaching screws and conve
accomplishing initial installation of the rotor nience panel assembly from aft side of
brake components into the aircraft. In general, canted bulkhead 78.50 structure.
procedures are applicable to either left hand or
right hand command configurations. Where (5). Remove transmission cover panel
pertinent, differences are specified. assembly from fuselage structure.
(6). Cover exposed trim panels to prevent
Illustrations are included to provide data
damage and soiling.
pertinent to aircraft modifications required for
installation of the rotor brake components. All (7). Remove main transmission from
items and tools required to install the rotor aircraft (Ref. Sec. 63-20-00/25).
brake are standard and should be procured
locally. Alternate items of comparable charac (8). Remove tail rotor (Ref. Sec. 64-20-00),
teristics and equal quality can be used. tail rotor transmission (Ref. Sec.
63-25-10) and tail rotor drive shaft
A. Aircraft Preparation (Ref. Sec. 63-15-10).
Preparation for installation of rotor brake C. Removing Components to be Replaced
components include removal of certain original
equipment items to gain access, or for replace Certain rotor brake and related components
ment. Preparations also include permanent are mounted on the main transmission, and
installation of certain rotor brake components. are installed in the aircraft as a unit with the
transmission. Some of these transmission-
B. Installation Access mounted components replace similar item
counterparts that were used in the original
NOTE: The main transmission must be re installation.
moved from the aircraft to permit installa
tion of the transmission-mounted rotor (1). The tail rotor drive coupling installed
brake components. on the transmission output shaft must
be replaced by a new drive coupling on
(1). Remove both crew compartment and which the brake disc is mounted.
cargo/passenger compartment doors. Remove coupling and failsafe device (if
used) from transmission output shaft
(2). Remove crew compartment seats. (Ref. Sec. 63-15-10). Leave laminated
shim washers on output shaft and
(3). Remove map case assembly from retain coupling bolt for reassembly use.
forward side of canted bulkhead 78.50
structure. Remove both (LH and RH) (2). The tachometer generator installed on
upper forward panel assemblies from the tail rotor cover assembly on main
bulkhead structure. Remove conve transmission must be replaced by a new
nience panel cover assembly from unit that provides clearance for the
convenience panel assembly. rotor brake disc. Remove attaching nuts
Page 901
MAINTENANCE MANUAL
and washers, tachometer generator and (4). Attach angle assembly to shoulder
gasket from tail rotor cover assembly. beam with blind rivets.
Retain nuts and washers for re-as
sembly use. Tachometer generator will E. Master Cylinder Linkage Assembly and
not be reinstalled. Discard gasket. Mount Bracket Installation
(3). The tail rotor cover assembly is in (Ref. Figure 901) The master cylinder linkage
stalled on the main transmission assembly bracket must be installed on canted
housing with nuts and washers in bulkhead 78.50 vertical member as a means of
stalled on twelve studs. Four of the attachment for the master cylinder assembly
studs, with special nuts and washers, and the other components of the master
will be used for installing the rotor cylinder linkage assembly.
brake caliper mounting bracket.
Remove four nuts and washers (at 1, 2,
10, and 11 o'clock positions). These nuts Consumable Materials
and washers will not be used at (Ref. Section 91−00−00)
reinstallation. Item Nomenclature
CM318 Primer
D. Angle Assembly Installation (500D)
(Ref. Figure 901) The angle assembly must be NOTE: Because of its method of attachment, it
installed on canted bulkhead 78.50 shoulder can be more convenient to install the link
beam as a means of attachment for the age assembly bracket and then assemble
convenience panel cover assembly and the the other components on the bracket. Al
rotor brake forward cover assembly. though the procedures given in steps (1).
thru (3). below consider installation of the
assembly, they are also applicable for instal
Consumable Materials lation of the bracket. Steps (4). thru (7). be
(Ref. Section 91−00−00) low describe procedures for assembling com
Item Nomenclature ponents to the bracket.
CM318 Primer
(1). Position master cylinder linkage
assembly on canted bulkhead 78.50
(1). Lay out and mark location for angle vertical member. Hold assembly (with
assembly on portion of forward bulk bracket) firmly in position as a guide
head aft panel assembly that covers and use a No. 15 drill bit to line drill
canted bulkhead 78.50 shoulder beam. four holes in vertical member, taking
care to prevent point of drill bit from
(2). Insert piece of cardboard (or similar penetrating into vertical member more
material) under aft panel assembly to than 1/4 inch (6.35 mm).
protect shoulder beam and use a sharp
knife to make panel cut out to accom (2). Line ream holes 0.199-0.202 inch
modate angle assembly, taking special (5.0546-5.1308 mm) diameter. Remove
care not to cut outside marked area. linkage assembly, deburr holes in both
parts, and touch up raw metal surfaces
(3). Position angle assembly on shoulder with primer (CM318).
beam as a guide and drill two
0.128-0.132 inch (3.2512-3.3528 mm) (3). Attach bracket to vertical member with
diameter holes through angle assembly Jo-bolt blind fasteners.
and one wall of shoulder beam, taking
care that point of drill bit does not (4). Secure pin (Ref. Figure 402) in bracket
penetrate into shoulder beam more with nut and washer.
than 1/4 inch (6.35 mm). Deburr holes
in both parts and touch up raw metal (5). Install grip on handle. Install new roll
surfaces with primer (CM318). pins through handle and fitting.
Page 902
MAINTENANCE MANUAL
RIGHT-HAND
INSTALLATION
JO-BOLT
0.75 IN.
(19.05 MM)
0.50 IN.
(12.70 MM)
NOTE:
LEFT-HAND INSTALLATION SHOWN, RIGHT-HAND
OPPOSITE EXCEPT WHERE NOTED.
G63-2200-901-1
Figure 901. Locating Permanently Installed Components (Sheet 1 of 2)
Page 903
MAINTENANCE MANUAL
1.00 IN.
(2.54 CM) 0.50 IN.
0.063 IN.
(1.6002 MM) (12.70 MM)
(STOCK)
1.50 IN.
0.47 IN. (3.81 CM) 1.00 IN.
(11.938 MM) (2.54 CM)
0.31 IN.
0.75 IN. 2.00 IN. (7.87 MM)
(19.05 MM) (5.08 CM)
2.26 IN. 0.54 IN.

(5.7404 CM) (13.716 MM)
4.80 IN. 0.38 IN.

(12.192 CM) (9.652 MM)
1.80 IN. 0.25 IN.

(4.572 CM) (6.35 MM) (TYP)
0.70 IN.
(17.78 MM)
0.40 IN. 0.38 IN.

3.07 IN. 0.50 IN.
(10.16 MM) (9.652 MM) 0.38 IN. (7.7978 CM) (12.70 MM)
0.50 IN. (TYP) (9.652 MM)
(12.7 MM) 2.38 IN.
4.57 IN. (6.0452 CM)
(11.6078 CM)
0.32 IN.
0.62 IN. (8.128 MM)
(15.748 MM)
0.50 IN.
(12.70 MM)
23.80 IN.
(60.452 CM)
HANDLE RETAINER ASSY
G63-2012-2
Figure 901. Locating Permanently Installed Components (Sheet 2 of 2)
Page 904
MAINTENANCE MANUAL
(6). Install bolt, spacer, and nut on lever. Remove retainer assembly and use a
Attach assembled handle parts to lever, 1/8 inch (3.175 mm) drill bit to drill out
with clevis pin, washers, and new cotter marked rivets.
pin.
(3). Lay out hole patterns on handle
When parts are assembled, retainer assembly to match drilled rivet
WARNING spring force is constantly ex holes. Use No. 30 drill bit to drill two
erted to inhibit inadvertent brake holes in retainer.
application. Care must be taken as the
spring is engaged to prevent injury to (4). Cleco retainer assembly in place. Use
personnel or equipment damage. retainer as guide and use a No. 15 drill
bit to drill two holes into face of vertical
(7). Install lever with attached parts, and member. Remove handle retainer
spring on pin and secure with washer, assembly from vertical member.
nut, and new cotter pin. Engage free
end of spring under head of clevis pin. (5). Deburr holes and touch up with primer
(CM318).
F. Handle Retainer Assembly Installation
(6). Attach handle retainer assembly to
(Ref. Figure 901) The handle retainer assem vertical member with four blind rivets.
bly must be installed on canted bulkhead 78.50
vertical member to secure the rotor brake G. Rivnut Installation
operating handle in the stowed (raised)
position. (Ref. Figure 902) A rivnut must be installed in
the main rotor mast pan as an attachment
point for one of the clamps used to secure
hydraulic tube assembly. For R/H rotor brake
Item Nomenclature
installation, a rivnut must be installed in the
canted bulkhead 78.50 vertical member for
CM318 Primer attachment of the hydraulic relief valve.
NOTE: The master cylinder linkage assembly Consumable Materials

must be installed so that the handle retain (Ref. Section 91−00−00)
er assembly can be positioned correctly. Item Nomenclature
(1). Position handle retainer assembly on CM318 Primer
canted bulkhead 78.50 vertical member
so that when rotor brake operating
Care must be taken when drill
handle is in the stowed position, CAUTION ing the mast pan for rivnut in
retainer clip engages handle just below
stallation to prevent damage to wiring har
the rubber grip.
nesses which are installed on the upper side
To prevent damage to compo of the pan, or to critical structure members
CAUTION nents, point of drill bit must not to which the pan is riveted. A drill stop or
be allowed to penetrate through wall of ver other suitable means should be used to pre
tical member more than 1/4 inch (6.35 mm). vent point of drill from penetrating more
than 1/4 inch (6.35 mm) into vertical mem
NOTE: The tunnel beam web is secured to the ber.
vertical members by a series of rivets. Two
of these rivets must be removed and re (1). Lay out location for hole in transmis
placed by rivets that also attach the handle sion pan. Use 1/4 inch (6.35 mm) drill
retainer assembly. bit to drill hole through pan, deburr
hole, and touch up raw metal surfaces
(2). Mark two rivets on front of vertical with primer (CM318). Install rivnut in
member that most closely match accordance with standard shop practice
position of handle retainer assembly. and manufacturer's instructions.
Page 905
MAINTENANCE MANUAL
BOLT
BRAKE CALIPER WASHERS
BLEED
SCREW
WASHERS
MOUNTING BRACKET
(369D25100 TRANSMISSION)
BRAKE CALIPER INSTALLATION
(369D25100 TRANSMISSION|
INSTALLATION SHOWN)
MASTER CYLINDER INSTALLATION
G63-2013-1B
Figure 902. Rotor Brake Installation (Sheet 1 of 2)
Page 906
MAINTENANCE MANUAL
NUT
CLAMP
BLEEDSCREW
SCREW
WASHER TEE
RIVNUT
BLEEDSCREW
CLAMP TEE
SPECIAL NUT
SHIM
SCREW WASHER
WASHER
COUPLING
DISC
MASTER
CYLINDER
TACH
GENERATOR
HANDLE
ASSEMBLY
G63−2200−902−2
Figure 902. Rotor Brake Installation (Sheet 2 of 2)
Page 907
MAINTENANCE MANUAL
(2). Lay out location for hole in vertical in tail rotor cover assembly for use as
member. Use 1/4 inch (6.35 mm) drill spacers. Position caliper mounting
bit to drill hole through outer face of bracket on studs and secure with
vertical member. Deburr hole and touch washers and nuts. Torque nuts to 50 -
up raw metal surfaces with primer. 70 inch-pounds (5.65 - 7.91 Nm).
Install rivnut in accordance with
standard shop practice and manufac (2). Secure installation with lockwire
turer's instructions. (CM702).
H. Window Support Channel Modification J. Caliper Assembly, Brake Disc and Drive
Coupling Installation
(Ref. Figure 903) Three clamps are used to
attach hydraulic tube assembly to the window (Ref. Figure 902) The caliper assembly is
support channel. Modifications to the channel bolted to a mounting bracket which is installed
are required to accommodate two of the on the main transmission tail rotor cover. The
clamps. brake disc is bolted on the drive coupling
which is installed on the transmission output
shaft. For clarity, the brake disc and drive
Consumable Materials coupling are considered as a single item,
(Ref. Section 91−00−00) herein referred to as the disc/coupling unit.
Item Nomenclature Although the caliper assembly and the
CM318 Primer disc/coupling unit are not mechanically
connected, they are installed on the transmis
sion with the outer portion of the disc posi
(1). Use 1/8 inch (3.175 mm) drill bit to tioned between the two halves of the caliper
remove one (3rd rivet from front) of the assembly. This arrangement makes it neces
four rivets used to attach forward sary to install both units at the same time.
nutplate angle clip to channel. Enlarge
hole to 0.188-0.218 inch (4.7752-5.5372
mm) with 3/16 inch (4.7625 mm) drill Consumable Materials
bit, deburr hole, and touch up raw (Ref. Section 91−00−00)
metal surfaces with primer (CM318). Item Nomenclature
(2). Lay out location for hole in channel as CM116 Grease, aircraft and instrument
shown. Use 3/16 inch (4.7625 mm) drill
to drill hole in channel, deburr hole, CM434 Thread sealant
and touch up raw metal surfaces with CM702 Lockwire CRES
primer.
I. Caliper Mounting Bracket Initial Axial positioning of the

Installation
WARNING drive coupling is critical as
it controls the mechanical interface be
(Ref. Figure 902) The caliper mounting bracket tween the coupling and the tail rotor
is installed on four of the twelve studs used to drive shaft. Excessive axial loads can
secure the tail rotor cover assembly on the contribute to coupling failure which
main transmission housing. could result in injury to personnel or
equipment damage. Refer to Section
63-15-10 for shimming procedures for
Consumable Materials installing coupling disc on shaft.
Item Nomenclature NOTE: Before installing caliper, brake disc and
CM702 Lockwire CRES drive coupling, install new tachometer gen
erator and gasket. Ensure that mechanical
drive components are correctly engaged and
(1). Place three washers on each of the four electrical receptacle is at the 11 o'clock posi
studs (1, 2, 10, and 11 o'clock positions) tion.
Page 908
MAINTENANCE MANUAL
369D23012-5 REF
369D23012-13 REF
G63-2019
Figure 903. Modifying Window Support Channel

(1). Measure (with a micrometer) and (5). Remove bleed screws from ports in ends
record thickness of brake disc at four of caliper assembly. Coat all but first
locations around the disc. Calculate and two threads of bleed screws, tees, and
record average of thickness measure plugs with thread sealant (CM434).
ments.
(6). Install plugs in bleed screw ports,
(2). Position brake disc on tail rotor drive adapters on tees, and bleed screws in
coupling with raised center side of disc adapters. Remove and discard hard
seated firmly on shoulder of coupling ware used to hold caliper halves
and with bolt holes aligned. Secure disc together.
to coupling with attaching hardware NOTE: The caliper assembly consists of two
and torque nuts (in an alternating identical halves. When received, the halves
sequence) to 100 - 140 inch-pounds are held together by commercial hardware.
(11.30 - 15.82 Nm). This hardware is replaced by qualified stan
(3). Measure (with an inside micrometer) dard hardware which also secures the cali
and record gap between brake puck per assembly on the mounting bracket.
faces. Subtract brake disc thickness (7). Insert bolts through one caliper half,
calculated in step (1). from gap mea position assembled parts of mounting
surement and divide the difference by bracket and screw bolts into bracket
two to determine the optimum puck-to- finger tight to maintain alignment of
disc clearance. caliper half. Use a C-clamp or other
suitable means to clamp caliper half
(4). Install tees (MS20825-2D, 2 ea) in top firm against bracket.
of caliper assembly (ref. Figure 902,
Sheet 2). Torque each tee to 50 - 55 (8). Coat, completely but sparingly, splines
inch lbs (5.65 - 6.21 Nm). Apply more of transmission output shaft with
torque to align tees with tube assem grease (CM116) and threads of coupling
blies (369A8010, 2 ea). with anti-seize compound (CM113), or
Page 909
MAINTENANCE MANUAL
equivalent. Install coupling/disc unit on to ensure that coupling is seated firmly

shaft and install bolt into end of shaft against shim washers on shaft.
TUBE ASSY
BAFFLE ASSY
MAST SUPPORT
PAN GROMMET
NOTE: CHANNEL ASSY

LEFT-HAND INSTALLATION
RIGHT-HAND OPPOSITE G63-2020
Figure 904. Hydraulic Tube Installation

The caliper assembly must NOTE: Fore-and-aft positioning of the caliper
WARNING be installed so that caliper- assembly, which determines the puck-to-
to-disc clearances on both sides of disc disc clearance relationship, is established by
are approximately equal. Improper in installing shim washers between the caliper
stallation can cause malfunctions assembly and the mounting bracket. Nine
which could result in injury to person washers are provided for each attaching
nel or equipment damage. bolt; those not required for shimming must
be installed under the bolt heads.
(9). Measure gap between brake caliper (10). Remove bolts and place the correct
housing and forward face of disc with a number (nine less the number required
thickness gage. Subtract desired for shimming) of washers on each bolt.
caliper-to-disc clearance calculated in Insert bolts through caliper halves and
step (3). from this measurement to screw one bolt finger tight into mount
determine amount of shimming (wash ing bracket. Release clamped caliper
ers) to be installed between caliper half and move it away from bracket,
assembly and mounting bracket. Divide place required number of shim washers
the difference by 0.032 inch (0.8128 on second bolt as it is pushed through
mm) (washer thickness) to determine caliper assembly, and screw bolt into
number of shim washers needed. bracket a few turns. Repeat procedure
Page 910
MAINTENANCE MANUAL
to install shim washers on other bolt.

Tighten bolts firmly to secure installa
4389 GRIP
tion. (1 REQD)
(11). Check caliper-to-disc clearances with a

thickness gage. If clearances are
approximately equal, torque mounting
bolts to 160 - 190 inch pounds (18.08
- 21.47 Nm) and secure with lockwire
(CM702). Torque coupling bolt to 250 -
300 inch-pounds (28.25 - 33.90 Nm)
plus drag torque.
MASTER
CYLINDER
(12). After the rotor brake components have
been installed on the main transmis
sion, the built-up unit must be in
stalled in the aircraft (Ref. Sec. 0.02 IN. (0.508 MM) GAP
0.04 IN. (1.016 MM)
63-20-00/25).
The main transmission must

WARNING be installed in the aircraft
with special care to avoid damage to
rotor brake components. Installation G63-2022A
damage could lead to system failure
which could result in injury to person Figure 905. Positioning Master Cylinder
nel or equipment damage.
(3). Install new cap and reworked gasket on
(13). If tachometer generator is installed on master cylinder with attaching screws
transmission, connect electrical plug installed finger tight.
(P202) on aircraft wiring harness to
receptacle on tachometer generator. (4). Coat all but first two tapered pipe
threads of nipples and elbow with
thread sealant (CM434). Install nipples
K. Master Cylinder Assembly Initial in cap and elbow in master cylinder.
Installation
(5). Place one washer on each bolt, place
(Ref. Figure 902) The master cylinder assem stop on bolts and insert bolts through
bly is mounted on the master cylinder linkage master cylinder. Place two washers on
assembly bracket. each bolt as spacers. Position as
sembled parts on linkage assembly
bracket and secure installation with
Consumable Materials washers and nuts. Tighten nuts only
(Ref. Section 91−00−00) finger tight.
Item Nomenclature
CM434 Thread sealant NOTE: Mounting holes in bracket are elon
gated to enable lateral position adjustment
of master cylinder assembly.
(1). Remove attaching screws and vendor- (6). With actuating handle in stowed
supplied cap from master cylinder. position, adjust position of master
Vendor cap is not used. cylinder assembly so that clearance
(measured with a thickness gage)
(2). Rework vendor-supplied gasket (Ref. between actuating lever (Ref.
Figure 906). Figure 905) and master cylinder piston
Page 911
MAINTENANCE MANUAL
is 0.020-0.040 inch (0.508-1.016 mm). ing hardware loosely to hold clamps

Tighten nuts to hold master cylinder (and tube assembly) to pan and window
assembly firmly in position. channel.
L. Hydraulic Relief Valve Initial Installation (4). Connect tube assembly loosely to elbow
in master cylinder and to tee.
(Ref. Figure 902) The hydraulic relief valve is
attached by means of a clamp to the canted (5). With all tube assemblies and fittings
bulkhead 78.50 vertical member, and is connected, tighten nuts on tube assem
connected hydraulically, by means of tube blies. Tighten attaching hardware for
assemblies, between the master cylinder all clamps.
assembly and the caliper assembly.
NOTE: It is not necessary to tighten tube as
(1). Place new O-ring on reducer and screw sembly nuts at this time. The tube assembly
reducer into relief valve. Connect relief will have to be removed to permit filling the
valve to tube assembly and tighten tube hydraulic system.
nut. Install clamp on relief valve.
(6). Connect tube assembly to nipple in
(2). Position assembled parts with relief master cylinder cap and tighten tube
valve in ``V'' of handle retainer assem nut.
bly. Install attaching hardware loosely
to hold assembled parts on canted N. Rotor Brake Installation Servicing
bulkhead 78.50 vertical member.
After all operating components of the rotor
NOTE: Screw is threaded into nutplate for LH brake system have been installed, the hydrau
installation, and into rivnut for RH installa lic system must be filled with hydraulic fluid
tion. and have all entrapped air bled off. Refer to
Rotor Brake Hydraulic System Bleeding.
M. Hydraulic Tube Assemblies Initial
Installation 0.50 IN. (12.70 MM) DIA.
(Ref. Figure 902) Two tube assemblies are 0.56 IN. 0.56 IN.
(14.224 MM) (14.224 MM)
installed to connect the master cylinder
assembly and the caliper assembly.
Item Nomenclature
CM418 Cement, epoxy
(1). Connect tee loosely to tube assembly.

Make straight radial cut into center
hole of grommet and install grommet
and clamps on tube assembly.
(2). Position assembled parts on window

channel so that grommet can be
engaged in slot of air baffle. Connect
tube assembly loosely to tee on caliper
assembly and connect tee loosely to
EXISTING HOLES
tube assembly on hydraulic relief valve. G63-2021A
(3). Bond grommet into air baffle slot with Figure 906. Reworking Master Cylinder
epoxy cement (CM418). Install attach Gasket
Page 912
MAINTENANCE MANUAL
O. Installing Interior Furnishings to be drilled on rotor brake forward

cover panel.
After the operating components of the rotor
brake installation have been checked out, the (3). Use No. 42 drill bit to drill holes at
various items of interior furnishings (trim marked location for attaching screws.
panels, cover assemblies, seats, etc.) and the
fuselage doors must be reinstalled. This NOTE: It can be more convenient to remove
includes those items that are specific for the convenience panel cover assembly while
rotor brake installation, and those that were drilling hole.
removed to permit access for installing the
rotor brake components. (4). On the 500D, secure convenience panel
cover assembly with doublers to angle
P. Map Case Assembly Modification and assembly with attaching screw. On the
Installation others, the convenience panel cover
assembly will be permanently fastened
(Ref. Figure 907) Before the map case assem down when mated with the rotor brake
bly can be reinstalled, it must be modified to forward cover assembly.
accommodate the rotor brake forward cover
assembly. R. Rotor Brake Forward Cover Assembly
Installation
(1). Mark map case panel for cutout. Use a
sharp knife to cut out marked area, (Ref. Figure 908) The rotor brake forward
taking special care to avoid cutting cover assembly mates with the convenience
outside of marked area. panel cover assembly to enclose and protect
the rotor brake components (master cylinder,
(2). Install map case assembly on canted
etc.) installed on the canted bulkhead 78.50
bulkhead 78.50 structure with three
structure. It is installed over the forward
attaching screws.
portion of the master cylinder assembly and
NOTE: A fourth screw will also be used to at incorporates cutouts to accommodate the
tach the rotor brake forward cover assembly brakes handle and retaining clips.
(Ref. Figure 908).
(1). Position rotor brake forward cover
Q. Convenience Panel Cover Assembly assembly on map case assembly with
Modification and Installation aft edge overlapping forward edge of
convenience panel cover assembly and
(Ref. Figure 908) The convenience panel cover with brake and retaining clips extend
assembly mates with the rotor brake forward ing through cutouts.
cover assembly to enclose and protect the rotor
brake components installed on the canted NOTE: If aircraft is equipped with optional
bulkhead 78.50 structure. particle separator, it can be necessary to
trim the forward cover assembly for clear
(1). Position new convenience panel cover ance.
assembly with the aft edge overlapping
the forward edge of the transmission (2). On the 500D, mark location for hole in
cover panel. Install attaching screws to upper corner of forward cover assembly
hold panels in position. to line up with isolator mount, and in
lower corner to line up with nutplate in
(2). On the 500D, mark location for hole in angle assembly on canted bulkhead
the forward corner of convenience panel 78.50 shoulder beam. On the others,
cover assembly to line up with nutplate mark location for hole in upper corner
on angle assembly on canted bulkhead of forward cover assembly to line up
78.50 shoulder beam. On the others, with isolator mount and in upper and
mark location for holes in forward lower outboard corners to line up
corner of convenience panel cover parallel with holes previously drilled in
assembly to line up parallel with holes the convenience panel cover assembly.
Page 913
MAINTENANCE MANUAL
3.00 IN. (7.62 CM)
27.25 IN.
(69.22 CM)
23.38 IN.
(59.39 CM)
18.25 IN.
(46.36 CM)
369E/FF
15.00 IN.
(38.10 CM)
9.87 IN.
(25.07 CM)
369D
G63-2015A
Figure 907. Modifying Map Case Panel
Page 914
MAINTENANCE MANUAL
0.220-0.226 IN. (5.588-5.7404 MM)

DIA. HOLE TO MATCH MAP CASE
ASSEMBLY AND ISOLATOR
MOUNT
DRILL 0.220-0.226 IN.
(5.588-5.7404 MM)
DIA. HOLE (2 PL)
SHIM
3.00
2.00 IN.
(50.80 MM)
SHIM
1.50 IN.
(38.10 MM)
DRILL 0.220-0.226 IN.

(5.588-5.7404 MM)
DIA. HOLE (2 PL)
369E/FF
G63-2018-1A
Figure 908. Modifying Rotor Brake Cover Panel Assemblies (Sheet 1 of 2)
Page 915
MAINTENANCE MANUAL
DRILL 0.220-0.226 IN. (5.588-5.7404 MM)

DIA. HOLE TO MATCH NUTPLATE
DRILL 0.220-0.226 IN. (5.588-5.7404 MM)

DIA. HOLE TO MATCH MAP CASE
ASSEMBLY AND ISOLATOR MOUNT
NOTE:
LEFT-HAND ROTOR BRAKE INSTALLATION SHOWN,
RIGHT-HAND INSTALLATION OPPOSITE. G63-2018-2A
Figure 908. Modifying Rotor Brake Cover Panel Assemblies (Sheet 2 of 2)
Page 916
MAINTENANCE MANUAL
(3). Use No. 42 drill bit to drill holes at the outboard edge of forward cover
marked locations for attaching screws. assembly and convenience panel cover
assembly.
NOTE: It can be more convenient to remove for
ward cover panel assembly while drilling (5). Push panel boot aft on brake handle
holes. approximately 2 inches (5.08 cm) and
secure boot fastener tape.
(4). Secure forward cover assembly and S. Weight and Balance
map case panel assembly with attach
ing screws. On the 500D, install screw (Ref. Table 901) After installing the rotor
through nutplate in angle assembly. On brake, incorporate changes in helicopter
the others, install screws into shims on weight and balance record.
lb (kg) in. (cm) in−lb (kg−cm)
500D (left side)
Added +7.5 (+3.40) 106.6 (270.764) +800 (9216.96)
Removed 0.0 − 0.0
Changed +7.5 (+3.40) 106.6 (270.764) +800 (9216.96)
500D (right side)
Added +6.8 (3.08) 108.9 (276.606) +741 (8537.21)
Removed 0.0 − 0.0
Changed +6.8 (3.08) 108.9 (276.606) +741 (8537.21)
369E/FF − 500N (left and right)
Added +7.5 (+3.40) 106.5 (270.51) +799 (9205.44)
Removed 0.0 − 0.0
Changed +7.5 (+3.40) 106.5 (270.51) +799 (9205.44)
600N (left and right)
Added +7.6 (+3.45) 98.4 (294.44) +748 (862.3)
Removed 0.0 − 0.0
Changed +7.6 (+3.45) 98.4 (294.44) +748 (862.3)
Page 917
MAINTENANCE MANUAL
Page 918
MAINTENANCE MANUAL
Section
63−25−10
Tail Rotor
Transmission (Two
and Four Blade)
(369D/E/FF)
MAINTENANCE MANUAL
TAIL ROTOR TRANSMISSION (TWO AND FOUR BLADE)

1. Tail Rotor Transmission Description B. Tail Rotor Transmission Installation
NOTE: The maintenance provided in this chap Consumable Materials

ter is approved for field maintenance. Fur (Ref. Section 91−00−00)
ther maintenance to the tail rotor gearbox Item Nomenclature
more than what is contained here will be
performed by MDHI approved facilities. CM318 Primer
(Ref. 01-00-00, Table 201).
Do not carry or otherwise sup
The tail rotor transmission is a right-angle CAUTION port transmission by coupling,
transmission with a magnesium alloy housing.
as coupling diaphragm can be permanently
A magnetic chip detector is located on the aft
distorted. During performance of all mainte
end of the transmission, a breather-filler is
nance on transmission, use extra care to
located on the top and a sight gage is mounted
keep contaminants such as paint, dirt, etc
on the aft end (two-bladed) or on the right side
from areas around input and output shaft
(four-bladed) of the transmission.
seals.
2. Tail Rotor Transmission Replacement (1). Install tail rotor drive shaft on tail rotor
transmission (Ref. Sec. 63-15-10).
A. Tail Rotor Transmission Removal
(Ref. Figure 205) Ensure securi
CAUTION ty of tail rotor transmission
(1). Disconnect tail rotor driveshaft from
mount studs. Maximum allowable side play
transmission (Ref. Sec. 63-15-10).
at end of stud is 0.004 inch (0.102 mm), max
imum allowable axial play is 0.005 inch
(2). Disconnect chip detector wire. (0.127 mm). For stud replacement, refer to
the Structural Repair Manual (SRM).
(3). (369D/E) Remove four nuts and
washers from transmission mount NOTE: Ensure all paint and sealant is removed
studs. from mating surfaces. Remove excessive
sealant, as required, from transmission to
(4). (369FF) Remove four bolts, eight gain clean mounting surfaces. Ensure that
washers and four nuts between trans no gap in sealant coverage exists around the
mission and tailboom extension. transmission bearing cover assembly.
NOTE: Retain any shimming washers that can (2). Visually inspect mounting studs for
be between tail rotor transmission and tail damage or deformation. Replace
boom for transmission installation. damaged or deformed stud (Ref. SRM).
(3). Apply primer (CM318) in holes and on

(5). With assistance, support transmission the grip area of the mounting studs.
and shaft in line for minimum deflec Install tail rotor transmission or
tion of coupling and remove tail rotor tailboom extension while primer is still
drive shaft and transmission as a unit. wet.
(6). Remove tail rotor from tail rotor (4). With assistance, support transmission
transmission (Ref. Sec. 64-20-00). and shaft in line for minimum deflec
tion of coupling and install tail rotor
(7). Remove tail rotor drive shaft from tail drive shaft and transmission as a unit
rotor transmission (Ref. Sec. 63-15-10). (Ref. Sec. 63-15-10).
Page 201
MAINTENANCE MANUAL
NOTE: Record the drag torque for each nut and 3. Tail Rotor Transmission Inspection
its location on the transmission in the heli
copter for later use. (Ref. Figure 207, Table 201, Table 202,
Table 203)
(1). Check transmission for leaks, cracks
(a). (369D/E) Secure tail rotor transmis
and corrosion. Refer to Fluid Leak
sion to four tailboom mounting studs
Analysis (Ref. Sec. 12-00-00).
with washers and nuts. Torque nuts
to 75—95 inch-pounds (2). Inspect Sta. 284 bellcrank hole for
(8.47—10.73 Nm) plus drag elongation (Ref. Table 201).
torque.
(3). Check input shaft for:
(b). (369FF) Secure tail rotor transmis (a). Axial play by moving shaft in and
sion to tailboom extension with four out. Transmission must be cold. Axial
bolts, eight washers and four nuts. play is limited to 0.004 inch (0.102
Torque nuts to 75—95 inch-pounds mm) maximum.
(8.47—10.73 Nm) plus drag (b). Measure runout. Mark high and low
torque. extremes on outer end of shaft with
grease pencil (CM???). Total runout
should be less than 0.002 inch (0.051
(5). Apply torque stripe paint. mm).
(4). Check output shaft for:
(6). Between 2 and 10 hours of helicopter
operation (to allow parts to seat), check (a). Axial play. No axial movement is
the torque of each mounting nut as permitted.
follows:
(b). Measure runout. Mark high and low
extremes on outer end of shaft with
(a). Use the drag torque as measured and grease pencil (CM???). Total runout
apply a torque load of 75—95 inch- should be less than 0.0025 inch
pounds (8.47—10.73 Nm) plus the (0.0635 mm).
noted drag torque (noted for each (5). While gently pulling out on input shaft,
individual nut) to each mounting nut check gearset backlash:
of the transmission.
(a). Two-bladed gearset backlash should
be 0.004—0.008 inch (0.102—0.203
(b). Re-apply torque stripe paint. mm).
(b). Four-bladed gearset backlash should
(7). Install tail rotor on tail rotor transmis be 0.0025—0.0050 inch
sion (Ref. Sec. 64-20-00). (0.0635—0.127 mm).
NOTE: Placing marks on end of output shaft is
(8). Connect chip detector wire. Torque nut not required, but provides guides for subse
to 12—15 inch-pounds (1.36—1.69 quent installation of tail rotor assembly in a
Nm). manner that reduces the chances of high
frequency vibrations and lessens the possi
bility of requirement for tail rotor balancing.
(9). Connect tail rotor drive shaft to main
transmission (Ref. Sec. 63-15-10). (6). Inspect all scoring or scratching of
output shaft to determine if marks
penetrate through cadmium plating
(10). Drain residual preservative oil and and into steel shaft. Penetration of steel
service transmission with lubricating shaft is allowable to maximum depth of
oil (Ref. Sec. 12-00-00). 0.010 inch (0.254 mm).
Page 202
MAINTENANCE MANUAL
Table 201. General Inspection − Transmission Housing and Shaft Covers

Inspect Index No.
(Ref. Figure 204, Maximum Maximum
Figure 206) Serviceable Limits Repairable Limits Corrective Action
NOTE: All inspections are visual unless otherwise noted.
Housing assembly for:
Corrosion, chips, nicks, or Broken lockwire holes if Minor surface damage Repair (Ref. Minor Nicks,
other damage to housing lockwire can be Scratches, and Corro-
accomplished sion).
Inserts for:
Damaged threads or play No damage or play Not repairable Replace inserts (Ref.
in mating bore 6.D.).
Support arm bolt hole for:
Elongation Elongation will not be Not repairable Replace transmission.
more than 0.312—0.313
inch (7.9248—7.9502
mm)
All aluminum parts for corrosion:
Mating surface Not serviceable if surfaces Light corrosion or light Remove corrosion and
are corroded pitting that extends to treat (Ref. Minor Nicks,
max. of 10% of surface Scratches, and Corro-
sion).
Non−mating surfaces Not serviceable if surfaces Corrosion that can be Remove corrosion to
are corroded removed without removing eliminate all indications
more than 10% of wall and treat (Ref. Minor
thickness in affected area Nicks, Scratches, and
Corrosion).
All ferrous parts for corrosion (identify by weight and appearance):
Non−plated surfaces Not serviceable if surfaces Light corrosion and pitting Remove using 400—600
are corroded grit abrasive paper.
Plated surfaces Not serviceable if surfaces Corrosion that does not Remove corrosion to
are corroded extend into parent metal depth of plating if
necessary and replace
cadmium plating (Ref.
Minor Nicks, Scratches,
and Corrosion).
All magnesium parts for corrosion:
Mating surfaces Not serviceable if surfaces Light corrosion and light Treat (Ref. Minor Nicks,
are corroded pitting that extends to Scratches, and Corro-
max. of 10% of the sion).
surfaces
Non−mating surfaces Not serviceable if surfaces Corrosion that can be Remove corrosion to
are corroded removed without removing eliminate all indications
more than 10% of wall and treat (Ref. Minor
thickness in affected area Nicks, Scratches, and
Corrosion).
Page 203
MAINTENANCE MANUAL
Table 202. Detailed Inspection − Associated Transmission Housing Parts

Inspect Index No. Maximum Maximum
(Ref. Figure 202) Serviceable Limits Repairable Limits Corrective Action
Drain valve and chip detector for:
Damaged threads No damaged threads Total thread damage does Rethread with same size
not exceed 1/2 of one die. Break burrs with hard
thread stone.
Disassemble and check No defects Not repairable Replace valve and chip
valve plunger for freedom detector.
of movement
Hexagon surfaces Scratches Nicks and burrs Remove burrs and nicks
with hard stone or 400 −
600 grit abrasive paper.
Electrical connection for No defects Not repairable Replace valve and chip
security detector.
Breather−filler− assembly for:
Obstructed orifice Unobstructed orifice Orifice may be cleaned Clean orifice (Ref. Oil
Breather Filler Assy).
Damaged threads No damaged threads Total thread damage does Rethread with same size
not exceed 1/2 of one die. Break burrs with hard
thread stone.
Liquid level plug for:
Broken or clouded sight No clouding, breaks or Not repairable Replace plug.
face cracks
Table 203. Detailed Inspection − Components of Output Gearshaft Assembly

Inspect Index No. Maximum Maximum
(Ref. Figure 201) Serviceable Limits Repairable Limits Corrective Action
Output Gearshaft assembly for:
Damaged splines No broken or chipped Not repairable Replace transmission.
splines
Wear If wear is evident, check Not repairable Replace transmission.
dimensions shown in
Figure 201.
Grooved oil seal journal or No wear Groove not exceeding Install or replace protective
damaged protective sleeve 0.005 inch (0.127 mm) sleeve (Ref. Para .8.A.)
depth
Surface corrosion in area 1 Not serviceable if surface Repair to conform to Repair (Ref. Minor Nicks,
(Figure 201) corroded Figure 201 Scratches, and Corrosion).
Page 204
MAINTENANCE MANUAL
REJECT ACCEPT
SCORING WILL APPEAR AS ABRASIONS AT THE TOP OF THE TOOTH LIGHT SCORING IS ACCEPTABLE WHEN, AFTER POLISHING WITH NO.
PROFILE. REJECT WHEN THE ABRADED AREA IS CONTINUOUS. 600 ABRASIVE PAPER, THE CONDITION APPEARS AS SEPARATED
BURNISHED SPOTS.
SPALLING WILL APPEAR AS IRREGULAR SHAPED CRATERS WHEN SEPARATED PITTTING IS ACCEPTABLE IF THE CROSS SECTION OF
MATERIAL HAS FLAKED OFF AND IS USUALLY ACCOMPANIED BY THE PITS DOES NOT EXCEED 0.010 INCH (0.254 MM) OR THE
CONCENTRATED PITTING. DISTANCE BETWEEN PERIMETERS IS 0.060 INCH (1.524 MM) MINIMUM.
WEAR IS USUALLY ACCOMPANIED BY CONCENTRATED PITTING.

REJECT WHEN THERE IS CONNECTED PITTING OR THERE IS A
STEP AT THE EDGE OF THE WEAR PATTERN.
H63−203
Figure 201. Serviceability Criteria − Gear Teeth of Output Shaft
Page 205
MAINTENANCE MANUAL
4. Cleaning (3). Mask identification plate and warning

plate.
Consumable Materials (4). Feather-edge any chipped or peeling
(Ref. Section 91−00−00) paint, using abrasive paper (CM801)
Item Nomenclature and crocus cloth (CM803).
CM318 Primer
(5). Clean all surfaces thoroughly, using a
1:1 mixture of MPK (CM219) and
Most cleaning solvents are isopropyl alcohol (CM217); dry with
WARNING flammable and must be kept clean lint free cloth (CM803) or com
away from heat or open flame. Avoid pressed air.
inhalation of fumes and extended con
tact with skin. B. Exterior Paint Touchup
Do not spin or touch outer races Touchup exterior surfaces when required as
CAUTION of bearings after cleaning. Roll follows:
ing surfaces of bearings will be damaged. (1). Prepare surface (Ref. Surface Prepara
Apply thin coat of lubricant (CM126) to each tion steps (1). thru (5).)
bearing after cleaning and wrap in clean lint
free cloth (CM803). (2). Apply one coat of wash primer (CM303)
to bare metal surface; allow to dry
Clean using standard shop practices and thoroughly.
approved cleaning solvents/agents prior to
inspection. (3). Apply one coat of epoxy primer (CM214)
to primed surface; allow to dry thor
5. Painting oughly.
NOTE: Allow first coat of paint to dry four
Consumable Materials hours before applying second coat.
Item Nomenclature (4). Apply two coats of epoxy-polyamide
CM318 Primer paint (CM304) to primed surface.
C. Complete Exterior Painting
Paint the transmission as required according
Paint complete transmission exterior when
to the following paragraphs.
required, as follows:
Do not paint mounting surfaces,
CAUTION holes or pads on main housing.
(1). Perform all procedures in surface
preparation (Ref. Surface Preparation).
Do not paint shaft extensions. Do not paint
liquid plug window or terminal threads on (2). Apply one coat of wash primer (CM303)
valve and ship detector. Do not paint input to surface of main housing and bearing
and output seals. retainers; allow to dry thoroughly.
A. Surface Preparation (3). Apply one coat of epoxy primer (CM214)
to surface of main housing and bearing
Prior to painting, prepare surfaces as follows: retainers; allow to dry thoroughly.
(1). Mask all exposed gearshafts, input and (4). Apply one thin coat of epoxy-polyamide
output seals, mounting surfaces, holes paint (CM304); allow to dry four hours.
and pads on housing with masking tape
(CM729). (5). Apply second coat of epoxy-polyamide
paint (CM304); allow to dry four hours.
(2). Mask window of liquid level plug (5,
Figure 204) and threads on drain valve (6). Remove all masking tape after paint is
and chip detector (6). thoroughly dry.
Page 206
MAINTENANCE MANUAL
6. Tail Rotor Transmission Parts NOTE: Some models use an adapter with an
Repair/Replacement additional O-ring. On those models, install
adapter with O-ring, then install breather-
(Ref. Figure 202) filler.
Consumable Materials C. Oil Breather−Filler

Item Nomenclature
NOTE: If oil breather-filler assembly becomes
clogged, use light air pressure, approxi
CM114 Petrolatum mately 5 psig (34 kPa) or a 0.125 inch (3.175
CM217 Isopropyl alcohol mm) dia. rod applied into the threaded end
CM311 Coating, logo white / Thinner to dislodge debris. Ultrasonically clean
CM702 Lockwire CRES breather in isopropyl alcohol (CM217) for
ten minutes.
NOTE: Replace liquid level plug, chip detector Torque breather-filler to 45—55 inch-lbs
and breather-filler using torque values in (5.08—6.21 Nm). Safety with lockwire
following paragraphs. Lubricate mating (CM702).
bores of O-rings with petrolatum (CM114)
to prevent damage to O-rings. Repair other D If equipped with a 369A5429 breather, hole
components or replace tail rotor transmis in breather filler must be directed rearward
sion oil seals. at final torque. Locating vent at any angle
aft of output shaft centerline (viewed from
A. Chip Detector above) adequately directs vent rearward.
(1). Torque valve body 50—60 inch- D One or two washers can be added between
pounds (5.65—6.78 Nm). O-ring and breather flange (one washer
(2). Torque chip detector 40—50 inch- changes orientation by approximately 100
pounds (4.52—5.65 Nm).Safety with degrees).
lockwire (CM702).
D. Damaged Inserts
NOTE: If level-lines and lettering of liquid lev
el plug cannot be made parallel with axis of Remove and replace damaged threaded inserts
transmission output shaft when plug is (28, 29, Figure 206) using standard removal
torqued within range, clean glass by firmly procedures and manufacturers instructions.
rubbing with soft cloth, then mix white coat
(1). Replace slightly loose inserts with the
ing (CM311) with equal amount of thinner
same size inserts and secure with grade
and apply lines and lettering.
A locking compound (29, Table 902).
B. Liquid Level Plug
(2). When mating threads are damaged to
Torque liquid level plug to 50—60 inch-lbs an extent that locking compound cannot
(5.65—6.78 Nm). Safety with lockwire be used satisfactorily, replace with the
(CM702). next oversize insert.
Page 207
MAINTENANCE MANUAL
LIQUID LEVEL PLUG BREATHER-FILLER

BREATHER-FILLER
(4-BLADED T/R) O-RING
O-RING
O-RING ADAPTER
O-RING
LIQUID
LEVEL PLUG
(2-BLADED T/R)
SEE SHEET 2
INPUT SHAFT
OUTPUT SHAFT
0.04 INCH
0.046 IN. (1.1684 MM) 0.10 INCH (2.54 MM) (1.016 MM)
LINE-WIDTH (TYP) HIGH LETTERS (TYP) (TYP)
0.34 INCH
(8.636 MM)
FULL FULL
AXIS OF PINION
0.406 IN. ADD
(10.3124 MM) ADD
AXIS OUTPUT SHAFT

0.10 INCH (2.54 MM) 0.06 INCH
0.06 IN. ALTERNATE HIGH LETTERS (TYP) (1.524 MM)
(1.524 MM)
LIQUID LEVEL PLUG MARKINGS (4-BLADED T/R)
DRAIN
HOLE
INPUT SHAFT BREATHER

HOLE
BREATHER-FILLER
OUTPUT SHAFT
85°
85°
BREATHER HOLE ORIENTATION

G63-2510-202-1
Figure 202. Replacement of Liquid Level Plug and Breather−Filler (Sheet 1 of 2)
Page 208
MAINTENANCE MANUAL
0.380 INCH
(9.652 MM)
0.750 INCH
(19.050 MM)
0.125 INCH (3.175 MM)
HIGH LETTERS (3 PL)
0.187 INCH (4.7498 MM) SPACE (2 PL)
FILL
TOP
TO
NOTE
AXIS OF INPUT GEAR
NOTE:
369D25300-501 ARE MARKED FILL TO TOP.
369D25300-BSC, -11 ARE MARKED FILL TO CTR.
G63-2510-202-2
Figure 202. Replacement of Liquid Level Plug and Breather−Filler (Sheet 2 of 2)
7. Input Gearshaft Cover Oil Leak Repair The procedures that follow cover repair of
output gearshaft using speedi-sleeve under
Contact Field Service Representative for the following conditions:
further instructions (Ref. 01-00-00, Table
201).
(1). Output shaft did not have a spee
di-sleeve installed and has wear within
8. Output Gearshaft Cover Oil Leak Repair
limits specified in Table 203.
(Ref. Figure 204)
(2). Output shaft has speedi-sleeve in
Repair oil leaks at output gearshaft cover by stalled with plastic steel adhesive
installing a protective sleeve (Speedi-Sleeve) (CM436) and is worn or damaged
on the gearshaft area contacted by the oil seal within limits specified in Table 203.
lip.
A. Protective Sleeve (Speedi−Sleeve) Output gearshaft (Figure 204) seal journal

Installation wear, caused by rubbing of the output cover
seal lip, which does not exceed 0.005 inch
(0.127 mm) depth, may be repaired by install
Consumable Materials ing a protective sleeve (Speedi-Sleeve) over
(Ref. Section 91−00−00) the damaged area.
Item Nomenclature
CM114 Petrolatum (3). Replacement of worn or damaged
CM217 Isopropyl alcohol original factory installed Speedi-Sleeve
on output shaft.
Page 209
MAINTENANCE MANUAL
Use care not to cut into or dam (7). Clean shaft sleeve mating surface with
CAUTION age gearshaft when removing lint free cloth dampened with dry
damaged sleeve. cleaning solvent (CM234).
NOTE: Disregard steps (4). thru (6). for initial
installation of protective sleeve (Spee (8). If seal journal on shaft is worn
di-Sleeve). (grooved) and groove does not exceed
0.005 inch (0.127 mm) depth, apply a
(4). Use file or other suitable instrument to light coat of plastic steel (CM436) to
cut through edge of sleeve. Carefully shaft-sleeve mating surface.
pry/cut edge away from shaft.
(5). Grasp raised edge with pliers and peel (9). If seal journal is not worn apply surface
damaged sleeve off shaft. primer (CM321) on shaft-sleeve mating
surface. Allow primer to air dry at
(6). Remove any plastic steel (CM436) or ambient temperature for a minimum of
locking compound residue from shaft 30 minutes. Then apply locking com
using the following methods: pound (CM431) to shaft-sleeve mating
(a). Remove plastic steel residue from surface.
shaft using lint free cloth dampened
with dry cleaning solvent (CM234). (10). While plastic steel or locking compound
Use care when using stainless (whichever is used) is wet, install new
CAUTION steel brush not to remove exces speedi-sleeve on shaft flange down, and
sive plating from shaft. press or tap into place using a 1-1/4
inch pipe bottomed on flange of sleeve.
(b). Remove any residual locking com Unflanged end of sleeve must be even
pound from shaft with a stainless with outboard end of 1.088—1.090 inch
steel bristle tooth brush. Clean shaft (2.764—2.769 cm) diameter portion of
with a lint free cloth dampened in shaft. Tap end of pipe with hammer or
locking compound remover (CM216). mallet as necessary to correctly position
sleeve on shaft. Wipe any excess plastic
(c). Apply protective sleeve (Spee steel or locking compound from shaft
di-Sleeve) adhesives according to the using a clean lint free cloth.
following two methods:
NOTE: NOTE: Leave the protective sleeve (Spee
D If seal journal of gearshaft is worn di-Sleeve) flange intact unless clearance is
(grooved) proceed to step (8). required.
D For initial installation or replacement of
protective sleeve (Speedi-Sleeve) on gear (11). If necessary use side cutters to clip
shaft without evidence or wear proceed to flange and peel away from shaft along
step (9). notch line.
Page 210
MAINTENANCE MANUAL
B. Output Gearshaft Seal Installation (a). Remove seal (10) and packing (12).
Thimble
(b). Apply light coat of petrolatum to
Fabricate an output gearshaft seal installation outer surface of seal installation
thimble (CM803) as shown in Figure 203. thimble and place thimble over
splined portion of output gearshaft
C. Output Shaft Seal Replacement assembly.
(Ref. Figure 204) (c). Apply light coat of petrolatum
(CM114) to lip and faces of oil seal
(10).
(Ref. Section 91−00−00) (d). Install output cover assembly (11)
Item Nomenclature and clamp-up shim over seal instal
CM114 Petrolatum lation thimble and gearshaft.
CM217 Isopropyl alcohol (e). Remove seal installation thimble.
(f). Install washers (8) and bolts (9).
(1). Remove three bolts (9), washers (8), Torque bolts to 65—75 inch-lbs
output cover (11) and clamp-up shim(s) (7.34—8.47 Nm).
(20).
(g). Safety wire three output cover bolts
(2). Secure output cover assembly (11) in (9) together. Run twisted safety wire
suitable holding device. around cover boss.
5.04 INCH (12.80 CM) + 0.06 INCH (1.524 MM)
0.75 INCH (19.05 MM)

±0.06 INCH (1.542 MM) 1.128-1.138 INCH
(2.865-2.891 CM)
1.094 INCH
(2.779 CM)
DIAMETER
15° + 2°
SMOOTH
TRANSITION
NOTE: MATERIAL: C 1018 STEEL ROD

1. 125 MICRO - INCH SURFACE FINISH. SIZE: 1.250 INCH (3.175 CM) DIAMETER H63-2026A
Figure 203. Output Gearshaft Seal Installation Thimble − Fabrication
Page 211
MAINTENANCE MANUAL
2
3
7
5 6
4
ROTATED
TAIL ROTOR OUTPUT

GEARBOX (REF) GEARSHAFT
ASSEMBLY (REF) 8
13 9
SHIM (REF)
12
11
10
G63-2510-205-1
1. BREATHER−FILLER ASSEMBLY 8. WASHER (3)

2. WASHER 9. BOLT (3)
3. PACKING 10. SEAL
4. PACKING 11. OUTPUT COVER
5. LIQUID LEVEL PLUG 12. PACKING
6. DRAIN VALVE AND CHIP DETECTOR 13. SPEEDI−SLEEVE
7. PACKING
Figure 204. 369D25400 Tail Rotor Transmission Assembly
Page 212
MAINTENANCE MANUAL
9. Tail Rotor Transmission Housing Do not remove material in

Assembly Repair/Rework (PN 369D25401) WARNING excess of specified dimen
sion.
(Ref. Figure 206) (b). Blend chamfer into existing radius at

the bottom and radius it at the top.
Width of chamfer must be
An interference condition can exist between 0.060—0.090 inch (1.524—2.286
the tail rotor transmission housing and the tail mm).
rotor control bellcrank with the tail rotor pedal
at extreme right position. The following (c). Apply surface touchup treatment
procedure provides inspection criteria and (Ref. Sec. 20-30-00).
rework instructions, if necessary, for the tail (4). Record compliance of this rework in the
rotor transmission housing to correct this aircraft logbook.
condition should it exist.
AXIAL PLAY 0.005 IN.
(0.127 MM) MAX
(1). With assistance, depress and hold right
tail rotor pedal to extreme right
position and inspect web area of tail
SIDE PLAY 0.004 IN.
rotor transmission housing that comes (0.102 MM) MAX
in close contact with tail rotor control
bellcrank. If adequate clearance exist
between transmission housing and
control bellcrank, no rework action is
necessary.
(2). Sign off aircraft logbook to indicate

completion of this inspection.
(3). If contact occurs, rework tail rotor

transmission housing as follows:
G63-2023A
(a). Chamfer the web on transmission
housing to dimensions shown in Figure 205. Tail Rotor Transmission Mount
Figure 206. Stud Limits
Page 213
MAINTENANCE MANUAL

A
0.350 IN. (8.89 MM) MIN.

A
REWORK AREA
(END VIEW)
0.500 IN.
REWORK AREA (12.70 MM) R
OUTPUT SHAFT
0.060-0.090 IN.
(1.524-2.286 MM) X 45°
BLEND INTO
EXISTING RADIUS TAIL ROTOR
HOUSING
ASSEMBLY
G63-2017A
Figure 206. Rework of Tail Rotor Transmission Housing Assembly

10. Tail Rotor Transmission Stripping chip detector stud during handling,
shipping or storage.
(Ref. Figure 207)
11. Tail Rotor Transmission Buildup
NOTE: Stripping of the tail rotor transmission
is not required following its removal from (Ref. Figure 207)
the helicopter. Do the following stripping
procedure if in preparation for transmission
shipment or storage only. Consumable Materials
Item Nomenclature
(Ref. Section 91−00−00) CM111 Grease, aircraft
Item Nomenclature CM112 Anti-seize compound high temperature
CM208 Barrier material
(1). Coat coupling splines with grease

(1). Remove coupling bolt and coupling from (CM111) and coupling bolt threads with
input shaft. anti-seize compound (CM112) before
re-assembly.
NOTE: For tail rotor transmission replace
ment, further stripping is not required. A re (2). Install coupling and bolt:
placement transmission is equipped with all
other accessories. (a). Torque coupling bolt to 250—300
(2). Drain oil from transmission (Ref. Sec. inch-pounds (28.25—33.90 Nm)
12-00-00). Residual operating lubri plus drag torque.
cant is approved internal preservative
for shipping or storage. (b). Check coupling bolt for drag torque
serviceability of 25 inch-pounds
(3). Wrap transmission in barrier material (2.82 Nm) minimum, 200 inch-
(CM208) to protect shaft splines and pounds (22.60 Nm) maximum.
Page 214
MAINTENANCE MANUAL
TRANSMISSION
COUPLING (BENDIX) FAILSAFE
(CAUTION: DO NOT LIFT COUPLING BOLT
ASSEMBLY FROM FLANGE)
FAILSAFE
SOCKET
COUPLING BOLT
OUTPUT SHAFT
BREATHER FILLER
COUPLING
(KAMATIC)
INPUT SHAFT
LIQUID LEVEL
PLUG
CHIP DETECTOR
2-BLADED TAIL ROTOR TRANSMISSION
LIQUID LEVEL
PLUG
CHIP DETECTOR
4-BLADED TAIL ROTOR TRANSMISSION
G63-2014
Figure 207. Tail Rotor Transmission − Stripping/Buildup
Page 215
MAINTENANCE MANUAL
Page 216
MAINTENANCE MANUAL
Section
63−25−30
NOTAR )
Fan Transmission
(500/600N)
MAINTENANCE MANUAL
NOTAR® ANTI−TORQUE SYSTEM FAN TRANSMISSION

1. Fan Transmission B. Fan Transmission Installation
The function of the fan transmission is to step (Ref. Figure 201)
up RPM from the main transmission output to
the fan via fan drive shaft, gears, and intercon Do not carry or support trans
CAUTION mission by coupling as damage
nect shaft. The transmission housing is made
of magnesium, and contains input and output can occur to coupling. During performance
gear shafts, two angular contact bearings, of maintenance on transmission, use extra
coupling, seals, packings, output cover assy, care to keep contaminants such as paint,
chip detector, sight glass, and oil breather dirt etc from areas around input and output
assembly. shaft seals.
2. Fan Transmission Replacement (1). Install fan drive shaft (Ref. Sec.
63-15-30).
Remove and install fan transmission according
to the following procedures. (2). Locate and align transmission with
mounting holes on helicopter. Install
A. Fan Transmission Removal four bolts and washers on transmission.
Torque bolts to 70—90 inch pounds
(Ref. Figure 201) (7.90—10.17 Nm); torque-stripe bolts.
(1). Remove inlet screen, inlet fairing,
(3). Connect previously identified chip
engine plenum access cover, and fan
detector wires.
hub transmission fairing (Ref. Sec.
53-30-30). (4). Remove cap and connect drain line on
(2). Remove tailboom (Ref. Sec. 53-40-30). elbow at bottom of transmission.
(3). Drain fan transmission of oil. Discon (5). Install fan interconnect shaft (Ref. Sec.
nect drain line and cap elbow at bottom 63-15-30).
of transmission. (6). Install fan pitch control rod (Ref. Sec.
(4). Remove fan drive shaft (Ref. Sec. 67-20-30).
63-15-30). (7). Drain any residual preservative oil (if
(5). Remove fan pitch control rod (Ref. Sec. new transmission) and service with
67-20-30). lubricating oil (Ref. Sec. 12-00-00).
(6). Remove fan interconnect shaft (Ref. (8). Install fan hub transmission fairing
Sec. 63-15-30). (Ref. Sec. 53-30-30).
NOTE: Identify chip detector wires for future (9). Install engine plenum access cover (Ref.
re-installation. Sec. 53-30-30).
(7). Disconnect chip detector wires. (10). Install engine inlet fairing (Ref. Sec.
53-30-30).
(8). Remove four transmission mounting
bolts, washers, and transmission from (11). Install inlet screen (Ref. Sec.
helicopter. 53-30-30).
Page 201
MAINTENANCE MANUAL
BOLT
(4 PL)
WASHER
(4 PL)
FAN TRANSMISSION
SUPPORT ASSY
FAN TRANSMISSION
BULKHEAD
G63-2024
Figure 201. Fan Transmission Removal/Installation
Page 202
MAINTENANCE MANUAL
3. Fan Transmission Inspection NOTE: Replace liquid level plug, chip detector,
and breather assy using torque values in the
(1). Check transmission for leaks, cracks, following paragraphs. Lubricate O‐rings
and corrosion. To evaluate oil leakage with petrolatum (CM114) to prevent dam
refer to Component Fluid Leak Analy age to O‐rings. Repair other components or
sis (Ref. Sec. 12-00-00). For further replace transmission oil seals if required
inspection criteria, please contact (Ref. COM).
MDHC Customer Support Department.
4. Tube Support Inspection (1). Chip Detector Torque valve body (large
hex) to 50—60 inch pounds
(1). Inspect mount bolts for security and (5.65—6.78 Nm) or 40—50 inch
corrosion, lockwire intact. pounds (4.52—5.65 Nm) (smaller
hex).
(2). Inspect tube support for dents,
scratches, nicks, gouges and corrosion, (2). Liquid Level Plug Torque liquid level
none allowed. plug to 50—60 inch pounds
(3). Inspect for visible step in splined area. (5.65—6.78 Nm). If level lines and
lettering of liquid level plug cannot are
(4). If step is evident: not parallel with axis of transmission
output shaft when torqued within
(a). Measure between splines using 50—60 inch pound (5.65—6.78 Nm)
0.0864 in. (2.19456 mm) diameter range, clean glass by firmly rubbing
pins. with soft cloth, then mix white coating
(b). Maximum measurement between (CM311) with equal amount of thinner
pins is 0.390 in. (9.906 mm). and apply lines and lettering. Safety
with lockwire (CM702).
5. Fan Transmission Parts Replacement
(3). Oil Breather Assy Torque breather
(Ref. Figure 202) assy to 45—55 inch pounds
(5.08—6.21 Nm). Ensure breather hole
Consumable Materials is facing up. Safety with lockwire
(Ref. Section 91−00−00) (CM702).
Item Nomenclature
CM114 Petrolatum
NOTE: If oil breather assy becomes clogged,
use light air pressure, approximately 5 psig
CM217 Isopropyl alcohol (34 kPa) or a 0.125 inch (3.175 mm) dia. rod
CM311 Coating, logo white / Thinner applied into the threaded end to dislodge de
CM702 Lockwire CRES bris. Ultrasonically clean breather in iso
propyl alcohol (CM217) for ten minutes.
Page 203
MAINTENANCE MANUAL
BREATHER
O-RING
CHIP
DETECTOR
VALVE
LIQUID
LEVEL
PLUG O-RING
O-RING
VALVE
O-RING
0.10 IN. (2.54 MM)

LETTER HEIGHT (TYP)
0.046 IN.
(1.1684 MM)
LINE WIDTH
(TYP)
AXIS OUTPUT SHAFT
0.406 IN. ROTATED VIEW

(10.3124 MM)
LIQUID LEVEL PLUG MARKINGS
0.060 IN.
(1.524 MM) G63−2025A
Figure 202. Fan Transmission Parts Replacement
Page 204
MAINTENANCE MANUAL
Section
63−30−00
Main Rotor Static
Mast (369D/E/FF −
500/600N)
MAINTENANCE MANUAL
MAIN ROTOR STATIC MAST

1. Main Rotor Static Mast (1). Apply silicone sealant (CM430) on
bottom surface of mast tube and base at
(Ref. Figure 201) The main rotor mast provides drive shaft opening to seal base to mast
support for the main rotor, main transmission support structure at installation.
and drive shaft, and consists of an assembled
machined steel tube with a machined alumi
num forged base. (2). Position main rotor mast so that holes
in base align with holes in mast support
2. Main Rotor Static Mast Replacement structure.
(369D25100 Transmission Installation)
A. Main Rotor Static Mast Removal (3). Install holddown bolts, washers and
(369D25100 Transmission Installation) mast mounting nuts; torque nuts to
700—820 inch-pounds (79.09—92.65
(Ref. Figure 201) Nm).
Main rotor mast is highly
CAUTION stressed. Do not allow tools to (4). Check underside of mast support
strike mast or mast to strike any object. Any structure at left aft stud hole location.
impact damage can require replacement of Stud-to-pan doubler surface must be
mast. clean to bare metal for electrical
bonding. Install main transmission
(1). Remove main rotor hub (Ref. Sec. mounting studs, plate spacers and nuts.
62-20-00/60). Torque studs to 160—190 inch-
pounds (18.08—21.47 Nm).
(2). Remove main rotor controls (Ref. Chap.
67).
(5). Using 0.0010-0.0015 inch
(3). Remove main transmission (Ref. Sec. (0.254-0.0381 mm) feeler gage, check
63-20-00/25). for gap between self-locking nuts and
plate spacers. No gap is allowed.
(4). Remove four studs, washers and nuts.
NOTE: Nuts securing studs have left-hand (6). If gap exists, remove nut and replace
threads. with new self-locking nut. Torque studs
into replacement nuts to 160—190
(5). Remove shaft support holddown nuts,
inch-pounds (18.08—21.47 Nm) and
washers and bolts.
repeat step (5). above. Continue until
(6). Lift main rotor mast from helicopter. each nut is flush against its spacer.
Seal bare bond area with clear lacquer
B. Main Rotor Static Mast Installation (CM306).
(369D25100 Transmission Installation)
(Ref. Figure 201) (7). Install main transmission (Ref. Sec.
63-20-00/25).
(Ref. Section 91−00−00) (8). Install main rotor controls (Ref. Chap.
Item Nomenclature 67).
CM306 Lacquer, clear
CM430 Sealant, solvent resistant (9). Install main rotor hub (Ref. Sec.
62-20-00/60).
Page 201
MAINTENANCE MANUAL
HUB SLEEVE BEARING

SURFACE
MAIN ROTOR MAST
NUT PLATE
(LEFT-HAND SPACER
TAPE THREADS)
MAST
BASE
RIVET
MAST SUPPORT
STRUCTURE PAN
NOTE 2
DRAIN
HOLE
TUNNEL BEAM WEB

MAST SUPPORT FITTING
MAST MOUNTING
NUT
MAIN TRANSMISSION
MOUNTING STUD
NOTE 1
AFT BULKHEAD
CHANNEL
TUNNEL BEAM
SIDE-CHANNEL WATERLINE 34.00
WATERLINE 45.36
NOTES:
1. THIS STUD REQUIRES ELECTRICAL BOND TO STRUCTURAL PAN.
2. MAIN ROTOR MAST IS SEALED TO STRUCTURE PAN (INSIDE MAST
G63-3000A
TUBE AT BASE) WITH SILICONE RUBBER (CM430).
Figure 201. Main Rotor Mast and Support Structure (369D25100 Transmission Installation)
Page 202
MAINTENANCE MANUAL
3. Main Rotor Static Mast Replacement (4). Using 0.0010-0.0015 inch

(369F5100 Transmission Installation) (0.0254-0.0381 mm) feeler gage, check
for gap between self-locking nuts and
(Ref. Figure 202) plate spacers. No gap is allowed.
A. Main Rotor Static Mast Removal (5). If gap exists, remove nut and replace
(369F5100 Transmission Installation) with new self-locking nut. Torque bolts
into replacement nuts to 160—190
Main rotor mast is highly inch-pounds (18.08—21.47 Nm) plus
CAUTION stressed. Do not allow tools to drag torque and repeat step e. above.
strike mast or mast to strike any object. Any Continue until each nut is flush against
impact damage can require replacement of its spacer. Seal bare bond area with
mast. clear lacquer (CM306).
(1). Remove main rotor hub (Ref. Sec. (6). Install main transmission (Ref. Sec.
62-20). 63-25).
(2). Remove main rotor controls (Ref. Sec. (7). Install main rotor controls (Ref. Sec.
67-10). 67-10).
(3). Remove main transmission (Ref. Sec. (8). Install main rotor hub (Ref. Sec.
63-25). 62-20).
(4). Remove four bolts, washers and nuts. 4. Main Rotor Static Mast Inspection and
Repair
(5). Lift main rotor mast from helicopter.
(Ref. Figure 203)
(369F5100 Transmission Installation) Consumable Materials
Consumable Materials Item Nomenclature
(Ref. Section 91−00−00) CM115 Grease, oscillating bearing
Item Nomenclature CM234 Solvent, dry-cleaning
CM306 Lacquer, clear CM235 Cleaner
CM430 Sealant, solvent resistant CM304 Enamel, epoxy
CM305 Lacquer, acrylic
(1). Apply silicone sealant (CM430) on CM318 Primer
bottom surface of mast tube and base at CM323 Primer
drive shaft opening to seal base to mast CM713 Tape, pressure sensitive
support structure at installation. CM802 Abrasive cloth, aluminum oxide
CM803 Crocus cloth
(2). Position main rotor mast so that holes
in base align with holes in mast support
structure. (1). Inspect all areas of main rotor mast for
cracks, nicks, scratches and evidence of
(3). Check underside of mast support impact damage.
structure at left aft stud hole location.
Stud-to-pan doubler surface must be (2). Inspect bearing surfaces for scoring and
clean to bare metal for electrical galling.
bonding. Install main transmission
mounting bolts, plate spacers and nuts. (3). Inspect threads for damage.
Torque nuts to 160—190 inch-pounds
(18.08—21.47 Nm) plus drag torque. (4). Inspect threads for damage.
Page 203
MAINTENANCE MANUAL
(5). Check that tape (Ref. Figure 201) on (b). Remove main transmission (Ref. Sec.
forward edge of mast tube is secure and 63-20-00 or 63-20-25, Main Trans
undamaged; replace if defective. mission Replacement).
(a). Peel defective tape from mast. (c). Remove static mast (Ref. Main Rotor
(b). As required, polish area to remove Static Mast Replacement).
burrs and sharp areas with abrasive
cloth (CM802) or crocus cloth (d). Thoroughly clean interior tube with
(CM803). Solvent (CM234).
(c). Clean mast thoroughly with cleaner (e). Inspect for any corrosion, none
(CM235) and allow to dry. allowed.
(d). Apply primer (CM318) and paint (f). Remove paint from bad areas and
(CM305) to affected area. lightly feather paint edge with crocus
(e). Apply pressure sensitive tape cloth (CM803), remove any residue
(CM713) to mast. from feathering.
NOTE: To inhibit corrosion of mast when oper (g). Apply primer (CM318), or (CM323),
ating in salt water environment, check tape to repair areas.
at frequent intervals. Also, apply thin
grease film (CM115) to bearing journals. (h). Allow to cure per manufacturer's
instructions.
(6). Inspect internal bore for paint chipping,
orange peeling or flaking, none allowed. (i). Apply white paint (CM304) to
internal bore of mast.
NOTE: Chipping, orange peeling or flaking
paint will normally be at the base of the (j). Allow to cure per manufacturer's
static mast tube. instructions.
(7). Re-apply finish to mast internal bore
as follows: (k). Reinstall static mast.
(a). Remove main rotor hub (Ref. Sec. (l). Reinstall main transmission.
62-20-00 or 62-20-60, Main Rotor
Hub Replacement). (m). Reinstall main rotor hub.
Page 204
MAINTENANCE MANUAL
HUB SLEEVE
BEARING SURFACE
NUT
MAIN ROTOR MAST
PLATE
SPACER
TAPE
MAST
BASE
RIVET
DRAIN HOLE NOTE 2
MAST SUPPORT
STRUCTURE PAN
MAST SUPPORT
FITTING
MAST MOUNT BOLT

(NOTE 1)
NOTES:
1. THIS BOLT REQUIRES ELECTRICAL BOND TO STRUCTURAL PAN.
2. MAIN ROTOR MAST IS SEALED TO STRUCTURE PAN (INSIDE MAST
TUBE AT BASE) WITH SILICONE RUBBER (CM430). 6G63-034
Figure 202. Main Rotor Mast and Support Structure (369F5100 Transmission Installation)
Page 205
MAINTENANCE MANUAL
MAXIMUM REMOVAL
AREA REPAIRABLE OF
DAMAGE REPAIR PROCEDURE
MATERIAL (DEPTH)
POLISH DEFECTIVE AREA SMOOTH WITH

CORROSION AND 0.010 IN. ABRASIVE CLOTH (CM802 AND CM803) IF
SCRATCHES (0.254 MM) CADMIUM PLATING HAS BEEN
PENETRATED. TREAT REWORKED AREA
WITH PRIMER (CM318).
THICKNESS OF POLISH AREA SMOOTH WITH ABRASIVE

CHIPPING OF CADMIUM PLATING CLOTH (CM802 AND CM803). TREAT
CADMIUM PLATING (0.0035 IN. (0.0889 MM REWORKED AREA WITH PRIMER (CM318)
MAXIMUM) AND LACQUER (CM306).
LONGITUDINAL
SCRATCHES THAT
DO NOT
PENETRATE
THROUGH NICKEL MUST NOT
PENETRATE NICKEL POLISH AREA WITH ABRASIVE CLOTH
PLATE. SCRATCHES PLATING, 0.003-0.007 (CM802 AND CM803) TO REMOVE BURRS
MUST BE A IN. (0.076-0.178 MM) AND SHARP EDGES ONLY.
MINIMUM OF 0.25 IN. THICK
(6.35 MM) APART.
RADIAL SCRATCHES
ARE NOT
PERMITTED.
MUST NOT PENETRATE

THICKNESS OF SILVER
PLATING BY AN AREA
NO LARGER THAN 0.5
IN.2 (3.2258 CM2). NO
MORE THAN TWO WIPE AREA CLEAN USING CHEESE CLOTH
SUCH AREAS NO (CM820) DAMPENED IN ISOPROPYL
CORROSION AND CLOSER THAN 1.5 IN. ALCOHOL (CM217). SPRAY UNIFORM
SCRATCHES (3.81 CM) APART MAY COATING, 0.002-0.005 IN. (0.051-0.127 MM)
EXIST. IF WEAR THICK, ON WORN AREA WITH LUBRICANT
EXCEEDS LIMITS, (CM103).
CONTACT MDHI
AREA WARRANTY REPAIR
ENCLOSED DEPARTMENT FOR
BY MAST REWORK DISPOSITION.
BASE ONLY MDHI CAN
PERFORM PLATING
REPAIRS.
REMOVE DEFECTIVE TAPE. POLISH

DEFECTIVE AREAS TO REMOVE BURRS
CORROSION AND 0.010 IN. AND SHARP SURFACES WITH ABRASIVE
REPLACEMENT OF (0.254 MM) CLOTH (CM802 AND CM803). TOUCH UP
TAPE. REWORKED AREAS WITH PRIMER (CM318)
AND LACQUER (CM305). REPLACE TAPE
(CM713).
NOTE: FOR MAGNETIC PARTICLE INSPECTION,

REMOVE PAINT FROM APPLICABLE SURFACE
G63−3001B
Figure 203. Main Rotor Mast − Inspection and Repair
Page 206
MAINTENANCE MANUAL
Chapter
64
Anti−Torque
Assembly
MAINTENANCE MANUAL
TABLE OF CONTENTS
64-00-00 Anti-Torque Assembly (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . A

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Tail Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Anti-Torque Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Troubleshooting Tail Rotor and Vibrations . . . . . . . . . . . . . . . . . . . . . . . 101
64-00-05 Four-Bladed Tail Rotor Assembly Initial Installation (369D/E) . . . . . . . A
1. Four-Bladed Tail Rotor Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Tail Rotor and Transmission Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Existing Tail Rotor and Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Four-Bladed Tail Rotor Transmission Build-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Drive Shaft, Tail Rotor Transmission and Tail Rotor Installation . . . . . . . . . . . . . 901
Figure 901. Tail Rotor Index Stripe Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 902
E. Tail Rotor Control Over-Center Trim System Rework . . . . . . . . . . . . . . . . . . . . . . . 903
F. Two-Bladed Over-Center Trim System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
G. Four-Bladed Over Center Trim System Initial Installation . . . . . . . . . . . . . . . . . . 903
Figure 902. Over Center Trim System Installation . . . . . . . . . . . . . . . . . . . . . . . . . 904
H. Four-Bladed Tail Rotor Controls Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
I. Horizontal Stabilizer Tip Weight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
J. N2 and NR (Rotor) Tachometer Indicator Replacement . . . . . . . . . . . . . . . . . . . . . 906
K. Four-Bladed Tail Rotor System Completion of Installation . . . . . . . . . . . . . . . . . . 906
L. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Figure 903. Bracket Installation - Sta. 78.50 Canted Wall . . . . . . . . . . . . . . . . . . 908
64-10-00 Tail Rotor Blades (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Tail Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Tail Rotor Blade Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Abrasion Strip Dye Penetrant and Tap Test Inspection . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Tail Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Inspection of Tail Rotor Blade Abrasion Strip . . . . . . . . . . . . . . . . . . . 203
4. Tail Rotor Blade Tip Cap Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203. Installation of Tip Cap-To-Tail Rotor Blade Rivets . . . . . . . . . . . . . . 205
5. Tail Rotor Blade Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Tail Rotor Abrasion Strip Riveting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 204. Tail Rotor Blade Abrasion Strip Riveting . . . . . . . . . . . . . . . . . . . . . . . 208
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MAINTENANCE MANUAL

7. Tail Rotor Blade Abrasion Strip Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

8. Tail Rotor Blade Protective Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 205. Tail Rotor Blade Abrasion Strip Modification . . . . . . . . . . . . . . . . . . . 211
9. Tail Rotor Blade Leading Edge Crack Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
A. Tail Rotor Blades with New-Style Abrasion Strips . . . . . . . . . . . . . . . . . . . . . . . . . 212
B. Tail Rotor Blades with Old-Style Abrasion Strips . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Figure 206. Tail Rotor Blade Leading Edge Crack Inspection . . . . . . . . . . . . . . . . 214
64-20-00 Tail Rotor Hub and Fork (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Tail Rotor Hub and Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Tail Rotor Hub and Fork Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Tail Rotor Hub and Fork Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Tail Rotor Hub and Strap Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Tail Rotor Hub and Fork Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Hub and Fork Assembly Installation (Two-Bladed) . . . . . . . . . . . . . . 204
Figure 203. Hub and Fork Assembly Installation (Four-Bladed) . . . . . . . . . . . . . 205
3. Tail Rotor Hub and Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4. Conical Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5. Elastomeric Fork Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 204. Blade Flapping Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Elastomeric Bearing Care and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
64-25-30 Anti-Torque Fan (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Anti-Torque Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Anti-Torque Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Anti-Torque Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Anti-Torque Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Anti-Torque Fan Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Anti-Torque Fan Blade Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Anti-Torque Fan Blade Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Anti-Torque Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
4. Fan Blade Strap and Pitch Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Fan Blade Strap and Pitch Horn Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Fan Blade Strap and Pitch Horn Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
5. Retention Plate and Pitch Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Retention Plate and Pitch Plate Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Page ii
MAINTENANCE MANUAL

B. Retention Plate and Pitch Plate Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

6. Support Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Support Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Support Shaft Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
7. Fan Balance Stud Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Fan Balance Stud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Fan Balance Stud Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 402. Anti-Torque Fan Support Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
8. Pitch Horn Counterweight Set Screw Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 403. Pitch Horn Counterweight Set Screw Replacement . . . . . . . . . . . . . . 407
1. Anti-Torque Fan Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Support Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Anti-Torque Fan Liner (Felt Metal Seal) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4. Fan Blade Inspection (100-Hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
5. Fan Pitch Slider Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Anti-Torque Fan Liner (Felt Metal Seal) Replacement . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Anti-Torque Fan Liner (Felt Metal Seal) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 801
B. Anti-Torque Fan Liner (Felt Metal Seal) Installation . . . . . . . . . . . . . . . . . . . . . . . 801
C. Anti-Torque Fan Liner (Felt Metal Seal) Machining . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Anti-Torque Fan Liner (Felt Metal Seal) . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 802. Anti-Torque Fan Liner Felt Metal Seal Machining . . . . . . . . . . . . . . 803
2. Anti-Torque Fan Bearing Regreasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 803. Fan Bearing Regreasing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 804. Fan Bearing Regreasing Tool (ST614) . . . . . . . . . . . . . . . . . . . . . . . . . . 807
64-30-00 Tail Rotor Pitch Control Assembly (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . A
1. Tail Rotor Pitch Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Tail Rotor Pitch Control Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Tail Rotor Pitch Control Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Pitch Control Assembly - Wobble Check . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 202. Swashplate-to-Pitch Control Housing Clearance . . . . . . . . . . . . . . . 202
B. Tail Rotor Pitch Control Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Tail Rotor Pitch Control Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 203. Tail Rotor Pitch Control Assembly (Two-Bladed) . . . . . . . . . . . . . . . . 203
Figure 204. Tail Rotor Pitch Control Assembly (Four-Bladed) . . . . . . . . . . . . . . . 204
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MAINTENANCE MANUAL

