2 Csp-Hmi-2 - I0r44p PDF

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

ISSUED: 31 OCTOBER 1990
NOTE
This manual has been reprinted and now contains
Revisions 1 through 44 (5 July 2011)
PRINT DATE: 6 July 2011
MDHI MODEL HELICOPTERS

MODELS 369D/E/FF 500/600N
Basic Handbook of Maintenance Instructions
(CSPHMI2)
SERVICING AND MAINTENANCE
4555 East McDowell Road
Mesa, Arizona 852159734
Copyright E 1999-2011 by MD Helicopters, Inc.

All rights reserved under the copyright laws.
Issued: 31 October 1990

Revision No. 44: 05 July 2011
PROPRIETARY RIGHTS NOTICE

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

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MAINTENANCE MANUAL
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04001
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MAINTENANCE MANUAL
CSP-HMI-2
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 23 . . . . . . . . . . . . . . . . . . . . 01 June 1999
Revision 1 . . . . . . . . . . . . . . . . . . . . 29 March 1991
Revision 24 . . . . . . . . . . . . . . . 07 December 1999
Revision 2 . . . . . . . . . . . . . . . . . . . . . . 10 May 1991
Revision 25 . . . . . . . . . . . . . . . . . . . . . 28 April 2000
Revision 3 . . . . . . . . . . . . . . . . 09 September 1991
Revision 26 . . . . . . . . . . . . . . . . . . 17 August 2000
Revision 4 . . . . . . . . . . . . . . . . . . 20 January 1992
Revision 27 . . . . . . . . . . . . . . . . . 09 October 2000
Revision 5 . . . . . . . . . . . . . . . . . . . 24 August 1992
Revision 28 . . . . . . . . . . . . . . . 30 November 2000
Revision 6 . . . . . . . . . . . . . . . . 21 December 1992
Revision 29 . . . . . . . . . . . . . . . . . . . . . 11 May 2001
Revision 7 . . . . . . . . . . . . . . . . . . . . . 01 June 1993
Revision 30 . . . . . . . . . . . . . . . . . . . . . 11 July 2001
Revision 8 . . . . . . . . . . . . . . . . . . . . . . 23 July 1993
Revision 9 . . . . . . . . . . . . . . . . . . . . . . 22 April 1994
Revision 32 . . . . . . . . . . . . . . . . . . . 18 March 2002
Revision 10 . . . . . . . . . . . . . . . 26 September 1994
Revision 33 . . . . . . . . . . . . . . . . . . . . 24 June 2002
Revision 11 . . . . . . . . . . . . . . . . . 18 January 1995
Revision 34 . . . . . . . . . . . . . . . . . . 21 August 2003
Revision 35 . . . . . . . . . . . . . . . . . . . . . 20 May 2004
Revision 13 . . . . . . . . . . . . . . . . . . . . . 31 May 1996
Revision 14 . . . . . . . . . . . . . . . 13 September 1996
Revision 38 . . . . . . . . . . . . . . . . . . . . . 25 May 2006
Revision 16 . . . . . . . . . . . . . . . . . 06 January 1997
Revision 39 . . . . . . . . . . . . . . . . . . . . . 10 April 2007
Revision 17 . . . . . . . . . . . . . . . . . 24 February 1997
Revision 41 . . . . . . . . . . . . . . . . . . . 03 March 2008
Revision 42 . . . . . . . . . . . . . . . . . . . . 01 June 2009
Revision 20 . . . . . . . . . . . . . . . . . . . . 01 June 1998
Revision 21 . . . . . . . . . . . . . . . . . . 24 August 1998
Revision 44 . . . . . . . . . . . . . . . . . . . . . 05 July 2011
Revision 22 . . . . . . . . . . . . . . . . . . . 10 March 1998
Cover/Title
Cover/Title . . . . . . . . . . . . . . . . . . . . . . Revision 44
Change Request
CRi and CRii . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Temporary Revision
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
List of Effective Pages
A thru L . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
Table of Contents
i................................
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
v and vi . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 42
Revision 29
Revision 34
Revision 38
Revision 29
Chapter 01
i................................
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010000
1 ...............................
2 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . .
5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . .
7 ...............................
8 ...............................
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203 thru 214 . . . . . . . . . . . . . . . . . . . . .
LOEP
Revision 26
Revision 43
Revision 26
Revision 23
Revision 26
Revision 29
Revision 28
Revision 23
Revision 40
Revision 43
Page A
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
Chapter 04
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . .
040000
1 thru 16 . . . . . . . . . . . . . . . . . . . . . . . .
040001
1 ...............................
2 ...............................
Chapter 05
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . .
050000
1 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . .
051000
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . .
3 ...............................
4 ...............................
052000
1 ...............................
2 ...............................
3 ...............................
4 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . .
7 thru 12 . . . . . . . . . . . . . . . . . . . . . . . .
052010
1 thru 3 . . . . . . . . . . . . . . . . . . . . . . . . .
4 ...............................
052015
1 ...............................
2 ...............................
3 ...............................
4 ...............................
052020
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . .
3 ...............................
4 ...............................
5 ...............................
6 ...............................
055000
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . .
3 thru 12 . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 06
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . .
060000
201 thru 203 . . . . . . . . . . . . . . . . . . . . .
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page B
Revision 44
207 thru 210 . . . . . . . . . . . . . . . . . . . . . Revision 23

Revision 34
Revision 42
Revision 26
Revision 43
Revision 44
211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
Chapter 07
i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
070000
201 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 23
Revision 38
Revision 44
Revision 37
Revision 44
Chapter 08
i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
080000
201 thru 203 . . . . . . . . . . . . . . . . . . . . . Revision 23
Revision 35
Revision 39
Revision 40
Revision 35
Revision 39
Revision 39
Revision 38
Revision 29
Revision 43
Revision 31
Revision 43
Revision 43
Revision 38
Revision 43
Revision 38
Revision 36
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
081000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39
202 and 203 . . . . . . . . . . . . . . . . . . . . . Revision 27
204 thru 210 . . . . . . . . . . . . . . . . . . . . . Revision 23
211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
212 thru 217 . . . . . . . . . . . . . . . . . . . . . Revision 23
218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
Chapter 09
i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
090000
201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 23
Chapter 10
i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
Revision 44
Revision 42
101000
Revision 34
102000
Revision 23
Revision 44
Revision 23
Revision 39
LOEP
201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 23

201 thru 203 . . . . . . . . . . . . . . . . . . . . . Revision 23
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
103000
201 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 23
MAINTENANCE MANUAL
Chapter 11
i................................
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110000
201 thru 217 . . . . . . . . . . . . . . . . . . . . .
218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114000
201 thru 211 . . . . . . . . . . . . . . . . . . . . .
212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 12
i................................
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120000
301 and 302 . . . . . . . . . . . . . . . . . . . . .
303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
306 and 307 . . . . . . . . . . . . . . . . . . . . .
308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
310 and 311 . . . . . . . . . . . . . . . . . . . . .
312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 18
i thru iii . . . . . . . . . . . . . . . . . . . . . . . . . .
iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
181000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203 and 204 . . . . . . . . . . . . . . . . . . . . .
401 thru 403 . . . . . . . . . . . . . . . . . . . . .
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
503 thru 505 . . . . . . . . . . . . . . . . . . . . .
506 and 507 . . . . . . . . . . . . . . . . . . . . .
508 and 509 . . . . . . . . . . . . . . . . . . . . .
510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
181060
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 and 203 . . . . . . . . . . . . . . . . . . . . .
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
401 and 402 . . . . . . . . . . . . . . . . . . . . .
403 and 404 . . . . . . . . . . . . . . . . . . . . .
501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
503 thru 509 . . . . . . . . . . . . . . . . . . . . .
CSP-HMI-2
510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 37
Revision 23
Revision 43
511 and 512 . . . . . . . . . . . . . . . . . . . . . Revision 23
Revision 23
Revision 44
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
Revision 23
Revision 44
Revision 23
Revision 32
Revision 23
Revision 24
Revision 34
Revision 26
Revision 24
Revision 26
Revision 23
Revision 32
Revision 23
182000
202 and 203 . . . . . . . . . . . . . . . . . . . . . Revision 23
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
182030
201 thru 205 . . . . . . . . . . . . . . . . . . . . . Revision 23
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
Chapter 20
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 41
201000
201 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 38
202000
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 23
203000
Revision 23
Revision 43
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 23
Revision 23
Revision 31
Revision 37
Revision 44
Revision 23
Revision 23
Revision 34
Revision 23
Revision 24
Revision 23
Revision 39
204000
Revision 23
Revision 31
Revision 44
Revision 44
Revision 23
Revision 23
Revision 34
Revision 23
214000
203 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 34

201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 23
209000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 38
202 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 40
Chapter 21
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
211000
201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 23
201 thru 207 . . . . . . . . . . . . . . . . . . . . . Revision 23
208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 27
209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
901 thru 911 . . . . . . . . . . . . . . . . . . . . . Revision 23
912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
LOEP
Page C
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
Chapter 25
i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24
ii thru vii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 43
250000
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
251000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203 thru 205 . . . . . . . . . . . . . . . . . . . . .
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
207 and 208 . . . . . . . . . . . . . . . . . . . . .
Revision 23
Revision 44
Revision 23
Revision 24
Revision 23
251500
201 thru 203 . . . . . . . . . . . . . . . . . . . . . Revision 23
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
901 and 902 . . . . . . . . . . . . . . . . . . . . . Revision 23
252000
201 thru 205 . . . . . . . . . . . . . . . . . . . . .
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
207 thru 211 . . . . . . . . . . . . . . . . . . . . .
212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 23
Revision 44
Revision 23
Revision 44
252100
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
901 thru 908 . . . . . . . . . . . . . . . . . . . . . Revision 23
253000
201 thru 214 . . . . . . . . . . . . . . . . . . . . . Revision 23
254000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203 thru 207 . . . . . . . . . . . . . . . . . . . . .
208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 23
Revision 44
Revision 23
Revision 44
255000
101 thru 106 . . . . . . . . . . . . . . . . . . . . .
401 thru 408 . . . . . . . . . . . . . . . . . . . . .
601 and 602 . . . . . . . . . . . . . . . . . . . . .
901 thru 907 . . . . . . . . . . . . . . . . . . . . .
908 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 23
Revision 23
Revision 23
Revision 23
Revision 44
256000
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 23
256300
201 thru 216 . . . . . . . . . . . . . . . . . . . . . Revision 23
901 thru 910 . . . . . . . . . . . . . . . . . . . . . Revision 23
Page D
Revision 44
LOEP
Chapter 26
i................................
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
261000
201 thru 203 . . . . . . . . . . . . . . . . . . . . .
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
262000
201 and 202 . . . . . . . . . . . . . . . . . . . . .
Revision 23
Revision 43
Revision 23
Revision 44
Revision 23
Chapter 28
i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
ii and viii . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
280000
1 ...............................
2 ...............................
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102 and 103 . . . . . . . . . . . . . . . . . . . . .
104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201 and 202 . . . . . . . . . . . . . . . . . . . . .
401 and 402 . . . . . . . . . . . . . . . . . . . . .
403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
406 thru 408 . . . . . . . . . . . . . . . . . . . . .
409 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
410 thru 414 . . . . . . . . . . . . . . . . . . . . .
415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
416 and 417 . . . . . . . . . . . . . . . . . . . . .
418 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
421 and 422 . . . . . . . . . . . . . . . . . . . . .
501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
502 thru 504 . . . . . . . . . . . . . . . . . . . . .
505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
507 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
508 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
509 and 510 . . . . . . . . . . . . . . . . . . . . .
601 thru 603 . . . . . . . . . . . . . . . . . . . . .
604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
606 and 607 . . . . . . . . . . . . . . . . . . . . .
608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
801 thru 807 . . . . . . . . . . . . . . . . . . . . .
808 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 19
Revision 44
Revision 29
Revision 19
Revision 23
Revision 19
Revision 19
Revision 44
Revision 19
Revision 44
Revision 19
Revision 44
Revision 19
Revision 36
Revision 44
Revision 19
Revision 44
Revision 19
Revision 44
Revision 44
Revision 19
Revision 36
Revision 19
Revision 29
Revision 19
Revision 44
Revision 19
Revision 28
Revision 44
Revision 19
Revision 44
Revision 19
Revision 44
MAINTENANCE MANUAL
280060
1 thru 3 . . . . . . . . . . . . . . . . . . . . . . . . .
4 ...............................
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
401 thru 405 . . . . . . . . . . . . . . . . . . . . .
406 and 407 . . . . . . . . . . . . . . . . . . . . .
408 thru 413 . . . . . . . . . . . . . . . . . . . . .
414 and 415 . . . . . . . . . . . . . . . . . . . . .
416 thru 422 . . . . . . . . . . . . . . . . . . . . .
501 and 502 . . . . . . . . . . . . . . . . . . . . .
503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 thru 605 . . . . . . . . . . . . . . . . . . . . .
606 thru 608 . . . . . . . . . . . . . . . . . . . . .
801 thru 805 . . . . . . . . . . . . . . . . . . . . .
806 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
282500
1 ...............................
2 ...............................
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201 and 202 . . . . . . . . . . . . . . . . . . . . .
203 thru 205 . . . . . . . . . . . . . . . . . . . . .
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 and 602 . . . . . . . . . . . . . . . . . . . . .
603 thru 605 . . . . . . . . . . . . . . . . . . . . .
606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
901 and 902 . . . . . . . . . . . . . . . . . . . . .
903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
904 thru 918 . . . . . . . . . . . . . . . . . . . . .
Chapter 32
i................................
ii thru vi . . . . . . . . . . . . . . . . . . . . . . . . .
321000
1 ...............................
2 ...............................
301 thru 308 . . . . . . . . . . . . . . . . . . . . .
401 and 402 . . . . . . . . . . . . . . . . . . . . .
403 and 404 . . . . . . . . . . . . . . . . . . . . .
405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 19
Revision 44
Revision 29
Revision 19
Revision 21
Revision 44
Revision 32
Revision 39
Revision 19
Revision 34
Revision 19
Revision 43
Revision 19
Revision 22
Revision 21
Revision 44
Revision 19
Revision 31
Revision 43
Revision 19
Revision 44
Revision 39
Revision 20
Revision 20
Revision 44
Revision 20
Revision 19
Revision 44
Revision 20
Revision 19
Revision 44
Revision 20
Revision 28
Revision 19
CSP-HMI-2
406 and 407 . . . . . . . . . . . . . . . . . . . . .