4. Tail Rotor and Pitch Control Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

5. Tail Rotor Pitch Control Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Tail Rotor Blade Stop Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 205. Tail Rotor Pitch Control Arm Inspection . . . . . . . . . . . . . . . . . . . . . . . . 208
7. Tail Rotor Pitch Control Link Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8. Tail Rotor Conical Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
9. Tail Rotor Pitch Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
10. Tail Rotor Swashplate Bearing Regreasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 206. Tail Rotor Swashplate Bearing Regreasing . . . . . . . . . . . . . . . . . . . . . 210
Figure 207. Tail Rotor Swashplate Bearing Regreasing Tool . . . . . . . . . . . . . . . . . 211
Figure 208. Tail Rotor Swashplate Holding Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Figure 209. Tang Washer Inspection and Application of Torque Stripe . . . . . . . . 213
Page iv
MAINTENANCE MANUAL
Section
64−00−00
Anti−Torque
Assembly
(369D/E/FF −
500/600N)
MAINTENANCE MANUAL
ANTI−TORQUE ASSEMBLY
FAULT ISOLATION
1. Tail Rotor Assembly quick-release pins on top of pedal arms and
repositioning pedals.
The tail rotor, mounted on the tail rotor
transmission at the end of the tailboom, The two-bladed tail rotor assembly consists
counteracts main rotor torque and controls mainly of two tail rotor blades, a hub, drive
heading of the helicopter. The tail rotor control fork, two pitch control links, and a pitch
system changes the pitch of the tail rotor control assembly.
blades. The antitorque pedals move a system
of bellcranks and control rods routed through The four-bladed tail rotor assembly consists
the fuselage and tailboom to a pitch control of four tail rotor blades, two hubs, drive fork,
assembly which moves links that attach to four pitch control links and a pitch control
blade-pitch arms on the blades. assembly. The blades are held together on the
hub by a laminated tension-torsion strap pack
The pitch control assembly slides axially on that permits the blades to rotate axially on the
the tail rotor transmission output shaft. hub. The hub pivots in the drive fork. Control
Pushing forward on the left pedal changes of blade pitch is from the pitch control assem
heading to the left; forward right pedal bly through pitch control links that connect to
movement changes heading to the right. pitch arms on the blade root fittings.
For two-bladed tail rotor system, blade pitch
movement is -13 degrees to -15 degrees thrust 2. Anti−Torque Fan Assembly
to the left and +27 degrees to +29 degrees to
the right. The anti-torque fan is an axial fan with
thirteen variable pitch blades. The fan
For four-bladed tail rotor system, blade pitch provides anti-torque by furnishing variable
movement is -13 degrees to -15 degrees thrust flow of low pressure high volume air through
to the left, +31 degrees to +32 degrees thrust the tailboom and thrusters.
to the right and +6.5 degrees to +8.5 degrees
thrust to the right at neutral. During flight, pedal position and pressure
required to maintain a desired heading varies
During flight, pedal position and pressure with main rotor torque variations, altitude and
required to maintain a desired heading varies airspeed conditions. Control linkage includes a
with main rotor torque variations, altitude and bungee spring that relieves left pedal forces in
airspeed conditions. Control linkage includes a flight.
bungee spring that relieves left pedal forces in
flight. When the helicopter is on the ground, pedal-
to-seat distance is adjusted by removing
When the helicopter is on the ground, pedal- quick-release pins on top of pedal arms and
to-seat distance is adjusted by removing repositioning pedals.
Table 101. Troubleshooting Tail Rotor and Vibrations

Heavy medium−frequency vibration Tail rotor out of balance. Rebalance tail rotor assembly (Ref.
in tail rotor assembly; vibration Section 18−20−00).
sometimes felt in pedals as a
buzzing sensation. Runout of tail rotor transmission Replace transmission if shaft runout
output shaft excessive. exceeds 0.0025 inch (0.0635 mm)
T.I.R. No axial play allowed. (Ref.
Section 63−25−10).
Page 101
MAINTENANCE MANUAL
Table 101. Troubleshooting Tail Rotor and Vibrations

High frequency vibration, primarily Tail rotor blades slightly out of Rebalance tail rotor assembly (Ref.
in pedals as a buzzing sensation. balance. Section 18−20−00).
Tail rotor blade pitch bearings Replace tail rotor pitch bearings (Ref.
worn. CSP−COM−5).
Excessive wear in pitch control link Replace pitch control link bearings
bearings. (Ref. CSP−COM−5).
NOTE: High frequency vibrations in Excessive wear of swashplate or Replace swashplate or repair pitch
the helicopter can also be large bearings in housing of pitch control assembly (Ref.
caused by components of other control assembly. CSP−COM−5).
systems (Ref. Sec. 18−20−00,
53−40−00, 63−25−10 and Excessive play in tail rotor fork Replace fork bearings (Ref.
Chap. 71). bearings. CSP−COM−5).
Tail rotor hub−to−fork play. Repair (Ref. CSP−COM−5).
Excessive dents in leading edge of Replace blade(s) or tail rotor

blades. assembly. (Ref. CSP−COM−5).
Insufficient torque on stabilizer Retorque mount bolts (Ref. Chapter

mount bolts. 53).
Insufficient torque on tail rotor Retorque retaining nut (Ref. Section

assembly retaining nut. 64−30−00).
Excessive play in pitch control link Worn pitch control link bearings. Replace pitch control link bearings
assemblies. (Ref. CSP−COM−5).
High left pedal forces required in Bungee spring (Sta. 63) Reconnect or replace bungee spring
flight. disconnected, broken or stretched. (Ref. Section 67−20−00).
Pedals binding. Excessive drag of pitch control Clean swashplate bore and
swashplate on transmission shaft. transmission shaft splines.
Re−lubricate splines.
Snapping noise heard in Noise is normal action of strap None required.
non−operating tail rotor when pitch pack and caused by laminates
angle changed from one extreme twisting and bending when blade is
to the other. feathered without centrifugal load
present.
Page 102
MAINTENANCE MANUAL
Section
64−00−05
Four−Bladed Tail
Rotor Assembly
Initial Installation
(369D/E)
MAINTENANCE MANUAL
FOUR−BLADED TAIL ROTOR ASSEMBLY

1. Four−Bladed Tail Rotor Initial Installation (5). Remove existing station 284 bellcrank
and tail rotor control rod (Ref. Sta. 284
This section contains procedures for initial Bellcrank Removal).
installation of four-bladed tail rotor kit, which
includes tail rotor; tail rotor transmission; and C. Four−Bladed Tail Rotor Transmission
parts for modifying over-center trim system Build−Up
controls and engine/rotor tachometer indicator.
(Ref. Figure 901) Build-up the four-bladed tail
This kit can be installed on all Model 500D
rotor transmission as follows.
and 500E helicopters at the owner's/operator's
discretion.
NOTE: Components of the four-bladed tail ro (Ref. Section 91−00−00)
tor drive system kit are assembled and bal Item Nomenclature
anced at the factory. Prior to installation of CM112 Anti-seize compound high temperature
the kit, some existing equipment must be re
CM305 Lacquer, acrylic
moved from the helicopter, and other equip
ment must be modified.
Do not lift transmission assem
A. Tail Rotor and Transmission Initial CAUTION bly by coupling flange.
Installation
(1). Install shims, coupling and coupling
Install the four-bladed tail rotor transmission bolt. Coat threads of bolt with anti-
and tail rotor assembly according to the seize compound (CM112). Torque bolt to
following procedures. 250—300 inch-pounds (28.25—33.90
Nm) plus drag torque.
B. Existing Tail Rotor and Transmission
Removal (2). Add stripe of white paint (CM305)
approximately 0.0125 inch (3.175 mm)
Remove the following equipment from helicop wide between ends of decal to allow for
ter before installing four-bladed tail rotor indexing of aft end of drive shaft.
transmission and tail rotor assemblies.
NOTE: To locate new coupling index, use flash
(1). Remove existing two-bladed tail rotor light and look through control tube rod hole
(Ref. Section 64-20-00). in aft tailboom fitting. Rotate output shaft
until index stripe on coupling is at six o'clock
(2). Remove tail rotor transmission and position.
driveshaft (Ref. Section 63-25-10).
D. Drive Shaft, Tail Rotor Transmission and
NOTE: Retain bolt for use when building up Tail Rotor Installation
four-bladed tail rotor transmission, cou (Ref. Figure 901) Install drive shaft, transmis
pling is a limited-life item. If sufficient ser sion and tail rotor on helicopter as a unit. Do
viceable life remains on coupling, it can be not install with blades mounted.
reused with four-bladed tail rotor installa
tion. If not, discard and replace coupling
bolt. Consumable Materials
(3). Remove bolt, coupling and shims from Item Nomenclature
transmission output shaft (Ref. Section CM305 Lacquer, acrylic
63-15-10).
(4). Remove index stripe on drive shaft at (1). Install existing drive shaft on tail rotor
Sta. 137.5. transmission (Ref. Section 63-15-10).
Page 901
MAINTENANCE MANUAL
TAIL ROTOR
TRANSMISSION
DAMPER
COUPLING
TAIL ROTOR
DRIVESHAFT
STA. 137.50
COUPLING
TAIL ROTOR
TRANSMISSION
(4-BLADED)
WHITE STRIPES
1/8 INCH (3.175 MM)
WIDE
(NEW CONFIGURATION)
TAIL ROTOR
DRIVE SHAFT
DOUBLER
WHITE PAINT MARKING

AT 6 0'CLOCK
WHITE STRIPES
1/8 IN. (3.175 MM) WIDE
STA. 137.50 RING
STA. 137.50
(LOOKING FORWARD)
NOTE: ADD STRIPE OF WHITE PAINT ON COUPLING AT LOCATION
SHOWN, APPROXIMATELY 0.125 IN. (3.175 MM) WIDTH AND
LENGTH, AND AT CONTROL ROD HOLE AT AFT SIDE OF HOUSING. G64−0001A
Figure 901. Tail Rotor Index Stripe Requirements
Page 902
MAINTENANCE MANUAL
(2). Install assembled unit on helicopter Install bungee installation

(Ref. Section 63-15-10). WARNING tool (ST508) before discon
necting any pilot's collective stick
(3). Paint 0.125 inch (3.175 mm) wide and hardware. There is strong bungee
0.125 inch (3.175 mm) long stripe spring pressure present in stick link
(contrasting color to aft tailboom age. If suddenly released, spring reac
fitting) at six o'clock position of control tion in linkage can cause personal inju
rod in aft tailboom fitting to align stripe ry or parts damage.
on coupling.
(3). Remove bellcranks and collective
(4). Add white index stripe (CM305) on tail bungee spring and bracket; disconnect
rotor drive shaft to match stripe on and retract lateral cyclic trim actuator
doubler at Sta. 137.5. assembly.
(5). Install new tail rotor control rod. Turn off electrical switches
WARNING and disconnect any external
(6). Attach new Sta. 284 bellcrank to new
tail rotor pitch control assembly. power from helicopter prior to refuel
ing or defueling. Static discharge spark
(7). Temporarily install bellcrank to new in presence of fuel vapors can cause
control rod assembly. fire or an explosion.
(8). Install blades on hubs. Install inboard (4). Drain all fuel from fuel cells; purge cells
blades first (Ref. Section 64-10-00). with dry filtered compressed air.
E. Tail Rotor Control Over−Center Trim (5). Fold and displace left fuel cell to permit
System Rework bucking of rivets at aft side of canted
wall.
The tail rotor over-center trim system must be
reworked when four-bladed tail rotor is G. Four−Bladed Over Center Trim System
installed. Necessary parts for this rework are Initial Installation
included with four-bladed tail rotor kit.
(Ref. Figure 902)
F. Two−Bladed Over−Center Trim System
Removal
Special Tools
Prior to rework of over center trim system, (Ref. Section 91-00-00)
following existing equipment must be removed Item Nomenclature
and preparations made.
ST508 Collective bungee installation tool
Special Tools
(Ref. Section 91-00-00) (1). Locate and clamp fitting (1) and
Item Nomenclature serrated plate (2) together with serra
ST508 Collective bungee installation tool tions facing away from fitting. Drill one
0.159 inch (4.0386 mm) diameter rivet
hole with a #21 bit and countersink
(1). Remove tail rotor bungee; disconnect hole.
floor-routed tail rotor control rod and
remove and discard spring fitting from (2). Locate serrated plate (3) and clamp to
rod. Remove tail rotor idler bellcrank seat support structure (4). Ensure
under pilot seat. serrations are facing away from seat
support structure. Mark rivet and
(2). Disconnect tunnel-routed tail rotor screw holes on serrated plate (3) and
control rod and lateral mixer control seat support structure. Remove ser
rod at lower rod end. rated plate from seat support structure.
Page 903
MAINTENANCE MANUAL
9
7
11 34
36
35
20
12
14 21 9
(NOTE 2)
13
23 15
2 (REF) 3 (REF) NOTE 1
21
22
8
(NOTE 2)
24
1.00 IN. 1.00 IN.
(2.54 CM) 26
(2.54 CM) 25 19
26
0.612 IN. 32
0.612 IN. .250 IN.
(15.5448 MM)
(15.5448 MM) (6.35 MM)
33
31
10
30 27
30 28
29
5
18
17
1
2
6
3 1.75 IN.
CL
(4.445 CM)
4 1.00 IN. 2.00 IN.
(2.54 CM) (5.08 CM)
16
3.31 IN. PILOT'S FLOOR

(8.4074 CM) (REF)
NOTES:
1. REMOVE 0.12-0.14 IN. (3.048-3.556 MM) ON 369A7304 BRACKET.
2. NOT REQUIRED WHEN 369D27304 BRACKET IS INSTALLED. G64-0002A
Figure 902. Over Center Trim System Installation
Page 904
MAINTENANCE MANUAL

1. FITTING 19. RIVET
2. SERRATED PLATE 20. BOLT
3. SERRATED PLATE 21. WASHER
4. SEAT SUPPORT STRUCTURE 22. NUT
5. RIVET 23. COTTER PIN
6. RIVET 24. BOLT
7. BRACKET 25. BUSHING
8. BRACE 26. WASHER
9. BRACKET 27. NUT
10. BELLCRANK 28. COTTER PIN
11. BOLT 29. BOLT
12. BUSHING 30. WASHER
13. WASHER 31. NUT
14. WASHER 32. COTTER PIN
15. NUT 33. TAIL ROTOR BUNGEE
16. BOLT 34. SCREW
18. NUT 36. NUT
NOTE: Head of rivets not to protrude past base (8). Install fitting (1) on seat support
of serrations. structure using bolts (16), washers (17)
and nuts (18).
(3). Attach fitting (1) and serrated plate (2)
together with one rivet (5). NOTE: Shim -BSC bracket (9), as required, for
proper fit on canted wall. Shims are not re
(4). Locate and drill two 0.250—0.254 inch quired for -3 bracket (9).
(6.35—6.4516 mm) diameter screw
holes and two 0.098 inch (2.4892 mm) (9). Locate and clamp bracket (9). Drill five
diameter rivet holes using a #40 bit 0.193—0.199 inch (4.9022—5.0546
through seat support structure to mm) diameter holes using existing
match previously marked locations rivet pattern (Ref. Figure 903).
(step (2).). Countersink rivet holes. (10). Attach bracket (9) to canted wall using
five rivets (19) or alternate method of
(5). Drill two 0.098 inch (2.4892 mm) five screws (34), washers (35) and nuts
diameter rivet holes with a #40 bit thru (36).
serrated plate (with round bolt holes)
using previously marked locations (step (11). Grasp brace (8) and hold against
(2).). Attach serrated plate (3) to seat bracket (9). Mark mating holes on brace
support structure using two rivets (6). (8) with those on bracket (9).
NOTE: Check part number of bracket (7). If (12). Remove brace (8) from bellcrank (10)
bracket is a 369A7304, proceed with step and bracket (7). Drill two 0.250—0.254
(6). If 369D27304 bracket is installed, or inch (6.35—6.4516 mm) diameter
600N2608-9 bracket is installed, brace (8) holes at locations marked in step (11)..
and bracket (9) are not required, proceed to (13). Install brace (8) on bracket (9) with
step (14). bolts (20), washers (21) and nuts (22).
(6). Remove 0.12-0.14 inch (3.048-3.556 Align opposite end of brace (8) between
mm) maximum material, as required, bracket (7) and bellcrank (10).
from bracket (7) boss lug to achieve a (14). Install bolt (11), bushing (12) and
snug fit between brace (8), bracket (7) washers (13, 14) thru bracket (7) and
and bellcrank (10). bellcrank (10). Install nut (15) and
cotter pin (23).
(7). Temporarily attach bellcrank (10),
brace (8) and bracket (7) with bolt (11), (15). Reinstall tunnel-routed control rods
bushing (12), washers (13, 14) and nut and floor-routed control rods, with
(15) finger tight. spring fitting removed.
Page 905
MAINTENANCE MANUAL
Always use bungee installa assembly of collective bungee. Coat

WARNING tion tool (ST508) when re parts with grease (CM111) as in
moving attaching hardware. Reaction structed. Ensure that 0.120 inch (3.048
of spring when pressure is suddenly re mm) of threads are visible between nut
leased can cause personal injury or and rod end of bungee female bearing
parts damage. assembly.
NOTE: Adjust tail rotor pedal force by tighten Remove bungee installation
ing or loosening the 0.120 inch (3.048 mm) WARNING tool only as instructed.
thread adjustment on bungee female bear There is strong bungee spring pressure
ing assembly. Tighten to maximum 0.120 present with four-bladed tail rotor
inch (3.048 mm) thread adjustment on bun bungee installed. If suddenly released,
gee female bearing assembly increases ped spring could cause personal injury
al force approximately five pounds; loosen and/or parts damage.
ing decreases pedal force. Bungee spring
can be attached to any of four holes in fitting (2). Attach assembled bungee to fitting (1)
(1). If excessive left pedal force is required, using attaching hardware (29 thru 32)
position spring at lower hole. and to bellcrank (10) using attaching
hardware (24 thru 28). Ensure bushing
H. Four−Bladed Tail Rotor Controls Rigging (25) extends 0.010—0.080 inch
(0.254—2.032 mm) beyond surface of
bungee rod end.
(Ref. Section 91−00−00) I. Horizontal Stabilizer Tip Weight Removal
Item Nomenclature
Tip weights installed in horizontal stabilizer
CM111 Grease, aircraft for two-bladed tail rotor operation are not
used with four-bladed tail rotor system.
Special Tools Remove and discard four screws securing tip
(Ref. Section 91-00-00) plates and weights to horizontal stabilizer.
Item Nomenclature Reinstall tip plates using four new screws (P/N
ST508 Collective bungee installation tool NAS1403-15).
ST510 Bungee spring compression tool rod and J. N2 and NR (Rotor) Tachometer Indicator
channel Replacement
ST606 T/R swashplate rigging tool
Remove and replace existing tach indicator
with indicator supplied in four-bladed tail
Rigging of four-bladed tail rotor controls is to rotor kit (Ref. Section 95-30-00).
be done with tail rotor bungee spring removed.
Tail rotor pitch angles at 3/4 radius shall be: K. Four−Bladed Tail Rotor System
Completion of Installation
Full right pedal 14° ±1° Upon completion of kit installation, the
following actions must be completed.
Full left pedal 31° +1°−0°
Neutral pedal 7.5° ±1° (1). Replace all components, access panels,
covers, etc. removed to gain access to
Rig tail rotor controls per Tail Rotor Controls work area.
Rigging except use four-bladed tail rotor (2). Check installation of four-bladed tail
control rigging tool (ST606). After rigging, rotor control linkage for discrepancies.
reinstall tail rotor bungee and carefully
remove bungee installation tool (ST508) using (3). Fill tail rotor transmission with oil (Ref.
bungee compression tool rod and channel Section 12-00-00).
(ST510).
(4). Refuel helicopter and do an operational
(1). Assemble bungee using bungee installa check of four-bladed tail rotor control
tion tool (ST508) and instructions for system (Ref. PFM).
Page 906
MAINTENANCE MANUAL
(5). Ensure that Pilot Flight Manual L. Weight and Balance

Supplement is inserted in Section IX,
Rotorcraft Flight Manual.
Weight and balance changes resulting from
(6). Ensure that installation of four-bladed installation of four-bladed tail rotor kit are
tail rotor kit and appropriate part listed in Table 901. After kit installation,
numbers, serial numbers and limited- incorporate changes in helicopter weight and
life data are recorded in helicopter log balance record as instructed (Ref. Section
book. 08-10-00).
Pounds (kg) inches (cm) in−lb (kg cm)
Added +9.4 (+4.2638) 257.2 (653.228) +2417.68 (27854.574)

Removed 0.0 0.0 0.0
Net Change +9.4 (+4.2638) 257.2 (653.228) +2417.68 (27854.574)
Page 907
MAINTENANCE MANUAL
BL 0.00
BRACKET
BRACE
OK TO LEAVE
RIVET (5 REQ'D) EXISTING RIVETS.
(USE EXISTING (NOTE)
RIVET PATTERN)
WL 13.10
BRACKET
0.032 IN.
(0.8128 MM)
STATION 78.50
CANTED WALL BL 0.00 BL 6.00 L.H.
-3
NOTE:
BL 0.00 OMIT THESE TWO RIVETS WHEN
INSTALLING 369D27003-5 ONLY.
BRACKET
BRACE
RIVET (4 REQ'D)
(USE EXISTING OK TO LEAVE
RIVET PATTERN) EXISTING RIVET
SHIM AS REQUIRED BETWEEN
BULKHEAD AND BRACKET
WL 13.10
BRACKET
SHIM AS REQUIRED BETWEEN

0.032 IN.
BULKHEAD AND BRACKET
(0.8128 MM)
BL 6.00 L.H.
BL 0.00
STATION 78.50
CANTED WALL
-BSC
G64-0003A
Figure 903. Bracket Installation − Sta. 78.50 Canted Wall
Page 908
MAINTENANCE MANUAL
Section
64−10−00
Tail Rotor Blades
(369D/E/FF)
MAINTENANCE MANUAL
TAIL ROTOR BLADES

1. Tail Rotor Blades Scratches that do not exceed 0.020 inch
(0.508 mm) depth are permissible if
Blades are cambered for high thrust to provide repaired.
directional control at high altitude. Each
consists of an aluminum honeycomb spar, (4). Loose or missing tip weights and
aluminum skin, riveted aluminum blade attachment hardware.
fittings and an aluminum tip cap; all structur (5). Clogged drain openings.
ally bonded together.
(6). Adhesive separation at exposed edges.
At manufacture, static balancing moments of
all blades are within plus or minus 40 gram (7). Debonding of tip cap from tail rotor
inches of each other by use of a special blade (Ref. Tail Rotor Blade Tip Cap
balancing fixture and prebalancing with tip Repair).
weights. Although erosion or allowable repairs (8). Tip cap rivets for installation and
can cause minor balance moment changes, condition (Ref. Tail Rotor Blade Tip Cap
such changes are considered negligible enough Repair).
to allow direct replacement of any used blade
with a new one and interchangeable use of (9). Tail rotor blade pitch bearings for a
blades with remaining service life. In any case maximum 0.250 inch (6.350 mm) play
of blade selection or use, inspection, repair and measured at tip of blade.
serviceability requirements must be complied 3. Abrasion Strip Dye Penetrant and Tap
with. Retirement schedule and remaining Test Inspection
service life of a used blade should always be
considered when making decision to replace a (Ref. Figure 202)
single blade (Ref. Section 04-00-00).
2. Tail Rotor Blade Inspection (Ref. Section 91−00−00)
Item Nomenclature
(Ref. Figure 201) Do a balance check at
intervals specified (Ref. Section 05-20-00). If CM729 Tape, masking, pressure sensitive
any of following conditions exist, do appropri CM801 Abrasive paper, silicon carbide
ate detailed inspections and allowable repairs
(Ref. CSP-COM-5). (1). Using a 1/8 inch (3.175 mm) drill bit
(1). Surface cracks, scratches, nicks, and a pencil, fabricate a tapping
gouges, dents, pits or corrosion. hammer by taping drill bit to pencil.
Drill bit should be a minimum of 6.00
(2). Leading edge erosion or dents. Visually inches (15.24 cm) from end of pencil
check abrasion strip for paint cracking that is to be held while tapping.
or chipping along abrasion strip/airfoil NOTE: Voids are indicated by a dull, dead tone.
bond line. Use 10X glass to check Slight tone changes will occur near the tip
abrasion strip/airfoil bond line for cap and along the length of the strip. These
debonding between epoxy adhesive and should not be mistaken for voids.
abrasion strip. If debonding has
occurred, remove blade from service. (2). Using the fabricated tapping hammer,
tap test the entire abrasion strip. Hold
NOTE: If abrasion strip debonding is sus end of pencil opposite drill bit and tap
pected, but cannot be confirmed by visual with shank (rounded) end of drill bit. If
inspection, (Ref. Abrasion Strip Dye Pene void indications are noted, remove
trant and Tap Test Inspection). blade from service.
(3). Root fitting cracks, scratches, nicks and (3). Mask area of blade around abrasion
gouges. No cracks are allowable. strip with masking tape (CM729).
Page 201
MAINTENANCE MANUAL
DRAIN OPENING
BLADE BALANCE WEIGHT
TIP CAP
CLEAR LACQUER
DRAIN OPENING
ROOT FITTING
HUB
RED TRUNNION
CLEAR LACQUER
O-RING
NUT
WHITE
CRUSH WASHER
BUSHING
BOLT
BUSHING
CRUSH WASHER
3.0 IN. (7.62 CM) RED
3.0 IN. (7.62 CM) WHITE
BLADE
3.0 IN. (7.62 CM) RED
G64-1000A
Figure 201. Tail Rotor Blade
Page 202
MAINTENANCE MANUAL
SHOWN ABOVE: UNBONDING OF EPOXY ADHESIVE AND ABRASION STRIP

WITH SEPARATION BETWEEN ABRASION STRIP AND
AIRFOIL SURFACE, BLADE UNACCEPTABLE FOR SERVICE.
SHOWN RIGHT: UNBONDED AND DISPLACED ABRASION STRIP AT

BLADE TIP; SEPARATION BETWEEN ABRASION
STRIP/AIRFOIL SURFACE ALONG BOND LINE,
BLADE UNACCEPTABLE FOR SERVICE.
PENCIL
DRILL BIT, 1/8 IN.
(3.175 MM)
TAPE
MIN. 6.0 IN.
(15.24 CM)
TAPPING TOOL FOR FABRICATION
G64-1002A
Figure 202. Inspection of Tail Rotor Blade Abrasion Strip
Page 203
MAINTENANCE MANUAL
Do not use chemical paint re bleedout from under the abrasion strip, and
CAUTION mover to remove paint from will appear as a line along the edge of the
abrasion strip. Chemicals can attack the strip. The 5X magnifying glass will aid dis
abrasion strip to blade bonding agent. tinguishing between porosity voids and
bleedout from under the abrasion strip. It
(4). Using 220 grit abrasive paper (CM801), can be necessary to wipe off, then reapply
sand dry, removing all paint from the the developer to distinguish between poros
abrasion strip. Ensure abrasion to ity voids and bond separations. The most
airfoil bondline is exposed. Clean paint positive indication of bond failure will nor
dust from blade. mally appear during the first one to seven
minutes following developer application.
NOTE: Do not remove masking tape from blade
until completion of dye penetrant inspec (8). Using a 5X magnifying glass, examine
tion. bond line to determine if penetrant dye
is indicating a bond separation. If bond
(5). Visually check abrasion strip to blade
separation is noted, remove blade from
bonding using a 10X magnifying glass.
service.
If bond failure is obvious, remove blade
from service. (9). Remove masking tape from blade.
(6). Dye penetrant inspect, according to (10). Inspect blade for cleanliness and paint
manufacturer's instructions. damage. Clean and repair paint
(a). Inspect entire abrasion strip to blade damage as necessary (Ref. Section
bond line, including abrasion strip 20-30-00).
bond in blade tip cap area. NOTE: Do not repaint abrasion strip or abra
(b). Apply penetrant using a small brush sion strip to blade bond line.
or swab to prevent damage to blade
(11). Check tail rotor balance (Ref. Section
paint, and to minimize clean-up.
18-20-00).
(c). Allow penetrant to remain on surface
(12). If blade is removed from service
of abrasion strip bondline for five
because of separation or voids, contact
minutes minimum.
MDHI Warranty Department for
(d). Use dry lint free cloth or paper towel further instructions. Those blades in
to remove excess penetrant. which voids are found shall be sent to
an approved repair station for abrasion
(e). Apply remover to cloth or lint free strip replacement.
towel to remove remaining surface
penetrant. 4. Tail Rotor Blade Tip Cap Repair
NOTE: Never spray or flush area of inspection (Ref. Figure 203)
with cleaner.
(f). Ensure thorough penetrant removal Consumable Materials
from surface before applying develop (Ref. Section 91−00−00)
er. Item Nomenclature
(7). Apply a light film of developer on the
area of examination. CM318 Primer
NOTE: The epoxy adhesive used to bond abra CM804 Emery cloth, fine
sion strip to blade can have porosity voids.
The penetrant will form a circular pattern
around voids resulting from porosity. These (1). Remove tail rotor blade from helicopter
circular patterns do not indicate bond fail (Ref. Tail Rotor Blade Replacement
ure. Bond failure is indicated by penetrant Procedure).
Page 204
MAINTENANCE MANUAL
0.60 IN. (1.524 MM)

0.250 IN. (6.35 MM) (NOTE 1)
DIA HOLE
0.30 IN. (0.762 MM)
AFTER REMOVAL OF DEBRIS, SEAL 0.250 IN.

(6.35 MM) DIA. HOLE WITH 2 PLIES OF 120 0.390 ± 0.060 IN.
FIBERGLASS CLOTH & 3135 A & B EPOXY (9.91 ±1.524 MM)
RESIN (CREST PRODUCTS OR EQUIVALENT)
AS SHOWN. HOLE LOCATION
SURFACE PREPARATION: ABRADE SURFACE
WITH EMERY CLOTH AND WIPE WITH
ISOPROPYL ALCOHOL (CM217). DO NOT
ALLOW RESIN TO BUILD UP IN 0.250 IN. (6.35
MM) DIA. HOLE.
0.690 IN. (17.53 MM)

ALONG BLADE CONTOUR
NOTE 2
0.250 IN. 0.380 IN.
(6.35 MM) (9.65 MM)
0.30 IN. 0.250 IN.

(7.62 MM) (6.35 MM)
NOTE 2
0.50 IN. (12.70 MM)

ALONG BLADE CONTOUR
(NOTE 2)
NAS 1739B4-2 RIVET
(4 PL)
NOTES:
1. FIBERGLASS THIS AREA. DO NOT PLACE FIBERGLASS
CLOTH OVER OPENING FOR BALANCE WEIGHTS.
2. USE NO.27 DRILL AND 1005 COUNTERSINK WITH NO. 30
PILOT. COUNTERSINK TO MAXIMUM 0.035 IN. (0.889 MM) DEPTH.
INSTALL NAS 1739B4-2 RIVET. SEAL RIVET WITH CLEAR
EPOXY (CM411).
G64-1001A
Figure 203. Installation of Tip Cap−To−Tail Rotor Blade Rivets
Page 205
MAINTENANCE MANUAL
Handle blade carefully. Dents, 5. Tail Rotor Blade Replacement Procedure

CAUTION nicks or scratches can cause bal
ance problems at reinstallation, or make Consumable Materials
blade unserviceable. (Ref. Section 91−00−00)
Item Nomenclature
(2). With blade on a clean hard surface, CM318 Primer
measure and mark locations for rivet
holes.
NOTE: Always record number and location of
(3). Using No. 27 drill, carefully drill holes existing balance washers when replacing
at locations marked on outboard and blade. This record aids in dynamic balance
inboard surfaces of blade. troubleshooting.
(1). Remove cotter pin, nut, washer and
(4). Using 100 ±1° countersink with No. 30 pitch arm bolt from outboard end of
pilot, countersink holes to 0.035 inch pitch control link.
(0.889 mm) maximum depth.
Bolt, nut, washers and bushings
CAUTION can be reinstalled if serviceable.
(5). Apply primer (CM318) to holes and If bushing and crush washers are to be re
install rivets while primer is wet. used, they must be installed in the exact lo
cation from which they were removed. If ei
(6). Coat installed rivets with clear epoxy ther the blade or strap pack assembly from
(CM411). which they were removed is replaced, re
place crush washers and bushing. Bushings
(7). Drill a 0.250 inch (6.35 mm) diameter must be free of nicks and burrs.
hole through tip cap (Ref. Figure 203). NOTE: If same blade is to be reinstalled, retain
Tip cap is 0.070 inch (1.778 mm) thick intact for reuse. Note and record number
at point to be drilled. and type of balance washers and attach
ment hardware used on bolt at blade pitch
(8). Remove FOD from blade interior arm.
through hole.
(2). Remove bolt that secures blade to
outboard strap pack shoes.
(9). Abrade surface surrounding hole using
emery cloth (CM804); wipe clean using (3). Withdraw blade from hub trunnion.
clean cloth dampened with isopropyl Do not disassemble strap shoes
alcohol (CM217). CAUTION from end of strap pack protrud
ing from trunnion. Strap pack parts are not
Do not allow resin to build-up in individually replaceable and must remain
CAUTION hole. assembled. Avoid damaging strap pack.
Scratches or nicks on strap pack laminates
(10). Bond two plies of 120 fiberglass cloth can make strap pack unserviceable.
over hole with 3135A and B epoxy resin NOTE: No axial play is allowed in the strap as
or equivalent. Allow epoxy to cure sembly shoes. Rotational movement is per
according to manufacturer's instruc missible.
tions.
(4). If strap pack is to remain exposed for
(11). Reinstall tail rotor blade on helicopter any length of time, wrap exposed end of
(Ref. Tail Rotor Blade Replacement strap pack with wax paper or other
Procedure). similar non-abrasive material to
protect from damage.
(12). Check and adjust tail rotor blade (5). If blade being removed is to be rein
balance (Ref. Section 18-20-00). stalled, do not remove blade tip screw,
Page 206
MAINTENANCE MANUAL
any balance washers or weight from (13). Install pitch control links (Ref. Section
blade. 64-30-00).
NOTE: Remove old primer from mating sur NOTE: If same blade that was removed is being
faces and attaching hardware prior to reas reinstalled, install same number of balance
sembly. washers on pitch arm bolt that were present
(6). To install blade, remove any protective prior to removal of blade. For different
covering from strap pack extending blade, install balance washers required for
from hub trunnion. static chordwise balance of assembled tail
rotor which have been determined with a
(7). Install O-ring and slide blade on hub balance fixture.
with blade leading edge facing in
counterclockwise direction. Use care to (14). Balance tail rotor (Ref. Section
keep blade correctly aligned so that hub 18-20-00).
trunnion slides into blade pitch bear
ings. Do not use force. 6. Tail Rotor Abrasion Strip Riveting
(8). Align bolt holes in root fitting with hole (Ref. Figure 204) The following procedure is for
through bushing in outboard shoes of adding rivets at the outboard ends of the
strap pack. abrasion strip to provide a secondary failsafe
(9). Coat contacting surfaces of bushings, method of attachment.
washers, nuts and bolts with unthinned
primer (CM318) and immediately do This procedure is effective on tail rotor blades:
the following steps. 369A1613-7, -503, -505,
369D21606-BSC,
(10). Assemble and install bolt, bushings and 369D21613-11, -31, -41, -51,
washers in sequence (Ref. Figure 201). 369D21615-BSC, -21,
Make certain that direction of bolt is 421-088
opposite to that of opposing blade. Do
not force bolt; it must have an easy but
snug fit through blade, shoes and Consumable Materials
bushings. (Ref. Section 91−00−00)
Item Nomenclature
NOTE: It is recommended that the MS 21250 CM217 Isopropyl alcohol
bolt be replaced with any of the alternate
CM318 Primer
bolts with the higher torque at the operators
earliest convenience. CM804 Emery cloth, fine
N/A Fiberglass cloth, No. 120
(11). If an MS 21250 bolt is installed, install
nut and torque to 600—650 inch- N/A Epoxy resin, Spec. 3135A and B or any 2
pounds (67.79—73.44 Nm) while part (1:1) clear epoxy resin
primer is wet. If an MHS5482-6,
MHS4441-6, MS14181-06040P or an Do not attempt to do this proce
LWB22-6 bolt is installed, torque nut to CAUTION dure with the tail rotor blades
750—775 inch-pounds (84.74—87.56 installed on the helicopter. Failure to com
Nm). ply with this caution can result in defective
After blade is secured to strap rivet installation and possible blade dam
CAUTION pack assembly, do not allow age.
blade pitch travel from neutral to exceed 30
degrees in either direction. Rotating blade (1). Remove tail rotor blades from helicop
to excessive pitch angles can result in unde ter (Ref. Tail Rotor Blade Replacement
tected damage to strap assembly. Procedure).
(12). Check that bolthead is flat against (2). Using a 10X magnifying glass, do a
bushing. No gap is permitted. If gap is visual inspection of the tail rotor blade
found, replace bolt and bushing. abrasion strip bond lines for debonding.
Page 207
MAINTENANCE MANUAL
0.60 IN. (1.524 MM)

(NOTE 1)
0.250 IN. (6.35 MM)
HOLE 0.30 IN. (7.62 MM)
CL
NOTE 2
0.810 ±0.030 IN.
0.390 ±0.060 IN. (20.57 ±0.762 MM)
(9.91 ±1.524 MM)
HOLE LOCATION
1.160 ±0.030 IN.

(29.464 ±0.762 MM)
0.280 ±0.030 IN. (7.110 ±0.762 MM)

ALONG CONTOUR (BOTH SIDES)
ABRASION STRIP
BLADE SKIN
VIEW LOOKING DOWN
NOTE:
1. FIBERGLASS THIS AREA. DO NOT PLACE FIBERGLASS CLOTH OVER OPENING
FOR BALANCE WEIGHTS.
G64-1005A
2 COUNTERSINK HOLE 100° DEPTH 0 009 0 011 IN (0 229 0 2794 MM)
Figure 204. Tail Rotor Blade Abrasion Strip Riveting
Page 208
MAINTENANCE MANUAL
(3). If abrasion strip debonding is suspected (e). Inspect hole in abrasion strip.
but cannot be confirmed by visual
inspection, do the Abrasion Strip Dye (11). Remove FOD from interior of blade as
Penetrant and Tap Test Inspection. follows:
NOTE: Tail rotor blades removed for voids (a). Drill 0.250 inch (6.35 mm) hole
must be removed in ship sets. through tip cap as shown.
(b). Remove FOD from blade interior
(4). If voids are found in blade, remove and
through hole (there is space at tip cap
send to an authorized repair station for
end for debris to pass aft of spar).
repair.
(c). Install new rivet.
(5). Carefully secure tail rotor blade in a
suitable holding fixture. (d). Abrade surface surrounding tip cap
hole using emery cloth (CM804); wipe
NOTE: When doing the following step, use drill clean using clean, lint-free cloth
bit stop to prevent drilling through both dampened with isopropyl alcohol
sides of blade. (CM217).
(6). Using a No. 27 cobalt drill bit, drill Do not allow resin to build up in
holes at locations shown (light center CAUTION hole.
punch prior to drilling is allowed).
(e). Bond two plies of fiberglass cloth over
(7). Deburr holes with a 100° countersink to hole with epoxy resin.
a depth of not more than 0.011 inch
(0.2794 mm). (12). Repeat inspection of abrasion strip.
(8). Apply primer (CM318) to holes and (13). Reinstall tail rotor blades.
install CS2545-4-1 or CR3555-4-1
(14). Do the tail rotor balance (Ref. Section
rivets while primer is wet.
18-20-00, Tail Rotor Blade Balancing).
Installed rivet stems can be de
CAUTION burred using a file. Do not re 7. Tail Rotor Blade Abrasion Strip
move material from locking collar. Modification
(9). Inspect installed rivets.
application of a 0.0027 inch (0.06858 mm).
(10). If rivet installation is not satisfactory, thick strip of stainless steel tape over the
remove as follows: inboard end of the abrasion strip.
During removal of defective riv This procedure is effective on tail rotor blades:
CAUTION et, observe the following: 369A1613-7, -503, -505, -509,
Do not damage or enlarge hole. 369D21606-BSC, -509,
Do not drive or force rivet stem from hole. 369D21613-11, -31, -41, -51, -71,
Do not remove rivets common to tip cap. 369D21615-BSC, -21, -41,
421-088
(a). Carefully grind off locking collar and
upper portion of rivet head. Consumable Materials
(b). Carefully push center stem through
Item Nomenclature
rivet sleeve.
(c). Using a drill stop, drill through rivet CM801 Abrasive paper, silicon carbide
sleeve using care to prevent hole
enlargement.
NOTE: Abrasion strip must have rivets
(d). Push remaining rivet sleeve through installed before applying stainless steel
hole. tape.
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MAINTENANCE MANUAL
(1). Using a 10X magnifying glass, do a 8. Tail Rotor Blade Protective Tape
visual inspection of the tail rotor blade Installation
abrasion strip bond lines for debonding.
(2). If abrasion strip debonding is suspected
but cannot be confirmed by visual
Item Nomenclature
inspection, remove blades and do the
Abrasion Strip Dye Penetrant and Tap CM220 Naphtha aliphatic
Test Inspection. CM304 Enamel, epoxy
NOTE: Tail rotor blades removed for voids N/A 3M aerosol primer MITO-0081
must be removed in ship sets.
N/A 3M mylar tape P/N Y8671-1
(3). If voids are found in blade, remove and
send to an authorized repair station for NOTE: This installation is only approved on
repair. tail rotor blades equipped with the new
abrasion strips.
(4). Lightly abrade faying surface of tail
rotor blade in area where tape is to be In an effort to reduce the amount of erosion in
installed with 400-grit abrasive paper the area inboard of the abrasion strip, MDHI
(CM801). has approved the installation of mylar tape to
the blade leading edge. Installation of the tape
(5). Wipe abraded area with naphtha is optional.
(CM220) to eliminate grease and dirt
film. The length of the tape can vary, up to 2.0
inches in length, but must be equal on both
NOTE: Do not allow temperature to exceed blades.
120°F (49°C).
It is recommended to start with 1.5 inch (3.81
(6). Using a heat gun, or equivalent, heat cm) length and increase the length as erosion
abraded area. occurs by replacing the tape.
Do not cut or trim tape after
(7). Remove backing and apply stainless CAUTION installation on blade, damage to
steel tape to leading edge of tail rotor blade will occur.
blade.
(1). Measure length of eroded area on blade
(a). Apply tape so it overlaps each side of with the most erosion.
blade equally.
NOTE: Tape must be of equal length on both
(b). Tape should overlap the inboard end blades to ensure proper balance.
of abrasion strip 0.47—0.53 inch
(11.938—13.462 mm) at the leading (2). Cut tape long enough to cover erosion
edge of blade. plus approximately 0.50 inch (12.70
mm) overlap on leading edge abrasion
NOTE: Abrasion tape must be free of surface strip.
wrinkles or air bubbles. (3). Round off square corners of tape to
reduce peeling.
(8). Smooth and press tape into place by
hand. (4). Lightly abrade faying surface of tail
rotor blade in area where tape is to be
(9). Re-apply pressure by hand following installed with 400 grit abrasive paper
initial installation to ensure proper (CM801).
bonding.
(5). Wipe abraded area with naphtha
(10). Do the tail rotor balance (Ref. Section (CM220) to eliminate grease and dirt
18-20-00, Tail Rotor Blade Balancing). film.
Page 210
MAINTENANCE MANUAL
1.00 IN.
(2.54 CM)
3.00 IN.
(7.62 CM)
0.50 IN.
(12.70 MM)
1.00 IN.
(2.54 CM)
OLD STYLE ABRASION STRIP

NOTES 1, 2
0.50 IN.
(12.70 MM)
0.50 IN.
(12.70 MM)
NEW ABRASION STRIP
NOTES:
1. 304 STAINLESS STEEL OR MYLAR TAPE SHALL BE APPLIED; 0.50 IN. (12.70 MM)
TO ABRASION STRIP AND 0.50 IN. (12.70 MM) TO TAIL ROTOR BLADE.
G64-1006C
2 APPLY TAPE EQUALLY TO BOTH SIDES OF BLADE
Figure 205. Tail Rotor Blade Abrasion Strip Modification
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MAINTENANCE MANUAL
(6). Treat any bare metal with epoxy-type (2). If cracks are suspected, do a dye
paint (CM304). penetrant inspection of the suspect area
as follows:
NOTE: Do not allow temperature to exceed
120°F. (a). Lightly abrade faying surface of tail
rotor blade in area where tape is to
(7). Using a heat gun, or equivalent, heat be installed with 400-grit abrasive
abraded area. paper (CM801).
(8). Apply aerosol primer to bonding area (b). Wipe abraded area with naphtha
and allow to dry. (CM220) to eliminate grease and dirt
film.
(9). Remove backing and apply tape to
(c). Do a dye penetrant inspection on the
leading edge of blade.
suspected area per MIL-I-25135, or
(a). Apply tape so it overlaps each side of equivalent.
blade equally. (d). Tail rotor blades with evidence of
cracking must be removed from
(b). Tape should overlap the inboard end
service.
of abrasion strip 0.47—0.53 inch
(11.938—13.462 mm) at the leading NOTE: Tail rotor blades with the new abrasion
edge of blade. strip configuration cannot be intermixed
with tail rotor blades that have the old abra
NOTE: Tape must be free of surface wrinkles or sion strip configuration.
air bubbles.
(e). If there is no evidence of cracking,
(10). Smooth and press tape into place by the blade can be cleaned and touch-
hand. up epoxy paint applied to the affected
area.
(11). Re-apply pressure by hand following
initial installation to ensure proper (3). To reduce erosion, apply protective tape
bonding. to the blades (Ref. Tail Rotor Blade
Protective Tape Installation).
(12). Do the tail rotor balance (Ref. Section
(4). Do a tail rotor balance (Ref. Section
18-20-00).
18-20-00, Tail Rotor Blade Balancing).
9. Tail Rotor Blade Leading Edge Crack B. Tail Rotor Blades with Old−Style
Inspection Abrasion Strips
(Ref. Figure 206) (1). Remove stainless steel tape from the
leading edge at the inboard end of the
abrasion strip.
(Ref. Section 91−00−00) (2). Inspect that area for evidence of cracks;
Item Nomenclature no cracks are allowed.
CM220 Naphtha aliphatic (3). If cracks are suspected, do a dye
CM801 Abrasive paper, silicon carbide penetrant inspection of the suspect area
as follows:
(a). By lightly abrading the blade skin,
Do not use any chemicals to re
CAUTION move the paint and do not pene
carefully remove the paint from the
suspected area.
trate the metal skin of the blade.
(b). Do a dye penetrant inspection on the
A. Tail Rotor Blades with New−Style suspected area per MIL-I-25135, or
Abrasion Strips equivalent.
(1). Inspect leading edge for any evidence of (c). Tail rotor blades with evidence of
cracking in the area shown; no cracks cracking must be removed from
are allowed. service.
Page 212
MAINTENANCE MANUAL
NOTE: Tail rotor blades with the new abrasion (c). Using a heat gun, or equivalent, heat
strip configuration cannot be intermixed abraded area.
with tail rotor blades that have the old abra
sion strip configuration. (d). Remove backing and apply stainless
steel tape to leading edge of tail rotor
(d). If there is no evidence of cracking, blade.
the blade can be cleaned and touch- 1). Apply tape so it overlaps each side
up epoxy paint applied to the affected of blade equally.
area.
2). Tape should overlap the inboard
(4). Install new 0.0027 inch (0.06858 mm) end of abrasion strip 0.47—0.53
thick stainless steel tape in the same inch (11.938—13.462 mm) at the
location as follows (Ref. Figure 205): leading edge of blade.
(a). Lightly abrade faying surface of tail NOTE: Abrasion tape must be free of surface
rotor blade in area where tape is to wrinkles or air bubbles.
be installed with 400-grit abrasive
(e). Smooth and press tape into place by
paper (CM801).
hand.
(b). Wipe abraded area with naphtha (f). Re-apply pressure by hand following
(CM220) to eliminate grease and dirt initial installation to ensure proper
film. bonding.
NOTE: Do not allow temperature to exceed (5). Do a tail rotor balance (Ref. Section
1205F (495C). 18-20-00, Tail Rotor Blade Balancing).
Page 213
MAINTENANCE MANUAL
PAY PARTICULAR
ATTENTION TO THIS
AREA FOR CRACKING
OLD STYLE ABRASION STRIP
PAY PARTICULAR
ATTENTION TO THIS
AREA FOR CRACKING
NEW STYLE ABRASION STRIP
88-754
Figure 206. Tail Rotor Blade Leading Edge Crack Inspection
Page 214
MAINTENANCE MANUAL
Section
64−20−00
Tail Rotor Hub and
Fork (369D/E/FF)
MAINTENANCE MANUAL
TAIL ROTOR HUB AND FORK

1. Tail Rotor Hub and Fork control arm movement of approximately
one inch in either direction. Unrestricted
(Ref. Figure 201) This section covers mainte rotation of blades on hub can excessively
nance of the hub, strap pack and fork as an bend or stretch strap pack and cause un
assembled unit. For all other maintenance detected damage to strap pack and an
instructions pertaining to hub and fork out-of-balance tail rotor when reas
assembly, and the hub assembly, strap pack sembled.
and fork assemblies as separately-maintain
D To prevent balance problems at reassemb
able components, Ref. CSP-COM-5.
ly of parts and hardware, mark exact
number, locations and positions of all
When blades are removed from
CAUTION hub, exposed ends of strap pack
items before removal for correct reinstal
lation.
should be protected with covering (Ref. Sec
tion 64-10-00). Hub and fork should be D On two-bladed tail rotor system do not
handled carefully to avoid damage to strap remove hub-to-drive fork hinge bolt to
pack. remove tail rotor assembly. On four-
bladed tail rotor system hub-to-drive
2. Tail Rotor Hub and Fork Replacement fork hinge bolt removal is required. This
bolt should only be removed according to
A. Tail Rotor Hub and Fork Removal instructions Ref. CSP-COM-5. Damage
to strap pack can occur if any other proce
dure is used.
(2). Disconnect pitch control links from
Special Tools blade pitch control arms.
Item Nomenclature (3). Pull rotating boot out of groove in fork.
ST607 Adapter, torque wrench
(4). On four-bladed tail rotor system
remove inboard and outboard blades
and hubs to access fork tang washer
On four-bladed tail rotor
WARNING system, there is strong and nut.
spring pressure in installed tail rotor
linkage. Disconnect the in-line bungee
NOTE: Helicopters Serial Nos. D0003 thru
D1024 had a two-piece retaining nut and
before beginning disassembly. Failure
stop support. Helicopters subsequent to
to disconnect the bungee can result in
D1024 have a one-piece retaining nut and
personal injury and/or parts damage.
stop support.
(1). On four-bladed tail rotor, disconnect
(5). Straighten tang of tang washer.
in-line bungee (Ref. Section 67-20-10)
if tail rotor is installed on helicopter.
(6). Using torque wrench adapter (ST607),
loosen retaining nut and slide tail rotor
CAUTION outward on output shaft of tail rotor
transmission to remove blade stop and
D Whenever blades and hub are removed as stop support.
an assembly, or whenever pitch control
links are disconnected, do not allow blade (7). Remove nut, tang washer, tapered ring,
pitch to exceed 30 degrees from neutral and split-ring halves that fit into recess
pitch position. This is equal to blade pitch at inboard end of fork.
Page 201
MAINTENANCE MANUAL
OUTBOARD
STRAP SHOES
FORK
HUB
STRAP PACK
ASSEMBLY
INBOARD STRAP
SHOES
30°
30°
HUB TRUNNION (SEE CAUTION)
PITCH CONTROL LINK

DRAIN
OPENING
BALANCE
WEIGHT
TIP CAP
DRAIN
OPENING
CHORDLINE AT
NEUTRAL PITCH
LOOKING AT BLADE
CAUTION: END (TIP)
SHOES NOT TO BE REMOVED FROM STRAP PACK, AVOID DAMAGING
STRAP PACK; SCRATCHES OR NICKS ON STRAP LAMINATES MAY MAKE
G64-2000
STRAP PACK UNSERVICEABLE
Figure 201. Tail Rotor Hub and Strap Pack
Page 202
MAINTENANCE MANUAL
Tail rotor tang washer must not It is possible for pitch control
CAUTION be reused. CAUTION swashplate to be misaligned by
one-half spline in relation to drive fork.
NOTE: Placing grease pencil mark on drive Make sure drive fork, pitch links and swash
fork to key it to transmission output shaft plate are in exact alignment with transmis
enables subsequent installation of tail rotor sion shaft centerline. If incorrectly as
assembly at same position. sembled, swashplate will be misaligned
approximately 10 degrees from drive fork.
Application of small painted matchmark To correct this condition, remove tail rotor
next to centerline splined groove on both assembly (leaving pitch control assembly in
pitch control assembly and tail rotor drive stalled), rotate tail rotor assembly 180 de
fork aids reassembly at same position on grees and reinstall it.
transmission shaft. (3). Slide tail rotor assembly onto shaft
with drive fork-to-hub pivot bolt
One spline groove of fork is located directly aligned with swashplate lugs. Position
on centerline passing through centers of the tail rotor assembly on shaft so that
two fork bearings while, at opposite side of approximately two threads at shaft end
spline bore, same centerline passes through are exposed outboard of drive fork.
a spline tooth. A similar condition exists
with respect to swashplate splines, except (4). Coat tapered ring with primer (CM318)
that reference centerline originates between and install it on shaft, making certain
swashplate arms. that tapered edge parallels chamfer in
fork. Do the following steps while
For illustrations showing matchmarks and primer is wet.
additional information, Ref. CSP-COM-5. NOTE: Pre-assembly of tang washer, nut, stop
support and stop as a unit aids in their in
(8). Slide tail rotor assembly off output stallation when performing steps (5). thru
shaft. (7). below. Marking outer tang that is next to
inner key on tang washer, before assembly
B. Tail Rotor Hub and Fork Installation of parts, simplifies alignment with keyway
on shaft. Teeter blades to start tang washer
(Ref. Figure 202 and Figure 203) on shaft.
(5). Slip new tang washer over exposed
Consumable Materials threads of shaft; key tang must face
(Ref. Section 91−00−00) inboard toward gearbox. Install nut
Item Nomenclature approximately two full turns on shaft
CM115 Grease, oscillating bearing threads to verify threads engaged.
CM318 Primer (6). Slide tail rotor assembly outboard
CM702 Lockwire CRES against nut. Install stop support by
inserting it in drive shaft end.
Special Tools In next step do not force stop
CAUTION into position with screwdriver;
Item Nomenclature this can crack the stop.
ST607 Adapter, torque wrench (7). Coat contacting surfaces of stop with
grease (CM115) and insert it in stop
support.
(1). Attach rotating boot; attach to pitch
(8). Install split ring halves in shaft groove
control assembly using safety wire
and slide fork inboard until ring halves
(CM702).
are secured by recess in fork.
(2). Install split ring on output shaft of (9). Visually align a tang on tang washer
transmission. with any convenient reference point.
Page 203
MAINTENANCE MANUAL
PITCH CONTROL ASSEMBLY
NOTE 1 SPLIT RING

(WIRE SPRING)
TAIL ROTOR
ROTATING BOOT
ASSEMBLY
FORK
HINGE BOLT
TRANSMISSION
OUTPUT SHAFT
FORK BEARING
TANG WASHER (NOTE 2)
RETAINING NUT
STOP SUPPORT
TAPERED RING
PITCH ARM STOP
NOTE 3
NOTE 3
TORQUE WRENCH
AND ADAPTER
NOTES:
1. CENTERLINE TOOTHSPACE MATCHMARK MUST ALIGN WITH
CENTERLINE TOOTH-SPACE MARK ON FORK WHEN ASSEMBLED ON
OUTPUT SHAFT.
2. DISCARD USED TANG WASHER; BEND TWO TANGS TO SECURE NUT.
G64-2001E
3. TOOL PN 369D29823 (ST607).
Figure 202. Hub and Fork Assembly Installation (Two−Bladed)
Page 204
MAINTENANCE MANUAL
NOTE 1
PITCH CONTROL
ROTATING BOOT PITCH ARM
SPLIT RINGS
FORK
TAIL ROTOR ASSEMBLY
RING, FORK SUPPORT
NUT, STOP SUPPORT

NOTE 3
TANK WASHER
(NOTE 2)
INBOARD BLADE
STOP TORQUE WRENCH AND
ADAPTER
NOTES:
1. CENTERLINE TOOTHSPACE MATCHMARK MUST ALIGN WITH
CENTERLINE TOOTH-SPACE MARK ON FORK WHEN ASSEMBLED ON
OUTPUT SHAFT.
2. DISCARD USED TANG WASHER; BEND TWO TANGS TO SECURE NUT.
3. TOOL PN 369D29826 (ST607).
G64−2002D
Figure 203. Hub and Fork Assembly Installation (Four−Bladed)
Page 205
MAINTENANCE MANUAL
(10). Torque retaining nut, using torque 3. Tail Rotor Hub and Fork Inspection
wrench adapter (ST607), to:
(Ref. Figure 201) Hub inspection is accom
(a). Torque two-bladed retaining nut to plished with tail rotor blades removed.
450—500 inch-pounds
(50.84—56.49 Nm). (1). Inspect areas on hub trunnions that
mate with blade pitch bearings for
(b). Torque four-bladed retaining nut to excessive wear and for damage.
(2). Check hub and fork for axial play or
(62.14—67.79 Nm) and ensure
bearing roughness when hub is pivoted
wire-spring split ring halves are
from one extreme to the other.
firmly imbedded in fork recess.
(3). Check torque of fork hinge bolt. Apply
NOTE: Tang washer movement of more than 125 inch-pounds (14.12 Nm) torque
one tang width is an indication that tang
to nut or bolt. If bolt or nut does not
washer inner key tang is sheared. This con
rotate, preload is correct. If bolt or nut
dition requires replacement of tang washer
rotates, retorque. (For repair limit,
and reassembly of parts according to initial
torquing requirements and replacement
installation procedure.
criteria, Ref. CSP-COM-5).
(11). Check that tang has not moved more (4). Check visible areas of strap pack for
than one tang width in relation to nicks or scratches on strap laminates,
reference point noted in step (9). cracked or kinked laminates and sharp
(12). Measure clearance between tang bends or permanent twists in lami
washer and fork. nates. Any one of these defects, except
minor outer surface defects that can be
(13). If clearance is less than 0.005 inch removed by abrasive polishing, requires
(0.127 mm), replace tapered ring and/or replacement of strap pack. (For infor
fork assembly. mation on allowable repairs, service
ability requirements and replacement,
(14). Bend two tangs on tang washer to lock Ref. CSP-COM-5).
retaining nut. When bending tangs, do
not force-form tang to match nut 4. Conical Bearing Inspection
contour; maintain natural bend radius
that develops at tang root. Visually inspect conical bearings installed in
fork assembly, at intervals specified (Ref.
(15). Apply torque stripe paint across nut, Section 05-20-00).
tang washer and fork assembly in
location that can be checked visually. (1). Play is not permitted in conical drive
fork bearings.
(16). Insert edge of rotating boot into groove
of drive fork. 5. Elastomeric Fork Bearing Inspection
(17). Install pitch control links (Ref. Section Visually inspect elastomeric bearings installed
64-30-00). in fork assembly, at intervals specified (Ref.
Section 05-20-00) for damage and debonding
(18). Position tail rotor pedals in neutral from fork as follows.
position and recheck that drive fork,
pitch links and swashplate are in exact Elastomeric materials can be
CAUTION damaged by solvents, grease or
alignment with transmission shaft
centerline. oil. If cleaning is necessary, refer to Elasto
meric Bearing - Care and Cleaning.
(19). On four-bladed tail rotor system,
reconnect bungee (Ref. Section (1). Apply teetering force by hand to rotor
67-20-10). blades (stop-to-stop). Check for
fork-to-bearing bond failure. Failure is
(20). Check rigging of tail rotor controls (Ref. indicated by any motion between outer
Section 67-20-10). bearing cage and fork (bearing turns in
Page 206
MAINTENANCE MANUAL
fork). If failure is noted, remove bearing (8). Reinstall rubber blade stop.
and rebond in fork according to instruc
tions in the CSP-COM-5.
(2). Teeter blades stop-to-stop. Observe
four radial molded ridges on each
bearing as teetering takes place. If
ridges assume continuous curved
shape, bearings are intact. Discontinu
TAIL ROTOR
ity in molded ridges indicates bearing
failure and bearing must be replaced.
(3). Check bearing for general condition.
Replace bearing if damaged. Evidence
STRING SPRING SCALE
of light swelling, pock marks and 2.00 IN.
crumbs are surface conditions and are (5.08 CM)
not indications of bearing failure.
(4). Elastomeric bearings are suspected of 1.00 IN. 369F/FF
(2.54 CM)
being unserviceable if visual inspection
reveals rubber deterioration or separa
tion, or a vibration is reported. Do the 369D/E
following steps to check blade flapping SPRING SCALE
STRING
resistance measurement to determine if
3.00 IN. 3.00 IN.
suspected elastomeric bearing has (7.62 CM) (7.62 CM)
failed. ZERO LOAD POSITION
(5). To do the measurement, remove rubber VIEW LOOKING AFT G64-2003A
blade stop between tail rotor hub and
fork on inboard hub. The outboard tail Figure 204. Blade Flapping Resistance
rotor assembly can be checked without Check
any disassembly.
6. Elastomeric Bearing Care and Cleaning
Do not remove hub-to-drive
CAUTION fork hinge bolt to remove Elastomeric bearings are not inherently
2-bladed tail rotor assembly. This bolt resistant to grease, oils or solvents if im
should only be removed according to in mersed. They are, however, somewhat resis
structions in the CSP-COM-5. Damage to tant to occasional splash or spoilage of these
strap pack can occur if any other procedure materials if exposed on an occasional basis. If
is used. elastomeric materials do come in contact with
these fluids, the elastomer surface should be
(6). The rubber blade stop must be re immediately cleaned. If cleaning is accom
moved. Reassemble tail rotor with plished properly, the effect of greases, oils or
rubber blade stop removed. solvents on the performance of the elastomeric
(7). Measure flapping resistance of blades material will be minimal. If replacement of
using spring scale attached within 1.00 elastomeric bearing is required, refer to
inch (2.54 cm) for 369D/E or 2.00 inch CSP-COM-5.
(5.08 cm) for 369FF inboard of blade tip (1). If greases, oils or solvents come in
(Ref. Figure 204). Block or hold tail contact with the elastomeric material,
rotor pedal in neutral position. While wipe immediately with clean, dry rag.
pulling 90 degrees from plane of
rotation, record spring scale value when (2). If wiping is not sufficient (oil or grease
blade tip is 3.00 inches (7.62 cm) is too thick), clean the affected area of
inboard and outboard from no-load the elastomer with a soft bristle brush
position. Scale must indicate 1.5—5.0 and a solution of pure soap and water.
pounds (6.672—22.24 N). If load is not
within specified limit, replace bearing. (3). Rinse with tap water.
Page 207
MAINTENANCE MANUAL
Page 208
MAINTENANCE MANUAL
Section
64−25−30
Anti−Torque Fan
(500/600N)
MAINTENANCE MANUAL
ANTI−TORQUE FAN
1. Anti−Torque Fan Assembly B. Anti−Torque Fan Installation
The purpose of the fan is to provide anti-tor
que control using a variable flow of air, across Consumable Materials
variable pitch blades, down the tailboom. The (Ref. Section 91−00−00)
anti-torque fan liner, felt metal seal, provides Item Nomenclature
a controlled gap between the fan and the felt CM702 Lockwire CRES
metal seal for optimum efficiency of the fan
during flight.
Locknut will become loose if not
CAUTION
NOTE: The NOTARr anti-torque control sys installed facing the correct di
tem must be re-rigged immediately after re rection.
placement of any component, control rods,
(1). Align and install fan assembly on
or linkages, and if helicopter operation re
support shaft.
veals a rigging deficiency.
(2). Install washer on shaft.
2. Anti−Torque Fan Replacement
(3). Install locknut and torque nut to
(Ref. Figure 401 and Figure 402) 40—42 foot-pounds (54—57 Nm).
Install lock washer.
Special Tools (4). Install pitch bearing housing using six
(Ref. Section 91-00-00) bolts and washers, Torque bolts to
Item Nomenclature 80—100 inch-pounds (9.04—11.30
ST605 Fan nut socket Nm) and lockwire (CM702).
(5). Install fan pitch control tube (Ref.
A. Anti−Torque Fan Removal Section 67-20-30, Fan Pitch Control
Tube Installation).
(1). Remove tailboom (Ref. Section
53-40-30). (6). Install tailboom (Ref. Section
53-40-30).
(2). Remove nut and lock washer from aft
tube assembly. 3. Anti−Torque Fan Blade Replacement
(3). Remove fan pitch control tube (Ref. (Ref. Figure 401)
Section 67-20-30, Fan Pitch Control
NOTE: When a blade needs replacement for
Tube Removal).
any reason, whether it be service related or
(4). Remove six bolts, washers and pitch at overhaul, replace associated bolt, washer,
control housing from fan. and nut.
(5). Remove lock washer from nut and shaft A. Anti−Torque Fan Blade Removal
by releasing the holding tangs from lock (1). Remove anti-torque fan from helicopter
nut and pull locking ring from support (Ref. Anti-Torque Fan Removal).
shaft knurl.
(2). Remove fan blade from strap assembly
(6). Remove locknut in a counter-clockwise by removing cotter pin, washer and pin.
direction, using coupling socket (ST605)
and coupling holding fixture tool. B. Anti−Torque Fan Blade Installation
(7). Remove washer from shaft. (1). Install fan blade and align retention
hole with upper strap assembly reten
(8). Remove fan from helicopter. tion hole.
Page 401
MAINTENANCE MANUAL
EXAMPLE OF INK MARK DATE
MDHC P/N 500N5311−5

11/04
BLADE
ASSY
OO7
XX/XX
STRAP ASSY
EXPIRATION DATE
SHELTON CT.USA
S/N LK1014
(NOTE 1)
WASHER
STUD VIEW LOOKING

FORWARD
COLLAR NUT
HUB - BLADE
BUSHING
BOLT
PIN
WASHER
WASHER
(COUNTERSUNK)
COTTER PIN (NOTE 2)
PITCH HORN
WASHER
PITCH PLATE
NUT
FAN HUB
RETENTION PLATES
NOTE:
1. INSTALL STRAP WITH SERIAL NUMBER FACING AFT DIRECTION.
2. INSTALL WASHER WITH COUNTERSINK AGAINST BOLT-HEAD. G64-2005C
Figure 401. Anti−Torque Fan
Page 402
MAINTENANCE MANUAL
(2). Install pin, washer and cotter pin. NOTE: Inspect strap assembly for condition
and expiration date. Pay particular atten
(3). Reinstall anti-torque fan in helicopter tion to area around the two spools. Inspect
(Ref. Anti-Torque Fan Installation). for cracks in the polyurethane coating. If
any cuts or breaks are more than 0.020 inch
(4). Do a fan balance check (Ref. Section (0.508 mm) in depth or 0.25 inch (6.35 mm)
18-20-30, Fan Balance Check). in length, replace the strap.
D Tension-torsion straps have a life limit
Consumable Materials that starts when their package is opened.
(Ref. Section 91−00−00) If the date the package was opened is un
Item Nomenclature known, the 5 year calendar life is based
on the manufacturing cure date.
CM312 Ink stamp, permanent
D Tension-torsion straps can be put back in
their package, and life limit not started, if
not out of the package more than five
4. Fan Blade Strap and Pitch Horn days.
Replacement
(2). If tension-torsion strap is removed
(Ref. Figure 401) Remove and install the pitch from package for no more than five
horn and strap assembly using the following days, do the steps that follow:
procedures. (a). Replace desiccant in package, use
desiccant (CM826).
NOTE: NOTE: If you can not seal package; put, ten
D The following procedure covers the indi sion-torsion strap, package, and desiccant
vidual removal of one strap assembly and (CM826) in new plastic bag.
pitch horn. If disassembly of all is re (b). Put tension-torsion strap in package
quired, use the following steps for each and seal package opening with tape.
one requiring removal. (c). Put package in box and seal box with
tape.
D When strap is replaced, replace related
bolt, washer, and nut. (3). If replacement strap is new, remove
from package and write the words
A. Fan Blade Strap and Pitch Horn EXPIRATION DATE on the strap face
Disassembly and date five years after the package is
(1). Remove anti-torque fan from helicopter opened. Use permanent ink (CM312).
(Ref. Anti-Torque Fan Removal). (4). Make an item component record card
for each tension-torsion strap.
(2). Remove fan blade(s) (Ref. Anti-Torque NOTE: Install tension-torsion straps so that
Fan Blade Replacement). the cure date is in view when fan is as
(3). Remove bolt and washer retaining sembled.
bottom half of strap assembly between (5). Insert strap assembly thru top of fan
two retention plates. hub and pitch horn until lower (smaller
(4). Remove strap assembly thru top hole of diameter) hole is aligned between holes
fan hub. of two retention plates.
(6). Install blade and align spar before
(5). Remove pitch horn from fan hub. torquing inboard nut, this ensures
B. Fan Blade Strap and Pitch Horn proper alignment of strap with blade.
Reassembly (7). Install new bolt, washers (countersunk
washer against bolt-head), and nut
NOTE: Counterweights on pitch arms are set thru holes of retention plates and of
by the factory; do not attempt to adjust. strap assembly.
(1). Install pitch horn in fan assembly. (8). Install fan blade(s) and torque bolts to
Ensure ball on lower side of pitch horn 100 inch-pounds (11.30 Nm) (Ref.
is inserted in bushing of pitch plate. Anti-Torque Fan Blade Installation).
Page 403
MAINTENANCE MANUAL
(9). Reinstall anti-torque fan in helicopter A. Support Shaft Disassembly

(Ref. Anti-Torque Fan Replacement).
(1). Remove anti-torque fan from helicopter
(10). Do a fan balance (Ref. Section (Ref. Anti-Torque Fan Removal).
18-20-30, Fan Balance Check). (2). Remove fan pitch control tube (Ref.
Section 67-20-30).
5. Retention Plate and Pitch Plate
Replacement (3). Remove fan interconnect driveshaft
(Ref. Figure 401) Remove and install the
retention strap and pitch plate using the (4). Remove fan interconnect shaft coupling
following procedures. from support shaft (Ref. Section
63-15-30).
A. Retention Plate and Pitch Plate
Disassembly (5). Remove support shaft and fan hub
housing from fan support assembly by
(1). Remove anti-torque fan from helicopter removing four cotter pins, nuts,
(Ref. Anti-Torque Fan Removal). washers and bolts.
(2). Remove fan blades (Ref. Anti-Torque (6). Remove hub spacer from shaft.
Fan Blade Replacement). (7). Remove bearing retainer from support
(3). Remove strap assemblies and pitch housing.
horns. (8). Press shaft and fan support bearing out
of support housing.
(4). Remove pitch plate and retention plates
from fan hub. NOTE: Removal of bearing seal at disassembly
is not required unless seals need replace
B. Retention Plate and Pitch Plate ment.
Reassembly
(9). Remove bearing seal from support
(1). Position retention plates in fan hub. housing and bearing retainer.
NOTE: Install tension-torsion straps so that (10). Press bearing off support shaft using
the cure date is in view when fan is as removal ring.
sembled.
B. Support Shaft Reassembly
(2). Install pitch horn and strap assemblies
(Ref. Strap and Pitch Horn Reassemb Consumable Materials
ly). (Ref. Section 91−00−00)
Item Nomenclature
(3). Place pitch plate over retention plates
within fan hub.
(4). Install fan blades (Ref. Anti-Torque
Fan Blade Installation).
(1). Install removal ring on support shaft
(5). Reinstall anti-torque fan in helicopter until firmly seated against shoulder of
(Ref. Anti-Torque Fan Installation). support shaft.
(2). Install support bearing on support
6. Support Shaft Replacement shaft.
(Ref. Figure 402) Remove and install the (3). Install bearing seal in support housing
support shaft using the following procedures. and bearing retainer using sealant
(CM425).
NOTE: When replacing pitch plate and/or sup
port shaft bearings, do not use 900R bear (4). Fill seal cavity with 3.3—4.0 CCs of
ings in the 500/600N helicopters. grease (CM111).
Page 404
MAINTENANCE MANUAL
(5). Install support bearing and shaft in (d). Place the motor on the drive socket
support housing. and unscrew the collar using reverse
drive.
(6). Install bearing retainer and align bolt
holes on support housing. (e). Tap out the pin with a nonmetallic-
faced mallet.
(7). Install hub spacer on shaft.
(2). Removal with Hand Tool:
(8). Install support shaft and housing on (a). Insert the applicable size hex wrench
fan support assembly. using four bolts, into the pin wrenching cavity and
washers, and nuts. Torque nuts to hold securely to prevent pin rotation.
40—50 inch-pounds (4.52—5.65
Nm). Install cotter keys. (b). Rotate the collar counterclockwise
with pliers or vise grips to remove.
(9). Install fan interconnect shaft coupling
on support shaft (Ref. Section (c). Tap out pin with a nonmetallic-faced
63-15-30). mallet.
(10). Install fan interconnect driveshaft (Ref. B. Fan Balance Stud Installation
Section 63-15-30).
Pins can be reused, provided the finish has not
(11). Install fan pitch control tube (Ref. been marred and the threads and wrenching
Section 67-20-30). cavity are in acceptable condition.
(12). Install anti-torque fan on helicopter

(Ref. Anti-Torque Fan Installation). Consumable Materials
Item Nomenclature
(13). Check fan balance (Ref Section
18-00-30) CM409 Adhesive, epoxy
7. Fan Balance Stud Replacement (1). Apply adhesive (CM409) to pin and
insert, while wet, using a nonmetallic-
A. Fan Balance Stud Removal faced mallet or rivet set into hole.
Ensure Pin is seated flush against fan
The following procedure is for removal of the hub.
balance studs when the lock collars have
become loose and allow the stud to rotate. (2). Manually screw the collar onto the pin
a minimum of two threads.
(1). Removal with Pneumatic Tool: Pneu
matic tools can be used only on fasten (3). Installation with Pneumatic Tool:
ers in interference fit holes and fasten
ers with aluminum collars. (a). Insert the hex wrench tip of the
power driver into the wrenching
(a). Select the applicable removal tool. Fit cavity in the pin
removal tool to a 0.375 inch (9.525
mm) square socket drive that will fit (b). Press the power driver socket firmly
a reversible screwdriver motor. against the collar and actuate the
(b). Place the collar removal tool over the driver until the collar wrenching
collar and press firmly. device is torqued off.
(c). Rotate the tool counterclockwise by (c). Withdraw the hex wrench tip from
hand until the teeth bite into the the wrenching cavity and discard the
collar. wrenching collar.
Page 405
MAINTENANCE MANUAL
AFT CONTROL TUBE

(REF)
SUPPORT SHAFT
COTTER KEY
WASHER
NUT
FAN SUPPORT ASSEMBLY

FAN SUPPORT (REF)
BEARING
BEARING
HOUSING
BEARING
RETAINER
RING
WASHER
BEARING
BOLT SEAL
FAN
(REF)
WASHER
BEARING LOCKWASHER
SEAL
HUB
SPACER
LOCKNUT
PITCH WASHER
SLIDER
BOLT
INNER BEARING
RETAINER
PITCH BEARING LOCKWASHER PITCH BEARING

PLATE HOUSING
PITCH BEARING NUT

RETAINER
WASHER BOLT
G64-2006A
Figure 402. Anti−Torque Fan Support Shaft
Page 406
MAINTENANCE MANUAL
(4). Installation with hand tool: (6). Apply grade T primer (CM321) to
(a). Press socket from hand tool firmly threads of new set screw; allow to dry
onto collar. for 30 minutes at ambient temperature.
(b). Insert hex wrench though center of NOTE: Ensure counterweight-to-pitch horn
tool and hold pin to prevent it from index mark aligns correctly. All counter
rotating. weights are indexed the same.
(c). Turn socket clockwise, while holding
hex wrench, until collar is firmly (7). Align index mark on counterweight to
seated against fan hub; wrenching match with mark on pitch horn and
collar will torque off when proper install into pitch horn.
torque is reached. Discard wrenching
collar. (8). Apply grade B locking compound
(CM321) to threads of set screw and
8. Pitch Horn Counterweight Set Screw install into pitch horn. Tighten set
Replacement screw.
(Ref. Figure 403) If, during fan inspection, a
counterweight is found to be loose, the set
screw must be replaced. COUNTERWEIGHT
INDEX MARK
COUNTERWEIGHT
Item Nomenclature
CM216 Loctite remover
CM321 Surface primer locking compound
(1). Apply heat to loose counterweight.

PITCH HORN
(2). Remove and discard set screw. INDEX MARKS
SET SCREW
(3). Remove retaining ring and washer. PITCH HORN
(4). Inspect threads in counterweight for

G64-2011
condition and cleanliness.
(5). Clean pitch horn threads with Loctite Figure 403. Pitch Horn Counterweight Set
remover (CM216). Screw Replacement
Page 407
MAINTENANCE MANUAL
Page 408
MAINTENANCE MANUAL
ANTI−TORQUE FAN
INSPECTION/CHECK
1. Anti−Torque Fan Inspection (c). Scoring; axial marks from bearing
installation or removal.
Inspect the anti-torque fan for the following
conditions: (d). Damaged spines; none allowed.
(1). All components for cracks, nicks, (e). Corrosion and pitting.
corrosion or excessive wear.
(2). Fan support bearing for free movement
(2). Tension-torsion straps for nicks or cuts of set.
in polyurethane coating. No exposed
kevlar fibers allowed. Spools for cracks. (3). Fan support bearing retainer and
housing for:
(3). Hub-to-blade bushings for cracks.
(a). Cracks; none allowed.
(4). Pitch horn for excessive wear (out-of-
(b). Wear.
round condition).
(c). Scoring; axial marks from bearing
(5). Counterweights on pitch horn for
installation or removal.
security. If loose, do the Pitch Horn
Counterweight Set Screw Replacement. (4). Bearing seals for condition.
NOTE: Access the forward counterweights (5). Hub spacer for cracks and wear.
through the fan inlet. Fan hub fairing must
be removed for access (Ref. Section 3. Anti−Torque Fan Liner (Felt Metal Seal)
53-30-30). Inspection
(6). Pitch plate bushing for excessive wear, (1). Inspect for cracks and debonding of
grooves or cracking. liner material.
(7). Blades for cracks, nicks or impact (2). Inspect for cracks around the radius
damage. cutouts of fan support.
(8). Inspect gap between fan blade and tip (3). If cracks are found, stop drill and
seal. Inspect gap between fan blade and inspect every 50 hours (Ref. Section
hub (inboard end of the blade). If gap 05-20-20).
for any blade end exceeds the average
NOTE: Cracks protruding into the Felt Metal
gap of the other blades by more than
Seal are unacceptable, replace seal (Ref.
0.10 inch (2.54 mm), remove and
Anti-Torque Fan Liner (Felt Metal Seal)
inspect the tension-torsion strap for
Replacement).
that blade.
(4). Inspect aft P-seal for tears, deteriora
2. Support Shaft Inspection tion and debonding.
Inspect the support shaft and its associated 4. Fan Blade Inspection (100−Hour)
components as follows:
NOTE: Ensure proper pitch plate and/or sup Consumable Materials
port shaft bearings are installed. 900R bear (Ref. Section 91−00−00)
ings are not to be used in the 500/600N heli Item Nomenclature
copters. CM437 Sealing compound
(1). Support shaft for:
(a). Cracks; none allowed. (1). Inspect polypropylene portion of fan
blade for nicks, scratches, abrasions
(b). Wear. and bulges; pay particular attention to
Page 601
MAINTENANCE MANUAL
leading edge and area around the pin outboard end of blade are reason for
near the outboard edge of blade. blade rejection.
(3). Seal cracks up to 0.10 inch (2.54 mm),
(a). Nicks and abrasion pits that are less coming from area of pin with sealing
than 0.040 inch (1.016 mm) deep and compound (CM437).
0.25 inch (6.35 mm) in diameter can
be blended out. (No more than two (4). If any cracks larger than 0.10 inch (2.54
such repairs can be made per blade.) mm) are found, replace blade.
5. Fan Pitch Slider Inspection
(b). Nicks, scratches and abrasion pits
less than 0.020 inch (0.508 mm) and (1). Inspect slider for dents, scratches,
1.5 inch (3.81 cm) long can be nicks, gouges and corrosion, none
blended out. (Total length of all allowed.
repairs not to exceed 2.0 inch (5.08
cm).) (2). Inspect Karon coating on slider for
condition.
(2). Any bulges or blisters over 0.10 inch (3). Measure across slider, minimum
(2.54 mm) long in area of pin near diameter is 0.805 in. (20.447 mm).
Page 602
MAINTENANCE MANUAL
ANTI−TORQUE FAN
REPAIRS
1. Anti−Torque Fan Liner (Felt Metal Seal) NOTE: On installation of liner assembly, peel
Replacement shim laminates equally among the four
shims to provide a tight fit without deform
(Ref. Figure 801) ing the liner at screw holes and aircraft
structure.
A. Anti−Torque Fan Liner (Felt Metal Seal)
Removal (2). Install four screws. Torque screws per
standard aircraft practices.
(1). Remove tailboom (Ref Section
53-40-30). Do not install sealant in butt
CAUTION splices of liner until after felt
(2). Disconnect safety wire and remove nut, metal is turned/cut to correct clearance. Do
lockwasher, 3 bolts, washers and pitch ing so will damage cutting tool and cause in
bearing retainer plate. correct cutting radius to liner seal.
(3). Remove pitch bearing and inner pitch (3). Install sealant (CM425) in mating bores
bearing retainer; remove pitch slider (cutouts) and around liner edges.
from pitch bearing housing (Ref.
Section 67-20-30). (4). After installing the fan liner and before
installing the fan, trim liner felt metal
(4). Remove fan assembly (Ref. Anti-Torque seal (Ref. Anti-Torque Fan Liner (Felt
Fan Replacement). Metal Seal) Machining). Refer to MD
Helicopter Field Service Representative
(5). Remove sealant around liner edges for additional information.
with plastic scraper.
C. Anti−Torque Fan Liner (Felt Metal Seal)
(6). Remove four screws that secure the Machining
liner to the aircraft structure.
NOTE: Mark liner to aircraft structure to en
sure proper clocking upon installation. If Special Tools
liner is not installed in same position, felt (Ref. Section 91-00-00)
metal seal machining will be necessary for Item Nomenclature
correct fan clearance. ST603 Tip seal cutting fixture
(7). Carefully slide liner aft through
support structure and fan support NOTE:
struts.
D Do this procedure only after a new fan lin
B. Anti−Torque Fan Liner (Felt Metal Seal) er is installed.
Installation D Felt metal material can cause FOD con
tamination.
Consumable Materials (1). Apply masking tape and plastic sheet to
(Ref. Section 91−00−00) fan duct and fan diffuser areas.
Item Nomenclature
Use only cutter and equipment
CM425 Sealing compound CAUTION supplied with fan tip seal tool
ST603 tip seal tool.
(1). Install fan liner so that the larger NOTE: Make sure fan tip seal tool ST603 tip
cutouts fit around the fan support seal tool is clean before you install it.
struts and the smaller cutouts fit
around the rivets that secure the fan (2). Install pin (5) and spacer (6) in fan
inlet fairing. support assembly.
Page 801
MAINTENANCE MANUAL
FELT METAL SEAL

FELT METAL SEAL
BEFORE TRIM
AFTER TRIM
ÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇ
P-SEAL
SCREW
LINER
P-SEAL SHIM
FAN
G64-2007
Figure 801. Anti−Torque Fan Liner (Felt Metal Seal)
Page 802
MAINTENANCE MANUAL
10 FAN SUPPORT ASSEMBLY (REF)

7 21 (4 PL)
8 20 (4 PL)
20 (4 PL)
19 (4 PL)
11 9
15 (REF) 1 (REF)
16 (REF)
6
18
CUTTING
CL 5 DIRECTION
2
CUTTER
7 12
4
22
1
15
13 (2 PL)
14 (2PL)
16
23 (2 PL)
17
CALIBRATION OF CUTTING TOOL HEIGHT G64-2008A
1. FAN TIP SEAL TOOL (PART 1) 13. CAP SCREW

2. CALIBRATION ARM 14. WASHER
3. CUTTER 15. POSITION LOCK KNOB
4. MOTOR COLLET 16. ADJUSTMENT KNOB
5. PIN 17. SPEED HANDLE
6. SPACER 18. AIR PRESSURE VALVE
7. THRUST BEARING 19. BOLT
8. SPACER 20. WASHER
9. NYLON WASHER 21. NUT
10. THRUST BEARING RETAINER 22. BALL LOCK PIN
11. THREADED KNOB 23. SPACER
12. FAN TIP SEAL TOOL (PART 2)
Figure 802. Anti−Torque Fan Liner Felt Metal Seal Machining
Page 803
MAINTENANCE MANUAL
(3). Install bolts (19), washers (20), and Eye protection, a respirator,
nuts (21). Torque nuts. WARNING gloves, and protective cloth
ing must be worn during fan liner ma
(4). Put cutter (3) in motor collet (4). Do not chining.
tighten collet.
(22). Loosen position lock knob (15) and turn
(5). Apply a thin film of oil to inner side of adjustment knob (16) to position cutter
pin (5) and outer side of tool (1) shaft. (3) for a cut of not more than one fourth
width of cutter (3). Tighten lock knob.
(6). Put thrust bearing (7) on tool (1) shaft.
(23). Connect speed handle (17) to tool (12).
(7). Put tool (1) in pin (5) and push forward.
(24). Connect pneumatic pressure source to
(8). Turn tool (1) by hand and adjust cutter tool (12).
(3) to highest point on fan liner. Tighten
collet (4). (25). Turn valve (18) to adjust cutter (3)
speed.
(9). Remove tool (1).
(26). Turn speed handle (17) and turn tool (1)
(10). Remove thrust bearing (7) from tool (1) counter-clockwise at a moderate to
shaft. slow rate. Do not force cut.
(11). Put calibration arm (2) on tool (1). (27). After one full turn, again loosen
position lock knob (15) and turn
(12). Measure dimension between cutter (3) adjustment knob (16) to position cutter
and stop on calibration arm (2). (3) for a cut of not more than one fourth
width of cutter (3). Tighten lock knob.
(13). Loosen motor collet (4) and move cutter
(3) out 0.040—0.050 in. (1.02—1.27 (28). Do step (27). again and again until fan
mm) or until cutter touches stop on liner is fully machined.
calibration arm (2). Tighten collet.
(29). Disconnect pneumatic pressure source
(14). Loosen position lock knob (15) and turn to tool (12).
adjustment knob (16) until cutter (3) is
at aft most position. Tighten position (30). Disconnect speed handle (17) from tool
lock knob. (12).
(31). Remove cap screws (13), washers (14),
(15). Put thrust bearing (7) on tool (1) shaft.
and spacers (23).
(16). Put tool (1) in pin (5) and push forward. (32). Remove ball lock pin (22) and tool (12).
(17). Install spacer (8), thrust bearing (7), (33). Remove threaded knob (11), nylon
thrust bearing retainer (10), nylon washer (9), thrust bearing retainer (10),
washer (9), and threaded knob (11). thrust bearing (7), and spacer (8).
Tighten knob.
(34). Remove tool (1).
(18). Put tool (12) on tool (1) and install ball
lock pin (22). (35). Remove thrust bearing (7) from tool (1)
shaft.
(19). Install cap screws (13), washers (14),
and spacers (23). Torque cap screws. NOTE: The following clearance can vary be
cause of variations in blade length.
(20). Make sure there is no radial or axial
movement in tool (1). (36). Install fan assembly and check for a
0.10 in. (2.54 mm) maximum clearance
(21). Lubricate tool motor, use pneumatic between fan blade ends and felt metal
tool oil. seal.
Page 804
MAINTENANCE MANUAL
(37). In step (13). did cutter touch stop on (41). Install fan assembly (Ref. Anti-Torque
calibration arm? Fan Replacement).
(a). No, go to step (11).
(b). Yes, go to step (38). (42). Install interconnect driveshaft (Ref.
Section 63-15-30).
(38). Remove nuts (21), washers (20), and
bolts (19).
(43). Install fan pitch control rod (Ref.
(39). Remove pin (5) and spacer (6) from fan Section 67-20-30).
support assembly.
(40). Clean fan duct and diffuser areas and
remove masking tape and plastic sheet. (44). Install pitch slider and inner pitch
bearing retainer (Ref. Section
NOTE: The anti-torque control system must be 67-20-30).
re-rigged immediately after removal or re
placement of control rods, linkages and com
ponents or if helicopter operation reveals a (45). Install tailboom (Ref. Section
rigging deficiency. 53-40-30).
Page 805
MAINTENANCE MANUAL
2. Anti−Torque Fan Bearing Regreasing (2). Carefully remove both seals from
bearings (seals will be reused at
reassembly).
Special Tools
(Ref. Section 91-00-00) (3). Inspect seals for damage; no damage is
Item Nomenclature allowed.
ST614 Fan bearing regreasing tool (4). Install bearings between regreasing
tools with a 4 inch (10 cm) 10-24
threaded bolt, washers and wing nut.
(Ref. Figure 803 and Figure 804) The following
procedure is for the regreasing of the NOTE: The following procedure provides 100%
500N5364 and 500N7120 bearings. grease fill. Normal grease fill is 30 to 50%.
Excess grease will extrude past seals for
several hours of operation until the proper
Consumable Materials level is met.
Item Nomenclature (5). Purge bearing with grease (CM111)
CM111 Grease, aircraft until clean grease protrudes from all
four holes in back of tool.
(6). Remove regreasing tool.
NOTE:
(7). Hand spin bearing to purge excess
D Ensure proper pitch plate and shaft sup
grease.
port bearings are installed. 900R bear
ings are not to be used in the 500/600N NOTE: Ensure seals are serviceable. If new
helicopters. seals are required, seals and bearings must
D Refer to Figure 804 for instructions on come from the same vendor.
the manufacture of a regreasing tool. (8). Carefully install seals.
(1). Remove bearings from fan assembly (9). Reinstall bearings (Ref. Support Shaft
(Ref. Support Shaft Disassembly). Reassembly).
BOLT
WASHER
FAN BEARING
WASHER
NUT
REGREASE TOOL
PART A
REGREASE TOOL
PART B
GREASE FITTINGS
G64-2010A
Figure 803. Fan Bearing Regreasing Procedure
Page 806
MAINTENANCE MANUAL
0.50 IN.
A (12.7 MM)
0.125 IN. (3.175 MM)
0.188 IN. (4.7752 MM) (NOTE 1)
DIA THRU HOLE
3.00 IN.
0.580 IN.
(7.62 CM)
(14.732 MM)
1.980 IN.
(5.0292 CM) 1.180 IN.
(2.9972 CM)
0.870 IN.
1.640 IN. (22.098 MM)
(4.1656 CM)
2.280 IN.
(5.7912 CM)
0.094 IN. (2.3876 MM) DIA 0.040 IN.

THRU HOLE (8 PL) (1.016 MM)
A
EQUALLY SPACED AND PART A SECTION A-A
CENTERED BETWEEN GREASE FITTING
MACHINED GROOVES MS15002-1 (2 PL)
B 0.094 IN. (2.3876 MM) DIA THRU
HOLE (2 PL) EQUALLY SPACED 1/4-28 TAPER
AND CENTERED BETWEEN THREADS
MACHINED GROOVES (NOTE 2)
SEAL MATERIAL (3PL) (PARTS

A AND B) USE LOCALLY
AVAILABLE MATERIAL FIRM
HARDNESS [ 75
SECTION B-B
B
PART B QUANTITY STOCK SIZE DESCRIPTION
NOTES:
1 4 x 4 x .50 PLATE
1. DIMENSION MAY VARY DEPENDING ON SEAL MATERIAL THICKNESS AVAILABLE.
2. ALL OTHER DIMENSIONS SAME AS PART A. 1 4 x 4 x .50 PLATE
1 AN23-64 BOLT
MATERIALS:
2 AN960D10L WASHER
1. 6061-T651 ALUMINUM PER QQ-A-250/11 OR EQUIVALENT.
2. SURFACE FINISH 125 RMS. 1 AN315-3R NUT
3. BREAK SHARP EDGES 0.002-0.015 IN. (0.0508-0.381 MM). 2 MS15002-1 GREASE FITTING
4. CHEMICAL FILM TREAT PER MIL-C-5541. 1 M6855/2 RUBBER
5. DIMENSION TOLERANCE ±0.010 IN. (±0.254 MM).
6. GROOVE DIAMETERS TO BE CONCENTRIC TO 0.188 IN. 4.7752 MM) DIA WITHIN 0.002 IN. (0.0508 MM). G64-2009B
Figure 804. Fan Bearing Regreasing Tool (ST614)
Page 807
MAINTENANCE MANUAL
Page 808
MAINTENANCE MANUAL
Section
64−30−00
Tail Rotor Pitch
Control Assembly
(369D/E/FF)
MAINTENANCE MANUAL
TAIL ROTOR PITCH CONTROL ASSEMBLY

1. Tail Rotor Pitch Control Assembly On four-bladed tail rotor
WARNING system, there is strong
(Ref. Figure 203 and Figure 204) The pitch spring pressure in installed tail rotor
control assembly consists of a swashplate that
linkage. Disconnect the in-line bungee
rotates in a matched set of two bearings
before beginning disassembly. Failure
swaged inside a housing. A self-aligning
bearing staked in place at the underside of the to disconnect the bungee can result in
housing provides a pivot for transferring personal injury and/or parts damage.
motion of Sta. 284 bellcrank to the housing.
Clevis ears on end of the swashplate provide
for connection of pitch control links. Movement (1). Remove tail rotor hub and fork assem
of Sta. 284 bellcrank shifts the housing axially bly (Ref. Section 64-20-00).
on the output shaft of the tail rotor transmis
sion and moves pitch control links inward and
outward to change pitch of tail rotor blades. NOTE: The manner in which the pitch control
The swashplate is retained in the pitch control assembly is installed determines rotor-
housing by a washer and locknut. blade orientation to transmission splined
shaft. Installing rotor blades at 90 degrees
2. Tail Rotor Pitch Control Assembly to high and low extremes of shaft runout,
Replacement using reference marks placed on shaft at
time of shaft inspection (Ref. Section
A. Tail Rotor Pitch Control Assembly
Removal 63-25-10) reduces chance of high-frequen
cy vibration and lessens likelihood of having
(Ref. Figure 203 and Figure 204) to rebalance tail rotor.
DIRECTION OF PITCH CONTROL
ASSEMBLY WOBBLE ON OUTPUT SHAFT
0.020 IN.
(0.508 MM)
MAX. BOLT HOLE PITCH CONTROL
CENTERLINE ASSEMBLY
0-10 LB (0-50 N)
SPRING SCALE
(NOTE 1)
TWINE
PIVOT WASHER
PIN (NOTE 2)
NOTES:
1. FORCE REQUIRED TO SLIDE PITCH CONTROL
ASSEMBLY INWARD OR OUTWARD ON OUTPUT
SHAFT MUST NOT EXCEED THREE POUNDS (13.4 N) PITCH
WITH PITCH LINKS, BELLCRANK AND RUBBER BOOTS CONTROL LINK STA. 284
DETACHED FROM PITCH CONTROL ASSEMBLY. BELLCRANK
2. ADD ONE OR TWO AN960KD516 WASHERS AS
REQUIRED FOR CLEARANCE AT PEDAL FULL STROKE. G64-3000A
Figure 201. Pitch Control Assembly − Wobble Check
Page 201
MAINTENANCE MANUAL
0.015 IN. (0.381 MM) install Sta. 284 bellcrank. Rotate

MIN. CLEARANCE
bellcrank back and forth to align
bellcrank bearing with transmission
arm.
(5). If previously disconnected, reconnect
HOUSING tail rotor bungee.
SWASHPLATE 3. Tail Rotor Pitch Control Link Replacement

SWASHPLATE-TO-HOUSING Consumable Materials

CLEARANCE G64-3001A
Figure 202. Swashplate−to−Pitch Control Item Nomenclature
Housing Clearance CM318 Primer
(2). Remove Sta. 284 bellcrank from

transmission (Ref. Section 67-20-10) so Prior to removal of pitch control
that pivot pin in bellcrank is disen CAUTION links, color-code pitch arm bolt
gaged from self-aligning pivot bearing and all washers used at each arm. The bolt,
in pitch control housing. or an identical one, and same combination of
washers must be reassembled at locations
(3). Cut lockwire and pull non-rotating boot from which removed, or tail rotor balance
from groove in pitch control housing. can be seriously affected. Do not allow blade
angles to exceed 30 degrees, approximately
(4). Slide pitch control assembly off trans
1.00 inch (2.54 cm), in each direction. Unde
mission output shaft.
tected damage to tension-torsion strap pack
B. Tail Rotor Pitch Control Assembly can occur.
Installation
(1). Disconnect ends of pitch control link
(Ref. Figure 203 and Figure 204) from clevis ear of swashplate and from
blade pitch control arm.
Consumable Materials (2). To install, insert either end of pitch
(Ref. Section 91−00−00) control link between clevis ears of
Item Nomenclature swashplate.
(3). Install color-coded attaching hardware
CM702 Lockwire CRES and tighten nut to 30—40 inch-
pounds (3.39—4.52 Nm); install cotter
(1). Insert edge of small end of non-rotating pin with wet primer (CM318).
boot into tail rotor transmission (4). Pull pitch control assembly inboard or
housing groove. Make certain that outboard as required to align pitch
drain holes in boot are downward. control link bearing with pitch control
(2). Align spline index marks and slide arm bushing.
pitch control assembly on shaft.
(5). Place special (reduced outside diame
(3). Insert non-rotating boot edge into ter) washer and large-diameter spring
groove of pitch control housing and washer on pitch arm bolt so that
secure with lockwire (CM702). concave surface of spring washer is
against bolt head. With washers in
(4). Apply grease (CM115) to Sta. 284 place on bolt, insert bolt through
bellcrank pivot pin, insert pin into pitch bearing of pitch control link and
housing self-aligning bearing and bushing in pitch control arm.
Page 202
MAINTENANCE MANUAL
PITCH CONTROL
LINK (2 PL)
NUT
PITCH ARM
BOLT (STUD) SPRING SPECIAL WASHER
BALANCE WASHER(S) WASHER (NOTE 4)
(NOTE 3)
NOTE 1
SPLIT RING
(WIRE SPRING)
TAIL ROTOR
ASSEMBLY
PITCH CONTROL
ASSEMBLY (NOTE 5) HINGE
BOLT
TRANSMISSION
OUTPUT SHAFT
ROTATING
BOOT
FORK NOTE 2
FORK BEARING
PITCH ARM
0.255 IN. (6.477 MM)

ORIGINAL THICKNESS
BLADE PITCH ARM
ROOT FITTING
PITCH
0.070 IN. (1.778 MM) MAX. WEAR CONTROL
ALLOWED (2 PL) EACH END LINK
LINK WEAR LIMIT
HUB
0.02 IN. (0.508 MM) MAX.
0.001-0.130 IN. NOTES:

(0.025-3.302 MM 1. CENTERLINE TOOTHSPACE MATCHMARK
MUST ALIGN WITH CENTERLINE TOOTHSPACE
LINK MARK ON FORK WHEN ASSEMBLED ON
SWASHPLATE OUTPUT SHAFT.
BEARING HUB-TO-BLADE PITCH
ARM-CLEARANCE (2 PL) 2. INSTALL WITH WET PRIMER.
3. QUANTITY (IF ANY) DETERMINED BY BALANCE
LINK BEARING AXIAL PLAY REQUIREMENTS.
4. REDUCE OUTER DIAMETER.
5. FOR DISASSEMBLY, REFER TO CSP-COM-5.
G64−3002C
Figure 203. Tail Rotor Pitch Control Assembly (Two−Bladed)
Page 203
MAINTENANCE MANUAL
PITCH CONTROL
LINK (2 PL)
STATIONARY BOOT COTTER KEY
(NOTE 2)
NUT
WASHER
NUT
NOTE 1
WASHER
BOLT
PITCH CONTROL
PITCH ASSEMBLY (NOTE 5)
CONTROL
LINK PITCH ARM
ROTATING BOOT
SPLIT RINGS
BLADE PITCH ARM
PITCH CONTROL
LINK (2 PL)
SPECIAL
ROOT FITTING WASHER TAIL ROTOR
(NOTE 4) ASSEMBLY
SPRING
WASHER
PITCH ARM BOLT (STUD)

HUB
BALANCE WASHER(S) (NOTE 3)
NUT
0.001-0.130 IN.
(0.025-3.302 MM
0.02 IN. (0.508 MM) MAX.
HUB-TO-BLADE PITCH
ARM-CLEARANCE (2 PL)
SWASHPLATE 0.255 IN. (6.477 MM)
ORIGINAL THICKNESS
LINK BEARING AXIAL PLAY
0.070 IN. (1.778 MM) MAX. WEAR

ALLOWED (2 PL) EACH END
LINK WEAR LIMIT

NOTES:
1. CENTERLINE TOOTHSPACE MATCHMARK MUST ALIGN WITH CENTERLINE
TOOTHSPACE MARK ON FORK WHEN ASSEMBLED ON OUTPUT SHAFT.
2. INSTALL WITH WET PRIMER.
3. QUANTITY (IF ANY) DETERMINED BY BALANCE REQUIREMENTS.
4. REDUCE OUTER DIAMETER.
5. FOR DISASSEMBLY, REFER TO CSP-COM-5.
G64-3003C
Figure 204. Tail Rotor Pitch Control Assembly (Four−Bladed)
Page 204
MAINTENANCE MANUAL
(6). Install washer and nut on end of the assembly on shaft of tail rotor transmis
bolt that extends through pitch arm. sion. Note that pitch control links, Sta.
Torque nut to 50—60 inch-pounds 284 bellcrank and rubber boots must be
(5.65—6.78 Nm); install cotter pin with detached from the assembly during
wet primer (CM318). drag check. If drag is more than 3.00
pounds (13.4 N), remove pitch control
(7). Check for clearance between pitch link assembly and clean swashplate and
and tail rotor hub pivot bolt. transmission shaft splines. Use solvent
(CM234) and grade 400 abrasive paper
(8). If removed from pitch arm bolt, install
(CM801) or crocus cloth (CM803). Clean
balance washer(s) of same color code as
again with solvent (CM234) and coat
pitch control arm and secure with nut.
output shaft splines with light film of
4. Tail Rotor and Pitch Control Assembly grease (CM115).
Repair (2). Inspect fork and hub for scratches,
nicks, dents, cracks, corrosion and
(Ref. Figure 203 and Figure 204) similar surface defects. Check for wear
caused by rubbing of aluminum
Consumable Materials support. Scratches and nicks that are
(Ref. Section 91−00−00) not more than 0.005 inch (0.127 mm)
Item Nomenclature depth, 0.120 inch (3.048 mm) depth at
CM801 Abrasive paper, silicon carbide inside corner of fork, can be repaired
(Ref. CSP-COM-5). Worn areas
resulting from rubbing of aluminum
support up to 0.060 inch (1.524 mm)
Repair allowable surface defects on fork and depth can be repaired (Ref. CSP-
hub that can be reworked by using grade 320 COM-5).
abrasive paper (CM801) to round out and (3). Check wire-spring split ring halves for
blend defect. Apply exterior surface touchup damage.
treatment and paint touchup (Ref. Section
20-30-00). (Repairable damage limits are (4). If brinelling wear of inner surfaces of
defined in the Component Overhaul Manual.) swashplate clevis ears is detected,
0.003 inch (0.076 mm) depth is
5. Tail Rotor Pitch Control Assembly allowable without rework or repair. For
Inspection wear of greater depth, Ref. CSP-
COM-5, for limits and allowable
(Ref. Figure 203, Figure 204 and Figure 205) repairs.
(5). If there is evidence of swashplate
Consumable Materials contact with housing, check that
(Ref. Section 91−00−00) minimum clearance of 0.015 inch
Item Nomenclature (0.381 mm) exists through 360 degrees
CM115 Grease, oscillating bearing of rotation with axial loading applied. If
contact is apparent or if axial play can
be measured, replace swashplate or
CM234 Solvent, dry-cleaning bearings (Ref. CSP-COM-5).
CM236 Paint remover
NOTE: Wobble can be accurately measured by
CM721 Tape, aluminum foil
attaching dial indicator support to tail rotor
CM801 Abrasive paper, silicon carbide drive fork, with indicator probe contacting
CM803 Crocus cloth swashplate clevis ear. Use care not to allow
pitch control assembly to slide on output
shaft while measuring wobble.
(1). If tail rotor control system drag or
friction is suspected, use spring scale (6). If pitch control assembly wobbles on
(Ref. Figure 201) to measure drag transmission output shaft, up to 0.020
(sliding friction) of pitch control inch (0.508 mm) is allowable. If greater
Page 205
MAINTENANCE MANUAL
amount of wobble is present, replace from debris and paint remover. Use
swashplate, pitch control housing, aluminum tape (CM721) that is
bearings (Ref. CSP-COM-5) or the resistant to paint remover.
complete assembly.
(7). Check that hub-to-blade pitch arm Extreme care shall be taken to
clearance is 0.001—0.130 inch CAUTION prevent debris or paint remover
(0.025—3.302 mm). contamination in bearing and
(8). Inspect all bolts and nuts for security. bushing areas and tail rotor
blade bond surfaces and cavit
(9). Inspect boots for installation and ies.
deterioration.
Failure to comply with the (c). Remove paint from tail rotor blade
WARNING following inspection can res pitch control arm (all four sides and
ult in the pitch control arm separating the pocket) as shown in Figure 205
from the tail rotor blade. This will lead with paint remover (CM236). (Ref.
to an unbalanced condition, vibration, Section 20-30-00).
partial loss of tail rotor pitch control
and possible loss of directional control
of the helicopter. The pitch control arm area is
CAUTION shot peened and has a protective
(10). For the following tail rotor assemblies chemical coating. No abrasive
only (Ref Figure 205): cleaning, sanding or blending is
MDHI P/N 369D21640-501 and -503 allowed.
HTC P/N 500P3100-101
to include “M”, “MT”, “I” and “IT”
MDHI P/N 369D21641-501 and -503 (d). (Ref. Figure 205 hatched area). Use a
HTC P/N 500P3100-301 bright light and 10X magnifying
to include “M”, “MT”, “I” and “IT” glass to inspect the tail rotor blade
MDHI P/N 369D21642-501 and -503 pitch control arm (all four sides and
HTC P/N 500P3500-701 the pocket) for corrosion, corrosion
to include “M”, “MT”, “I” and “IT” pitting or cracks. No corrosion,
MDHI P/N 369D21643-501 and -503 corrosion pitting or cracks are
HTC P/N 500P3300-501 allowed. If corrosion, corrosion
pitting or cracks are present, replace
Inspect pitch horn area for corrosion or blade assembly before next flight.
evidence of suspect corrosion due to (Ref. Section 64-10-00). Mark the
paint blistering at times specified (Ref. defective tail rotor blade assembly as
Section 05-20-15). scrap and destroy.
(a). Remove tail rotor blade assembly
(e). Make sure the inspection area has a
Use care when handling pitch “dimpled” shot peen surface texture.
CAUTION bearings. Teflon reinforced lin If the inspection area surface is not
ings are easily damaged if mis shot peened or there is evidence of
handled or exposed to contami blending or material removal that
nants. If lining is damaged or affected the shot peened surface,
contaminated, bearing service replace blade assembly before next
life will be shortened or bearing flight. (Ref. Section 64-10-00). In
replacement can be required. addition, check rotorcraft mainten
ance records to make sure no rework
(b). (Ref. Figure 205, Note 2) Carefully was done in this area. Mark the
tape around bearing, bushing and defective tail rotor blade assembly as
blade areas to prevent contamination scrap and destroy.
Page 206
MAINTENANCE MANUAL
(f). If no corrosion, corrosion pitting or (12). Inspect for evidence of rotational

cracks exist and the inspection area binding by hand-turning tail rotor
has an acceptable shot peen surface assembly a few turns while listening for
texture, refinish stripped pitch unusual sounds. If condition is ques
control arm as follows: tionable, do applicable inspection.
1). Apply chemical coating (alodine)

(CM206) per instructions con 6. Tail Rotor Blade Stop Inspection
tained in Section 20-40-00).
2). Apply primer and paint to match NOTE: Change of blade pitch angle when tail
original as required (Ref. Section rotor is not rotating can produce audible
20-30-00). snapping noise. Noise results as lamina
tions of blade strap pack are twisted and
(g). Install tail rotor blade assembly (Ref bent without a centrifugal load. Such noise
Section 64-10-00). is normal and does not indicate a defect.
(11). Do the following inspections for pitch (1). Teeter blades back and forth and check
control bearings at times specified (Ref. for evidence of abnormal binding. Some
Section 05-20-00) and when bearing stiffness is normal, especially when
condition is questionable. blade stop is newer.
(a). Remove cotter pin, nut, washers and
bolt securing Sta. 284 bellcrank to (2). Inspect blade stop for deterioration. Be
transmission. Separate pivot pin on sure to check for cracking or splitting in
bellcrank from pitch control assem stem area of stop. Allowable wear for
bly. rubber stop is to surface of aluminum
support. Stop (and support) can be
(b). Rotate pitch control housing by hand; rotated 90 degrees if stop is excessively
check for rough, binding or hard worn at contact point. Replace rubber
turning. Inspect for grease leakage. If stop if damaged, or if worn area cannot
any of these conditions exist, remove be rotated away from contact point.
pitch control assembly and inspect
for further evidence of damage.
NOTE: If replacement of stop support is re
(c). Check that self-aligning bearing on quired, replace with one-piece stop support
underside of pitch control housing is and retaining nut.
adequately lubricated (packed
approximately 40 percent full) with (3). Check aluminum support for condition
grease (CM115), is movable and is and wear. Replace aluminum support if
serviceable. damaged, or if excessive wear reduces
clearance between tail rotor blade and
(d). Ensure that pivot pin on Sta. 284 tail boom to less than 0.50 inch (12.70
bellcrank is lubricated with grease mm) minimum. Measure allowable
(CM115). Position bellcrank to clearance between tip of tail rotor blade
engage pivot pin with pitch control and tail boom while holding hub
assembly. Secure bellcrank to trans against support, and with assistant
mission with bolt, washers, nut and applying full right tail rotor pedal.
cotter pin.
NOTE: For more detailed information, refer to NOTE: For any questionable items, refer to
inspection, damage, wear and repair limits, complete and detailed inspection, damage,
and requirements for pitch control assembly wear and repair limits, and requirements
(Ref. CSP-COM-5). for tail rotor assembly in CSP-COM-5.
Page 207
MAINTENANCE MANUAL
PITCH CONTROL ARM
A
NOTE 2
NOTE 1
NOTE 1
NOTE 2
A
SECTION A-A
ROTATED
NOTES:
1. REMOVE PAINT FROM ALL FOUR (4) SIDES OF PITCH CONTROL ARM.
2. PROTECT AREAS FROM PAINT STRIPPER, ALODINE AND PAINT.
G64-0004
Figure 205. Tail Rotor Pitch Control Arm Inspection
Page 208
MAINTENANCE MANUAL
7. Tail Rotor Pitch Control Link Inspection (1). Maximum allowable pitch bearings play
is 0.250 inch (6.350 mm).
(Ref. Section 91−00−00) 10. Tail Rotor Swashplate Bearing Regreasing
Item Nomenclature
CM318 Primer
(Ref. Figure 206)
(1). Maximum axial play for bearing in

pitch control link is 0.020 inch (0.508 Consumable Materials
mm). (Ref. Section 91−00−00)
Item Nomenclature
NOTE: Since bearing wear usually occurs only
at blade pitch control arm from displace CM111 Grease, aircraft
ment during operation, links can be re CM217 Isopropyl alcohol
versed and continued in service until either
or both bearings exceed wear tolerance.
Special Tools
(2). Replace pitch control link if worn (Ref. Section 91-00-00)
beyond 0.070 inch (1.778 mm) limit. If Item Nomenclature
wear area(s) are within limits, touch-
ST608 Pitch control assembly holding block
up with primer (CM318) and paint (Ref.
Section 20-30-00) at inspection. ST609 Adapter, torque wrench
8. Tail Rotor Conical Bearing Inspection

(1). Play is not permitted in conical drive (1). Remove tail rotor from helicopter (Ref.
fork bearings (Ref. CSP-COM-5). Section 64-20-00, Tail Rotor Hub and
Fork Replacement).
9. Tail Rotor Pitch Bearing Inspection
NOTE: In the following step, physical check for (2). Remove swashplate from helicopter
pitch bearing wear that causes root fitting (Ref. Tail Rotor Pitch Control Assembly
play on hub can be made by holding one Replacement).
blade firmly and measuring flapping play at
tip of opposite blade. Measured play indi (3). Remove pitch control links from
cates combined wear of pitch bearings. swashplate assembly.
Page 209
MAINTENANCE MANUAL
Tail rotor swashplate bearings

CAUTION cannot be removed from hous
ing without damage to the bearings. If bear
ings are removed from housing, install new
bearings.
TAIL ROTOR SWASHPLATE

BEARING ASSEMBLY
REGREASE
TOOL
G64-3007
Figure 206. Tail Rotor Swashplate Bearing Regreasing
NOTE: For 4-Bladed tail rotor swashplates, NOTE: The following procedure provides 100%
holding block (ST608) will need to be modi grease fill. Normal grease fill is 20 to 40%.
fied. Accomplish modification, or build new Excess grease will extrude past seals for
block, as per Figure 208. several hours of operation until the proper
level is met.
(4). Using wrench (ST609) and holding (8). Purge bearings with grease (CM111).
block (ST608), Remove nut and tang
washer from threaded end of swash (a). Purge bearings slowly to prevent
plate. Discard tang washer. damage to outer seal.
(5). Carefully remove bearing grease seal at (b). Rotate bearings while greasing.
gearbox end of housing (seal will be (9). Remove plastic wedge (or equivalent
reused at reassembly). plug) and regreasing tool.
(6). Inspect seal for damage; no damage is (10). Hand rotate bearing to remove excess
allowed. grease.
NOTE: Ensure seal is serviceable. If new seal is

(7). Install regreasing tool (Ref. Figure 207) required, seals and bearings must come
and plug tang washer groove with from the same vendor.
locally fabricated plastic wedge (or
equivalent plug). (11). Install serviceable seal.
Page 210
MAINTENANCE MANUAL
0.75 IN. (19.05 MM) A

0.25 IN. (6.35 MM)
1.563-18 UNJS-3B
THREADS PER MIL-S-8879
3.00 IN.
(7.62 CM) 2.25 IN.
(5.715 CM)
MS15002-1 GREASE FITTING

SEAL MATERIAL 1/4-28 TAPER THREADS 0.093 IN.
SECTION A-A (2.3622 MM) DIA THRU HOLE
0.50 IN.
(12.70 MM) A
MATERIAL:
1. MATERIAL 6061-T651 ALUM PER QQ-A-250/11 OR EQUIVALENT.
2. SURFACE FINISH 125 RMS.
3. BREAK SHARP EDGES 0.002-0.015 IN. (0.051-0.381 MM).
4. CHEMICAL FILM TREAT PER MIL-C-5541.
5. DIMENSIONAL TOLERANCE ±.030 IN. (±0.762 MM); DIAMETERS TO BE G64-3006A
Figure 207. Tail Rotor Swashplate Bearing Regreasing Tool

NOTE: Using a 5X to 10X magnifying glass, in (14). Clean surface of locknut and swash
spect tang washer center tang to ensure it is plate with a lint-free cloth dampened
acceptable (Ref. Figure 209). with alcohol (CM217).
(12). Install nut with a new tang washer. NOTE: Avoid getting torque seal in swashplate
Using wrench (ST609) and holding splines.
block (ST608), torque nut to 550—600
inch-pounds (62.14—67.79 Nm). (15). Apply a 0.125 inch (3.175 mm) wide
(13). Bend one tang of washer into any torque strip, using torque seal or
aligned slot on nut. equivalent, to surface of swashplate
assembly and locknut in two places
NOTE: Avoid getting alcohol in bearings. (Ref. Figure 209).
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MAINTENANCE MANUAL
1.50 IN. 0.980-1.010 IN.

(3.81 CM) (24.892-25.654 MM)
0.62 IN. 0.50 IN.
(15.748 MM) (12.70 MM)
.31 R (4 PL)
0.980-1.010 IN.
75° (24.892-25.654 MM)
7.50 IN. 5.75 IN. 5.25 IN.

(19.05 CM) (14.605 CM) (13.335 CM)
2.25 IN. 2.62 IN.

(5.715 CM) (6.6548 CM)
DIA THRU
0.50 IN.
(12.70 MM)
1.13 IN.
0.06 R (TYP) (2.8702 CM)
1.50 IN.
0.88 IN. (3.81 CM)
3.00 IN.
(22.352 MM) (7.62 CM)
MODIFICATION OF 369D29822-3 HOLDING BLOCK FOR USE

WITH 4 - BLADED PITCH CONTROL ASSEMBLY (369D21820).
G64-3008A
Figure 208. Tail Rotor Swashplate Holding Block
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MAINTENANCE MANUAL
TORQUE STRIPE
LOCATIONS
ACCEPTABLE
UNACCEPTABLE
G64-3009
Figure 209. Tang Washer Inspection and Application of Torque Stripe
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Chapter
67
Flight Controls
MAINTENANCE MANUAL
TABLE OF CONTENTS
67-00-00 Flight Controls (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Main Rotor Flight Control System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Anti-Torque Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3. Anti-Torque and Control System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4. Stability Augmentation System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Troubleshooting Main Rotor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Table 102. Isolating Main Rotor Control System Troubles . . . . . . . . . . . . . . . . . . . 103
Table 103. Isolating Tail Rotor Control System Troubles . . . . . . . . . . . . . . . . . . . . 104
Table 104. Anti-torque Fan System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 101. YSAS Electrical Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 102. YSAS Troubleshooting (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 103. YSAS Ground Test Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
67-10-00 Main Rotor Flight Controls (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Cyclic Control Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Cyclic Trim Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Collective Control Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Mixer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E. One-Way Lock Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F. Roof-Mounted Control Rods (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
G. Roof-Mounted Bellcranks (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 1. LH Command Main Rotor and Control System
(369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2. Main Rotor and Control System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. Introduction (369D/E/FF—500N/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Table 401. Flight Controls Command Applicability Matrix
(369D/E/FF—500N/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Pilot Collective Stick Replacement (LHC, LHS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Copilot Collective Stick Replacement (LHC, LHS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 401. Co-Pilot Collective Stick Assembly Installation (LHC, LHS) . . . . . 405
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MAINTENANCE MANUAL

Figure 402. Collective Controls (LHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

4. Pilot Collective Stick Replacement (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Pilot Collective Stick Removal (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Pilot Collective Stick Installation (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
5. Copilot Collective Stick Replacement (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Copilot Collective Stick Removal (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Copilot Collective Stick Installation (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 403. Dual Collective Controls (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
6. Collective Stick Socket Assembly (Inboard) Replacement . . . . . . . . . . . . . . . . . . . . . . 410
A. Collective Stick Socket Assembly (Inboard) Removal . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Collective Stick Socket Assembly (Inboard) Installation . . . . . . . . . . . . . . . . . . . . . 410
7. Collective Torque Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Collective Torque Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Collective Torque Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Figure 404. Collective Stick Socket Assembly (Inboard) (LHC) . . . . . . . . . . . . . . . 412
8. Controls Support Bracket and Bellcrank Replacement . . . . . . . . . . . . . . . . . . . . . . . . 413
A. Controls Support Bracket and Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 413
B. Controls Support Bracket and Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . 413
Figure 405. Controls Support Bracket, Idler Bellcranks
and Cyclic Trim Actuators Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 415
9. Collective Bungee and Over-Center Fitting Replacement . . . . . . . . . . . . . . . . . . . . . 416
A. Collective Bungee and Over-Center Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . 416
B. Collective Bungee and Over-Center Fitting
Installation and Preliminary Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Figure 406. Collective Torque Tube, Gas Producer
Torque Tube and Collective Bungee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
10. Command Cyclic Stick Replacement (RH and LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
A. RH Command Cyclic Stick Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
B. RH Command Cyclic Stick Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
C. LH Command Cyclic Stick Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
D. LH Command Cyclic Stick Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Figure 407. Cyclic Stick Assembly Installation (sheet 1 of 2) . . . . . . . . . . . . . . . . . 420
11. Lateral Control Rods and Sta. 67 Lateral
Cyclic Bellcrank Replacement (LHC, LHS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
A. Lateral Control Rods and Sta. 67 Lateral
Cyclic Bellcrank Removal (LHC, LHS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
B. Lateral Control Rods and Sta. 67 Lateral
Cyclic Bellcrank Installation (LHC, LHS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
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MAINTENANCE MANUAL

Figure 408. Cyclic Controls (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422

12. Lateral Control Rods and Sta. 67 Lateral
Cyclic Bellcrank Replacement (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
A. Lateral Control Rods and Sta. 67 Lateral
Cyclic Bellcrank Removal (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Cyclic Bellcrank Installation (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
13. Cyclic Torque Tube Replacement (LHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
A. Cyclic Torque Tube Removal (LHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
B. Cyclic Torque Tube Installation (LHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Figure 409. Cyclic Torque Tube and One-Way Lock Installation . . . . . . . . . . . . . 425
14. Cyclic Torque Tube Replacement (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
A. Cyclic Torque Tube Removal (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
B. Cyclic Torque Tube Installation (RHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
15. Cyclic Trim Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
A. Cyclic Trim Actuator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
B. Cyclic Trim Actuator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
16. One-Way Lock Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
A. One-Way Lock Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
B. One-Way Lock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
17. Tunnel-Routed Control Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
A. Tunnel-Routed Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
B. Tunnel-Routed Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Figure 410. Tunnel-Routed Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . 430
18. Roof-Mounted Control Rod Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A. Roof-Mounted Control Rod Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Roof-Mounted Control Rod Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
19. Roof-Mounted Bellcrank Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A. Roof-Mounted Bellcrank Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Roof-Mounted Bellcrank Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
20. Link Assembly Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A. Link Assembly Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Link Assembly Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Figure 411. Roof-Mounted Controls Installation (600N) . . . . . . . . . . . . . . . . . . . . . 432
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MAINTENANCE MANUAL

Adjustment / Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

1. Collective and Cyclic Control System Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2. LH Command Control System Rigging (369D/E/FF-500N) . . . . . . . . . . . . . . . . . . . . 501
A. Collective Controls (LH Command) (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . 501
B. Cyclic Controls (LH Command) (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . 502
3. RH Command Control System Rigging (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . 504
A. Collective Controls (RH Command) (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . 504
B. Cyclic Controls (RH Command) (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . 505
Table 501. Travel Distance (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Figure 501. Main Rotor Controls Rigging for Models
369D/E/FF - 500N (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Figure 502. Cyclic and Collective Controls Rigging Tools (RH Command) . . . . . 510
4. LH Command Control System Rigging (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
A. Collective Controls (LH Command) (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
B. Cyclic Controls (L/H Command) (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
5. RH Command Control System Rigging (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
A. Collective Controls (RH Command) (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
B. Cyclic Controls (RH Command) (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Table 502. Travel Distance (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
Figure 503. Main Rotor Control System
Rigging for the 600N (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
6. Cyclic Controls Rigging (L/H Command) (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . 521
7. Cyclic Controls Rigging (R/H Command) (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . 521
8. Cyclic Controls Rigging (L/H Command) (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
9. Cyclic Controls Rigging (R/H Command) (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
10. Deleted — Ref. Section 76-20-00, Adjustment / Test . . . . . . . . . . . . . . . . . . . . . . . . . . 521
Figure 504. Deleted — Ref. Section 76-20-00, Adjustment / Test . . . . . . . . . . . . 522
13. Collective Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
A. Friction Mechanism Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Figure 507. Collective Stick Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
14. Collective Bungee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
A. Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
Figure 508. Adjustment of the Collective Bungee . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
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15. Cyclic Trim Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530

A. Bench Test for Models 369D/E/FF - 500N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
Figure 509. Cyclic Trim Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
B. Bench Test for Model 600N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
16. Special Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
A. Field Rigging Aid for Models 369D/E/FF-500N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
Figure 510. Make a 369D/E/FF - 500N Field Rigging Aid . . . . . . . . . . . . . . . . . . . 535
B. Field Rigging Aid for Model 600N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
Figure 511. Make a 600N Field Rigging Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
C. Mixer Rigging Plate (ST503) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
Figure 512. Make a Mixer Rigging Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
Figure 513. Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
Figure 514. Deleted — Ref. Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
Figure 515. Deleted — Ref. Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
1. Tunnel-Routed Control Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Tunnel-Routed Control Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 602
2. Controls Support Bracket and Bellcrank Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
3. Pilot's Collective Pitch Stick Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4. Copilot's Collective Pitch Stick Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
5. Collective Stick Friction Mechanism Operational Check . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 602. Outboard Collective Stick Inspection (L/H Command) . . . . . . . . . . . 604
Figure 603. Outboard Collective Stick Inspection (R/H Command) . . . . . . . . . . . 605
6. Collective Control Interconnecting Torque Tube Inspection . . . . . . . . . . . . . . . . . . . . 606
7. Collective Bungee Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
8. Inboard Collective Stick Socket Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 606
9. Pilot's Cyclic Control Stick Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
10. Copilot's Cyclic Control Stick Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
11. One-Way Lock Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
12. Cyclic Trim Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
13. Cyclic Control System Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Figure 604. Cyclic Stick and Friction Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
14. Main Rotor Flight Control System 600-Hour Inspection . . . . . . . . . . . . . . . . . . . . . . 609
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Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Tunnel-Routed Control Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Tunnel-Routed Control Tube Inspection and Sleeve Installation . . . . . . . . . . . . . . . 801
A. Control Tube End Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Sleeve Fabrication and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Table 801. Control Tube Re-Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 802. Control Tube Boot Rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
B. Straight Area Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Table 802. Control Tube Straight Area Repair Limits . . . . . . . . . . . . . . . . . . . . . . . 805
3. Controls Support Bracket and Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
A. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
B. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
C. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
4. Pilot Collective Stick (LH Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
A. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
B. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 803. Wiring Diagram and Cable Routing — Collective Stick . . . . . . . . . . 807
C. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
5. Pilot Collective Stick (RH Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
A. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
B. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
6. Copilot Collective Stick (LH and RH Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
A. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
B. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
C. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
7. Collective Control Torque Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
8. Collective Bungee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
A. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
B. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
9. Inboard Collective Stick Socket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
A. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
B. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
C. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
10. Cyclic Control Stick Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
11. Cyclic Friction Mechanism Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
12. Lateral Control Rods and Sta. 67 Bellcrank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
Figure 804. Wiring Diagram and Cable Routing — Cyclic Stick . . . . . . . . . . . . . . 815
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13. Cyclic Torque Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816

14. One-Way Lock Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816
15. Cyclic Trim Actuator Spring Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 816
16. Cyclic Trim Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 817
A. Housing or Trim Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 817
B. Motor/Gear Drive Mechanism Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 817
C. Rework (Calco PNs 8222M6 and 8222M7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 817
67-10-20 Collective and Cyclic Stick Grips (369D/E/FF - 500/600N) . . . . . . . . . . . . . A
1. Collective Pitch Stick Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Collective Pitch Stick Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Cyclic Stick Grip Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Cyclic Control Stick Grip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Cyclic Control Stick Grip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Cyclic Control Stick Grip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Collective Pitch Stick Switch Replacement . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Cyclic Stick Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 203. Cyclic Stick Grip Disassembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . 204
5. Cyclic Stick Grip Switch Replacement (Standard Grip) . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Cyclic Stick Grip Disassembly (Optional T-Grip, PN 369D297846 Only) . . . . . . . . 207
7. Cyclic Stick Grip Reassembly and Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 204. Rework of Cyclic Stick Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
67-20-10 Anti-Torque Flight Controls (Two and Four Blade) (369D/E/FF) . . . . . . A
1. Tail Rotor Control Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Upper Fuselage and Tailboom Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 101. Tail Rotor and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. Sta. 120 Control Rod or Sta. 142 Bellcrank Replacement . . . . . . . . . . . . . . . . . . . . . . 401
A. Sta. 120 Control Rod or Sta. 142 Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Sta. 120 Control Rod or Sta. 142 Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Upper Fuselage and Boom Tail Rotor Control Linkage . . . . . . . . . . . 402
2. Sta. 284 Bellcrank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Sta. 284 Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Sta. 284 Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Tailboom Control Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
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A. Tailboom Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

B. Tailboom Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4. Sta. 95 Bellcrank and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Sta. 95 Bellcrank and Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Tail Rotor Pedal Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 404
B. Sta. 95 Bellcrank and Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
C. Tail Rotor Pedal Assembly - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
D. Co-Pilot's Pedal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
5. Tail Rotor Pedal Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Tail Rotor Pedal Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Tail Rotor Pedal Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
6. Dual Tail Rotor Pedal Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Tail Rotor Controls Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Figure 501. Rigging — Tail Rotor Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 502
2. Tail Rotor Bungee Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Figure 502. Tail Rotor Bungee Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
1. Upper Fuselage and Tailboom Control Linkage Inspection . . . . . . . . . . . . . . . . . . . . . 601
2. Tail Rotor Pedal Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Table 601. Isolating Control System Troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Floor- and Tunnel-Routed Control Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Floor-Routed Tail Rotor Control Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Upper Fuselage and Tailboom Control Linkage Repair . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Rework of Sta. 142 Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . 803
4. Station 78.50 Tail Rotor (Tunnel-Routed) Control Rod . . . . . . . . . . . . . . . . . . . . . . . . 803
A. Tail Rotor Idler Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
5. Tail Rotor Pedal Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
6. Tail Rotor Pedal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
7. Tail Rotor Pedal Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
8. Tail Rotor Bungee Spring Forward Attachment Relocation . . . . . . . . . . . . . . . . . . . . 804
Figure 802. Relocation of Tail Rotor Bungee
Spring Forward Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
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67-20-30 NOTAR Anti-Torque System Flight Controls (500/600N) . . . . . . . . . . . . . . A

1. NOTARR Anti-Torque System Control
Linkages Configuration and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Stability Augmentation System Description and Operation . . . . . . . . . . . . . . . . . . . . 1
3. 500NM7301 YSAS Fin Position Indicator (U.K. Only) . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 1. 500NM7301 YSAS Fin Position Indicator Components . . . . . . . . . . . . . . 2
Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Anti-Torque Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Upper Fuselage Sta. 97.50 (500N) or Sta. 95 (600N)
Bellcrank and Support Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Sta. 97.50 (500N) or Sta. 95 (600N)
Bellcrank and Support Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Sta. 97.50 (500N) or Sta. 95 (600N)
Bellcrank and Support Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Forward Directional Control Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Forward Directional Control Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Forward Directional Control Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4. Splitter Bungee Spring Replacement (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Splitter Bungee Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Splitter Bungee Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
5. Upper Fuselage Station 113.00 Splitter
Assembly and Bellcrank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Station 113.00 Splitter Assembly and Bellcrank Removal . . . . . . . . . . . . . . . . . . . 402
B. Station 113.00 Splitter Assembly and Bellcrank Installation . . . . . . . . . . . . . . . . 402
6. Intermediate Control Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Intermediate Control Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401. Anti-Torque Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Intermediate Control Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
7. Station 137.50 Support Bracket and Bellcrank Replacement . . . . . . . . . . . . . . . . . . . 404
A. Station 137.50 Support Bracket and Bellcrank Removal . . . . . . . . . . . . . . . . . . . . 404
B. Station 137.50 Support Bracket and Bellcrank Installation . . . . . . . . . . . . . . . . . . 404
8. Fan Pitch Control Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Fan Pitch Control Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Fan Pitch Control Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
9. Forward Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Forward Cable Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 402. Upper Fuselage and Boom Control Linkage (Sheet 1 of 2) . . . . . . . . 407
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B. Forward Cable Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

10. Center Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Center Cable Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Center Cable Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
11. Aft Control Rod Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Aft Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Aft Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
12. Sector Assembly and Control Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Sector Assembly and Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Sector Assembly and Control Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
13. Drum Assembly and Idler Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Drum Assembly and Idler Pulley Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Drum Assembly and Idler Pulley Installation (500N) . . . . . . . . . . . . . . . . . . . . . . . 412
C. Drum Assembly and Idler Pulley Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . 412
14. Anti-Torque Pedal Friction Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Anti-Torque Pedal Friction Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Anti-Torque Pedal Friction Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
15. Anti-Torque Pedal Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Anti-Torque Pedal Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Figure 403. Pedal Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
B. Anti-Torque Pedal Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
16. Stability Augmentation System (S.A.S.) Actuator Replacement . . . . . . . . . . . . . . . . 415
A. S.A.S. Actuator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. S.A.S. Actuator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
17. SAS Rate Gyro and Electronic Control Box (Computer) Replacement . . . . . . . . . . . 416
A. SAS Rate Gyro and Electronic Control Box (Computer) Removal . . . . . . . . . . . . . 416
B. SAS Rate Gyro and Electronic Control Box (Computer) Installation . . . . . . . . . . 416
18. YSAS Circuit Breaker and Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Figure 404. YSAS Circuit Breaker and Switch Location . . . . . . . . . . . . . . . . . . . . . 416
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Directional Controls Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2. Fan Pitch Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Figure 501. Fan Pitch Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
3. Pilot Pedal Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Figure 502. Pilot Pedal Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
4. Anti-Torque Pedal Friction Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . 505
5. Thruster Control Rigging (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
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MAINTENANCE MANUAL

Figure 503. Thruster Control Rigging (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 506

6. Thruster Control Rigging (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
7. Left Vertical Stabilizer Assembly Rigging (500N, and 600N with YSAS) . . . . . . . . 508
8. Stability Augmentation System Rigging Instructions
(500N, and 600N with YSAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Figure 504. Left Vertical Stabilizer Rigging
(500N, and 600N with YSAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
Figure 505. Stability Augmentation System S.A.S. (Sheet 1 of 2) . . . . . . . . . . . . 511
Figure 506. Vertical Stabilizer Rigging (600N without YSAS) . . . . . . . . . . . . . . . . 513
9. Vertical Stabilizer Assembly Rigging (600N without YSAS System) . . . . . . . . . . . . 514
10. Vertical Stabilizer Trim Tab Adjustment and
Tool Manufacturing (600N without YSAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
A. Trim Tab Tool Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Figure 507. Vertical Stabilizer Trim Tab Bending Tool . . . . . . . . . . . . . . . . . . . . . . 515
B. Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Table 501. Flight Controls Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
1. Upper Fuselage and Tailboom Control Linkage Inspection . . . . . . . . . . . . . . . . . . . . . 601
2. Anti-Torque Pedal Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Sta. 97.50 (500N) or Sta. 95 (600N) Bellcrank and Support Bracket Inspection . . 601
4. Forward and Intermediate Directional Control Tube, and Link Inspection . . . . . . 601
5. Splitter Bungee Spring Inspection (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
6. Sta. 113.00 Splitter Assembly and Bellcrank Inspection . . . . . . . . . . . . . . . . . . . . . . . 602
7. Forward and Center Cable Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
8. YSAS Actuator, Rate Gyro and Electronic Control Box Inspection . . . . . . . . . . . . . . 602
9. Fan Pitch Control Tube Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Table 601. Isolating Control System Troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 601. Control Cable Coupling Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 602. Forward and Center Cable Relief Area Inspection . . . . . . . . . . . . . . . 604
Figure 603. Control Cable Telescopic Swivel End Inspection . . . . . . . . . . . . . . . . . 605
10. Sector Assembly, Control Cables and Drum Assembly Inspection . . . . . . . . . . . . . . . 606
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Anti-Torque Flight Control Repair - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Sta. 97.50 (500N) or Sta. 95 (600N) Bellcrank and Support Bracket Repair . . . . . 801
3. Forward Directional Control Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
4. Upper Fuselage Sta. 113.00 Splitter Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . 801
5. Intermediate Control Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
6. Sta. 137.50 Support Bracket and Bellcrank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
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MAINTENANCE MANUAL

7. Fan Pitch Control Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802

8. Forward Cable Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
9. Center Cable Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
10. Aft Control Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
11. Thruster Sector Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
12. Drum Assembly and Idler Pulleys Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
13. Anti-Torque Pedal Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
14. Anti-Torque Pedal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
15. Anti-Torque Pedal Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
16. YSAS Actuator Regrease Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
A. YSAS Actuator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
B. YSAS Actuator Regrease and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Figure 801. YSAS Actuator (Cross-Section View) . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Page xii
MAINTENANCE MANUAL
Section
67−00−00
Flight Controls
(369D/E/FF −
500/600N)
MAINTENANCE MANUAL
FLIGHT CONTROLS
FAULT ISOLATION
1. Main Rotor Flight Control System D Floor-routed control tube
Troubleshooting
D Tunnel-routed control tube
Sudden onset of excessive
WARNING and/or unusual main rotor D Sta. 120 control tube
vibrations must be investigated as to D Tail boom control rod that transmits input
cause, before continued flight. Under through a series of bellcranks and idlers.
no circumstance can main rotor track
ing be attempted to correct the prob 3. Anti−Torque and Control System
lem until a thorough inspection of the Troubleshooting
main rotor blades, hub assembly, and
strap pack assembly has been done. Troubleshooting information is divided into:
Make sure that the rotor con (1). Investigation of operational vibration
CAUTION trols are not struck by an object. problems that begin with the tail rotor
Many components are highly stressed and or symptoms that can be recognized
cannot be returned to service if there is sur (ref. Chapter 64)
face damage. When maintenance work is (2). Isolation and localization of an unusual
done near the engine air inlet, comply with controls malfunction (ref. Table 103 or
precautions (ref. Chapter 71) to prevent the Table 104)
entry of foreign objects in the engine.
4. Stability Augmentation System
Troubleshooting information is divided into:
Troubleshooting
(1). Investigation of main rotor vibrations
Death or injury can occur if
(ref. Chapter 62) WARNING safety precautions are not
(2). Investigation of symptoms (ref. taken during electrical system checks
Table 101) with the electrical power ON.
(3). Isolation of troubles (ref. Table 102) Maintenance personnel other

CAUTION than the approved manufactur
First determine which major installation is er representative must not attempt to repair
defective. Isolate each linkage installation the YSAS system and its subsystems and
from others until area of malfunction is components.
located. Then investigate and determine exact
location of malfunction and repair or replace Do the troubleshooting of the yaw stability
defective component(s). Since first indication of augmentation system (YSAS) with:
trouble usually is felt at cyclic or collective D The wiring diagrams (ref. Figure 101 and
pitch stick, isolation procedures in Table 101 Figure 102)
and Table 102 begin with symptoms detected
during operation of these controls. D The fault isolation tree (ref. Figure 103)
2. Anti−Torque Flight Controls D And the ground test box (ref. Figure 104)
Anti-torque flight controls are: Isolate the trouble to a system unit/component

malfunction or a defective unit/component.
D Anti-torque pedals
For removal or replacement of YSAS compo
D Torque tube nents refer to the applicable section.
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MAINTENANCE MANUAL
Table 101. Troubleshooting Main Rotor Controls
Cyclic stick pressure in one Check for continuity between pin S If continuity exists, replace cyclic trim
direction; hands off condition − and pins R, U, V, and X of switch, Cyclic Stick Grip Switch
stick drifts in direction of connector(s) P109 and/or P130. Replacement (Standard Grip).
pressure.
Symptom remains. Isolate wiring to circuit components. If short exists, repair as necessary. If
Check for short circuit between ground short does not exist, replace cyclic trim
and suspect trim mode circuit. actuator.
Cyclic control stick pressures Trim actuator inoperative. Replace actuator.

cannot be reduced by
operating trim switch. Defective components in trim actuator Troubleshoot control circuits: replace
control circuit. defective electrical component(s).
Trim change is too slow. Defective trim actuator. Replace actuator.
Cyclic control sticks have Low fluid in one−way lock fluid Add fluid to one−way lock reservoir.
tendency to move to aft reservoir.
position.
Inadequate cyclic control Helicopter loaded out of center of Check and correct weight and
during flight. gravity range. balance.
Incorrect cyclic rigging. Correct cyclic rigging.
Excessive pressure required Lateral and/or longitudinal friction Loosen lateral and/or longitudinal
for lateral and/or longitudinal device improperly adjusted. friction device.
movement of cyclic control
stick on ground and during Swashplate spherical bearing surface Replace swashplate bearing assembly
flight. (Some droop friction is damaged. if torque required to rotate bearing
always felt when there is no exceeds 32 inch−pounds (3.61 Nm).
rotor rpm.) Scissors crank bearings or hub lower Replace defective bearings.
shoe bearings binding or frozen.
Lateral and/or longitudinal Realign rod end bearing.

interconnecting rod end bearing
binding due to incorrect alignment.
Droop stop plungers sticking. Clean plungers and mating shoe

bushings with isopropyl alcohol
(CM217).
Droop stop followers, rollers and/or Apply rust inhibitor and lubricants
stop ring rusty or corroded. (CM204) to followers, rollers and
droop stop ring.
Droop stop striker plate(s) or cam Replace striker plate and/or cam roller.
roller(s) damaged.
One−way lock check valve, or push Replace one−way lock assembly.

rod shaft that unseats the valve, is
galled or seized.
Page 102
MAINTENANCE MANUAL
Table 102. Isolating Main Rotor Control System Troubles

Binding, locking−up and Disconnect one−way lock. If symptom gone, replace one−way
erratic action of cyclic control lock.
stick.
Symptom remains. Disconnect upper ends of longitudinal If symptom gone and rod ends are
and lateral control rods. serviceable, disassemble and inspect
main rotor mixer controls until
defective part is located.
Symptom remains. Reconnect upper ends of longitudinal If symptom gone and rod ends are
and lateral control rods, and serviceable, disassemble and inspect
disconnect lower ends. pilot compartment controls until
Trouble corrected (Reconnect all control linkage).
Binding, locking−up and CAUTION: Before disconnecting collective pitch control rod, install collective
erratic action of collective bungee installation tool (ST508) to prevent spring reaction on control rod.
control stick.
Disconnect upper end of collective If symptom gone and rod end is
pitch control rod and operate stick. serviceable, disassemble and inspect
main rotor mixer controls until
Symptom remains. Leave upper end of collective pitch Trouble is in pilot compartment
control rod disconnected. collective control linkage.
Symptom remains. WARNING: Do not disconnect any hardware from pilot‘s collective stick unless
collective bungee installation tool (ST508) is installed. Strong bungee spring
pressure can cause linkage reaction and severe personal injury, or parts
damage.
Disconnect gas producer control rod If symptom gone, trouble is in engine

from collective stick. Disconnect droop controls.
control override link from collective
controls torque tube.
Symptom remains. Leave gas producer control rod and Disassemble and inspect pilot
droop control override link compartment collective control linkage
disconnected. until defective part is located.
Trouble corrected (Reconnect all control linkage)
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MAINTENANCE MANUAL
Table 103. Isolating Tail Rotor Control System Troubles

Binding, locking up and erratic Disconnect pitch control links from If symptom gone, replace tail rotor
action of foot pedals. (Do not pitch control assembly. assembly or repair (Ref.
force controls) CSP−COM−5).
Symptom remains. Disconnect Sta. 284 aft boom If symptom gone, clean swashplate
bellcrank from pitch control assembly. bore and output shaft splines.
Lubricate splines. Replace swashplate
if necessary. Check for elongation of
bolt hole in support arm portion of
main housing assembly of tail rotor
gear box, caused by looseness of
bellcrank fulcrum bolt and nut. Repair
(Ref. CSP−COM−5).
Symptom remains. Disconnect floor−routed tail rotor If symptom gone, inspect tail rotor
control rod from foot pedal torque tube control rods and bellcranks until
fitting. defective part is located.
Symptom remains. Loosen foot pedal torque tube If symptom gone, pedal torque tube
brackets mounted on front of floor misaligned; shim for correct alignment.
structure. If symptom remains, disassemble and
inspect tail rotor foot pedal installation
until defective part is located (same
section).
Trouble corrected.
Table 104. Anti−torque Fan System Troubleshooting

Excessive resistance against Binding in controls linkage. Isolate damage or obstruction and
pedal movements. remove.
Restriction against rotating cone. Isolate restriction or damage and
remove.
Binding, locking up or erratic Control rod or cable restrictions or Inspect control rod and control cable
action of pedal movement. misalignment. connections, rod end condition and
bearing movement, replace
components as required.
Pedals feel rachety. Flat spotting on thruster rollers. Replace rollers (Ref. Sec. 53−40−30).
Degraded movement or Restriction or malfunction at splitter Inspect splitter range and freedom of
response of fan control assembly. movement.
linkage.
Degraded travel of force limiting Isolate damage or malfunction and
control rod or diffuser bellcrank replace components.
connections.
Incorrect rigging. Correct rigging.
Inadequate anti−torque/direc- Incorrect rigging. Correct rigging.
tional movement or response
during flight.
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MAINTENANCE MANUAL
G67-0000-101-1
Figure 101. 500N YSAS Electrical Diagram
Page 105
67-00-00 TR18-001
MAINTENANCE MANUAL
G67-0000-101-2
Figure 102. 600N YSAS Electrical Diagram
Page 106
MAINTENANCE MANUAL
G67-2017-1A
Figure 103. YSAS Troubleshooting (Sheet 1 of 4)
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67-00-00 TR18-001
MAINTENANCE MANUAL
G67-2017-2A
Page 108
TR18-001 67-00-00
MAINTENANCE MANUAL
G67-2017-3A
Page 109
67-00-00 TR18-001
MAINTENANCE MANUAL
G67-2017-4A
Page 110
TR18-001 67-00-00
MAINTENANCE MANUAL
ACCEL ACTUATOR
POSITION
EXTEND
OFF
YAW SERVO RETRACT

RATE COMMAND
-15 +15 GROUND

VDC VDC
G67-2018
Figure 104. YSAS Ground Test Box
Page 111
67-00-00 TR18-001
MAINTENANCE MANUAL
Page 112
MAINTENANCE MANUAL
Section
67−10−00
Main Rotor Flight
Controls (369D/E/FF
− 500/600N)
MAINTENANCE MANUAL
MAIN ROTOR FLIGHT CONTROLS

NOTE: The helicopter can be configured three combined motion through pitch control rods to
ways: left-hand single command, left-hand the main rotor blades. Forward and rearward
or right-hand dual command. Chapter 67 movement of the cyclic pitch stick causes
Description and Operation is written for a helicopter motion in a longitudinal direction,
left-hand (LH) dual command configura while side-to-side movement provides motion
tion. Right-hand (RH) dual command is as in a lateral direction. This action varies lift
sembled and operates the same, unless oth developed by main rotor blades and serves as
er instruction is given. primary control by horizontal flight. Pilot's
compartment cyclic controls include the control
(Ref. Figure 1 and Figure 2) stick, a lateral interconnecting rod, lateral
cyclic bellcrank, longitudinal cyclic control
1. Main Rotor Flight Controls interconnecting torque tube and lateral and
The main rotor flight controls system consists longitudinal friction mechanism.
of: (1). Pilot Cyclic Control Stick
D Cyclic control stick The pilot's cyclic control stick consists of a grip
and a tube riveted in a socket. The cyclic grip
D Collective control stick
contains a toggle switch for cyclic trim control
D Mixer controls and a trigger switch for radio/interphone
- lateral bellcrank communication. A blank switch socket is
- longitudinal idler provided at the left of the trim switch for
- collective pitch mixer bellcrank optional equipment. Coiled, insulated and
- longitudinal bellcrank open-ended wiring is provided in the grip for
- longitudinal control-mixer link connection to an optional switch.
- longitudinal link (2). Copilot Cyclic Control Stick
- two lateral mixer links
The copilot cyclic control stick is similar to the
D (369D/E/FF- 500N)Five (5) pitch control pilot except electrical wiring exits above the
rods stick socket. The copilot cyclic stick is detach
D (600N) Six (6) pitch control rods able and can be removed or installed by use of
two quick-release pins.
D Swashplates and Scissors (Ref. 62-30-00
B. Cyclic Trim Actuators
and 62-30-60 Swashplate and Mixer)
Each of the two cyclic trim actuators consists
Movement of the collective pitch stick and
of an actuator, housing support, trim tube and
cyclic control stick is transferred to the mixer
spring assembly. The actuator is essentially a
controls through the control rods routed up
motor-driven, variable length shaft that
through the controls tunnel at the center of
compresses a spring assembly, counteracting
Sta. 78.50 bulkhead. The mixer controls
feedback forces from the main rotor and
transfer a required combination of collective,
compensating for imbalance conditions such as
longitudinal and lateral travel through the
those imposed by crosswinds or unevenly
swashplates to the main rotor blades.
distributed cargo. Cyclic trim is controlled by
A. Cyclic Control Stick the cyclic trim switch on top of cyclic stick grip.
The cyclic trim switch has five positions:
The cyclic pitch control system is a fully normally OFF at the center, and momentary
mechanical control system. Any combination of DWN (forward), UP (aft), LEFT, and RIGHT.
lateral and longitudinal cyclic pitch stick When the trim switch is moved off center to
movement is mixed by cyclic lateral and any of the four trim positions, one of the trim
longitudinal control mixers and transferred to motors operates to provide trim spring force in
the main rotor swashplate, which applies the the desired direction. By momentary activation
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MAINTENANCE MANUAL
of the switch, very small trim increments are increasing or decreasing friction. Friction can
obtained. Trim forces cannot be applied in two be applied or released with one hand by
directions simultaneously; when both lateral rotating the friction adjustment grip.
and longitudinal trim corrections are required,
it is necessary to apply first one, then the (2). Pilot Collective Stick
other. Travel of the cyclic pitch control stick is The pilot collective pitch stick consists
not limited by the cyclic trim mechanism; trim primarily of a switch housing, throttle grip and
spring tension can be overridden at any time. friction mechanism, collective stick tube and
friction mechanism and gas producer control
C. Collective Control Stick
shaft with right angle (pinion and bevel gear)
Collective stick friction mecha drive. Collective pitch stick controls include:
CAUTION nism is designed so that stick the N1 throttle and idle stop release ring, N2
cannot be locked in maximum friction point. governor trim switch, landing light switch,
Safety of flight considerations require that stick friction adjustment grip throttle friction
pilot be able to instantly change any estab nut and a starter-ignition switch.
lished collective pitch stick position, without (3). Copilot Collective Stick
changing friction adjustment in event of a
power failure. There is no suitable check The copilot collective stick consists primarily of
that pilot can make, with helicopter on the a switch housing, N1 throttle grip, stick tube,
ground, to determine if maintenance adjust and internal gas producer control shafts
ment of collective friction is correct. This is having right angle (pinion and bevel) gear
due to large force application necessary to drive. The gear drive linkage is essentially the
override collective bungee and blades rest same as in pilot collective stick housing. The
ing on droop stops. If stick friction is inade copilot collective controls include an N2
quate during flight, a maintenance check governor trim switch.
should be done. Once friction adjustment is
determined to be correct at low friction (4). Collective Bungee
point, any further mechanical adjustment to The collective bungee installation consists of a
alter (increase) friction at low point can male bearing assembly, female bearing
cause stripping of mechanism when grip is assembly, spring and retainer. This unit
fully rotated for maximum friction. attaches between the bungee over-center
fitting and bungee bracket of collective
Collective controls consist of collective pitch interconnecting torque tube. The collective
stick, collective bungee, and the interconnect bungee helps maintain selected collective pitch
ing shaft and linkage. All components, except stick position in flight by counteracting forces
the stick and tunnel-routed collective mixer that are fed back in collective pitch stick(s)
control rod, are located within the seat (blade pitching moments, rotor head strap
structure. Dual control provisions are incorpo pack torsion when collective pitch stick is
rated into the compartment collective controls raised or lowered from mid-position, and
installation. combined imbalance of forces in the controls
A dual-start control is available. This option system). Flight characteristics of the helicopter
allows the copilot to also start the aircraft. It is are such that collective forces are relatively
installed on the forward end of the collective low during most stick travel from low to high
control stick in the pilot and co-pilot positions. blade pitch. At a point near full pitch, stick
forces reverse and become heavy. The purpose
(1). Collective Stick Friction of the adjustable bungee and the overcenter
bracket attachment is to counteract these
Pilot collective pitch stick friction allows the forces so that collective stick loads are
pilot to vary the amount of effort required to relatively constant throughout full range of
raise and lower the collective pitch stick as travel. There are two adjustments provided to
well as increasing stick resistance to position establish or correct collective flight loads. The
change resulting from sudden changes in main collective bungee spring corrects variation in
rotor collective forces. The grip is marked with collective load from low pitch (level flight) to
arrows indicating direction of rotation for high pitch (climb). Setting of overcenter bolt to
Page 2
MAINTENANCE MANUAL
raise or lower bungee fitting reduces or The collective interconnecting torque tube
increases overall collective forces in both low consists of the tube, bungee bracket, bungee
pitch (level flight) and high pitch (climb). fitting and a tube support bearing. The torque
tube interconnects the outboard collective
(5). Collective Stick Socket Assembly pitch stick and the inboard collective stick
socket assembly. The torque tube is supported
NOTE: at the left end by a bearing installed in seat
D With LH command, the pilot socket as structure, and at the right end by the controls
sembly is outboard. support bracket.
D With RH command, the pilot socket as (4). Pilot Compartment Lateral and
sembly is inboard. Longitudinal Cyclic Control Linkage
The collective stick socket assembly is a cast Pilot compartment lateral and longitudinal
magnesium housing that contains gas produc cyclic control linkage consists of two control
er linkage and provisions for attachment of rods and a bellcrank that interconnect lateral
dual collective controls. Internal gas producer control movement, and the cyclic torque tube
drive gear linkage is essentially the same as and one-way lock control system that inter
that in the pilot collective stick housing with connect longitudinal control movement of pilot
the addition of a splined N1 pinion gear for cyclic stick to tunnel-routed mixer control
simplified installation or removal of a copilot rods.
collective stick. In LH command, the N1 pinion NOTE: In the R/H command configuration
gear is integral to the socket. The lower end of there is an additional lateral control rod
the collective mixer (tunnel-routed) control rod that attaches the lower end of copilot cyclic
is attached to the socket housing and the control stick to the lateral cyclic bellcrank.
exterior bellcrank, idler and link transfer (Ref. CSP-IPC-4, 67-10-00, Cyclic Pitch
movement of the pilot collective stick throttle Control Installation - RH Command.)
to the gas producer controls routed through
the fuselage to the engine. E. One−Way Lock Control System
The one-way lock of the cyclic control system
D. Mixer Controls is located in longitudinal control linkage
(1). Collective Mixer, Lateral and Longitu within the pilot seat structure. The one-way
dinal Mixer (Tunnel-Routed) Control lock control system is essentially a self-con
Rods tained, closed-loop hydraulic unit - consisting
of a check valve, relief valve and pushrod
Tunnel-routed control rods mechanically mechanism. The check valve is seated when
transfer displacement of flight controls to longitudinal control force (feed-back) originat
associated bellcranks and the idler at the front ed by main rotor tends to move the one-way
of main rotor mast base. All tunnel-routed lock (and cyclic stick) in an aft direction.
control rods are removed, inspected, repaired Seating the check valve prevents unwanted aft
and installed in same manner. movement of cyclic stick and shunts feed-back
force to helicopter structure. Normally, only
(2). Controls Support Bracket and very slight aft movement of the cyclic stick is
Bellcranks required to unseat the check valve. Should the
check valve (or pushrod shaft that unseats the
The controls support bracket is below the pilot valve) gall and freeze in the valve-closed
seat cover, between right and left inboard sides position, a force of approximately 30 pounds is
of the seat structure. The bracket provides the necessary to open the relief valve and bypass
hingeline for longitudinal and lateral idler the check valve. This force is then required for
bellcrank, tail rotor bellcrank, and the engine each subsequent aft movement of the cyclic
droop control bellcrank. It also provides stick. Conversely, should the check valve
inboard support for the collective torque tube. spring fail, the one-way lock does not function
to shunt longitudinal feedback forces to
(3). Collective Control Interconnecting structure. The unit is mounted in two pivoting
Torque Tube supports attached to seat structure, and has a
Page 3
MAINTENANCE MANUAL
transparent, vented reservoir with a capacity blies, via the aft roof-mounted bellcranks, at
of approximately 0.67 fluid ounce (20 cc). The the mixer assembly.
one-way lock control system is serviced
through the filler with hydraulic oil (6, Table G. Roof−Mounted Bellcranks (600N)
203).
(Ref. Figure 2)
F. Roof−Mounted Control Rods (600N)
(Ref. Figure 2) The forward roof-mounted bellcrank transfer
controls input from the tunnel-routed control
The roof-mounted control rods transmit cyclic rods to the roof-mounted control rods. The aft
and collective flight control input from the roof-mounted bellcranks transfer controls
tunnel-routed control rods, via the forward input from the roof-routed control rods to the
roof-mounted bellcranks, to the link assem link assemblies.
Page 4
MAINTENANCE MANUAL
1. MAIN ROTOR DRIVE SHAFT 1

2. DAMPER
3. BLADE ATTACH PIN
4. MAIN ROTOR BLADE
5. ROTOR MAST SUPPORT
6. ROTATING SWASHPLATE
7. MAIN ROTOR CONTROLS (MIXER, IDLER
BELLCRANKS AND LINKS)
8. LATERAL MIXER CONTROL ROD (CYCLIC)
9. LONGITUDINAL MIXER CONTROL ROD (CYCLIC)
10. COLLECTIVE MIXER CONTROL ROD
11. STATIONARY SWASHPLATE
3 2
4
11
10
7 7
9
6 5
8
25
12. COLLECTIVE CONTROL TORQUE TUBE

27 13. COPILOT'S COLLECTIVE PITCH STICK
14. DROOP CONTROL OVERRIDE LINK
15. COPILOT'S CYCLIC STICK
24 16. LATERAL CYCLIC FRICTION KNOB
23 17. CYCLIC LATERAL CONTROL ROD
18. LATERAL CYCLIC TRIM ACTUATOR
13 19. LONGITUDINAL CYCLIC TRIM ACTUATOR
22 20. LONGITUDINAL CYCLIC FRICTION KNOB
21. ONE-WAY LOCK
22. CYCLIC CONTROL TORQUE TUBE
23. GAS PRODUCER CONTROL ROD
12 24. COLLECTIVE CONTROL BUNGEE
25. ANTI-TORQUE CONTROL ROD (REF)
26. PILOT'S COLLECTIVE PITCH STICK
27. PILOT'S CYCLIC STICK
14
15
21
20
19 17
16 26
18
G67-1000-1-1
Figure 1. LH Command Main Rotor and Control System (369D/E/FF − 500N)
Page 5
MAINTENANCE MANUAL
1. MAIN ROTOR DRIVE SHAFT

2. DAMPER
3. BLADE ATTACH PIN 4
4. MAIN ROTOR BLADE
5. ROTATING SWASHPLATE 2 1
6. MAIN ROTOR CONTROLS (MIXER, IDLER
BELLCRANKS AND LINKS)
7. LATERAL MIXER CONTROL ROD (CYCLIC)
8. LONGITUDINAL MIXER CONTROL ROD (CYCLIC)
9. COLLECTIVE MIXER CONTROL ROD
10. COLLECTIVE CONTROL TORQUE TUBE
11. COPILOT COLLECTIVE PITCH STICK
3
12. COPILOT CYCLIC STICK
13. LATERAL CYCLIC FRICTION KNOB
14. CYCLIC LATERAL CONTROL ROD
15. LATERAL CYCLIC TRIM ACTUATOR
16. LONGITUDINAL CYCLIC TRIM ACTUATOR
17. LONGITUDINAL CYCLIC FRICTION KNOB
18. ONE-WAY LOCK
19. CYCLIC CONTROL TORQUE TUBE
20. GAS PRODUCER CONTROL ROD
21. COLLECTIVE CONTROL BUNGEE
22. ANTI-TORQUE CONTROL ROD (REF)
23. PILOT COLLECTIVE PITCH STICK
24. PILOT CYCLIC STICK
5
9
6
8
22
21 7
12
20
24
19
18 23
10
11
17
16 14
13
15
6G67-035A
Figure 2. Main Rotor and Control System (600N)
Page 6
MAINTENANCE MANUAL

1. Introduction (369D/E/FF—500N/600N) Table 401. is a quick command applicability
matrix to aid in task location for the necessary
The helicopter can be set up in: command. The tasks are linked from the table.
D Dual right-hand command (RHC).
Keep the bolts, washers, and nuts from
D Dual left-hand command (LHC) removed components for reinstallation. (Ref.
CSP-IPC-4, 67-00-00 for a complete
D Single left-hand command (LHS) breakdown of installations).
Table 401. Flight Controls Command Applicability Matrix

(369D/E/FF—500N/600N)
NOTE: In dual right−hand command, the pilot collective is inboard, and the co−pilot collective is outboard.
Pilot Collective Remove and Install (RHC) Para 4.
Co−Pilot Collective Remove and Install (RHC) Para 5.
Collective Stick Socket Assembly (Inboard) Replacement Para 6.
Collective Torque Tube Assembly Replacement Para 7.
Controls Support Bracket and Bellcrank Replacement Para 8.
Collective Bungee and Over−Center Fitting Replacement Para 9.
Cyclic Stick Assembly Replacement (Left) Para 10.
Cyclic Stick Assembly Replacement (Right) Para 10.
Dual RHC
Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank (RHC) Para 12.
Cyclic Torque Tube Replacement (RHC) Para 14.
Cyclic Trim Actuator Replacement Para 15.
One−Way Lock Replacement Para 16.
Tunnel−Routed Control Rod Replacement Para 17.
Roof−Mounted Control Rod Replacement (600N) Para 18.
Roof−Mounted Bellcrank Replacement (600N) Para 19.
Link Assembly Replacement (600N) Para 20.
Page 401
MAINTENANCE MANUAL
NOTE: In dual left−hand command, the pilot collective is outboard, and the co−pilot collective is inboard.
Pilot Collective Stick Replacement (LHC) Para 2.
Co−Pilot Collective Stick Replacement (LHC) Para 3.
Cyclic Stick Assembly Replacement (Right) Para 10.
Dual LHC
Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank (LHC) Para 11.
Cyclic Torque Tube Replacement (LHC) Para 13.
NOTE: In single left−hand command, the pilot collective is outboard.