408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 thru 605 . . . . . . . . . . . . . . . . . . . . .
606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
801 thru 805 . . . . . . . . . . . . . . . . . . . . .
806 and 807 . . . . . . . . . . . . . . . . . . . . .
808 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
901 thru 908 . . . . . . . . . . . . . . . . . . . . .
Revision 26
Revision 44
Revision 31
Revision 26
Revision 44
Revision 19
Revision 26
Revision 44
Revision 19
321060
1 ...............................
2 ...............................
301 thru 303 . . . . . . . . . . . . . . . . . . . . .
304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
405 and 406 . . . . . . . . . . . . . . . . . . . . .
407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
801 thru 803 . . . . . . . . . . . . . . . . . . . . .
804 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 19
Revision 44
Revision 19
Revision 44
Revision 19
Revision 26
Revision 34
Revision 20
Revision 19
Revision 20
Revision 44
Revision 31
Revision 19
Revision 22
Revision 44
Revision 19
Revision 44
324000
201 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 19
324060
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 19
Revision 19
Revision 26
328100
201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 19
901 thru 910 . . . . . . . . . . . . . . . . . . . . . Revision 19
Revision 19
Revision 44
Revision 19
Revision 19
Revision 26
Revision 19
328200
201 thru 206 . . . . . . . . . . . . . . . . . . . . .
401 thru 407 . . . . . . . . . . . . . . . . . . . . .
408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
901 thru 912 . . . . . . . . . . . . . . . . . . . . .
LOEP
Revision 19
Revision 19
Revision 44
Revision 19
Page E
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
Chapter 52
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
534030
521000
201 thru 213 . . . . . . . . . . . . . . . . . . . . .
214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
215 and 216 . . . . . . . . . . . . . . . . . . . . .
217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
218 thru 224 . . . . . . . . . . . . . . . . . . . . .
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
Revision 25
Revision 44
Revision 36
Revision 25
Revision 36
524000
201 thru 205 . . . . . . . . . . . . . . . . . . . . . Revision 18
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
525000
201 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 18
207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 31
208 thru 210 . . . . . . . . . . . . . . . . . . . . . Revision 18
Chapter 53
i thru vi . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
530000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 44
Revision 37
Revision 19
Revision 20
531000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
202 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 19
532000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
202 and 203 . . . . . . . . . . . . . . . . . . . . . Revision 19
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
533000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 and 203 . . . . . . . . . . . . . . . . . . . . .
204 and 205 . . . . . . . . . . . . . . . . . . . . .
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
208 and 209 . . . . . . . . . . . . . . . . . . . . .
210 thru 214 . . . . . . . . . . . . . . . . . . . . .
Revision 35
Revision 19
Revision 38
Revision 44
Revision 38
Revision 44
Revision 38
533030
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 and 203 . . . . . . . . . . . . . . . . . . . . .
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
205 thru 210 . . . . . . . . . . . . . . . . . . . . .
Revision 26
Revision 34
Revision 44
Revision 34
534000
201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 19
Page F
Revision 44
LOEP
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
205 and 206 . . . . . . . . . . . . . . . . . . . . . Revision 39
207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
208 thru 214 . . . . . . . . . . . . . . . . . . . . . Revision 39
801 and 802 . . . . . . . . . . . . . . . . . . . . . Revision 44
535010
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 19
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
204 and 205 . . . . . . . . . . . . . . . . . . . . . Revision 37
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 40
207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
535030
201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 42
203 and 204 . . . . . . . . . . . . . . . . . . . . . Revision 33
205 thru 212 . . . . . . . . . . . . . . . . . . . . . Revision 40
Chapter 62
i thru viii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 37
620000
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 31
621000
401 thru 403 . . . . . . . . . . . . . . . . . . . . .
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 thru 605 . . . . . . . . . . . . . . . . . . . . .
606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
607 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
609 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
610 and 611 . . . . . . . . . . . . . . . . . . . . .
612 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
802 thru 808 . . . . . . . . . . . . . . . . . . . . .
809 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
810 and 811 . . . . . . . . . . . . . . . . . . . . .
812 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 20
Revision 44
Revision 20
Revision 40
Revision 20
Revision 33
Revision 29
Revision 35
Revision 20
Revision 33
Revision 20
Revision 34
Revision 20
Revision 44
MAINTENANCE MANUAL
622000
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
402 and 403 . . . . . . . . . . . . . . . . . . . . .
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
405 and 406 . . . . . . . . . . . . . . . . . . . . .
601 and 602 . . . . . . . . . . . . . . . . . . . . .
603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
605 thru 607 . . . . . . . . . . . . . . . . . . . . .
608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
609 and 610 . . . . . . . . . . . . . . . . . . . . .
801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
802 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
803 thru 810 . . . . . . . . . . . . . . . . . . . . .
811 thru 813 . . . . . . . . . . . . . . . . . . . . .
814 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
815 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
816 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
817 and 818 . . . . . . . . . . . . . . . . . . . . .
819 and 820 . . . . . . . . . . . . . . . . . . . . .
622060
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
403 and 404 . . . . . . . . . . . . . . . . . . . . .
405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 and 602 . . . . . . . . . . . . . . . . . . . . .
603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
606 and 607 . . . . . . . . . . . . . . . . . . . . .
608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
609 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
610 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
801 thru 804 . . . . . . . . . . . . . . . . . . . . .
805 thru 808 . . . . . . . . . . . . . . . . . . . . .
809 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
810 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
811 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
812 and 813 . . . . . . . . . . . . . . . . . . . . .
814 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
623000
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
403 and 404 . . . . . . . . . . . . . . . . . . . . .
405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CSP-HMI-2
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 27
Revision 36
Revision 20
Revision 36
Revision 20
Revision 20
Revision 29
Revision 25
Revision 20
Revision 37
Revision 20
Revision 20
Revision 34
Revision 20
Revision 37
Revision 21
Revision 35
Revision 34
Revision 40
Revision 37
Revision 36
Revision 20
Revision 36
Revision 20
Revision 44
Revision 20
Revision 33
Revision 20
Revision 34
Revision 33
Revision 20
Revision 25
Revision 20
Revision 20
Revision 37
Revision 22
Revision 37
Revision 22
Revision 34
Revision 37
Revision 20
Revision 36
Revision 31
Revision 36
407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 35
601 and 602 . . . . . . . . . . . . . . . . . . . . . Revision 32
801 thru 807 . . . . . . . . . . . . . . . . . . . . . Revision 20
808 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
623060
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 27
403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 31
404 thru 406 . . . . . . . . . . . . . . . . . . . . . Revision 35
407 and 408 . . . . . . . . . . . . . . . . . . . . . Revision 44
601 and 602 . . . . . . . . . . . . . . . . . . . . . Revision 32
801 and 802 . . . . . . . . . . . . . . . . . . . . . Revision 20
Chapter 63
i thru x . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42
630000
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28
102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29
103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 30
104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28
631000
401 thru 403 . . . . . . . . . . . . . . . . . . . . . Revision 20
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 36
405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 27
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42
407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32
409 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 39
410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32
411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
412 thru 414 . . . . . . . . . . . . . . . . . . . . . Revision 32
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
604 thru 606 . . . . . . . . . . . . . . . . . . . . . Revision 20
801 thru 804 . . . . . . . . . . . . . . . . . . . . . Revision 20
LOEP
Page G
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
631510
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
402 thru 404 . . . . . . . . . . . . . . . . . . . . .
405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
406 and 407 . . . . . . . . . . . . . . . . . . . . .
408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
409 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 thru 603 . . . . . . . . . . . . . . . . . . . . .
604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
801 and 802 . . . . . . . . . . . . . . . . . . . . .
631530
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203 thru 207 . . . . . . . . . . . . . . . . . . . . .
208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
632000
201 thru 203 . . . . . . . . . . . . . . . . . . . . .
204 and 205 . . . . . . . . . . . . . . . . . . . . .
206 and 207 . . . . . . . . . . . . . . . . . . . . .
208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
632025
201 and 202 . . . . . . . . . . . . . . . . . . . . .
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206 thru 209 . . . . . . . . . . . . . . . . . . . . .
210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
632100
401 and 402 . . . . . . . . . . . . . . . . . . . . .
403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
404 thru 407 . . . . . . . . . . . . . . . . . . . . .
408 thru 410 . . . . . . . . . . . . . . . . . . . . .
411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
801 and 802 . . . . . . . . . . . . . . . . . . . . .
803 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
804 and 805 . . . . . . . . . . . . . . . . . . . . .
Page H
Revision 44
Revision 20
Revision 42
Revision 43
Revision 42
Revision 20
Revision 43
Revision 28
Revision 20
Revision 37
Revision 20
Revision 44
Revision 20
Revision 20
Revision 43
Revision 20
Revision 43
Revision 20
Revision 36
Revision 20
Revision 44
Revision 20
Revision 41
Revision 28
Revision 24
Revision 29
Revision 44
Revision 20
Revision 28
Revision 20
Revision 42
Revision 43
Revision 42
Revision 43
Revision 42
Revision 41
Revision 36
Revision 37
Revision 36
Revision 22
Revision 37
Revision 36
LOEP
806 and 807 . . . . . . . . . . . . . . . . . . . . . Revision 37