Pilot Collective Stick Replacement (LHC) Para 2.
Co−Pilot Collective Stick Replacement (LHC) Para 3.
Single LH Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank (LHC) Para 11.
Cyclic Torque Tube Replacement (LHC) Para 13.
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MAINTENANCE MANUAL
2. Pilot Collective Stick Replacement (LHC, (1). Install the collective control stick
LHS) housing as follows:
(Ref. Figure 402) (a). Lubricate the stick housing socket

A. Removal (b). Align the stick housing to its position
on the collective control torque tube.
Special Tools (c). Install the stick housing in its
(Ref. Section 91-00-00) position.
Item Nomenclature
ST508 Collective bungee installation tool (d). Tighten the hardware sequentially
and by small increments until tight.
(2). Install the collective stick as follows:
(1). Remove the outboard collective stick
cover. (a). Align the collective stick to the
torque tube.
(2). Disconnect the pilot collective stick
electrical connector. (b). Move the stick housing inboard
toward its installed position on the
(3). Remove the guide from the structure torque tube.
bracket.
(c). Move the collective torque tube
Use the collective bungee in outboard.
WARNING stallation tool to prevent the (d). Move the bungee bracket to the side
collective stick from sudden movement and install the cradle cap.
that can damage the flight controls and
cause injury to personnel. (e). Move the bungee bracket to the side
and install the cradle cap.
(4). Install the collective bungee installa
tion tool (ST508). (f). For the 369D/E/FF - 500N aircraft
only, connect the droop control
(5). Remove the collective bungee and override link.
inboard collective socket. (g). Install the inboard collective socket
and the collective bungee.
(6). (369D/E/FF - 500N) Disconnect the
droop control override link. (3). Remove the collective bungee installa
tion tool (ST508).
(7). Move the bungee bracket to the side
and remove the cradle cap, then move (4). Install the guide to the structure
the collective torque tube inboard. bracket.
(5). Attach the pilot collective stick electri
(8). Remove the stick housing from the cal connector.
torque tube.
(6). Make sure that the wiring does not
(9). Move the stick outboard and off of the catch when the stick is raised and
torque tube. lowered.
B. Installation (7). Install the outboard collective stick
cover.
Consumable Materials (8). Remove the snap plug from the exterior
(Ref. Section 91−00−00) skin.
Item Nomenclature
(9). Turn the throttle between the gas
CM116 Grease, aircraft and instrument producer tube and the hexagonal ID of
the drive gearshaft in the stick housing.
Page 403
MAINTENANCE MANUAL
NOTE: You must have zero backlash at each (1). Lubricate the stick housing socket with
end of the torque tube. grease (CM116).
(10). Tighten the pipe plug in the end of the
torque tube. (2). Turn the pilot and copilot throttle grips
so that the grip bolts are down.
(11). Adjust the pilot collective stick gas
producer control linkage so the inboard (3). Install the copilot stick on the inboard
stick socket gears are mid-travel when housing socket extension.
the pilot stick throttle grip is set to
mid-travel. (4). Move the copilot throttle back and forth
3. Copilot Collective Stick Replacement to engage the socket pinion and adapter
(LHC, LHS) splines.
(Ref. Figure 401) (5). Align the copilot stick to its position.
A. Removal
(6). Install the copilot stick.
(1). Remove the collective stick cover from
the seat structure. NOTE: The wiring must not catch when the
(2). Disconnect the copilot collective stick is raised and lowered.
(7). Attach the copilot collective electrical
(3). Remove the stick tube socket adapter. connector.
(4). Move the stick assembly forward and
off of the inboard stick housing. NOTE: The correct distance is 0.030—0.150
inch (0.762—3.302 mm) between the
B. Installation downstop and the seat structure with the
collective stick in full down position.
(Ref. Section 91−00−00) (8). Install the downstop assembly.
Item Nomenclature
CM116 Grease, aircraft and instrument (9). Install the collective cover on the seat
structure.
Page 404
MAINTENANCE MANUAL
STICK ASSEMBLY
COLLECTIVE PITCH STICK ASSEMBLY
NOTE 2
NOTES:
1. 0.030-0.150 IN. (0.762-3.81 MM) MUST BE MAINTAINED BETWEEN 0.030-0.150 IN.
STOP AND BRACKET WHEN PILOT COLLECTIVE CONTROL IS IN (0.762-3.81 MM)
FULL DOWN POSITION. (NOTE 1)
2. LUBE SOCKET WITH GREASE BEFORE STICK INSTALLATION.
DOWNSTOP CLEARANCE
G67-1005A
Figure 401. Co−Pilot Collective Stick Assembly Installation (LHC, LHS)
Page 405
MAINTENANCE MANUAL
COLLECTIVE MIXER
NOTE 3 TUNNEL-ROUTED
CONTROL ROD
INBOARD COLLECTIVE
GAS PRODUCER STICK SOCKET
CONTROL ROD
BUNGEE OVER-CENTER
ADJUSTMENT BOLT
(NOTE 1)
BUNGEE
GAS PRODUCER
INTERCONNECTING
TORQUE TUBE
COLLECTIVE CONTROL
INTERCONNECTING
TORQUE TUBE
BUNGEE SPRING
ADJUSTMENT NUT (NOTE 2 N2 DROOP CONTROL OVERRIDE
- SEE CAUTION) LINK (369D/E/FF - 500N)
COLLECTIVE STICK FRICTION
MECHANISM AND GUARD
PILOT'S COLLECTIVE
PITCH STICK
NOTE 5 NOTE 4
THROTTLE FUSELAGE
THROTTLE FRICTION SKIN
GUIDE
SLEEVE
BUSHING NOTE 5
NOTES:
1. ROTATED CLOCKWISE TO INCREASE, COUNTERCLOCKWISE TO
DECREASE OVERALL COLLECTIVE DOWNLOADS.
2. (LOOKING AFT AT THE BUNGEE) ROTATED CLOCKWISE TO INCREASE
COUNTERCLOCKWISE TO DECREASE, BUNGEE PRELOAD.
CAUTION: DO NOT ADJUST BUNGEE SPRING TENSION WHILE BUNGEE
INSTALLATION TOOL IS INSTALLED. USE OVER-CENTER ACTION OF STICK TO
COMPRESS SPRING TO REMOVE TOOL.
3. BUSHINGS MUST PROTRUDE A MINIMUM OF 0.010 IN. (0.254 MM) TO
A MAXIMUM OF 0.060 IN. (1.524 MM) AFTER BOLT IS TIGHTENED.
4. FOUR NUTS TORQUED EQUALLY AND BY SMALL INCREMENTS.
5. WASHERS ARRANGED TO ALIGN GUIDE WITH STICK; LOOSELY
SPACED WITH THREE WASHERS.
G67−1003B
Figure 402. Collective Controls (LHC)
Page 406
MAINTENANCE MANUAL
4. Pilot Collective Stick Replacement (RHC) B. Pilot Collective Stick Installation (RHC)
NOTE: In right-hand command, the pilot col
lective is inboard, and the co-pilot collective Consumable Materials
is outboard. (Ref. Section 91−00−00)
Item Nomenclature
(Ref. Figure 403) CM116 Grease, aircraft and instrument
A. Pilot Collective Stick Removal (RHC)
(1). Lubricate the stick housing socket with
Special Tools grease (CM116).
(2). Make sure that the pilot and copilot
Item Nomenclature
throttle grips are in the same position
ST508 Collective bungee installation tool and move the pilot stick housing on the
collective torque tube.
(1). Remove the stick cover from the seat (3). Align and install the stick housing on
structure. the collective control torque tube.
(2). Disconnect the pilot collective stick (4). Attach the gas producer control rod.
(5). Align the bellcrank centerline, gear
(3). Remove the hardware from the seat shaft assembly gear cutout, and the
structure bracket. pilot throttle.
The collective bungee instal (a). Tighten pipe plug on gas producer
WARNING lation tool prevents rapid, torque tube.
uncontrolled movement of the collec
tive which could damage the flight con (b). Check throttle rigging.
trols and cause injury to personnel.
(6). Put the friction guide in the seat
(4). Install the collective bungee installa structure bracket with the plain
tion tool (ST508). bushing, slotted bushing, and three
washers spaced between bracket ears so
(5). Remove the collective bungee and that the guide is in line with the stick.
inboard collective socket.
(7). Install the bolt, two washers, nut, and
(6). For the 369D/E/FF — 500N only, new cotter pin.
disconnect the droop control override
link. (8). Attach the pilot collective stick electri
cal connector.
(7). Move the bungee bracket and remove
the cradle cap. (9). Make sure the wiring does not catch
when the stick is raised and lowered.
(8). Move the collective torque tube inboard.
(10). Do an operational check of the collective
(9). Disconnect the gas producer control stick friction to adjust the friction
rod. mechanism.
(10). Remove the pilot stick housing from the (11). Install the collective stick cover on the
torque tube. seat structure.
Page 407
MAINTENANCE MANUAL
5. Copilot Collective Stick Replacement B. Copilot Collective Stick Installation (RHC)

(RHC)
A. Copilot Collective Stick Removal (RHC) Item Nomenclature
CM116 Grease, aircraft and instrument
Special Tools
(Ref. Section 91-00-00) (1). Install the collective stick and cover as
Item Nomenclature follows:
(a). Lubricate the stick housing socket
(1). Remove the outboard collective stick
cover. (b). Align and install the stick housing on
the collective control torque tube.
(2). Disconnect the copilot collective stick
electrical connector. (c). Tighten the hardware sequentially
and in small increments until tight.
NOTE: The RHC does not have a friction guard.
The full pilot collective stick cover is the (d). Move the collective torque tube
guard for the RHC configuration. Only the outboard.
LHC has a guard that is not included in the (e). Move the bungee bracket to the side
full LHC configuration. and install the cradle cap.
(3). Remove the seat structure bracket. (f). For the 369D/E/FF - 500N only,
connect the droop control override
The collective bungee instal
WARNING lation tool prevents rapid, link.
uncontrolled movement of the collec (g). Install collective bungee and inboard
tive which could damage the flight con collective socket.
(2). Remove the collective bungee installa
(4). Install the collective bungee installa tion tool (ST508).
tion tool (ST508).
(3). Attach the copilot collective stick
(5). Remove collective bungee and inboard electrical connector.
collective socket.
(4). Make sure the wiring will not catch
(6). For the 369D/E/FF - 500N only, when the stick is raised and lowered.
disconnect the droop control override
link. (5). Remove the snap plug from the exterior
skin.
(7). Move the bungee bracket to the side
You must have zero backlash at
and remove the cradle cap. CAUTION both ends of the tube. Tighten
(8). Move the collective torque tube inboard. the pipe plug in the end of the torque tube to
prevent backlash.
(9). Remove the stick housing from the
torque tube. (6). Turn the throttle between the gas
producer tube and hexagonal ID of the
(10). Move the stick off of the torque tube. drive gearshaft in the stick housing.
Page 408
MAINTENANCE MANUAL
PILOT'S COLLECTIVE
PITCH STICK COVER
COLLECTIVE
FRICTION GUIDE FLEXIBLE
CLOSURE
THROTTLE
PILOT'S FRICTION
THROTTLE NUT
GRIP
GAS PRODUCER INTERCONNECTING

TORQUE TUBE
COLLECTIVE CONTROL
INTERCONNECTING
TORQUE TUBE
IDLE STOP COLLECTIVE
RELEASE RING STICK FRICTION
CONTROL PILOT'S COLLECTIVE
N2 DROOP CONTROL
PITCH CONTROL STICK
OVERRIDE LINK
(369D/E/FF - 500N)
NOTE 3
COPILOT'S COPILOT'S
PLAIN THROTTLE COLLECTIVE PITCH
BUSHING GRIP CONTROL STICK
NOTE 1
NOTE 1
SLOTTED
BUSHING
(NOTE 2)
BUSHING INSTALLATION
NOTES:
1. ARRANGE WASHERS TO LINE UP GUIDE WITH STICK; SPACE LOOSELY WITH
THREE WASHERS.
2. SLOTTED BUSHING MUST PROTRUDE A MINIMUM OF 0.010 INCH (0.254 MM) TO A
MAXIMUM OF 0.060 INCH (1.524 MM) AFTER BOLT IS TIGHTENED.
3. FOUR NUTS TORQUED; EQUALLY AND BY SMALL INCREMENTS.
4. ALLOWABLE FREE PLAY IN CO-PILOT'S TWIST GRIP IS ±5°.
G67-1004A
Figure 403. Dual Collective Controls (RHC)
Page 409
MAINTENANCE MANUAL
6. Collective Stick Socket Assembly (3). (369D/E/FF - 500N) Install the NR

(Inboard) Replacement disable switch and attach the socket
assembly housing to the collective
(Ref. Figure 404) torque tube. (Ref. CSP-HMI-3, Section
A. Collective Stick Socket Assembly 95-00-00)
(Inboard) Removal
(1). Remove the pilot seat cover and (4). Turn the pilot throttle and make sure
controls access door. there is no backlash between the gas
producer torque tube and hexagonal
(2). Disconnect the collective mixer tunnel- interior of drive gearshaft in the socket
routed control rod. assembly housing.
(3). Disconnect the gas producer control rod
from the idler. NOTE: If the installed plug does not expand the
(4). Remove the four nuts and washers that tube, a 1/8-27 internal-wrenching pipe plug
attach the socket assembly to collective 0.38 inch (9.65 mm) can be used. The plug
torque tube and remove the assembly. must not stick out more than 0.030 inch
(0.762 mm).
(5). (369D/E/FF - 500N) Remove the NR
disable switch (Ref. Chapter 95).
(5). To prevent backlash:
NOTE: If disassembly is not intended, install
four spacers and install washers and nuts
on protruding bolts to keep assembly intact. (a). Remove the housing cap, the gear
B. Collective Stick Socket Assembly shaft, and the pipe plug from the end
(Inboard) Installation of the torque tube.
Consumable Materials (b). Put anti-seize compound (CM129) on

(Ref. Section 91−00−00) the pipe plug.
Item Nomenclature
(c). Prevent backlash by tightening the
pipe plug in the end of the torque
(1). Remove four nuts, washers and spacers tube. Zero backlash is required at
from socket assembly mounting bolts. both ends of the tube.
(2). With pilot collective throttle grip at
midtravel, turn the bellcrank to engage (6). Install the gearshaft and housing cap.
the socket assembly to gearshaft on the
hexagonal end of the gas producer
torque tube. (7). Install the gas producer control rod to
NOTE: the idler.
D With the pilot throttle grip at midtravel,
two grip attach bolts should be straight (8). Install the collective mixer tunnel-rout
down. At the same time, the idler-to-gas ed control rod.
producer control rod bolt holes should be
in line with centerline of inboard stick as
sembly housing cap. (9). Remove the bungee installation tool.
D At midtravel, the inboard N1 pinion gear
spline wide toothspace should be at one
o'clock as viewed looking aft into the open (10). Install the pilot seat cover and the
end of the socket. controls access door.
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MAINTENANCE MANUAL
7. Collective Torque Tube Replacement (10). Remove the gas producer torque tube
out of collective torque tube.
(Ref. Figure 406)
B. Collective Torque Tube Installation
Special Tools
(1). Install the gas producer torque tube
into the collective torque tube.
Item Nomenclature
ST508 Collective bungee installation tool (2). Insert the torque tube into the lighten
ing hole in the seat structure. Do not
scrape the edge of the hole.
WARNING lation tool prevents rapid, (3). Leave space between the tube end and
uncontrolled movement of the collec the fuselage skin for installation of the
tive which could damage the flight con stick housing on the end of the tube.
(4). Lubricate the stick housing with grease
A. Collective Torque Tube Removal (CM116).
(1). Install the collective bungee installa (5). Move the stick housing on the collective
tion tool (ST508) and remove the torque tube.
collective bungee.
NOTE: The stick housing must be placed on
(2). Remove the inboard collective socket torque tube before installing the torque tube
assembly (Ref. Para 6.). attaching hardware.
(3). (369D/E/FF - 500N) Disconnect the aft
(6). Insert the tube and put the left end of
end of the droop control override link
tube in fixed bearing bore. Turn torque
from the torque tube droop control
tube slowly back and forth until right
bracket.
end bearing rests in cradle of controls
(4). Remove the bungee support bracket support bracket.
reinforcement strap and the torque
tube to controls support bracket. (7). Make sure the two slotted bushings are
in place in the upper lugs of the bungee
(5). If installed, move the bungee bracket bracket.
and remove the controls bracket cradle
cap and the reinforcement strap. (8). If installed, make sure the cap-to-cra
dle index grooves are matched and
(6). Move the collective control torque tube install the torque tube, controls bracket
to the right of the seat structure to cradle cap, reinforcement strap, and
remove the LH collective stick housing bungee bracket on the controls support
from the end of the tube. bracket.
(7). Remove hardware that connects stick (9). Apply a thin layer of grease (CM116) to
housing to torque tube. sliding surfaces of bungee overcenter
fitting.
(8). Move the stick outboard and off of the
torque tube. (10). (369D/E/FF - 500N) Install the droop
control override link to the torque tube
(9). Move the torque tube to the right side droop control bracket.
of seat structure to disengage left end
from support bearing inside left torque (11). Install the inboard collective socket
tube support. Provide support at seat assembly.
structure lightening hole and remove
torque tube from structure. (12). Install the collective bungee.
Page 411
MAINTENANCE MANUAL
GAS PRODUCER INTERCONNECT

N1 PINION GEAR TORQUE TUBE
AFT BEARING
(NOTE 4)
SNAP RING PIPE PLUG
SNAP RING
CLIP
SLOTTED (3 PLCS)
BUSHING
SOCKET HOUSING
SPACER
(NOTE 1)
BEARING (NOTE 4)
BACKLASH SHIM
FORWARD BEARING
(NOTES 2, 4)
SHAFT ASSEMBLY
BACKLASH SHIM
BEARING (NOTE 4)
LINK
(NOTE 3)
NR DISABLE SWITCH
AND BRACKET
(NOTE 5)
ACTUATING CAM
(NOTE 5)
HOUSING CAP
IDLER
BELLCRANK
IDLER BEARING
(NOTE 4)
NOTES:
1. FOUR SPACERS USED ONLY ON REMOVED SOCKET ASSEMBLY TO KEEP ASSEMBLY INTACT.
2. N1 PINION FORWARD BEARING IS LIGHT PRESS FIT IN HOUSING BORE.
3. LINK MUST BE BOLTED TO BELLCRANK BEFORE BELLCRANK AND SHAFT ASSEMBLY ARE INSTALLED.
4. BEARINGS INSTALLED WITH LOCKING COMPOUND. THE TWO SHAFT ASSEMBLY BEARINGS BONDED
ONLY AFTER SHIMMING FOR BACKLASH.
5. USED ON 369D/E/FF - 500N HELICOPTERS ONLY. G67-1007B
Figure 404. Collective Stick Socket Assembly (Inboard) (LHC)
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MAINTENANCE MANUAL
8. Controls Support Bracket and Bellcrank B. Controls Support Bracket and Bellcrank
Replacement Installation
(Ref. Figure 405) (1). Install assembled support bracket and
bellcranks between seat structure
bulkheads.
Special Tools
(Ref. Section 91-00-00) (2). Install Sta. 72 droop control bellcrank
Item Nomenclature in support bracket.
ST508 Collective bungee installation tool NOTE: Cap is matched to cradle of each control
support bracket. Check that numbers on
The collective bungee instal each part are identical.
WARNING lation tool prevents rapid,
(3). Check that two slotted bushings are in
uncontrolled movement of the collec place in bungee support bracket.
tive which could damage the flight con
trols and cause injury to personnel. (4). Install collective torque tube and
bungee bracket on support bracket
A. Controls Support Bracket and Bellcrank cradle.
Removal
(5). Install the 369A7304 strap
(1). Remove foot fairings and controls (369D27304-BSC/-11, 600N2608-1,
access door (Sta. 78.50) and the pilot and 369N2608-1 supports do not
seat cover. require straps).
(2). Install the collective bungee installa (6). Make sure the index groove in edge of
tion tool (ST508) and remove the cap that clamps torque tube to support
collective bungee. bracket cradle mates with matching
(3). Remove the tunnel-routed control rods. index at bracket cradle parting surface.
(4). Remove the upper end of each cyclic (7). Install the collective stick.
trim actuator. (8). Install the aft end of droop control
(5). Remove the floor-routed tail rotor override link to collective torque tube
control rod from the tail rotor bellcrank. droop control bracket.
(6). Remove Sta. 70 lateral control rod from (9). Install one-way lock to longitudinal
the lateral idler bellcrank. idler bellcrank.
(7). Remove the one-way lock from longitu

NOTE: Make sure that the slotted bushing is in
the bellcrank ear.
dinal idler bellcrank.
(10). Install Sta. 70 lateral control rod to
(8). Remove the collective stick.
lateral idler bellcrank.
(9). Provide support for the collective torque
(11). Install floor-routed tail rotor control
tube and remove the bolts, washers and
rod to tail rotor bellcrank.
nuts from the bungee support bracket
and the collective torque tube to (12). Install upper end of each cyclic trim
controls support bracket. actuator.
(10). Remove aft end of droop control NOTE: The lateral actuator uses a 0.1875 or
override link from collective torque tube 3/
16 inch (4.763 mm) diameter bolt. The
bracket. longitudinal actuator must have a 0.25 or ¼
inch (6.035 mm) diameter bolt.
(11). Remove Sta. 72 droop control bellcrank
from support bracket. (13). Install lower ends of tunnel-routed
control rods.
(12). Remove support bracket from the seat
structure. Prevent striking any bell (14). Install collective bungee and remove
cranks and pushrods. collective bungee installation tool.
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MAINTENANCE MANUAL
COLLECTIVE TORQUE
BUNGEE SUPPORT BRACKET TUBE
WASHER (SPECIAL)
* *
* * CONTROLS SUPPORT
BRACKET
DROOP CONTROL
OVERRIDE LINK
*
BEARING
(COUNTERSUNK)
BEARING * * TAIL ROTOR BELLCRANK
LATERAL IDLER
BUSHING
BELLCRANK
(NOTE 3)
NOTE 2
*
BEARING FLOOR-ROUTED TAIL
3/16 IN.
AND SPACER ROTOR CONTROL ROD
(4.7625 MM)
* DIAMETER
*
BUSHING *
*
(NOTE 3)
1/4 IN.
(6.35 MM)
DIA BEARING STA 70 LATERAL
CONTROL ROD
*
(COUNTERSUNK)
BEARING
SPACER
* * LONGITUDINAL
IDLER BELLCRANK NOTE 6
LATERAL CYCLIC STA. 72 DROOP

TRIM ACTUATOR CONTROL BELLCRANK
ONE-WAY
LOCK
LONGITUDINAL CYCLIC *
TRIM ACTUATOR *
NOTE 4
NOTE 6
BOLT INSTALLATION
HOLE
2. SHIM WASHERS USED AS REQUIRED TO OBTAIN NO SIDELOAD

* ON ONE-WAY LOCK.
3. BUSHING AND BOLT MUST NOT ROTATE WITH TRIM UNIT
AFTER INSTALLATION.
NOTES: 4. BOND JUMPER ATTACHMENT TYPICAL FOR BOTH ACTUATORS.
1. ASTERISK (*) IDENTIFIES SLOTTED BUSHINGS. EDGE OF BUSHINGS 5. DOUBLE ASTERISK (**) INDICATES PARTS THAT MAY BE EITHER
MUST PROTRUDE A MINIMUM OF 0.010 IN. (0.254 MM) TO A MAXIMUM MAGNESIUM OR ALUMINUM ALLOY.
OF 0.080 IN. (2.032 MM) ABOVE OUTSIDE SURFACE OF PART AFTER 6. REPLACEMENT PARTS HAVE NUTPLATE RIVETED IN PLACE.
NUT IS TIGHTENED. WASHER, NUT AND COTTER PIN NOT REQUIRED. G67-1002A
Figure 405. Controls Support Bracket, Idler Bellcranks and Cyclic Trim Actuators Installation
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MAINTENANCE MANUAL
9. Collective Bungee and Over−Center B. Collective Bungee and Over−Center

Fitting Replacement Fitting Installation and Preliminary
Adjustment
(Ref. Figure 406)
(1). Lubricate sliding surfaces of over-cen
Consumable Materials ter fitting with grease (CM116) and
(Ref. Section 91−00−00) position on collective torque tube.
Item Nomenclature
CM116 Grease, aircraft and instrument (2). Install bolt and washer though fitting
and torque tube, and adjust to obtain
0.30 in. (7.62 mm) adjustment between
Special Tools upper surface of fitting and tips on
(Ref. Section 91-00-00) torque tube fitting.
Item Nomenclature
(3). Install washer and nut on bolt and
torque to 30—40 inch-pounds
(3.39—4.52 Nm). Install cotter pin.
A. Collective Bungee and Over−Center
Fitting Removal
(4). Position collective bungee, compressed
The collective bungee instal in installation tool (ST508) so that
WARNING lation tool prevents rapid, female bearing assembly is forward and
uncontrolled movement of the collec aligns with mating hole in bungee
tive which could damage the flight con bracket. Check that slotted bushing for
trols and cause injury to personnel. bracket lug is in place, install bolt, two
washers, nut and cotter pin.
(1). Remove the pilot seat cover from seat
structure. (5). Position male bearing to align with
mating hole in bungee over-center
(2). Raise collective stick and use torque fitting. Install bolt, washers, nut and
tube over-center action to compress install cotter pin.
bungee spring until bungee installation
tool (ST508) fits over spring retainers.
Secure tool halves in place with clamp. Do not turn female bearing as
CAUTION sembly spring retainer while
(3). With stick in over-center position, bungee installation tool is spring loaded.
remove cotter pin, nut, washer and bolt
that secure male bearing to bungee (6). Raise collective stick so that torque
over-center fitting. tube over-center action compresses
spring until bungee installation tool can
(4). Remove cotter pin, nut, two washers be removed. Remove tool.
and bolt that attach female bearing end
of bungee to the bungee bracket.
(7). With collective stick at full down
(5). Remove collective bungee and installa position, preliminary adjustment of
tion tool as a unit. bungee installation is:
369D/E/FF - 500N;
(6). Remove cotter pin, nut and washer 2.15—2.25 inches (5.461—5.715 cm)
from over-center fitting. 600N;
2.65—2.75 inches (6.733—6.987 cm).
(7). Remove the bolt that secures over-cen
ter fitting to collective torque tube and (8). Flight test helicopter and complete
remove fitting. adjustment of collective bungee.
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MAINTENANCE MANUAL
FUSELAGE SKIN SNAP PLUG
COLLECTIVE CONTROL INTERCONNECTING

TORQUE TUBE
GAS PRODUCER INTERCONNECT
TORQUE TUBE
DROOP CONTROL
BUSHING OVERRIDE LINK
(NOTE 1) BRACKET (NOTE 4)
CLIP (3 PL)
NR DISABLE SWITCH TORQUE TUBE
AND BRACKET (NOTE 4) SUPPORT BEARING
ACTUATING CAM 0.30 IN. (7.62 MM)
(NOTE 4) (NOTE 3)
PIPE PLUG CONTROLS BRACKET CRADLE
INDEX GROOVE
NOTE 5
THREADED TORQUE TUBE SUPPORT
INSERT BEARING
CONTROLS
SUPPORT
INBOARD BRACKET
COLLECTIVE BUNGEE OVER-CENTER
STICK SOCKET ADJUSTMENT BOLT
GAS PRODUCER
CONTROL ROD ASSEMBLY BUNGEE OVER-CENTER
FITTING
FITTING
MALE BEARING
NOTE 2
SLOTTED
BUSHING
(NOTE 1)
RETAINER
SPRING
BUNGEE FEMALE
INSTALLATION TOOL BEARING
ASSEMBLY
(NOTE 2)
RETAINER
NOTES: (NOTE 2)
1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM
OF 0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.080 IN.
(2.032 MM) ABOVE OUTSIDE SURFACE OF PART
AFTER NUT IS TIGHTENED.
2. LUBRICATION POINTS FOR GREASE.
3. PRELIMINARY ADJUSTMENTS ONLY.
4. USED ON 369D/E/FF - 500N HELICOPTERS ONLY. COMPRESSION TOOL
5. WITH COLLECTIVE STICK AT FULL DOWN POSITION, ROD AND CHANNEL BUNGEE ASSEMBLY-EXPLODED VIEW
PRELIMINARY ADJUSTMENT OF BUNGEE
INSTALLATION IS:
369D/E/FF - 500N; 2.20 ±0.05 IN. (5.588 ±0.127 CM)
600N; 2.70 ±0.05 IN. (6.86 ±0.127 CM).
G67-1006B
Figure 406. Collective Torque Tube, Gas Producer Torque Tube and Collective Bungee
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MAINTENANCE MANUAL
10. Command Cyclic Stick Replacement (RH The top of the bushing in the aft
and LH) CAUTION bolt-hole of the cleves of the
cyclic stick socket must be from 0.010 inch
(Ref. Figure 407) (0.254 mm) to 0.060 inch (1.524 mm)
above the outer surface area after the nut is
tightened so that the control rod end will not
NOTE: The applicable pilot command (LH or catch during operation.
RH) cyclic stick is permanently assembled
into its socket. The socket is included with (2). Install the bolt (1), washers (2), nut (4),
the command cyclic stick in removal and in and cotter pin (3) to attach the lateral
stallation. control rod assembly (5) to the socket of
the RH cyclic stick assembly (17).
NOTE: The applicable (LH or RH) copilot cyclic
stick is not permanently assembled into its (3). Install the bolt (9), washers (8), nut (7),
socket. It contains two quick-disconnect and cotter pin (6) to attach the torque
pins for removal and installation of the copi tube assembly (13) to the socket of the
lot cyclic stick from its socket. The socket RH cyclic stick assembly (17).
can remain installed in the helicopter.
(4). Install the bolt (14), washers (11), nut
(12), and cotter pin (10) to attach the
A. RH Command Cyclic Stick Removal lower end of the lateral guide (15) to the
torque tube assembly (13).
(1). Disconnect the RH control stick
electrical connector (16). (5). Connect the RH control stick electrical
connector (16).
(2). Remove the bolt (14), washers (11), nut C. LH Command Cyclic Stick Removal
(12), and cotter pin (10) to release the
lower end of the lateral guide (15) from (1). Disconnect the LH control stick electri
the torque tube assembly (13). cal connector (28).
(3). Remove the bolt (9), washers (8), nut (2). Remove the bolt (31), washers (21), nut
(7), and cotter pin (6) to release the (20), and cotter pin (19) to release the
torque tube assembly (13) from the lower end of the lateral guide (34) from
socket of the RH cyclic stick assembly the torque tube assembly (33).
(17).
(3). Remove the bolt (30), washers (24), nut
(4). Remove the bolt (1), washers (2), nut torque tube assembly (33) from the
(4), and cotter pin (3) to release the socket of the LH cyclic stick assembly
lateral control rod assembly (5) from (18).
the socket of the RH cyclic stick
assembly (17). (4). Remove the bolt (29), washers (27), nut
(5). Remove the RH cyclic stick assembly lateral control rod assembly (32) from
(17), together with the lateral guide (5), the socket of the LH cyclic stick
from the helicopter. assembly (18).
B. RH Command Cyclic Stick Installation (5). Remove the the LH cyclic stick assem
bly (18), together with the lateral guide
(34), from the helicopter.
(1). Align the RH cyclic stick assembly (17),
together with the lateral guide (5), to D. LH Command Cyclic Stick Installation
its position on the the torque tube
assembly (13) and the lateral control (1). Align the LH cyclic stick assembly (18),
rod assembly (5). together with the lateral guide (34), to
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MAINTENANCE MANUAL
its position on the the torque tube socket of the LH cyclic stick assembly
assembly (33) and the lateral control (18).
rod assembly (32).
The top of the bushing in the aft (23), and cotter pin (22) to attach the
CAUTION bolt-hole of the cleves of the
torque tube assembly (33) to the socket
cyclic stick socket must be from 0.010 inch of the LH cyclic stick assembly (18).
(0.254 mm) to 0.060 inch (1.524 mm)
above the outer surface area after the nut is (4). Install the bolt (31), washers (21), nut
tightened so that the control rod end will not (20), and cotter pin (19) to attach the
catch during operation. lower end of the lateral guide (34) to the
torque tube assembly (33).
(26), and cotter pin (25) to attach the (5). Connect the LH control stick electrical
lateral control rod assembly (32) to the connector (28).
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MAINTENANCE MANUAL
16
11
SOCKET (REF)
9
1
8
3 2
10
2 6
4 8 11
12
15 5
13
FRICTION
KNOB (REF) 7
11
14 11
BUSHING
17
PILOT'S CYCLIC
STICK GUARD
CYCLIC STICK
SOCKET AND LATERAL
LONGITUDINAL FRICTION INSTALLATION
CONTROL FRICTION
MECHANISM
RH LATERAL COPILOT'S CYCLIC

CONTROL STICK ASSY (REF)
FRICTION
MECHANISM
(REF) 5 (REF)
13 (REF)
CYCLIC CONTROLS
CENTER GUARD (REF)
QUICK
DISCONNECT (REF)
Figure 407. Cyclic Stick Assembly Installation (Sheet 1 of 2)
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MAINTENANCE MANUAL
LH LATERAL
CONTROL FRICTION
MECHANISM (REF)
18
19
20
22
21 23
24
34
25
26
33 27
32
28
24
31
27
29
21
30
G67-1000-407-2
1. BOLT 18. RH COMMAND CYCLIC STICK ASSEMBLY

3. COTTER PIN 20. NUT
4. NUT 21. WASHER
5. LATERAL CONTROL ROD ASSEMBLY 22. COTTER PIN
6. COTTER PIN 23. NUT
7. NUT 24. WASHER
9. BOLT 26. NUT
10. COTTER PIN 27. WASHER
11. WASHER 28. ELECTRICAL CONNECTOR
12. NUT 29. BOLT
13. TORQUE TUBE ASSEMBLY 30. BOLT
14. BOLT 31. BOLT
15. LATERAL GUIDE 32. LATERAL CONTROL ROD ASSEMBLY
16. ELECTRICAL CONNECTOR 33. TORQUE TUBE ASSEMBLY
17. LH COMMAND CYCLIC STICK ASSEMBLY 34. LATERAL GUIDE
Figure 407. Cyclic Stick Assembly Installation (Sheet 2 of 2)
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MAINTENANCE MANUAL
11. Lateral Control Rods and Sta. 67 Lateral (6). If rod or rod ends require replacement,
Cyclic Bellcrank Replacement (LHC, LHS) measure and record distance between
rod end bearing centers.
(Ref. Figure 408)
A. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Installation (LHC, LHS)
Cyclic Bellcrank Removal (LHC, LHS)
(1). With the slotted bushing in the upper
(1). Remove the large (central) cyclic stick web of the seat structure fitting and
guard. install Sta. 67 lateral cyclic bellcrank.
(2). Remove the pilot seat cover, and
controls access door from Sta. 78.50 (2). Check that slotted bushings are in
canted bulkhead. place and install Sta. 70 lateral control
rod and the pilot lateral control rod.
(3). Remove the pilot lateral control rod, if
necessary. (3). Move cyclic stick full forward, then full
aft and set the pilot lateral control rod
(4). Remove Sta. 70 lateral control rod, if end bearing angularity so that bearings
necessary. do not jam at full travel positions.
(5). Remove Sta. 67 lateral cyclic bellcrank (4). If control rod or rod ends are replaced,
from seat structure fitting. do a cyclic control rigging check.
CYCLIC STICK LATERAL CYCLIC

ASSEMBLY BELLCRANK
STRAP
LATERAL CONTROL ROD

(NOTE 2)
QUICK RELEASE NOTES:
PIN 1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM
OF 0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.060 IN.
(1.524 MM) ABOVE OUTSIDE SURFACES OF PART
QUICK AFTER NUT IS TIGHTENED.
RELEASE 2. CONTROL ROD END BEARINGS MUST NOT JAM
PIN SLOTTED BUSHING THROUGHOUT FULL RANGE OF LONGITUDINAL
(NOTE 1) TRAVEL (34°).
G67-1008A
Figure 408. Cyclic Controls (RHC)
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MAINTENANCE MANUAL
12. Lateral Control Rods and Sta. 67 Lateral B. Lateral Control Rods and Sta. 67 Lateral
Cyclic Bellcrank Replacement (RHC) Cyclic Bellcrank Installation (RHC)
(Ref. Figure 408)
(1). With the slotted bushing in upper web
A. Lateral Control Rods and Sta. 67 Lateral of seat structure fitting install Sta. 67
Cyclic Bellcrank Removal (RHC) lateral cyclic bellcrank.
(1). Remove the cyclic stick guards.
(2). Remove the large (central) cyclic stick (2). With the slotted bushings in place
guard, the pilot seat cover, and controls install Sta. 70 lateral control rod.
access door.
(3). Remove the pilot collective pitch stick (3). Install both lateral control rods at each
cover, controls access door and left foot end with a bolt, two washers, nut and
support fairing from Sta. 78.50 canted new cotter pin.
bulkhead.
(4). Remove the cotter pin, two washers and (4). Move both cyclic sticks full forward,
bolt from each end of the pilot lateral then full aft and set both lateral control
control rod, the copilot lateral control rods so that rod end bearings do not
rod, or Sta. 70 lateral control rod, if jam at full throw positions.
necessary.
(5). Remove the rod assembly. (5). Hold the rod ends and tighten jam nuts.
(6). Remove cotter pin, nut, two washers
and bolt securing Sta. 67 lateral cyclic (6). If the control rod or rod ends were
bellcrank to seat structure fitting; replaced, do a cyclic control rigging
remove bellcrank. check.
(7). If rod or rod ends require replacement,
measure and record the distance (7). Install cyclic stick guards, the pilot
between rod end bearing centers. Use collective pitch stick cover, controls
the trammel method, or equivalent. access door, and foot fairing.
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MAINTENANCE MANUAL
13. Cyclic Torque Tube Replacement (LHC) right side of each support bearing, and
install two wide support spacers and
(Ref. Figure 409) support bolts.
A. Cyclic Torque Tube Removal (LHC) NOTE: Support bolts can be installed from ei
(1). Remove the pilot seat cover. ther direction, and two narrowest (RH) sup
port spacers are to be interchanged for best
(2). Position the pilot cyclic stick to align alignment of torque tube with one-way lock.
holes in one-way lock support links
with bolt that attaches forward end of (2). Check that slotted bushing is in torque
one-way lock to torque tube; tighten tube arm, and fit one-way lock rod end
longitudinal friction. Disconnect rod against unbushed lug of arm. If tighten
end from torque tube arm. ing of attachment bolt will apply
sideload on the rod end, interchange
(3). Remove the pilot cyclic stick. two narrowest (RH) support spacers,
and/or adjust lateral position shimming
(4). Remove all of cyclic stick guard instal
of longitudinal idler bellcrank or
lation except small guard next to the
one-way lock rod ends until there is no
pilot cyclic stick.
sideload on one-way lock control
(5). Remove longitudinal control friction system. Check that no structural
mechanism. interference results from spacer
interchange.
(6). Remove the pilot lateral control rod
from Sta. 67 lateral cyclic bellcrank. (3). Without sideload on one-way lock,
install and tighten support nuts. Using
(7). Cut lockwire and remove support nuts, lockwire (CM702), safetywire each nut
support bolts and two wide (LH) to hole in threaded end of mating bolt.
support spacers from seat structure When installing lockwire do not
fitting lugs and torque tube. Prevent damage aluminum nut and bolt.
torque tube from dropping as bolts are
removed. (4). Install the pilot lateral control rod
(riveted rod) end to Sta. 67 lateral cyclic
(8). Remove torque tube and two narrow bellcrank.
(RH) support spacers.
(5). Install longitudinal control friction
B. Cyclic Torque Tube Installation (LHC) mechanism.
Consumable Materials (6). Install the cyclic stick guards.

(Ref. Section 91−00−00) (7). Install the pilot cyclic stick.
Item Nomenclature
CM702 Lockwire CRES (8). Position the pilot cyclic stick to align
bolt holes in torque tube arm with holes
in one-way lock support links; install
(1). Align cyclic torque tube support attaching hardware.
bearings with holes in structure fitting
lugs. Place narrow support spacer on (9). Install the pilot seat cover.
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MAINTENANCE MANUAL
CONTROLS
NOTES: SUPPORT
1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF BRACKET
0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.080 IN. (2.032 MM)
ABOVE OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.
2. MAY BE INSTALLED IN EITHER DIRECTION.
3. MAY BE INTERCHANGED TO ALIGN ONE-WAY LOCK.
4. INSTALLED WITH GREASE ON OUTSIDE CIRCUMFERENCE.
5. INSTALLED WITH LOCKING COMPOUND.
6. SHIM WASHERS AS REQUIRED TO ALIGN ONE-WAY LOCK (REMOVE
SIDELOAD).
CAUTION:
DO NOT HAMMER RIVETS: SQUEEZE ONLY.
LONGITUDINAL IDLER
BELLCRANK
SHIM WASHER
(NOTE 6)
ONE-WAY
LOCK SLOTTED BUSHING
(NOTE 1)
INPUT END
CYCLIC STICK
PIVOT BEARING
OUTPUT
END
SHIM WASHER
SLOTTED BUSHING (NOTE 6)
(NOTE 1) PIVOT BUSHING
CYCLIC PITCH
INTERCONNECTING SUPPORT LINK
TORQUE TUBE
SUPPORT BEARING
(NOTE 5)
RETAINER FLANGE
BUSHING
SUPPORT BOLT
(NOTE 2) SLEEVE
BUSHING
SUPPORT SPACER,
0.20 IN. (5.08 MM) WIDE
(NOTE 3) CYCLIC STICK
PIVOT BEARING
SUPPORT SPACER, 0.430 IN. SUPPORT BEARING
(10.29 MM) WIDE (NOTE 4)
RIVET SUPPORT RIVET

(SEE CAUTION) NUT
STUD
SUPPORT SPACER,
0.260 IN. (6.60 MM) WIDE SUPPORT BOLT
(NOTE 2) SPRING PIN
(NOTE 3)
SUPPORT SPACER, 0.520 IN.
(13.21 MM) WIDE STUD (FRICTION
MECHANISM) (TYPICAL)
G67-1011A
Figure 409. Cyclic Torque Tube and One−Way Lock Installation
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MAINTENANCE MANUAL
14. Cyclic Torque Tube Replacement (RHC) B. Cyclic Torque Tube Installation (RHC)
(Ref. Figure 408) (1). Align cyclic torque tube support

bearings with holes in structure fitting
lugs. Place narrow support spacer on
Consumable Materials right side of each support bearing, and
(Ref. Section 91−00−00) install two wide support spacers and
Item Nomenclature support bolts.
CM702 Lockwire CRES NOTE: Support bolts can be installed from ei
ther direction, and two narrowest (RH) sup
port spacers are to be interchanged for best
A. Cyclic Torque Tube Removal (RHC) alignment of torque tube with one-way lock.
(1). Remove the pilot seat cover. (2). Make sure the slotted bushing is in the
torque tube arm, and fit the one-way
(2). Position the pilot cyclic stick to align lock rod end against the lug of the arm
holes in one-way lock support links that does not have a bushing.
with bolt that attaches forward end of (a). If the attachment bolt applies a
one-way lock to torque tube; tighten sideload on the rod end, interchange
longitudinal friction. Disconnect rod the two narrowest (RH) support
end from torque tube arm. spacers, and/or adjust lateral position
shimming of longitudinal idler
(3). Remove the pilot cyclic stick.
bellcrank or one-way lock rod ends
(4). Remove all of cyclic stick guard instal until there is no sideload on the
lation except small guard next to the one-way lock control system.
pilot cyclic stick. (b). Make sure there is no structural
interference with spacer interchange.
(5). Remove longitudinal control friction
mechanism. (3). Without sideload on one-way lock,
install and tighten support nuts.
(6). Remove the pilot lateral control rod (a). Lockwire each nut to the hole in the
from Sta. 67 lateral cyclic bellcrank. threaded end of mating bolt with
lockwire (CM702).
(7). Cut lockwire and remove support nuts,
support bolts and two wide (LH) (4). Install the pilot lateral control rod
support spacers from seat structure (riveted rod) end to Sta. 67 lateral cyclic
fitting lugs and torque tube. Prevent bellcrank.
torque tube from dropping as bolts are (5). Install longitudinal control friction
removed. mechanism.
(8). Remove torque tube and two narrow (6). Install the cyclic stick guards.
(RH) support spacers.
(7). Install the pilot cyclic stick.
(9). Remove the pilot collective stick cover. (8). Position the pilot cyclic stick to align
bolt holes in torque tube arm with holes
(10). Remove the pilot cyclic stick and copilot in one-way lock support links; install
cyclic stick. attaching hardware.
(11). Remove the cyclic stick guards. (9). Install the pilot seat cover.
(10). Install pilot and copilot lateral control
(12). Remove longitudinal control friction rods (riveted rod ends) to Sta. 67 lateral
mechanism. cyclic bellcrank.
(13). Remove both lateral control rods from (11). Install longitudinal control friction
Sta. 67 lateral cyclic bellcrank. mechanism.
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MAINTENANCE MANUAL
(12). Install cyclic stick guards. (2). Remove hardware supplied in housing
end of new trim actuator.
(13). Install pilot cyclic stick and copilot
cyclic stick. (3). With the slotted bushings in place in
(14). Install pilot collective stick cover. actuator housing, place one washer
around each side of pivot bearing in
15. Cyclic Trim Actuator Replacement center beam support lug.
(Ref. Figure 406) (4). Align the actuator housing with bearing
and install bolt, two washers and nut
A. Cyclic Trim Actuator Removal (and cotter pin if old style).
(1). Jack helicopter (Ref. Section 07-00-00)
until landing gear is fully extended and (5). Align actuator with idler bellcrank.
clears ground.
(6). With the slotted bushing in the bell
(2). Remove foot fairing, controls access crank lug, install the actuator pivot
door from Sta. 78.50 canted bulkhead bushing if actuator is a replacement.
and open pilot compartment floor access
door. (7). Pivot bushing must turn freely in the
actuator.
(3). Remove bonding jumper and electrical
connector from actuator housing. (8). Install the bolt, two washers, nut and
(4). Remove upper end of trim actuator. new cotter pin. After bolt is tightened,
Keep pivot bushing with actuator pivot bushing must not turn in idler
unless actuator is being replaced. bellcrank.
(5). Disconnect lower end of trim actuator. NOTE: Lateral actuator upper hingeline has
Access to attaching nut is through hole 3/16 inch (4.7625 mm) bolt hole; longitudi
in under-floor compartment aft nal has 1/4 inch (6.35 mm) bolt hole.
bulkhead, near centerline beam.
(9). Attach the bonding jumper.
(6). Remove trim actuator. Install original
lower end attaching hardware if (10). Attach the electrical connector to
actuator is being replaced; new actuator actuator.
includes this hardware.
(11). With main rotor blades removed or
B. Cyclic Trim Actuator Installation lifted off droop stops, complete a
(1). Make sure the trim actuator spring power-on operational check of cyclic
assembly has free play between spring trim actuator. Actuator must not bind
and spring adapters. throughout travel range in either
direction, and must maintain at least
(a). Adjust spring adapter screw until 0.015 inch (0.381 mm) minimum
0.010—0.050 inch (0.254—1.27 clearance with center beam structure.
mm) is felt while pushing or pulling
on spring assembly. (12). Lower helicopter and remove jacks.
Page 426
MAINTENANCE MANUAL
16. One−Way Lock Replacement attach each link with bolt, sleeve
bushing, washer, nut and cotter pin.
(Ref. Figure 409)
(4). Make sure the slotted bushing is in
A. One−Way Lock Removal place in longitudinal idler bellcrank.
(1). Remove the pilot seat cover or inboard (5). Fit the lower rod end bearing against
collective pitch stick cover and controls the lug of bellcrank that does not have
access door from Sta. 78.50 canted a bushing.
bulkhead.
(a). There must be no sideload of one-
(2). Remove the cyclic stick guard. way lock mechanism. Arrange shim
washers, as necessary to position
(3). Position the pilot cyclic stick to align longitudinal idler bellcrank and/or
holes in one-way lock support links lower rod end for alignment without
with bolt that attaches forward end of sideload.
one-way lock to cyclic torque tube;
tighten longitudinal friction. Disconnect (6). Put the pilot cyclic stick to align the
rod end from torque tube arm. holes in support links with hingeline for
upper end of one-way lock and cyclic
(4). Disconnect one-way lock lower rod end torque tube arm; tighten longitudinal
from longitudinal idler bellcrank. friction.
(5). Disconnect upper end of each support (7). Repeat check for sideload on one-way
link from seat structure and remove lock, step (4)., and arrange shim
one-way lock with links attached. washers, if necessary, to position upper
rod end for alignment without sideload.
(6). Remove two cotter pins, washers and
links. Do not remove pivot bushings NOTE: Two narrowest (RH) cyclic torque tube
from links unless replacement is support spacers can also be interchanged to
necessary. align one-way lock.
(8). Without sideload on one-way lock,
B. One−Way Lock Installation secure each rod end bearing with
(1). Check that rod end bearing center-to- attaching hardware.
center distance is correct. (9). Check reservoir fluid level (Ref. Section
12-00-00).
(2). Attach lower ends of links to one-way
lock with bushings, washers and cotter (10). Install cyclic stick guard.
pins.
(11). Install the pilot seat cover or inboard
(3). Align upper ends of links with mating collective pitch stick cover and control
holes in seat structure fitting and access door.
Page 427
MAINTENANCE MANUAL
17. Tunnel−Routed Control Rod Replacement (9). Remove bolt from bottom of 7012 tube
and lower to belly of aircraft and angle
(Ref. Figure 410) up through the double hole.
A. Tunnel−Routed Control Rod Removal (10). Remove bolts from bottom of 7007 tube
and lower to the belly of aircraft, then
Special Tools
angle up through the double hole.
(Ref. Section 91-00-00) (11). Move 7009 tube to the other side of
Item Nomenclature center beam and angle up through the
ST508 Collective bungee installation tool double hole.
B. Tunnel−Routed Control Rod Installation
WARNING lation tool prevents rapid, The collective bungee instal
uncontrolled movement of the collec WARNING lation tool prevents rapid,
tive which could damage the flight con uncontrolled movement of the collec
trols and cause injury to personnel. tive which could damage the flight con
(1). Install collective bungee installation
tool (ST508) and remove collective Use care with removal and in
CAUTION stallation of control rods. Any
bungee. (Ref. Para 9. Collective Bungee
Replacement.) surface damage caused by removal and in
stallation can result in unserviceable con
(2). For access to lower rod ends, remove trol rods.
controls access door at base of canted
bulkhead in cargo compartment. (1). Move blue blade pitch housing down as
far as it will go. This will allow the
(3). Hand turn main rotor blades to align tubes to go past the housing.
blue blade to right side of aircraft.
(2). Move 7009 tube to the other side of
(4). Disconnect upper end of control rod. center beam and angle 7011 up through
the double hole.
(5). Remove double boot from control tunnel
cover. All tubes will be removed (3). Angle 7007 tube up through the double
through the double hole. hole and install bolts in bottom of tube.
Use care with removal and in (4). Angle 7012 tube up through the double
CAUTION stallation of control rods. Any hole and install bolt at bottom of tube.
surface damage caused by removal and in
stallation can result in unserviceable con (5). Install bolts to bottom of 369A7009 and
trol rods. 7011 tubes.
(6). After installation of all tubes, install
(6). Move blue blade pitch housing down as
double boot on control tunnel cover.
far as it will go. This will allow the
tubes to go past the housing. (7). Attach upper end of control rod.
(7). Remove bolts from bottom of 369A7009 (8). Hand turn main rotor blades to align
and 7011 tubes. blue blade to right side of aircraft.
(8). Move cyclic controls so that the 7012 (9). Install controls access door at base of
tube moves to its highest point. Place canted bulkhead in cargo compartment.
7009 tube to the far right and lower out
of way. Lower 7011 tube to the left side (10). Remove collective bungee installation
of center beam. This will allow 7011 tool (ST508) and install collective
tube to angle up through the double bungee. (Ref. Para 9. Collective Bungee
hole. Replacement.)
Page 428
MAINTENANCE MANUAL
DOUBLE BOOT
369A7009
369A7007 DOUBLE BOOT
369A7011 HOLE
369A7012
369A7012
369A7011
369A7007
369A7009
VIEW LOOKING FORWARD VIEW LOOKING FORWARD

VIEW A VIEW B
DOUBLE BOOT 369A7007 DOUBLE BOOT

HOLE HOLE
369A7012
369A7007
369A7009 369A7009

VIEW LOOKING FORWARD VIEW D
VIEW C
DOUBLE BOOT
HOLE
369A7009

VIEW E
G67-1001
Figure 410. Tunnel−Routed Control Rod Installation
Page 429
MAINTENANCE MANUAL
18. Roof−Mounted Control Rod Replacement 19. Roof−Mounted Bellcrank Replacement

(600N) (600N)
(Ref. Figure 411) Replacement of the roof-
mounted bellcranks is the same procedure for
(Ref. Figure 411) the forward and aft bellcranks.
A. Roof−Mounted Bellcrank Removal (600N)
Special Tools (1). Install collective bungee installation
(Ref. Section 91-00-00) tool (ST508) and remove collective
Item Nomenclature bungee.
(2). For access to roof-mounted control rods
ST508 Collective bungee installation tool and bellcranks, remove upper fuselage
controls fairing.
(3). Remove hardware connecting rod from
A. Roof−Mounted Control Rod Removal bellcrank.
(600N)
(4). Remove hardware from bellcrank pivot
point and remove bellcrank.
(1). Install collective bungee installation B. Roof−Mounted Bellcrank Installation
tool (ST508). (600N)
NOTE: Make sure bellcranks are installed in
(2). For access to roof-mounted control proper position. If bellcranks are installed
rods, remove upper fuselage controls in the wrong position, rigging will be impos
fairing. sible (ref. CSP-IPC-4).
(1). Install bellcrank in mount with word
FORWARD facing up and arrow
NOTE: If same rods are to be reinstalled, mark pointing towards front of aircraft.
rods for proper positioning upon reinstalla
tion. If new rods are installed, main rotor (2). Install hardware connecting bellcrank
flight controls must be re-rigged. to mount. Torque nuts 30—40 inch-
pound (3.39—4.52 Nm) and install
cotter pin.
(3). Mark control rod for proper reinstalla (3). Reinstall disconnected control rods.
tion.
(4). Remove collective bungee installation
tool.
(4). Remove hardware from control rods (5). Reinstall upper fuselage controls
and remove rods from aircraft. fairing.
20. Link Assembly Replacement (600N)
B. Roof−Mounted Control Rod Installation
(600N) (Ref. Figure 411)
(1). Install control rods in bellcranks and The aluminum 600N7617-1
WARNING link assembly has a life-lim
make sure RH threaded rod end is
forward. it if used as either a collective or longi
tudinal link assembly (ref. Chapter 4,
(2). Install hardware connecting control CSP-HMI-2). If the part is not replaced,
rods. Torque nuts 30—40 inch-pounds there is a risk of injury or loss of life.
A. Link Assembly Removal (600N)
(3). Remove collective bungee installation
tool. Special Tools
(4). Reinstall upper fuselage controls
Item Nomenclature
fairing.
(5). Do the flight controls rigging check.
Page 430
MAINTENANCE MANUAL
(1). Install collective bungee installation (2). Make sure the bushing protrudes 0.010
tool (ST508). inch (0.25 mm) minimum to 0.060
inch (1.52 mm) maximum beyond the
(2). Remove upper fuselage controls fairing. the surface of the mixer.
(3). Torque nuts 30—40 inch-pound
NOTE: Upper link bolt has a bushing in the (3.39—4.52 Nm) and install cotter pin.
mixer bellcrank.
NOTE: Make sure bushings seat against rod
(3). Remove hardware from link and end when attaching hardware is torqued. If
remove link from aircraft. space is present then reinstall bushing with
primer still wet and torque hardware.
B. Link Assembly Installation (600N) (4). Remove collective bungee installation
tool.
(1). Install link between lower bellcrank
and mixer bellcrank with hardware (5). Reinstall upper fuselage controls
previously removed. fairing.
LINK ASSEMBLY
AFT ROOF-MOUNTED
BELLCRANKS
ROOF-MOUNTED
CONTROL RODS
FORWARD
ROOF-MOUNTED
BELLCRANKS ROTATING
SWASHPLATE
MAIN ROTOR CONTROLS

COLLECTIVE MIXER (MIXER, IDLER BELLCRANKS
CONTROL ROD AND LINKS)
DIRECTIONAL
LONGITUDINAL MIXER CONTROL ROD
CONTROL ROD
CYCLIC) LATERAL MIXER
CONTROL ROD 6G67-039
(CYCLIC)
Figure 411. Roof−Mounted Controls Installation (600N)
Page 431
MAINTENANCE MANUAL
Page 432
MAINTENANCE MANUAL

ADJUSTMENT / TEST
1. Collective and Cyclic Control System (1). Remove the main rotor blades (ref.
Rigging 62- 10- 00, Removal and Installation,
Procedure 2. Main Rotor Blade Replace-
Rigging of the main rotor control system must ment).
be done immediately after the replacement of
linkage that cannot be accurately measured (2). As necessary, remove the fairings.
(for example, by trammeling) before installa-
tion in the main rotor control system, or if (3). Install ST501 collective rigging fixture
during helicopter operation a rigging deficien- (ref. Figure 501, View C):
cy is found.
(a). Release the control friction grip.
NOTE:
D Rigging of the collective and cyclic con- (b). Lift the pilot collective stick.
trols must be done in sequence — begin
with the collective controls first. (c). Put ST501 collective rigging fixture
in the outboard lower end of the slot
D Control rodend bearing adjustments are
in the collective friction guide.
made to the nearest half- turn to get the
correct rigging. (d). Lower the pilot collective stick on
D Always hold the rodend with a wrench to ST501 collective rigging fixture.
prevent a bearing jam, when the jamnut
at the adjustable end of a control rod is (e). Tighten the control friction grip.
tightened.
D 600N Only — Make all rigging adjust- (4). Install ST503 mixer rigging plate on
ments with the roof- mounted control the mast support fitting.
rods.
NOTE: 500N Only — To install ST503 mixer
D 600N Only — Adjust the tunnel- routed rigging plate, removal of the splitter bungee
control rods only if a flight control compo- and bracket can be necessary (ref. Section
nent forward of the roof- mounted bell- 67- 20- 30, Removal / Installation, Proce-
cranks is replaced. dure 4. Splitter Bungee Spring Replace-
ment).
2. LH Command Control System Rigging
(369D/369E/369FF/500N) (5). Measure the distance from the horizon-
tal centerline of the hingeline bolt that
A. Collective Controls (LH Command)
attaches the mast support bracket and
(Ref. Figure 501 and Table 501) longitudinal pitch idler bellcrank to the
top surface of ST503 mixer rigging
plate (ref. View A).
Special Tools
(Ref. Section 91-00-00) (a). Record the measurement as Dimen-
Item Nomenclature sion A.
(LH command) NOTE: Dimension A is used as the basic di-
ST503 Mixer rigging plate mension for rigging the mixer controls.
(6). Measure the distance from the horizon-

NOTE: To help the field rigging of the collective tal centerline of the hingeline bolt that
control (up and down) and the cyclic control attaches the collective and longitudinal
(both forward and aft, and right and left) op- pitch mixer bellcranks to the top
tional field rigging aids can be made (ref. surface of ST503 mixer rigging plate
Procedure 16., Special Tooling). (ref. View B).
Page 501
67- 10- 00 TR18- 001
MAINTENANCE MANUAL
MAST SUPPORT
LONGITUDINAL BRACKET
PITCHIDLER
BELLCRANK
DIM. A
(NOMINAL)
BOLT (HEADLEFT),
WASHERS, NUT,
COTTERPIN
MIXERRIGGING
MAST SUPPORT PLATE
INITIAL RIGGINGPLATE MEASUREMENT FITTING
LONGITUDINAL PITCH
MIXERBELLCRANK
COLLECTIVE PITCH
MIXERBELLCRANK
COLLECTIVE PITCH
CONTROL ROD
DIM. B
COLLECTIVE
RIGGING
FIXTURE
RIGGINGPLATE MEASUREMENT
FIXTURE INSTALLATION
CONTROL
FRICTIONGRIP
(DRIVE GEAR)
COLLECTIVE FRICTION
PILOT COLLECTIVE GUIDE LINK
PITCHSTICK
G67-1012-1
Figure 501. Main Rotor Controls Rigging for Models 369D/369E/369FF/500N (Sheet 1 of 2)
Page 502
TR18- 001 67- 10- 00
MAINTENANCE MANUAL
LONGITUDINAL
PITCHIDLER
CLEARANCE
BOLT (HEADLEFT),
WASHERS, NUT,
COTTERPIN
MIXERRIGGINGPLATE
LONGITUDINAL PITCH LONGITUDINAL PITCH
MIXERBELLCRANK CONTROL MIXER
MIXERTRAVEL
PITCHCONTROL ROD
ELASTOMERRING
(THIS SIDE, CURRENT
CONFIG. ONLY)
ELASTOMERRING
SLOTTEDBUSHING
LATERAL BELLCRANK
LONGITUDINAL
FRICTIONGUIDE STATIONARY
LINK PITCHCONTROL ROD SWASHPLATE
INSTALLATION(5 PLACES) MIXERLINK
CLEARANCE
KNURLEDTHUMBNUT
FRICTION
KNOB
MIXERTRAVEL
CYCLICSTICK LONGITUDINAL
RIGGINGFIXTURE
LONGITUDINAL RIGGING
FIXTURE INSTALLATION LATERAL PITCH
CONTROL ROD
FRICTIONKNOB
LATERAL FRICTION
GUIDE LINK
KNURLEDTHUMBNUT CYCLICSTICK LATERAL

RIGGINGFIXTURE
LATERAL RIGGING
G67-1012-2
Figure 501. Main Rotor Controls Rigging for Models 369D/369E/369FF/500N (Sheet 2 of 2)
Page 503
67- 10- 00 TR18- 001
MAINTENANCE MANUAL
Table 501. Travel Distance (369D/369E/369FF/500N)

Cyclic Control Nominal Measurements
Stick Travel Down Travel, Minimum Up Travel, Minimum
Collective 0.74 inch (18.8 mm) Down 0.74 inch (18.8 mm) Up
Lateral 0.50 to 0.53 inch (12.7 to 13.5 mm) Left 0.43 inch (10.9 mm) Right
Longitudinal 0.57 inch (14.5 mm) Aft 1.19 to 1.22 inch (30.2 to 31.0 mm) FWD
(a). Record the measurement as Dimen- (e). If necessary, adjust the rod end of the
sion B. collective pitch control rod to meet
the specified limits.
(b). Dimension B must equal Dimen-
sion A. (f). After the adjustment is complete,
tighten the jamnut.
1). If the dimensions are not equal:
(9). If the mixer bellcranks are in dimen-
a). Loosen the check- nut. sion with reference to ST503 mixer
rigging plate the collective and cyclic
b). Remove cotter pin, nut, washers, controls are correctly rigged.
and bolt from the upper rodend
of the collective control rod. (a). The dimensions in steps (5).(a).,
(6).(a)., and (8).(b). and (d). must
1. Discard the cotter pin. agree with the dimensions on the
field rigging tool.
c). Adjust the rodend to nearest
half- turn of the rodend bearing Do not adjust the control rod
CAUTION end past the witness hole.
until the dimensions are equal.
Tighten the jamnut after the final adjust-
d). Connect the upper end of the ment. Failure to obey this caution can cause
collective pitch control rod with parts damage and/or equipment failure.
washers, bolt, nut, and new
cotter pin. (b). If the dimensions agree, go to Step
(10).
(7). Remove ST501 collective rigging
(c). If the dimensions do not agree go to
fixture.
Procedure 2.B.
(8). Do a check of the mixer travel (ref. (d). Make sure that the length of the
View D): control rod did not change.
(a). Move the pilot collective stick to the (10). Remove ST503 mixer rigging plate.
downstop.
(11). 500N Only — If necessary, install the
(b). The centerline of the collective pitch splitter bungee and bracket (ref.
mixer bellcrank bolt (ref. View B) Section 67- 20- 30, Removal / Installa-
must move down so that Dimension tion, Procedure 4. Splitter Bungee
A (ref. Step (5).(a).) decreases 0.74 Spring Replacement).
inch (18.8 mm) minimum (ref.
Table 501). (12). Connect the collective pitch control rod.
(13). Install the fairings.
(c). Move the collective stick to the
up- stop. (14). Install the main rotor blades (ref.
62- 10- 00, Removal / Installation,
(d). The centerline of the collective pitch Procedure 2.B. Main Rotor Blade
mixer bellcrank bolt must move up so Installation).
that Dimension B (ref. Step (5).(a).)
increases 0.74 inch (18.8 mm) (15). Track the main rotor blades and adjust
minimum (ref. Table 501). the autorotation rpm (ref. 18- 10- 00,
Page 504
TR18- 001 67- 10- 00
MAINTENANCE MANUAL
Adjustment / Test, Procedure 1. Blade (b). Move the cyclic stick to the forward-
Tracking Procedure). stop.
B. Cyclic Controls (LH Command) 1). If necessary, move ST503 mixer

rigging plate to get a clearance
(Ref. Figure 501 and Table 501) with the longitudinal bellcrank.
2). Make sure the centerline of the

Special Tools bolt in the longitudinal bellcrank
(Ref. Section 91-00-00) moves up 1.19 to 1.22 inch (30.2
Item Nomenclature to 31.0 mm) minimum above the
ST501 Collective rigging fixture centerline of Dimension A (ref.
(LH command) Table 501).
ST503 Mixer rigging plate (c). Move the cyclic stick to the aft- stop.
(LH command) 1). The centerline of the bolt in the
longitudinal bellcrank must move
(LH command)
down 0.57 inch (14.5 mm) mini-
mum below the centerline of
Dimension A (ref. Table 501).
NOTE: All cyclic control rigging is done with (d). If necessary, adjust the rodend to
the collective stick on ST501 collective rig- get the specified limit.
ging fixture.
(6). Adjust the longitudinal cyclic trim for
(1). Remove the main rotor blades (ref. NO- LOAD.
62- 10- 00, Removal / Installation, 2.
Main Rotor Blade Replacement). (7). Install ST504 longitudinal rigging
fixture (ref. View F).
(2). As necessary, remove the fairings.
(8). Remove ST506 lateral rigging fixture.
(3). Install ST501 collective rigging fixture
(ref. View C): (9). Do a lateral travel rig check:
(a). Release the control friction grip. (a). Move the cyclic stick to the left stop.