808 and 809 . . . . . . . . . . . . . . . . . . . . . Revision 36
810 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
632200
201 and 202 . . . . . . . . . . . . . . . . . . . . .
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
401 thru 413 . . . . . . . . . . . . . . . . . . . . .
414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 and 602 . . . . . . . . . . . . . . . . . . . . .
901 thru 917 . . . . . . . . . . . . . . . . . . . . .
918 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 20
Revision 42
Revision 20
Revision 20
Revision 44
Revision 20
Revision 20
Revision 44
632510
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
204 thru 207 . . . . . . . . . . . . . . . . . . . . .
208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 36
Revision 20
Revision 40
Revision 20
Revision 44
632530
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 36
Revision 20
Revision 33
Revision 20
633000
201 and 202 . . . . . . . . . . . . . . . . . . . . .
203 and 204 . . . . . . . . . . . . . . . . . . . . .
205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 20
Revision 36
Revision 29
Revision 36
Chapter 64
i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 42
640000
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21
102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
640005
901 thru 908 . . . . . . . . . . . . . . . . . . . . . Revision 21
641000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 thru 206 . . . . . . . . . . . . . . . . . . . . .
207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
208 thru 210 . . . . . . . . . . . . . . . . . . . . .
211 thru 214 . . . . . . . . . . . . . . . . . . . . .
Revision 34
Revision 21
Revision 32
Revision 21
Revision 22
MAINTENANCE MANUAL
642000
201 thru 203 . . . . . . . . . . . . . . . . . . . . .
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
642530
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
402 and 403 . . . . . . . . . . . . . . . . . . . . .
404 thru 407 . . . . . . . . . . . . . . . . . . . . .
408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
802 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
803 thru 808 . . . . . . . . . . . . . . . . . . . . .
643000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203 and 204 . . . . . . . . . . . . . . . . . . . . .
205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206 and 207 . . . . . . . . . . . . . . . . . . . . .
208 thru 210 . . . . . . . . . . . . . . . . . . . . .
Chapter 67
i thru xii . . . . . . . . . . . . . . . . . . . . . . . . .
670000
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102 and 103 . . . . . . . . . . . . . . . . . . . . .
104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105 and 106 . . . . . . . . . . . . . . . . . . . . .
107 thru 111 . . . . . . . . . . . . . . . . . . . . .
112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
671000
1 thru 5 . . . . . . . . . . . . . . . . . . . . . . . . .
6 ...............................
401 thru 405 . . . . . . . . . . . . . . . . . . . . .
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
407 thru 411 . . . . . . . . . . . . . . . . . . . . .
412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
415 thru 417 . . . . . . . . . . . . . . . . . . . . .
418 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 21
Revision 28
Revision 21
Revision 44
Revision 21
Revision 44
Revision 41
Revision 42
Revision 41
Revision 34
Revision 42
Revision 39
Revision 42
Revision 21
Revision 42
Revision 21
Revision 36
Revision 21
Revision 40
Revision 34
Revision 21
Revision 42
Revision 30
Revision 21
Revision 29
Revision 42
Revision 30
Revision 43
Revision 21
Revision 44
Revision 21
Revision 37
Revision 21
Revision 29
Revision 24
Revision 21
Revision 29
Revision 39
Revision 21
Revision 29
421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
501 thru 503 . . . . . . . . . . . . . . . . . . . . .
504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
507 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
508 and 509 . . . . . . . . . . . . . . . . . . . . .
510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
512 thru 515 . . . . . . . . . . . . . . . . . . . . .
516 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
517 thru 521 . . . . . . . . . . . . . . . . . . . . .
522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
523 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
525 and 526 . . . . . . . . . . . . . . . . . . . . .
527 thru 530 . . . . . . . . . . . . . . . . . . . . .
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
606 and 607 . . . . . . . . . . . . . . . . . . . . .
608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
609 and 610 . . . . . . . . . . . . . . . . . . . . .
801 thru 813 . . . . . . . . . . . . . . . . . . . . .
814 and 815 . . . . . . . . . . . . . . . . . . . . .
816 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CSP-HMI-2
Revision 21
Revision 29
Revision 31
Revision 29
Revision 21
Revision 42
Revision 34
Revision 21
Revision 34
Revision 21
Revision 24
Revision 38
Revision 21
Revision 36
Revision 21
Revision 36
Revision 29
Revision 31
Revision 36
Revision 21
Revision 44
Revision 21
Revision 28
Revision 39
Revision 21
Revision 39
Revision 28
Revision 39
Revision 21
Revision 31
Revision 21
671020
201 thru 202 . . . . . . . . . . . . . . . . . . . . . Revision 21
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 40
204 thru 208 . . . . . . . . . . . . . . . . . . . . . Revision 21
672010
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . .
401 and 402 . . . . . . . . . . . . . . . . . . . . .
403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
405 thru 407 . . . . . . . . . . . . . . . . . . . . .
408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
501 thru 504 . . . . . . . . . . . . . . . . . . . . .
601 and 602 . . . . . . . . . . . . . . . . . . . . .
801 thru 806 . . . . . . . . . . . . . . . . . . . . .
LOEP
Revision 21
Revision 21
Revision 34
Revision 26
Revision 21
Revision 44
Revision 21
Revision 21
Revision 21
Page I
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
672030
1 ...............................
2 ...............................
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
409 thru 412 . . . . . . . . . . . . . . . . . . . . .
413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
414 thru 416 . . . . . . . . . . . . . . . . . . . . .
501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
507 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
508 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510 and 511 . . . . . . . . . . . . . . . . . . . . .
512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
513 thru 516 . . . . . . . . . . . . . . . . . . . . .
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
603 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
604 and 605 . . . . . . . . . . . . . . . . . . . . .
606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
801 thru 803 . . . . . . . . . . . . . . . . . . . . .
804 thru 806 . . . . . . . . . . . . . . . . . . . . .
Chapter 71
i thru x . . . . . . . . . . . . . . . . . . . . . . . . . .
710000
1 ...............................
2 ...............................
401 thru 405 . . . . . . . . . . . . . . . . . . . . .
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
407 thru 411 . . . . . . . . . . . . . . . . . . . . .
412 and 413 . . . . . . . . . . . . . . . . . . . . .
414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
710030
1 ...............................
2 ...............................
Page J
Revision 44
Revision 34
Revision 25
Revision 18
Revision 34
Revision 18
Revision 33
Revision 38
Revision 34
Revision 38
Revision 25
Revision 33
Revision 25
Revision 30
Revision 33
Revision 18
Revision 20
Revision 18
Revision 30
Revision 18
Revision 26
Revision 30
Revision 37
Revision 30
Revision 36
Revision 30
Revision 34
Revision 35
Revision 39
Revision 24
Revision 39
Revision 18
Revision 42
Revision 36
Revision 22
Revision 44
Revision 22
Revision 30
Revision 22
Revision 26
Revision 44
Revision 22
Revision 44
LOEP
401 thru 404 . . . . . . . . . . . . . . . . . . . . .

405 and 406 . . . . . . . . . . . . . . . . . . . . .
407 thru 411 . . . . . . . . . . . . . . . . . . . . .
412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 22
Revision 34
Revision 22
Revision 26
710047
1 thru 3 . . . . . . . . . . . . . . . . . . . . . . . . .
4 ...............................
401 thru 406 . . . . . . . . . . . . . . . . . . . . .
407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
408 thru 411 . . . . . . . . . . . . . . . . . . . . .
412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 22
Revision 44
Revision 22
Revision 36
Revision 29
Revision 44
711000
201 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 22
711005
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 44
901 thru 904 . . . . . . . . . . . . . . . . . . . . . Revision 22
711010
1 ...............................
2 ...............................
3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . .
101 thru 106 . . . . . . . . . . . . . . . . . . . . .
201 thru 207 . . . . . . . . . . . . . . . . . . . . .
208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 and 603 . . . . . . . . . . . . . . . . . . . . .
604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
801 thru 814 . . . . . . . . . . . . . . . . . . . . .
901 thru 923 . . . . . . . . . . . . . . . . . . . . .
924 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 22
Revision 36
Revision 22
Revision 36
Revision 22
Revision 44
Revision 22
Revision 37
Revision 22
Revision 44
Revision 39
Revision 22
Revision 38
Revision 22
Revision 22
Revision 44
711060
1 ...............................
2 ...............................
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
402 thru 404 . . . . . . . . . . . . . . . . . . . . .
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision 22
Revision 44
Revision 22
Revision 44
Revision 22
Revision 29
Revision 29
Revision 33
MAINTENANCE MANUAL
712000
1 ...............................
2 ...............................
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
403 and 404 . . . . . . . . . . . . . . . . . . . . .
405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
802 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
713000
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . .
101 thru 103 . . . . . . . . . . . . . . . . . . . . .
104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
401 thru 410 . . . . . . . . . . . . . . . . . . . . .
411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
413 and 414 . . . . . . . . . . . . . . . . . . . . .
601 and 602 . . . . . . . . . . . . . . . . . . . . .
801 thru 804 . . . . . . . . . . . . . . . . . . . . .
901 thru 905 . . . . . . . . . . . . . . . . . . . . .
906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
716000
201 thru 205 . . . . . . . . . . . . . . . . . . . . .
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 75
i................................
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
751000
201 thru 203 . . . . . . . . . . . . . . . . . . . . .
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
205 and 206 . . . . . . . . . . . . . . . . . . . . .
Chapter 76
i................................
ii thru iv . . . . . . . . . . . . . . . . . . . . . . . . .
760000
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . .
101 and 102 . . . . . . . . . . . . . . . . . . . . .
761000
201 thru 209 . . . . . . . . . . . . . . . . . . . . .
210 thru 213 . . . . . . . . . . . . . . . . . . . . .
Revision 22
Revision 44
Revision 26
Revision 22
Revision 34
Revision 22
Revision 44
Revision 22
Revision 44
Revision 22
Revision 44
Revision 22
Revision 22
Revision 44
Revision 22
Revision 43
Revision 22
Revision 26
Revision 32
Revision 22
Revision 22
Revision 44
Revision 22
Revision 44
Revision 22
Revision 43
Revision 22
Revision 37
Revision 22
Revision 44
Revision 37
Revision 22
Revision 22
Revision 22
Revision 44
214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
216 and 217 . . . . . . . . . . . . . . . . . . . . .
218 and 219 . . . . . . . . . . . . . . . . . . . . .
220 and 221 . . . . . . . . . . . . . . . . . . . . .
222 and 223 . . . . . . . . . . . . . . . . . . . . .
224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
762000
201 thru 213 . . . . . . . . . . . . . . . . . . . . .
214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
764700
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 and 203 . . . . . . . . . . . . . . . . . . . . .
204 thru 212 . . . . . . . . . . . . . . . . . . . . .
Chapter 78
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . .
782000
201 thru 203 . . . . . . . . . . . . . . . . . . . . .
204 thru 209 . . . . . . . . . . . . . . . . . . . . .
210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
783000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202 thru 204 . . . . . . . . . . . . . . . . . . . . .
Chapter 79
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . .
790000
201 thru 212 . . . . . . . . . . . . . . . . . . . . .
791010
201 and 202 . . . . . . . . . . . . . . . . . . . . .
901 thru 903 . . . . . . . . . . . . . . . . . . . . .
904 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 91
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . .
910000
1 ...............................
2 ...............................
3 ...............................
4 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . .
7 ...............................
8 thru 16 . . . . . . . . . . . . . . . . . . . . . . . .
17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 thru 20 . . . . . . . . . . . . . . . . . . . . . . .
21 and 22 . . . . . . . . . . . . . . . . . . . . . . .
LOEP
CSP-HMI-2
Revision 22
Revision 35
Revision 42
Revision 35
Revision 22
Revision 35
Revision 22
Revision 22
Revision 44
Revision 44
Revision 37
Revision 44
Revision 35
Revision 38
Revision 22
Revision 44
Revision 38
Revision 35
Revision 23
Revision 23
Revision 44
Revision 23
Revision 44
Revision 43
Revision 23
Revision 34
Revision 36
Revision 41
Revision 44
Revision 41
Revision 42
Revision 43
Revision 41
Page K
Revision 44
CSP-HMI-2
MAINTENANCE MANUAL
Page L
Revision 44
LOEP
MAINTENANCE MANUAL
CSP-HMI-2
TABLE OF CONTENTS
CSPHMI2
Cover / Title Page
Technical Manual Recommended Change Report
Record of Temporary Revisions
List of Effective Pages
01
Introduction
04
Airworthiness Limitations
05
Continued Airworthiness Checks / Inspections
06
Dimensions and Areas
07
Lifting and Jacking
08
Leveling / Weight and Balance
09
Towing
10
Parking and Mooring
11
Placards and Markings
12
Servicing
18
Vibration and Noise Analysis
20
Standard Practices
21
Environmental Control System
25
Equipment / Furnishings
26
Fire Protection
28
Fuel System
32
Landing Gear
52
Doors
53
Fuselage
62
Main Rotor
63
Transmission and Drive System
64
AntiTorque Assembly
67
Flight Controls
71
Power Plant
75
Engine AntiIce System
76
Engine Power Controls
78
Engine Exhaust System
79
Engine Oil Supply System
91
Charts
Contents
Page i
Revision 42
CSP-HMI-2
MAINTENANCE MANUAL
CSPHMI3
95
Instruments
96
Electrical Power
97
Avionics
Page ii
Revision 29
Contents
MAINTENANCE MANUAL
CSP-HMI-2
NOTE: The following sections are applicable to the helicopter models denoted to the right of the
section.
Section
01
Title
369D 369E 369FF 500N 600N
INTRODUCTION
010000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
04
Checks/Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Component Overhaul/Recommended Replacement . . . . . . . . . . X
100Hour or Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
300Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Yearly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Special Inspections Hourly and Calendar . . . . . . . . . . . . . . . . . . . . X
Conditional Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
SERVICING
120000 Helicopter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
18
X
X
X
X
X
X
X
PLACARDS AND MARKINGS
110000 Placards and Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

114000 Placards and Markings (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
X
X
PARKING AND MOORING
101000 Parking and Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