(b). Lift the pilot collective stick.
bolt head (forward end) in the
lateral bellcrank moves down 0.50
(c). Put ST501 collective rigging fixture
(12.7 mm) minimum to 0.53
in the outboard lower end of the slot
inch (13.5 mm) maximum below
in collective friction guide link.
the centerline of Dimension A
(ref. Table 501).
(d). Lower the pilot collective stick on
ST501 collective rigging fixture. (b). Move the cyclic stick to the right
stop.
(e). Tighten the control friction grip
(drive gear). 1). Make sure the centerline of the
bolt head (forward end) in the
(4). Put ST503 mixer rigging plate in lateral bellcrank moves up 0.43
position on the mast support fitting. inch (10.9 mm) minimum above
the centerline of Dimension A
(5). Do a longitudinal travel rig check: (ref. Table 501).
(a). Install ST506 lateral rigging fixture (c). If necessary, adjust the rodend to
(ref. View E). get the specified limit.
Page 505
67- 10- 00 TR18- 001
MAINTENANCE MANUAL
Do not adjust the control rod (a). Move the collective stick full down
CAUTION end past the witness hole. and the cyclic stick full aft.
ment. Failure to obey this caution can cause 1). The clearance must be 0.030 inch
parts damage and/or equipment failure. (0.76 mm) minimum.
(10). Adjust the pitch change links to 6.25 2). As necessary, adjust the longitudi-
inch (158.8 mm) nominal. nal pitch control rod (recommend-
ed) or the collective pitch control
NOTE: The final adjustment of the pitch rod.
change links is made during the tracking
and autorotation rpm procedure (ref. Sec- (17). Do a clearance check between the
tion 18- 10- 00, Adjustment / Test, Blade rotating swashplate and the scissors
Tracking Procedures). fitting, and the scissors rotating link
and lower hub shoe.
(11). Remove ST504 longitudinal rigging (a). Move the collective stick to full up
fixture. and the cyclic stick to full forward
and full left.
(12). Remove ST503 mixer rigging plate.
1). The clearance for both checks must
(13). Remove ST501 collective rigging be 0.030 inch (0.76 mm) mini-
fixture. mum.
(14). Do a check of the clearance between the 2). Turn the hub 360_ to find the
rotating swashplate and the longitudi- location of minimum clearance.
nal pitch idler bellcrank (ref. View H):
3). As necessary, adjust the collective
(a). Move the collective stick full down control mixer rod.
and the cyclic stick full forward and
full left. (18). Do a clearance check between the
rotating swashplate and the scissors
1). The clearance must be 0.125 inch fitting, and the scissors rotating link
(3.18 mm) minimum. and lower hub shoe.
2). As necessary, adjust the collective (a). Move the collective stick full up and
control rod. the cyclic stick full forward and full
right.
(15). Do a check of the clearance between the
lateral bellcrank and the collective 1). The clearance for both checks must
pitch mixer bellcrank of the mixer be 0.030 inch (0.76 mm) mini-
controls: mum.
2). Turn the hub 360_ to find the

(a). Move the collective stick full up and location of minimum clearance.
the cyclic stick full left (in a position
fore or aft). (19). Install the fairings.
1). The clearance must be 0.030 inch (20). Install the main rotor blades (ref.
(0.76 mm) minimum. 62- 10- 00, Removal / Installation,
Procedure 2.B. Main Rotor Blade
2). As necessary, adjust the lateral Installation).
pitch control rod.
(21). Track the main rotor blades and adjust
(16). Do a check of the clearance between the the autorotation rpm (ref. 18- 10- 00,
aft longitudinal bellcrank and the mast Adjustment / Test, Procedure 1. Blade
base: Tracking Procedure).
Page 506
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MAINTENANCE MANUAL
3. RH Command Control System Rigging longitudinal pitch control idler to the

(369D/369E/369FF/500N) top surface of ST503 mixer rigging
plate (ref. Figure 501, View C).
A. Collective Controls (RH Command)
(a). Record the measurement as Dimen-
(Ref. Figure 501 and Figure 502) sion A.
Special Tools
NOTE: Dimension A is used as the basic di-
mension for rigging the mixer controls.
Item Nomenclature (6). Measure the distance from the horizon-
ST502 Collective rigging fixture tal centerline of the bolt that attaches
(RH command) the collective and longitudinal pitch
ST503 Mixer rigging plate mixer bellcranks to the top surface of
ST503 mixer rigging plate (ref. View B).
NOTE: To help the field rigging of the collective (a). Record the measurement as Dimen-
control (up and down) and the cyclic control sion B.
(both forward and aft, and right and left) op-
tional field rigging aids can be made (ref. (b). Dimension B must equal Dimen-
Procedure 16., Special Tooling). sion A.
(1). Remove the main rotor blades (ref. 1). If the dimensions are not equal:
Procedure 2. Main Rotor Blade Replace- a). Loosen the check- nut.
ment). b). Remove cotter pin, nut, washers,
(2). As necessary, remove the fairings. and bolt from the upper end of
the collective control rod.
(3). Install ST502 collective rigging fixture
(ref. Figure 502, View C): 1. Discard the cotter pin.
(a). Release the control friction grip. c). Adjust the rod end to nearest
half- turn of the rod end bearing
(b). Lift the pilot collective stick. until the dimensions are equal.
(c). Put ST502 collective rigging fixture d). Connect the upper end of the
in the inboard lower end of the slot in collective control rod with wash-
the collective friction guide. ers, bolt, nut, and new cotter
pin.
ST502 collective rigging fixture. (7). Remove ST502 collective rigging
fixture.
(e). Tighten the control friction grip.
(8). Do a check of the mixer travel (ref.
(4). Install ST503 mixer rigging plate on View D).
the mast support fitting.
(a). Move the pilot collective stick to the
NOTE: 500N Only — To install ST503 mixer downstop.
rigging plate, removal of the splitter bungee
and bracket can be necessary (ref. Section (b). The centerline of the collective pitch
67- 20- 30, Removal / Installation, Proce- mixer bellcrank bolt (ref. View B)
dure 4. Splitter Bungee Spring Replace- must move down so that Dimension
ment). A decreases 0.74 inch (18.8 mm)
minimum (ref. Table 501).
(5). Measure the distance from the horizon-
tal centerline of the hingeline bolt that (c). Move the pilot collective stick to the
attaches the mast support bracket and up- stop.
Page 507
67- 10- 00 TR18- 001
MAINTENANCE MANUAL
COLLECTIVE
FRICTIONGUIDE
COLLECTIVE RIGGING
FIXTURE
COLLECTIVE RIGGING
LONGITUDINAL
FRICTION FRICTIONKNOB
KNOB
LATERAL
FRICTION
GUIDE LINK CYCLICSTICK
LONGITUDINAL
RIGGINGFIXTURE
CYCLICSTICK LATERAL
RIGGINGFIXTURE
LONGITUDINAL FRICTION
GUIDE LINK
CYCLICSTICK LATERAL RIGGING
CYCLICSTICK LONGITUDINAL
RIGGINGFIXTURE INSTALLATION G67-1013
Figure 502. Cyclic and Collective Controls Rigging Tools (RH Command)
Page 508
TR18- 001 67- 10- 00
MAINTENANCE MANUAL
(d). The centerline of the collective pitch B. Cyclic Controls (RH Command)
mixer bellcrank bolt must move up so
that Dimension A (ref. Step (5).(a).) (Ref. Figure 501 and Figure 502)
increases 0.74 inch (18.8 mm)
minimum. Special Tools
(e). If necessary, adjust the rod end of the Item Nomenclature
collective pitch control rod to meet ST502 Collective rigging fixture
the specified limits. (RH command)
(f). After the adjustment is complete, ST503 Mixer rigging plate
tighten the jamnut. ST505 Longitudinal rigging fixture
(RH command)
(9). If the mixer bellcranks are in dimen- ST507 Lateral rigging fixture
sion with reference to ST503 mixer (RH command)
rigging plate the collective and cyclic
controls are correctly rigged.
NOTE: All cyclic control rigging is done with
(a). The dimensions in steps (5).(a)., the collective stick on ST502 collective rig-
(6).(a)., (8).(b). and (d). must agree ging fixture.
with the dimensions on the field
rigging tool. (1). Remove the main rotor blades (ref.
Do not adjust the control rod Procedure 2. Main Rotor Blade Replace-
CAUTION end past the witness hole. ment).
ment. Failure to obey this caution can cause (2). As necessary, remove the fairings.
parts damage and/or equipment failure. (3). Install ST502 collective rigging fixture
(b). If the dimensions agree, go to Step (ref. Figure 502, View A):
(10). (a). Release the control friction grip.
(c). If the dimensions do not agree go to (b). Lift the pilot collective stick.
Procedure 3.B.
(d). Make sure that the length of the in the outboard lower end of slot in
control rod did not change. collective friction guide link (ref.
View A).
(10). Remove ST503 mixer rigging plate.
(11). 500N Only — If necessary, install the ST502 collective rigging fixture.
splitter bungee and bracket (ref.
Section 67- 20- 30, Removal / Installa- (e). Tighten the control friction grip
tion, Procedure 4. Splitter Bungee (drive gear).
Spring Replacement (500N)). (4). Put ST503 mixer rigging plate in
position on the mast support fitting
(12). Connect the collective pitch control rod. (ref. Figure 501, View B).
(13). Install the fairings. (5). Adjust the longitudinal cyclic trim for
(14). Install the main rotor blades (ref. NO- LOAD.
62- 10- 00, Removal / Installation, (6). Install ST505 longitudinal cyclic fixture
Procedure 2.B. Main Rotor Blade on the forward side of the lateral
Installation). friction guide with the fixture cutout
positioned over the friction knob stud
(15). Track the main rotor blades and adjust (ref. Figure 502, View B).
the autorotation rpm (ref. 18- 10- 00,
Adjustment / Test, Procedure 1. Blade (a). Install the fixture hook in the lower
Tracking Procedure). inboard end of slot.
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67- 10- 00 TR18- 001
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(b). Tighten the knurled thumbnut to 1). Make sure the centerline of the
the seat the bushing at the upper bolt head (forward end) in the
outboard end. lateral bellcrank moves down 0.50
inch (12.7 mm) minimum to
(c). Tighten the lateral friction knob. 0.53 inch (13.5 mm) maximum
below the centerline of the hinge-
(7). Do a longitudinal travel rig check: line bolt (ref. View D).
(a). Move the cyclic stick to the forward- (b). Move the cyclic stick to the right
stop. stop.
1). Make sure the centerline of the bolt head (forward end) in the
bolt in the longitudinal bellcrank lateral bellcrank moves up 0.43
moves up 1.19 inch (30.2 mm) inch (10.9 mm) minimum above
minimum to 1.22 inch (31.0 the centerline of the hingeline
mm) maximum above the center- bolt.
line of the hingeline bolt.
(c). If necessary, adjust the rod end to get
2). As necessary, adjust the installa- the specified limit.
tion of ST503 mixer rigging plate (11). Remove ST502 collective rigging
to get a clearance with the longitu- fixture.
dinal bellcrank.
(12). Do a check of the clearance between the
(b). Move the cyclic stick to the aft- stop. scissors link and the edge of the pocket
in the rotating swashplate:
1). The centerline of the bolt in the (a). Move the collective stick to full up
longitudinal bellcrank must move and the cyclic stick to full aft and full
down 0.57 inch (14.5 mm) mini- left.
mum below the centerline of the
hingeline bolt. 1). The clearance must be 0.006 inch
(0.15 mm) minimum.
(c). If necessary, adjust the rodend to 2). Turn the hub 360_ to find the
get the specified limit. location of minimum clearance.
(8). Adjust the longitudinal cyclic trim for (13). Do a check of the clearance between the
NO- LOAD. scissors link and the edge of the pocket
in the rotating swashplate:
(9). Install ST507 lateral cyclic fixture on (a). Move the collective stick to full up
the forward side of the lateral friction and the cyclic stick to full aft and full
guide with the fixture cutout positioned right.
over the friction knob stud (ref.
Figure 502, View C). 1). The clearance must be 0.006 inch
(0.15 mm) minimum.
(a). Install the fixture hook in the lower 2). Turn the hub 360_ to find the
inboard end of slot. location of minimum clearance.
(b). Tighten the knurled thumbnut to (14). As necessary, adjust the collective
the seat the bushing at the upper control mixer rod to get the minimum
outboard end. clearance.
(15). Do steps (12). and (13). again to do a
(c). Tighten the lateral friction knob. second check of all clearances.
(10). Do a check for lateral travel: NOTE: Do steps (16). and (17). to make sure
that the mixer control motion travels and
(a). Move the cyclic stick to the left stop. the minimums are met.
Page 510
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MAINTENANCE MANUAL
(16). Do Step 3.A.(8). again. NOTE: The collective bungee has a very high
over- center spring pressure. Make sure the
(17). Do Step (4). and steps (6). thru (10). collective stick is fully seated on the rigging
again. fixture or the rigging will not be correct.
(d). Lower the collective stick on ST501
(19). Install the main rotor blades (ref. collective rigging fixture.
Procedure 2.B. Main Rotor Blade (e). Tighten the control friction grip.
Installation).
(4). Adjust the longitudinal cyclic trim for
(20). Track the main rotor blades and adjust NO- LOAD.
the autorotation rpm (ref. 18- 10- 00,
Adjustment / Test, Procedure 1. Blade (5). Install ST504 longitudinal rigging
Tracking Procedure). fixture (ref. View D).
4. LH Command Control System Rigging (6). Adjust the lateral cyclic trim for
(600N) NO- LOAD.
A. Collective Controls (LH Command) (7). Install ST506 lateral rigging fixture
(Ref. Figure 503) (ref. View E).
NOTE: For both longitudinal and lateral cyclic

Special Tools rigging fixtures, make sure that the bolt of
(Ref. Section 91-00-00) the friction lock is engaged in the slot of the
Item Nomenclature rigging fixture and that the hook of the fix-
ST501 Collective rigging fixture ture is engaged with the check- nut tight-
(LH command) ened.
ST503 Mixer rigging plate
ST504 Longitudinal rigging fixture (8). Put ST503 mixer rigging plate in
(LH command) position on the mast support fitting
ST506 Lateral rigging fixture (ref. View A).
(LH command)
(a). If the mixer bellcranks are in dimen-
sion with reference to the ST503
NOTE: To help the field rigging of the collective
mixer rigging plate the collective and
control (up and down) and the cyclic control
cyclic controls are correctly rigged.
tional field rigging tools can be made (ref. (b). The dimensions in Step (9). must
Procedure 16., Special Tooling). agree with the dimensions on the
(1). Remove the main rotor blades (ref. field rigging tools.
Procedure 2. Main Rotor Blade Replace- (c). If the dimensions do not agree, the
ment). full rigging procedure must be done.
(2). As necessary, remove the fairings. (9). Measure the distance from ST503
mixer rigging plate to the center of the
(3). Install ST501 collective rigging fixture hingeline bolt with a 6.00 inch (16
(ref. View C): cm) scale.
(a). Release the control friction grip. (a). Record the measurement as Dimen-
(b). Lift the pilot collective stick. sion N.
(c). Put ST501 collective rigging fixture NOTE: Dimension N is used as the basic di-
in position in the outboard lower end mension for the nominal setting to find the
of the slot in the collective friction height of the bolts (to the nearest half- turn
guide link. of the control rodend fitting).
Page 511
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MAINTENANCE MANUAL
MIXER
RIGGINGPLATE
MAST MAST
SUPPORT FITTING SUPPORT
BRACKET
LONGITUDINAL PITCH
IDLERBELLCRANK
DIM. N
COLLECTIVE MIXER
CONTROL ROD
MIXERRIGGING
PLATE
INITIAL RIGGINGPLATE MEASUREMENT
LONGITUDINAL PITCH
MIXERBELLCRANK
COLLECTIVE PITCH
COLLECTIVE FRICTION MIXERBELLCRANK
GUIDE LINK
DIM. N
PILOT COLLECTIVE
PITCHSTICK
CONTROL FRICTIONGRIP
(DRIVE GEAR)
RIGGINGPLATE MEASUREMENT
COLLECTIVE RIGGING
FIXTURE
6G67-037-1B
Figure 503. Main Rotor Control System Rigging for the 600N (Sheet 1 of 2)
Page 512
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MAINTENANCE MANUAL
LONGITUDINAL MIXER LONGITUDINAL KNURLED

CONTROL ROD FICTIONGUIDE THUMBNUT
(CYCLIC) LINK
LATERAL MIXER
CONTROL ROD
(CYCLIC)
FRICTIONKNOB
LONGITUDINAL RIGGING
CLEARANCE
LATERAL FRICTION FRICTIONKNOB

GUIDE LINK
LONGITUDINAL PITCH
MIXERBELLCRANK MIXERRIGGINGPLATE
MIXERTRAVEL
KNURLED CYCLICSTICK LATERAL

THUMBNUT RIGGINGFIXTURE
LATERAL RIGGING
PITCHCONTROL ROD
LATERAL BELLCRANK
ELASTOMERRING
(THIS SIDE, CURRENT
CONFIG. ONLY)
ELASTOMER
RING
STATIONARY
SLOTTED SWASHPLATE
BUSHING MIXERLINK
CLEARANCE
PITCHCONTROL ROD
INSTALLATION(6 PL) MIXERRIGGINGPLATE
MIXERTRAVEL
6G67-037-2A
Figure 503. Main Rotor Control System Rigging for the 600N (Sheet 2 of 2)
Page 513
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MAINTENANCE MANUAL
Do not scribe or mark the bolts B. Cyclic Controls (LH Command)

CAUTION with the pointer of the test fix-
ture. (Ref. Figure 503 and Table 502)
Do not change the tool setting. Special Tools

CAUTION This can cause the adjustments (Ref. Section 91-00-00)
to be incorrect. Item Nomenclature
(b). Adjust the collective control rod so (LH command)
that the centerline of the hingeline ST503 Mixer rigging plate
bolt of the collective bellcrank equals ST504 Longitudinal rigging fixture
Dimension N (to the nearest (LH command)
half- turn on the rodend bearing). ST506 Lateral rigging fixture
(LH command)
(c). Adjust the longitudinal control rod so
that the centerline of the hingeline NOTE: All cyclic control rigging is done with
bolt of the longitudinal bellcrank the collective stick on ST501 collective rig-
equals Dimension N (to the nearest ging fixture.
half- turn on the rodend bearing).
(1). Remove the main rotor blades (ref.
(d). Adjust the lateral control rod so that 62- 10- 00, Removal / Installation,
the centerline of the hingeline bolt Procedure 2. Main Rotor Blade Replace-
of the lateral bellcrank equals ment).
Dimension N (to the nearest (2). As necessary, remove the fairings.
half- turn on the rodend bearing).
(3). Install ST501 collective rigging fixture:
(10). Remove ST501 collective rigging (a). Release the control friction grip.
fixture.
(b). Lift the pilot collective stick.
(11). Do a check of the travel of the collective (c). Position ST501 collective rigging
stick: fixture in the outboard lower end of
the slot in the collective friction guide
(a). Move the collective stick to the link (ref. View C).
downstop. (d). Lower the collective stick on ST501
collective rigging fixture.
1). The centerline of the hingeline (e). Tighten the friction lock.
bolt in the collective bellcrank
must move down 0.71 inch (18.0 (4). Adjust the lateral cyclic trim for
mm) minimum below Dimen- NO- LOAD.
sion N (ref. Table 502).
(5). Install ST506 lateral rigging fixture.
(b). Move the collective stick to the (6). Put ST503 mixer rigging plate in
up- stop. position on the mast support fitting.
(7). Do a check of the longitudinal travel:
1). The centerline of the bolt in the
collective bellcrank must move up (a). Move the cyclic stick to the forward-
0.83 inch (21.0 mm) minimum stop.
above Dimension N (ref. 1). The centerline of bolt in longitudi-
Table 502). nal bellcrank must move up 1.05
inch (26.7 mm) minimum above
(c). As necessary, adjust the rodend to the centerline of hingeline bolt
get the specified limits. (ref. Table 502).
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MAINTENANCE MANUAL
2). As necessary, adjust the installa- NOTE: The final adjustment of the pitch
tion of ST503 mixer rigging plate change links is during the track of the main
to get a clearance with the longitu- rotor blades (ref. Step (25).) and adjustment
dinal bellcrank. of the autorotation rpm (ref. Step (26).).
(b). Move the cyclic stick to the aft- stop. (13). Remove ST504 longitudinal rigging
fixture.
1). The centerline of the bolt in the
bellcrank must move down 0.65 (14). Remove ST503 mixer rigging plate.
inch (16.5 mm) minimum below (15). Remove ST501 collective rigging
centerline of hingeline bolt (ref. fixture.
Table 502).
(16). Do a clearance check between the
2). As necessary, adjust the rodend to rotating swashplate and the longitudi-
get the specified limits. nal pitch idler bellcrank (ref. View H):
(8). Adjust the longitudinal cyclic trim for (a). Move the collective stick full down
NO- LOAD. and the cyclic stick full forward and
full left.
(9). Install ST504 longitudinal rigging
fixture (ref. View D). 1). The clearance must be 0.125 inch
(3.18 mm) minimum.
(10). Remove ST506 lateral rigging fixture.
(11). Do a check of the lateral travel (ref. control rod to get the specified
View E): limit.
(a). Move the cyclic stick to left- stop. (17). Do an interference check between the
lateral bellcrank and the collective
1). The centerline of the bolt head bellcrank of the mixer controls:
(forward end) of the bolt in the
(a). Move the collective stick full up and
lateral bellcrank must move down
0.52 inch (13.2 mm) minimum
fore or aft).
below the centerline of the collec-
tive hingeline bolt (ref. 1). The clearance must be 0.030 inch
Table 502). (0.76 mm) minimum.
(b). Move the cyclic stick to right- stop. 2). As necessary, adjust the forward
lateral rod to get the specified
1). The centerline of the bolt head in limit.
the lateral bellcrank must move up
0.37 inch (9.4 mm) minimum (18). Do a clearance check between the aft
above the centerline of the collec- longitudinal bellcrank and the mast
tive hingeline bolt (ref. base:
Table 502).
(a). Move the collective stick full down
(c). As necessary, adjust the rodend to and the cyclic stick full aft.
get the specified limits. 1). The clearance must be 0.030 inch
(0.76 mm) minimum.
Do not adjust the control rod
CAUTION end past the witness hole. 2). As necessary, adjust the longitudi-
Tighten the jamnut after the final adjust- nal control rod (recommended) or
ment. Failure to obey this caution can cause the collective control rod to get the
parts damage and/or equipment failure. specified limit.
(12). Set the pitch change links to 6.25 inch (19). Do a clearance check between the
(158.8 mm) nominal. rotating swashplate and the scissors
Page 515
67- 10- 00 TR18- 001
MAINTENANCE MANUAL
fitting, and the scissors fitting and the 2). The clearance must be 0.006 inch
lower hub shoe. (0.15 mm) minimum.
(a). Move the collective stick full up and (b). Move the collective stick full up and
the cyclic stick full forward and full the cyclic stick full aft and full right.
left.
1). The allowable clearance for both location with minimum clearance.
conditions is 0.030 inch (0.76
mm) minimum. 2). The clearance must be 0.006 inch
(0.15 mm) minimum.
location with minimum clearance. (21). Do steps (16). thru (20). again to make
sure of the clearances.
(b). Move the collective stick full up and
(22). Do steps (7). and (11). again to make
the cyclic stick full forward and full
sure of the minimum travels and
right.
clearances.
location with minimum clearance.
(24). Install the main rotor blades (ref.
2). The allowable clearance for both
conditions is 0.030 inch (0.76
mm) minimum.
Installation).
(c). As necessary, adjust the rodend to (25). Do the Blade Tracking Procedure for
get the specified limits. the main rotor blades (ref. Section
(20). Do a clearance check between the 18- 10- 60, Adjustment / Test, Procedure
scissors link and the edge of the pocket 1. Blade Tracking Procedure).
in the rotating swashplate. (26). Do the Main Rotor Autorotation
(a). Move the collective stick full up and Percentage Check and adjust the main
the cyclic stick full aft and full left. rotor blades as necessary (ref. Section
18- 10- 60, Adjustment / Test, Procedure
1). Turn the hub 360_ to find the 3. Main Rotor Autorotation Percentage
location with minimum clearance. Check).
Page 516
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MAINTENANCE MANUAL
5. RH Command Control System Rigging (5). Install ST505 longitudinal rigging

(600N) fixture (ref. View D).
A. Collective Controls (RH Command) (6). Adjust the lateral cyclic trim for
(600N) NO- LOAD.
(Ref. Figure 502 and Figure 503) (7). Install ST507 lateral rigging fixture
(ref. View E).
Special Tools
NOTE: For both longitudinal and lateral cyclic
rigging fixtures, make sure that the bolt of
Item Nomenclature
the friction lock is engaged in the slot of the
ST502 Collective rigging fixture rigging fixture and that the hook of the fix-
(RH command) ture is engaged with the check- nut tight-
ST503 Mixer rigging plate ened.
(RH command) (8). Put ST503 mixer rigging plate in
position on the mast support fitting.
(RH command) (a). If the mixer bellcranks are in dimen-
sion with reference to ST503 mixer
NOTE: To help the field rigging of the collective rigging plate the collective and cyclic
control (up and down) and the cyclic control controls are correctly rigged.
(b). The dimensions in Step (9). must
tional field rigging tools can be made (ref.
agree with the dimensions on the
Procedure 16., Special Tooling).
field rigging tools.
(1). Remove the main rotor blades (ref.
62- 10- 00, Removal / Installation, (c). If the dimensions do not agree, the
Procedure 2. Main Rotor Blade Replace- full rigging procedure must be done.
ment).
(9). Measure the distance from ST503
(2). As necessary, remove the fairings. mixer rigging plate to the center of the
hingeline bolt with a 6.00 inch (15.2
(3). Install ST502 collective rigging fixture cm) scale.
(ref. View C):
(a). Record the measurement as Dimen-
(a). Release the control friction grip. sion N.
(b). Lift the pilot collective stick. NOTE: Dimension N is used as the basic di-
mension for the nominal setting to find the
(c). Put ST502 collective rigging fixture height of the bolts (to the nearest half- turn
in position in the outboard lower end of the control rodend fitting).
of the slot in the collective friction
guide link. Do not scribe or mark the bolts
CAUTION with the pointer of the test fix-
NOTE: The collective bungee has a very high
ture.
over- center spring pressure. Make sure the
collective stick is fully seated on the rigging Do not change the tool setting.
fixture or the rigging will not be correct. CAUTION This can cause the adjustments
(d). Lower the collective stick on ST502 to be incorrect.
collective rigging fixture.
(b). Adjust the collective control rod so
(e). Tighten the control friction grip. that the centerline of the bolt of the
collective bellcrank equals Dimen-
(4). Adjust the longitudinal cyclic trim for sion N (to the nearest half- turn on
NO- LOAD. the rodend bearing).
Page 517
67- 10- 00 TR18- 001
MAINTENANCE MANUAL
(c). Adjust the longitudinal control rod so (1). Remove the main rotor blades (ref.
that the centerline of the bolt of the 62- 10- 00, Removal and Installation,
longitudinal bellcrank equals Di- Procedure 2. Main Rotor Blade Replace-
mension N (to the nearest half- turn ment).
on the rodend bearing).
(2). As necessary, remove the fairings.
(d). Adjust the lateral control rod so that
the centerline of the bolt of the (3). Install ST502 collective rigging fixture
lateral bellcrank equals Dimension (ref. Figure 503, View C):
N (to the nearest half- turn on the
rodend bearing). (a). Release the control friction grip.
(10). Remove ST502 collective rigging fixture (b). Lift the pilot collective stick.
(ref. View C).
(11). Do a check of the travel: in position in the outboard lower end
(a). Move the collective stick to the of the slot in the collective friction
downstop. guide link.
1). The centerline of the bolt in the (d). Lower the collective stick on ST502
collective bellcrank must move collective rigging fixture.
down 0.71 inch (18.0 mm) mini-
mum below the nominal setting (e). Tighten the friction lock.
(ref. Table 502).
(4). Adjust the lateral cyclic trim for
(b). Move the collective stick to the NO- LOAD.
up- stop.
(5). Install ST507 lateral rigging fixture on
1). The centerline of the bolt in the the forward side of the lateral friction
collective bellcrank must move up guide, with the fixture cutout posi-
0.83 inch (21.0 mm) minimum tioned over the friction knob stud (ref.
above the nominal setting (ref. View E).
Table 502).
(a). Install the fixture hook in the lower
(c). As necessary, adjust the rodend to inboard end of the slot.
get the specified limits.
(b). Tighten the knurled thumbnut until
B. Cyclic Controls (RH Command) (600N) it touches the bushing at the upper
(Ref. Figure 502, Figure 503, and Table 502) outboard end.
(c). Tighten the lateral friction knob.

Special Tools
(Ref. Section 91-00-00) (6). Put ST503 mixer rigging plate in
Item Nomenclature position on the mast support fitting.
(RH command)
(7). Do a check of the longitudinal travel
(ref. View A):
ST503 Mixer rigging plate
ST505 Longitudinal rigging fixture (a). Move the cyclic stick to forward- stop.
(RH command)
ST507 Lateral rigging fixture 1). The centerline of the bolt in the
(RH command) longitudinal bellcrank must move
up 1.05 inch (26.7 mm) mini-
mum above the centerline of the
NOTE: All cyclic control rigging is done with hingeline bolt (ref. Table 502).
the collective stick on ST502 collective rig-
ging fixture. (b). Move the cyclic stick to the aft- stop.
Page 518
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MAINTENANCE MANUAL
Table 502. Travel Distance (600N)

Nominal Measurement Down Travel, Minimum Up Travel, Minimum
Collective 0.71 inch (18.0 mm) Down 0.83 inch (21.1 mm) Up
Lateral 0.52 inch (13.2 mm) Left 0.37 inch (9.4 mm) Right
Longitudinal 0.65 inch (16.5 mm) Aft 1.05 inch (26.7 mm) Forward
1). The centerline of the bolt in the 1). The centerline of the bolt head in
bellcrank must move down 0.65 the lateral bellcrank must move up
inch (16.5 mm) minimum below 0.37 inch (9.4 mm) minimum
centerline of the hingeline bolt above the centerline of the collec-
(ref. Table 502). tive hingeline bolt (ref.
Table 502).
(c). As necessary, adjust the rod end to
get the specified limits. (c). As necessary, adjust the rodend to
get the specified limits.
(d). As necessary, adjust the installation
Do not adjust the control rod
of the mixer plate to get a clearance CAUTION end past the witness hole.
with the longitudinal bellcrank.
(8). Adjust the longitudinal cyclic trim for ment. Failure to obey this caution can cause
NO- LOAD. parts damage and/or equipment failure.
(9). Install ST505 longitudinal rigging (12). Set the pitch change links at 6.25 inch
fixture on the outboard side of the (158.8 mm) nominal.
longitudinal friction guide, with the NOTE: The final adjustment of the pitch
fixture cutout positioned over the change links is during the track of the main
friction knob stud (ref. View D). rotor blades (ref. Step (25).) and adjustment
of the autorotation rpm (ref. Step (26).).
(a). The bushing end of the fixture
touches the upper end of the slot in (13). Remove ST505 longitudinal rigging
the guide. fixture (ref. View D).
(b). Install the fixture hook in the lower (14). Remove ST503 mixer rigging plate.
end of the slot. (15). Remove ST502 collective rigging fixture
(ref. View C).
(c). Tighten the knurled thumbnut until
it touches the bushing at the upper (16). Do a clearance check between the
end. rotating swashplate and the longitudi-
nal pitch idler bellcrank:
(d). Tighten the friction knob.
(a). Move the collective stick to full down
(10). Remove ST506 lateral rigging fixture. and the cyclic stick forward and full
left.
(11). Do a check of the lateral travel (ref.
View E): 1). The clearance must be 0.125 inch
(3.18 mm) minimum.
(a). Move the cyclic stick to left- stop.
1). The centerline of the bolt head control rod to get the specified
(forward end) of the bolt in the limit.
lateral bellcrank must move down (17). Do an interference check between the
0.52 inch (13.2 mm) minimum lateral bellcrank and the collective
below the centerline of the collec- bellcrank of the mixer controls:
tive hingeline bolt (ref.
Table 502). (a). Move the collective stick full up and
(b). Move the cyclic stick to right- stop. fore or aft).
Page 519
67- 10- 00 TR18- 001
MAINTENANCE MANUAL
1). The clearance must be 0.030 inch (c). As necessary, adjust the collective
(0.76 mm) minimum. control mixer rod.
2). If there is an interference, length- (20). Do a clearance check between the
en the forward lateral rod to get scissors link and the edge of the pocket
the specified clearance. in the rotating swashplate:
(18). Do a clearance check between the aft (a). Move the collective stick full up and
longitudinal bellcrank and the mast the cyclic stick full aft and full left.
base: 1). Turn the hub 360_ to find the
(a). Move the collective stick full down location with minimum clearance.
and the cyclic stick full aft. 2). The clearance must be 0.006 inch
(0.15 mm) minimum.
1). The clearance must be 0.030 inch
(0.76 mm) minimum. (b). Move the collective stick full up and
the cyclic stick full aft and full right.
2). As necessary, adjust the longitudi-
nal control rod (recommended) or 1). Turn the hub 360_ to find the
the collective control rod to get the location with minimum clearance.
specified limit.
2). The clearance must be 0.006 inch
(19). Do a clearance check between the (0.15 mm) minimum.
rotating swashplate and the scissors
(21). Do steps (16). thru (20). again to make
fitting, and the scissors fitting and the
sure of the clearances.
lower hub shoe.
(22). Do steps (7). and (11). again to make
(a). Move the collective stick full up and sure of the minimum travels and
the cyclic stick full forward and full clearances.
left.
1). The allowable clearance for both
conditions is 0.030 inch (0.76 (24). Install the main rotor blades (ref.
mm) minimum. 62- 10- 00, Removal / Installation,
2). Turn the hub 360_ to find the Installation).
location with minimum clearance.
(25). Do the Blade Tracking Procedure for
(b). Move the collective stick full up and the main rotor blades (ref. Section
the cyclic stick full forward and full 18- 10- 60, Adjustment / Test, Procedure
right. 1. Blade Tracking Procedure).
1). Turn the hub 360_ to find the (26). Do the Main Rotor Autorotation
location with minimum clearance. Percentage Check and adjust the main
rotor blades as necessary (ref. Section
2). The allowable clearance for both 18- 10- 60, Adjustment / Test, Procedure
conditions is 0.030 inch (0.76 3. Main Rotor Autorotation Percentage
mm) minimum. Check).
Page 520
TR18- 001 67- 10- 00
MAINTENANCE MANUAL
6. Cyclic Controls Rigging (L/H Command) 10. Deleted — Ref. Section 76−20−00,
(369D/E/FF − 500N) Adjustment / Test
NOTE: This procedure is now Procedure 2.B.,
Cyclic Controls (LH Command) (369D/E/FF NOTE: This procedure, Gas Producer Linkage
- 500N). Adjustment, has been moved to Section
76-20-00, Adjustment / Test.
7. Cyclic Controls Rigging (R/H Command)
(369D/E/FF − 500N) 11. Deleted — Ref. Section 76−20−00,
NOTE: This procedure is now Procedure 3.B., Adjustment / Test
Cyclic Controls (RH Command) (369D/E/FF
- 500N). NOTE: This procedure, Pipe Plug Adjustment,
has been moved to Section 76-20-00, Ad
8. Cyclic Controls Rigging (L/H Command) justment / Test.
(600N)
NOTE: This procedure is now Procedure 4.B., 12. Deleted — Ref. Section 76−20−00,
Cyclic Controls (LH Command) (600N). Adjustment / Test
9. Cyclic Controls Rigging (R/H Command)
(600N) NOTE: This procedure, Gas Procedure Inter
connecting Torque Tube Assembly Shim
NOTE: This procedure is now Procedure 5.B., ming, has been moved to Section 76-20-00,
Cyclic Controls (RH Command) (600N). Adjustment / Test.
Page 521
MAINTENANCE MANUAL
DELETED
Figure 504. Deleted — Ref. Section 76−20−00, Adjustment / Test
Page 522
MAINTENANCE MANUAL
DELETED
Page 523
MAINTENANCE MANUAL
DELETED
Page 524
MAINTENANCE MANUAL
13. Collective Stick NOTE: The ratio of the idler gear to gear as
sembly is 3:1, which allows for a fine adjust
A. Friction Mechanism Adjustment ment. When repositioning idler gear, be sure
to install the same number of washers that
(Ref. Figure 507) were removed from between the cotter pin
and idler. These washers limit the gear end-
For collective friction mecha play to 0.010 inch (0.254 mm) maximum .
CAUTION nism to be correctly adjusted for The gear train must turn freely after assem
maximum friction, three actions must occur bly.
at same time:
(6). Install phenolic washer, Teflon washer,
D The drive gear must touch the stick fit retainer assembly, and nut.
ting fixed stop.
Do not overtighten the retainer
D The spring retainer housing washer must CAUTION nut so that the retainer washer
touch the retainer internal stop. contacts the retainer stop before the friction
D The gear assembly pin must be at the ap drive gear reaches stick fitting stop. Adjust
proximate peak of the cam. ment that does not produce approximately
simultaneous contact will allow too much
(1). Remove the friction mechanism guard. additional rotation of the drive gear grip
and cause the nylon gears to be stripped.
(2). Turn the friction drive gear counter (7). With drive gear still at the maximum
clockwise to the maximum friction friction position, tighten the retainer
position. nut until it just touches the retainer
stop.
(3). Remove cotter pin, nut, retainer
assembly, Teflon washer, and one (8). Turn the friction drive gear clockwise to
phenolic washer. the minimum friction stop position.
Carefully slide the gear assem (a). Release the grip.

CAUTION bly out. The washers and spacer (b). Do the checks in steps (9). and (10).
can fall off.
(9). If pin has overridden the low point of
(4). Slide the gear assembly out far enough the cam (desired minimum friction
to disengage it from the idler gear. position), and the grip-to-stick friction
prevents spring-back of the pin-to-cam
(5). Engage the gear assembly with the low point, turn the grip and move the
idler gear to position the pin on the pin to the low point.
peak of the cam.
NOTE: A drive gear that does not turn freely on
(a). Make sure that drive gear is still at collective stick tube must be replaced.
maximum friction stop position. (10). With the pin on the cam low point, turn
the retainer assembly.
(b). If the gear assembly does not correct
ly position the pin, reposition the NOTE: It should turn freely on shaft of gear as
idler gear on the drive gear. sembly with only light finger pressure.
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MAINTENANCE MANUAL
GUARD
WASHER(S)
(NOTE 1) STICK FITTING
COTTER
PIN FRICTION
DRIVE GEAR
PHENOLIC WASHERS (ROTATING
STOP)
TEFLON
WASHER
RETAINER HOUSING
COTTER PIN MAXIMUM
IDLER FRICTION
GEAR NUT
STICK FITTING
(FIXED STOP)
FRICTION CONTROL
DRIVEN WASHER
GEAR STOP SPRING
GEAR SPACER
ASSEMBLY
(NOTE 2) CAM GUIDE
ALUMINUM
WASHER
GUARD
FRICTION MECHANISM ATTACHMENT
NYLON STRAP
GEAR ASSEMBLY PIN

(NOTE 4)
NOTE 3 NOTE 5
NOTE 6
NOTES:
1. SHIMMED AS REQUIRED FOR 0.010 IN. (0.254 MM) MAXIMUM
END PLAY. GEAR TRAIN MUST ROTATE FREELY. CAM ACTION
2. GEAR ASSEMBLY MUST SLIDE AND ROTATE FREELY IN FITTING.
GREASE APPLIED TO SHAFT.
3. ACCEPTABLE MINIMUM FRICTION POSITION.
4. DESIRED MINIMUM FRICTION POSITION (CAM LOW POINT).
5. CORRECT MAXIMUM FRICTION POSITION (CAM HIGH POINT).
6. UNACCEPTABLE MAXIMUM FRICTION POSITION. G67-1016B
Figure 507. Collective Stick Friction Adjustment
Page 526
MAINTENANCE MANUAL
(11). Adjust the retainer nut to the nearest (c). Do the flight evaluation of the
castellation that has zero friction (no collective forces with:
drag on the retainer assembly during
rotation). 1). A helicopter takeoff weight of 2350
pound (1066 kg).
(a). Install a new cotter pin.
2). N2 at 103%.
NOTE: If there are unwanted collective forces
(“light”, “heavy”, or “creeping”) in the collec 3). Zero collective stick friction.
tive stick during flight, do not increase the
collective friction. This condition must be (2). Before the test flight, establish a
corrected elsewhere in the control system half-way point of collective friction
(ref. Procedure 4.A., LH Collective Controls, adjustment grip (drive gear) as follows:
and Procedure 14.A., Collective Bungee Ad (a). Use a soft colored pencil to index the
justment). collective friction adjustment grip at
zero friction.
14. Collective Bungee
(b). Roll on maximum friction (approxi
A. Adjustment
mately 275_ rotation).
(Ref. Figure 508)
1). Record the travel distance.
NOTE: Adjust the collective bungee only when
the helicopter is on ground. 2). Reset the friction grip half-way.
3). Hold in this position.
WARNING
(c). Make a mark with a dot of white
D Do not adjust the collective bungee paint or similar method to temporar
during flight. Control jamming can ily show the top of the friction grip
occur. and the adjacent exposed area of the
D Use all necessary precautions to pre collective stick.
vent the possible entry of foreign ob 1). The friction half-way index mark
jects into the controls linkage ex must be visible to the pilot.
posed by the removal of the pilot seat
cover to adjust the collective bungee. (3). With the helicopter on the ground,
adjust the bungee as necessary to avoid
(1). Adjustments made in the main rotor
an upload in flat pitch at normal rpm.
system can have an effect on the
collective load forces — obey these (a). This adjustment must also provide
conditions: an absence of an excessive download
(a). Only adjust the bungee when: or upload while in hover and at a
120-knot level cruise.
1). The main rotor blades are in track.
(b). Land the helicopter after each flight
2). The autorotation rpm is set. check.
(b). Make sure that the collective stick (c). Do the corrective adjustment, as
friction is correctly adjusted. necessary.
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MAINTENANCE MANUAL
COLLECTIVE MIXER
NOTE 3 TUNNEL-ROUTED
CONTROL ROD
INBOARD COLLECTIVE
GAS PRODUCER STICK SOCKET
CONTROL ROD
BUNGEE OVER-CENTER
ADJUSTMENT BOLT
(NOTE 1)
BUNGEE
GAS PRODUCER
INTERCONNECTING
TORQUE TUBE
COLLECTIVE CONTROL
INTERCONNECTING
TORQUE TUBE
BUNGEE SPRING
ADJUSTMENT NUT (NOTE 2 N2 DROOP CONTROL OVERRIDE
- SEE CAUTION) LINK (369D/E/FF - 500N)
COLLECTIVE STICK FRICTION
MECHANISM AND GUARD
PILOT'S COLLECTIVE
PITCH STICK
NOTE 5 NOTE 4
THROTTLE FUSELAGE
THROTTLE FRICTION SKIN
GUIDE
SLEEVE
BUSHING NOTE 5
NOTES:
1. ROTATED CLOCKWISE TO INCREASE, COUNTERCLOCKWISE TO
DECREASE OVERALL COLLECTIVE DOWNLOADS.
2. (LOOKING AFT AT THE BUNGEE) ROTATED CLOCKWISE TO INCREASE
COUNTERCLOCKWISE TO DECREASE, BUNGEE PRELOAD.
CAUTION: DO NOT ADJUST BUNGEE SPRING TENSION WHILE BUNGEE
INSTALLATION TOOL IS INSTALLED. USE OVER-CENTER ACTION OF STICK TO
COMPRESS SPRING TO REMOVE TOOL.
3. BUSHINGS MUST PROTRUDE A MINIMUM OF 0.010 IN. (0.254 MM) TO
A MAXIMUM OF 0.060 IN. (1.524 MM) AFTER BOLT IS TIGHTENED.
4. FOUR NUTS TORQUED EQUALLY AND BY SMALL INCREMENTS.
5. WASHERS ARRANGED TO ALIGN GUIDE WITH STICK; LOOSELY
SPACED WITH THREE WASHERS.
G67−1003B
Figure 508. Adjustment of the Collective Bungee
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MAINTENANCE MANUAL
(f). When a relatively constant upload

CAUTION condition prevails during flat pitch at
D After each bungee adjustment is made, normal rpm on the ground, at hover,
collective stick must be slowly moved and at a 120-knot level cruise, turn
through its full travel range to make sure the bungee over-center adjustment
there is no binding or restriction of stick bolt clockwise to decrease the upload.
motion, and that the spring does not bot
tom at the overcenter position. (g). When a relatively constant download
D Do not turn the female bearing assembly condition prevails during flat pitch at
spring retainer while the bungee installa normal rpm on the ground, at hover,
tion tool is spring loaded. and at a 120-knot level cruise, turn
the bungee over-center adjustment
D During adjustment of the bungee over bolt counterclockwise to decrease the
center fitting, make sure the nut turns download.
during the bolt adjustment. The cotter pin
can shear if the nut does not turn with the
bolt. NOTE: Rotation of the adjustment bolt head is
the only mechanical operation necessary to
(d). If an upload exists on ground at flat adjust an over-center position of the bungee
pitch and normal rpm but a down fitting.
load prevails during hover and at
120-knot level cruise, turn the (h). After minimum and balanced collec
bungee adjustment retainer nut tive forces are found, not more than
clockwise to increase the preload in one-half of available collective stick
the bungee system. friction (friction grip at the half-way
(e). To correct a download on ground index) must cancel the collective
during flat pitch at normal rpm and forces during flight test at a
an upload condition during hover and 140-knot level cruise.
120-knot level cruise, turn the
bungee adjustment retainer nut (i). If the friction applied in Step (h). is
counterclockwise to decrease the not sufficient to cancel the collective
preload in the bungee system. forces, do Procedure 14.A. again.
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MAINTENANCE MANUAL
15. Cyclic Trim Actuator NOTE: PN 369D27001 (8222M7) Actuator:

D When power is applied to the actuator, it
A. Bench Test for Models 369D/E/FF − 500N will move in the commanded direction un
til it reaches the end of the stroke.
(Ref. Figure 509)
D If, during mid-travel, an opposite power
is applied simultaneously, it will stop and
(1). Connect the cyclic trim actuator to the remain stopped.
test harness and equipment.
D When one of the inputs is removed, the
(2). Mount the actuator in suitable fixture actuator can or cannot start.
for vertical extension and retraction D If it does not restart, it has been latched
without interference. in the OFF state by the current surge gen
erated upon applying the second input.
(3). Set the direct-current power to ON.
D The actuator has a built-in current limit
circuit that latches it OFF if the actuator
(a). Adjust the output from 25.75 to current is more than 2.7 amp.
26.25 Vdc.
D All power must be removed to unlatch it.
Do not retract the spring assem
CAUTION bly during the tests. Do not re (5). Set the test switch to RETRACT.
tract the spring assembly (ram) so that ac
tuator length is less than 13.50 inch (a). Let the actuator ram retract to a
(34.29 cm) between the centers of the at length of 13.50 inch (34.29 cm)
tached bolts. between the centers of the attached
bolts.
(4). With the actuator spring assembly (6). Use a stopwatch to measure the travel
(ram) approximately halfway between time of the check actuator ram from
travel limits (actuator length at 14.46 fully retracted to fully extended.
inch (36.73 cm) between the centers of
the attached bolts), set up a test dial (7). Do a check of the time interval for
indicator to measure ram end-play. actuator motor tested.
(a). During adjustment of the screw, (a). Each actuator will travel at a greater
make sure that there is thread-lock speed than others.
ing friction from the self-locking
threaded insert. (b). Intervals of less time are acceptable.
(b). The end-play must be 0.010 to 0.050

inch (0.25 to 1.27 mm). Actuator Motor Maximum Time
(PN) Interval (Seconds)
(c). If the end-play is too much, replace 369A7001 58.4
the actuator.
369A7014 (High Speed) 38.0
NOTE: PN 369A7014 (8222M6) Actuator:
369D27001 (Super Fast) 17.5
D When power is applied to the actuator, it
will move in the commanded direction un
til it reaches the end of the stroke. (8). Measure the length of the extended
ram.
D If, during mid-travel, an opposite power
is applied simultaneously, it will stop and (a). Subtract the measurement from Step
remain stopped until one or the other in (5). from the measurement of Step
put is removed. (8).
Page 530
MAINTENANCE MANUAL
RIVET (4 PL)
G67-1017B
Figure 509. Cyclic Trim Actuator Assembly
Page 531
MAINTENANCE MANUAL
(b). The result must be 1.92 inch (48.8 (b). Over- travel is limited to 0.020 inch
mm) minimum. (0.51 mm) with an overriding
(aiding) load — otherwise there must
Do not run the actuator against be no over- travel.
CAUTION the extend limit stop with the
163- pound (74- kg) weight to help actua- (16). Remove the 163- pound (74- kg) load.
tion. The actuator thrust bearing can be
damaged. (17). Do Step (4). again.
(9). Connect a 163- pound (74- kg) load to (18). Run actuator until arm is extended
the actuator. 1.75 inch (44.5 mm).
(19). Set power to OFF.

(10). Set the switch to RETRACT.
(20). Disconnect the cyclic trim actuator.
(11). Measure the time it takes the ram to
travel 1.72 to 1.78 inch (4.37 to 4.52 B. Bench Test for Model 600N
cm) to retract stop.
(Ref. Figure 509)
(12). Do a check of the retraction time for the
actuator motor tested. (1). Connect the cyclic trim actuator to the
test harness and equipment.
Actuator Motor Time Interval (2). Mount the actuator in a suitable fixture
(PN) (Seconds) that allows vertical extension and
retraction.
369A7001 30 to 50
369A7014 (High Speed) 15 to 25 (3). Set direct- current power to ON.
369D27001 (Super Fast) 7 to 12 (a). Adjust the output 25.75 to 26.25

Vdc.
(13). Operating current under load condi- During these tests, do not re-
tions cannot be more than 1.2 amperes
CAUTION tract the spring assembly (ram)
running and 2.0 amperes stalled. so that the actuator length is less than 13.50
inch (34.29 cm) between the centers of the
NOTE: It is not necessary to extend or retract attached bolts.
the actuator ram more than 0.25 inch (6.4
mm) in steps (14). or (15). (4). With actuator spring assembly (ram)
approximately halfway between travel
(14). Reduce the voltage input to 21 Vdc. limits (actuator length at 14.46 inch
(36.73 cm) between the centers of the
attached bolts), set up the test dial
(a). The actuator ram must retract and
indicator and measure the ram end-
extend.
play.
(b). Over- travel is limited to 0.020 inch (a). As the screw is adjusted, make sure
(0.51 mm) with an overriding there is thread- locking friction from
(aiding) load — otherwise there must the self- locking threaded insert.
be no over- travel.
(b). The end- play must be 0.010 to 0.050
(15). Increase input voltage to 28 Vdc. inch (0.25 to 1.27 mm).
(a). Actuator ram must retract and (c). If the end- play is too much, replace
extend. the actuator.
Page 532
TR18- 001 67- 10- 00
MAINTENANCE MANUAL
NOTE: When power is applied to the 8222M21 Do not run the actuator against
(600N7001) actuator, it will move as com CAUTION the extend limit stop with the
manded. 163 pound (74 kg) load to help actuation.
The actuator thrust bearing can be dam
D If power is applied simultaneously in the
aged.
opposite direction, it will stop.
D When one of the inputs is removed, the (9). Connect a 163 pound (74 kg) load to
actuator can or cannot start. the actuator.
D If it does not start, it has been latched in (10). Set the switch to RETRACT.
the OFF state by the current surge gener
(11). Measure the time it takes the ram to
ated when the second input was applied.
travel 1.72 to 1.78 inch (4.37 to 4.52
D The actuator has a built-in current limit cm) to a retract stop.
circuit that latches it OFF if the actuator
current is more than 3.1 amp. (12). Do a check of the retraction time for the
actuator motor tested.
D All power must be removed to unlatch it.
Actuator Motor Time Interval
(5). Position the test switch to RETRACT. PN (Seconds)
(a). Let the actuator ram retract to a 600N7001−1 (longitudinal) 7 to 12

length of 13.50 inch (34.29 cm)
between the centers of the attached 369D27001−3 (lateral) 7 to 12
bolts.
600N7014−1 (lateral, with YSAS) 7 to 12
(6). Use a stopwatch to measure the travel
time of the check actuator ram from (13). Operating current under load condi
fully retracted to fully extended. tions must not be more than 1.2
amperes running and 2.0 amperes
(7). Do a check of the time interval for the stalled.
actuator motor tested.
NOTE: It is not necessary to extend or retract
actuator ram more than 0.25 inch (6.4 mm)
NOTE: The time in the chart below is maxi
for test in steps (14). or (15).
mum time. Some actuators will travel at a
greater speed than others. Intervals of less (14). Reduce voltage input to 21 Vdc.
time are acceptable.
(a). Actuator ram must retract and
extend.
Actuator Motor Time Interval
PN (Seconds) (b). Over-travel is limited to 0.020 inch
(0.51 mm) with an overriding
600N7001−1 (longitudinal) 6.6 (aiding) load — otherwise there must
be no over-travel.
369D27001−3 (lateral) 11.0
(15). Increase input voltage to 28 Vdc.
600N7014−1 (lateral, with YSAS) 11.0
(a). Actuator ram must retract and
extend.
(8). Measure length of the extended ram.
(b). Over-travel is limited to 0.020 inch
(a). Subtract the measurement from Step (0.51 mm) with an overriding
(5). from the measurement from Step (aiding) load — otherwise there must
(8). be no over-travel.
(16). Remove the 163 pound (74 kg) load.
(b). The result must be 1.92 inch (4.88
cm). (17). Do Step (4). again.
Page 533
MAINTENANCE MANUAL
(18). Run the actuator until the arm extends T-angle plate.
1.75 inch (4.45 cm).
(19). Set the power to OFF. (2). Holes in vertical T-angle to be slotted
(20). Disconnect the cyclic trim actuator. to adjust to the nominal dimension of
the mixer support bolt.
16. Special Tooling
A. Field Rigging Aid for Models (3). Scribe the NOM markings on the
369D/E/FF−500N vertical T-angle where shown.
(Ref. Figure 510)
(1). Make from 2024-T4 aluminum alloy (4). Install 2 screws, 4 washers, and 2 nuts.
Page 534
MAINTENANCE MANUAL
DIM. A
DIM. B
DIM. A
DIM. K
DIM. C
DIM. J
DIM. D
FWD DIM. S
DIM. H
DIM. E DIM. R
NOM NOM NOM
DIM. F DIM. P
DIM. H
DIM. L
DIM. N
DIM. M
FRONT VIEW SIDE VIEW

DIM. G
G67-1000-510-1
DIMENSION A 2.25 INCH (57.2 MM) DIMENSION J 0.45 INCH (11.4 MM)
DIMENSION B 1.00 INCH (25.4 MM) DIMENSION K 0.75 INCH (19.1 MM)
DIMENSION C 0.75 INCH (19.1 MM) DIMENSION L 1.92 INCH (48.8 MM)
DIMENSION D 0.76 INCH (19.3 MM) DIMENSION M 1.05 INCH (26.7 MM)
DIMENSION E 0.43 INCH (10.9 MM) DIMENSION N 0.32 INCH (8.1 MM)
DIMENSION F 0.50 INCH (12.7 MM) DIMENSION P 0.57 INCH (14.5 MM)
DIMENSION G 0.125 INCH (3.18 MM) DIMENSION R 2.25 INCH (57.2 MM)
DIMENSION H 0.74 INCH (18.8 MM) DIMENSION S 1.190 INCH (30.23 MM)
Figure 510. Make a 369D/E/FF − 500N Field Rigging Aid
Page 535
MAINTENANCE MANUAL
B. Field Rigging Aid for Model 600N (2). Holes in vertical T-angle to be slotted
to adjust to the nominal dimension of
the mixer support bolt.
(Ref. Figure 511)
(3). Scribe the NOM markings on the
vertical T-angle where shown.
(1). Make from 2024-T4 aluminum alloy
T-angle plate. (4). Install 2 screws, 4 washers, and 2 nuts.
DIM. A
DIM. B
DIM. A
DIM. C DIM. M
DIM. L
DIM. D
FWD DIM. S
DIM. K
DIM. E DIM. R
NOM NOM NOM
DIM. F DIM. P
DIM. J
DIM. H
DIM. N
FRONT VIEW SIDE VIEW

DIM. G
G67-1000-511-1
DIMENSION A 2.25 INCH (57.2 MM) DIMENSION J 0.71 INCH (18.0 MM)
DIMENSION B 1.00 INCH (25.4 MM) DIMENSION K 0.83 INCH (21.1 MM)
DIMENSION C 0.75 INCH (19.1 MM) DIMENSION L 0.48 INCH (12.2 MM)
DIMENSION D 0.79 INCH (20.1 MM) DIMENSION M 0.75 INCH (19.1 MM)
DIMENSION E 0.37 INCH (9.4 MM) DIMENSION N 0.50 INCH (12.7 MM)
DIMENSION F 0.52 INCH (13.2 MM) DIMENSION P 0.65 INCH (16.5 MM)
DIMENSION G 0.125 INCH (3.18 MM) DIMENSION R 2.25 INCH (57.2 MM)
DIMENSION H 0.29 INCH (7.4 MM) DIMENSION S 1.05 INCH (26.7 MM)
Figure 511. Make a 600N Field Rigging Aid
Page 536
MAINTENANCE MANUAL
C. Mixer Rigging Plate (ST503) (3). All machined surfaces must have a
0.125 finish.
(Ref. Figure 512)
(1). Make from 2024-T351 aluminum alloy (4). Do an impression stamp for the part
plate (ref. Specification SAE AMS-QQ- number and locators.
A-250/4).
(a). The letters and numbers are to be
(a). The initial size is: approximately 0.12 inch (3.0 mm)
1). 0.375-inch (9.5 mm) wide, high.
2). 4.24-inch (107.7 mm) tall, and (b). Make sure the surface is flat after
the impression stamp.
3). 12.25-inch (311.2 mm) long.
(2). Cut to the dimensions shown in (5). Anodize the mixer rigging plate (ref.
Figure 512. MIL-A-8625, Type I).
DIM. C
DIM. B
DIM. A RAD. D DIM. J
DIA. E (2 PL)
DIM. G
DIM. V
DIM. U
DIM. F
DIM. T 369A9930 FWD

THIS SIDE UP MIXER RIGGING PLATE DIM. H
DIM. S
RAD. N DIM. K
DIM. R DIM. L
ANGLE M
DIM. P
0.015 (0.38)
0.015 (0.38)
A 0.010 (0.25) A
G67-1000-512-1
DIMENSION A 0.81 INCH (20.6 MM) DIMENSION L 0.94 INCH (23.9 MM)
DIMENSION B 6.71 INCH (170.4 MM) ANGLE M 90_ 0”
DIMENSION C 9.30 INCH (236.2 MM) RADIUS N 0.09 INCH (2.3 MM)
RADIUS D 0.09 INCH (2.3 MM) DIMENSION P 11.38 INCH (289.1 MM)
DIAMETER E 0.25 INCH (6.4 MM) DIMENSION R 8.56 INCH (217.4 MM)
DIMENSION F 1.12 INCH (28.4 MM) DIMENSION S 2.18 INCH (55.4 MM)
DIMENSION G 1.75 INCH (44.5 MM) DIMENSION T 1.75 INCH (44.5 MM)
DIMENSION H 4.18 INCH (106.2 MM) DIMENSION U 2.75 INCH (69.9 MM)
DIMENSION J 0.375 INCH (9.5 MM) DIMENSION V 0.75 INCH (19.1 MM)
DIMENSION K 2.18 INCH (55.4 MM)
Figure 512. Make a Mixer Rigging Plate
Page 537
MAINTENANCE MANUAL
DELETED
Figure 513. Deleted
Page 538
MAINTENANCE MANUAL
DELETED
Figure 514. Deleted — Ref. Repairs
Page 539
MAINTENANCE MANUAL
DELETED
Figure 515. Deleted — Ref. Repairs
Page 540
MAINTENANCE MANUAL

INSPECTION/CHECK
1. Tunnel−Routed Control Rod Inspection (c). Lightly deflect tube laterally from
one extreme to other (maintain
(Ref. Figure 601)
preload).
(1). Inspect rod end bearings for binding (d). With dial indicator or 6.00 inch
and excessive wear, 0.040 inch (1.016 (15.25 cm) rule, measure total
mm) maximum axial play. horizontal movement at top of tube
where rod end enters.
(2). Inspect control rod for surface damage (e). If total movement is more than
and evidence of bending. 0.0625 inch (1.5875 mm) rod
assembly must be replaced with
(3). Inspect upper 2.00 inches (5.08 cm) of serviceable parts.
each tunnel routed control rod for wear.
Replace rods with wear depth exceeding (f). Movement less than 0.0468 inch
0.020 inch (0.508 mm), or having outer (1.190625 mm) is considered negligi
diameter (OD) less than minimum ble.
which follow. (g). If movement is between 0.0468 and
0.0625 inch (1.5875 and 1.190625
Minimum OD mm), inspect rod threads, step (6).,
Control Rod Inches (mm) or rod insert, step (7).
Collective mixer 0.470 (11.938) (6). Rod Assembly P/N - 369A7007-5,
369A7009-5, 369A7011-5 and
Longitudinal mixer 0.520 (13.208) 369A7012-5 - For early control tubes
Lateral mixer 0.530 (13.462) without swaged inserts:
(a). If total lateral movement of upper
Tail rotor 0.470 (11.938)) end of tube is found to be between
3/64 and 1/16 inch (1.5875 and
(4). Inspect for loose rivet at fixed rod end 1.190625 mm), check rod threads.
(lower end).
(b). Disconnect upper (adjustable) rod
end from control system.
CAUTION
(c). Screw rod end completely out of
D When tightening loosened jam nuts on control rod.
rod ends as in steps (5). and (6). or (7). be (d). Use 0.339 inch (8.6106 mm) diameter
low, always hold rod end with wrench. drill (size R), free of burrs, to check
D Do not disconnect rod ends from mixer as rod threads.
sembly to do this inspection except as in 1). If drill can be inserted, rod assem
structed. bly is unserviceable and must be
replaced.
(5). Inspect upper end of tunnel-routed
control rod assemblies for excessive rod 2). If drill cannot be inserted, rod is
end play. serviceable.
(e). Reinstall rod end, reconnect rod to
(a). Loosen jam nut minimum of two control system and tighten jam nut.
threads.
(7). Rod Assembly P/N - 369A7007-9,
369A7009-9, 369A7011-9 and
(b). Preload rod end against either side of
369A7012-9 - For current control rods
attaching clevis with light finger
with swaged inserts:
pressure to eliminate play other than
in area being inspected and effect of (a). Disconnect upper (adjustable) rod
bearing play. end from control system.
Page 601
MAINTENANCE MANUAL
LONGITUDINAL PITCH IDLER

COLLECTIVE PITCH MIXER BELLCRANK
LONGITUDINAL MIXER
CONTROL ROD
COLLECTIVE MIXER
CONTROL ROD
LATERAL BELLCRANK
TAIL ROTOR CONTROL ROD

LATERAL MIXER CONTROL ROD
INITIAL ROD LENGTH (BEFORE RIG)
DIM L
CONTROL ROD INCH (CM)
56.67 (143.9418)
LONGITUDINAL MIXER 56.51 (143.5354)
COLLECTIVE PITCH FITTING
LATERAL MIXER 55.67 (141.4018)
COLLECTIVE MIXER 53.14 (134.9756)
RIVET 2.00 IN. (5.08 CM

(NOTE)
MAXIMUM ALLOWABLE AXIAL

PLAY 0.040 IN. (1.016 MM)
CONTROLS
SUPPORT BRACKET
LONGITUDINAL IDLER
BELLCRANK
LATERAL IDLER BELLCRANK
NOTE:
INSPECT FOR WEAR. REPLACE RODS WITH WEAR
DEPTH EXCEEDING 0.020 IN. (0.508 MM) OR HAVING
OD LESS THAN ALLOWABLE MINIMUM.
G67-1020A
Figure 601. Tunnel−Routed Control Rod Inspection
Page 602
MAINTENANCE MANUAL
(b). Back off jam nut sufficiently enough NOTE: Pitch stick housing and cap can be ei
to inspect insert. ther magnesium or alloy casting. (For corro
sion control and identification of magne
(c). Inspect insert for proper installation, sium or aluminum alloys, Ref. Section
flush to a maximum of 0.010 inch 20-40-00.)
(0.254 mm) below the surface of the
rod. 4. Copilot’s Collective Pitch Stick Inspection
(d). Check that insert is tight inside of (Ref. Figure 603)
rod.
(1). Inspect bearings for binding or play.
1). If insert is loose or protrudes above
surface of rod, rod assembly is (2). Inspect all gears for cracks, and
unserviceable and must be repla chipped or broken teeth.
ced.
(3). Inspect stick tube and gas producer
2). If insert is tight and swaged flush control tube for corrosion, deformation
to 0.010 inch (0.254 mm) below the and loose rivets.
surface of the rod, rod is servi
ceable.
5. Collective Stick Friction Mechanism
(e). Reconnect rod to control system and Operational Check
tighten jam nut.
(Ref. Figure 602)
(8). Check rigging of re-connected control
system. (1). Remove guard from collective stick.
(2). Check that teeth of friction drive gear,

2. Controls Support Bracket and Bellcrank
idler gear, and driven gear are not
Inspection
stripped or otherwise damaged.
(Ref. Figure 405)
(3). Rotate friction drive gear grip counter
(1). Inspect bearings in bellcranks for clockwise to maximum friction stop;
binding. gear train must rotate freely. Check
position of shaft assembly pin. Pin
(2). Do the fluorescent dye penetrant should be at highest point of cam.
inspection on any suspected part.
(4). If pin is not at approximate peak of cam
NOTE: Parts identified with double asterisk or has overridden peak, friction mecha
(**) (Ref. Figure 405) can be either magne nism must be readjusted. If pin is in
sium or aluminum alloy. (For corrosion con correct position, continue with step (5).
trol and identification of magnesium and below.
aluminum alloys, Ref. Section 20-40-00.)
(5). Rotate drive gear grip clockwise to
3. Pilot’s Collective Pitch Stick Inspection minimum friction position and release
grip; gear train must rotate freely. Pin
(Ref. Figure 602) should be at approximate low point of
cam.
(1). Inspect bearings for binding or play.
(6). With pin on low point of cam, hand
(2). Inspect all gears for cracks, and rotate spring release housing. If there is
chipped or broken teeth. drag on retainer, there is friction on
guide and collective friction must be
(3). Inspect stick tube and gas producer readjusted. If retainer rotates freely,
control tube for corrosion, deformation without obvious play, low point friction
and loose rivets. setting is correct.
Page 603
MAINTENANCE MANUAL
THROTTLE FRICTION
NUT (NOTE 1)
FRICTION WASHER
(FELT)
BACKUP DISC
(METAL)
THROTTLE GRIP
(NOTE 1)
FRICTION DISC (NYLON) MOUNTING DISTANCE

SWITCH HOUSING
SHIM (CUT)
COVER
SPRING BACKUP DISC (METAL)
BEARING
(NOTE 3)
GAS PRODUCER
GRIP ATTACH BOLTS
CONTROL TUBE
IDLE STOP RELEASE RING HOUSING SOCKET
(NOTE 1) FITTING PINION
SETSCREW NYLON STRAP (NOTE 1)
(NOTE 5)
SHIM WASHER
IDLER GEAR
NYLON BEARING BACKLASH
STICK STRAP (NOTE 3) SHIM GEARSHAFT
FITTING BACKLASH SHIM
GUARD
BEARING
NYLON STRAP (NOTE 3)
GEAR CAP
(NOTE 1) CAM PHENOLIC WASHERS
(NOTE 1) (NOTE 2) FRICTION ADJUSTMENT
TEFLON WASHER
STICK TUBE
FRICTION
SPACER
NOTE 1 DRIVE GEAR
(NOTE 1)
(NOTE 4)
SETSCREW RETAINER
WIRE GUIDE GUIDE
NOTES:
1. SURFACES IN CONTACT DURING ROTATION, OR OTHERWISE
NOTED, TO BE LUBRICATED WITH GREASE.
2. NEW PHENOLIC WASHERS ABRADED TO REMOVE GLAZE.
3. BEARINGS INSTALLED WITH GRADE A LOCKING COMPOUND
AFTER SHIMMING.
4. DRIVE GEAR END PLAY 0.002-0.010 IN. (0.0508-0.254 MM).
5. USED ONLY WITH OPTIONAL EQUIPMENT.
G67-1021B
Figure 602. Outboard Collective Stick Inspection (L/H Command)
Page 604
MAINTENANCE MANUAL
MOUNTING DISTANCE SHIM

(CUT)
BEARING
(NOTE 2) COVER
GAS PRODUCER CONTROL TUBE
PINION
HOUSING SOCKET
(NOTE 1)
BEARING
(NOTE 2)
BACKLASH SHIM
GEARSHAFT
NYLON STRAP BACKLASH SHIM
STICK TUBE
ELECTRICAL
WIRING
BEARING
(NOTE 2)
CONNECTOR CAP
NOTE 1
PIN
SETSCREW
WIRE GUIDE
SETSCREW
ADJUSTMENT NUT
THROTTLE GRIP
NOTES:
GRIP ATTACH BOLT 1. SURFACES IN CONTACT DURING ROTATION
TO BE LUBRICATED OR OTHERWISE NOTED,
SETSCREW WITH GREASE (CM116).
SWITCH HOUSING 2. INSTALL BEARINGS WITH GRADE A LOCKING
COMPOUND (CM431) AFTER SHIMMING FOR
MOUNTING DISTANCE AND BACKLASH.
44-162B
Figure 603. Outboard Collective Stick Inspection (R/H Command)
Page 605
MAINTENANCE MANUAL
6. Collective Control Interconnecting Torque NOTE: Bungee support bracket can be either
Tube Inspection an aluminum or magnesium casting. (For
corrosion control and identification of mag
(Ref. Figure 402) nesium and aluminum alloys, Ref. Section
20-40-00.)
(1). Remove pilot's seat cover, control access
door, and left side foot support fairing. 8. Inboard Collective Stick Socket Assembly
Inspection
(2). Inspect collective interconnecting (Ref. Figure 404)
torque tube for cracks, bends or (1). Inspect all bearings for binding or play.
distortions.
(2). Inspect gears for cracks, and chipped or
broken teeth.
(3). Inspect bungee bracket and bungee
fitting for security and condition. (3). Inspect all components for cracks,
Ensure cotter pin in over-center corrosion and deformation.
adjustment bolt is not sheared.
NOTE: Bellcrank and idler can be either an
(4). Inspect all accessible rivets for play. aluminum or magnesium casting. (For cor
inspect support bearings for security rosion control and identification of magne
and evidence of binding. sium and aluminum alloy parts, Ref. Sec
tion 20-40-00.)
(5). Reinstall pilot's seat cover, controls
access door and foot support fairing. 9. Pilot’s Cyclic Control Stick Inspection
(Ref. Figure 604)
7. Collective Bungee Inspection
NOTE:
(Ref. Figure 406) D For this inspection, friction stop nut must
be loosened.
NOTE: Replace any bungee parts in question D Socket can be either an aluminum or
able condition. magnesium casting. (For corrosion con
trol and identification of magnesium and
(1). Inspect bearings in male and female aluminum alloys, Ref. Section 20-40-00.)
bearing assemblies for evidence of
binding, corrosion and galling. (1). Inspect stick tube attachment to socket
for evidence of loose rivets, distortion
and corrosion.
(2). Inspect female bearing assembly
threads for damage. (2). Inspect parts of friction mechanism for
physical damage. Free length of friction
(3). Inspect spring for evidence of deforma spring should be approximately 0.580
tion. Free length of spring must be; inch (14.732 mm).
(a). Effectivity: 369D/E/FF-500N (3). To check installation, loosen lateral and

3.58— 3.70 inches (90.932—93.980 longitudinal friction knobs, move cyclic
mm) control stick and check for binding or
unusual noises. Check that rod end
bearings of pilot's lateral control rod do
(b). Effectivity: 600N not jam when stick is full forward and
4.475—4.525 inches full aft.
(113.665—114.935 mm)
NOTE: Set minimum friction so that phenolic
(4). Inspect male bearing rod for cracks, washers can be slightly turned by hand. If
evidence of binding, corrosion and minimum friction is set too low, stick shake
deformation. will occur.
Page 606
MAINTENANCE MANUAL
10. Copilot’s Cyclic Control Stick Inspection (4). Replace protective boot if it is cracked,
torn or deteriorated.
(Ref. Figure 604)
(5). Replace one-way lock if exposed portion
of piston has nicks, scratches or wear
Consumable Materials penetrates chrome plating.
Item Nomenclature (6). Replace external mounting bushing if
CM114 Petrolatum
outside diameter is less than 0.4979
inch (12.64666 mm).
(7). One-way lock must be replaced if nicks,

(1). Inspect quick-release pins for secure dents and scratches to body are more
fit, also stick tube and socket for than 0.040 inch (1.016 mm) depth
security, distortion and corrosion. after repair.
Check for presence of a light coating of
grease in socket and on stick tube end. (8). One-way lock must be replaced if end
Apply thin coating of petrolatum play between rod ends is more than
(CM114), on contact surfaces. 0.010 inch (0.254 mm) measured at
input (forward) end.
(2). To check controls installation, loosen
lateral and longitudinal friction knobs, (9). One-way lock must be replaced if
move stick and check for binding or leaking, except as noted for reservoir in
unusual noises. Check that rod end step (1). above.
bearings of copilot's lateral control rod
do not jam throughout full range of 12. Cyclic Trim Actuator Inspection
stick travel.
(Ref. Figure 509)
NOTE: Set minimum friction so that phenolic
washers can be slightly turned by hand. If (1). Inspect electrical connector for evidence
minimum friction is set too low, stick shake of damage, and broken or missing
will occur. contacts.
(2). Inspect exterior of trim actuator for

11. One−Way Lock Inspection evidence of damage and deformation.
(1). Replace reservoir if cracked, leaking or (3). When actuator speed (response and/or
has loose or damaged filler cap (Ref. travel time) is questionable, do a bench
CSP-COM-5). test (Ref. Cyclic Trim Actuator Bench
Test).
NOTE: It is normal for a thin hydraulic oil film
to remain on piston as a result of wiping 13. Cyclic Control System Operational Check
contact with the piston seal. This should not
be considered leakage or cause for rejection. Excessive slack or free play in the cyclic
control system can result in premature control
(2). Replace forward input rod end bearing stop contact or roughness of the helicopter and
if bearing binds. fanning out (out of track) of the main rotor tip
path plane (Ref. Section 18-10-00/60). Areas
Do not attempt to adjust larger to be checked include mixer linkages (Ref.
CAUTION (aft) of two rod ends and do not Section 62-30-00/60) at the base of the main
remove cotter pin; malfunction of lock will rotor mast, rotating controls above the
likely result. (For overhaul and replacement swashplate, trim actuators, and cyclic control
instructions, Ref. CSP-COM-5). stick in the pilot's compartment. If total free
play at the top of the cyclic grip exceeds 0.375
(3). Replace one-way lock if aft (output) end inch (9.525 mm) in either longitudinal or
bearing binds. lateral direction, do the following:
Page 607
MAINTENANCE MANUAL
NOTE 2
SLEEVE BUSHING
NOTE 2
LINK
NOTES:
FRICTION 1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF
MECHANISM STUD * 0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.060 IN. (1.524 MM)
ABOVE OUTSIDE SURFACE OF PART AFTER BOLT IS
TIGHTENED.
2. WASHERS ARRANGED TO ALIGN LINK WITH TORQUE
TUBE; LOOSELY SPACED WITH THREE WASHERS.
KNOB 3. CAP NUT ADJUSTED TO STOP KNOB WITH SPRING AT
(NOTE 4) FREE LENGTH ±1/32 IN (0.79375 MM).
4. CYCLIC STICK LATERAL FRICTION MECHANISM IS SIMILAR
(SEE MAIN VIEW).
SPRING 5. IF NUT CAN BE TURNED WITH FINGER PRESSURE, NUT
MUST BE REPLACED.
DISC RETAINER CAP NUT
TORQUE TUBE (NOTE 3, 5)
CYCLIC STICK LONGITUDINAL

FRICTION MECHANISM
(NOTE 4)
SCREW
PILOT'S LATERAL
CONTROL ROD
SLOTTED BUSHING
(NOTE 1)
NYLON STRAP AND

MOUNTING PLATE
STA. 67 LATERAL DIM L

CONTROL ROD INCH (CM) ANGLE A
CYCLIC BELLCRANK
PILOT'S LATERAL 12.63 (32.0802) 42°
STA 70 LATERAL 6.65 (16.891) 90°
MAXIMUM ALLOWABLE AXIAL
PLAY 0.040 IN. (1.016 MM)
A (INBOARD END) RIVET
LATERAL CONTROL ROD
INBOARD END ATTACHMENT
G67−1022
Figure 604. Cyclic Stick and Friction Inspection
Page 608
MAINTENANCE MANUAL
When replacing control rod (4). Check for axial play in cyclic trim
CAUTION ends, measure length accurate actuators.
ly to ensure that replacement rod is exactly
the same length as the original. Control rods (a). Disconnect lower end of cyclic control
are factory adjusted at installation to pro rods from aft ends of trim actuators
vide necessary clearances. and check for free play. Remove free
play by adjusting spring adjustment
(1). With the rotor stopped, check for free screw located in center recess at aft
play at the cyclic stick grip. While end of actuator. If end play is more
moving cyclic stick through free play than 0.0075 inch (0.1905 mm),
range, have assistant check controls replace actuator. Reconnect control
mixer area for any free play motion. rod.
(a). Check pivot bolt areas where mixer (b). Check for free play in attachments
bellcranks attach to control rod and linkages between trim actuators
bellcranks. If free play is noted, and cyclic pitch interconnecting
remove pivot bolts and inspect for torque tube. Replace parts as re
wear and/or play between bolts, quired; Install controls tunnel access
bushings, and bellcranks. Replace door.
parts as required. 14. Main Rotor Flight Control System
(b). Check control rod assemblies by 600−Hour Inspection
Pressing sidewards near the rod end (Ref. Figure 509)
bearing. Replace rod end as required.
(1). With the rotor stopped, check for free
(2). Check for free play in blade pitch links play at the cyclic stick grip.
which connect rotating swashplate to
blade pitch housings. Replace rod ends
NOTE: If total free play at the top of the cyclic
grip is 0.375 inch (9.525 mm) or less in ei
having free play more than 0.040
ther longitudinal or lateral direction inspec
inch (1.016 mm) side motion.
tion is not required. If total free play at the
NOTE: Rod ends on pitch links should be top of the cyclic grip exceeds 0.375 inch
checked under a no-load condition which is (9.525 mm) in either longitudinal or lateral
best achieved by removing blades. direction, do the following:
(3). While moving cyclic stick through free (2). While moving cyclic stick through free
play range, check lower controls for free play range, have assistant check
play motion; Remove controls tunnel controls mixer area for any free play
access door. motion.
(a). Check each pivot bolt area where
(a). Check control rod assemblies by lateral mixer bellcranks attach to
pressing sidewards near the rod end collective bellcranks. If free play is
bearings. Looseness indicates axial noted at the lateral bellcranks,
play in rod end bearing. Replace rod remove pivot bolts and inspect for
end as required. wear and/or looseness between bolt,
(b). Check pivot bolt areas of lateral and bushings and bellcrank. Replace
longitudinal bellcranks. If free play is parts as required.
noted, remove pivot bolts and inspect (b). Check control rod assemblies by
for wear and/or play between bolts, pressing sidewards near the rod end
bushings, and bellcranks. Replace bearings; motion here indicates axial
parts as required. play in rod end bearing. Replace rod
end as required.
(c). Check lower end of cyclic stick and
play at attachment of cyclic intercon (3). Check for free play in blade pitch links
necting torque tube. Replace bearings which connect rotating swashplate to
and bushings as required. blade pitch housings.
Page 609
MAINTENANCE MANUAL
NOTE: Both rod ends on each pitch link should (b). Check for looseness in longitudinal
be checked under a no load condition which and lateral cyclic control rod ends,
is best achieved by removing blades. Re located in tunnel. Replace rod ends
place rod ends having free play more than as required.
0.040 inch (1.016 mm) side motion.
(4). Inspect lower controls for slack between (c). Check for free play in attachments
cyclic stick and attachment of the and linkages between trim actuators
longitudinal and lateral control rods to and cyclic pitch interconnecting
the mixer mechanisms, located just torque tube. Replace parts as re
forward of the main rotor mast. quired. Reinstall access door.
(5). Check lower end of cyclic stick for
looseness at the attachment point to When replacing adjustable rod
cyclic pitch interconnecting torque tube. CAUTION ends, measure length accurate
Replace bearings and/or bushings as ly to ensure that replacement rod is exactly
required. same length as original. Mixer control rods
(6). Check interconnecting torque tube are factory adjusted at original installation
bearings for free play; replace bearings to provide necessary clearances.
if excessive free play is noted.
(7). Check for axial play in cyclic trim (8). Recheck for free play at the top of the
actuators (remove access door at lower cyclic stick grip; as required, repeat
end of pilot's bulkhead center tunnel in steps (1). thru (3). until total free play
the cargo compartment). at top of grip is 0.375 inch (9.525 mm)
or less in either longitudinal or lateral
(a). Disconnect lower end of longitudinal direction.
cyclic control rod from aft end of trim
actuator and check for axial play.
Remove free play by adjusting spring (9). If replacement of parts is required do a
adapter screw located in center rigging of main rotor controls (Ref.
recess at aft end of actuator assem Collective Controls Rigging and Cyclic
bly. Controls Rigging).
Page 610
MAINTENANCE MANUAL

REPAIRS
1. Tunnel−Routed Control Rod Repair A. Control Tube End Sleeve Installation

Item Nomenclature
(1). Do a straightness check on control rod CM219 Methyl−propyl−ketone (MPK)
that appears bent or bowed. Total CM229 Paint remover
length of any tunnel-routed rod
CM230 Paint remover
(excluding rod ends) must be straight
within 0.050 inch (1.270 mm), with CM231 Plastic bead, spherical 20 - 30 mesh
straightness variation limited to CM318 Primer
maximum of 0.010 inch (0.254 mm) in CM409 Adhesive, epoxy
each foot of length.
(1). Remove all four control rods (Ref.

Dye-check for cracking Tunnel-Routed Control Rod Replace
WARNING must always be done after ment).
cold-straightening. Replace cracked
rod, or cracked or bent rod end. (2). Using paint remover (CM229, CM230
or CM231) remove paint approximately
six inches back from end of each tube,
(2). Cold-straighten bent rod that is not tape and cover-rap remaining area of
within tolerance (step (1). above) tube.
provided there are no nicks or sharp
dents in bent length. Do not use rod NOTE: Control tubes that are cracked must be
ends to support rod during straighten removed from service.
ing.
(3). Dye penetrant inspect external surface
of stripped area for cracks.
Use care when drilling to re
CAUTION move or install riveted rod end; (a). Cracked are indicated by heavy bleed
rod end is steel and rod is aluminum. out. It can be necessary to wipe off
and reapply the developer to distin
guish between surface defects caused
(3). Replace control rod end if bearing axial during swaging operation.
play is more than 0.040 inch (1.016
mm). Set initial control rod length (Ref. (b). Light penetrant indications are not
Figure 601). cause for rejection.
(4). If no cracks are found; inspected control

tube can be reworked for sleeve instal
2. Tunnel−Routed Control Tube Inspection lation. All four control tubes are to be
and Sleeve Installation reworked as follows:
(a). Measure and record length of control

(Ref. Figure 801) The following procedures are tubes for reinstalling rod ends and to
for inspection and installation of reinforcing prevent rerigging after tube rein
sleeves to the tunnel-routed control tubes. stallation.
Page 801
MAINTENANCE MANUAL
0.097-0.102 IN. 0.340 IN. *

(2.4638-2.5908 MM) DIA (8.635 CM)
SLEEVE
CONTROL TUBE
0.750 IN. *
A DIA (19.05 MM) DIA.
7° ±0.5°
0.000-0.080 IN.
(0.000-2.032 MM)
0.720 IN. *
(18.288 MM)
0.910 IN. *
(23.114 MM)
G67-1035A
Dimensional Table
Sleeve No. Dim A Tube O.D.