102000 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
103000 Blade Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
11
TOWING
090000 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
10
LEVELING / WEIGHT AND BALANCE
080000 Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
081000 Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
09
LIFTING AND JACKING
070000 Lifting and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
08
DIMENSIONS AND AREAS
060000 Dimensions and Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
07
CONTINUED AIRWORTHINESS
050000
051000
052000
052010
052015
052020
055000
06
AIRWORTHINESS LIMITATIONS
040000 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

040001 Airworthiness Limitations Supplements . . . . . . . . . . . . . . . . . . . . . .
05
VIBRATION AND NOISE ANALYSIS
181000
181060
182000
182030
Main Rotor Track and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

Main Rotor Track and Balance (600N) . . . . . . . . . . . . . . . . . . . . . .
Tail Rotor Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Notarr AntiTorque System Fan Balance . . . . . . . . . . . . . . . . . . . .
Contents
X
Page iii
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
Section
20
Title
369D 369E 369FF 500N 600N
STANDARD PRACTICES
201000 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
202000 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
203000 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
204000 Corrosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
209000 Nondestructive Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
211000 Ventilation Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
214000 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
250000 Equipment/Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
251000 Upholstered Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
251500 Mesh Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
252000 Seat Belts/Inertia Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
252100 Seating/Belts (Four on the Floor) . . . . . . . . . . . . . . . . . . . . . . . . . . . X
253000 Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
254000 Miscellaneous Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
255000 Cargo Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
256000 Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
256300 Hoist Passenger/Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
21
25
26
ENVIRONMENTAL CONTROL SYSTEM
EQUIPMENT / FURNISHINGS
FIRE PROTECTION
261000 Engine Fire Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

262000 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
28
X
X
FUEL SYSTEM
280000 Fuel System (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . X

280060 Fuel System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
282500 AntiIce / Airframe Fuel Filter (369D/E 500/600N) . . . . . . . . . . X
32
X
X
LANDING GEAR
321000 Landing Gear System (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . X

321060 Landing Gear System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
324000 Ground Handling Wheels (369D/E/FF 500N) . . . . . . . . . . . . . . . X
X
X
324060 Ground Handling Wheels (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . .
328100 Utility Float System (369D/E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
328200 Emergency Float System (369D/E/FF 500N) . . . . . . . . . . . . . . . X
521000 Crew, Passenger, Cargo Doors and Windows . . . . . . . . . . . . . . . . X
524000 Engine Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
525000 Miscellaneous Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
52
DOORS
Page iv
Revision 38
Contents
MAINTENANCE MANUAL
Section
53
632200
632510
632530
633000
X
X
X
X
X
X
X
X
X
X
Main Rotor (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . X

Main Rotor Blade (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . X
Main Rotor Hub (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . . . . . . X
Main Rotor Hub (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swashplate and Mixer (369D/E/FF 500N) . . . . . . . . . . . . . . . . . . X
Swashplate and Mixer (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X
X
X
X
X
X
X
X
X
X
X
X
X
Transmission and Drive System (369D/E/FF 500/600N) . . . . . X

Drive Shafts / Clutches / Couplings (369D/E/FF 500/600N) . . X
Tail Rotor Drive Shaft (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . X
NOTARr AntiTorque System Drive Shafts (500/600N) . . . . . . .
369D25100 Main Transmission (369D/E/FF 500N) . . . . . . . . . . X
369F5100 Main Transmission (369D/E/FF 500/600N) . . . . . . . X
Main Transmission Lubrication and Cooling System
(369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Rotor Brake (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . . . . X
Tail Rotor Transmission (Two and Four Blade) (369D/E/FF) . . . . X
NOTARr AntiTorque Fan Transmission (500/600N) . . . . . . . . . .
Main Rotor Static Mast (369D/E/FF 500/600N) . . . . . . . . . . . . . X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
ANTI-TORQUE ASSEMBLY
640000
640005
641000
642000
642530
643000
67
X
X
X
X
TRANSMISSION AND DRIVE SYSTEM
630000
631000
631510
631530
632000
632025
632100
64
Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Windshields and Aft Section Windows . . . . . . . . . . . . . . . . . . . . . . X
Lower Center Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Upper Aft Section Fuselage (369D/E/FF) . . . . . . . . . . . . . . . . . . . . X
Upper Aft Section Fuselage (500/600N) . . . . . . . . . . . . . . . . . . . . .
Tailboom (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Tailboom (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer (TTail) (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Stabilizer (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN ROTOR
620000
621000
622000
622060
623000
623060
63
369D 369E 369FF 500N 600N
FUSELAGE
530000
531000
532000
533000
533030
534000
534030
535010
535030
62
Title
CSP-HMI-2
AntiTorque Assembly (369D/E/FF 500/600N) . . . . . . . . . . . . . X

FourBladed Tail Rotor Assembly Initial Installation (369D/E) . . X
Tail Rotor Blades (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Tail Rotor Hub and Fork (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . X
AntiTorque Fan (500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tail Rotor Pitch Control Assembly (369D/E/FF) . . . . . . . . . . . . . . . X
FLIGHT CONTROLS
670000
671000
671020
672010
Flight Controls (369D/E/FF 500/600N) . . . . . . . . . . . . . . . . . . . . X

Main Rotor Flight Controls (369D/E/FF 500/600N) . . . . . . . . . . X
Collective and Cyclic Stick Grips (369D/E/FF 500/600N) . . . . . X
AntiTorque Flight Controls (Two and Four Blade)
(369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
672030 NOTARr AntiTorque System Flight Controls (500/600N) . . . . .
Contents
Page v
Revision 29
MAINTENANCE MANUAL
CSP-HMI-2
Section
71
Title
369D 369E 369FF 500N 600N
POWER PLANT
710000 Power Plant (250C20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
710030 Power Plant (250C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X
X
710047 Power Plant (250C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
711000 Engine Air Intake System (369D/E/FF 500/600N) . . . . . . . . . . . X
711005 Engine Compressor Water Wash Kit (369D/E/FF

500/600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
711010 Engine Air Particle Separator (369D/E/FF 500N) . . . . . . . . . . . X
711060 Engine Air Particle Separator (600N) . . . . . . . . . . . . . . . . . . . . . . .
712000 Engine Mounts (250C20B, 250C20R/2, 250C30

and 250C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
713000 Engine Ignition Control System (250C20B, 250C20R/2

and 250C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
716000 Engine Cooling System (250C20B, 250C20R/2, 250C30

and 250C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
760000 Engine Power Controls (250C20B, 250C20R/2

and 250C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
761000 Power Turbine Governor Controls (250C20B, 250C20R/2

and 250C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
762000 Gas Producer Controls (250C20B, 250C20R/2 and

250C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
75
ENGINE ANTI-ICE SYSTEM
751000 Engine AntiIcing System (250C20B, 250C20R/2,

250C30 and 250C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
76
ENGINE POWER CONTROLS
764700 Engine Power Controls (250C47) . . . . . . . . . . . . . . . . . . . . . . . . .
78
ENGINE EXHAUST SYSTEM
782000 Engine Exhaust System (250C20B and 250C20R/2) . . . . . . . . X
783000 Engine Exhaust System (250C30 and 250C47) . . . . . . . . . . . .
79
X
X
ENGINE OIL SUPPLY SYSTEM
790000 Engine Oil Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
791010 Engine Scavenge Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
91
CHARTS
910000 Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Page vi
Revision 29
Contents
MAINTENANCE MANUAL
Chapter
01
Introduction
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
01-00-00 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.
Proprietary Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.
369D/E/FF - 500/600N Helicopter Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Figure 1. Helicopter - Major Components (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . 2
4.
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.
ATA Numbering System and Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Figure 2. ATA Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.
Division of Subject Matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7.
Page Number Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8.
Figure and Table Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
9.
Associated MDHI Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

A. Illustrated Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Component Overhaul Manual (Overhaul Data) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. Structural Repair Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10. Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

11. MDHI Publications Changes and Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
B. Reprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. Service Information Notices and Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12. Application of Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
13. Service and Operations Report Form 1601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.
Maintenance and Operational Check Requirements and Precautions . . . . . . . . . . . 201

A. Pilot's or Rotorcraft Flight Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.
Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.
Maintenance Information Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4.
Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5.
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Table 201. Related Publications and Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 202. Optional Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
01 Contents
Page i
Revision 26
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS (Cont.)

Para/Figure/Table
Title
Page ii
Revision 43
01 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
010000
Introduction
MAINTENANCE MANUAL
CSP-HMI-2
INTRODUCTION
DESCRIPTION AND OPERATION
1. Proprietary Rights
MD Helicopters, Inc. proprietary rights are
included in the information disclosed herein.
Recipient, by accepting this document, agrees
that neither this document nor any part
thereof shall be reproduced or transferred to
other documents or used or disclosed to others
for manufacturing or any other purpose,
except as specifically authorized in writing by
MD Helicopters, Inc. All rights are reserved
under the copyright laws by MD Helicopters,
Inc.
2. Introduction
All helicopters described in this manual are
manufactured by MD Helicopters Inc. (MDHI),
Mesa, Arizona. The design features and
performance characteristics of all helicopters
are essentially the same. The main differences
between helicopters are the type and arrange
ment of interior furnishings and equipment,
the pilot's flight control position, engine power,
anti-torque system and a variety of optional
equipment.
3. 369D/E/FF 500/600N Helicopter
Description
NOTE: Throughout this manual, references to

the 369FF model helicopters also includes
the 369F model helicopters, unless other
wise stated.
(Ref. Figure 1) The Model 369D/E/FF 500/600N helicopters are turbine-powered,
rotary-wing aircraft constructed primarily of
aluminum alloy. The main rotor system for the
369D/E/FF - 500N helicopter is five-bladed
and fully-articulated. The main rotor system
for the 600N helicopter is six-bladed and
fully-articulated. The anti-torque system may
be two bladed, an optional four-bladed
installation or a NOTARR anti-torque system.
Engine output is delivered to the main and
anti-torque system by drive shafts and two
transmissions. A one-way overrunning clutch
between the engine and main transmission
permits the main rotor to freewheel for

autorotational descent.
The fuselage is a semi-monocoque construc
tion divided into three sections. The structure
consists of a central framework, a mast
support structure, two bulkheads and a center
beam. The forward section includes the crew
and cargo or passenger compartment. The
crew compartment is equipped with seats for
the pilot and either one or two passengers. The
crew compartment left seat is the pilot's seat
(LH command position) except in a RH
command configuration helicopter. The cargo
compartment is behind the crew compartment
and contains provisions for bench-type or
folding passenger seats. Passenger seats may
be folded out of the way or completely removed
to accommodate cargo. The aft section houses
the engine and includes structure for tailboom
attachment and in the case of the 500/600N,
the fan assembly and fan transmission for the
NOTARR anti-torque system. The lower
section is divided by a center beam and
provides two bays containing two fuel cells
that make up the fuel tank.
The 369D/E/FF tailboom is a monocoque
structure of aluminum alloy frames and skin.
The tailboom is the supporting structure for
the vertical and horizontal stabilizers, tail
rotor transmission and tail rotor. The tailboom
also houses the tail rotor transmission drive
shaft and tail rotor blade-angle control rod.
The 500/600N tailboom assembly is a fully
monocoque construction of carbon fiber
composites. The tailboom is the supporting
structure for the stator assembly, horizontal
stabilizer, two thruster assemblies and control
cable assembly.
The main rotor group consists of five or six
main rotor blades, a fully-articulated main
rotor hub with offset flapping hinges, a
scissors assembly, and a swashplate and
associated mixer control mechanisms. The
main rotor blades are secured to the rotor hub
with standard hardware and quick-release
pins.
01-00-00
Page 1
Revision 26
MAINTENANCE MANUAL
CSP-HMI-2
HORIZONTAL STABILIZER
MAIN ROTOR INSTALLATION

VERTICAL STABILIZER
TAIL ROTOR
TRANSMISSION
TAILBOOM
AFT SECTION
INSTALLATION
TAIL ROTOR
ASSEMBLY
FLIGHT CONTROL
INSTALLATION
ENGINE
INSTALLATION
FORWARD SECTION
INSTALLATION
MAIN TRANSMISSION AND

POWER TRAIN
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 2
Revision 23
01-00-00
MAINTENANCE MANUAL
CSP-HMI-2
VERTICAL STABILIZER ASSEMBLY
MAIN ROTOR INSTALLATION

SAS CONTROL ACTUATOR
STATOR
TAILBOOM
ASSEMBLY
AFT SECTION
INSTALLATION
FAN
GEARBOX
FLIGHT CONTROLS
INSTALLATION
FORWARD SECTION
INSTALLATION
MAIN TRANS
MISSION
ENGINE
INSTALLATION
ENGINE ACCESS
DOOR ASSEMBLY
CARGO DOOR ASSEMBLY
LOWER SECTION INSTALLATION
PILOT DOOR
ASSEMBLY
LANDING GEAR
500N HELICOPTER
G01-0003
01-00-00
Page 3
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
6-BLADED MAIN ROTOR

INSTALLATION
MAIN TRANSMIS
SION
FAN
GEARBOX
FAN
FLIGHT CONTROLS
INSTALLATION
MID DOOR
ASSEMBLY
HORIZONTAL
STABILIZER
STATOR
AFT DOOR
ASSEMBLY
TAILBOOM
ASSEMBLY
ENGINE
INSTALLATION
VERTICAL STABILIZER
ASSEMBLY
AFT SECTION
INSTALLATION
ENGINE ACCESS
DOOR ASSEMBLY
LANDING GEAR
FORWARD SECTION
INSTALLATION
PILOT DOOR
ASSEMBLY
LOWER SECTION
INSTALLATION
600N HELICOPTER
6G01-001A

Page 4
Revision 23
01-00-00
MAINTENANCE MANUAL
The fixed skid landing gear is attached to the
fuselage at 12 points. Fairings cover the struts
from the fuselage to the skids. Nitrogencharged dampers between the struts and
structure cushion landing loads.
4. Scope
CSP-HMI-2
handbooks and other published documents by

their titles and/or identifying numbers. These
documents are the primary servicing, mainte
nance and repair information file for vendorsupplied helicopter components.
5. ATA Numbering System and Format
MDHI maintenance manuals provide system

descriptions, servicing and maintenance
procedures, periodic and special inspections,
overhaul schedules, limited life component
replacement schedules, and weight and
balance calculations.
This MDHI Maintenance Manual and asso

ciated MDHI manuals are prepared in general
compliance with Air Transport Association
Specification for Manufacturers Technical
Data (ATA-100).
This manual is one of a group of publications

that form the information file for the helicop
ter. The maintenance and inspection proce
dures are to be used for the 369D/E/FF 500/600N helicopters only. Study the contents
to gain an understanding of the arrangement
and use of this and associated manuals before
working on the aircraft.
Table 201, Related Publications and Direc
tives, lists vendor/supplier manuals, catalogs,
The uniform numbering system established by

ATA-100 is used. This numbering system
provides a means for dividing material into
Chapter, Section, Subject and Page. The
number is composed of three elements, which
consist of two digits each (Ref. Figure 2). The
chapter and section elements (sub-assembly
10, 20, 30, etc.) are assigned by ATA-100.
Subject/Unit element numbers are assigned by
MDHI.
2ND ELEMENT
1ST ELEMENT
3RD ELEMENT
32
10
10
CHAPTER/SYSTEM LANDING GEAR

SYSTEM
SUBJECT/UNIT LANDING
GEAR
SECTION/SUB-ASSEMBLY LANDING GEAR
Figure 2. ATA Numbering System
01-00-00
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Revision 26
MAINTENANCE MANUAL
CSP-HMI-2
6. Division of Subject Matter
8. Figure and Table Numbering
This Maintenance Manual is contained in two

books.
Illustrations and tables use the same number

ing as the page block in which they appear. For
example, Figure 202 would be the second
figure in a Maintenance Practices section.
When referring to a figure or table within the
same section, it is referenced as follows; (Ref.
Figure 202). When referring to a figure or
table within another section, it is referenced as
follows; (Ref. Table 1, 91-00-00).
CSP-HMI-2 contains general mechanical

maintenance data.
CSP-HMI-3 contains maintenance data on
instruments, electrical and avionics.
7. Page Number Blocks
Page number blocks used for each Section in
the Maintenance Manual logically arrange the
material as follows:
NOTE:
D Maintenance Practices consists of either a
brief subtopic or a combination of the fol
lowing subtopics: Servicing, Removal/Ins
tallation, Adjustment/Test, Inspection/
Check, Cleaning/Painting and Approved
Repairs. Two methods are used for num
bering maintenance practices page
blocks:
D If a single subtopic or all subtopics under
Maintenance Practices are brief, they are
combined into one topic. All such topics
are numbered within page number block
201 - 300.
D If individual subtopics become so lengthy
that a combination would require numer
ous pages, each topic is broken out. Page
number blocks accordingly are as follows:
Description and Operation . . . . . . . . . . . . . . . . 1
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance Practices . . . . . . . . . . . . . . . . . 201
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Removal/Installation . . . . . . . . . . . . . . . . . . . 401
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . 501
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . 601
Cleaning/Painting . . . . . . . . . . . . . . . . . . . . . 701
9. Associated MDHI Manuals

Information beyond the scope of the Mainte
nance Manual may be found in these basic
associated manuals which are prepared as
separate publications but should always be
kept and used with this manual:
CSP-IPC-4, Illustrated Parts Catalog.
CSP-COM-5, Component Overhaul Manual.
CSP-SRM-6, Structural Repair Manual.
A. Illustrated Parts Catalog
(CSP-IPC-4) Illustrated Parts Catalog for
Models 369D/E/FF - 500/600N
(CSP-D-7) Illustrated Structures Catalog for
Model 369D and
(CSP-ISC-7) Illustrated Structures Catalog
for Models 369E/FF - 500N provide, with text
and illustrations, a complete definition of all
repair parts and spare items available for the
helicopter. Use the (IPC) only for the purpose
of parts procurement.
B. Component Overhaul Manual (Overhaul
Data)
The COM contains overhaul instructions for
major components such as the main transmis
sion, tail rotor transmission, overrunning
clutch, etc. When components must be
removed from service for overhaul, refer to the
COM and/or contact the appropriate manufac
turer or their field service representative for
desired publication information (Ref. Table
201).
C. Structural Repair Manual
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
The CSP-SRM-6, SRM contains illustrated

helicopter structural maintenance and repair
information.
Initial Installation . . . . . . . . . . . . . . . . . . . . . 901
10. Engine Data
Each page bears an effective date, either that

of original issue or of the latest revision.
The Model 250 Series gas turbine engines are

manufactured by the Allison Engine Company
Page 6
Revision 26
01-00-00
MAINTENANCE MANUAL
Inc.. Refer to the applicable Allison Engine
Repair and Maintenance Manual and the
Illustrated Parts Catalog supplied with the
engine for specific engine maintenance
information (Ref. Table 201, Related Publica
tions and Directives). Fault isolation and
maintenance procedures for the helicopter/en
gine interface systems are in divisions
specified by the index.
11. MDHI Publications Changes and
Revisions
Changes in the helicopter, equipment, mainte
nance practices, procedures and additional
information developed by experience affect
manual content. To ensure that MDHI
manuals continue to reflect current changes,
revised information is provided by one or more
of the following communications:
A. Revision
Alteration of portions of the manual by the
replacement, addition and/or deletion of pages
is accomplished by revision. The List of
Effective pages (LOEP) that accompany each
revision identifies all affected pages. Such
pages should be removed from the manual and
destroyed. Added or replaced pages should be
inserted and checked against the LOEP.
B. Reprint
When large numbers of changes are involved,
the manual is reprinted to include all prior
revisions.
C. Service Information Notices and Letters
Service information is to be considered as part
of the manual.
(1). Service Information Notices and
Bulletins are broken into two categories
as follows:
(a). Red Border Notices: The red border
notices deal with critical items that
must be corrected. These notices are
mandatory and require a record of
accomplishment. They may be
re-occurring (flight-time or calendar)
or one-time only notices.
CSP-HMI-2
(b). Blue Border Notices: The blue border

notices are not mandatory and can be
accomplished at the owner/operator's
discretion. When instructed, these
notices may require a record of
accomplishment. These notices deal
with non-critical or optional items
only.
(c). Service Bulletins: The Service
Bulletin deal with critical items that
must be corrected. These bulletins
are mandatory and require a record
of accomplishment. They may be
re-occurring (flight-time or calendar)
or one-time only bulletins. The
service bulletin replaces the red
border notice.
(d). Technical Bulletin: The Technical
Bulletins are not mandatory and can
be accomplished at the owner/opera
tor's discretion. When instructed,
these bulletins may require a record
of accomplishment. These bulletins
deal with non-critical or optional
items only. the technical bulletin
replaces the blue border notice.
(e). For a complete listing and explana
tion of current and cancelled notices,
refer to Service Information Notices
Index.
(2). Service Information Letters are strictly
information only. They may inform the
owner/operator of options available,
up-coming notices, bulletins, warranty/
repair changes, etc.
12. Application of Warnings, Cautions and
Notes
Throughout this manual, and associated
manuals, Warnings, Cautions and Notes are
used to emphasize instructions or information
considered to be unusual or critical.
WARNING and CAUTION statements are
always placed before the information or
instructions to which they apply.
A NOTE may appear in the text either before
or after instructions to which it applies,
depending on the relative significance of the
information.
The conditions that warrant use of Warnings,
Cautions and Notes are defined as follows:
01-00-00
Page 7
Revision 29
MAINTENANCE MANUAL
CSP-HMI-2
Operating procedures and
13. Service and Operations Report Form 1601
ly observed, may result in personal in

jury, or loss of life.
MDHI Service and Operations Report Form

1601 may be used to report to MD Helicopters,
Inc. in detail any service difficulties encoun
tered with any MDHI helicopter. Use of the
form is encouraged and recommended to
enable MDHI to provide owners and operators
improved service, support and product
improvements. The form also serves as a
convenient detailed record for owners and
operators. Copies of the form may be procured
by contacting the Product Support Dept.
WARNING practices which, if not strict
Operating procedures and prac

tices which, if not strictly ob
served, may result in damage to or destruc
tion of equipment.
CAUTION
NOTE: An operating procedure or condition

that is essential to highlight.
Page 8
Revision 28
01-00-00
MAINTENANCE MANUAL
CSP-HMI-2
INTRODUCTION
MAINTENANCE PRACTICES
1. Maintenance and Operational Check
Requirements and Precautions
All helicopter maintenance is to comply with
the following requirements and precautions.
A. Pilots or Rotorcraft Flight Manual
Maintenance checks requiring helicopter
operation must be performed in accordance
with requirements and limitations specified in
the applicable MDHI Flight Manual (PFM or
RFM) and all applicable Optional Equipment
Supplements.
Replace components that exhibit damage or

wear beyond tolerances, or that negatively
affect the proper function or integrity of an
assembly.
3. Maintenance Information Requests
After maintenance, modification, disassembly,

re-assembly, replacement, cleaning, repair or
installation; the affected parts, assemblies,
installations or systems shall be inspected and
an operational check will be performed prior to
releasing the helicopter for flight (Ref.
Maintenance Information Requests).
Address all questions regarding 369D/E/FF 500/600N helicopter maintenance to the MDHI
Field Service Representative assigned to the
geographical area in which the helicopter is
being operated. Should there be no factory
representative in the area, contact Product
Support Dept., Technical Publications, Mesa,
Arizona. If the item in question is vendor
supplied; i.e., engine, engine fuel control and
governor, starter-generator, fuel cells, etc.,
contact the manufacturer directly to get
definitive answers to your questions (Ref.
Table 201. Related Publications and Direc
tives, which lists component manufacturers,
suppliers and their addresses).
2. Inspections
4. Related Publications
Inspections specified in this manual are visual

inspections for cracks, corrosion, distortion,
security and other obvious defects or damage.
Publications and directives that form part of

the information file for helicopter component
maintenance are listed in Table 201. Related
Publications and Directives.
B. Operational Checks
Visual inspections of fuel and oil system hoses,

tubes and fittings include checks for corrosion,
leakage and distortion.
Specific inspection requirements, procedures
and wear tolerances may be provided in the
division text. Where inspection requirements
are not listed, inspections should be made per
Sections 05-10-00 thru 05-50-00.
5. Optional Equipment
All optional equipment available for and
usable on commercial model helicopters is
listed in Table 202 Optional Equipment.
Contact MDHI for compatibility of mixing
options.
01-00-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Related Publications and Directives

Component and
Manufacturer, or Source
Publication Title
Publication or
Directive No.
General Information
Superintendent of Documents
U.S. Government Printing Office
Division of Public Documents
Washington, D.C. 20402
Aerospace Industries Association of

America, Inc.
1725 De Sales Street, N.W.
Washington, 6, D.C.
Revision 40
FAA AC No. 43.131A (1)
Advisory Circular Corrosion Control for FAA AC No. 434 (1)

Aircraft
Nondestructive Testing Personnel
NAS410
Qualification and Certification
IHS Aviation & Aerospace

15 Inverness Way East
Englewood CO 80112
United States
Page 202
Acceptable Methods, Techniques and

Practices Aircraft Inspection and
Repair (GPO Catalog No. TD
428/2:972)