Rod No.
369D27013 inch (mm) inch (mm)
369A7007 −1 0.540—0.545 (13.716—13.843) 0.501—0.530 (12.7254—13.462)

369A7009 −2 0.510—0.515 (12.954—13.081) 0.470—0.500 (11.938—12.70)
−3 0.590—0.595 (14.986—15.113) 0.551—0.580 (13.9954—14.732)

369A7011
−4 0.560—0.565 (14.224—14.351) 0.520—0.550 (13.208—13.970)
369A7012 −5 0.570—0.575 (14.478—14.605) 0.530—0.560 (13.462—14.224)
NOTES:
(1) Material; 2024−T351 or T4 (QQA 225/6) bar or round stock
(2) Break sharp edges 0.005—0.015 inch (0.127—0.381 mm).
(3) Surface finish 125 RMS.
(4) Chemical film per MIL−C−5541.
(5) Tolerance * ±0.010 inch (±0.254 mm).
Figure 801. Sleeve Fabrication and Installation
Page 802
MAINTENANCE MANUAL
Drilled out rivets can damage Do not use heat gun. Use of heat
CAUTION threads upon removal. Visually CAUTION lamp is acceptable.
inspect control tube threads for damage
from rivet and rod end removal. Replace (i). Allow to cure for 24 hours at mini
damaged control tubes. Drilled rod ends are mum ambient temperature of 685F
matched drilled to each control tube and (205C) (alternate cure 4 hours at
must be reinstalled into control tube end 115—1405F (47—605C)).
from which removed.
(j). Repeat procedure for ends of each
control tube.
(b). Remove rod ends, MS20470AD3
rivets must be removed from fixed
end. (k). Using primer (CM318), touch-up
repaired area(s) of control tube.
(c). Measure outside diameter of control (l). Install rod ends into ends in which it
tube end and select proper sleeve. was removed. On fixed rod end, align
witness/rivet hole in sleeve and tube
with rivet hole in rod end. Drill (#40)
(d). Temporarily install sleeve onto thru opposite end of sleeve. Rivet
control tubes. Align sleeve and fixed end with MS20470AD3-15
control tube witness hole. If sleeve rivet.
protrudes past end of control tube,
trim end of sleeve flush to 0.000 inch (m). Adjust each control tube to its
(0.000 mm) or back 0.080 inch (2.032 previously measured length and
mm) from end of tube. paint the control tube ends with
primer. Paint adjustable ends of
control tube flat black.
NOTE: Bond integrity is dependent on clean
surfaces. (n). Reidentifiy, with permanent ink, the
control tubes that have been re
worked (Ref. Table 801).
(e). Thoroughly clean end of control tube
and interior surface of sleeve with
lint free cloth and MPK (CM219) or Table 801. Control Tube Re−Identification
equivalent.
Old Part Number New Reworked Part Number
369A7007 369A7007−5
(f). Mix epoxy adhesive (CM409) per 369A7009 369A7009−5
369A7011 369A7011−5
369A7012 369A7012−5
(g). Remove excessive adhesive with lint
free cloth moistened with MPK or
equivalent. Do not saturate the (o). Rework control tube boot (Ref.
cleaning cloth. Remove adhesive from Figure 802).
witness holes.
If control rod is not accurately
CAUTION measured, flight controls will
(h). Plug end of control tube to prevent require rerigging.
adhesive from entering threads. Bond
sleeve to control tube. Apply adhesive (p). Reinstall control tubes. Reinstall
to both surfaces and install sleeve. trimmed boot with vertical seam
Align witness/rivet hole in sleeve and facing aft. Check flight controls for
tube. interference or binding.
Page 803
MAINTENANCE MANUAL
SEWN SEAMS
SEWN SEAMS
(2 PL)
0.40-0.50 IN.
(10.16-12.70 MM)
(NOTE 1)
DOUBLE BOOT SINGLE BOOT
NOTES:
1. TRIM BOOTS BELOW HORIZONTAL SEAM.
CAUTION: DO NOT USE SOLVENTS OR PETROLEUM BASED CLEANING
FLUIDS ON VINYL BOOTS.
2. CLEAN INSIDE AND OUTSIDE OF VERTICAL SEAM AND TOP OF
BOOT WITH CLEAN CLOTH DAMPENED WITH ISOPROPYL ALCOHOL.
3. COAT BOTH SIDES OF VERTICAL SEAM WITH CONTACT CEMENT.
4. APPLY THIN COAT OF CONTACT CEMENT ALONG TRIMMED EDGE
AND 0.125-0.250 INCH (3.175-6.350 MM) DOWN INSIDE AND OUTSIDE
SURFACES OF BOOTS TO PREVENT FRAYING.
G67-1036A
Figure 802. Control Tube Boot Rework
B. Straight Area Sleeve Installation (2). Tape around area to be repaired.
This repair is permissible on the straight area (3). Using paint remover (CM229, CM230
of the tube only and increases the outside or CM231), strip paint 1.0 inch (2.54
diameter. cm) beyond area of repair.
Consumable Materials (4). Polish out burrs and sharp edges. Make
(Ref. Section 91−00−00) sure defects do not exceed allowable
Item Nomenclature limits (ref. Table 802). Dye penetrant
inspect area per MIL-I-25135; no
CM219 Methyl−propyl−ketone (MPK) cracks allowed.
CM229 Paint remover
CM230 Paint remover NOTE: Bond integrity is dependent on clean
CM231 Plastic bead, spherical 20 - 30 mesh surfaces.
CM318 Primer
(a). Thoroughly clean repair area of
CM409 Adhesive, epoxy control tube and interior surface of
sleeve with lint free cloth and MPK
NOTE: (CM219) or equivalent.
D Make sure adequate clearance exists (b). Mix epoxy adhesive (CM409) per
prior to doing the repair. Determine and manufacturer's instructions.
repair condition that caused damage.
D Maximum length of repair sleeve is 6.00 (c). Apply adhesive to both surfaces and
inches (15.24 cm). Two sleeve repairs per install sleeve.
mitted per control tube.
(d). Remove excessive adhesive with lint
(1). Remove damaged control rod(s) (ref. free cloth moistened with MPK or
Tunnel-Routed Control Rod Replace equivalent. Do not saturate the
ment). cleaning cloth.
Page 804
MAINTENANCE MANUAL
Table 802. Control Tube Straight Area Repair Limits

Nicks and Gouges (2) Dents and Depressions (2) Repair Sleeve (3)
Tube Max. Depth Max. Depth Max. Depth Max. Depth Wall
369A W/O Repair (4) With Repair (1) W/O Repair (4) With Repair (1) O.D.
Thickness
inch (cm)
Inch (mm) inch (mm) inch (mm) inch (mm) inch (mm)
7007 0.006 (0.152) 0.015 (0.381) 0.010 (0.254) 0.025 (0.635) 1.375 (3.4925) 0.049 (1.2446)
7009 0.008 (0.203) 0.020 (0.508) 0.010 (0.254) 0.025 (0.635) 1.50 (3.81) 0.049 (1.2446)
7011
0.010 (0.254) 0.025 (0.635) 0.010 (0.254) 0.025 (0.635) 1.625 4.1275) 0.049 (1.2446)
7012
NOTES:
(1) Sleeve repair not permitted in tapered area. Two sleeve repairs per control tube. Maximum defect area
0.375 in2 (2.41935 cm2) per sleeve.
(2) Must be free of burrs and sharp areas.
(3) Aluminum tube 6061−T6 WW−T−700/6 or 2024−T3 WW−T−700/3. Alternate: field fabricate from
2024−T351 or 2024−T4 (QQ−A−225/6 or QQ−A−200/3). Inside diameter to be 0.010−0.025 inch
(0.254−0.635 mm) larger than outside diameter of tube to be repaired. Outside diameter as listed in table,
±0.010 inch (±0.254 mm) and concentric to inside diameter 0.005 inch (0.127 mm). Maximum length of
repair sleeve 6 inches (15.24 cm). Break sharp edges 0.005—0.015 inch (0.127—0.381 mm).
(4) Maximum defect area without repair 0.10 in2 (0.64516 cm2) total. For threaded area, last 2 inches (5.08
cm) of both ends, maximum depth of defect 0.020 inch (0.508 mm).
Do not use heat gun. Use of heat B. Repair
CAUTION lamp is acceptable.
(Ref. Figure 405)
(e). Allow to cure for 24 hours at mini
mum ambient temperature of 68F Consumable Materials
(20C) (alternate cure 4 hours at (Ref. Section 91−00−00)
115—140F (47—60C)). Item Nomenclature
(f). Using primer (CM318), touch-up CM321 Surface primer locking compound
repaired area(s) of control tube. CM431 Sealing, locking and retaining compound
3. Controls Support Bracket and Bellcrank (1). Replace unserviceable bearings.

A. Disassembly (2). Install a new bearing with surface
primer (CM321) and locking compound
(Ref. Figure 405) (CM431).
NOTE: In following steps, do not remove slot NOTE: When idler bellcrank bearings are re
ted bushings unless replacement is neces placed, make sure that idler bellcrank spac
sary. ers are reinstalled between bearings.
(1). Remove lateral idler bellcrank. (3). Replace bellcranks or controls support
bracket that has distortion, cracks, or
(2). Remove tail rotor bellcrank. elongated holes.
(3). Remove longitudinal idler bellcrank. C. Assembly
NOTE: Shim washers between longitudinal (Ref. Figure 405)
idler bellcrank and support brackets align (1). Install longitudinal idler bellcrank.
one-way lock for no side-load. Keep shim
washers with bracket for use during re (2). Make sure that the slotted bushing is in
assembly. place in support bracket lug, and
Page 805
MAINTENANCE MANUAL
reinstall shim washers between (11). Remove gear shaft assembly. Keep
bellcrank and bracket for no side-load backlash shims with gear shaft.
of one-way lock.
(12). Remove cover from back of stick
NOTE: When doing following steps, make sure housing.
that slotted bushing is in support bracket
lug. (13). Remove gas producer control tube
through access hole at back of stick
(3). Install lateral idler bellcrank. housing. Remove mounting distance
shim only if necessary to adjust pinion
(4). Install tail rotor bellcrank. gear mounting distance.
4. Pilot Collective Stick (LH Command) B. Repair
A. Disassembly (Ref. Figure 602 and Figure 803)
(Ref. Figure 602 and Figure 803) Consumable Materials

(1). Cut two nylon straps. (Ref. Section 91−00−00)
Item Nomenclature
(2). Remove stick friction mechanism CM116 Grease, aircraft and instrument
guard.
(3). Remove setscrews from switch housing. (1). Replace bearings if corroded, excessive
ly worn, or if outer or inner races of
NOTE: Removal of additional setscrew is also bearings rotate on mating surfaces and
required on helicopters equipped with cargo locking compound is inadequate to
release mechanism. prevent rotation.
(4). Cut nylon strap or twine that secures (2). Replace loose rivets in gas producer
electrical wiring to stick tube. Push control tube.
wire slack into stick, carefully pull
housing and wiring from end of stick (3). Replace friction drive gear or idler gear
tube and disconnect wiring from with cracked, chipped or broken teeth.
switches.
(4). Replace friction drive gear if it does not
(5). Remove setscrew and wire guide from rotate freely on stick tube, or if rotating
forward end of stick. Tie string on each stop is damaged. To remove gear, drill
wire bundle to aid reassembly and out rivets that attach throttle friction
remove wiring. nut fitting to stick.
(6). Remove spring and idle stop release NOTE: Before replacing drive gear for binding,
ring. clean and lubricate bore with grease
(CM116). Reinstall gear on stick tube and
(7). Remove grip attach bolts. Slide throttle recheck for free rotation. If gear still binds it
grip friction washer and discs, and must be replaced.
friction nut from stick tube.
(5). Replace phenolic friction washers
(8). Remove friction mechanism and guide against guide if worn to less than 1/32
from stick fitting. inch thickness.
(9). Remove idler gear from stick fitting. (6). Replace friction gear assembly if driven
gear has cracked, chipped or broken
NOTE: In following steps, do not remove bear teeth or if cam pin is bent.
ings or pinion unless replacement is neces
sary. (7). Replace damaged idle stop release ring.
Ring must slide freely on tube and in
(10). Remove cap from stick housing. throttle grip.
Page 806
MAINTENANCE MANUAL
G67-1018A
Figure 803. Wiring Diagram and Cable Routing — Collective Stick
Page 807
MAINTENANCE MANUAL
C. Assembly NOTE: Steps (6). thru (8). below are used to de
termine gas producer control tube pinion
(Ref. Figure 602 and Figure 803) mounting distance.
(6). Install approximate required thickness
of split shims between pinion bearing
and housing to establish gas producer
Item Nomenclature
control tube pinion mounting distance.
CM431 Sealing, locking and retaining compound (7). Use throttle friction nut to pull gas
producer torque tube forward until not
CM807 Twine, nylon
less than 10 pounds (44.48 N) of force is
CM815 Solder applied to compress shims.
(8). Add or subtract shims to provide
(1). Check gearshaft bearings in housing 0.699—0.709 inch (17.7546—18.0086
cap a housing for security of outer mm) dimension (Ref. Figure 504).
races. Use grade A locking compound Repeat step (7). during each measure
(CM431) to install replacement bear ment.
ings. Use care to prevent compound
from entering bearings, and make sure (9). After mounting distance shimming is
that each bearing is seated against its correct, remove gas producer control
bore shoulder. tube and apply grade A locking com
pound (CM431) to outside diameter
(2). Using grease (CM116), lubricate stick pinion bearing outer race and stick
tube interior where gas producer housing bore. Reinstall control tube,
control tube fitting makes contact. and check that compound does not
(3). Attach strings routed through stick enter bearing and that bearing outer
tube during disassembly, and thread race and shims are firmly seated
electrical wire bundles from plug against housing bore.
through exit hole, throttle friction nut, (10). Install throttle friction nut, friction
friction washers and discs, throttle grip, discs and washers.
idle stop release ring and spring. Pull
wiring out through front end of stick (11). Using grease (CM116), lubricate
tube. interior of throttle grip and install grip
on stick tube. Align grip and gas
(4). Install wire guide so that it divides producer control tube fitting and install
switch wiring: three wires in one cutout grip attach bolts. When tightened, bolts
and four in the other. Align guide with must be flush or not more than 0.010
matching hole in stick tube and install inch (0.254 mm) below outer face of
setscrew. When tightened, setscrew grip.
must be flush or not recessed more than
0.010 inch (0.254 mm) below outer tube (12). Establish gas producer control tube
surface. pinion and shaft assembly bevel gear
backlash by temporarily installing
NOTE: Make sure gas producer control tube is driven gear, shaft, and two bearings,
installed into stick housing with elongated plus approximate required thickness of
area of fitting facing down. backlash shims in housing. Temporarily
install housing cap. Add or subtract
(5). Install gas producer control tube shims to provide maximum backlash
through access hole in back of stick of 0.003 inch (0.076 mm) without bind
housing, and through stick tube until in gears. Make certain that bearings
control tube fitting engages wire guide are completely seated in bores while
bore. Reinstall mounting distance establishing this backlash adjustment.
shims forward side of pinion bearing if
removed during disassembly. (One edge (13). After backlash shimming is correct,
of shim must be cut for installation.) remove housing cap and gear shaft.
Page 808
MAINTENANCE MANUAL
(14). Lubricate teeth of pinion gear and shaft 5. Pilot Collective Stick (RH Command)
assembly bevel gear with grease
(CM116). A. Disassembly
(15). Apply grade A locking compound
(CM431) to secure gearshaft to bear (1). Disassemble collective stick to extent of
ings. Do not allow compound to enter removing friction mechanism idler gear
bearings. With throttle grip at mid- from stick fitting, except also remove
travel, install driven gear. Note that at screw and nut to disconnect electrical
throttle-grip mid-travel, cut out terminals from stick housing.
portion of the driven gear is to be
opposite pinion gear. (Centerline of (2). Detach link and idler.
center tooth of driven gear is two (3). Remove idler from socket housing. Do
degrees and fifty minutes from center of not remove idler bearing unless
driven gear cutout.) replacement is necessary.
NOTE: With throttle grip at mid-travel, two (4). Remove four bolts and washers that
grip attach bolts are positioned approxi attach housing cap to socket housing.
mately straight down. Rotate shaft assembly until gear tooth
cutout clears pinion (bellcrank ears at
(16). Install housing cap on shaft assembly approximately 195 degrees);, then
and seat with hand pressure while separate bellcrank, housing cap and
slowly rotating grip back and forth. shaft assembly from housing.
Secure cap to side of housing and cover
to back of housing. (5). Remove bellcrank from shaft assembly
to separate housing cap from shaft. Do
(17). Using solder (CM815), connect wiring not press bearings from cap or housing
to stick switches. Pull electrical wiring unless replacement is necessary. Keep
slack out through exit holes in stick backlash shims with shaft assembly.
tube, position release ring and. spring (6). Remove link from bellcrank.
and install switch housing with
setscrews. Using nylon strap, or twine (7). Remove gas producer control tube
(CM807), secure electrical wiring to through access hole at back of pilot's
stick tube approximately one inch aft of collective stick housing.
exit holes.
(8). Remove mounting distance shim only if
(18). Install friction cam and driven gear necessary to adjust pinion gear mount
assembly on stick fitting. Temporarily ing distance.
mesh idler gear and driven gear, and (9). Remove pinion and bearing from
rotate friction drive gear counterclock control tube only if replacement is
wise to maximum stop. necessary.
(19). Hold drive gear at stop and mesh idler B. Assembly
gear and driven gear so that gear
assembly pin is at high point of cam. (Ref. Figure 603 and Figure 803)
(20). Use shim washers sufficient to limit Consumable Materials

gear end play to maximum of 0.010 inch (Ref. Section 91−00−00)
(0.254 mm), and secure idler gear with Item Nomenclature
cotter pin. CM431 Sealing, locking and retaining compound
(21). Assemble remainder of friction mecha
nism. (1). Check gearshaft bearings in housing
cap and housing for security of outer
(22). Adjust collective friction mechanism. races. Use grade A locking compound
Page 809
MAINTENANCE MANUAL
(CM431) to install replacement bear (7). Remove cap from stick housing. Do not
ings. Use care to prevent compound remove bearing from cap unless
from entering bearings, and make sure replacement is necessary.
that each bearing is seated against its
bore shoulder. (8). Remove gearshaft assembly. Keep
backlash shims with gearshaft and do
(2). Completely reassemble pilot's collective not remove bearing from stick housing
stick to the extent of assembling unless replacement is necessary.
friction mechanism.
(9). Remove cover from back of stick
(3). Connect two electrical terminals to housing.
stick housing. (10). Remove gas producer control tube
through access hole in back of stick
(4). Shim and adjust pinion mounting
housing. Remove mounting distance
distance and backlash.
shim only if necessary to adjust pinion
(5). After backlash shimming is correct, gear mounting distance. Remove pinion
install bellcrank on shaft assembly and and bearing from control tube only if
link to bellcrank; then install, seat and replacement is necessary.
secure housing cap on stick housing. Do B. Repair
not adjust collective friction mechanism
at this point of assembly. (1). Replace bearings if locking compound
does not prevent outer or inner races
(6). Install idler to the stick housing, and from rotating on mating surfaces, if
link to the idler. corroded, or if excessively worn.
(7). Adjust the collective friction mechanism (2). Replace loose rivets in gas producer
(Ref. Collective Stick Friction Mecha control tube, or damaged pinion gear.
nism Adjustment).
C. Assembly
6. Copilot Collective Stick (LH and RH
Command) Consumable Materials
A. Disassembly Item Nomenclature
(1). Cut nylon strap or twine securing CM116 Grease, aircraft and instrument
wiring to stick tube. CM431 Sealing, locking and retaining compound
CM807 Twine, nylon
(2). Remove setscrews that secure the CM815 Solder
switch housing.
(3). Push wire slack into stick and carefully (1). Check gearshaft bearings in housing
pull switch housing from end of stick cap and housing for security of outer
tube; disconnect wiring from N2 switch races. Use grade A locking compound
(Ref Chapter 96). (CM431) to install replacement bearing.
Use care to prevent compound from
(4). Remove grip attach bolts and grip. entering bearings, and make sure each
bearing is seated against its bore
(5). Remove adjusting nut pin and throttle
shoulder.
end play adjusting nut only if stick tube
replacement is necessary, or if end play (2). Using grease (CM116), lubricate stick
must be adjusted. tube interior where gas producer
control tube fitting makes contact.
(6). Remove setscrew and wire guide. Tie a
``fish'' string on end of wire bundle to (3). Attach ``fish'' string (routed through
aid reassembly, and then remove the stick during disassembly) and thread
wiring. electrical wire bundle from electrical
Page 810
MAINTENANCE MANUAL
plug through exit hole in stick tube and (11). Lubricate teeth of pinion gear and
out front end of tube. gearshaft bevel gear with grease
(CM116).
(4). Install wire guide in stick tube so it
positions wire bundle in right cutout of (12). Apply grade A locking compound
guide. Align guide with matching hole (CM431) to gearshaft and ID of bear
in stick tube, and install setscrew. ings. With throttle grip at mid-travel,
When tightened, setscrew must be at install shaft assembly gear.
least flush and not recessed more than
0.010 inch (0.254 mm) below outer (13). Install housing cap on gearshaft and
surface of tube. seat with hand pressure while slowly
(5). Install gas producer control tube rotating grip back and forth. Secure cap
through access hole in back of stick on side of housing and cover on back of
housing, and through stick tube until housing.
control tube fitting engages wire guide
(14). Check throttle grip for zero end play on
bore. Reinstall mounting distance
stick tube and that not more than 1
shims at forward side of pinion bearing
pound torque is required to rotate the
if removed during disassembly. (One
grip. If these conditions exist, proceed
edge of shims must lie cut for installa
with step (18). below. If there is end
tion.)
play, or too much torque is required to
(6). Establish gas producer control tube rotate the grip, do steps (15)., (16). and
pinion mounting distance (Ref. Gas (17).
Producer Linkage Adjustment).
(15). Remove grip attach bolts and grip.
(7). After mounting distance shimming is
correct, remove gas producer control (16). Insert 3/64 inch (1.190625 mm) diame
tube and apply grade A locking com ter drift punch into access hole on
pound (CM431) to OD of pinion bearing forward face of adjusting nut and drive
outer race, and stick housing bore. grooved taper pin from adjusting nut
Reinstall control tube and check that and threaded fitting of stick tube.
compound does not enter bearing and
that bearing outer race and shims are (17). Reinstall grip with grip attach bolts
firmly seated against housing bore. and establish zero end play and correct
rotational friction, 1 pound (4.448 N)
(8). Using grease (CM116), lubricate ID of maximum, between nut and grip. The
throttle grip and install grip on stick match-drill 3/64 inch (1.190625 mm)
tube. Align grip and gas producer maximum diameter stick tube fitting
control tube fitting and install grip threads to existing pin groove in nut,
attach bolts. When tightened, bolts and install pin.
must be at least flush and not recessed
more than 0.010 inch (0.254 mm) below (18). Using solder (CM815), connect wiring
outer surface of grip. to N2 switch. Pull electrical wiring
(9). Establish gas producer control tube slack out through exit hole in stick tube
pinion and gearshaft bevel gear and install switch housing with
backlash. setscrews. Using nylon strap or twine
(CM807), secure electrical wiring to
(10). After backlash shimming is correct, stick tube, approximately 1.00 inch
remove housing cap and gearshaft. (2.54 cm) aft of exit hole.
Page 811
MAINTENANCE MANUAL
7. Collective Control Torque Tube Repair (4). Slowly open vise and remove bungee
components.
(Ref. Figure 406)
NOTE: Do not disassemble female bearing as
(1). Replace loose or binding torque tube sembly; if defective, replace as a unit.
support bearings. Drill out rivets
securing retainer and doubler to seat B. Assembly
structure to replace left support
(Ref. Figure 406)
bearing. Drill out three rivets securing
right end fitting to torque tube to
replace right support bearing. Install Consumable Materials
new bearings and rivets at existing (Ref. Section 91−00−00)
holes. Item Nomenclature
(2). Replace torque tube if it is cracked or
has elongated holes.
Special Tools
NOTE: Torque tube droop control bracket can (Ref. Section 91-00-00)
be either an aluminum or magnesium cast Item Nomenclature
ing. (For corrosion control and identification ST508 Collective bungee installation tool
of magnesium and aluminum alloy parts, ST509 Not used at this time
Ref. Section 20-40-00.) ST510 Bungee spring compression tool rod and
(3). Replace bent or stripped bungee channel
adjusting bolt. Torque nut to 30—40
inch-pounds (3.39—4.52 Nm). (1). Lubricate cups of spring retainers and
threads and bore of female bearing
(4). Replace scratched, nicked or otherwise assembly with grease (CM116).
damaged reinforcement strap.
(2). Assemble retainer, spring and female
8. Collective Bungee bearing assembly. Install compression
tool rod and channel (ST510). Insert a
A. Disassembly 1/4 inch (6.35 mm) bolt through channel
and female bearing rod end.
(Ref. Figure 406)
(3). Position assembly in bench vise.
Special Tools Compress bungee spring until bungee
(Ref. Section 91-00-00) installation tool (ST508 or ST509) fits
Item Nomenclature over retainers. Secure tool halves in
place with clamp.
ST510 Bungee spring compression tool rod and
channel (4). Open vise slowly and remove bungee
compression tool rod and channel.
(1). Remove male bearing from bungee (5). Install male bearing in compressed
clamped in compression by installation bungee.
tool.
9. Inboard Collective Stick Socket Assembly
(2). Install bungee compression tool rod and
channel (ST510) on compressed bungee. A. Disassembly
Insert 1/4 inch (6.35 mm) bolt through (Ref. Figure 404)
channel and female bearing rod end.
(1). Disconnect link from idler.
(3). Place compression tool and bungee in
vise so that vise jaws make contact with (2). Remove idler from socket housing. Do
tool rod and channel. Compress vise not remove idler bearing unless
and remove bungee clamp. replacement is necessary.
Page 812
MAINTENANCE MANUAL
(3). Remove four bolts and washers that C. Assembly

attach housing cap to socket housing.
(Ref. Figure 404)
Rotate shaft assembly until gear tooth
cutout clears pinion (bellcrank ears at
approximately 195 degrees); then Consumable Materials
separate bellcrank, housing cap and (Ref. Section 91−00−00)
shaft assembly from housing. Item Nomenclature
(4). Remove bellcrank from shaft assembly CM431 Sealing, locking and retaining compound
to separate housing cap from shaft. Do
not press bearings from cap or housing
unless replacement is necessary. Keep (1). Check gearshaft bearings in housing
backlash shims with shaft assembly. cap and housing for security of outer
races. Use grade A locking compound
(5). Remove link from bellcrank. (CM431) to install replacement bear
ings. Use care to prevent compound
(6). Remove snap ring that retains N1 from entering bearings, and make sure
pinion gear aft bearing in housing. that each bearing is seated against bore
Press pinion gear and aft bearing, as an shoulder.
assembly, out through access hole at the (2). Apply grade A locking compound
back of housing. Disassemble pinion (CM431) to pinion gear aft bearing
bearings from pinion and housing only outer circumference and matching bore
if replacement is necessary. in socket housing. Install assembled N1
pinion gear and aft bearing; seat
B. Repair bearing firmly against bore shoulder.
(Ref. Figure 404) (3). Install snap ring that retains aft-bear
ing in housing bore. Apply locking
compound to bond pinion shaft to
Consumable Materials forward bearing and to bond forward
(Ref. Section 91−00−00) bearing to housing bore. Press bearing
Item Nomenclature firmly against housing shoulder.
(Housing is machined to provide a light
press-fit.)
(4). Establish N1 pinion and shaft assembly
(1). Replace bearings if corroded, excessive bevel gear backlash by rotating N1
ly worn, or if outer or inner races of pinion gear assembly so that wide
bearings rotate on mating surfaces and tooth-space on spline is at about one
locking compound does not prevent o'clock when viewed from socket
rotation. Install new bearings with (looking aft). Install backlash shims to
grade A locking compound (CM116). obtain maximum backlash of 0.003 inch
Check that replacement bearing is (0.076 mm) with bearings firmly seated
properly seated in mounting bore. in bores.
(2). Replace a cracked part. (5). After backlash shimming is correct,

remove housing cap and gearshaft.
(3). Replace entire link if bearings are (6). Install bellcrank on shaft assembly, and
defective; link bearings are not replace link to bellcrank.
able.
NOTE: Bellcrank attachment bolt must be in
stalled with head slightly down and for
(4). Replace pinion gear or shaft assembly
ward.
bevel gear when correct backlash
cannot be maintained because of tooth (7). Lubricate teeth of pinion gear and shaft
irregularities caused by wear or assembly bevel gear with grease
deformation. (CM116).
Page 813
MAINTENANCE MANUAL
(8). Apply grade A locking compound 12. Lateral Control Rods and Sta. 67
(CM431) to bond bevel gearshaft and Bellcrank Repair
bearings. With centerline of wide
tooth-space of N1 pinion gear spline up (Ref. Figure 408)
(on top), install shaft assembly gear at
mid-travel position. Consumable Materials
NOTE: N1 pinion shaft spline wide tooth-space Item Nomenclature
should be positioned up at approximately
one o'clock position, as viewed looking aft in
to open end of socket.
(1). Replace Sta. 67 lateral bellcrank if it
(9). Install four bolts, eight washers, four has elongated holes or is cracked.
spacers and nuts to secure cap to Replace pivot bearing if it binds or is
housing. excessively worn; install with grade A
locking compound (CM431). Check free
(10). Install idler to housing, and link to play of bellcrank with newly installed
idler. pivot bearing by applying light up and
down pressure at forward end of
NOTE: When installed, idler to gas producer bellcrank with bearing secured. For
control rod bolt holes should be in line with bearing to be acceptable, bellcrank total
centerline of stick assembly housing cap play measured at centerline of bolt that
when gearshaft and pinion gears are posi attaches pilot's lateral control rod end
tioned as outlined in step (8). above. must not exceed ±0.024 inch (±0.6096
mm).
10. Cyclic Control Stick Repair
NOTE: Sta. 67 lateral bellcrank can be either
(Ref. Figure 408 and Figure 804) Disassemble an aluminum or magnesium machined forg
cyclic control stick only as necessary to replace ing. (For corrosion control and identification
damaged or faulty parts. Pilot's stick tube of magnesium and aluminum alloys, Ref.
should not be removed from stick socket; the Section 20-40-00.)
assembly should only be replaced as a unit.
(2). Do a straightness check on control
rod(s) that appear bent or bowed. Total
11. Cyclic Friction Mechanism Repair length of rod (excluding rod ends) must
be straight within 0.010 inch (0.254
(Ref. Figure 603 and Figure 804) mm). Cold-straightening of rod is
permissible if no nicks or sharp dents
(1). Remove cap nut from friction stud and
exist in bend length, and rod ends are
disassemble friction mechanism from not used to support rod during straight
stick socket or torque tube. ening process. Dye-check for cracking
is to be done after cold-straightening.
(2). Replace bent or stripped friction stud.
Replace cracked rod, or cracked or bent
Drill out rivet and press stud from
rod end.
socket; install new stud and rivet in
place. Press replacement spring pin Use care when drilling to re
into friction stud until one end of pin is CAUTION move or install riveted rod end;
flush with surface of stud. rod end is steel and rod is aluminum. Do not
tighten adjustable rod end jam nut on pilot's
(3). Assemble friction mechanism to stick lateral control rod until rod is installed and
socket or torque tube. cyclic stick longitudinal travel is checked.
(4). Adjust friction knob cap nut to stop (3). Replace control rod end if bearing axial
knob when spring extends to free play is more than 0.040 inch (1.016
length, no compression ±1/32 inch mm). Set initial control rod length and
(±0.79375 mm). bearing angularity.
Page 814
MAINTENANCE MANUAL
G67-1019
Figure 804. Wiring Diagram and Cable Routing — Cyclic Stick
Page 815
MAINTENANCE MANUAL
13. Cyclic Torque Tube Repair by polishing with crocus cloth (CM803);
maintain smooth transition into
(Ref. Figure 409) surrounding area. After repair treat
area with chemical film (CM206).
Consumable Materials (2). When replacing input (forward) shaft
(Ref. Section 91−00−00) rod end bearing, with piston at mid
Item Nomenclature stroke make sure bearing center-to-
CM116 Grease, aircraft and instrument center distance is 8.55—8.61 inches
CM431 Sealing, locking and retaining compound (217.170—218.694 mm). Adjust as
required. After correct length is set,
tighten and safety lock nut with
NOTE: Cyclic torque tube can be either a ma lockwire.
chined magnesium or aluminum casting.
(For corrosion control and identification of NOTE: Support links can be either forged alu
magnesium and aluminum alloys, Ref. Sec minum or magnesium castings. (For corro
tion 20-40-00.) sion control and identification of magne
sium and aluminum parts, Ref. Section
(1). Replace torque tube if it is cracked, has 20-40-00.)
elongated holes or deformed bearing
supports. 15. Cyclic Trim Actuator Spring Assembly
Replacement
(2). Replace main support bearings or cyclic
stick pivot bearings if they bind or are (Ref. Figure 509)
excessively worn. Drill out four rivets
and remove bearing retainer to replace Consumable Materials
right support bearing. Install cyclic (Ref. Section 91−00−00)
stick pivot bearing and right support Item Nomenclature
bearing with grade A locking compound CM116 Grease, aircraft and instrument
(CM431).
NOTE: Left support bearing is a slip-fit in
torque tube lug; coat outer circumference of
(1). Insert screwdriver into open end of
bearing with grease (CM116) prior to inser
spring guide and remove screw that
tion in lug.
connects two spring adapters.
(3). Replace bent or stripped friction stud. NOTE: Identify screw for lateral or longitudi
Drill out rivet; install and rivet new nal trim; screws are not interchangeable.
stud in place. Insert spring pin with one Lateral actuator screw is 2-7/8 inches
end flush with stud. (73.025 mm) long; longitudinal screw is
2-5/8 inches (66.675 mm) long.
14. One−Way Lock Repair
(2). Slide spring assembly out of trim tube.
For overhaul information, Ref. CSP-COM-5.
(3). Clean inside of trim tube with solvent
(CM234).
(Ref. Section 91−00−00) (4). Coat outside of replacement spring
Item Nomenclature assembly tube lightly with grease
CM206 Chemical coating (CM116).
CM801 Abrasive paper, silicon carbide (5). Slide replacement spring assembly into
CM803 Crocus cloth trim tube.
(6). Install spring adapter screw in open
(1). Remove dents, nicks and scratches by end of spring assembly and tighten
using grade 400 abrasive paper screw until 0.010—0.050 inch
(CM801) to remove rough edges. Finish (0.254—1.27 mm) play is felt while
Page 816
MAINTENANCE MANUAL
pushing or pulling on spring assembly. B. Motor/Gear Drive Mechanism

While tightening screw, check that Replacement
friction exists from self-locking thread
ed insert. (Ref. Figure 509)
(1). Remove actuator spring assembly.
(7). Wipe off all excess grease.
(2). Remove trim tube.
(8). Do a bench test to check actuator
operation. (3). Support actuator tube and press out
spring pin.
16. Cyclic Trim Actuator (4). Unscrew adapter from actuator and
remove actuator from housing.
A. Housing or Trim Tube Replacement
(5). Screw adapter into replacement
(Ref. Figure 509) actuator shaft until it bottoms. If spring
pin hole drilled in adapter does not
align with guide hole in adapter,
Consumable Materials adapter must be replaced; otherwise
(Ref. Section 91−00−00) adapter can be reused.
Item Nomenclature
(6). Use 1/16 inch (0.0625) drill to drill
CM318 Primer
spring pin hole through adapter and
actuator; deburr hole.
(1). Remove actuator spring assembly. (7). Reassemble actuator housing and trim
tube.
(2). Carefully drill out four rivets attaching
trim tube. Remove trim tube. (8). Install actuator in housing. Screw
adapter on actuator.
(3). Remove actuator from actuator hous
ing. Check housing for condition and (9). Support actuator shaft; press in spring
evidence of corrosion. pin. make sure that pin is flush with
shaft.
NOTE: Housing can be either aluminum or (10). Install actuator spring assembly.
magnesium casting. (For corrosion control
and identification of magnesium and alu (11). Bench test actuator.
minum alloys, ref. Section 20-40-00.)
C. Rework (Calco PNs 8222M6 and 8222M7)
(4). Use dimensions to assemble replace The following procedure is for tightening the
ment actuator housing and trim tube. If trim actuator drive gear retention nut and also
replacement part is undrilled, drill #40 testing stalled actuators.
- 0.098 inch (2.4892 mm) four attaching
rivet holes. NOTE: Rework is NOT applicable to actuators
having letter “R” following vendor part
(5). Coat mating surfaces of trim tube and number on actuator housing.
actuator housing with primer (CM318).
Assemble while primer is still wet. (1). Remove cyclic trim actuator from
helicopter.
(6). Install four mechanically expanding (2). If actuator is inoperative, bench test
rivets. unit to determine whether mechanical
(stalled), electrical or other mechanical
(7). Reinstall actuator. failures exists.
(8). Reinstall actuator spring assembly. (a). A reading of 0.0—0.1 amperes
indicates electrical failure; replace
(9). Do a bench test. actuator.
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MAINTENANCE MANUAL
(b). The motor runs, but the output shaft (b). If the nut is loose, rework the actua
does not move, indicates a mechani tor (ref. steps (5). thru (12).).
cal failure; replace actuator.
(5). Remove the nut.
(c). A reading of 0.7 amperes (approxi
mately), or actuator extends part way (6). Clean the threads.
and stalls, indicates stalled failure;
rework actuator (ref. steps (3). thru (7). Install the nut with Loctite #290 on the
(12).). threads.
(3). Remove lockwire and six screws (8). Torque the nut 30 to 40 inch-pound
securing actuator cover to housing. (3.39 to 4.52 Nm).
During removal of the housing,
CAUTION make a note of the location and
(9). Install the actuator cover with screws.
number of shims on each gear for reassem (a). Safety the screws with lockwire.
bly in the correct location.
NOTE: Step (4). is not applicable if the actuator (10). Add the letter “R” at the end of the
is operative. Do steps (5). thru (12). vendor part number on the actuator
housing.
(4). Using fingers only, do a check of the
gear drive retention (hex) nut for (11). As necessary, install the trim actuator.
looseness.
(12). Record the rework of the trim actuator
(a). If the nut is NOT loose, replace the in the Components Record of the
actuator assembly. Rotorcraft Log Book (RLB).
Page 818
MAINTENANCE MANUAL
Section
67−10−20
Collective and
Cyclic Stick Grips
(369D/E/FF −
500/600N)
MAINTENANCE MANUAL
COLLECTIVE AND CYCLIC STICK GRIPS

1. Collective Pitch Stick Switches provided at the left of the trim switch for
optional equipment. Coiled, insulated and
(Ref. Figure 201) The START, N2 GOV and open-ended wiring is provided in the grip for
LDG LT switches are on the collective stick connection to an optional switch.
assembly. Wiring for the switches is routed
down through the collective stick tube and NOTE: Cyclic stick grip configurations vary
interconnects with electrical system wiring and can have additional switches. Switch
through a connector at the base of the stick. functions are described in appropriate sec
tions.
2. Collective Pitch Stick Switches
Replacement 4. Cyclic Control Stick Grip Replacement
(Ref. Figure 201) A. Cyclic Control Stick Grip Removal
(Ref. Figure 203)

(1). Disconnect removable contacts from
Item Nomenclature
electrical plug.
CM703 Tie strap
CM807 Twine, nylon (2). Remove nylon strap that secure wiring
to stick socket. Remove strap mounting
plate only if it is unserviceable.
Ensure all electrical power is
CAUTION OFF. (3). Remove screw from grip and separate
grip from tube.
(1). Disconnect grounding terminals.
(4). Tie a string to each wire bundle to aid
(2). Remove attaching hardware securing reassembly. Push wire slack into wiring
stick grip switch housing. Remove exit holes in stick socket while pulling
housing and switchplate. grip wiring from stick tube. Remove
grip and wiring; leave strings in tube.
(3). Disconnect wiring and remove affected
switch. B. Cyclic Control Stick Grip Installation
(4). Install replacement switch in reverse (Ref. Figure 203)

order of removal. If nylon strap
(CM703) is not available, use twine (1). Separate grip wiring into approximate
(CM807) to secure wiring to collective ly equal size color-coded bundles,
pitch stick. according to wiring diagram.
(5). Do a operational check of switch and (2). Install an 8.00 inch (20.32 cm) length of
associated system or equipment (Ref. AWG Size No. 3 electrical insulation
appropriate PFM). sleeving on each bundle and push
sleeving up into grip.
3. Cyclic Stick Grip Switches
(3). Route wiring through stick tube and
(Ref. Figure 202) The pilot's cyclic stick grip out wiring exit holes with aid of strings
contains a toggle switch for cyclic trim control inserted at stick removal. Push wires at
and a trigger switch for radio/interphone grip end while pulling slack out of
communications. A blank switch socket is socket.
Page 201
MAINTENANCE MANUAL
KNOB
SETSCREW
PANEL NUT
LOCKWASHER
KNOB
PANEL NUT SWITCH IDENTIFICATION
LOCKWASHER PLATE
CHECK NUT
CHECK NUT N2 GOV SWITCH

(TYPICAL)
LANDING LIGHT
SWITCH
IDLE STOP SETSCREW

RELEASE SPRING
START SWITCH
(HALF)
RETAINING RING
PILOT'S STICK GRIP

SWITCH HOUSING
THROTTLE SETSCREW
START SWITCH
(HALF)
SELF-TAPPING SCREW
(SUPPIED WITH SWITCH)
IDLE STOP
RELEASE RING
G67-1027
Figure 201. Collective Pitch Stick Switch Replacement
Page 202
MAINTENANCE MANUAL
SWITCH (S102)
(TOGGLE RED)
SWITCH (S4) *(S1)

(RED PUSHBUTTON WITH GUARD)
SWITCH (S103) *(S107)

(TRIM BLACK)
SWITCH (S1) *(S4)
SWITCH (S111) *(S112)

(ROCKER, OLIVE)
SWITCH (S5)
TRIGGER SWITCH
WITH GUARD
STANDARD GRIP VENDOR NAME AND

P/N IDENTIFICATION
OPTIONAL ``T'' GRIP
NOTE:
OPTIONAL GRIP AN ASTERISK (*) INDICATES - 3 VERSION
OF GRIP AND APPLICABLE SWITCH NUMBER.
G67-1028A
Figure 202. Cyclic Stick Grips
Page 203
MAINTENANCE MANUAL
CYCLIC TRIM SWITCH (S107)

HOOK SWITCH (S4)
AND GUARD
TRIGGER PIN
XMIT/ICS TRIGGER
SWITCH (S112)
FLOAT INFLATE/ HOIST
CUTTER SWITCH (S1/S5)
AND GUARD
PLUG BUTTON
GRIP ASSEMBLY
G67-1025-1A
Figure 203. Cyclic Stick Grip Disassembly (Sheet 1 of 2)
Page 204
MAINTENANCE MANUAL
OPTIONAL
T-GRIP
CYCLIC
GRIP
TUBE SQUARE
ASSEMBLY CONNECTOR
NYLON
STRAP
ROUND
CONNECTOR
FOUR-WAY
TRIM SWITCH
SWITCH (S103) *(S107) TOGGLE SWITCH
(S1) *(S4) (S102)
PUSHBUTTON
SWITCH TRIGGER
(S4) *(S1) GUARD
ROCKER SWITCH
(S111) *(S112)
RETURN
SPRING
SWITCH (S5) TRIGGER
SWITCH
(S101)
GRIP ASSEMBLY TRIGGER
PIN
ROTATED FOR CLARITY
OPTIONAL T-GRIP
(P/N 369D297846)
NOTE:
ASTERISK (*) INDICATES -3 VERSION OF
GRIP AND APPLICABLE SWITCH NUMBERS. G67-1025-2A
Figure 203. Cyclic Stick Grip Disassembly (Sheet 2 of 2)
Page 205
MAINTENANCE MANUAL
(4). Install an additional 8.00 inch (20.32 (6). Push slack wiring into wiring exit holes
cm) length of insulation sleeving to in stick socket while pulling grip wiring
protect each wire bundle where routed from stick tube.
through exit holes in socket.
(7). Remove trim switch cap by carefully
(5). Position grip on stick tube and install pulling cap off.
screw. (8). Remove all attaching hardware secur
(6). Push as much wire slack as possible ing switches to grip, carefully remove
back into stick. Secure wiring to socket switches and attached harness from
with new nylon strap, or equivalent. grip assembly.
(9). Tag, identify and un-solder wires of
(7). Cut wiring to correct length and switch to be disconnected.
reinstall replaceable contacts and
electrical plug and wiring diagram. (10). Clean grip, wiring and switches with
alcohol (CM217).
5. Cyclic Stick Grip Switch Replacement
(11). Reconnect all electrical wires using
(Standard Grip)
solder (CM815), remove identification
(Ref. Figure 203) tags from wires.
(12). Carefully position switches to their
Consumable Materials approximate location within the grip.
(Ref. Section 91−00−00) NOTE: Ensure that switches are correctly posi
Item Nomenclature tioned with any applicable keyway, pin hole,
CM217 Isopropyl alcohol etc, for proper alignment of mating parts.
(13). Install attaching hardware securing
CM703 Tie strap switches onto grip.
CM815 Solder
(14). Install trigger and trigger attach pin.
(15). Install cyclic trim switch cap.
Ensure that all electrical
WARNING power is OFF. (16). Reinstall grip on stick tube, route grip
wiring through stick tube and attach
(1). Disconnect cyclic grip wiring connector connector.
from plug at lower end of cyclic stick.
(17). Check switch operation and wiring
(2). Remove strap securing wiring to stick continuity.
socket; remove strap mounting plate if
it is unserviceable. (18). Apply sealing compound (CM425) to all
screw holes and insert holes.
(3). Remove exterior sealant from grip
(19). Secure wiring to stick with nylon straps
assembly covering switch mounting
(CM703).
hardware and attaching screws.
Cyclic trim actuators should be
(4). Drive trigger pivot pin from grip to CAUTION operated only momentarily to
release trigger. Pin is removed from prevent damage to equipment.
right to left while holding grip in
normal position. Remove trigger. (20). Check operation of switch by momen
tarily cycling in all modes ensuring that
(5). Remove screw from grip and separate the associated system operates correct
grip from stick tube. ly.
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MAINTENANCE MANUAL
6. Cyclic Stick Grip Disassembly (Optional cal wires using solder (CM815) and
T−Grip, PN 369D297846 Only) reinstall switches as applicable.
(Ref. Figure 203) NOTE: Ensure that switch is correctly posi
tioned with any applicable keyway, pin hole,
Ensure that all electrical etc, for proper alignment of matching parts.
WARNING power is OFF.
(2). Insert replacement switch at the
(1). Remove the grip cap by removing six approximate mounting position on the
screws. grip subassembly.
NOTE: The grip is to be disassembled only to (3). Using solder (CM815), connect wiring
the extent required for replacement of the to terminals of the replacement switch.
switches. The wiring through the grip as Remove identification tags from wires.
sembly is tied with nylon twine and covered NOTE:
with a 2.00 inches (5.08 cm) insulating
sleeve. Do not remove the twine and sleeves D Helicopters (369D) S/N 003 thru 480 can
unless wire replacement is required. require trigger switch rework to accom
modate replacement switch (Ref.
(2). Detach the rocker switch (S111) by Figure 204).
removing two screws. D Rework is not necessary for the following
(3). Unscrew the trigger pin and carefully cyclic grip assemblies; PN 369D27133 or
withdraw it while holding the trigger A218-964401-00.
guard and trigger switch (S101) in (4). If rework is required, do steps (a). thru
place. Then remove the trigger guard (c). before continuing.
and switch and separate them with care
to prevent distorting or losing the (a). Press or pull insert from top of grip.
return spring. (b). Make template of profile of new
(4). Remove toggle switch (S102). Switch A218-158698-05 trigger switch.
button is separated from housing by (c). Using file, blade or equivalent
pressing out the pin. routing tool, remove material from
lower inside edge of hole for trigger
(5). Unsolder wiring connected to terminals
switch to permit installation of new
on the switch to be disconnected. Tag
switch. Use template to determine
and identify wires to facilitate correct
amount and location of material to be
reconnection.
removed.
7. Cyclic Stick Grip Reassembly and (5). As applicable, secure or attach the
Modification trigger switch, (trigger guard and
return spring for 369D297846 cyclic
(Ref. Figure 203 and Figure 204) grips) to the grip housing using the
original attaching hardware.
(6). Apply sealing compound (CM425) to all
open screw holes and insert hole.
Item Nomenclature
CM217 Isopropyl alcohol (7). Secure the grip cap (for 369D297846
CM314 Varnish, moisture resistant cyclic grips) to the grip subassembly
with six screws; coat the screws with
varnish (CM314) before installation
CM703 Tie strap into grip.
CM815 Solder
(8). Reinstall grip on stick tube. Using
attached strings, route grip wiring
(1). Clean grip, wiring and switches with through stick tube and reconnect at
alcohol (CM217). Reconnect all electri electrical plug.
Page 207
MAINTENANCE MANUAL
(9). Check switch operation and wiring Cyclic trim actuators should be
continuity. CAUTION operated only momentarily to
prevent damage to equipment.
(10). Secure wiring to stick socket with nylon (12). Check operation of the switch by
strap (CM703). momentarily activating it and ensuring
that the associated system operates
(11). Energize the electrical system. correctly.
REMOVE THIS INSERT
A218-158698-05 SWITCH
REOMOVE MATERIAL HERE
NOTE:
TRIM INSIDE EDGE OF CYCLIC GRIP AS REQUIRED
FOR INSTALLATION OF NEW TRIGGER SWITCH. G67-1026
Figure 204. Rework of Cyclic Stick Grip
Page 208
MAINTENANCE MANUAL
Section
67−20−10
Anti−Torque Flight
Controls (Two and
Four Blade)
(369D/E/FF)
MAINTENANCE MANUAL
ANTI−TORQUE FLIGHT CONTROLS

(TWO AND FOUR BLADE)
1. Tail Rotor Control Configuration control pedals with left copilot's dual
controls. Foot rest not installed.
The helicopter can be equipped with either of
two basic pilot's tail rotor foot pedal control
configurations. The tail rotor and control 2. Upper Fuselage and Tailboom Control
linkage to the foot pedals are identical on Linkage
either basic configuration.
(1). Basic Left-Hand Command Tail Rotor Upper fuselage tail rotor controls consist of
Controls. Single left position pilot's tail Sta. 95 bellcrank and support at the front of
rotor control pedals. Foot rest can be the main rotor mast base, Sta. 120 control rod
installed at right side of crew compart and Sta. 142 bellcrank inside the boom fairing.
ment in place of right-hand foot pedals. Boom linkage consists of tailboom control rod,
supported by seven bushings (grommets), and
(2). Basic Right-Hand Command Tail Rotor Sta. 284 Bellcrank mounted on the tail rotor
Controls. Right position pilot's tail rotor transmission.
Page 1
MAINTENANCE MANUAL
PITCH CONTROL ASSEMBLY
CONTROL ROD BUSHING

(GROMMET) (7 PL)
TAILBOOM CONTROL ROD STA. 284

BELLCRANK
TAIL ROTOR ASSEMBLY
STA. 95 BELLCRANK
BOOT
STA. 120 CONTROL ROD
TAIL ROTOR CONTROL SUPPORT
RIGHT POSITION
FOOT REST
STA. 78.50 (TUNNEL-ROUTED)
CONTROL ROD
IDLER BELLCRANK
FLOOR-ROUTED
CONTROL ROD
TORQUE TUBE
MOUNTING BRACKET
TORQUE TUBE PEDAL
LEFT POSITION PEDAL

MOUNTING BRACKET
G67-0001A
Figure 101. Tail Rotor and Control System
Page 2
MAINTENANCE MANUAL

1. Sta. 120 Control Rod or Sta. 142 Bellcrank (2). Ensure that slotted bushings are in
Replacement place at each end of bellcrank; then
position riveted rod end in bellcrank
A. Sta. 120 Control Rod or Sta. 142 and install bolt, two washers, nut and
Bellcrank Removal cotter pin. Make sure that hump of
bellcrank faces forward.
(Ref. Figure 401) The Sta. 142 bellcrank and
Sta. 120 control rod must be removed as an (3). Carefully feed assembled control rod
assembled unit. and bellcrank through forward air
(1). Remove tail rotor control bellcrank intake at left side of control mixer
access door from left side of boom installation while an assistant guides
fairing. the assembly through boot support tube
to bellcrank support bracket.
(2). Disconnect tailboom control rod from
lower end of Sta. 142 bellcrank. (4). Position rubber boot in place at Sta.
137.50.
(3). Remove hardware that secures Sta. 142
bellcrank to boom fairing brackets. (5). Position Sta. 142 bellcrank in support
bracket and install bolt, two washers,
(4). Open hinge-mounted access door on nut and cotter pin.
engine air inlet aft fairing. Remove
clamp on boot support tube at Sta. Check Sta. 142 bellcrank for
137.50. CAUTION clearance with support struc
(5). Disconnect forward end of Sta. 120 ture. Pay particular attention to area above
control rod from Sta. 95 bellcrank. 369A7951-23 bearing when top of bellcrank
is in forward position. If contact is noted,
NOTE: Sta. 95 bellcrank must also be detached machine surface of bellcrank (machine sur
from its support for clearance from air inlet face with interference only) (Ref.
fairing for rod-end bolt removal. Figure 801).
(6). Carefully pull forward end of control (6). Check that slotted bushing is in place
rod and withdraw assembled rod and in Sta. 95 bellcrank; then install
bellcrank out through boot support tube forward rod end in bellcrank with bolt
at plenum chamber Sta. 137.50. (head to left), two washers, nut and
cotter pin.
(7). Disconnect control rod from upper end
of bellcrank. (7). Reinstall Sta. 95 bellcrank in its
support with bolt, two washers, nut and
B. Sta. 120 Control Rod or Sta. 142 cotter pin.
Bellcrank Installation
(Ref. Figure 401) Sta. 142 bellcrank and Sta. (8). Secure rubber boot at support tube with
120 control rod must be installed as a unit by nylon strap. Then clamp tail rotor
routing assembled end of bellcrank and control pedals in neutral, set free length of
rod through boot support tube at plenum bellows portion of boot at approximately
chamber station (Sta. 137.50). 5.5 inches and secure end to control rod
with nylon strap.
(1). For access to bellcrank support bracket,
use access door in boom fairing. (9). Check rigging of tail rotor controls.
Page 401
MAINTENANCE MANUAL
STA. 137.50 NOTE 2
BUSHING (GROMMET) NYLON

(7 PLACES) STRAP
* STA. 142 BELLCRANK
BOOT NOTE 2 BEARING STATION 284

BELLCRANK PIVOT PIN
STA. 120
CONTROL ROD
(NOTE 1)
SPECIAL
WASHER
* STA. 95 BELLCRANK
* SUPPORT
WASHER
NOTE 2 (NOTE 5)
TAILBOOM
CONTROL ROD
(NOTE 3)
BEARING
MAXIMUM ALLOWABLE
LOOSENESS 0.040 IN.
(1.016 MM)
RIVET RIVET BEARING

ADAPTER
A
ROD LENGTH AND BEARING

ANGULARITY - BEFORE RIG
L DIMENSION
CONTROL ANGLE
ROD L
INCHES (CM) A
STA. 120 45.88 (116.5352) IN LINE

NOTES:
1. MINIMUM OF 0.060 IN. (1.524 MM) CLEARANCE FOR FULL RANGE OF TAILBOOM 143.80 (365.252) 63°
TRAVEL THRU STA. 137.50 BULKHEADS.
2. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF 0.010 IN. (0.254 MM)
TO A MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE OUTSIDE SURFACE OF
PART AFTER NUT IS TIGHTENED.
3. MINIMUM OF 0.010 IN. (0.254 MM) CLEARANCE FOR FULL RANGE OF
TRAVEL BETWEEN BOOM AND TAIL ROTOR TRANSMISSION.
4. ASTERISK ( * ) INDICATES PARTS THAT MAY BE EITHER ALUMINUM OR
MAGNESIUM ALLOY. FOR ALLOY IDENTIFICATION AND CORROSION
CONTROL (REF. SEC. 20-40-00).
5. ADD ONE OR TWO AN960KD516 WASHERS AS REQUIRED FOR CLEARANCE
AT PEDAL FULL STROKE.
G67−2000B
Figure 401. Upper Fuselage and Boom Tail Rotor Control Linkage
Page 402
MAINTENANCE MANUAL
2. Sta. 284 Bellcrank Replacement (4). Slowly pull aft end of control rod and
withdraw rod through opening in tail
A. Sta. 284 Bellcrank Removal rotor transmission mounting frame.
(Ref. Figure 401) B. Tailboom Control Rod Installation
(1). Disconnect bellcrank from tailboom (Ref. Figure 401)

control rod.
NOTE: Tailboom control rod is routed through
boom with forward rod end removed.
(2). Disconnect bellcrank from tail rotor
transmission. Disengage bellcrank
(1). Deleted
pitch control pin from pitch control
housing and remove bellcrank.
(2). Guide control rod through boom aft
frame opening and carefully route
B. Sta. 284 Bellcrank Installation through seven bushings (grommets).
Rotate rod slightly to start it through
(Ref. Figure 401) each grommet.
(1). Insert bellcrank pivot pin into pitch (3). Check that slotted bushing is in place
control housing self-aligning bearing. in lower lug of Sta. 284 bellcrank; then
attach aft rod to bellcrank.
(2). Position bellcrank to align with mating
hole in tail rotor transmission arm and (4). Using measurement recorded at time of
install bolt. rod removal, install forward rod end
bearing. Align rod ends so that bearings
(3). Check that slotted bushing is in place have equal space for angular throw;
in lower lug of bellcrank; then attach hold rod end and tighten jam nut.
tailboom control rod to bellcrank with
bolt, two washers, nut and cotter pin. (5). Check that slotted bushing is in place
in lower end of Sta. 142 bellcrank; then
(4). Check rigging of tail rotor controls (Ref. attach forward rod end to bellcrank.
Tail Rotor Controls Rigging).
(6). Check rigging of tail rotor controls (Ref.
3. Tailboom Control Rod Replacement
(7). Close plenum chamber access door.
A. Tailboom Control Rod Removal
4. Sta. 95 Bellcrank and Support
(Ref. Figure 401) Replacement
(1). Disconnect control rod from Sta. 284 A. Sta. 95 Bellcrank and Support Removal
bellcrank.
(Ref. Figure 401)
(2). Remove tail rotor control bellcrank
access door from left side of boom (1). Disconnect tunnel-routed control rod
fairing. from bellcrank.
(3). Accurately measure and record distance (2). Disconnect bellcrank from support.
between unchamfered edge of forward
rod end bearing jam nut and center of (3). Disconnect bellcrank from Sta. 120
bearing attach bolt hole. Hold forward control rod and remove bellcrank.
rod end, loosen jam nut and unthread
control rod from rod end by turning aft (4). Remove hardware that secures support
end of rod. to mast structure; remove support.
Page 403
MAINTENANCE MANUAL
INITIAL CONTROL ROD LENGTH STA. 95 BELLCRANK

- BEFORE RIG
CONTROL DIMENSION L
ROD INCHES (CM)
TUNNEL-ROUTED 57.95 (147.193)
FLOOR-ROUTED 30.06 (76.3524) STA. 97.50
(TUNNEL-ROUTED)
CONTROL ROD
RIVET
CONTROLS SUPPORT
BRACKET
L
MAXIMUM ALLOWABLE AXIAL SPRING FITTING

PLAY 0.040 IN. (1.016 MM) AFT EYEBOLT
STA. 63.00 TAIL ROTOR
BUNGEE IDLER BELLCRANK
SPRING
NOTE 2
FORWARD EYEBOLT
NOTE 1
NOTE 2 FLOOR-ROUTED
CONTROL ROD
NOTE 3
TORQUE TUBE BUSHING ASSY
* TORQUE TUBE BRACKET (NOTE 4)
(NOTE 5)
CONTROL ROD FITTING NOTE 1 NOTE 3
NOTE 1
PIN
WASHER
NOTE 4
* LEFT PEDAL
BEARING NOTE 1
STOP BOLT
* RIGHT PEDAL
JAMNUT BEARING
NOTE 2
* PEDAL ARM NOTE 3
NOTE 1
BUSHING * PEDAL ARM
(TEFLON-LINED) NOTE 1
NOTE 4 * PEDAL BRACKET
NOTE 2
BUSHING
(TEFLON-LINED) NOTES:
BUSHING ASSY 1. SHIM BETWEEN BRACKET AND BULKHEAD WITH AN960PD416
(NOTE 4) AND/OR -416L WASHERS AS REQUIRED FOR ALIGNMENT WITHIN
NOTE 2 0.010 IN. (0.254 MM).
LINK
2. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF 0.010 IN.
(0.254 MM) TO A MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE OUTSIDE
SURFACE OF PART AFTER NUT IS TIGHTENED.
NOTE 2 3. DIRECTION OF BOLTS IS OPTIONAL.
BEARING
4. ADJUSTABLE BUSHINGS MUST HAVE A MINIMUM PROTRUSION OF
BELLCRANK 0.002 INCH (0.051 MM) AT EACH END.
5. INSTALLED WITH BEARING RECESS FACING FITTING.
6. ASTERISK (*) INDICATES PART THAT MAY BE EITHER MAGNESIUM OR
ALUMINUM ALLOY. FOR ALLOY IDENTIFICATION AND CORROSION
CONTROL (REF. SEC. 20-40-00). G67-2001-1D
Figure 402. Tail Rotor Pedal Installation (Sheet 1 of 2)
Page 404
MAINTENANCE MANUAL
STOP BOLT (2)
NOTE 1
ADJUSTABLE JAMNUT
BUSHING ASSEMBLY NOTE 2
(NOTE 4)
NOTE 3
TORQUE TUBE
SLEEVE
ADJUSTABLE TORQUE TUBE

BUSHING ASSEMBLY
(NOTE 4)
RIGHT POSITION TAIL ROTOR PEDALS G67-2001-2A
Figure 402. Tail Rotor Pedal Installation (Sheet 2 of 2)
B. Sta. 95 Bellcrank and Support Installation (4). Attach tunnel-routed control rod to
bellcrank.
(Ref. (Ref. Figure 401)
C. Tail Rotor Pedal Assembly − General
(1). Install bellcrank support to mast
structure with three bolts, seven (Ref. (Ref. Figure 402) Tail rotor pedal
washers and three nuts. Forward bolt installation consists of a pair of adjustable
requires an extra washer under pedals, pedal arms with interconnecting
bolthead; two thin washers are used at linkage, pedal mounting bracket for left
all three locations. Torque nuts to control position, torque tube with control rod
80—100 inch-pounds (9.04—11.30 fitting and torque tube mounting bracket.
Nm). Forward pressure on right pedal rotates torque
tube, moving control system linkage to
(2). Check that slotted bushings are in increase tail rotor blade pitch. Pressure on left
place in bellcrank; then attach Sta. 120 pedal decreases tail rotor blade pitch. A
control rod to bellcrank with bolt (head bungee spring is installed at aft end of
to left). floor-routed control rod in underseat tail rotor
control linkage. This spring relieves left pedal
(3). Install bellcrank in support. forces during flight and causes left pedal to
Page 405
MAINTENANCE MANUAL
remain at forward position when helicopter is (9). Remove two nuts, four washers, any
on ground and not operating. shim washers and two bolts that secure
torque tube bracket to bulkhead. Keep
NOTE: Parts identified with an asterisk (*) can shim washer selection with bracket to
be either magnesium or aluminum alloy. simplify torque tube alignment during
(Ref. Section 20-40-00 for corrosion control reinstallation.
and identification of magnesium and alumi
num alloys). (10). Remove four nuts, eight washers, any
shim washers and four bolts that secure
D. Co−Pilot’s Pedal Installation pedal bracket to bulkhead. Remove
control pedal installation. Keep shim
(Ref. Figure 402) The copilot's pedal installa washer selection with bracket.
tion is essentially the same as the pilot's. A
B. Tail Rotor Pedal Assembly Installation
sleeve couples a torque tube extension to the
pilot's torque tube. Dual pedal installation is (Ref. Figure 402)
also equipped with pedal stop nuts, heel strips,
retaining springs and attachment hardware. NOTE: Install both left and right pedal brack
ets for right-hand command helicopters.
5. Tail Rotor Pedal Assembly Replacement (1). Install pedal bracket with four bolts,
eight washers and four nuts. Add shim
A. Tail Rotor Pedal Assembly Removal washers as required at pedal bracket
attachment points to keep centerline
(Ref. Figure 402) alignment of pedal bracket bearings
within 0.010 inch (0.254 mm). Correct
(1). Pull two hinge pins from pilot's com alignment is indicated by free rotation
partment floor access door hinges and al movement of torque tube after nuts
remove door. Remove access panel from are tightened.
each side of instrument panel lower
support structure. (2). Position torque tube bracket over
mating holes in bulkhead and check
(2). Remove battery (Ref. Chapter 96). alignment with bulkhead. Add shim
washers as required at bracket attach
(3). Remove pins securing pedals to pedal ment points to maintain bearing
arms and remove pedals. alignment established in step a above.
Install two bolts, four washers and two
(4). For access to bungee, remove access nuts.
cover between pilot's seats and/or by
removing left passenger's footwell on (3). Install forward eyebolt, using same
aft side of canted bulkhead. number of washers removed, on bungee
and then hook aft end of bungee into
(5). Block left tail rotor control pedal at full eyebolt on floor-routed control rod
forward position to relieve tension on fitting.
bungee.
NOTE: If tail rotor pedal forces are not zero
(6). Remove eyebolt and washers at Sta. 63 during level flight at 130 to 140 knots, tail
with bungee attached. Keep washers rotor force adjustment can be accomplished
with eyebolt for reinstallation. by removing washers as required from the
eyebolt at Sta. 63 bracket.
(7). Disconnect bungee from eyebolt and (4). Using spring tension tool install bungee
fitting at aft end of floor-routed control into position at Sta. 63 bracket; install
rod by using spring tension removal washer and nut on eyebolt.
tool (75, Table 203, Section 91-00-00).
(5). Check that slotted bushing is in place;
(8). Remove cotter pin, nut, two washers then install floor-routed control rod in
and bolt that connect floor-routed torque tube fitting and install bolt, two
control rod to torque tube fitting. washers, nut and cotter pin.
Page 406
MAINTENANCE MANUAL
(6). Check rigging of tail rotor controls and (5). Check that spherical bearings are in
pedal-to-canopy clearance (Ref. Tail place; then attach bellcrank to pedal
Rotor Controls Rigging). Pedals should bracket with bolt, two washers, nut and
keep clear of windows by a minimum of cotter pin.
0.20 inch (5.1 mm) with 20 pounds
(88.96 N) of force applied. (6). Check that slotted bushings are in
place; then fasten each link to bellcrank
6. Dual Tail Rotor Pedal Initial Installation with bolt, two washers, nut and cotter
pin.
(Ref. Figure 402)
NOTE: Before pedal installation, remove the (7). Check that slotted bushings are in
bushing assembly that secures pilot's left place; then fasten each link in pedal
pedal arm to the torque tube. This will allow arm lugs with bolt, two washers, nut
the tube to rotate far enough to install the and cotter pin.
bushing assemblies.
(8). Install pedal bracket assembly with
(1). Thread a stop nut on each of the two four bolts, eight washers and four nuts.
stop-bolts and install bolts into Add shim washers as required at pedal
threaded inserts of pedal bracket. bracket attachment points to keep
centerline alignment of pedal bracket
(2). Locate pedal bracket and pedal arms bearings no less than 0.010 inch (0.25
for correct position on torque tube. mm). Correct alignment is indicated by
(3). Fasten left pedal arm to torque tube free rotational movement of torque tube
with adjustable bushing assembly; after nuts are tightened.
install bushing bolt so that shank of the
bolt head end protrudes at least 0.002 (9). Reinstall bushing assembly previously
inch (0.05 mm). Install nut and torque removed from the pilot's left pedal arm.
to 80 inch-pounds (9.04 Nm) plus
drag torque, do not allow bolt to turn. (10). Install pedals on pedal arms and secure
with pins provided.
(4). Make sure that each end of bushing
protrudes no less than 0.002 inch (0.05 (11). Install heel strips with pins, washers
mm). If not, loosen nut and repeat prior and cotter pins. Direction of pin head is
step. optional.
Page 407
MAINTENANCE MANUAL
Page 408
MAINTENANCE MANUAL

ADJUSTMENT/TEST
1. Tail Rotor Controls Rigging (b). Sta. 95 bellcrank: the centerline of
tunnel-routed control rod attach bolt
(Ref. Figure 501) The tail rotor control system must be 4.21—4.39 inches
must be re-rigged immediately after replace (106.9—111.5 mm) above the mast
ment of linkage that cannot be accurately base structure.
measured (by trammeling, etc) before it is
installed in the tail rotor control system, or if (c). Sta. 142 bellcrank: the centerline of
helicopter operation reveals a rigging deficien the tailboom control rod attach bolt
cy. must be 4.50—5.00 inches
(114.3—127.0 mm) from the aft face
of Sta. 137.50 bulkhead. For access to
Special Tools the bellcrank, remove the tail rotor
(Ref. Section 91-00-00) control bellcrank access door.
Item Nomenclature
(3). Loosen the rod end jam nut at the
ST606 T/R swashplate rigging tool forward end of the tailboom control rod.
(4). On tail rotor transmission, remove
Remove the pilot's and copilot's hardware attaching tailboom control
CAUTION (if installed) pedals to prevent rod to inboard end of Sta. 284 bellcrank.
possible contact with the lower windshield (5). Tie back tail rotor rotating boot. Place
during the rigging sequence. midtravel portion of swashplate rigging
tool (ST606) between swashplate and
NOTE: Control rod end bearing adjustments tail rotor fork split-ring retainer (ref.
are to be made to nearest half turn that pro
Figure 501, Detail B). Make sure that
duces correct rigging.
rigging tool contacts ring and not fork.
D When tightening the jam nut at the ad (6). Turn tailboom control rod at aft end.
justable end of a control rod, always hold Adjust rod length to nearest half turn of
the rod end with a wrench to prevent jam rod end that allows swashplate rigging
ming of bearing. tool to just slide between split-ring
retainer and swashplate.
D Never install a used cotter pin — always
install a new one. (7). Make sure that the centerline of the
tailboom control rod forward attach bolt
(1). Disconnect the bungee spring at the aft is 4.50—5.00 inches (114.3—127.0
end of the floor-routed control rod (ref. mm) from the aft face of the Sta.
Figure 402). 137.50 bulkhead. Also check the
forward rod end for not less than one
(2). Use two pieces of wood and a C-clamp and one-half exposed threads with jam
or rope, to secure the pilot's foot pedal nut snug against rod. If either condition
arms so they are aligned (ref. does not exist, disconnect the forward
Figure 501, Detail A). With pilot's foot end of Sta. 120 control rod and readjust
pedals clamped in neutral and control both control rods until the Sta. 142
rod lengths adjusted (ref. Figure 401 bellcrank position and exposed threads
and Figure 402), control system of both control rods are within toler
bellcrank positions can be checked as ance.
follows:
(8). Make sure that the slotted bushing is in
(a). Tail rotor idler bellcrank (pilot's place in the bottom ear of Sta. 284
compartment): the centerline of the bellcrank and the inboard ear of Sta. 95
aft arm must be 88—92 degrees to bellcrank. Connect control rods (ref.
the Sta. 78.50 bulkhead. Figure 401).
Page 501
MAINTENANCE MANUAL
0.250 IN. (6.35 MM)

MAX. MISALIGNMENT
BETWEEN PEDALS NOTES:
1. ROTATING BOOT NOT SHOWN. NORMALLY IT
IS TIED BACK TO LOCATE RIGGING TOOL.
2. TAILBOOM CONTROL ROD AND STA. 120 CONTROL
ROD LENGTHS ARE ADJUSTED FOR CORRECT
CLAMPING BLOCKS MID-TRAVEL RIGGING.
3. ST606, TABLE 3, SEC. 91-00-00
STOP
NUT
RIGHT STOP BOLT
LEFT STOP BOLT
PEDAL ARM ALIGNMENT AND

STOP BOLT ADJUSTMENT
NON-ROTATING SWASHPLATE
BOOT RIGGING TOOL
(NOTE 3)
TAILBOOM CONTROL ROD
(NOTE 2)
TAIL ROTOR FORK
SPLIT-RING
RETAINER
BELLCRANK ACCESS DOOR
STA. 120 CONTROL ROD
(NOTE 2)
MID-TRAVEL RIGGING
(NOTES 1, 2)
LEFT RIGHT
MID RIG
PEDAL PEDAL
LEFT PEDAL RIGGING RIGHT PEDAL RIGGING
G67−2002B
Figure 501. Rigging — Tail Rotor Control System
Page 502
MAINTENANCE MANUAL
(9). Check witness holes for proper thread (15). Operate pedals through full range of
engagement. Align rod ends to get travel. While controls are being moved,
approximately equal angular throw in check that there is never less than
bellcranks; tighten jam nuts. 0.060 inch (1.524 mm) clearance
around Sta. 120 control rod where it
(10). Remove clamping device from foot pedal passes through structure at Sta. 137.50
arms. and that there is never less than
0.010 inch (0.254 mm) clearance
around tailboom control rod where it
(11). Loosen jam nuts on pedal stop bolts (A,
exits between boom and tail rotor
Figure 501). Screw in pedal stop bolts
transmission.
approximately 0.50 inch (12.70 mm).
(16). Connect bungee spring between aft end
Use care when actuating pedals of floor-routed control rod and Sta. 63
CAUTION to avoid possibility of damaging
bracket (Ref. Figure 402) and check
tool or windshield. that pilot's left pedal moves to its
normal forward position.
NOTE: Adjust copilot's pedal stop bolts to
match pilot's pedal travel, 0.001—0.003 (17). Install Sta. 142 bellcrank access door.
inch (0.025—0.076 mm) gap between stop
bolts and pedals. 2. Tail Rotor Bungee Adjustment
(12). Adjust right pedal stop bolt (A, (Ref. (Ref. Figure 502)
Figure 501) so that when pedal arm is
held against stop, right pedal portion of (1). 2-Bladed bungee adjustment:
swashplate rigging tool just slides
between split-ring retainer and (a). Increase pedal force by removing
swashplate (view C). Fit should be tight washers from under bungee spring
enough to support weight of tool. eyebolt.
Without changing adjustment of bolt or
tool fit, tighten jam nut on stop bolt. (b). If tail rotor pedal forces are not zero
during level flight at 130—140 knots,
(13). Adjust left pedal stop bolt (A, tail rotor force adjustment can be
Figure 501) so that when pedal arm is accomplished by removing a desired
held against stop with 20—25 pounds number of AN970-3 washers.
(88.96—111.20 N) pressure (or pull on
right pedal), left pedal portion of (2). 4-bladed bungee adjustment:
swashplate rigging tool just slides
between split-ring retainer and (a). Adjust tail rotor pedal force by
swashplate (view D). Fit should be tight tightening or loosening the 0.120
enough to support weight of tool. inch (3.048 mm) thread adjustment
Without changing adjustment of bolt or on bungee female bearing assembly.
tool fit, tighten jam nut on stop bolt.
Remove swashplate rigging tool and (b). Tighten to maximum 0.120 inch
restore rotating boot to normal installed (3.048 mm) thread adjustment on
position. bungee female bearing assembly
increases pedal force approximately
(14). Reinstall pedals. Slowly press outboard five pounds; loosening decreases
pedal to its full forward travel position pedal force.
against stop bolt. With not more than
20 pounds pressure applied, upper and (c). Bungee spring can175 be attached to
lower edges of pedal must clear canopy any of four holes in fitting. If exces
glass by not less than 0.20 inch sive left pedal force is required,
(0.508 mm). position spring at lower hole.
Page 503
MAINTENANCE MANUAL
MS24665-143
COTTER PIN
AN42B-C10A EYEBOLT BUNGEE
STA AN970-3 WASHER (8 REQD) ASSEMBLY
63.00 MS21042-3 NUT
369A2541 AN960-10L WASHER
BRACKET
MS17826-4
NUT
AN960KD416L AN960KD416L
WASHER WASHER
NAS1104-11D
BOLT
369D27521
SPRING 369DSK83-19
FITTING
TAIL ROTOR BUNGEE TAIL ROTOR BUNGEE

(2-BLADED) (4-BLADED)
G67-2019
Figure 502. Tail Rotor Bungee Adjustment
Page 504
MAINTENANCE MANUAL

INSPECTION/CHECK
1. Upper Fuselage and Tailboom Control 2. Tail Rotor Pedal Assembly Inspection
Linkage Inspection
(Ref. Figure 402)
(Ref. Figure 401)
(1). Inspect rod end bearings for binding NOTE: Inspect components at left and right po
and excessive wear, 0.040 inch (1.016 sition on the right-hand command models.
mm) maximum axial play. Inspect Check that corresponding pedals contact
rivet at fixed rod end. stops simultaneously.
(2). Inspect control rod for surface damage
(1). Inspect pedals and pedal arms for
and evidence of bending.
cracks, elongated pedal attach holes
(3). Inspect rubber boot just forward of Sta. and open drain holes. Inspect teflon-
137.50 bulkhead for condition. reinforced bushing liners for deteriora
tion.
(4). Inspect tailboom control rod surfaces
that pass through all grommets. (2). Inspect pedal-to-arm quick-release
Serviceable wear is limited to thickness locking pin for condition and positive
of hard anodic coating. Check that all spring action.
bushings are secure.
(5). Inspect bellcranks for scratches, cracks, (3). Inspect links and bellcrank for cracks
corrosion and similar surface defects. and bends, and bearings for excessive
play.
(6). Inspect bellcrank bearings for looseness
and binding. (4). Inspect control rod fitting, torque tube
(7). Inspect for obstructions in drain slot of mounting bracket and pedal mounting
Sta. 284 bellcrank. bracket for cracks and corrosion. Using
an 8X magnifying glass, mirror and
(8). Inspect for corrosion or excessive wear flashlight, closely inspect pedal link
on Sta. 284 bellcrank pivot pin. bellcrank fitting of pedal bracket in
center forward area where fitting (fork
(9). Visually inspect doublers on Sta. 142 piece) joins tubular section. If any
bellcrank supports for cracking/da cracks are detected, replace bracket
mage. assembly. Inspect bracket bearings for
NOTE: MDHI Notice DN-49 contains informa excessive looseness.
tion relative to repair of damaged doublers
on bellcrank supports. MDHI Notice (5). Inspect torque tube for cracks,
DN-102 contains information required to scratches, nicks, dents and similar
modify the particle separator fairing and surface defects.
cover assemblies to prevent possible chafing
of the Sta. 120 tail rotor control rod. (6). Inspect pedal brackets for corrosion.
Page 601
MAINTENANCE MANUAL
Table 601. Isolating Control System Troubles

Binding, locking−up and erratic Disconnect pitch control links from If symptom is gone, replace tail rotor
action of foot pedals (Do not force pitch control assembly. assembly. Repair (Ref.
controls). CSP−COM−5).
Symptom remains. Disconnect Sta. 284 aft boom If symptom is gone, clean
bellcrank from pitch control swashplate bore and output shaft
assembly. splines. Lubricate splines. Replace
swashplate if necessary. Check for
elongation of bolt hole in support arm
portion of main housing assembly of
tail rotor gearbox, caused by
looseness of bellcrank fulcrum bolt
and nut. Repair (Ref. CSP−COM−5).
Symptom remains. Disconnect floor−routed tail rotor If symptom is gone, inspect tail rotor
control rod from foot pedal torque control rods and bellcranks until
tube fitting. defective part is located.
Symptom remains. Loosen foot pedal torque tube If symptom is gone, pedal torque
brackets mounted on front of floor tube misaligned; shim for correct
structure. alignment. If symptom remains,
disassemble and inspect tail rotor
control foot pedal installation until
Trouble corrected.
Page 602
MAINTENANCE MANUAL