Standard Terminology for
Nondestructive Examinations
ASNTSNTTC1A
National Aerospace Standard

(Title as applicable)
NAS No. as applicable
01-00-00
ASTM E 1316
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Related Publications and Directives (Cont)

Component and
Publication Title
Publication or
Directive No.
MDHI Publications
MD Helicopters Inc.
M615G048
4555 E. McDowell Rd.
Mesa, AZ 852159734
Technical Publications Order Desk:
(480) 3466373 or (800) 3883378
FAX: (480) 3466809
369D Pilots Flight Manual (with

applicable Equipment Supplements)
CSPD1 (1)
369E Pilots Flight Manual (with

CSPE1 (1)
369FF Pilots Flight Manual (with

500N Pilots Flight Manual (with
600N Pilots Flight Manual (with
Illustrated Parts Catalog (IPC), Model
369D/E/F 500/600N
Basic Handbook of Maintenance
Instructions (HMI2) Servicing and
Maintenance, Model 369D/E/F
500/600N
CSPFF1 (1)
Basic Handbook of Maintenance

Instructions (HMI3) InstrumentsElectricalAvionics, Model 369D/E/F
500/600N
CSPHMI3 (1)
Component Overhaul Manual (COM),

Model 369D/E/F 500/600N
Structural Repair Manual (SRM), Model
369D/E/F 500N
Illustrated Structures Catalog (ISC),
Model 369D
Illustrated Structures Catalog (ISC),
Model 369D/E/FF 500N
Corrosion Control Manual
CSPDEF5 (1)
CSP520N1 (1)
CSP600NRFM1 (1)
CSPIPC4 (1)
CSPHMI2 (1)
CSPDEF6 (1)
CSPD7 (1)
CSPICS7 (1)
CSPA4
Battery
Marathon Battery Company
Cold Spring, NY 10516
Phone: (817) 7760650
(formerly Sonotone)
Marathon Battery Instruction Manual
01-00-00
BA89
(REV 271)
Page 203
Revision 43
MAINTENANCE MANUAL
CSP-HMI-2

Component and
Publication Title
Publication or
Directive No.
Engine
Operation and Maintenance Manual,
Turboshaft Engine Model 250C20,
C20B
10W2 (1)
Overhaul Manual, Turboshaft Engine

Model 250C20, C20B
Illustrated Parts Catalog, Turboshaft
Engine Model 250C20, C20B
Installation Bulletin, Three Cubic Inch
Accumulator for 250C20 Bendix Fuel
System
Turboshaft Engine Model 250C20R/2
Model 250C20R/2
Engine Model 250C20R/2
Turboshaft Engine Model 250C30
Model 250C30
Engine Model 250C30
Turboshaft Engine Model 250C47M
Model 250C47M
Engine Model 250C47M
10W3 (1)
Aircraft Parts Corporation

160 Finn Court
Farmingdale, NY 11735
Phone: (516) 2493053
Datafax: (516) 2492577
Brush Seating APC Brushes in High

Speed Starter Generators: MDHI Part
Nos. 369A4550 and 369D28550
SB150SG105
Overhaul Manual With Illustrated Parts

Breakdown
TM 101
TRW Aeronautical Systems

Lucas Aerospace
30 Van Nostrand Ave.
Englewood, NJ 076314396
Phone: (201) 5413250
Datafax: (201) 8941965
Overhaul Instructions with Parts

Breakdown, Models 23032010,
23032011, 23032020, 23032022,
23032028, 23081001
Call or write
Fargo Manufacturing Co.

2750 North Elston Ave.
Chicago, Illinois 606447
Starter/Generator Cooling System

Supplemental Type Certificate
STC No. SH907GL
RollsRoyce Corporation
P.O. BOX 420
Indianapolis, IN 46206 USA
Phone: 3172303774
Fax: 3172306084
email: indy.pubs.services@rolls
royce.com
10W4 (1)
1005 (1)
GTP52322 (1)
GTP52323 (1)
GTP52324 (1)
14W2 (1)
14W3 (1)
14W4 (1)
CSP 21004 (1)
CSP 22004 (1)
CSP 23001 (1)
StarterGenerator
Page 204
Revision 43
01-00-00
MAINTENANCE MANUAL
CSP-HMI-2

Component and
Publication Title
Publication or
Directive No.
Avionics Equipment
VHF/COMM Transceiver
RCA Aviation Equipment Dept.
11819 W. Olympic Blvd.
Los Angeles, CA 90064
AVC110 VHF Communications

Transceiver Instruction Manual
IB8029004
VHF/NAV Receiver
RCA Aviation Equipment Dept.
AVN210 Series Integrated Navigation

Systems
IB96460
University Sound of LTV Ling Altec, Inc.

Oklahoma City, OK
Operators Manual, SA250 and SA500

High Power Sound and Siren Systems
Operators Manual, Model 500 Super
High Power SolidState Amplifier and
Model RMC1 Remote Control
KR 85 Automatic Direction Finder
Installation Manual (has repair/overhaul
information)
006004300

Maintenance/Overhaul Manual
006508400
NAV/COMM Receiver
King Radio Corp.
KX 155 NAV COMM Receiver

006517900
NAV/COMM Transceiver and COMM

Transceiver
King Radio Corp.
KX 170A/B KX 175B NAV/COMM

Transceiver and KY 195B
Communications Transceiver
006505300
COMM Transceiver
King Radio Corp.
KY 196 VHF COMM Transceiver

006516900
Transponder
King Radio Corp.
KT 76A Transponder Maintenance/Overhaul Manual
006514300
VOR Indicator
King Radio Corp.
KI 201C VOR Indicator Maintenance/

Overhaul Manual
006505200
KI 208 VOR Indicator Maintenance/Overhaul Manual
006513700
KMA 24H70/71 Audio Selector Panel

and Interphone System Maintenance/
Overhaul Manual
006558600
Automatic Direction Finder

King Radio Corp.
400 North Rogers Road
Olathe, KS
Audio Control Panel

King Radio Corp.
01-00-00
006518400
Page 205
Revision 43
MAINTENANCE MANUAL
CSP-HMI-2

Component and
Publication Title
Publication or
Directive No.
Automatic Direction Finder System

Collins General Aviation Division
Avionics Group
Rockwell International Corp.
Cedar Rapids, Iowa 52498
ADF60 Automatic Direction Finder

System Instruction Book
523076618400611A
CTLX2 Controls and CAD62 Control

Adaptor Instruction Book
Collins Pro Line II Com/Nav/Pulse
System Instruction Book
523077249400111A
ALT55 Radio Altimeter System

Publication Dept. 124212
400 Collins Rd. NE
ALT55 Radio Altimeter System

Instruction Book (Repair Manual
5230766793
Automatic Direction Finder System

ADF650/650A Automatic Direction

Finder System RCR650/650A
Receiver, ANT650 Antenna,
IND650/650A Indicator and ADA650
ADF to RMI Adaptor Instruction Book
523076620700411A
COMM Transceiver
VHF22B VHF COMM Transceiver

Instruction Book
523077185400311A
VHF251 Communications Transceiver

and PWC150 Power Convertor
Instruction Book
523076602900511A
NAV Receiver
VIR351 Navigation Receiver, IND350

Indicator, and PWC150 Power
Convertor Instruction Book
523076603000511A
Transponder
TDR950 Transponder Instruction Book
523076646400311A
VHF AM/FM AN/ARC186(V)

Collins Government Avionics Division
Avionics & Missiles Group
Rockwell International
Collins VHF186 Transceiver Instruction 523077025100111A

Book
ICS Control Panel (C6533/ARC)

Andrea Radio Corp.
1140 45 Road
Long Island City, NY 11101
A3011 Communication Control

Technical Manual Installation,
Operation and Maintenance
C465020 027
COMM Transceiver
Sunair Electronics, Inc.
3101 S.W. Third Avenue
Fort Lauderdale, FL 33315
ASB125, ASB60 SSB

Communications Equipment
Maintenance Manual
99655
Page 206
Revision 43
01-00-00
523077271900211A
MAINTENANCE MANUAL
CSP-HMI-2

Component and
Spilsbury & Tindall, Ltd.
120 E. Cordova Street
Vancouver 4, B.C. Canada
Publication Title
Publication or
Directive No.
Instruction Manual, Stringer Model

AC21 Mobile Antenna System
65018
Recommended Handling, Storage and

Repair Procedures For NonSelfSealing Flexible Fuel, Oil And Water Alcohol
Cells
FC147373
Repair Procedure For SelfSealing Fuel

Cells
RK1034
Maintenance and Repair Manual,

VITHANE\R Fuel Tanks,
July 1988, ATA 281013
AP 368
Fuel Cells
Uniroyal, Inc.
Engineered Systems Department
Mishawaka, Indiana 46544
Phone: (219) 2552181
Engineered Fabrics Corp.

Formerly: Loral Systems Group
669 Goodyear Street
Rockmart, GA 301532417
Phone: (404) 6847855
Naval Publications & Forms

East:
5801 Tabor Avenue
Philadelphia, PA 19120
Phone: (215) 6972179
Datafax: (215) 6975914
West:
Bookstore No. 10
ARCO Plaza, Level C
505 S. Flower Street
Phone: (213) 8945841
AP 472
Quick Cure Repair for Engineered
Fabrics Corp. Fuel Tanks of VITHANE\R
Construction,
March 1988, ATA 281015
Repair & Maintenance Manual, Bladder,
Self Sealing, & NonSelfSealing
Tanks, ARM Type Constructions,
April 1987, ATA 281016
AP 430
Repair & Maintenance Manual, Bladder

Fuel Tanks,
Nitrile Type Constructions,
June 1988, ATA 28101
AP 2584
Military Standard Inspection &

Acceptance Standards For Propulsion
Fluid Cells & Fittings
MILSTD801A
NOTE: Naval Publications personnel do not accept telephone orders. You must mail or FAX your written
request. There is no charge for the material.
01-00-00
Page 207
Revision 43
MAINTENANCE MANUAL
CSP-HMI-2

Component and
Publication Title
Publication or
Directive No.
Hoist Equipment
BL1660012 Series 300 Pound
Capacity Hoist Operating Instructions
Hoist Winch Assembly

Breeze Corporations, Inc.
700 Liberty Avenue
Union, NJ 07083
HB136
BL1660040 Series Hoist Operating

Instructions
Use and Maintenance of Aircraft Hoist
Cable
Maintenance and Test Equipment

ChadwickHelmuth Operation and
Model 177M6 Balancer
Service Instruction Handbooks are
Model 8350 Balancer
normally supplied with the equipment.
Model 192A Balancer
Model 8500 Balancer
Model 135M11 Strobex Blade Tracker
Model 135M12 Strobex Blade Tracker
must be used with Model 8500 Balancer
ChadwickHelmuth Co., Inc.
4601 N. Arden Drive
El Monte, CA 91731
Phone: (818) 5756161
Datafax: (818) 3504236
Call or write
Landing Gear Equipment

Helicopter Float Assemblies
GarrettAir Cruiser Company
P.O. Box 180
Belmar, NJ
Overhaul Manual with Illustrated Parts

List, Helicopter Float Assemblies,
Utility Floats 21D243681/2,
Emergency Floats D244845/6
Transmissions
Threaded Inserts
Newton Insert Co.
6500 Avalon Blvd.
Keenserts
Catalog D
Service Overhaul Manual, Harrison

Aluminum Plate Type LiquidtoAir
Coolers
HES66 77F
Revised Sept 30, 1973
Engine Oil Cooler

Harrison Radiator Division
General Motors Corp.
Lockport, NY 14094
Stewart Warner Corp.
Southwind Division
1514 Drover Street
Indianapolis, Indiana 46221
Phone: (317) 6328411
Page 208
Revision 43
01-00-00
MAINTENANCE MANUAL
CSP-HMI-2

Component and
Publication Title
Publication or
Directive No.
Scavenge Oil Filter

Filter Products Division
Facet Enterprises, Inc.
8439 Triad Drive
Greensboro, NC 27409
Phone: (919) 6684444
TWX 5109227331
Facet Kit No. 174105001 Installation

and Service Manual Scavenge Lube Oil
Filter
E947, Rev. D 3/10/89 (1)
Vortex Tube Repair
PLMTM801
Engine Intake Air Particle Separator