REPAIRS
1. Floor− and Tunnel−Routed Control Rods (5). If removed, install rivet to secure rod
end.
(Ref. Figure 401 and Figure 402) The floor-
and tunnel-routed control rods connect the tail (6). Check that slotted bushing is in place;
rotor pedal installation with the upper then secure control rod in torque tube
fuselage and tailboom control linkage. The two fitting or idler bellcrank with bolt, two
control rods are linked by a tail rotor idler washers, nut and cotter pin.
bellcrank mounted on the underseat controls
support bracket. (7). Install bungee spring.
(8). Install access doors.
2. Floor−Routed Tail Rotor Control Rod
Repair (9). Check rigging of tail rotor controls (Ref.
(Ref. Figure 401) Replace rod end if bearing
axial play is more than 0.040 inch (1.016 3. Upper Fuselage and Tailboom Control
mm). Riveted rod end bearing is replaceable Linkage Repair
without rod removal if located at forward end
of rod. If riveted rod end is aft, rod removal is (Ref. Figure 401)
required to replace rod end bearing.
NOTE: Floor-routed control rod normally does (Ref. Section 91−00−00)
not require replacement unless helicopter Item Nomenclature
receives extensive impact or crash damage.
Remove control rod forward through land CM318 Primer
ing light wiring grommet hole after landing CM431 Sealing, locking and retaining compound
light (if installed) is removed (Ref. Chapter CM802 Abrasive cloth, aluminum oxide
96).
(1). Disconnect control rod from pedal (1). Do a straightness check on control rod
torque tube fitting or from tail rotor that appears bent or bowed. Total
idler bellcrank (Ref. Figure 402). length of Sta. 120 control rod, excluding
Remove bungee spring (Ref. Section rod ends, must be straight within 0.040
67-10-00). inch (1.016 mm), with straightness
variation limited to maximum of 0.010
(2). Accurately measure and record distance inch (0.254 mm) in each foot of length.
between unchamfered edge of rod end Total length of tailboom control rod,
jam nut and center of rod end bearing excluding rod ends, must be straight
hole. within 0.120 inch (3.048 mm), with
straightness variation limited to
Use care when drilling to re maximum of 0.010 inch (0.254 mm) in
CAUTION move or install riveted rod end; each foot of length.
rod end is steel and rod is aluminum.
A dye check for cracking
(3). If necessary, drill out rivet. Loosen jam WARNING must always be done after
nut and unscrew rod end. cold-straightening. Replace cracked
rod, or cracked or bent rod end.
(4). Screw another rod end into rod to
obtain same measurement made in step (2). Cold-straighten bent rod that is not
(2). above. Align control rod ends so within tolerance (step (1). above)
that bearings have equal space for provided there are no nicks or sharp
angular throw; tighten jam nut. dents in bend length. Do not use rod
Page 801
MAINTENANCE MANUAL
ends to support rod during straighten (6). Repair minor surface defects such as
ing process. scratches, nicks and corrosion on
bellcranks and support bracket. Use
Use care when drilling to re abrasive cloth, grade 400—600
CAUTION move or install riveted rod end; (CM802), to smooth out and blend in
rod end is steel and rod and bearing adapter such defects. Following rework limits
are aluminum. represent total limits, including effects
of all previous repairs to any given
(3). Replace control rod end if bearing axial area.
mm). Set initial control rod length and NOTE: Parts identified (Ref. Figure 401) with
bearing angularity. an asterisk ( * ) can be either magnesium or
aluminum alloy. For corrosion control and
(4). Replace unserviceable control rod identification of magnesium and aluminum
bearing adapter. Trammel method (or alloys, refer to Section 20-40-00.
equivalent) can be used to establish rod
length when replacing an adapter. (a). Cast surfaces can be reworked to
depth of 0.020 inch (0.508 mm).
(a). Measure length and record position
of rod end in adapter; then remove (b). Flat machined surfaces, except clevis
affected rod end. inner ears, can be reworked to depth
of 0.015 inch (0.381 mm). Clevis
(b). Comply with precaution above and inner ear surfaces can be reworked to
drill out rivets securing adapter to depth of 0.020 inch (0.508 mm).
rod and aft rod end.
(c). Machined holes can have 0.003 inch
(c). Install rod end in replacement (0.076 mm) removed from bore wall
adapter and position at recorded in an area no greater than 15 percent
measurement. of circumference and 50 percent of
depth.
(d). Fit adapter into rod and position to (d). All edges can have 0.030 inch (0.762
fit trammel point spacing; pick up mm) removed except around ma
and drill through existing rivet holes chined holes, which are limited to
in rod and install rivets to secure 0.010 inch (0.254 mm) chamfer.
adapter to rod; at aft end, drill and
rivet rod end to adapter. (e). All rework must be smoothly blended
into adjacent surfaces and finish
(5). Replace unserviceable bellcrank and must be restored (Ref. preceding
support pivot bearings. Install bearing NOTE).
with grade A locking compound
(CM431). Make sure that bearing seats (7). Repair surface abrasion on Sta. 120
against bore shoulder. control rod by smoothing area with
grade 400 abrasive cloth (CM802) and
NOTE: restoring protective finish with primer
D Installation direction of Sta. 142 bell (CM318). Replace rod if wear or depth
crank bearing can be from either side, de of repair is more than 0.004 inch
pending on location of bearing shoulder. (0.102 mm).
There must not be less than 0.010 inch
(0.254 mm) protrusion of bearing inner (8). Replace tailboom control rod if hard
race beyond sides of bellcrank after bear anodic coating is worn through and
ing is installed. aluminum base metal is visible.
D If contact is noted between Sta. 142 bell (9). Replace split or torn boot. Remove Sta.
crank and mount bracket, rework bell 120 control rod. Replace boot and
crank to clear bracket (Ref. Figure 801). reinstall Sta. 120 control rod.
Page 802
MAINTENANCE MANUAL
BELLCRANK AND SUPPORT

(2 PLS) (NOTE 1)
ÇÇÇÇÇ
0.002 IN. NOTES
(0.508 MM) A S
ÇÇÇÇÇ
2&3
ÇÇÇÇÇ
ÇÇÇÇÇ
ÇÇÇÇÇ
0.750 IN.
NOTES (19.05 MM)
0.090 IN. (2.286 MM) R 2&3 MIN.
369A7951-23
(TYP) BEARING
NOTES:
1. 0.010 MINIMUM CLEARANCE REQUIRED IN THIS AREA.
2. TREAT MACHINED AREA WITH CHROMIC ACID SOLUTION (CM207).
3. TOUCH UP COLOR 34151 GREEN (CM304). G67-2003A
Figure 801. Rework of Sta. 142 Bellcrank Assembly

4. Station 78.50 Tail Rotor (Tunnel−Routed) temporarily reinstall washer and nut
Control Rod on bolt.
All tunnel-routed control rods are removed, (5). Slide pedal bracket and pedal arms off
inspected, repaired and installed in same end of torque tube.
manner. For initial length and rod end
angularity, Ref. Figure 402. For maintenance (6). Do not remove two teflon-lined bush
information, Ref. Section 67-10-00. ings from right pedal arm, unless
replacement is required.
A. Tail Rotor Idler Bellcrank
(7). Do not remove two stop bolts, jam nuts
(Ref. Controls Support Bracket and Bellcrank, on stop bolts or bearings from pedal
Section 67-10-00) bracket unless replacement is required.
5. Tail Rotor Pedal Disassembly (8). Slide torque tube bracket and control
rod fitting off torque tube.
(Ref. Figure 402)
6. Tail Rotor Pedal Repair
(1). Before disassembly of tail rotor pedal
installation, matchmark mating pedal (Ref. Figure 402)
arms, links and bellcranks with pedal
brackets to avoid intermixing compo Consumable Materials
nents between locations at reassembly. (Ref. Section 91−00−00)
Item Nomenclature
(2). Disconnect links from pedal arms and
bellcrank; remove links. CM425 Sealing compound
(3). Remove bellcrank from pedal bracket.
(4). Remove nut and washer of two bushing (1). Replace parts that are cracked or have
assemblies that secure left pedal arm elongated attachment holes. Do not
and control rod fitting to torque tube. attempt to straighten bent torque tube
Carefully remove bushing bolt and or pedal link.
Page 803
MAINTENANCE MANUAL
(2). Replace unserviceable pedal covers. mm). Torque nut to 50—80 inch-
Apply sealing compound (CM425) to pounds (5.65—9.04 Nm) plus drag
approximately 30 percent of upper and torque. Do not allow bolt to turn.
lower edge surfaces that contact pedal.
Cure according to container instruc (6). Check that each end of bushing assem
tions. bly shank protrudes at least 0.002 inch
(0.051 mm). If not, loosen and repeat
(3). Replace complete pedal link if it is step (4). above.
cracked or contains unserviceable
bearings; bearings are not replaceable. (7). Check that slotted bushing is in place;
then attach bellcrank to pedal bracket
(4). Replace unserviceable bearings in with bolt, two washers, nut and cotter
mounting brackets or pedal link pin.
bellcrank. Install replacement with
grade A locking compound (CM431). (8). Check that slotted bushings are in
place; then fasten each link to bellcrank
Right pedal arm bushings are with bolt, two washers, nut and cotter
CAUTION glass-filled phenolic. Make cer pin.
tain that bushing does not cock during re
placement, and that it is fully seated in arm (9). Check that slotted bushings are in
bore. Keep tools from contact with bushing place; then fasten each link in pedal
liners to avoid fraying. arm lugs with bolt, two washers, nut
and cotter pin.
(5). Replace bearings in right pedal arm
when teflon-reinforced liner is galled or (10). Ensure outboard pedals clear windows
frayed. Pull bushing to remove; press to by a minimum of 0.20 inch (0.508 mm)
install. with 20 pounds (88.96 N) of force
applied.
(6). Remove corrosion from pedal brackets
(Ref. Section 20-40-00 and CSP-A-3, 8. Tail Rotor Bungee Spring Forward
Corrosion Control Manual). Attachment Relocation
(Ref. Figure 802) The information given in this
7. Tail Rotor Pedal Reassembly procedure is for the relocation of the tail rotor
(Ref. Figure 402) bungee spring forward attachment on 369D
helicopters, Serial No. 003D—0467D. This
(1). When reassembling components, check rework allows for the installation of washers,
for correct matchmark identification. for bungee adjustment, to adjust for minimum
pedal loads in cruise.
(2). If previously removed, thread jam nut
on each of two stop bolts and install two Consumable Materials
stop bolts into threaded inserts of pedal (Ref. Section 91−00−00)
brackets. Item Nomenclature
(3). Slide torque tube bracket and control CM207 Chromic acid solution
rod fitting onto torque tube. CM318 Primer
(4). Locate pedal bracket and pedal arms
for correct position on torque tube; slide
bracket and arms onto torque tube. (1). Remove access cover between pilot's
seats and/or passenger's footwell on aft
(5). Fasten left pedal arm and control rod side of canted bulkhead.
fitting to torque tube with adjustable
bushing assemblies. Install bushing (2). Block left tail rotor control pedal at full
bolt so that shank at bolt-head end forward position to relieve tension on
protrudes at least 0.002 inch (0.051 bungee.
Page 804
MAINTENANCE MANUAL
CL SHIP
OLD HOLE
3.25 IN. (8.255 CM)
NEW HOLE
3.37 IN. (8.5598 CM)
1.75 IN. (4.445 CM)
0.190-0.194 IN. DIA. HOLE

(4.826-4.9276 MM)
C-C VIEW LOOKING AFT
C
AN42B-C10A EYEBOLT
AN970-3 WASHER (8 REQD)
STA MS21042-3 NUT
63.00 AN960-10L WASHER
369A2541 BRACKET
CL SHIP
3.37 IN. B B
(8.5598 CM) 1.75
0.190-0.194 IN. C
(4.826-4.9276 MM) DIAMETER THRU BRACKET 369D27521 SPRING
B-B VIEW LOOKING DOWN

VIEW LOOKING INBOARD LH SIDE
G76-2007A
Figure 802. Relocation of Tail Rotor Bungee Spring Forward Attachment
Page 805
MAINTENANCE MANUAL
(3). Disconnect bungee spring from eyebolt end of 369D27521 bungee spring to
and remove and retain nut and washer eyebolt. Insert eyebolt in new hole in
attaching eyebolt to bracket at Sta. 63, 369A2541 bracket and secure with
discard eyebolt. washer and nut retained from prior
step. Torque nut to 20—25 inch-
(4). Locate position and drill new hole using pounds (2.26—2.82 Nm).
No. 10 drill, deburr as required.
NOTE: If tail rotor pedal forces are not zero
(5). Seal old eyebolt hole with adhesive during level flight at 130—140 knots, tail ro
(CM411). Allow to dry per manufactur tor force adjustment can be accomplished by
er's instructions. removing a desired number of AN970-3
washers.
(6). Treat edge of new hole with chromic
acid solution (CM207) and touch up (8). Remove block from left tail rotor control
with zinc chromate primer (CM318). pedal.
(7). Install eight AN970-3 washers on one (9). Reinstall access cover between pilot's
AN42B-C10A eyebolt and hook forward seats and/or passenger's footwell.
Page 806
MAINTENANCE MANUAL
Section
67−20−30
NOTAR
Flight Controls
(500/600N)
MAINTENANCE MANUAL
NOTAR® ANTI−TORQUE SYSTEM FLIGHT CONTROLS

1. NOTARR Anti−Torque System Control a stability augmentation system
Linkages Configuration and Description (S.A.S.).
(1). The helicopter can be equipped with 2. Stability Augmentation System

either of two basic configurations, Description and Operation
single left-hand command or right-
hand command, (dual control are NOTE: Aircraft equipped with YSAS cannot be
optional). flown with any component of the system re
moved.
NOTE: (1). The Yaw Stability Augmentation
D The 600N helicopter does not have a System provides increased directional
spring on the splitter assembly like the stability and allows for a lower pilot
500N helicopter. workload in the directional axis.
D Some 600N helicopters are not equipped (2). The YSAS adds an actuator that is
with a YSAS system. located inside the right side of the
D The 600N helicopter has a Sta. 95 bell horizontal stabilizer and is mechanical
crank instead of a Sta. 97.50 Bellcrank. ly bolted to the horizontal stabilizer on
the outboard side.
(2). The control linkages for the foot pedals (3). Two access panels on the horizontal
installation are identical to the basic stabilizer allows access to the actuator,
helicopter, with the exception of a pedal bellcranks, control rod and electrical
friction mechanism with a preset connectors.
friction tension. The pedal friction
mechanism (500N only) offers the pilot (4). A yaw rate gyro is located under the
an artificial feel or workload of a pilot's seat structure on the foreword
conventional tail rotor system. bulkhead. Access to the gyro is through
the rear access panel (footwell) Sta.
(3). A splitter bungee spring (500N only) 78.50 canted bulked.
which is incorporated in the flight
control system at the mast base The yaw rate gyro provides short term
between the 97.50 bellcrank support rate signals to the computer, propor
bracket and splitter pinion gear tional to the rate of angular displace
dampens control feedback. ment about the axis perpendicular to
the gyro's mounting surface damping in
(4). Fuselage controls linkages consist of the directional axis signal electronical
Sta. 97.50 bellcrank and a support at ly.
the front of the main rotor mast base,
fwd control tube, splitter bungee spring, (5). A YSAS electronic control box (comput
splitter assembly, intermediate control er) is installed below the rate gyro. It is
tube, Sta. 137.50 support bracket and a equipped with an internally-mounted
bellcrank at the fan transmission lateral accelerometer.
support assembly, aft control tube and a The lateral accelerometer enhances
two piece cable assembly to the thrust direction stability by feeding back to
er. the YSAS computer signals measured
during flight. The computer processes
(5). Empennage controls consist of a the signals received and sends them to
thruster installation, four piece cable the actuator.
and drum assembly, a control rod,
vertical stabilizer control tubes and (6). The 600N helicopters come equipped
bellcranks and, in the case of the 500N, with an indicator mounted in the
Page 1
MAINTENANCE MANUAL
console to alert the pilot in case of a

YSAS failure.
3. 500NM7301 YSAS Fin Position Indicator
(U.K. Only)
(Ref. Table 1) The 500N helicopters sold in the
United Kingdom come equipped with an
indicating system to alert the pilot in case of a
YSAS failure. Because this is a very limited
option, the parts are not listed in CSP-IPC-4.
The following table is for ordering the major
components of this system.
Table 1. 500NM7301 YSAS Fin Position

Indicator Components
Component Part Number
Edge light panel 369D26454−27
Indicator 500N7305−3
Vne card set 500N6530−31
369D24506−9 Indicator
PFM Flight Manual Supplement CSP−520N−1C
369D26454−17 Decal
Page 2
MAINTENANCE MANUAL

1. Anti−Torque Flight Controls 3. Forward Directional Control Tube
Replacement
NOTE:
(Ref. Figure 401)
D The NOTARR anti-torque control system
must be re-rigged after removal or re A. Forward Directional Control Tube
placement of control rods, linkages and Removal
components or if helicopter operation re (1). Remove fairings, access covers and
veals a rigging deficiency. doors necessary to facilitate mainte
D Refer to adjustment and test control rig nance (Ref. Section 53-30-30, Upper
ging, during flight control installation. Aft Section Fuselage).
(2). Disconnect forward directional control
2. Upper Fuselage Sta. 97.50 (500N) or Sta. tube from Sta. 97.50 (Sta. 95) bell
95 (600N) Bellcrank and Support Bracket crank.
Replacement
(3). Disconnect forward directional control
(Ref. Figure 401) tube from the lever assembly gear
pinion rack Sta. 113.00 splitter and
A. Sta. 97.50 (500N) or Sta. 95 (600N) remove control tube.
Bellcrank and Support Bracket Removal B. Forward Directional Control Tube
Installation
(1). Disconnect anti-torque control tube
(Sta. 87.50) and Fwd directional control (1). Forward directional control rod initial
tube from Sta. 97.50 (Sta. 95) bell length is 15.42 inches (39.17 cm),
crank. measured center of rod end to center of
rod end. Install forward directional
(2). Remove nuts, washers and bolts from control tube on pinion gear rack lever
main rotor mast base support bracket. assembly Sta. 113.00 splitter and on
Remove bellcrank and support bracket Sta. 97.50 (Sta. 95) bellcrank.
as an assembly. (2). Ensure slotted bushings are in place.
Split bushings must protrude
B. Sta. 97.50 (500N) or Sta. 95 (600N) 0.010—0.060 inch (0.254—1.524 mm)
Bellcrank and Support Bracket above surface of bellcranks.
Installation
(3). Install washers, bolts and nuts. install
(1). Position bellcrank and support bracket cotter pins and safety wire jamnuts as
on mast base structure,and install required.
three bolts, seven washers and three
nuts. Most forward bolt requires extra (4). Install fairings and panels.
thick washer under head of bolt. Torque 4. Splitter Bungee Spring Replacement
bolt to 80—100 inch-pounds (500N)
(Ref. Figure 401)
(2). Ensure slotted bushings are in place
and connect anti-torque control tube Special Tools
and fwd rod end of Fwd directional (Ref. Section 91-00-00)
control tube to bellcrank and cotter pin. Item Nomenclature
Split bushings must protrude ST601 Rigging pin
0.010—0.060 inch (0.254—1.524 mm) ST602 Spring tension removal tool
above surface of bellcrank.
Page 401
MAINTENANCE MANUAL
A. Splitter Bungee Spring Removal (4). Remove nut, washer, link assy. and
spacer and disconnect intermediate
(1). Using two pieces of wood and C-clamp control tube from gear pinion stud.
or rope, secure pilots pedals in mid
position so they are aligned. (5). Remove four bolts and washers, and
remove splitter assembly.
(2). Insert rigging pin (ST601) into the
upper hole of bracket assembly and B. Station 113.00 Splitter Assembly and
through the the slot marked ``M'' in the Bellcrank Installation
gear pinion rack. (View B).
(1). Position splitter bracket on structure
Bungee spring is under ten and install four bolts and washers.
WARNING sion, use care to prevent
personal injuries or damage to air (2). Position intermediate control tube on
craft. gear pinion stud. Install link, spacer,
washer and nut; install cotter pin.
(3). Disconnect spring from links, either aft
or fwd., using a spring expansion tool (3). During installation of walking lever
(ST602). and bracket, align the index marks
together and install pivot bolt, spacer,
B. Splitter Bungee Spring Installation washers and nut and torque to 50—60
(1). Insert rigging pin (ST601) into the Ensure bushings and bearings are in
upper hole of bracket assembly and place; install cotter pin.
through the the slot marked ``M'' in the
gear pinion rack Sta. 113.00 splitter. (4). Install forward cable assembly rodend
and fwd directional control tube rodend.
(2). With a spring expansion tool (ST602), Ensure bushings are in place. Torque
expand the spring the amount neces nuts and install cotter pin.
sary to secure the spring to the forward
and aft links. (5). 500N Only: Install splitter bungee
spring.
(3). Remove rigging pin.
6. Intermediate Control Tube Replacement
5. Upper Fuselage Station 113.00 Splitter
Assembly and Bellcrank Replacement (Ref. Figure 402)
(Ref. Figure 402) A. Intermediate Control Tube Removal
A. Station 113.00 Splitter Assembly and (1). 500N Only: Remove splitter bungee
Bellcrank Removal spring from Sta. 113.00 splitter assem
bly pinion gear (Ref. Splitter Bungee
(1). 500N Only: Remove splitter bungee Spring Replacement (500N)).
spring from Sta. 113.00 splitter assem
bly pinion gear (Ref. Splitter Bungee (2). Disconnect intermediate control tube
Spring Replacement (500N)). from gear pinion stud by removing nut,
washer, link and spacer.
(2). Disconnect forward cable assembly
rodend and rodend of forward direction (3). Disconnect aft end of intermediate
al control tube from walking lever. control tube at Sta. 137.50 bellcrank by
depressing pin in head of bolt to release
NOTE: Note relationship of index marks on locking ball while removing nut. With
splitter assembly. pin still depressed, remove bolt.
(3). Align index marks on gear teeth. (4). Remove control tube boot ty-strap, and
Remove walking lever from splitter move control tube carefully forward
bracket by removing nut, pivot bolt, through boot, support tube at plenum
washers and spacer. chamber inlet.
Page 402
MAINTENANCE MANUAL
AFT CONTROL ROD
SECTOR ASSEMBLY
TURNBUCKLE
IDLER PULLEY
FWD TUBE
ASSEMBLY DRUM ASSEMBLY
MD500N
AFT CONTROL ROD
SECTOR ASSEMBLY
STA. 97.50
BELLCRANK
IDLER PULLEY
TURNBUCKLE
DRUM ASSEMBLY
MD500N VIEW ROTATED 180°
STA. 78.50 MD600N
CONTROL ROD FWD TUBE ASSEMBLY
DRUM AND SECTOR
ASSEMBLY
FWD DIRECTIONAL
CONTROL TUBE
STA. 95
BELLCRANK
SPLITTER SPRING
(MD500N ONLY)
STA. 78.50
CONTROL ROD
MD600N
ROOF-MOUNTED CONTROLS
FWD CONTROL RIGGING PIN

CABLE
INTERMEDIATE SPLITTER ASSEMBLY

CONTROL TUBE G67-2013A
Figure 401. Anti−Torque Control System
Page 403
MAINTENANCE MANUAL
B. Intermediate Control Tube Installation 7. Station 137.50 Support Bracket and

Bellcrank Replacement
(1). Carefully feed intermediate control
tube through boot if installed and (Ref. Figure 402)
forward air inlet to bellcrank at Sta. A. Station 137.50 Support Bracket and
137.50. Bellcrank Removal
(2). Connect control tube and check that (1). Disconnect intermediate control tube
bushings are in place. from upper end of Sta. 137.50 bellcrank
by depressing pin in head of bolt to
(3). Install impedance bolt as follows: disengage and release locking ball and
removing nut. With pin still depressed,
NOTE: Install bolt-head up, nut facing down. remove bolt.
(a). Depress pin in head of bolt to install (2). Disconnect link assembly at clevis,
bolt though clevis assembly. remove bolt in same manner as in
previous step.
NOTE: In the following step, pin is to remain (3). Remove four support bracket assembly
depressed while nut is torqued. bolts from fan transmission support.
(b). While pin is depressed, install nut (4). Bellcrank and bracket assembly can be
and torque to 40—50 inch-pounds separated by removing bolt.
(4.52—5.65 Nm). B. Station 137.50 Support Bracket and
Bellcrank Installation
(c). Release pin and retorque nut to
75—90 inch-pounds (8.47—10.17 NOTE: It is recommended to assemble link and
Nm) to ensure engagement of locking bracket assembly to bellcrank before install
balls with nut. ing bracket assembly on fan transmission
support bracket.
NOTE: Pin must be in the released position
(flush with bolt head) and bolt must pro (1). Reassemble bellcrank and bracket
trude past the nut for proper installation. assembly if necessary.
(2). Install impedance bolt as follows:
(d). Apply torque stripe.
(a). Depress pin in head of bolt to install
(4). Install alternate NAS6204-11D bolt bolt through bracket and bellcrank.
and MS17826-4 nut as follows: NOTE: In the following step, pin is to remain
depressed while nut is torqued.
(a). Install bolt, with one AN960KD416L
washer through clevis assembly. (b). Install nut and torque to 100—120
(b). Install AN960KD416L washer and
nut and torque to 20—40 inch- (c). Release pin and torque nut to
pounds (2.26—4.52 Nm); install 200—225 inch-pounds
MS24665-134 cotter pin. (22.60—25.42 Nm) to insure engage
ment of locking ball with nut.
(5). Position rubber boot in place. Secure NOTE: Pin must be in the released position
boot at support tube with nylon strap, (flush with bolt head) and bolt must pro
then clamp directional control pedals in trude past the nut for proper installation.
neutral, set free length of bellows
portion of boot at approximately 5.5 (d). Apply torque stripe.
inches (13.97 cm) and secure end to (3). Install alternate NAS6206-29D bolt
control tube with nylon strap. and MS17826-6 nut as follows:
(6). 500N Only: Install splitter bungee (a). Install bolt, with one AN960KD616L
spring. washer through clevis assembly.
Page 404
MAINTENANCE MANUAL
(b). Install AN960KD616L washer and NOTE: The Fan Pitch Control Tube can be re
nut and torque to 95—110 inch- moved in either one of the following steps.
pounds (10.73—12.43 Nm); install The fan assembly pitch bearing slider, pitch
MS24665-285 cotter pin. bearing retainer, pitch plate bearings and
bearing retainer nut with aft control tube
(4). Install lower bolt at link assembly and can be removed as a unit or individually.
bellcrank clevis, and upper bolt inter Use extreme care do not damage parts.
mediate control tube Sta. 137.50
bellcrank bolts as follows: (1) Remove locking wire and remove nut and
lock washer from fan pitch control tube.
NOTE: Install bolt-head up, nut facing down. Remove locking wire and remove three
bolts and washers from pitch bearing re
(a). Depress pin in head of bolt to install tainer housing. Pitch bearing slider, pitch
bolt through clevis end of bellcrank. plate bearings and, bearing retainer nut
NOTE: In the following step, pin is to remain with aft control tube can be removed as a
depressed while nut is torqued. unit.
(2) Remove locking wire and remove six pitch
(b). While pin is depressed, install nut
bearing housing assembly bolts. Remove
and torque to 40—50 inch-pounds
pitch bearing retainer housing assembly
(4.52—5.65 Nm).
as a unit.
(c). Release pin and retorque nut to
75—90 inch-pounds (8.47—10.17 B. Fan Pitch Control Tube Installation
Nm) to ensure engagement of locking NOTE:
balls with nut.
D Refer to Fan Pitch Control Rigging during
NOTE: Pin must be in the released position installation.
(flush with bolt head) and bolt must pro
trude past the nut for proper installation. D Before installing fan pitch control tube, do
a Fan Pitch Control Tube Inspection.
(d). Apply torque stripe.
(1). Install the aft control tube.
(5). Install alternate NAS6204-11D bolt
and MS17826-4 nut as follows: (2). Install convoluted boot on fan gearbox
or clevis.
(a). Install bolt, with one AN960KD416L
washer through clevis assembly. NOTE: In the following step, clevis should be
bottomed into control tube, approximately
(b). Install AN960KD416L washer and one thread showing after engagement.
nut and torque to 20—40 inch-
pounds (2.26—4.52 Nm); install (3). Install clevis assembly on aft control
MS24665-134 cotter pin. tube. Ensure that clevis has full thread
(6). Install four support bracket assembly engagement on control tube.
bolts and washers to fan transmission (4). Ensure locking washer tang tip is in
support. Torque bolts to 70—90 inch- slot. Tighten jam nut against locking
pounds (7.91—10.17 Nm); safety wire washer and safety wire from lock to
bolts. nut. Ensure safety wire pigtail is on the
nut.
8. Fan Pitch Control Tube Replacement
A. Fan Pitch Control Tube Removal (5). Install floating bushing in clevis.
(1). Remove tail boom fairing and tail (6). Install bolt, bolthead on floating
boom. bushing side of clevis, through clevis
and link assembly as follows:
(2). Remove bolt and clevis assembly at
Sta. 137.50 bellcrank. Remove convo (a). Depress pin in head of bolt to install
luted boot from fan gearbox. bolt through clevis end of bellcrank.
Page 405
MAINTENANCE MANUAL
NOTE: In the following step, pin is to remain of three threads protruding beyond the
depressed while nut is torqued. face of the jam nut.
(b). While pin is depressed, install nut (13). Install two lockwires on jamnut and
and torque to 40—50 inch-pounds lockwasher.
(4.52—5.65 Nm).
NOTE: After safety wiring nut and bolts, rotate
(c). Release pin and retorque nut to fan and ensure that safety wires do not have
75—90 inch-pounds (8.47—10.17 interference with each other on rotation.
Nm) to ensure engagement of locking
balls with nut. (14). Install tail boom (Ref. Section
53-40-30).
NOTE: Pin must be in the released position
(flush with bolt head) and bolt must pro 9. Forward Cable Assembly Replacement
trude past the nut for proper installation. (Ref. Figure 402)
(d). Apply torque stripe. A. Forward Cable Assembly Removal
(7). Install alternate NAS6204-11D bolt To prevent damage to the en
and MS17826-4 nut as follows: CAUTION gine install F.O.D. cover over
(a). Install bolt, with one AN960KD416L engine air inlet.
washer through clevis assembly. (1). Remove fairings, access doors and
(b). Install AN960KD416L washer and panels necessary to facilitate mainte
nut and torque to 20—40 inch- nance (Ref. Section 53-30-30).
pounds (2.26—4.52 Nm); install (2). Remove tailboom fairing.
MS24665-134 cotter pin.
(3). Disconnect the aft end of the anti-
NOTE: Before installing fan pitch slider, do a torque control cable by turning outside
Fan Pitch Slider Inspection. collar sleeve counter-clockwise and
back to expose the inner cable.
(8). Install pitch bearing slider and bearing
retainer per rigging instructions. (4). Apply sufficient right pedal to expose
inner cables.
(9). Install pitch bearing and pitch bearing
retainer housing using three bolts and (5). Without bending cable, slide male
washers. Torque bolts to 70—80 connector out of female connector.
inch-pounds (7.91—9.04 Nm); safety
wire bolts. (6). Disconnect cable assembly forward
rodend from Sta. 113.00 splitter
(10). Install lockwasher so that the face of assembly outboard bellcrank clevis.
the tang aligns with the tube assembly
keyway, and the lockwasher aligns with (7). Loosen jam nut at rodend and remove
one of the six slots in the face of the rodend from cable; remove jam nut.
bearing retainer. (8). Remove safety wire, jam nuts and
(11). Install jamnut on aft control tube. washers from cable assembly support
bracket, remove by pulling or sliding
(12). Torque nut to 95—110 inch-pounds cable assy. thru conduit and support
(10.73—12.43 Nm) leaving a minimum bracket.
Page 406
MAINTENANCE MANUAL
CABLE ASSY
INTERMEDIATE
SPLITTER ASSY TUBE ASSY
FORWARD
TUBE ASSY
STA. 137.50
BRACKET
STA. 137.50
BELLCRANK
NOTE 2
NOTE 1
FAN PITCH
CONTROL TUBE
FLOATING
BUSHING
NOTES: ROTATED
1. CLEVIS FULLY ENGAGED INTO FAN LINK ASSY
PITCH CONTROL TUBE.
2. SAFETY FROM LOCKING WASHER TO NUT. G67-2008-1E
Figure 402. Upper Fuselage and Boom Control Linkage (Sheet 1 of 2)
Page 407
MAINTENANCE MANUAL
CLAMP
STA. 304.00
STA. 123.30
MD500N
FITTING
SUPPORT BRACKETS
STA. 131.50 AND 151.00
STA. 303.30
SUPPORT BRACKET AND CABLE MD600N
ASSY. TAILBOOM STA. 264.00
RIGHT CONTROL ROD

BELLCRANK
CENTER
INNER MALE BELLCRANK
INNER FEMALE CONNECTOR SHAFT
CONNECTOR
LEFT CONTROL ROD
MD600N
TORQUE TUBE
HOUSING
FORWARD-TO-CENTER
CABLE CONNECTION
MD500N
VERTICAL STABILIZER
CONTROL RODS
G67-2008-2D
Figure 402. Upper Fuselage and Boom Control Linkage (Sheet 2 of 2)
Page 408
MAINTENANCE MANUAL
B. Forward Cable Assembly Installation (b). Without bending cable, insert inner
male connector into inner female
connector and ensure they are
Consumable Materials properly engaged together.
Item Nomenclature (c). Slide outside cable collar over
CM702 Lockwire CRES forward cable to engage locking
device and turn clockwise until fully
locked.
Before installation of cable, in
CAUTION spect cable (Ref. Forward and (12). Verify rigging of cable assembly from
Center Cable Assembly Inspection). Sta. 113.00 splitter assembly (Ref.
Adjustment/Test).
(1). Install one jam nut and washer on
cable and insert cable assembly (13). Install fairings, access doors and panels
through support bracket and conduit. removed for installation.
(2). Install washer and one jam nut on 10. Center Cable Assembly Replacement
cable forward side of support bracket.
(Ref. Figure 402)
(3). Ensure that the threaded portion is
centered in the support bracket. A. Center Cable Assembly Removal
NOTE: When tightening cable jamnuts, ensure (1). Remove rotating thruster cone (Ref.
smooth action of cable and alignment of Section 53-40-30).
cable hex end into cable socket. (2). Remove stationary thruster cone (Ref.
Section 53-40-30).
(4). Ensure cable hex end and cable socket
are aligned to ensure smooth action. (3). Remove cotter pin, nut, washers and
bolt from clevis end of control rod
(5). Slide cable in and out to ensure there is double rodend.
no binding and tighten jamnuts.
(4). Disconnect cable assembly double rod
(6). Slide cable in and out again to ensure end bearing from center tailboom
there is no binding. If cable slides bellcrank.
smoothly, safety jamnuts (CM702).
(5). Remove double rod end from cable
(7). Install rodend bearing with locking assembly.
device and jamnut.
(6). Remove tailboom fairing.
(8). Ensure that threads protrude past
witness hole. Tighten jamnut and (7). Disconnect the forward end of the
safety wire nuts. anti-torque control cable by turning
forward cable outside collar sleeve
(9). Connect cable assembly forward rodend counter-clockwise and back to expose
to Sta. 113.00 splitter assembly the inner cable.
outboard bellcrank clevis.
(8). Apply sufficient right pedal to expose
(10). Torque nut and install cotter pin. inner cables.
(11). Reconnect forward and center control (9). Without bending cable, slide male
cable couplings. connector out of female connector.
Failure to properly connect (10). Disconnect cable assembly forward
WARNING thruster cables could result rodend from Sta. 113.00 splitter
in uncoupling during flight and loss of assembly outboard bellcrank clevis.
anti-torque authority.
(11). Remove safety wire and aft jamnut
(a). Apply sufficient right pedal to expose from cable assembly support bracket.
inner cable female connector. Cable assembly can be removed by
Page 409
MAINTENANCE MANUAL
sliding or pulling cable assembly Failure to properly connect

through support bracket and conduit WARNING thruster cables could result
and through grommet. in uncoupling during flight and loss of
anti-torque authority.
B. Center Cable Assembly Installation
(a). Apply sufficient right pedal to expose
Before installation of cable, in inner cable female connector.
CAUTION spect cable (Ref. Forward and (b). Without bending cable, insert inner
Center Cable Assembly Inspection). male connector into inner female
connector and ensure they are
(1). Install one jam nut and washer on properly engaged together.
cable and route cable assembly thru
conduit of tailboom and thru support (c). Slide outside cable collar over
bracket. forward cable to engage locking
device and turn clockwise until fully
(2). Install washer and jamnut on cable aft locked.
side of support bracket. (11). Verify rigging of cable assembly from
Sta. 113.00 splitter assembly to vertical
(3). Ensure that the threaded portion is stabilizers is correct.
centered in the support bracket.
(12). Install stationary thruster cone.
NOTE: When tightening cable jamnuts, ensure
smooth action of cable and alignment of (13). Install rotating thruster cone.
cable hex end into cable socket. 11. Aft Control Rod Assembly Replacement
(4). Ensure cable hex end and cable socket (Ref. Figure 402)
are aligned to ensure smooth action.
A. Aft Control Rod Assembly Removal
(5). Slide cable in and out to ensure there is (1). Remove thruster cone (Ref. Section
no binding and tighten jamnuts. 53-40-30).
(6). Slide cable in and out again to ensure (2). Remove stationary thruster cone (Ref.
there is no binding. If cable slides Section 53-40-30).
smoothly, safety jamnuts (CM702). (3). Remove cotter pin, nut and washer
from sector input shaft.
(7). Install double rodend bearing with
locking device and jamnut. (4). Remove pan cover.
(5). Remove cotter pin, nut, washers and
(8). Ensure that threads protrude past
bolt from clevis end of control rod at
witness hole. Tighten jamnut and
double rodend bearing of tailboom
safety wire nuts.
center cable assembly.
NOTE: The split bushing is installed at the top (6). Remove and discard lockwire and then
of bellcrank. A minimum of 0.010 inch remove control rod bolt from sector
(0.254 mm) and a maximum of 0.060 inch assembly.
(1.524 mm) split bushing protrusion re
quired above surface. (7). Remove control rod.
B. Aft Control Rod Assembly Installation
(9). Install double rodend bearing and
forward bearing to bellcrank with bolt,
washers and nut. Tighten nut and Consumable Materials
install cotter pin. (Ref. Section 91-00-00)
Item Nomenclature
(10). Reconnect forward and center control CM702 Lockwire CRES
cable couplings.
Page 410
MAINTENANCE MANUAL
NOTE: Split bushing is installed at the top, (6). Remove control rod bolt from sector
shoulder bushing is installed at bottom. A assembly and lift sector assembly from
minimum of 0.010 inch (0.254 mm) and shaft.
maximum of 0.060 inch (1.524 mm) split
bushing protrusion required above surface. (7). Remove clevis pins from sector assem
bly and remove cables.
(1). Connect thruster control rod clevis end
B. Sector Assembly and Control Cable
to double rod end aft bearing of center
Installation
cable assembly.
(2). Install washer and bushing on bolt and Consumable Materials
then insert through rod end into sector (Ref. Section 91-00-00)
assembly. Item Nomenclature
(3). Torque bolt to 30—40 inch-pounds CM702 Lockwire CRES
(3.39—4.52 Nm) and install safety wire
(CM702). (1). Position the cable assembly around
thruster sector bellcrank, install cable
(4). Install bushings, bolt, washer and nut; clevis pins and cotter pins.
(3.39—4.52 Nm) and install cotter pin. (2). Install sector bellcrank on input shaft.
(5). Install pan cover. (3). Connect sector assembly aft control rod
to clevis.
(6). Install washer and nut on sector input
shaft; torque nut to 95—110 inch- (a). Install washer and bushing on bolt
pounds (10.73—12.43 Nm) and install and then insert through rod end into
cotter pin. sector assembly.
(b). Torque bolt to 30—40 inch-pounds
(7). Install stationary thruster cone.
(3.39—4.52 Nm) and install safety
(8). Install rotating thruster cone. wire (CM702).
(4). Install bushing, washer on sector input
12. Sector Assembly and Control Cable shaft.
Replacement
(5). Install pan cover.
(Ref. Figure 401)
(6). Install washer and nut on sector input
A. Sector Assembly and Control Cable shaft; torque nut to 95—110 inch-
Removal pounds (10.73—12.43 Nm) and install
cotter pin.
Section 53-40-30). (7). Install rotating thruster cone.
NOTE: Removed safety clips from turnbuckles (8). Do a rigging check.

are not to be reused.
13. Drum Assembly and Idler Pulley
(2). Disconnect cables from turnbuckles in Replacement
access hole provided (top of stationary (Ref. Figure 401)
cone).
A. Drum Assembly and Idler Pulley
(3). Remove cotter pin, nut and washers Removal
from sector input shaft.
(4). Remove pan cover. Section 53-40-30).
(5). Remove washer and bushing under pan NOTE: Removed safety clips from turnbuckles
cover from sector bellcrank input shaft. are not to be reused.
Page 411
MAINTENANCE MANUAL
(2). Disconnect cables from turnbuckles in (2). Install drum assembly on shaft and
access hole provided (top of stationary install guard pins.
cone).
(3). Install HS306-233H flat washer
(3). Remove cotter pin, nut and two wash against the bearing.
ers, remove drum assembly from shaft. (4). Install washer and nut; torque nut to
160—190 inch-pounds (18.08—21.47
(4). Remove guard pins to remove cable Nm) and install cotter pin.
assemblies.
(5). Install turnbuckles and cables.
B. Drum Assembly and Idler Pulley
Installation (500N) (6). Do a rigging check.
(7). Install rotating thruster cone.
NOTE: The long cable is 23.07 inches (58.60
cm) and is installed on the aft cable guide of 14. Anti−Torque Pedal Friction Replacement
the drum, or right side, up and around the (Ref. Figure 403)
right idler pulley. The short cable is 22.82
inches (57.96 cm) long and is installed on A. Anti−Torque Pedal Friction Removal
the fwd cable guide of the drum, or left side, (1). Remove bolt, washer and bushing from
up and round the left idler pulley. console support bracket.
(1). Install cables on drum assembly. (2). Remove nut and washers, remove
spring, retainer, spring and friction
(2). Install drum assembly on shaft and disc, and link.
install guard pins.
(3). Remove brace and clamp arm assembly
(3). Install HS306-233H flat washer from anti-torque tube assembly.
against the bearing. B. Anti−Torque Pedal Friction Installation
(4). Install washer and nut; torque nut to (1). Using two pieces of wood and C-clamp
160—190 inch-pounds (18.08—21.47 or rope, secure pilot's pedals in mid
Nm) and install cotter pin. position so they are aligned within 0.50
inch (1.27 cm) of each other.
(5). Install turnbuckles and cables.
(2). Install washer, bolt, bushing, and link
(6). Do a rigging check. assembly to bracket assembly on
instrument console.
(7). Install rotating thruster cone.
(3). Install brace and clamp arm assembly
C. Drum Assembly and Idler Pulley to anti-torque tube assembly.
Installation (600N)
(4). Install friction disc, link, retainer and
NOTE: The long cable is 23.76 inches (60.35 spring, install washer (shim washers if
cm) long and is installed on the aft cable required) and nut.
guide of the drum, or right side, over and (5). Torque brace and arm assembly bolts
around the left idler pulley. The short cable 30—35 inch-pounds (3.39—3.95
is 23.51 inches (59.72 cm) long and is in Nm). Torque nut against washer to
stalled on the fwd cable guide of the drum, obtain a pedal friction of 5—8 pounds
or left side, over and round the right idler (2.27—3.63 kg).
pulley.
15. Anti−Torque Pedal Assembly
(1). Install cables on drum assembly as Replacement
follows:
(Ref. Figure 403)
(a). Install left cable on forward groove of A. Anti−Torque Pedal Assembly Removal
drum and cross over to right pulley.
(1). Pull two hinge pins from pilot's com
(b). Install right cable on aft groove of partment floor access door hinges and
drum and cross over to left pulley. remove door.
Page 412
MAINTENANCE MANUAL
STA. 97.50 BELLCRANK
STA. 97.50
(TUNNEL-ROUTED)
CONTROL ROD
INITIAL CONTROL ROD ANTI-TORQUE PEDAL

LENGTH - BEFORE RIG CONTROLS SUPPORT
FRICTION BRACKET
CONTROL DIMENSION L
ROD INCHES (CM)
TUNNEL-ROUTED 57.95 (147.193)
FLOOR-ROUTED 30.06 (76.3524) SPRING FITTING
AFT EYEBOLT
RIVET STA. 63.00 TAIL ROTOR
BUNGEE IDLER BELLCRANK
SPRING
NOTE 2
FORWARD EYEBOLT
L
NOTE 1
MAXIMUM ALLOWABLE AXIAL NOTE 2 FLOOR-ROUTED
PLAY 0.040 IN. (1.016 MM) CONTROL ROD
NOTE 3
TORQUE TUBE BUSHING
* TORQUE TUBE BRACKET ASSY (NOTE 4)
(NOTE 5)
CONTROL ROD FITTING NOTE NOTE
1 3
NOTE 1
PIN
WASHER
NOTE 4
* LEFT PEDAL
BEARING NOTE
1
STOP BOLT
* RIGHT PEDAL
JAMNUT BEARING
NOTE 2
* PEDAL ARM NOTE 3
NOTE 1
BUSHING * PEDAL ARM
(TEFLON-LINED) NOTE 1
NOTE 4 * PEDAL BRACKET
NOTE 2
NOTES:
BUSHING 1. SHIM BETWEEN BRACKET AND BULKHEAD WITH AN960PD416
(TEFLON-LINED) AND/OR -416L WASHERS AS REQUIRED FOR ALIGNMENT WITHIN
0.010 IN. (0.254 MM).
BUSHING ASSY 2. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF 0.010 IN.
(NOTE 4) (0.254 MM) TO A MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE OUTSIDE
NOTE 2 LINK SURFACE OF PART AFTER NUT IS TIGHTENED.
3. DIRECTION OF BOLTS IS OPTIONAL.
4. ADJUSTABLE BUSHINGS MUST HAVE A MINIMUM PROTRUSION OF
0.002 IN. (0.051 MM) AT EACH END.
5. INSTALLED WITH BEARING RECESS FACING FITTING.
BEARING NOTE 2 6. ASTERISK (*) INDICATES PART THAT MAY BE EITHER MAGNESIUM OR
ALUMINUM ALLOY. FOR ALLOY IDENTIFICATION AND CORROSION
BELLCRANK CONTROL REF. SEC. 20-40-00.
G67-2001-3
Figure 403. Pedal Installation (Sheet 1 of 2)
Page 413
MAINTENANCE MANUAL
STOP BOLT (2)

RIGHT POSITION
ANTI-TORQUE PEDALS
NOTE 1
JAMNUT
ADJUSTABLE
BUSHING ASSEMBLY NOTE 2
(NOTE 4)
NOTE 3
SLOTTED BUSHING
(TYPICAL) (NOTE 2)
TORQUE TUBE
SLEEVE
ADJUSTABLE BUSHING TORQUE TUBE

ASSEMBLY (NOTE 4)
G67-2001-4
Figure 403. Pedal Installation (Sheet 2 of 2)

(2). Remove access panel from each side of simplify torque tube alignment during
instruction panel lower support struc reinstallation.
ture.
(8). Remove four nuts, eight washers, any
(3). Remove battery (Ref. Section shims washers and four bolts that
96-00-00). secure pedal bracket to bulkhead.
(4). Remove pins securing pedals to pedal (9). Remove control pedal installation. Keep
arms and remove pedals. shim washer selection with bracket for
reinstallation.
(5). Remove pedal friction mechanism. B. Anti−Torque Pedal Assembly Installation
(6). Remove cotter pin, nut, two washers (1). Install pedal bracket with four bolts,
and bolt that connect floor-routed eight washers and four nuts.
control rod to torque tube fitting.
(2). Add shim washers as required at pedal
(7). Remove two nuts, four washers, any bracket attachment points to keep
shim washers and two bolts that secure centerline alignment of pedal bracket
torque tube bracket to bulkhead. Keep bearings within 0.010 inch (0.254 mm).
shim washer selection with bracket to Correct alignment is indicated by free
Page 414
MAINTENANCE MANUAL
rotational movement of torque tube (4). Disconnect actuator control tube from
after nuts are torqued with no evidence vertical stabilizer torque tube bell
of binding. crank.
(3). Position the torque tube bracket over (5). Remove RH vertical stabilizer torque
the mating holes in the bulkhead tube bellcrank.
NOTE: Observed and note position of vertical
(a). Do an alignment check with the
stabilizer bellcrank for reinstallation pur
bulkhead.
poses.
(4). As necessary, add shim washers at the (6). Remove vertical stabilizer torque tube
bracket attachment points to keep the (Ref. Section 53-50-30, Vertical
bearing alignment established in Step Stabilizer Torque Tube and/or Bushing
15.B.(2). Replacement).
(a). Install two bolts, four washers, and (7). Disconnect electrical connector from
two nuts. actuator.
(5). Make sure that the slotted bushing is (8). Disconnect S.A.S. actuator from control
in place. rod.
(9). Remove bolts from actuator support
(6). Install the floor-routed control rod in bracket and carefully slide actuator out
torque tube fitting with bolt, two of access hole.
washers, nut, and cotter pin.
B. S.A.S. Actuator Installation
(a). The split bushing protrusion must be
between 0.010 inch (0.25 mm) NOTE: Whenever S.A.S. actuator or control
minimum and 0.060 inch (1.52 tube is replaced, S.A.S. rigging must be
mm) maximum above the surface. done.
(1). Slide the actuator through the access
(7). Install the anti-torque pedal friction panel and attach the actuator to the
mechanism. support bracket.
(8). Do a check of the rigging of pedal (2). Install the vertical stabilizer torque
assembly controls and pedal-to-canopy tube (Ref. Section 53-50-30, Vertical
clearance. Stabilizer Torque Tube Replacement).
(a). The pedals must clear the windows (3). Connect the actuator control tube to the
by 0.020 inch (0.51 mm) minimum vertical stabilizer torque tube bell
with a 20 pound (9.0718 kg) force crank.
applied. (a). Torque the nut 30—40 inch-pound
16. Stability Augmentation System (S.A.S.) (3.39—4.52 Nm).
Actuator Replacement (b). Install the cotter pin.
(Ref. Figure 505) NOTE: Care should be observed to position ver
tical stabilizer bellcrank in the same posi
A. S.A.S. Actuator Removal tion as removed.
(1). Disconnect electrical power from (4). Install the upper and lower RH vertical
aircraft. Make sure that battery power stabilizers (Ref. Section 53-50-30,
is disconnected. Vertical Stabilizer Replacement).
(2). Remove horizontal stabilizer center (5). Connect the electrical connector to the
access panels and RH end cap access actuator.
cover. (6). Do a S.A.S. actuator rigging check (Ref.
Stability Augmentation System Rigging
(3). Remove the upper and lower RH Instructions).
vertical stabilizers (Ref. Sec. 53-50-30,
Vertical Stabilizer Replacement). (7). Install access panels.
Page 415
MAINTENANCE MANUAL
17. SAS Rate Gyro and Electronic Control (4). Carefully remove component from rack.
Box (Computer) Replacement
B. SAS Rate Gyro and Electronic Control
Access to the rate gyro and electronic control Box (Computer) Installation
box (computer) is through the passenger
compartment footwell access panels. (1). Install component on rack.
The units are mounted on a rack under the (2). Reinstall mounting hardware.
pilot's seat structure against the seat structure (a). Torque screws 12—15 inch-pound
forward panel. (1.36—1.69 Nm) plus drag torque.
D The 500N has the components mounted (3). Connect electrical plug.
approximately 12 inch (30.48 cm) to the
right of centerline. (4). Install passenger compartment footwell
fairing (Ref. Section 52-50-00).
D The 600N has the components mounted
approximately 12 inch (30.48 cm) to the 18. YSAS Circuit Breaker and Switch
left of centerline. Replacement
A. SAS Rate Gyro and Electronic Control (Ref. Figure 404)
Box (Computer) Removal
The YSAS circuit breaker and switch are
(1). Remove appropriate passenger com located in the circuit breaker and switch panel
partment footwell fairing (Ref. Section of the instrument panel.
52-50-00).
(1). Replace the YSAS circuit breaker and
(2). Disconnect and remove electrical plug. switch, if there is damage (Ref. CSP-
HMI-3, Section 96-30-00, Circuit
(3). Remove mounting hardware. Breaker and Switch Replacement).
60 50
START ANTI−COLL PITOT

BAT
PUMP LT HTR YSAS
FIN
O YSAS
F
F L R
EXT PWR BRT
OFF LT D OFF OFF OFF
N
WA R
I M
P
SCAV U
S POS ANTI−ICE UTIL OVSPO FAULT
GEN AIR H LT PWR TEST TEST
OFF
OFF OFF OFF OFF OFF OFF
YSAS
YSAS CIRCUIT
BREAKER SWITCH
G67-2030-404-1
Figure 404. YSAS Circuit Breaker and Switch Location
Page 416
MAINTENANCE MANUAL

ADJUSTMENT/TEST
1. Directional Controls Rigging (3). Assemble the pitch plate control
bearing into slider and attach the
NOTE: bearing retainer plate using three bolts
and three washers.
D On the 500N, directional control rigging
is to be accomplished with the (Sta.
113.00) spring on the splitter assembly (4). Torque bolts to 70—80 inch-pounds
disconnected. (7.91—9.04 Nm) and safety (CM702).
D The NOTARR control system must be re- NOTE: Every 60° turn on bearing retainer is
rigged after replacement of control rods, equivalent to 0.6 degree change in fan pitch
linkages, and components or if helicopter angle.
operation reveals a rigging deficiency.
(5). Using the TICK marks on the fan blade
2. Fan Pitch Control Rigging assembly and on hub housing to
determine blade pitch angle, adjust
(Ref. Figure 501) bearing retainer to obtain a fan blade
pitch angle of 25—27° (View D).
NOTE:
Item Nomenclature D The aft control tube keyway should be in
CM702 Lockwire CRES stalled at the 12 O'clock position for ease
of installation.
Special Tools D Ensure that one of the six slots in the face
(Ref. Section 91-00-00) of the bearing retainer aligns with fan
Item Nomenclature pitch-aft control tube key way (View C).
ST601 Rigging pin
(6). Install lockwasher so that the face of
the lockwasher aligns with one of six
NOTE: Fan Pitch Control Rigging shall be ac slots of the bearing retainer.
complished with the tailboom and engine air
inlet fairings removed. (7). Install jam nut, torque nut to 95—110
inch-pounds (10.73—12.43 Nm)
(1). Position Sta. 113.00 splitter assembly leaving a minimum of three threads
pinion gear so the rigging slot aligns protruding beyond the face of the jam
with lower rigging hole in the bracket nut.
assembly; Insert the rigging pin
(ST601) (View A). (8). Check tick marks on fan blade assem
bly and hub housing, ensure that fan
(2). Adjust the bearing retainer so the pitch angle is 25—27°. If blade pitch is
flange of bearing retainer is screwed in 25—27°, proceed to step (9). If not,
on the tube assembly until it just remove jamnut and lockwasher and
touches the shoulder of the fan pitch- return to steps (5).
aft control tube (View B).
(9). Safety wire (CM702) nut and lockwash
NOTE: A gap of 0.015—0.025 inch er (2 places required).
(0.381—0.635 mm) between pitch bearing
housing and bearing retainer plate must (10). Rotate fan to ensure the safety wire
exist to ensure proper clamp-up. does not interfere.
Page 501
MAINTENANCE MANUAL
UPPER RIGGING
HOLE
FWD CONTROL
CABLE
SEVENTEEN TO SEVENTY-SEVEN BRACKET

DEGREES AT 5° INCREMENTS ASSY
PINION GEAR
LOWER RIGGING 500N9901
TICK MARKS HOLE RIGGING TOOL
26° ±1° FAN C/L
FAN HUB ASSY SPLITTER ASSEMBLY
77° 17°
RIGGING LOCATION
FAN BLADE ASSY

BEARING RETAINER
TICK MARK LOCATION ASSEMBLY
ON FAN ASSEMBLY PITCH PLATE CONTROL
BEARING
ONE OF SIX BEARING

SLOTS RETAINER
FAN PITCH
CONTROL TUBE SLIDER
FAN PITCH CONTROL BEARING RETAINER

TUBE ASSY LOCATION
KEYWAY TUBE
BEARING RETAINER SLOT

AND KEYWAY ALIGNMENT
G67-2010
Figure 501. Fan Pitch Control Rigging
Page 502
MAINTENANCE MANUAL
NOTE: they are aligned (View A). Maximum

D If the required adjustment of bearing re misalignment between pedals shall be
tainer, lockwasher and jamnut cannot be 0.50 inch (1.27 mm).
achieved, adjust the intermediate control
NOTE: Do not adjust the control rod beyond the
tube to meet requirements of specifica
witness hole. Do not tighten the locking
tions in steps (5). thru (10).
jamnut until after final adjustment.
D Do not adjust the control rodend beyond
the witness hole. Do not tighten jam nut (3). Anti-torque idler bellcrank position to
until after final adjustment. be checked as follows:
(11). Remove rigging pin. (a). Position pilot's foot pedals in neutral
and floor-routed control rod length
(12). Fan Pitch Control Rigging shall (initial control rod length is 30.06
produce the following results: inches (76.35 cm) before rigging).
(a). 500N:
(b). Adjust floor-routed control rod so
1). Full left pedal, 69—73 degrees. that centerline of bellcrank arm is
88—92° degrees to Sta. 78.50 canted
2). Full right pedal, 50—54 degrees. bulkhead (View B).
(b). 600N; (c). Sta. 97.50 bellcrank: Adjust the
1). Full left pedal, 71—75 degrees. tunnel-routed control rod so the
centerline of the tunnel-routed
2). Full right pedal, 52—56 degrees. control rod attach bolt in the transfer
bellcrank is 4.21—4.39 inches
NOTE: On the 600N helicopter, the pedal po (10.69—11.15 cm) above mast base
tentiometer rigging must be checked any structure (View C).
time the anti-torque system has been ad
justed. (4). Check witness holes for proper thread
engagement.
3. Pilot Pedal Rigging
(5). Tighten jamnuts and safetywire
(Ref. Figure 502) (CM702) as required.
Consumable Materials (6). Adjust rodends on the forward control

(Ref. Section 91−00−00) tube so the rigging pin can be inserted
Item Nomenclature into the bracket assembly upper hole
CM702 Lockwire CRES
and through the slot marked ``M” in the
gear pinion rack Sta. 113.00 splitter
assembly (View D).
NOTE: Directional control rigging shall be ac
complished with the (Sta.113) splitter (7). Remove rigging pin and remove
spring assembly disconnected (500N) and clamping device from foot pedal arms.
the fan pitch control rigging complete.
Use care when actuating pedals
CAUTION to avoid damaging tool or wind
(1). Remove left-hand air inlet fairing to
facilitate pedal rigging (Ref. Section shield.
53-30-30).
(8). Loosen jamnuts on pedal stop-bolts
Remove pilot's pedals and copi (View A).
CAUTION lot's (if installed) to prevent pos
sible contact with lower windshield during (9). Screw in pedal stop-bolts approximate
rigging sequence. ly 0.5 inch (12.7 mm).
(2). Using two pieces of wood and C-clamp (10). Adjust left-hand stop-bolt in the pilot's
or rope, secure pilot's foot pedal arms so pedal support.
Page 503
MAINTENANCE MANUAL
MID PEDAL FWD CONTROL

RIGGING HOLE TUBE
FWD CABLE
ASSEMBLY
FULL RIGHT
PEDAL RIGGING
HOLE
FULL LEFT PEDAL

RIGGING HOLE
RIGGING PIN
LOWER
STA 97.50 RIGGING HOLE
BELLCRANK
FULL LEFT PEDAL AND FULL RIGHT PEDAL
MIDTRAVEL RIGGING LOCATIONS
STA 113.00 SPLITTER ASSEMBLY
MAST BASE
4.30
±0.090
STA 78.50 (TUNNEL STA 78.50 (TUNNEL

ROUTED CONTROL ROD) ROUTED CONTROL ROD)
0.50 INCH MAXIMUM

MISALIGNMENT
BETWEEN PEDALS CONTROLS SUPPORT
BRACKET
STA 78.50
CANTED BULKHEAD
CLAMPING BLOCKS
90°+ 2°
RIGHT STOP BOLT

ANTI TORQUE
JAM NUT IDLER BELLCRANK
LEFT STOP BOLT JAM NUT

FLOOR MOUNTED
CONTROL ROD
PEDAL ARM ALIGNMENT AND

STOP BOLT ADJUSTMENT
G67-2011
Figure 502. Pilot Pedal Rigging
Page 504
MAINTENANCE MANUAL
(11). Apply full left pedal until the rigging 5. Thruster Control Rigging (500N)
pin can be inserted through the bracket
assembly upper hole and into the slot (Ref. Figure 503)
marked ``L'' in the gear pinion rack Sta.
113.00 splitter assembly (View D). Consumable Materials
(12). Adjust the left-hand stop-bolt in the Item Nomenclature
pilot's pedal support so that the stop
CM702 Lockwire CRES
just comes in contact with the link
assembly (View A).
Special Tools
(13). Remove the rigging pin assembly and (Ref. Section 91-00-00)
adjust right-hand stop-bolt in the Item Nomenclature
pilot's pedal support. ST601 Rigging pin
(14). Apply full right pedal until the rigging
pin assembly can be inserted through NOTE:
the bracket assembly upper hole and D Thruster control rigging to be accom
into the slot marked “R” in the gear plished with the splitter spring installed,
pinion rack Sta. 113.00 splitter assem the fan pitch control rigging completed,
bly (View D). the tailboom sector control rod assembly
(15). Adjust the right-hand stop-bolt in the and stationary thruster cone installed.
pilot's pedal support so that the stop D Do not adjust the control rodend beyond
just comes in contact with the link the witness hole, do not tighten jamnuts
assembly (View A). until after final adjustment.
NOTE: For dual installation, adjust the stop- (1). Insert rigging pin (ST601) into the
bolts in the co-pilot's support bracket to bracket assembly lower rigging hole
match the pilot's pedal travel. Repeat steps and through the slot on the pinion gear
(11). thru (13). rack Sta. 113.00 splitter assembly (View
D).
4. Anti−Torque Pedal Friction Installation
and Adjustment (2). Removed pan cover.
(3). Adjust rodend until it can be attached
(Ref. Figure 403)
to input clevis of sector assembly (View
(1). Using two pieces of wood and C-clamp C).
or rope, secure pilot's pedals in mid (4). Connect sector clevis control rod.
position so they are aligned within 0.50
inch (1.27 cm) of each other. (5). Install bushing, washer and bolt.
Torque bolt 30—40 inch-pounds
(2). Install washer, bolt, bushing, and link (3.39—4.52 Nm). Safety wire (CM702)
assembly to bracket assembly on bolt (Ref. Anti-Torque Flight Control
instrument console. Installation).
(3). Install brace and clamp arm assembly (6). Remove rigging pin from splitter
to anti-torque tube assembly. assembly.
(4). Install friction disc, link, retainer and NOTE: Removed safety clips from turnbuckles
spring, install washer (shim washers if are not to be reused.
required) and nut.
(7). Remove safety clips and adjust the two
(5). Torque brace and arm assembly bolts turnbuckles until a second rigging pin
30—35 inch-pounds (3.39—3.95 (ST601) can be inserted through a slot
Nm). Torque nut against washer to in the output drum assembly and
obtain a pedal friction of 5—8 pounds through holes in drum output support
(2.27—3.63 kg). (View A and B).
Page 505
MAINTENANCE MANUAL
CABLE
SAFETY CLIPS
500N
500N
CABLE
SAFETY CLIPS
600N
600N
G67-2014-1
Figure 503. Thruster Control Rigging (Sheet 1 of 2)
Page 506
MAINTENANCE MANUAL
RIGGING PIN
INPUT SECTOR
PAN COVER
ROD ASSEMBLY
PAN
RACK GEAR
ROTATING STATIONARY
THRUSTER CONE THRUSTER CONE
SLOT
0.00 +0.25 IN.
PINION GEAR (0.00 +6.4 MM) VIEW LOOKING FORWARD
RIGGING PIN
600N THRUSTER OPENING
G67-2014-2C
Figure 503. Thruster Control Rigging (Sheet 2 of 2)

(8). Using a cable tensiometer, adjust cable (12). Safety wire (CM702) bolts.
tension to 20—40 pounds (9.07—18.14
kg). (13). Thruster Control Rigging shall produce
the following results:
NOTE: Removed safety clips from turnbuckles
are not to be reused. (a). Full left pedal; rotating thruster cone
to be fully open to the left side of the
(9). Install safety clips in turnbuckles. tailboom.
(10). Remove rigging pins. (b). Full right pedal; rotating thruster
cone to be open a minimum of 11.80
(11). Install rotating thruster cone using inches (29.97 cm) when measured
three bolts and washers. Torque bolts from the lower edge of the right
70—90 inch-pounds (7.91—10.17 opening to the upper lip of the
Nm). rotating cone.
Page 507
MAINTENANCE MANUAL
6. Thruster Control Rigging (600N) (9). Remove rigging pins.
(Ref. Figure 503) (10). Install rotating thruster cone using

three bolts and washers.
Consumable Materials (11). Push full left pedal and verify bottom
(Ref. Section 91−00−00) edge of rotating thruster opening is
Item Nomenclature within 0.00 ±0.25 inch (0.0 ±6.4 mm) of
CM701 Lockwire CRES edge of stationary thruster cone (Ref.
Figure 503); adjust turnbuckles as
Special Tools necessary.
Item Nomenclature (12). Remove rotating thruster cone.
ST601 Rigging pin
(13). Verify cable tension.
NOTE: Do not adjust the control rodend beyond
the witness hole, do not tighten jamnuts un (14). Reinstall rotating thruster cone; Torque
til after final adjustment. rotating thruster cone bolts to 70—90
(1). Insert rigging pin (ST601) into bracket
assembly lower rigging hole and NOTE: On the 600N helicopter, the pedal po
through slot on the pinion gear Sta. tentiometer rigging must be checked any
113.00 splitter assembly (Ref. time the anti-torque system has been ad
Figure 503). justed.
(2). Removed pan cover. (15). Safety bolts with lockwire (CM701).
(3). Adjust rodend until it can be attached (16). Safety turnbuckles with clips.
to input clevis of sector assembly and
the rigging slot in input sector assem
7. Left Vertical Stabilizer Assembly Rigging
bly aligns with the rigging hole in pan.
(500N, and 600N with YSAS)
(4). Connect sector clevis control rod.
(Ref. Figure 504)
(5). Install bushing, washer and bolt.
Torque bolt 70—90 inch-pounds
(7.91—10.17 Nm). Safety bolt with
lockwire (CM701) (Ref. Anti-Torque
Item Nomenclature
Flight Control Installation).
CM702 Lockwire CRES
(6). Reinstall pan cover ensuring rigging
pin hole in pan cover aligns with Special Tools
rigging hole in sector assembly. If pin (Ref. Section 91-00-00)
cannot be inserted through fan cover, Item Nomenclature
sector assembly and pan, repeat above ST601 Rigging pin
steps.
(7). Adjust the two turnbuckles until a NOTE:

second rigging pin can be inserted D Rigging to be accomplished with the tail
through a slot in the output drum boom and vertical stabilizers, splitter as
assembly and through holes in drum sembly bungee spring and engine air inlet
output support. fairings installed.
(8). Using a cable tensiometer, adjust cable D Do not adjust the control rodend beyond
tension to 20—40 pounds (9.07—18.14 the witness hole, do not torque jamnuts
Kg) by adjusting the two turnbuckles. until after final adjustment.
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MAINTENANCE MANUAL
(1). 500N helicopters: Insert rigging pin (1). Turn OFF power supply, turn S.A.S.
(ST601) into the bracket assembly switch on the instrument panel to the
upper hole and into the slot marked OFF position.
``R'' in the gear pinion rack Sta. 113.00
splitter assembly (View A) splitter (2). Install the Yaw S.A.S (ST1013). Test
assembly upper hole. Box to the computer located and
mounted on the co-pilot's seat structure
(a). Adjust the left vertical stabilizer to forward bulkhead, the test box is now
6.0—7.0 degrees on the horizontal in series with the computer and
stabilizer degree plate (View C). actuator.
(3). Using the aircraft power supply or an
(b). Remove rigging pin.
external power source, activate S.A.S.
(2). 600N helicopters: With pedals set to full switch.
right position, adjust tip of the left (4). Adjust actuator to the fully extended
vertical stabilizer trailing edge to 12 position using the Yaw S.A.S. test box.
degrees.
(5). Turn aircraft power OFF, actuator
(3). Check witness holes for proper thread should remain in fully extended
engagement. Rodends are to be position.
installed equal distance on torque tube
to within 0.020 inch (0.508 mm) of each NOTE: The actuator and control tube can be
other. slid out the horizontal stabilizer end panel
far enough to remove safety wire and loosen
(4). Torque jamnuts 25—30 inch-pounds the jamnuts. The control tube can be rotated
(2.82—3.38 Nm). and adjusted similar to a turnbuckle.
(6). 500N helicopters: Using the top rig
(5). Safety jamnuts with lockwire (CM702).
plate, adjust right vertical stabilizer to
3.5—4.5 degrees.
8. Stability Augmentation System Rigging
Instructions (500N, and 600N with YSAS) (7). 600N helicopters: Using the top rig
plate, adjust top right vertical stabilizer
(Ref. Figure 505) to (-1.50)—(-2.00) degrees.
(8). After adjustment, slide actuator and
Consumable Materials control tube out far enough to torque
(Ref. Section 91−00−00) jamnuts 25—30 inch-pounds
Item Nomenclature (2.82—3.38 Nm).
CM702 Lockwire CRES
(9). Safety jamnuts with lockwire (CM702)
Special Tools (10). Reinstall actuator and control tube.

NOTE: On the 600N helicopter, the pedal po
Item Nomenclature
tentiometer rigging must be checked any
ST1013 Yaw S.A.S. test box time the anti-torque system has been ad
justed.
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MAINTENANCE MANUAL
HORIZONTAL
STABILIZER
VERTICAL STABILIZER
6.5° ±0.5 (LEFT)
INCEDENT
ANGLE
TOP VIEW
0°
500N9901
RIGGING PLATE
500N SHOWN
CONTROL TUBE
(LEFT) AFT CONTROL
ROD
STA 273.00
BELLCRANK
TOP VIEW
G67-20012A
Figure 504. Left Vertical Stabilizer Rigging (500N, and 600N with YSAS)
Page 510
MAINTENANCE MANUAL
0°
4.0±0.5 DEGREES
COMPUTER AND
RATE GYRO
VIEW LOOKING DOWN
RIGHT CONTROL ROD
S.A.S. ACTUATOR
STABILITY AUGMENTATION
SYSTEM
RIG PLATE
(VIEW LOOKING DOWN)
500N
G67-2015-1A
Figure 505. Stability Augmentation System S.A.S. (Sheet 1 of 2)
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MAINTENANCE MANUAL
0°
-1.75 ±0.25 DEGREES
BL 0.00
COMPUTER AND VIEW LOOKING DOWN

RATE GYRO
RIGHT CONTROL ROD
S.A.S. ACTUATOR
3 2 1 0 -1 -2 -3
3
2
1
0
1
2
37.07 IN.
3
(94.15 CM)
STABILITY AUGMENTATION
SYSTEM
RIG PLATE
(VIEW LOOKING DOWN)
BL 0.00
600N
G67-2015-2A
Figure 505. Stability Augmentation System S.A.S. (Sheet 2 of 2)
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MAINTENANCE MANUAL
10.5+0.5 14.5+0.5
DEGREES DEGREES
LEFT RIGHT
CONTROL CONTROL
TUBE TUBE
CL
LH RH
INCREASE PRESSURE L PEDAL INCREASE PRESSURE R PEDAL

DECREASE PRESSURE R PEDAL DECREASE PRESSURE L PEDAL
BOTTOM VIEW
DECREASE PRESSURE L PEDAL DECREASE PRESSURE R PEDAL
INCREASE PRESSURE R PEDAL INCREASE PRESSURE R PEDAL
TRIM TAB ADJUSTMENT

6G67-092-1A
Figure 506. Vertical Stabilizer Rigging (600N without YSAS)
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MAINTENANCE MANUAL
9. Vertical Stabilizer Assembly Rigging NOTE: On the 600N helicopter, the pedal po
(600N without YSAS System) tentiometer rigging must be checked any
time the anti-torque system has been ad
(Ref. Figure 506) justed.
10. Vertical Stabilizer Trim Tab Adjustment
Consumable Materials and Tool Manufacturing (600N without
(Ref. Section 91−00−00) YSAS)
Item Nomenclature
CM702 Lockwire CRES A. Trim Tab Tool Manufacturing
(Ref. Figure 507)
Special Tools
(1). Manufacture guide as follows:
Item Nomenclature (a). Cut guide from 0.130 inch (3.30 mm)
ST601 Rigging pin 2024-T3 aluminum sheet 7.00 inch
(17.78 cm) x 4.50 inch (11.43 cm).
NOTE: (b). Measuring 1.73 inch (4.39 cm) from

bottom, make V-cut in guide 1.030
D Rigging to be accomplished with the tail inch (2.62 cm) wide and 3.79 inch
boom and vertical stabilizers installed. (9.63 cm) deep.
D Do not adjust the control rodend beyond (c). File 0.070 inch (1.78 mm) wide x
the witness hole, do not torque jamnuts 0.260 inch (6.60 mm) deep slot in aft
until after final adjustment. end of V-cut.
(1). Insert rigging pin (ST601) into the (d). File smooth all surfaces of guide.
bracket assembly upper hole and into
the slot marked ``R'' in the gear pinion NOTE: Note the difference in the degree mark
rack Sta. 113.00 splitter assembly. ings between the top and bottom of the
guide.
(2). Push trailing edge of left vertical
stabilizer to the right using only enough (e). Etch degree marks in guide as
force to eliminate freeplay (5-lb (0.3 indicated in Figure 507.
Kg) max). (2). Manufacture angle tool as follows:
(3). Adjust control rod for the left vertical (a). Cut two plates from 0.130 inch (3.30
stabilizer to 10.0—11.0 degrees on the mm) 2024-T3 aluminum sheet 9.00
horizontal stabilizer degree plate. inch (22.86 cm) x 2.00 inch (5.08 cm).
(4). Push trailing edge of right vertical (b). Cut a spacer from 0.040 inch (1.016
stabilizer to the right using only enough mm) 2024-T3 aluminum sheet 9.00
force to eliminate freeplay, 5 lbs (0.3 inch (22.86 cm) x 1.00 inch (2.54 cm).
Kg) maximum. (c). File smooth all surfaces of spacer and
plates.
(5). Adjust control rod for the right vertical
stabilizer to 14.0—15.0 degrees on the (d). Chamfer one 9.00 inch (22.86 cm)
horizontal stabilizer degree plate. edge of each plate, 0.060 x 0.100 inch
(1.524 x 2.54 mm) (this will be the
(6). Remove rigging pin. front of the tool) as indicated in
Figure 507.
(7). Torque jamnuts 25—30 inch-pounds
(2.82—3.38 Nm). (e). Stack plates, chamfered edges facing
each other with spacer between
(8). Safety jamnuts with lockwire (CM702). plates and flush with aft side of
plates (un-chamfered edge).
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MAINTENANCE MANUAL
20°
10° 0.050 IN.
(12.70 MM)
0°
10° RIVETS
20° (4 PL)
THIS SIDE UP
9.00 IN.
(22.86 CM)
4.05 IN.
(10.29 CM)
3.79 IN.
(9.63 CM)
4.50 IN
(11.43 CM)
20°
10°
1.03 IN. (2.62 CM) 0°
10°
0.07 IN.
(1.78 MM) 20°
1.73 IN. 0.060-0.100 IN.
(4.40 CM) R (1.524-2.54 MM)
THIS SIDE DOWN 0.130 IN.
(3.302 MM)
MAX
7.00 IN. 0.040 IN.

(17.78 CM) (1.016 MM) 2.00 IN. 1.00 IN.
(5.08 CM) (2.54 CM)
GUIDE
6G67-092-2
Figure 507. Vertical Stabilizer Trim Tab Bending Tool

(f). Drill and rivet angle tool together, D Ensure there is no play between the
size and type of rivets optional. 500N7213-5 bellcrank assembly and the
500N7212-3 shaft.
B. Trim Tab Adjustment D Ensure there is minimal play between the
upper and lower vertical stabilizers.
(Ref. Figure 506) Adjust vertical stabilizer trim D When installing new upper vertical stabi
tabs to improve directional handling character lizers, if previous tab settings were not re
istics and to minimize pedal forces in forward corded, left trim tab should be set to zero
flight. degrees and right trim tab should be set
to 10° right (viewed looking forward from
For best results, aircraft should be weighted the rear).
down to normal operating weight during test D The right vertical stabilizer tends to af
flights while doing tab adjustments. fect pedal pressure more than the left.
The left vertical stabilizer tends to affect
NOTE: flight characteristics more than the right.
D Ensure vertical stabilizers are rigged cor
Left Vertical Tab Right Vertical Tab
rectly (Ref. Vertical Stabilizer Assembly
Rigging (600N)). 0° 10° Right
Page 515
MAINTENANCE MANUAL
(1). Determine which pedal requires excess (4). Bend tab in direction needed to relieve
pressure to attain proper trim during pedal pressure and improve flight
straight flight. characteristics.
NOTE: (5). Remove tab tools and fly aircraft, see
D Always adjust right vertical stabilizer chart below, to determine if pedal
trim tab first. If tab is bent to a maximum pressure was relieved.
of 20° before correct pedal pressure can be
achieved, go to left tab and continue ad (6). Repeat above steps until pedal pressure
justments. and handling characteristic are cor
D Limit tab adjustments to 5° increments rected.
between flights.
NOTE: After trim tab adjustments, position
D Exceeding 20° tab adjustments can cause guide on both the top and bottom of trim tab
a ”tail wag” condition. to ensure tab is straight.
(2). Position guide on right vertical
stabilizer over trim tab. (7). Log trim tab setting in log book.
(3). Position angle tool on trim tab.