Pall Land Marine Corp. (PLM)
Formerly: Aircraft Porous Media (APM)
7070 Moon Lake Road
New Port Richey, FL 33552
Phone: (813) 8499999
Fuel Filter Pressure Switch
R.W. Jensen, Inc.,
215 Arena Street
El Segundo, CA 90245
Pressure Switch Repairs
Trim Actuators
CEF Industries, Inc.,
Calco Division
TEL: (813) 4226419
FAX: (813) 4212069
Trim Actuator Overhaul
Searchlight
Alexair
25320 Bellanca Way
Torrance, CA 90505
Phone: (213) 3265222
SX Nightsun Searchlight
(Spectrolab)
STC No. SH2288NM
NOTES:
(1) Publication should be maintained and treated as part of the primary information file for the helicopter.
01-00-00
Page 209
Revision 43
MAINTENANCE MANUAL
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Table 202. Optional Equipment List

Nomenclature
Part Number
369D
369E
369FF
500N
600N
369D299913
369H90020
Seat assy. passenger compartment
369D290037
Litter kit (bubble doors and flat glass)
369H90011519
Litter kit (W/O doors)
369H90011521
Seat and belts (four on the floor)
369H90035
Seat (mesh)
369H90040
Hoist
369H90070
Cargo hook
369H90072
Seat belt assembly (pilot, copilot)
369H6541
Shoulder harness and seat belt inertia reel
421099
Litter kit
369D290170
Litter kit
TAHH0001
Forward equipment tray
369D292200
10 PARKING AND MOORING

M/R blade stowage rack
21 ENVIRONMENTAL CONTROL SYSTEM
Heating system
25 EQUIPMENT / FURNISHINGS
26 FIRE PROTECTION
Fire extinguisher
369H90001
Antiice fuel filter
369H90022
Airframe fuel filter
600N98110
Fuel tank, selfsealing
369H90029
Drain, auxiliary engine fuel filter
369H92255
Extended landing gear
369D290007
Extended landing gear
600N6000
Step assembly, extended landing gear
600N6501
Utility floats
369D290086
Emergency floats
369D290121
Ground handling wheels (pneumatic)
369H90045
Ground handling wheels (compact)
369H90126
Float lamp assembly
369D292032
Landing gear kit, winterized
369D290010
Landing gear kit, midtemp
369D290012
Metal landing gear fairings
SA4344
28 FUEL SYSTEM
X
X
X
32 LANDING GEAR
Page 210
Revision 43
01-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Table 202. Optional Equipment List (Cont)

Nomenclature
Part Number
369D
369E
369FF
500N
X
X
600N
52 DOORS
Door (litter)
369H90085
Magnesiumtoaluminum conversion kit
M30251501
Clear windshield kit
369H90026
Comfort window
369D290026
Side window (fwd extended canopy)
369D292491
Upper and lower windshield (Heliplex)
SH7443SW
Window, crew (Heliplex)
SH7404SW
Window, passenger (Heliplex)
SH7405SW
53 FUSELAGE
63 TRANSMISSION AND DRIVE SYSTEM

M/R transmission oil cooler drain
369D290120
Rotor brake
369H90123
369D292500
Dual controls, L/H command
369H90033
Cyclic stick grip kit
369H90129
Right hand command kit
369D297001
Yaw Stability Augmentation System
600N97300
64 ANTITORQUE ASSEMBLY
4Bladed tail rotor drive system
67 FLIGHT CONTROLS
X
X
71 POWER PLANT
Engine air inlet deflector kit
369D292044
Mist eliminator access panel
369D290270
Foriegn particle diverter kit
369D292045
250C20R/2 conversion kit
369D298000
Particle separator
369H90148
Particle separator filter

Particle separator
Particle separator fairing
600N90148
600N90125
600N90128
Engine compressor water wash kit
369H92537
Mist eliminator
369D290125
C30 maintenance fuel pump kit
369D298100
StarterGenerator cooling system A1400185
SH907GL
X
X
X
X
X
X
X
X
95 INSTRUMENTS
IVSI
369D294508
Heated pitot tube
369H90034
Heated pitot tube
600N90034
01-00-00
X
Page 211
Revision 43
MAINTENANCE MANUAL
CSP-HMI-2

Nomenclature
Part Number
369D
369E
369FF
500N
600N
Attitude gyro indicator
369H90038
AIM attitude gyro (5101BL)
600N96501
Directional gyro indicator
369H90039
AIM 200 directional gyro (200DCL)
600N96502
AIM 205 directional gyro (2051BL)
600N96503
Instantaneous vertical speed indicator
369H90044
Vertical speed indicator
600N96523
Instantaneous vertical speed indicator
600N96524
Auto direction finder (KR85)
369H90067
Auto direction finder (Collins ADF650A)
369D24165
Auto direction finder (KR87)
600N96508
Compass system (KCS55A)
600N96528
Altimeter indicator (millibar scale)
369H90124
Radar altimeter
600N96506
Encoding altimeter (United 5035)
600N96522
AIM turn/bank indicator (TS4001AL)
600N96504
Digital/Analog TOT indicator
369D294509
17AH nicad battery
369D290011
Dualstarting kit
M30306
FWD battery
369D222505
13AH nicad battery
369D24296
X
X
X
X
96 ELECTRICAL POWER
X
97 AVIONICS
Transponder, Mode S (KT70)
600N96509
Transponder (KT76A)
369H90073
Transponder (King KT76A)
369D24163
Transponder (Collins TDR950)
369H90009
Transponder (Collins TDR950)
369D24166
Transponder, Mode A/C (KT76A)
600N96511
GPS International (KLN 90B)
600N96507
NAV/COM (Collins)
369H90007
NAV/COM transceiver (KX170A)
369H90071
NAV/COM transceiver (KX155)
369D24147
NAV/COM transceiver (KX155)
600N96512
NAV/COM transceiver (King KX1756)
369D24162
NAV/COM (Collins VHF251 and VIR351)
369D24164
Transceiver (VHF22B)
369D24322
Page 212
Revision 43
01-00-00
X
X
X
X
X
MAINTENANCE MANUAL
CSP-HMI-2

Nomenclature
Part Number
369D
369E
369FF
500N
600N
Comm. receiver (Bendix/King KY196)
369D24167
Comm. receiver (KY196A30)
600N96513
ADF (Collins RCR650)
369H90008
ADF (King KR87)
369D24161
ADF (Collins 60A)
369D24333
ICS system
369H90068
ICS system
369D24118
NAT AA82/AA83 stereo ICS
600N96505
Copilot foot switch
600N96526
Rear seat transmit switch
600N96527
Radio (ASB/125/60)
369H90144
Headset, microphone assembly
369H92042
Switch and jack assembly, intercom
369H92492
Headset microphone
H1056
Harness assembly (VHF22B)
369D24321
Instrument and electrical (R/H command)
369D24175
Sterio audio control
600N96529
Audio control panel (KMA24H)
600N96514
Middle seat wire harness
600N96515
Collective Hobbs
600N96525
X
X
X
X
X
01-00-00
Page 213
Revision 43
CSP-HMI-2
MAINTENANCE MANUAL
Page 214
Revision 43
01-00-00
MAINTENANCE MANUAL
Chapter
04
Airworthiness
Limitations
CSP-HMI-2
MAINTENANCE MANUAL
CSPHMI2
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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
04 Contents
Page i
Revision 34
CSPHMI2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page ii
Revision 34
04 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
040000
Airworthiness
Limitations
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSP-HMI-2
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:
Original Issue:
Revision 1:
DATE
October 31, 1990
March 29, 1991
Revision 2:
May 10, 1991
TR 91001
August 12, 1991
Revision 3:
September 9, 1991
TR 91002
November 5, 1991
Revision 4:
January 20, 1992
TR 92004
May 20, 1992
Revision 5:
August 24, 1992
TR 92005
November 20, 1992
Revision 6:
December 21, 1992
Revision 7:
June 1, 1993
TR 93002
May 27, 1993
Revision 8:
July 23, 1993
TR 94001
January 21, 1994
Revision 9:
April 22, 1994
Revision 10:
September 26, 1994
TR 94002
October 24, 1994
FAA APPROVED
FAA SIGNATURE AND DATE

Not FAA approved
Not FAA approved this revision
Section 040000 Not Affected This Revision
04-00-00
Page 1
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2
REVISION:
DATE
Revision 11:
January 18, 1995
Revision 12:
October 6, 1995
TR 96002:
April 24, 1996
Revision 13:
May 31, 1996
Revision 14:
September 13, 1996
Revision 15:
Revision 16:
November 15, 1996

January 6, 1997
Revision 17:
February 24, 1997
TR 97001:
July 2, 1997
TR 97002:
August 19, 1997
Revision 18:
October 17, 1997
Revision 19:
December 16, 1997
TR 98001:
March 25, 1998
Revision 20:
June 1, 1998
TR 98002:
June 22, 1998
TR 98003:
3 August 1998
Revision 21:
24 August 1998
Revision 22:
Revision 23:
10 March 1999
1 June 1999
Revision 24:
7 December 1999
Revision 25:
28 April 2000
Revision 26:
17 August 2000
Revision 27:
Revision 28:
9 October 2000
30 November 2000
Page 2
Revision 42
04-00-00


T/R 97001 and 97002 Previously Signed

T/R 98001 Previously Signed


FAA APPROVED
MAINTENANCE MANUAL
REVISION:
DATE
Revision 29:
11 May 2001
Revision 30:
11 July 2001
TR 01001:
10 August 2001
Revision 31:
5 November 2001
TR 02002:
30 January 2002
Revision 32:
18 March 2002
Revision 33:
24 June 2002
TR 03001:
18 June 2003
TR 03002:
25 June 2003
Revision 34:
21 August 2003
TR 03003:
30 September 2003
TR 03004:
17 December 2003
Revision 35:
20 May 2004
TR 04001:
28 May 2004
Revision 36:
11 November 2004
Revision 37:
13 December 2005
TR 05002:
16 December 2005
Revision 38:
25 April 2006
FAA APPROVED
CSP-HMI-2




04-00-00
Page 3
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2
REVISION:
DATE
TR 06001:
05 July 2006
Revision 39:
TR 07001:
10 April 2007
11 April 2007
Revision 41:
03 March 2008
TR 08001
14 March 2008
TR 08002
07 November 2008
Revision 42


Revision 42:
Page 4
04-00-00
FAA APPROVED
MAINTENANCE MANUAL
CSP-HMI-2
2. Component Mandatory Replacement
The Airworthiness Limitation Replacement
Schedule specifies the mandatory replacement
time, structural inspection interval and related
structural inspection procedures approved per
the certificate basis of the Type Certificate
Data Sheet No. H3WE and CAR 6 (6.250,
6.251) and CFR 27.571 for models 500/600N
unique components only. At the listed finitelife, components or assemblies must be
removed from the helicopter and permanently
retired from service. At the listed inspection
interval, the components or assemblies must
be inspected in accordance with the Handbook
of Maintenance Instructions (HMI). The title
of the task and section of the HMI are referred
to which provide the inspection procedures and
criteria.
NOTE: Refer to CFR Part 43.10 for latest re

quirements for the removal, installation,
storage and disposition of life-limited parts.
(1). A ``life-limited'' part is a physical
component of the helicopter to which a
maximum number of allowable operat
ing hours or cycles are assigned.
Certain assemblies and components on
the helicopter have a limited life
established by MDHI and approved by
FAA Engineering. For example, a part
with an assigned limit of 1000 hours,
may accumulate 1000 hours of opera
tion in service. Upon completion of the
1000 hours of operation, useful life of
the part is ended. The finite-life
assigned to different parts varies
according to engineering fatigue tests,
part experience, etc. The parts listed in
this section must be removed from the
helicopter at the finite-life indicated
and identified as to it's expired life (Ref,
Table 1, Note (1)).
(2). All parts not having an assigned life or
stated to be of unlimited life, have a life
of not less than 20,000 hours.
(3). When a life-limited part or an assem
bly that incorporates a life-limited part
is installed on a new or used helicopter,
the nomenclature, part number, serial
FAA APPROVED
number, component time and current

helicopter hours are recorded in the Log
Book and component log for the
helicopter. Whether the life-limited
part is new or used, the remaining
number of useful life hours and pre
vious inspection time, if applicable, for
the part is added to the existing
helicopter time. The total helicopter
hours obtained then denotes the
subsequent time at which the part must
be removed from the helicopter or
inspected.
(4). If a life-limited part, is part of an
assembly, the assembly must be
removed from the helicopter when the
time expires. The assembly may be
overhauled and restored to maximum
number of hours of useful life by
installing new life-limited parts plus
all other parts specified in the overhaul
instructions (Refer to Component
Overhaul Manual).
(5). If interchanged between different model
helicopters (for instance, Model 369D to
369FF or vice versa), any component
having a limited life or overhaul
schedule must be restricted to the
lowest service life or TBO schedule
indicated for the helicopter models and
serial numbers affected.
(6). Refer to the appropriate Allison
Operation and Maintenance Manual for
engine component replacement require
ments.
3. Component Mandatory Inspections
Some components with mandatory inspection
intervals require inspections to be completed
in accordance with procedures detailed in
other sections of this maintenance manual.
The appropriate inspection procedures are
referenced in the Notes flagged to each
component to be inspected. All maintenance
manual procedures which are referenced in the
FAA Approved Airworthiness Limitations
Component Mandatory Replacement Schedule
are FAA approved procedures which cannot be
changed without FAA review and approval of
the proposed changes.
04-00-00
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MAINTENANCE MANUAL
CSP-HMI-2
4. Retirement Index Number (RIN)