Pedal Position Pedal Force
Do not bend tabs beyond 20° in
CAUTION either positive or negative direc
Hover
tion. Tabs and/or vertical stabilizer skin can *60 KIAS
be damaged. *80 KIAS
NOTE: *100 KIAS
D Bending tabs to the right will decrease *120 KIAS
left pedal pressure.
*130 KIAS
D Tab angles are acceptable when left pedal
NOTE: *Level flight
forces are between 2 and 5 lbs. (0.91 and
2.27 Kg) in stabilized flight and the flight Handling: Low pedal forces might require bending
characteristics are acceptable. tabs in opposite directions.
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MAINTENANCE MANUAL
Table 501. Flight Controls Troubleshooting

Pedal Kick−Thru or Binding
Noticeable hump in pedals (kick−thru) in flight.
yes ⇓
Are control cables Binding? no Is there binding in control rod at no Is there pedal binding in flight?
⇒ fan transmission? ⇒
yes ⇓ yes ⇓ yes ⇓
Replace worn or binding Adjust control rod for proper Check for dry roller bearings at
control cable(s). clearance. rotating cone.
Dutch Roll
Is there relative movement no Is there play when holding cone no Bend left tab to the left, starting
between upper and lower ⇒ and moving the vertical ⇒ with 5° left.
verticals? stabilizers?
yes ⇓ yes ⇓
Check for loose attaching Check for loose bellcrank at
hardware for the upper and control shaft.
lower verticals (NOTE).
NOTE: When tightening hardware, do not torque fasteners beyond specified torque limits.
Page 517
MAINTENANCE MANUAL
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MAINTENANCE MANUAL

INSPECTION/CHECK
1. Upper Fuselage and Tailboom Control (4). Inspect control rod fitting, torque tube
Linkage Inspection mounting bracket and pedal mounting
bracket for cracks and corrosion. Using
(Ref. Figure 401) an 8X magnifying glass, mirror and
flashlight, closely inspect pedal link
(1). Inspect rod end bearings for binding bellcrank fitting of pedal bracket in
and excessive wear (0.040 inch (1.016 center forward area where fitting (fork
mm) maximum axial play). Inspect piece) joins tubular section. If any
rivet at fixed rod end. cracks are detected, replace bracket
assembly. Inspect bracket bearings for
(2). Inspect control rod for surface damage excessive looseness.
and evidence of bending.
(5). Inspect torque tube for cracks,
(3). Inspect rubber boot just forward of Sta. scratches, nicks, dents and similar
137.50 bulkhead for condition. surface defects.
(4). Inspect control rod surfaces serviceabil (6). Inspect pedal brackets for corrosion.
ity, wear is limited to thickness of hard
anodic coating. 3. Sta. 97.50 (500N) or Sta. 95 (600N)
Bellcrank and Support Bracket Inspection
(5). Inspect bellcranks for scratches, cracks, (1). Inspect bellcrank and support bracket
corrosion and similar surface defects. for cracks, corrosion and other similar
Check that all bushings are secure. surface defects.
(6). Inspect bellcrank bearings for looseness (2). Check that all bushings are secure.
and binding. Check bellcrank bearings for looseness
and binding.
(7). Visually inspect bellcrank supports for
cracking/damage. (3). Inspect rod ends bearings for binding
and excessive wear (0.040 inch (1.016
2. Anti−Torque Pedal Assembly Inspection mm) maximum axial play). Inspect
control rod surface serviceability, wear
(Ref. Figure 502) is limited to thickness of hard anodic
coating. Inspect for safety wire at
NOTE: Inspect components at left and right po rodends and lockwasher as required.
sition on the right-hand command models. Bolts for cotter pins as required.
Check that corresponding pedals contact
stops simultaneously. 4. Forward and Intermediate Directional
Control Tube, and Link Inspection
(1). Inspect pedals and pedal arms for
(1). Inspect rodend and link bearings for
cracks, elongated pedal attach holes
binding and excessive wear (0.040 inch
and open drain holes. Inspect teflon-
(1.016 mm) maximum axial play).
reinforced bushing liners for deteriora
tion. (2). Inspect control tubes and link for
surface damage and wear. Inspect
(2). Inspect pedal-to-arm quick-release control tubes surface serviceability,
locking pin for condition and positive wear is limited to thickness of hard
spring action. anodic coating.
(3). Inspect links and bellcrank for cracks (3). Inspect for safety wire at rodends and
and bends, and bearings for excessive lockwasher as required. Bolts for cotter
play. pins as required.
Page 601
MAINTENANCE MANUAL
5. Splitter Bungee Spring Inspection (500N) and female connectors for corrosion
pitting or cracks; none allowed.
(1). Inspect spring support bracket for loose
rivets, loose screws, corrosion and (8). Inspect center cable hex end for wear
cracks and general condition. beyond allowable tolerance (Ref.
Figure 601).
(2). Check link assemblies for cracks, bends (9). Inspect collar for wear in locking
and dents. groove.
(3). Inspect spring for condition and a (10). Inspect relieved area, at Sta. 123.30,
positive spring action. between threads and swage for crack or
evidence of corrosion.
6. Sta. 113.00 Splitter Assembly and
Bellcrank Inspection (11). Inspect relieved area, at Sta. 164.00
(500N) or Sta. 292.00 (600N), between
(1). Visually inspect bellcrank and support threads and swage for crack or evidence
bracket for cracks and damage using 5X of corrosion.
magnifying glass. (12). Inspect forward cable coupling opening
(2). Inspect for cracks, corrosion and other for proper dimension (Ref. Figure 601).
similar surface defects. (13). Using a bright light and 10x magnify
ing glass, inspect the swaged area of
(3). Check that all bushings and bearings the telescopic swivel end for cracks
are secure. (Ref. Figure 603).
(4). Inspect rodend bearings for binding and (14). Inspect for any evidence of swivel ball
excessive wear (0.040 inch (1.016 mm) separation.
maximum axial play). Inspect control
rod surface serviceability, wear is 8. YSAS Actuator, Rate Gyro and Electronic
limited to thickness of hard anodic Control Box Inspection
coating. Inspect for safety wire at (1). Inspect YSAS actuator for damage, no
rodends and lockwasher as required. damage allowed.
Bolts for cotter pins as required.
(2). Inspect mounting hardware for proper
7. Forward and Center Cable Assembly installation and general condition.
Inspection (3). Inspect wiring for condition, no fraying,
cracking of insulation or chafing
(1). Inspect for freedom of movement and
allowed.
no binding.
(4). Inspect grommet for proper installation
(2). Check rodend bearings for corrosion, and deterioration, replace if deterio
and wear. rated.
(3). Cable housing for fraying, and security. (5). Inspect mounting bracket for cracks
(pay particular attention to area around
(4). Inspect cable couplings for wear, four rivet attach holes) no cracks
deformation or damage (Ref. allowed.
Figure 602).
(6). Inspect rate gyro and electronic control
(5). Inspect inner cable coupling hex for box for damage, security in mount and
proper alignment with outer cable ensure electrical plugs are secure.
coupling. (7). Inspect mounting bracket for cracks, no
(6). Inspect cable inner couplings for cracks allowed.
deformation or obvious damage. 9. Fan Pitch Control Tube Inspection
(7). Using a bright light and 10X magnify (1). Inspect tube for dents, scratches, nicks,
ing glass, inspect inner coupling male gouges and corrosion, none allowed.
Page 602
MAINTENANCE MANUAL
(2). Inspect for visible step in splined area. (b). Minimum measurement across pins
(3). If step is evident: is 0.640 in. (16.256 mm).
(a). Measure across splines using 0.096
in. (2.4384 mm) diameter pins.
Table 601. Isolating Control System Troubles
Binding, locking−up and erratic Disconnect fwd control tube from If symptom is gone, check from
action of foot pedals (Do not force Sta. 113.00 splitter assembly. splitter assembly aft.
controls).
0.250 INCH (6.35 MM)

HEX (REF)
CLOSED OPEN
POSITION POSITION
(REF TABLE)
HEX CONFIGURATION
FORWARD CABLE FEMALE END
ROUND CONFIGURATION ACCEPTABLE DIMENSIONS

CENTER CABLE (-5) (INSIDE TAIL BOOM) SLOT DIMENSION MALE CONNECTOR
IN (MM)
0.260 IN. (6.604 MM) MIN. 0.450 (11.43) HEX CONFIGURATION
(NOTE) 0.685 (17.40) ROUND CONFIGURATION
0.450 (11.43) ROUND CONFIGURATION
0.250 IN. UNACCEPTABLE DIMENSIONS
(6.35 MM)
0.685 (17.40) HEX CONFIGURATION
DIMENSION ACROSS HEX

(ROTATED)
NOTE: WHEN DIMENSION REACHES 0.260 IN. (6.604 MM) ACROSS ANY
TWO OPPOSING POINTS OF HEX, CABLE HAS REACHED IT'S MAXIMUM
WEAR AND MUST BE REPLACED WITH A SERVICEABLE CABLE. G67-2020B
Figure 601. Control Cable Coupling Inspection
Page 603
MAINTENANCE MANUAL
TAILBOOM FAIRING
CABLE ASSY
RELIEF AREA
INSPECT FOR CRACK
INNER FEMALE
CONNECTOR
OUTSIDE COLLAR SLEEVE CABLE END RELIEF AREA
(MUST BE FIRMLY LOCKED
IN PLACE BEFORE TAILBOOM
FAIRING IS INSTALLED)
INNER MALE
CONNECTOR
INNER COUPLING CONNECTOR
88_776
Figure 602. Forward and Center Cable Relief Area Inspection
Page 604
MAINTENANCE MANUAL
FORWARD CABLE
TAILBOOM FAIRING
CENTER CABLE
ASSY
INSPECT TELESCOPIC SWIVEL END

FOR CRACKS AND/OR TELECOPTIC
SWIVEL SEPERATION FROM
THRUSTER CABLE CONDUIT CAP
TELESCOPIC SWIVEL END

CONDUIT CAP
88_777
Figure 603. Control Cable Telescopic Swivel End Inspection
Page 605
MAINTENANCE MANUAL
10. Sector Assembly, Control Cables and (a). Fraying or corrosion; no fraying or
Drum Assembly Inspection corrosion allowed.
(Ref. Figure 402) (b). Proper installation of turnbuckle
safety clips.
(1). Inspect sector assembly for:
(c). Corrosion or cracking on turnbuckles;
(a). Proper installation of mounting
no corrosion or cracking allowed.
hardware.
(b). Remove access cover from pan (d). Proper cable tension.
assembly. (6). Reinstall access cover on top of station
(c). Center cable mounting bolt for ary thruster assembly (600N).
security and proper installation of
(7). Inspect control cable pulleys for:
safety wire.
In the following step, ensure (a). Proper installation of mounting
WARNING the anti-torque pedals are hardware.
not moved, personal injury can occur. (b). Guard pins installed.
(d). Check sector assembly for excess (c). Excessive groove in pulleys; evident
up-and-down play. in out-of-round pulley.
(e). Damage, cracks or corrosion; no
(8). Inspect drum assembly for:
damage, cracks or corrosion allowed.
(f). Reinstall access cover on pan assem (a). Proper installation of mounting
bly. hardware.
(2). Remove tip cap (500N). (b). Damage, cracks or corrosion; no

damage, cracks or corrosion allowed.
(3). Remove rotating cone assembly.
(c). Guard pins installed.
(4). Remove access cover from top of
stationary thruster assembly (600N). (9). Reinstall rotating cone assembly.
(5). Inspect control cables for: (10). Reinstall tip cap (500N).
Page 606
MAINTENANCE MANUAL

REPAIRS
1. Anti−Torque Flight Control Repair − have equal space for angular throw;
General tighten jamnut.
Use care when drilling to re (6). If removed, install rivet to secure
CAUTION move or install riveted rod end; rodend.
rod end is steel and rod and bearing adapter
(7). Ensure slotted bushing is in place.
are aluminum.
(8). Secure control rod in torque tube fitting
2. Sta. 97.50 (500N) or Sta. 95 (600N) or idler bellcrank with bolt, two
Bellcrank and Support Bracket Repair washers, nut and cotter pin.
4. Upper Fuselage Sta. 113.00 Splitter
Consumable Materials Assembly Repair
Item Nomenclature Refer to Field Service Department for repairs.
CM321 Surface primer locking compound 5. Intermediate Control Tube Repair
(1). Do a straightness check on intermedi
(1). Replace unserviceable bearings. ate control rod that appears bent or
bowed. Total length of control rod
(2). Install new bearings with surface (excluding rod ends) must be straight
primer (CM321) and grade A locking within 0.040 inch (1.016 mm), with
compound (CM431). straightness variation limited to
maximum of 0.010 inch (0.254 mm) in
NOTE: When idler bellcrank bearing are re each foot of length.
placed, ensure idler bellcrank spacers are
reinstalled between bearings. NOTE:
D A dye check for cracking must always be
(3). Replace bellcranks or control support done after cold-straightening. Replace
brackets that have cracks or enlongated cracked rod, or cracked or bent rod end.
holes.
D Do not use rod ends to support rod during
3. Forward Directional Control Tube Repair straightening process.
(2). Cold-straighten bent rod that is not
(1). Replace control rod end if bearing axial
within tolerance provided there are no
nicks or sharp dents in bend length.
mm). Set initial control rod length and
bearing angularity. (3). Replace control rod end if bearing axial
(2). Initial length forward directional mm). Set initial control rod length and
control tube is 15.42 inches (39.17 cm). bearing angularity.
Rod end angularity is 0 degrees
straight line within ±2 degrees. (4). Replace unserviceable control rod
bearing adapter if installed.
(3). Do a straightness check on control rods
that appear bent or bowed. (a). Measure length and record position
of rod end in adapter.
(4). Drill out rivet. Loosen jamnut and
unscrew rodend. (b). Remove affected rod end. Initial
installation length of intermediate
(5). Screw replacement rodend into rod to control rod is 23.68 inches (60.15 cm).
obtain same measurement made in step Rod end angularity is 38—42 de
b. Align control rodends so bearings grees.
Page 801
MAINTENANCE MANUAL
(c). Drill out rivets securing adapter to (8). Repair minor surface defects such as
rod and aft rod end. scratches, nicks and corrosion on
bellcranks and support bracket.
(d). Install rod end in replacement
adapter and position at recorded (9). Use abrasive cloth (CM802), grade 400
measurement. - 600, to smooth out and blend in such
defects.
6. Sta. 137.50 Support Bracket and Bellcrank (10). Cast surfaces can be reworked to depth
Repair of 0.020 inch (0.508 mm).
(11). Repair surface abrasion on control rod
Consumable Materials by smoothing area with grade 400
(Ref. Section 91-00-00) abrasive cloth (CM802) and restoring
Item Nomenclature protective finish with primer (CM318).
CM318 Primer (12). Replace rod if wear or depth of repair is
CM321 Surface primer locking compound more than 0.004 inch (0.102 mm).
CM802 Abrasive cloth, aluminum oxide (13). Replace tailboom control rod if hard
anodic coating is worn through and
aluminum base metal is visible.
(1). Replace unserviceable bearings.
(14). Replace split or torn boot.
(2). Install new bearings with surface
primer (CM321) and grade A locking 7. Fan Pitch Control Tube Repair
compound (CM431).
Refer to Field Service Department for repairs.
(3). Flat machined surfaces, except clevis 8. Forward Cable Assembly Repair
inner ears, can be reworked to depth of
0.015 inch (0.381 mm). Refer to Field Service Department for repairs.
(4). Clevis inner ear surfaces can be 9. Center Cable Assembly Repair
reworked to depth of 0.020 inch (0.508
mm). Refer to Field Service Department for repairs.
10. Aft Control Rod Repair
(5). Machined holes can have 0.003 inch
(0.076 mm) removed from bore wall in Refer to Field Service Department for repairs.
an area no greater than 15 percent of
circumference and 50 percent of depth. 11. Thruster Sector Assembly Repair
(6). All edges can have 0.030 inch (0.762 Refer to Field Service Department for repairs.
12. Drum Assembly and Idler Pulleys Repair
holes, which are limited to 0.010 inch
(0.254 mm) chamfer. Refer to Field Service Department for repairs.
(7). All rework must be smoothly blended 13. Anti−Torque Pedal Disassembly
into adjacent surfaces and finish must
be restored. (Ref. Figure 403)
NOTE: Before disassembly of pedal installa
NOTE: Installation direction of Sta. 137.50 tion, matchmark mating pedal arms, links
bellcrank bearing can be from either side, and bellcranks with pedal brackets to avoid
depending on location of bearing shoulder. intermixing components between locations
There must not be less than 0.010 inch at reassembly.
(0.254 mm) protrusion of bearing inner race
beyond sides of bellcrank after bearing is in (1). Disconnect links from pedal arms and
stalled. bellcrank; remove links.
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MAINTENANCE MANUAL
(2). Remove bellcrank from pedal bracket. Right pedal arm bushings are
CAUTION glass-filled phenolic. Do not
(3). Remove nut and washer of two bushing cock bushings during replacement; ensure
assemblies that secure left pedal arm bushing is fully seated in arm bore. Keep
and control rod fitting to torque tube. tools from contact with bushing liners to
avoid fraying.
(4). Carefully remove bushing bolt and
temporarily reinstall washer and nut (6). Replace bearings in right pedal arm
on bolt. when teflon-reinforced liner is galled or
frayed. Pull bushing to remove; press to
(5). Slide pedal bracket and pedal arms off install.
end of torque tube.
(7). Remove corrosion from pedal brackets
NOTE: (Ref. Section 20-40-00 and CSP-A-3,
D Do not remove two teflon-lined bushings Corrosion Control Manual).
from right pedal arm unless replacement
is required. 15. Anti−Torque Pedal Reassembly
D Do not remove two stop bolts, jam nuts on (Ref. Figure 403)
stop bolts or bearings from pedal bracket
unless replacement is required. (1). When reassembling components, check
for correct matchmark identification.
(6). Slide torque tube bracket and control
rod fitting off torque tube. (2). If previously removed, thread jamnut
on each of two stop bolts and install two
14. Anti−Torque Pedal Repair stop bolts into threaded inserts of pedal
brackets.
Consumable Materials (3). Slide torque tube bracket and control

(Ref. Section 91-00-00) rod fitting onto torque tube.
Item Nomenclature
(4). Locate pedal bracket and pedal arms
CM425 Sealing compound for correct position on torque tube; slide
CM431 Sealing, locking and retaining compound bracket and arms onto torque tube.
(5). Fasten left pedal arm and control rod
(1). Replace parts that are cracked or have fitting to torque tube with adjustable
elongated attachment holes. bushing assemblies.
Do not attempt to straighten
CAUTION bent torque tube or pedal link.
(6). Install bushing bolt so shank at
bolt-head end protrudes at least 0.002
(2). Replace unserviceable pedal covers. inch (0.051 mm).
Apply sealing compound (CM425) to (7). Torque nut to 50—80 inch-pounds
approximately 30 percent of upper and (5.65—9.04 Nm) plus drag torque; do
lower edge surfaces that contact pedal. not allow bolt to turn.
Cure according to container instruc
tions. (8). Ensure each end of bushing assembly
shank protrudes a minimum of 0.002
(3). Replace complete pedal link if cracked inch (0.051 mm). If not, loosen and
or contains unserviceable bearings; repeat above steps.
bearings are not replaceable.
(9). Ensure slotted bushing is in place; then
(4). Replace unserviceable bearings in attach bellcrank to pedal bracket with
mounting brackets or pedal link bolt, two washers, nut and cotter pin.
bellcrank.
(10). Ensure slotted bushings are in place;
(5). Install replacement with grade A then fasten each link to bellcrank with
locking compound (CM431). bolt, two washers, nut and cotter pin.
Page 803
MAINTENANCE MANUAL
(11). Ensure slotted bushings are in place; (f). Remeasure and record dimension
then fasten each link in pedal arm lugs ``C''.
with bolt, two washers, nut and cotter
pin. (6). Cut lockwire and remove the four
screws that hold the seal housing and
(12). Ensure outboard pedals clear windows splined housing.
by a minimum of 0.20 inch (5.08 mm)
with 20 pounds (9.07 kg) of force NOTE: It can be necessary to grasp the cylin
applied. drical portion of the seal housing or splined
housing with a rubber-tipped clamping tool
16. YSAS Actuator Regrease Procedure to loosen the housing because of primer ap
plied to the screws at assembly.
A. YSAS Actuator Disassembly
(Ref. Figure 801) (7). If there is an inspection seal at the

housing joint, remove enough of the
Do not attempt to loosen or label so that it cannot get pinched
CAUTION tighten nut by grasping actua between the housings when the actua
tor housing, damage to spline housing can tor is re-assembled. Leave some of the
occur. label on the actuator to aid in re-as
sembly. If there is no inspection seal,
(1). Cut and remove lockwire from lock use pieces of tape.
washer and nut.
NOTE: Belleville spring, spacer and shims (if
(2). Hold hex end of output shaft and loosen installed) are installed between the seal
nut. housing and splined housing.
(3). Remove rod end, nut and lockwasher. (8). Remove seal housing and splined
(4). Record output shaft orientation by housing.
marking the notch on the connector
side of the shaft with a pencil. (9). Note the order of assembly of these
parts.
(5). Measure endplay of the actuator as
follows: (10). Measure and record the thickness of the
spacer and the total thickness of the
(a). Push the output shaft in towards the shims (if installed) to avoid confusion
actuator housing by applying a load with the spacer and shims on the other
of 20—100 lbs (9.07—45.36 kg). side of the splined housing.
(b). Using a depth gage, measure and NOTE: The teflon washer attached to the end of
record dimension ``C''. the LVDT core is a close fit to the bore
through the LVDT housing, it can be neces
(c). Screw the rod end into the output sary to carefully tug a little to fully remove
shaft a few turns. the shaft.
(d). Pull on the output shaft by applying
a load of 20—100 lbs (9.07—45.36 (11). Unscrew and remove the output shaft.
kg). This shaft has the LVDT core and
associated hardware attached to it; Do
(e). Unscrew and remove the rod end not unscrew the nylon screw or the
without changing dimension ``C''. LVDT core.
NOTE: If the variation in dimension ``C'' is (12). Note the orientation of the belleville
more than 0.013 inch (0.3302 mm), the spring, spacer and shims (if installed).
actuator should be returned to the manufac Measure and record the thickness of the
turer for repair rather than regrease. spacer and shims.
Page 804
MAINTENANCE MANUAL
Do not use any cleaning sol NOTE: If you mix grease, only use Mobil
CAUTION vents. Damage to the motor Grease 28 which meets MIL-G-81322.
bearings and the molybdenum disulfide fin
ish on the acme nut and spline surfaces can (4). If necessary, mix 95% aircraft grease
occur. (CM111) with 5% molybdenum disulfide
powder (CM109) by weight.
(13). Wipe off old grease from all parts using
lint-free cloth. (5). Apply special grease (CM127) to acme
screw threads until scale is balanced
(14). Using cotton swabs, remove grease again.
from acme nut area. Be sure to reach
into the cavity just beyond the acme (6). Evenly distribute grease around the
nut threads to remove grease deposits. acme screw threads to form a fairly
even cylinder in order to fit through the
(15). Use the acme screw to remove grease belleville spring without scraping off
from the acme nut threads. too much grease.
(a). Run screw in and out, then wipe (7). With belleville spring, spacer and shims
threads clean. (if installed) in place within end bore in
motor housing, carefully assemble
(b). Repeat above step until no more greased output shaft to actuator.
grease appears on screw threads.
(a). Screw in the shaft until the leading
B. YSAS Actuator Regrease and edge of the spline on the shaft is
Reassembly about flush with the end of the motor
housing and oriented so that the
(Ref. Figure 801) splined housing can be put on in it's
proper orientation.
Consumable Materials (8). Apply grease (CM127) to splined
surfaces of splined housing until
Item Nomenclature
grooves are completely full. Install
CM109 Molybdenum disulfide powder lubricant splined housing as originally oriented.
CM127 Grease, YSAS Actuator (9). Apply film of grease (CM127) to
CM318 Primer smallest inside diameter of seal
CM731 Lockwire CRES housing.
(10). With belleville spring, spacer and shims
NOTE: Use YSAS actuator grease (CM127) or (if installed) in place within end bore of
mix aircraft grease (CM111) and molybde seal housing, slide seal housing into
num disulfide powder (CM109) to regrease position over output shaft as originally
the actuator. oriented.
(1). Prior to applying new grease, re-as (11). Replace four screws which hold down
semble the output shaft with attached seal housing; Use only
hardware (splined housing, belleville NAS1352-04H8P screws.
spring, spacer and shims (if installed))
to the actuator to avoid confusion at (a). Install screws with wet primer
re-assembly. (CM318).
(2). Remove and weigh output shaft with (b). Torque screws to 9 inch-pounds
LVDT core and associated hardware (1.02 Nm).
attached; Record weight.
(c). Using lockwire (CM731), safety
(3). Adjust scale up 2.5 grams. screws.
Page 805
MAINTENANCE MANUAL
(12). Re-install rod end, nut and lockwasher (13). Using lockwire (CM731), safety nut to
with rod end face (surface `À'') oriented lockwasher, washer can be oriented
at 88—92° with respect to surface ``B''. with lockwire end up or down.
(19.21—22.60 Nm).
SPLINED MOTOR
ÉÉÉÉÉ
HOUSING HOUSING
ÉÉÉÉÉ
SEAL
C HOUSING LVDT CORE
OUTPUT
1.10 ± 0.03 IN SHAFT
(27.9"0.76 MM)
ROD
END
LOCKWASHER
LOCKWIRE
BELLEVILLE
SPRING
SHIMS SHIMS
SPACERS SPACERS
SCREW A
SAFETY
WIRE
G67-2021
Figure 801. YSAS Actuator (Cross−Section View)
Page 806
MAINTENANCE MANUAL
Chapter
71
Power Plant
MAINTENANCE MANUAL
TABLE OF CONTENTS
71-00-00 Power Plant (250-C20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Power Plant Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Power Plant Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Models 250-C20B and 250-C20R/2 Power Plant Fault Isolation . . . . . . . . . . . . . . . 1
Table 1. Power Plant Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Engine Disconnecting for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Rolls-Royce 250-C20B and 250-C20R/2
Engine Removal/Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . 402
B. Removal of Disconnected Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
2. Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Engine Installation in Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Connecting an Installed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 402. Model 250-C20B and 250-C20R/2
Engine Stripping and Buildup (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 406
3. Engine Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 403. Model 250-C20B and 250-C20R/2 Engine Mounts
and Airframe Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
4. Engine Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
5. Modification of Accessory Drive Gearbox Overboard Vent Tube
(SN 0004D - 0519D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Figure 404. Extension of Engine Accessory Drive Overboard Vent Tube . . . . . . 414
71-00-30 Power Plant (250-C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
3. Model 250-C30 Power Plant Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Model 250-C30 Engine Removal and Installation
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Engine Installation in Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Page i
MAINTENANCE MANUAL

B. Connecting an Installed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

Figure 402. Engine Mounts and Structural Fittings . . . . . . . . . . . . . . . . . . . . . . . . 406
3. Engine Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 403. Model 250-C30 Engine Build-Up
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
4. Engine Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
71-00-47 Power Plant (250-C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
3. Model 250-C47 Power Plant Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Starter/Generator System Wiring Diagram
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2. Engine Wire Harness Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. Model 250-C47 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Engine Build-up Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 402. Engine Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
C. Engine Installation in Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
D. Connecting an Installed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 403. Starter/Generator Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 408
2. Model 250-C47 Engine Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
3. Model 250-C47 Engine Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
71-10-00 Engine Air Intake System (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . . . . . A
2. Air Inlet Screen Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Air Inlet Screen Removal (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Engine Air Inlet Screen Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . 202
B. Engine Inlet Screen Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
C. Air Inlet Screen Installation (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . 204
D. Engine Inlet Screen Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3. Air Inlet Bell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Air Inlet Bell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page ii
MAINTENANCE MANUAL

B. Air Inlet Bell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

4. Firewall Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5. Air Intake System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202. Firewall Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6. Firewall Seal Ring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7. Air Inlet Bell Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8. Plenum Chamber Drain Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
71-10-05 Engine Compressor Water Wash Kit (369D/E/FF - 500/600N) . . . . . . . . . . A
1. Engine Compressor Water Wash Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Engine Compressor Water Wash Kit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Engine Compressor Water Wash Kit Initial Installation . . . . . . . . . . . . . . . . . . . . . . . 901
A. Gaining Access to Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Airframe Modification and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
2. Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Figure 901. Engine Compressor Water Wash Kit Installation
(Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
71-10-10 Engine Air Particle Separator (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . A
Table 1. Engine Air Particle Separator Configurations . . . . . . . . . . . . . . . . . . . . . . 2
Figure 1. Particle Separator Operating Principle - Early Type
(Donaldson Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2. Particle Separator Operating Principle - Current Type
(APM Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Engine Air Particle Separator Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Engine Air Particle Separator Fault Isolation . . . . . . . . . . . . . . . . . . . . 101
Figure 101. 369H90148-503, -505, -507, -509 Particle Separator
Installation Wiring Diagram (Slim-Line Panel) . . . . . . . . . . . . . . . . . . 102
Figure 102. 369H90148-503, -505, -507, -509 Particle Separator Installation
Wiring Diagram (T-Panel with Center Console) . . . . . . . . . . . . . . . . . . 103
Figure 103. 369H90148-519, -521, -527, -529 Particle Separator
Installation Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 104. 369H90148-535,-537, -539, -541, -543, -545 and 500N90148-1, -3
Particle Separator Installation Wiring Diagram . . . . . . . . . . . . . . . . . . 105
Page iii
MAINTENANCE MANUAL


1. Air Bypass Door System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Solenoid Air Valve Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Air Pressure Sensing Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Air Bypass Door Rigging (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Air Bypass Door Rigging (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6. Particle Separator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
7. Mist Eliminator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 201. Air Bypass Door System (369D/E/FF) (Sheet 1 of 3) . . . . . . . . . . . . . 204
Figure 202. Air Bypass Door System (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1. PLM Particle Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. PLM Particle Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. PLM Particle Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. PLM Scavenge Ejector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. PLM Scavenge Ejector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. PLM Scavenge Ejector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3. PLM Ejector Nozzle and Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
4. Mist Eliminator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Helicopters With Mist Eliminator Access Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Helicopters Without Mist Eliminator Access Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 402
C. Mist Eliminator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
5. Donaldson Particle Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Donaldson Particle Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Donaldson Particle Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
1. Engine Air Inlet Bypass Door 300-Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. PLM Particle Separator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Donaldson Particle Separator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
4. Scavenge Air Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
5. Air Pressure Sensing Switch Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6. Mist Eliminator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 601. Air Pressure Sensing Switch Calibration Check . . . . . . . . . . . . . . . . . 604
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. PLM Particle Separator Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Vortex Tube Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
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B. Displaced Vortex Generator Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

Figure 801. Vortex Generator Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
C. Damaged Or Missing Vortex Generator Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
D. Damaged Or Missing Vortex Generator and Outlet Tubes . . . . . . . . . . . . . . . . . . . 803
E. PLM Particle Separator Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
F. Fairing Modifications (369D Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 802. Fairing Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
2. Mist Eliminator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
3. Particle Separator Alignment and Joint Surface Repair (369D/E/FF) . . . . . . . . . . . 805
4. Donaldson Particle Separator Repair (369D Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Figure 803. Donaldson Particle Separator Gasket Replacement . . . . . . . . . . . . . . 806
Figure 804. Mist Eliminator Bolt Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
5. Donaldson Particle Separator Auxiliary Fairings and Seals Installation . . . . . . . . 808
Figure 805. Auxiliary Fairings and Seals Installation
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
Figure 806. Auxiliary Fairings and Supports Fabrication
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
Figure 807. Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
1. Engine Air Particle Separator Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Filter Bypass Door and Aft Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Figure 901. Air Bypass Door Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 902
Figure 902. Aft Cable Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
B. Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
C. Handle and Forward Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
D. Bleed Air System Installation (Helicopters Without Cabin Heat) . . . . . . . . . . . . . 907
E. Bleed Air System Installation (Helicopters With Cabin Heat) . . . . . . . . . . . . . . . . 907
Figure 903. Handle and Forward Cable Installation (Sheet 1 of 3) . . . . . . . . . . . 908
F. Scavenge Air System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 911
Figure 904. Modifications and Installation (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . 912
G. Solenoid Valve and Pressure Switch Wire Harness Installation . . . . . . . . . . . . . . 916
Figure 905. Scavenge Air Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 917
H. Ejector Duct Doubler and Rib Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 918
I. Particle Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 918
Figure 906. Ejector Duct Doubler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919
Figure 907. Wiring Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 920
J. Instrument Panel Modifications; T-Pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 922
K. Slimline Panel Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 922
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L. Post-Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 923

M. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 923
71-10-60 Engine Air Particle Separator (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Engine Air Particle Separator Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Engine Air Particle Separator Fault Isolation . . . . . . . . . . . . . . . . . . . . 101
Figure 101. Air Intake and Particle Separator Circuits Wiring Diagram . . . . . . 101
1. Particle Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Particle Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Particle Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Scavenge Air Solenoid Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Scavenge Air Solenoid Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Scavenge Air Solenoid Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Air Filter Bypass Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Air Filter Bypass Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Air Filter Bypass Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4. Bypass Door Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Bypass Door Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Bypass Door Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
5. Bypass Door Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Bypass Door Cable Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Bypass Door Cable Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
6. Bypass Door Seal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
7. Particle Separator Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401. Engine Air Particle Separator Installation . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Bypass Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
1. Engine Air Particle Separator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Bypass Door Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3. Bypass Door Cable Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4. Air Pressure Sensing Switch Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601. Air Pressure Sensing Switch Calibration Check . . . . . . . . . . . . . . . . . 602
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71-20-00 Engine Mounts (250-C20B, 250-C20R/2, 250-C30 and 250-C47) . . . . . . . . A

1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Airframe Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Airframe Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Lower Engine Mount Replacement (250-C20/-C20R/2) . . . . . . . . . . . . . . . . . . . . . . . 401
A. Lower Engine Mount Removal (250-C20/-C20R/2) . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Lower Engine Mount Installation (250-C20/-C20R/2) . . . . . . . . . . . . . . . . . . . . . . 401
3. Upper Engine Mounts Replacement (250-C20/-C20R/2) . . . . . . . . . . . . . . . . . . . . . . 401
A. Upper Engine Mounts Removal (250-C20/-C20R/2) . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Upper Engine Mounts Installation (250-C20/-C20R/2) . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. 250-C20/-C20R/2 Engine Mounts
4. Lower-Aft Engine Mount Replacement (250-C30/-C47) . . . . . . . . . . . . . . . . . . . . . . 403
A. Lower-Aft Engine Mount Removal (250-C30/-C47) . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Lower-Aft Engine Mount Installation (250-C30/-C47) . . . . . . . . . . . . . . . . . . . . . 403
5. Upper Engine Mounts Replacement (250-C30/-C47) . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Upper Engine Mounts Removal (250-C30/-C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Upper Engine Mounts Installation (250-C30/-C47) . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Model 250-C30/-C47 Engine Mounts
Inspection/check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Engine Mounts and Fittings Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Upper Engine Mounts Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Engine Mount Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Mount Hole Repair (250-C20/-20R/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Painted Surfaces Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
71-30-00 Engine Ignition Control System (250-C20B,
250-C20R/2 and 250-C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Engine Ignition System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Automatic Re-ignition System Description and Operation . . . . . . . . . . . . . . . . . . . . . 1
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Engine Ignition System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Ignition System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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2. Automatic Re-ignition System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Table 102. Automatic Re-ignition System Fault Isolation
(369D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Table 103. Automatic Re-ignition System Fault Isolation
(369E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1. Automatic Re-ignition System Component Replacement . . . . . . . . . . . . . . . . . . . . . . 401
A. Automatic Re-ignition Test Switch (S11) Replacement . . . . . . . . . . . . . . . . . . . . . . 401
B. Armed Light/Switch (XDS9) Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . 401
C. Armed Light/Switch (XDS9) Lamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 401
D. Armed Lights/Switch (XDS9) Display Screen Replacement . . . . . . . . . . . . . . . . . . 401
E. K104/K304 Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
F. CR1/CR2 Diode Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401. Auto Re-ignition System Equipment
(Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Auto Re-ignition Wiring Diagram
(Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. Auto Re-ignition Schematic
(Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
1. Automatic Re-ignition System Check
(with Ground/Air Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Normal Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Automatic Re-ignition System Check
(without Ground/Air Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Auto Re-ignition System Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Preparation for Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Instrument Panel Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Electrical System Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Relocation of Auto Re-ignition Controls
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 802. Auto Re-ignition Rewiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
1. Auto Re-ignition Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
A. Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Preparation for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Automatic Re-ignition System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Diode Isolator Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
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E. Relay and Switch Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902

F. Relay and Switch Assembly Installation
(T-Panel with Center Console) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
71-60-00 Engine Cooling System (250-C20B, 250-C20R/2,
250-C30 and 250-C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Engine Cooling System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Engine Cooling System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Engine Cooling System Repair and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Engine Air Cooling System - 250-C20B
and 250-C20R/2 (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Engine Air Cooling System - 250-C30
and 250-C47 (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page ix
MAINTENANCE MANUAL

Page x
MAINTENANCE MANUAL
Section
71−00−00
Power Plant
(250−C20)
MAINTENANCE MANUAL
POWER PLANT
1. Power Plant Description helicopters consist of a combined four
stage axial and single stage centrifugal
(1). MDHI 369D/E helicopters can be flow compressor, an annular combus
powered by either a 250-C20B or tion chamber and a four stage turbine
250-C20R/2 turboshaft engine man system to extract power from the gas. A
ufactured by the Rolls-Royce Corpora two-stage gas producer turbine drives
tion. the compressor, gas producer fuel
control, accessory gear train and N1
(2). MDHI 500N helicopter is powered by a
tachometer-generator. A two-stage
250-C20R/2 turboshaft engine man
power turbine drives the helicopter
ufactured by the Rolls-Royce Corpora
rotor system, governor control and N2
tion.
tachometer-generator. A start counter
(3). The engine is secured in the helicopter is standard and part of the engine
by three mount assemblies and ac ignition system
cessed through two hinged, air-sealed
doors. (2). Rolls-Royce Operation and Mainte
nance Manuals are the primary
(4). A belt-driven blower provides external information source for engine fault
cooling air through strategically isolation and maintenance data (Ref.
positioned ducts that direct air onto Section 01-00-00). Refer to these
engine exterior surfaces and through manuals for specific engine mainte
the engine and transmission oil cooler nance procedures.
heat exchangers. Spent blower air is
exhausted aft through an annular (3). Starter operational limitations are in
opening between the engine exhaust the applicable Pilot's Flight Manual.
pipes and fuselage.
3. Models 250−C20B and 250−C20R/2 Power
(5). Engine intake air can be filtered Plant Fault Isolation
through a standard screen or optional
air particle separator/mist eliminator (Ref. Table 1)
assembly. Intake air is drawn through
a plenum chamber and into the engine (1). Check engine support systems, i.e.; chip
intake bell-mouth by the compressor. detectors, instruments, fuel supply,
Engine compartment air is separated electrical systems, etc., to ensure that
from compressor intake air by a seal helicopter equipment is functioning
ring. correctly before disassembling engine
systems for an indicated fault.
2. Power Plant Operation
(2). Inspect and isolate engine problems per
(1). Rolls-Royce turboshaft engines in the applicable Rolls-Royce Operation
stalled in 369D/E - 500N model and Maintenance Manual.
Table 1. Power Plant Fault Isolation

High frequency vibration (1) Loose engine mount bolts. Retorque engine mount bolts to
100—140 inch−pounds
(11.30—15.82 Nm).
NOTES:
(1) High frequency vibrations can be caused by other drive and rotor system components.
Page 1
MAINTENANCE MANUAL
Page 2
MAINTENANCE MANUAL
POWER PLANT
1. Engine Removal (e). Disconnect ground jumper at center
firewall stud.
A. Engine Disconnecting for Removal
(f). Unclamp and remove electrical
(Ref. Figure 401 and Figure 402) harness from right engine mount
After each opening, removal (369D only).
WARNING or replacement of any part
(5). Remove combustion chamber drain line
of the engine and/or aircraft fuel sys
from burner drain valve.
tem between the aircraft fuel tank and
the engine fuel nozzle, the fuel system (6). Disconnect fuel inlet line from engine.
must be bled to remove trapped air.
Failure to comply with this procedure (7). Disconnect fuel pump seal drain line.
can result in engine flameout or power
loss. (8). Disconnect compressor cabin air bleed
outlet tube from tee fitting on engine
Cap fluid lines and fittings with compressor scroll.
CAUTION approved devices. Do not use
tape to cover fuel and oil openings. Tape (9). Loosen compressor cooling air ducts at
adhesives loosened by fuel or oil can con firewall coupling and engine oil cooler
taminate systems. deflector coupling (Ref. Section
71-60-00).
(1). Set all switches OFF. Disconnect
external power. Disconnect battery. (10). Disconnect duct support bracket at
hoisting eye. Remove ducts from engine
NOTE: Tag all hardware, wire terminals, fuel compartment (Ref. Figure 401, view B).
and oil lines before removal to expedite en
gine installation. Identify and bag loose (11). Disconnect torque-meter oil line from
parts to prevent loss or damage. firewall.
(2). Remove main transmission drive shaft (12). Disconnect oil pressure indicator line
(Ref. Section 63-10-00). from firewall.
(3). Remove engine exhaust pipes (Ref.
(13). Disconnect N2 control rod from idler
Section 78-20-00). Cover engine bellcrank. Secure control rod to fire
exhaust outlet. wall.
(4). Disconnect electrical wiring from
engine; (14). Disconnect anti-icing system as follows:
(a). Disconnect engine electrical harness (a). Model 250-C20B;

ground lead and plug from recep Disconnect anti-ice control valve
tacle. lever (Ref. Figure 401, view A).
(b). Disconnect thermocouple wire leads (b). Model 250-C20R/2:

from terminal studs on engine Remove electrical connector from
compartment door frame (Ref. anti-ice solenoid valve. Unclamp and
Figure 401, view C). remove wiring harness from horizon
tal firewall shield.
(c). Remove thermocouple lead clamps
from door frame and exhaust pipe (15). Disconnect N1 control rod from gas
clamp. producer lever. Secure control rod to
firewall.
(d). Disconnect terminals E, C, and B
from starter-generator. (16). Disconnect accessory drive vent tube.
Page 401
MAINTENANCE MANUAL
CONTROL CABLE CONTROL VALVE

CLEVIS LEVER
SCREW (5 PL)
AIR INLET BELL (NOTE 1)
NUT (5 PL)
(NOTE 1)
NO. 1 BEARING ENGINE HOIST

OIL RETURN
LINE
EXHAUST DUCT
ANTI-ICING VALVE
INSTALLATION
(NOTE 2)
CABIN AIR
OUTLET TUBE THERMOCOUPLE LEAD
MOUNT FITTING
P307
(NOTE 3)
DRIVESHAFT
TORQUEMETER
OIL LINE
GROUND JUMPER
AIRFRAME HOIST
FITTING
N2 CONTROL ROD
FUEL PUMP SEAL FUEL CONTROL
BRACKET DRAIN LINE DRAIN LINE
FUEL SUPPLY HOSE COMBUSTION CHAMBER

DRAIN LINE
ROTATED
NOTES:
1. C20R/2 ENGINE (6 PL)
2. C20B ENGINES ONLY.
COMPRESSOR CASE 3. C20R/2 ENGINES ONLY.
COOLING AIR DUCT TURBINE CASE
COOLING AIR DUCT
G71-0000-1
Figure 401. Rolls−Royce 250−C20B and 250−C20R/2 Engine Removal/Installation (Sheet 1 of 2)
Page 402
MAINTENANCE MANUAL
THERMOCOUPLE
LEAD STUD
THERMOCOUPLE
LEAD
ENGINE DOOR
FRAME
THERMOCOUPLE LEAD INSTALLATION
AIR INLET
BELL
OIL PRESSURE LINE

MOUNT ADJUSTER
HARNESS OIL RETURN LINE
CLAMP
OIL SUPPLY LINE
RH MOUNT FITTING
ELECTRICAL
HARNESS
GROUND
THERMOCOUPLE
LEAD
LEAD
OIL VENT LINE
PLUG
LOWER MOUNT FITTING
ACCESSORIES
DRIVE VENT
TUBE FUEL CONTROL DRAIN
N1 CONTROL ROD
GENERATOR TERMINALS
G71-0000-2
Figure 401. Rolls−Royce 250−C20B and 250−C20R/2 Engine Removal/Installation (Sheet 2 of 2)
Page 403
MAINTENANCE MANUAL
(17). Disconnect fuel control drain line. Do not use fuel or oil lines as
CAUTION hand holds. Do not allow engine
The oil cooler is fragile. Unless to strike airframe while maneuvering it out
CAUTION otherwise required, disconnect of the helicopter.
oil supply and return lines only at engine.
(5). Align engine stand (ST401) under
Support oil cooler port boss with a backup
engine with adjustable support shaft on
wrench when oil line removal is required.
left side (Ref. Figure 402).
Do not strain or bend unsupported tubes.
(6). Slowly lower engine out of helicopter.
(18). Disconnect and cap engine oil inlet, Align engine side mount fittings
outlet and vent lines. between fixed and adjustable support
shafts.
B. Removal of Disconnected Engine
(7). Screw in adjustable support shaft until
engine mount fittings are securely
(Ref. Figure 401 and Figure 402) engaged with support shaft sockets.
(8). Insert detent pin through adjustable
Special Tools support shaft.
Item Nomenclature (9). Remove hoist from engine lift fitting.
ST401 Engine stand (10). If engine is to be stored or transported,
ST402 Engine hoist secure upper end of engine stand
transport and storage bar to engine
lifting eye fitting.
CAUTION 2. Engine Installation
D Do not remove engine mounts or disturb A. Engine Installation in Mounts

engine mount adjustments to remove the (Ref. Figure 401 and Figure 402)
engine (Ref. CSP-SRM-6).
D Engine-transmission alignment must be Consumable Materials
inspected and realigned whenever one or (Ref. Section 91−00−00)
more engine mount assemblies is re Item Nomenclature
placed or the existing engine-transmis
CM702 Lockwire CRES
sion alignment adjustment is disturbed.
Do not disturb adjustable engine mount
fittings unless an engine-transmission Special Tools
alignment check is planned. (Ref. Section 91-00-00)
Item Nomenclature
(1). Install engine hoist apparatus (ST402) ST402 Engine hoist
between airframe hoist fitting and
engine hoist eye. (1). Open engine access doors.
(2). Have an assistant apply tension to (2). Position engine to line up engine lifting
engine with hoist. eye under airframe lift fitting.
(3). Remove detent pin from adjustable
(3). Maintain downward pressure on rear of
support shaft on engine stand. Detach
engine during mount bolt removal.
transport and storage bar from engine
Unbolt lower engine mount assembly
lift fitting.
from engine fitting.
(4). Install engine hoist (ST402) between
(4). Unbolt left and right engine mount airframe fitting and engine hoist
assemblies from engine fittings. fitting.
Page 404
MAINTENANCE MANUAL
(5). Have an assistant tension hoist to Proper tightening of engine

support engine. Unscrew engine stand WARNING tubing connections is criti
adjustable support shaft. cal to flight safety. Correct torque val
ues must be used at all times. Excessive
(6). Move engine to disengage fixed shaft. torque on fuel or pneumatic sensing
Roll stand away from engine. system connections can result in crack
ing of the flare causing an air leak
which can cause flameout, power loss,
CAUTION or overspeed.
(1). Connect torque-meter oil line to
D Do not use tubes or hoses as hand holds. firewall.
Do not allow engine to strike airframe.
Avoid damaging engine intake bell. (2). Connect oil pressure gauge line to
D Prevent FOD, ensure that no foreign ob firewall.
jects are trapped in firewall seal ring. (3). Connect engine oil vent line. Torque
line nut to 140—160 inch-pounds
(7). Have hoist operator raise engine while (15.82—18.07 Nm). (Ref. Figure 401).
while pushing down to maintain correct
helicopter and engine alignment. Do not bend oil return line.
CAUTION Bending loads are transferred to
oil cooler port and can fracture cooler.
(8). Align left and right engine mount
assemblies with engine mount fittings (4). Connect engine oil inlet and outlet
and install bolts and washers (Ref. lines. Hand-tighten until snug.
Figure 403). Torque bolts to 100—140 Wrench-tighten approximately 1/4 turn
inch-pounds (11.30—15.82 Nm). or until definite resistance is felt.
Safety bolts to engine mounts using
lockwire (CM702). (5). Position accessory drive vent elbow and
connect with vent tube. Torque elbow
(9). Align hole in lower engine mount jamnut to 150—250 inch-pounds
assembly with engine mount fitting and (16.95—28.25 Nm). Torque tube nut to
install bolt and washer. Torque bolt to 20—30 inch-pounds (2.26—3.39 Nm)
100—140 inch-pounds (11.30—15.82 (Ref. Figure 402, detail B).
Nm). Safety bolt to engine mount using (6). Connect Nl control rod to lever with
lockwire (CM702). bolt, two washers and nut. Install bolt
with head outboard, one standard OD
(10). Ensure engine air inlet firewall seal washer under nut and one large 0.80
ring contacts firewall seal around its inch (20.32 mm) diameter washer
entire circumference. under bolt head. Torque nut to 40—45
inch-pounds (4.52—5.08 Nm). Install
(11). Remove hoist from helicopter. a new cotter pin.
(7). Connect short N2 control rod to gover
B. Connecting an Installed Engine nor lever with bolt head up, one
standard OD washer under head and
(Ref. Figure 401 and Figure 402) one large 0.80 inch (20.32 mm) OD
washer under nut. Install a new cotter
pin. Connect long N2 control rod with
Consumable Materials bolt head forward, two washers and
(Ref. Section 91−00−00) nut. Install a new cotter pin.
Item Nomenclature
(8). Connect engine fuel pump seal drain
CM702 Lockwire CRES line. Torque tube nut to 20—30 inch-
pounds (2.26—3.39 Nm).
Page 405
MAINTENANCE MANUAL
ENGINE MOUNT
FITTING SCREW (5 PL)
(NOTE 2) ENGINE AIR
INLET BELL VENT ELBOW
ANGLE
(NOTE 1) WASHER
(NOTE 2)
O-RING
JAM NUT
VENT ELBOW INSTALLATION

GROUND JUMPER ACCESSORY DRIVE
(NOTE 1)
ENGINE MOUNT FITTING

INSTALLATION (TYP)
N2 TACHOMETER
GENERATOR
NUT (5 PL)
(NOTE 2)
N1 TACHOMETER
GENERATOR
IGNITION EXCITER
OIL INLET COUPLING LEAD
OIL OUTLET COUPLING START COUNTER

KNIFE SPLICE
ELECTRICAL
HARNESS
CHIP DETECTOR
CONNECTORS
FUEL INLET REDUCER
FUEL FILTER SWITCH

KNIFE SPLICE
”D” WIRE LEAD

STARTER-GENERATOR
REDUCER ”A” WIRE LEAD
O-RING
OIL PRESSURE
SNUBBER ENGINE STAND
O-RING NOTES:
1. APPLIES ONLY TO LOWER MOUNT.
OIL PRESSURE REDUCER 2. C20R/2 ENGINES (6 PLCS).
FITTING INSTALLATION 3. C20B ENGINES ONLY.
4. REMOVE CLUTCH ASSEMBLY WITH SEAL, COUPLING
AND ASSOCIATED HARDWARE INTACT.
G71-0001-1B
Figure 402. Model 250−C20B and 250−C20R/2 Engine Stripping and Buildup (Sheet 1 of 2)
Page 406
MAINTENANCE MANUAL
AIR INLET
HOSE
BELL
FIREWALL SEAL RING
FUEL PUMP SEAL ELBOW NUT AND O-RING
SPECIAL TEE FITTING
SCREW BEFORE FILTER PORT (BF)
JAM NUT
(5 PLCS)
O-RING REDUCER O-RING
NUT
(5 PLCS)
CABIN AIR FITTING ANTI-ICE VALVE
INSTALLATION (NOTE 3)
O-RING
FIREWALL SEAL AFTER FILTER
PORT (AF)
OVERRUNNING FITTING
CLUTCH
(NOTE 4) PRESSURE SWITCH
SPARK IGNITER BUSHING
LEAD HOSE ASSEMBLY
FUEL CONTROL HOSE
DRAIN UNION FUEL PRESSURE SWITCH
INSTALLATION
DETENT PIN 3/8 IN. (9.525 MM)

DIA. BOLT
LIFT FITTING
5/16 IN. (7.9375 MM)

DIA. BOLT (2)
ENGINE LIFT FITTING
INSTALLATION
GOVERNOR CONTROL IDLER

SUPPORT, BELLCRANK AND N2
REDUCER
CONTROL ROD ASSEMBLY
O-RING
SNUBBER
O-RING
ACCUMULATOR
TORQUE OIL PRESSURE FITTING

INSTALLATION
G71-0001-2
Figure 402. Model 250−C20B and 250−C20R/2 Engine Stripping and Buildup (Sheet 2 of 2)
Page 407
MAINTENANCE MANUAL
(9). Connect fuel inlet line to fuel pump. (16). Attach thermocouple clamps in frame
Torque hose nut to 230—260 inch- and leads to terminal block studs
pounds (25.99—29.38 Nm). located on right upper engine door
frame with chromel and alumel nuts.
NOTE: Ensure burner drain valve and plug are
installed in combustion chamber with an O- (17). Install main transmission drive shaft
ring on each part. Ensure drain valve is in (Ref. Section 63-10-00).
the aft (lowest) position. (18). Remove all identifying tags from wires
and hardware.
(10). Install combustion chamber drain line
on drain valve. Misrigging of throttle controls
CAUTION can cause inadvertent flameout
(11). Connect fuel control drain line. Torque when throttle is rapidly closed to the idle po
drain line nut to 20—30 inch-pounds sition.
(2.26—3.39 Nm) (Ref. Figure 401).
(19). Rig gas producer (N1) and power
(12). Connect anti-ice system as follows: turbine (N2) controls (Ref. Chapter 76).
(a). Model 250-C20B: After each opening, removal

Connect anti-icing control cable to
anti-icing control valve lever with of the engine and/or aircraft fuel sys
clevis pin and washer. Secure with tem between the aircraft fuel tank and
cotter pin (Ref. Figure 401, detail A). the engine fuel nozzle, the fuel system
(b). Model 250-C20R/2: Failure to comply with this procedure
Install connector P307 to anti-ice can result in engine flameout or power
solenoid valve and secure anti-icing loss.
wiring harness with clamps. (20). Do a fuel system bleed.
(13). Install cooling air ducts and air duct (21). Do an engine deceleration check per the
support bracket on hoisting eye above Pilot's Flight Manual.
engine. Connect and tighten ducts on
firewall coupling and oil cooler deflec NOTE: Make engine adjustments per the
tor. Rolls-Royce Operation and Maintenance
Manual.
(14). Secure engine electrical harness to
(22). Do an anti-icing system operational
engine mount with cushioned loop
check (Ref. Section 75-10-00).
clamp. Connect harness plug to recep
tacle and safety with lockwire (CM702). (23). Inspect engine installation and connec
tions for proper routing and security.
(a). Install engine harness ground lead.
3. Engine Stripping
(b). Install E, C, and B generator leads on
starter-generator terminal block (Ref. Figure 402)
with washers and nuts.
Special Tools
(c). At lower engine mount fitting; install (Ref. Section 91-00-00)
bonding jumper on engine compart Item Nomenclature
ment firewall stud. Torque bolt to
ST401 Engine stand
(11.30—15.82 Nm). Safety bolt to ST402 Engine hoist
engine mount using lockwire
(CM702). (1). Install engine in engine stand (ST401).
(15). Install engine exhaust pipes and (2). Disconnect wire leads from generator A
thermocouple clamp support. and D terminals.
Page 408
MAINTENANCE MANUAL
(a). Loosen mounting clamp and remove (11). Remove fuel pressure switch installa
starter-generator. tion as follows:
(b). Remove mounting flange and gasket. (a). Remove hose, reducer and O-ring
from before filter (BF) port (Ref.
(c). Install cover on generator mounting Figure 402, view D).
pad.
(b). Remove bushing, fuel pressure
(3). Disconnect electrical connectors from: switch, fitting and O-rings from after
filter (AF) port.
(a). Chip detectors.
(12). Remove engine air inlet bell and
(b). Tachometer generators.
firewall seal.
(c). Ignition exciter. (13). Model 250-C20B Only:
(d). Start counter. Remove anti-icing valve lever assembly
from poppet guide (Ref. Figure 401,
(e). Fuel filter pressure switch. view A).
(f). Unclamp and remove electrical (14). Remove fuel pump seal drain port
harness from overrunning clutch and elbow and jamnut.
lower engine mount fitting.
(15). Remove governor control idler support,
(g). Remove entire engine electrical bellcrank and short N2 control rod as
harness. an assembly. Install vacuum/hydraulic
pump pad cover.
NOTE: Discard all used O-ring packings.
(16). Remove overrunning clutch and
(4). Remove fuel supply and return reduc firewall seal. Install cover on engine
ers/unions. pad.
(5). Remove oil supply and return reducers/ (17). Remove fuel control drain fitting.
unions.
(18). Remove pneumatic line accumulator
(6). Remove accessories drive vent elbow per Rolls-Royce installation bulletin
and jamnut. (Ref. Section 01-00-00).
(7). Remove compressor bleed air hose, tee (19). Hoist (ST402) engine out of engine
and jamnut (Ref. Figure 402. view C). stand.
(8). Remove oil pressure reducer/snubber. (20). Unbolt and remove engine mount
fittings.
(9). Remove torque-meter reducer/snubber.
(21). Install engine in shipping container.
(10). Remove N1 and N2 tachometer genera
tors and gaskets. (22). Remove engine hoist fitting.
Page 409
MAINTENANCE MANUAL
ENGINE HOIST BULKHEAD SPLICE

FITTING FITTING
FIREWALL BULKHEAD
STA 124.00 BULKHEAD SPLICE
FITTING
LOWER ENGINE
MOUNT
LOWER ENGINE
MOUNT ATTACH
FITTING
LOWER ENGINE MOUNT - INSTALLATION
ENGINE
FITTING
UPPER ENGINE
MOUNT ASSY
AIRFRAME
FITTING
LANDING GEAR
DAMPER FITTING
UPPER ENGINE MOUNT - INSTALLATION
NOTE:
THICK WASHERS ARE USED IN LOCATIONS
MARKED WITH ASTERISK ( * ). G71-0002
Figure 403. Model 250−C20B and 250−C20R/2 Engine Mounts and Airframe Fittings
Page 410
MAINTENANCE MANUAL
4. Engine Buildup (3). Hoist engine clear of shipping contain

er.
(4). Inspect engine as follows:
Proper tightening of engine
WARNING tubing connections is criti (a). If shipping container moisture
cal to flight safety. Correct torque val indicator was other than a light blue
ues must be used at all times. Excessive color, examine engine for corrosion.
torque on fuel or pneumatic sensing Do a corrosion corrective mainte
system connections can result in crack nance per Rolls-Royce Operation and
ing of the flare causing an air leak Maintenance Manual as required.
which can cause flameout, power loss,
(b). Inspect inlet guide vanes for damage.
or overspeed.
(c). Exhaust and inlet openings for FOD.
Consumable Materials (d). Turbine blades for damage.
Item Nomenclature (e). Install covers over intake and
CM113 Anti-seize compound low temperature exhaust ports.
CM114 Petrolatum (f). All fasteners for security, slippage
CM118 Grease marks for alignment, potting com
CM502 Sleeving, fiberglass pound and, or correctly installed
CM702 Lockwire CRES lockwire where applicable.
CM808 Lacing cord (g). Tubes and hoses for damage.
Special Tools
(5). Record engine serial number and
start-counter reading in appropriate
Item Nomenclature
log.
ST401 Engine stand Prevent damage to machined
CAUTION surfaces and contamination. Re
move covers from engine one at a time as re
(1). Review Rolls-Royce instructions for quired by the installation sequence.
removing engine from shipping contain
er in Rolls-Royce Operation and (6). Install lower engine mount fitting with
Maintenance Manual. angle and ground wire under aft bolt
head. Install side engine mount fittings,
Prevent FOD Inspect and clean bolts and washers. Torque bolts to
CAUTION all accessories and hardware 140—160 inch-pounds (15.82—18.08
prior to installing parts on engine. Nm). Install lockwire (CM702).
NOTE: Replace O-rings and gaskets with new (7). Install engine in engine stand (ST401).
parts. Lubricate fuel line packings with
clean jet fuel or petrolatum (CM114) prior to (8). Install accumulator in pneumatic line
installation. Lubricate oil line packings with per Rolls-Royce installation bulletin
clean engine oil prior to installation. Apply a (Ref. Section 01-00-00).
thin coating of anti-seize compound (9). Install fuel control drain fitting and
(CM113) to the male threads of unions and O-ring.
fittings before torquing.
(10). Remove overrunning clutch pad cover.
(2). Install engine hoist lift fitting and bolts. Install overrunning clutch, firewall seal
Torque 3/8 inch-diameter bolt to and engine electrical harness angle and
160—190 inch-pounds (18.08—21.47 clamp (Ref. Section 63-10-00).
Nm). Torque 5/16 inch-diameter bolts
to 140—160 inch-pounds (11). Install oil pressure gauge reducer/snub
(15.82—18.08 Nm). ber and O-ring.
Page 411
MAINTENANCE MANUAL
(12). Install torque-meter reducer/snubber (c). Install reducer and O-ring in BF

and O-ring. port.
Engine spark igniter wire lead (d). Install hose assembly between AF
CAUTION can obstruct governor arm on a and BF fittings.
new or overhauled engine. (20). Lubricate splines with grease (CM118)
and install N1 and N2 tachometer
(13). Reroute engine spark igniter lead below generators. Install washers and nuts.
governor as shown (Ref. Figure 402). Torque nuts to 70—90 inch-pounds
Support igniter lead only with cush (7.91—10.17 Nm).
ioned clamps and existing fasteners.
Replace and, or add clamps as required. (21). Install special tee, jamnut and O-ring
in compressor scroll bleed air port. Do
(14). Remove vacuum/hydraulic pump pad not torque at this time.
cover from gear case.
(22). Install hose between special tee and
(15). Install governor control idler support, compressor bleed air elbow. Torque tee
bellcrank and short N2 control rod as jamnut. Torque hose nuts to 150—250
an assembly. Do not connect control rod inch-pounds (16.95—28.25 Nm).
to governor lever.
(23). Install accessory gear case vent elbow,
Only high temperature all met jamnut and O-ring. Do not torque at
CAUTION al self locking nuts shall be used this time.
to fasten governor control idler support (24). Install oil inlet and outlet couplings and
bracket to engine accessory pad. O-rings.
(16). Install elbow with O-ring and jamnut (25). Install oil tank vent tube and O-rings.
in fuel pump seal drain port. Torque tube nuts to 140—160 inch-
pounds (15.82—18.07 Nm).
(17). Model 250-C20B Only:
Install anti-icing valve lever with (26). Install fuel inlet reducer and O-ring.
attaching hardware on poppet guide. (27). Install starter/generator.
Position poppet guide so that lever is
parallel with top of engine. Always support the weight of
CAUTION the starter/generator during re
(18). Install engine air inlet bell and firewall moval/installation. Damage can occur if
seal. weight is supported by the shear shaft.
(19). Install fuel pressure switch fitting and (a). Remove starter/generator pad cover.
O-ring in fuel pump AF port (Ref. Install starter/generator mount with
Section 28-00-00). gasket, washers and nuts. Torque
Ensure both halves of the fuel (11.29—15.81 Nm).
CAUTION filter pressure switch are
gripped by wrench when torquing the in (b). Install starter/generator with V-
stallation. An asymmetrical wrench grip clamp. Torque clamp nut to 50
can cause shearing motion between assem inch-pounds (5.64 Nm).
bly halves. Such damage can result in leak (c). Tap around clamp with a rawhide
age or failure to operate FUEL FILTER mallet to seat clamp on flange.
caution/warning light, or both. Retorque clamp nut to 50 inch-
pounds (5.64 Nm).
(a). Install fuel filter pressure switch and
O-ring. (d). Continue tapping around clamp and
retorquing clamp nut until nut no
(b). Install bushing and O-ring on longer turns when specified torque is
switch. applied.
Page 412
MAINTENANCE MANUAL
(28). Clamp engine electrical harness to (1). Disconnect accessory drive overboard
lower engine mount and starter-gener vent tube from elbow on engine accesso
ator. ry case; remove vent tube from helicop
ter.
(29). Connect ignition exciter wire lead and
starter-generator A and D wire leads.
(30). Attach electrical connectors to both chip (2). Install extension tube to existing vent
detectors and safety with lockwire tube as follows:
(CM702).
(31). Connect N1 and N2 tachometer genera (a). Position extension tube over vent
tors connectors. tube. Drill rivet holes in line thru
(32). Connect start counter lead and fuel tubing.
pressure switch wire lead splices.
Install fiberglass sleeving (CM502) over
splices and secure with high tempera (b). Apply sealant (CM425) between
ture lacing cord (CM808). tubes. Install two NAS1738B4-2
rivets. Fillet seal around circumfer
5. Modification of Accessory Drive Gearbox ence of tubes.
Overboard Vent Tube (SN 0004D − 0519D)
(Ref. Figure 404) The following procedure adds (3). Remove existing grommet at lower
a four inch extension tube to the existing
fuselage Sta. 127.00 and install new
engine accessory drive gearbox vent tube to
MS35489-22 grommet.
reduce oil spattering onto the lower fuselage.
Consumable Materials (4). Insert extension tube thru grommet

(Ref. Section 91−00−00) and connect vent tube to elbow on
Item Nomenclature engine accessory case. Torque line nut
CM425 Sealing compound to 120—140 inch-pounds
(13.56—15.82 Nm).
Page 413
MAINTENANCE MANUAL
NAS1738B4-2 RIVET FUSELAGE SKIN

(2 REQD.) STA. 127.00
MS35489-22 GROMMET
NOTE
EXTENSION TUBE
369A8010-615
TUBE ASSY.
0.250 IN.
(6.35 MM)
0.84 IN.
(21.34 MM)
4.85 IN.
NOTE: SEAL BETWEEN TUBES
(12.319 CM)
BEFORE ASSEMBLY AND FILLET
SEAL ABOUT CIRCUMFERENCE. 88-295A
Figure 404. Extension of Engine Accessory Drive Overboard Vent Tube
Page 414
MAINTENANCE MANUAL
Section
71−00−30
Power Plant
(250−C30)
MAINTENANCE MANUAL
POWER PLANT
1. Power Plant Description compressor, N1 tachometer-generator
and accessory gear train, and a two-
(1). MDHI 369FF helicopter is powered by stage power turbine driving the spare
a 250-C30 turboshaft engine manufac accessory pad, governor, N2 tachome
tured by the Rolls-Royce Corporation. ter-generator and helicopter rotor
(2). The engine is secured in the helicopter system. An overrunning clutch, drive
by three mount assemblies and ac shaft, starter generator, fuel, oil, drain
cessed through two hinged, air-sealed and bleed air lines, exhaust ducting,
doors. mounting and hoist fittings and control
levers adapt the engine to the helicop
(3). A belt-driven blower forces external ter.
cooling air through strategically
positioned ducts that direct the air onto (2). Rolls-Royce Operation and Mainte
engine exterior surfaces and through nance Manuals are the primary
the engine and transmission oil cooler information source for engine fault
heat exchangers. Spent cooling air is isolation and maintenance data (Ref.
exhausted aft through an annular Section 01-00-00). Refer to these
opening between the engine exhaust manuals for specific engine mainte
duct and fuselage. nance procedures.
(4). Engine intake air may be filtered (3). Starter operational limitations are in
through a standard screen or optional the applicable Pilot's Flight Manual.
air particle separator/mist eliminator
3. Model 250−C30 Power Plant Fault
assembly. Intake air is drawn through
Isolation
a plenum chamber and into the engine
intake bell-mouth by the compressor. (Ref. Table 1)
Engine compartment air is separated
from compressor intake air by a seal (1). Check engine support systems, i.e.; chip
ring. detectors, instruments, fuel supply,
electrical systems, etc., to ensure that
2. Power Plant Operation helicopter equipment is functioning
correctly before disassembling engine
(1). The Rolls-Royce 250-C30 turboshaft systems for an indicated fault.
engine consists of a single stage
centrifugal flow compressor, a can-an (2). Inspect and isolate engine problems per
nular combustion chamber, a two-stage the applicable Rolls-Royce Operation
gas producer turbine driving the and Maintenance Manual.
Table 1. Power Plant Fault Isolation

Symptom Probable trouble Corrective action
High frequency vibration (1) Loose engine mount bolts Retorque engine mount bolts to
100—140 inch−pounds
(11.30—15.82 Nm).
NOTES:
(1) High frequency vibrations may be caused by other drive and rotor system components.
Page 1
MAINTENANCE MANUAL
Page 2
MAINTENANCE MANUAL
POWER PLANT
REMOVAL AND INSTALLATION
1. Engine Removal (8). Loosen and remove remaining engine
cooling air ducts from engine compart
A. Engine Disconnecting for Removal ment (ref. Figure 402, views A and D).
(Ref. Figure 401 and Figure 402) (9). Remove combustion chamber drain line
from burner drain valve.
After each opening, removal
WARNING or replacement of any part (10). Disconnect fuel inlet line at engine-
of the engine and/or aircraft fuel sys mounted fuel pump and cap line.
the engine fuel nozzle, the fuel system (11). Disconnect and remove fuel pump seal
must be bled to remove trapped air. drain line.
Failure to comply with this procedure
can result in engine flameout or power (12). Disconnect and remove fireshield drain
loss. line.
Cap fluid lines and fittings with
CAUTION approved devices. Do not use
(13). Disconnect fuel control vent line and
cap line.
tape to cover fuel and oil openings. Tape
adhesives loosened by fuel or oil can con
(14). Disconnect customer bleed line at
taminate systems.
firewall.
(1). Set all switches OFF. Disconnect
external power. Disconnect battery. (15). Disconnect torque-meter oil line from
firewall.
NOTE: Tag all hardware, wire terminals, fuel
and oil lines before removal to expedite in (16). Disconnect oil pressure indicator line
stallation. Identify and bag loose parts to from firewall.
prevent loss or damage.
(17). Disconnect N2 control rod from idler
(2). Remove main transmission drive shaft bellcrank. Secure control rod to fire
(Ref. Section 63-10-00). wall.
(3). Remove engine exhaust duct (Ref. (18). Disconnect N1 control rod from gas
Section 78-30-00). Cover engine producer lever. Secure control rod to
exhaust outlet. firewall.
(4). On left engine compartment door (19). Disconnect and remove starter-genera
frame; unclamp and disconnect thermo tor cooling air duct from starter and
couple wire leads from terminal studs fuselage bracket.
(Ref. Figure 401, view B).
The oil cooler is fragile. Unless
(5). Unplug engine-airframe electrical CAUTION otherwise required, disconnect
harness connector from engine recep oil supply and return lines only at engine.
tacle. Support oil cooler port boss with a backup
wrench when oil line removal is required.
(6). Disconnect the pressure transducers. Do not strain or bend unsupported tubes.
(7). Disconnect thermal switch plug from (20). Disconnect and cap engine oil inlet,
firewall. outlet and vent lines.
Page 401
71-00-30 TR18-002
MAINTENANCE MANUAL
COMBUSTION
CHAMBER DRAIN LINE
STARTER-GENERATOR
COOLING DUCT
LONG RANGE FUEL FUEL PUMP

TANK LINE INLET
ENGINE GEARCASE
COOLING DUCT UPPER ENGINE MOUNT GENERATOR
LH SIDE SHOWN TERMINALS
RH SIDE OPPOSITE N1 CONTROL ROD (E, C, B ONLY)
UPPER ENGINE
MOUNT FITTING
THERMOCOUPLE
ENGINE MOUNTING LEAD STUD (2)
PAD ASSY
THERMOCOUPLE LEAD
UPPER ENGINE MOUNT ENGINE DOOR

FRAME
THERMOCOUPLE LEAD - INSTALLATION

LANDING GEAR
DAMPER FITTING
G71-0003-1
Figure 401. Model 250−C30 Engine Removal and Installation (Sheet 1 of 2)
Page 402
MAINTENANCE MANUAL
HOISTING EYE
LOWER ENGINE MOUNT FITTING
INSTALLATION
BRACKET
CLAMP
LOWER ENGINE
MOUNT
FIRESHIELD DRAIN
TUBE ASSY
LOWER ENGINE FUEL PUMP SEAL
MOUNT FITTING DRAIN TUBE ASSY POWER TURBINE COOLING
DUCT INSTALLATION
ENGINE AIR BLEED DUCT

INLET BELL
ENGINE OIL
INLET LINE
ENGINE OIL
OUTLET LINE
MAIN TRANSMISSION
DRIVESHAFT
TORQUEMETER
OIL PRESSURE
N2 CONTROL ROD
ENGINE HARNESS
DISCONNECT ENGINE MOUNTING
PAD ASSY
G71−0047−401−1
Page 403
71-00-30 TR18-002
MAINTENANCE MANUAL
ELECTRICAL
HARNESS
PRESSURE
TRANSDUCER
BULKHEAD UNION
WASHER (2X)
NUT
ENGINE OIL
PRESSURE LINE
ENGINE
TORQUEMETER
LINE
G71−0047−401−2
Page 404
TR18-002 71-00-30
MAINTENANCE MANUAL
B. Removal of Disconnected Engine between fixed and adjustable support

shafts.
(8). Screw in adjustable support shaft until
engine mount fittings are securely
Special Tools engaged with support shaft sockets.
Item Nomenclature (9). Insert detent pin through adjustable
ST401 Engine stand support shaft.
ST402 Engine hoist (10). Remove hoist from engine lift fitting.
(11). If engine is to be stored or transported,
CAUTION secure upper end of engine stand
transport and storage bar to engine
D Do not remove engine mounts or disturb lifting eye fitting.
engine mount adjustments to remove en
gine. 2. Engine Installation
D Engine-transmission alignment shall be A. Engine Installation in Mounts
inspected whenever one or more engine
mount assemblies is replaced or the exist (Ref. Figure 401 and Figure 402)
ing alignment is disturbed. Do not disturb
adjustable engine mount fittings unless Consumable Materials
an engine-transmission alignment check (Ref. Section 91−00−00)
is planned. Item Nomenclature
(1). Install engine hoist apparatus (ST402) CM702 Lockwire CRES
between engine hoist eye and airframe
hoist fitting. Special Tools
(2). Have an assistant apply tension to the Item Nomenclature
engine with hoist. ST402 Engine hoist
Take care not to damage rod end
CAUTION bearings. (1). Open engine access doors.
(3). Keep the downward pressure on the (2). Position engine to line up engine lifting
rear of the engine during removal of the eye under airframe lift fitting.
mount bolt removal.
(3). Remove detent pin from adjustable
(4). Unbolt engine at lower engine mount support shaft on engine stand.
fitting.
(4). Detach transport and storage bar from
(5). Unbolt left and right engine mount engine lift fitting.
assemblies from engine fittings.
(5). Install engine hoist (ST402) between
Do not use fuel or oil lines as airframe fitting and engine hoist
CAUTION hand holds. Do not allow engine fitting.
to strike airframe while maneuvering it out
(6). Have an assistant tension hoist to
of the helicopter.
support engine.
(6). Align engine stand (ST401) under (7). Unscrew engine stand adjustable
engine with adjustable support shaft on support shaft.
left side.
(8). Move engine to disengage fixed shaft.
(7). Slowly lower engine out of helicopter.
Align engine side mount fittings (9). Roll stand away from engine.
Page 405
71-00-30 TR18-002
MAINTENANCE MANUAL
UPPER ENGINE
MOUNT FITTING
(REF. SEC. 71-20-00)
UPPER ENGINE MOUNT
SIDE ENGINE MOUNT

ATTACH FITTING
LANDING GEAR
DAMPER FITTING
(REF. SEC. 71-20-00)
UPPER ENGINE MOUNT - INSTALLATION

ROTATED
ENGINE FITTING
LOWER ENGINE MOUNT
LOWER ENGINE MOUNT - INSTALLATION

LOWER ENGINE MOUNT
ATTACH FITTING
(REF. SEC. 71-20-00)
G71-0004A
Figure 402. Engine Mounts and Structural Fittings
Page 406
TR18-002 71-00-30
MAINTENANCE MANUAL
B. Connecting an Installed Engine

CAUTION
D Do not use tubes or hoses as hand holds.
Do not allow engine to strike airframe or Consumable Materials
components. Avoid damaging engine in (Ref. Section 91−00−00)
take bell. Item Nomenclature
CM702 Lockwire CRES
D Prevent FOD must sure that no foreign
objects are trapped in firewall seal ring.
Correct torques of engine
WARNING tube connections is critical
(10). Have hoist operator slowly raise engine to flight safety. Always use the correct
while pushing engine down to maintain torque values. Overtorque on fuel or
correct engine and transmission pneumatic sensor system connections
alignment. can cause cracks in the flare that result
in an air leak which can cause flame
out, power loss, or overspeed.
(11). Align left and right engine mount Examine the torquemeter/lubri
assemblies with engine fittings. CAUTION cation line for worn areas or po
tential wear. Make sure line is routed safely
to prevent rubbing.
(a). Install bolts and washers (ref.
Figure 403). (1). Connect torque-meter oil line to
firewall.
(b). Torque bolts 220 to 360 inch-pound (2). Connect oil pressure gauge line to
(24.86 to 40.67 Nm). firewall.
(3). Connect engine oil vent line.
(c). Safety bolts to engine mounts with (a). Torque line nut 140 to 160 inch-
CM702 lockwire pound (15.82 to 18.07 Nm).
Do not bend oil return line.
CAUTION Bending loads are transferred to
(12). Align hole in lower engine mount
oil cooler port and can fracture cooler.
assembly with engine fitting.
(4). Connect engine oil outlet and inlet
lines.
(a). Install bolt, washers, and nut.
(a). Hand-tighten until snug.
(b). Wrench-tighten approximately 1/4
(b). Torque nut 95 to 110 inch-pound
turn or until definite resistance is
(10.73 to 12.43 Nm) felt.
(5). Position accessory drive vent elbow and
(c). Install cotter pin as necessary. connect with vent tube.
(a). Torque elbow jamnut 150 to 250
(13). Make sure engine air inlet firewall seal inch-pound (16.95 to 28.25 Nm).
ring contacts firewall seal around its (b). Torque tube nut 20 to 30 inch-
entire circumference. pound (2.26 to 3.39 Nm).
(6). Connect N1 control rod to lever with
(14). Remove hoist from helicopter. bolt, two washers, and nut.
Page 407
71-00-30 TR18-002
MAINTENANCE MANUAL
(a). Install bolt with head outboard, one (13). Install cooling air ducts and air duct
standard OD washer under nut, and support bracket on airframe hoist
one large 0.80 inch (20.3 mm) OD fitting.
washer under head.
(a). Connect and tighten ducts on firewall
(b). Torque nut 4 to 45 inch-pound coupling and oil cooler deflector.
(4.52 to 5.08 Nm). (14). Install main transmission drive shaft
(ref. Section 63-10-00).
(c). Install a new cotter pin.
(15). Install exhaust duct (ref. Section
(7). Connect short N2 control rod to gover 78-30-00).
nor lever with bolt head up, one
standard OD washer under head, one (16). Remove all identification tags from
large 0.80 inch (20.3 mm) OD washer wires and hardware.
under nut, and a new cotter pin. Incorrect rigging of the throttle
CAUTION controls can cause an inadver
(8). Connect long N2 control rod with bolt tent flameout when the throttle is rapidly
head forward, two washers, nut, and a closed to the idle position.
new cotter pin.
(17). Rig gas producer (N1) and power
(9). Connect engine fuel pump seal drain turbine (N2) controls (ref. Chapter 76).
line.
After each opening, removal
(a). Torque tube nut 50 to 65 inch-
pound (5.65 to 7.34 Nm). of the engine and/or aircraft fuel sys
(10). Connect fuel inlet line to fuel pump. the engine fuel nozzle, the fuel system
(a). Torque hose nut 230 to 260 inch- Failure to comply with this procedure
pounds (25.99 to 29.38 Nm). can result in engine flameout or power
loss.
NOTE: Make sure burner drain valve and plug
are installed in combustion chamber with (18). Do a fuel system bleed.
an O-ring on each part. Make sure drain NOTE: Do a deceleration time check:
valve is in the aft (lowest) position.
D Use the applicable RFM after rigging and
(11). Install combustion chamber drain line testing power turbine controls for the
on drain valve. C250-C20 engines. Refer to Rolls-Royce
Operation and Maintenance Manual for
(12). Attach engine electrical harness to adjustment procedures if deceleration
engine mount with cushioned loop time is less than allowable minimum.
clamp. D A deceleration time check is not necessary
on C30 engines.
(a). Connect harness plug to receptacle.
(19). Do an engine deceleration check (ref.
1). Safety with CM702 lockwire. the applicable Rotorcraft Flight
Manual).
(b). Install engine harness ground lead.
NOTE: Make engine adjustments per the
(c). Install E, C, and B generator leads on Rolls-Royce Operation and Maintenance
starter-generator terminal block Manual.
with washers and nuts. (20). Do an anti-icing system operational
check (ref. Section 75-10-00).
(d). Attach thermocouple leads to termi
nal block studs located on right upper (21). Examine the engine installation and
engine door frame with chromel and connections for correct routing and
alumel nuts. installation.
Page 408
TR18-002 71-00-30
MAINTENANCE MANUAL
3. Engine Stripping (15). Remove hose a

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MDHI MODEL HELICOPTERS

Basic Handbook of Maintenance Instructions

Copyright E 1999-2018 by MD Helicopters, Inc. Issued: 31 October 1990

The technical data and information contained in this publication

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Manual: CSP- HMI- 2, Handbook of Maintenance Instructions — Maintenance & Servicing

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