(1). A Retirement Index Number (RIN) is a
number that accounts for different
usage spectra in assigning the retire
ment time for a component.
The RIN is calculated as the sum of an
adjustment factor times flight hours
plus another adjustment factor times
Torque Events.
When a component reaches 1,000,000
RIN's, it has reached it's maximum life
and is to be scrapped.
For external lift operators, an external

load is recorded as two (2) TE's (pickup and drop-off).
Hover taxi with no external load will
typically result in no TEs.
6. External Lift and Torque Event (TE)
Requirements
The 369D/E/F/FF - 500/600N helicopters are
multi-use helicopters. If the helicopter is used
primarily for external lifts or training flights
(high TE flights), there may be a reduction in
inspection intervals of some components.
For safe operation of the heli
copter, TE's must be recorded in
the Rotorcraft Log Book. Each external lift
will be recorded as two (2) TE's.
CAUTION
5. Torque Event (TE)

A Torque Event (TE) is defined as:
The transition to a hover from forward
flight.
Any external lift operation.
NOTE: An external lift can either be on the car

go hook, external hoist or in external bas
kets.
(1). Determine the number of TE's and

external lifts the helicopter accumu
lates per hour of flight time.
(2). Record all TE's in Rotorcraft Log Book
and continue to record all TE's.
(3). Perform required TE inspections.
Table 1. Airworthiness Limitations Schedule

Component
(1)
Blade assembly, main rotor
Page 6
Revision 42
Model
Part Number
(2)
Main Rotor System

369D/E(5)(6) 369D21100
369D21100516
369D21100517
369D21100517
369D21100523
369D21120501
369D21120503
369D21120505
369F/FF (6) 369D21102
369D21102503
369D21102517
369D21102517
369D21102523
369D21121501
369D21121503
369D21121505
04-00-00
Finite Life
Hours
(1)
3530
3530
2500
3530
4000
3530
3530
3530
3430
3430
2500
3430
4000
3430
3430
3430
(37)
(37)
(31)
(37)
(37)
(37)
(37)
(37)
(37)
(37)
(31)
(37)
(37)
(37)
(37)
(37)
Mandatory
Inspection
Hours
25 (11)(20)
100
(20)
25
(22)
100
(20)
100
(20)
100
(20)
100
(20)
100
(20)
25 (11)(20)
100
(20)
25
(22)
100
(20)
100
(20)
100
(20)
100
(20)
100
(20)
FAA APPROVED
MAINTENANCE MANUAL
CSP-HMI-2
Table 1. Airworthiness Limitations Schedule (Cont.)

Component
(1)
Blade assembly, main rotor
Folding pin, main rotor blade attach
Hub subassembly, main rotor

Pitch housing assembly, main rotor hub
Retention strap assembly, main rotor hub
Bolt leadlag hub, main rotor
FAA APPROVED
Finite Life
Hours
(1)
500N
(6) 369D21102503
3430
(37)
369D21102517
2500
(31)
369D21102517
3430
(37)
369D21102523
4000
(37)
369D21121501
3430
(37)
369D21121503
3430
(37)
369D21121505
3430
(37)
600N
(6) 369D21102517 (21) 1900 (32)(37)
369D21102523
3200 (33)(37)
369D21121501
3200 (33)(37)
369D21121503
3200 (33)(37)
369D21121505
3200 (33)(37)
369D/E/F/FF 369A1004
2850
369A10043
2850
369A10045
7600
500/600N
369A10045
7600
369D/E/F/FF 369D21201
8900
500N
369D
369D21300
9100
369D21300501
9100
369E/F/FF
369D21300501
9100
500N
369D
369D21210
2770
369D21210501
2770
369E/F/FF
369D21210501
2770
500/600N
369D21210501
2770
369D
369A1220
6120
369D/E/F/FF 369D21220
6120
500N
600N
369D21220
5400
(34)
Model
Part Number
(2)
04-00-00
Mandatory
Inspection
Hours
100
(20)
25
(22)
100
(20)
100
(20)
100
(20)
100
(20)
100
(20)
100
(20)
100
(20)
100
(20)
100
(20)
100
(20)
100
100
100
100
(4)
(4)
(4)
(4)
Page 7
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2

Component
(1)
Link assembly lead lag hub, main rotor
Lead lag damper main rotor
Drive shaft, main rotor
Mast assembly, main rotor
Page 8
Revision 42
Model
369D/E
Part Number
(2)
369H1203BSC
369H120321
369H120331
369H120351
369H120353
369H120361
369F/FF
369H120321
369H120331
369H120351
369H120353
369H120361
500N
369H120351
369H120353
369H120361
600N
369H120351
369H120353
369D
369D21400501
M50452
369D/E/F/FF 369D21400503
500/600N
369D/E
369D25510
369F/FF
369D25510
500N
369D2551021
369D/E
369F5510
369F/FF
369F5510
500N
369F5510
600N
600N5510
369D/E/F/FF 369D22014
500N
600N
369D22014
04-00-00
(39)
(39)
(39)
(39)
(40)
(39)
(39)
(39)
(39)
(40)
(39)
(39)
(40)
(39)
(39)
(40)
Finite Life
Hours
(1)
5762
5762
5762
11080
11080
11080
5762
5762
11080
11080
11080
11080
11080
11080
11080
11080
6060
On Cond.
On Cond.
Mandatory
Inspection
Hours
25
(23)
25
(23)
25
(11)
5020
3675
3260
(42)
(42)
(42)
14000
10450
300
300
300
25
25
(23)
(11)
(16)
(16)
(8)
(8)
(15)
(35)
3500
FAA APPROVED
MAINTENANCE MANUAL
CSP-HMI-2

Component
(1)
Model
Drive Shafts, Couplings and Clutches

Drive shaft, main rotor transmission
369D/E/F
369A5510
Coupling, main transmission drive shaft
369D/E/F/FF 369H5660
500N
369H5660
Overrunning clutch assembly
369D/E/F/FF 369F5450501
500/600N
Sprag assembly, overrunning clutch
369D/E/F/FF 369A5364
369D25351
500N
369D25351
369D/E/F/FF 369F5456
500/600N
Drive shaft, fan
500N
500N5200
600N
500N5200
Drive shaft, tail rotor
369D/E
369D25518
369F/FF
369DSK15211
369D25518503
Coupling tail rotor drive shaft (Bendix)
369D/E/F
369A5501
(NOTE: Not certified on 369FF Model) (9)
369H92564
AntiTorque System
Gearshaft assembly, tail rotor input
369D/E
369D25434
369F/FF
369D25434
Gearshaft, tail rotor output pinion
369D/E/F/FF 369D25430
Blade assembly, tail rotor
369D/E
369D21613
369D2161311
369D2161331
369D2161341
369D2161351
369D2161361
369D2161371
369D21640501
369D21640503
369D21640505
369D21640507
369F/FF
369D21606
369D21642501
369D21642503
369D21642505
369D21642507
FAA APPROVED
Finite Life
Hours
(1)
Part Number
(2)
3790
4300
3200
On Cond.
2620
1200
13900
13900
14610
4980
(7) 4980
(38)
(38)
(38)
(38)
(38)
(38)
(38)
(38)
Mandatory
Inspection
Hours
100
(24)
(3) 300
(10)
(3) 300
(3) 300
(10)
(17)
(36)
12000
3365
7290
5200
5140
5140
5140
5140
5140
5140
400
5140
5140
5140
5140
400
5140
5140
5140
04-00-00
Page 9
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2

Component
(1)
Blade assembly, tail rotor
(optional 4blade)
Hub, tail rotor

Retention strap assembly, tail rotor
Part Number
(2)
Model
369D/E
369D21615
369D21641501
369D21641503
369D21641505
369D21641507
369D/E/F/FF 369A1725
369D/E/F
369FF
Blade assembly, NOTAR fan
500N
Hub, fan
600N
500N
(38)
(38)
(38)
(38)
Finite Life
Hours
(1)
10000
400
10000
10000
10000
3450
369A1706
369A1706507
369A1706509
500N531015
500N531019
500N531019
500N53527
500N53529
500N53529
500N53115
5100
5100
5100
7500
7500
12500
7500
7500
7500
Shaft, NOTAR fan support
600N
500N
600N
600N
500N535713
4000
Pitch plate assembly
500/600N
500N53637
7500
Tube assembly, fan pitch

Rotating cone assembly
500N
500N
500N71133
600
Rotating cone assembly
600N
500N37401
500N374041
500N374061
10000
10000
10000
TensionTorsion Strap, NOTAR
Mandatory
Inspection
Hours
(43)(44)
(18)
Tailboom
Bolts, tailboom attach
Tailboom assembly
369D/E/F/FF MS2125006014
21950
369D/E
369F/FF
500N
10300
10300
10000
10000
10000
10000
2500
5900
1000
6000
6000
2500
5900
1000
On Cond.
On Cond.
600N
Empennage fittings
Page 10
Revision 42
600N
04-00-00
369D23500
369D23500507
500N350019
500N350029
500N3500501
500N3600501
600N3500503
600N3500505
600N3500507
600N3500509
600N3500511
600N3500513
600N3500515
600N3500517
500N35307/8
500N35309/10
100
(14)
100
(14)
100
100
(26)
(26)
(25)
(19)
(19)
(25)
FAA APPROVED
MAINTENANCE MANUAL
CSP-HMI-2

Component
(1)
Vertical stabilizer assembly
Torque tube, horizontal stabilizer
Horizontal stabilizer assembly
Longitudinal idler bellcrank assembly
Idler assembly, longitudinal pitch mixer

Longitudinal control rod
Socket, cyclic stick
Cyclic tube assembly
Housing, collective stick
Tube, collective pitch control
Tube assembly, collective pitch (pilot)
Socket, cyclic stick
Tube, collective pitch (copilot)
Tube assembly, collective pitch (copilot)
Fuselage Sta. 75 controls support bracket
Landing gear brace

Landing gear strut
Landing gear foot
FAA APPROVED
Finite Life
Mandatory
Hours
Inspection
(1)
Hours
369D/E
369D23600
12700
369F/FF
369D23600505
3388
500N
500N39505
5000
600N
500N39507
3000
600N3950
1000
(19)
369D
(12) 369D23601
7700
369E
(12) 421087505
7700
421087905
(13) 7700
369F/FF (12) 421087503
7700
421087903
7700
600N
500N391025
10000
(19)
500N391027
10000
(19)
Controls
369D
369A7301
6500
369A7301501
6500
369E/F/FF
369A7301501
6500
500N
369A7301501
2870
369D/E/F/FF 369A7603
13600
500N
369A7603
6050
500N
369A701113
7740
369A701115
7740
600N
369A7141
1000
8
(27)
600N
369D27132503
1200
8
(27)
600N
369A7347
450
600N
369A7348
400
600N
369H73543
600
600N
369A7802
1000
8
(27)
600N
369A7809
1800
600N
369A7820
450
600N
369H7837
450
600N
369H78383
1000
600N
369N260811
6000
(41)
600N26089
Unlimited
Airframe
600N
600N601017/19
5900
(28)
600N
600N60227/8
696
(29)
600N
600N60433
3900
(30)
Model
Part Number
(2)
04-00-00
Page 11
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2

Component
(1)
Squib cartridge, used on Emergency float
kit 369D2924735, 6, 9, 10, 11, 12
NOTE: Life is based from original date of
manufacture.
Stabilizer support, utility float
Model
Part Number
(2)
Floats
369D/E/F/FF 125521
500N
(Holex, Inc.)
281993
(Walter Kidde)
127541
(Holex, Inc.)
5003527
(Tavco)
369D/E
369D292036
369DSK66
Finite Life
Hours
(1)
Mandatory
Inspection
Hours
5 years
5 years
5 years
5 years
3190
3190
NOTES:
(1) Lifelimited components interchanged between models or configurations must be restricted to the lowest
service life indicated for the models or configurations affected. Lifelimited components removed at
retirement are to be mutilated/destroyed or conspicuously marked to prevent inadvertent return to service.
Parts are applicable only on models under which a service life is listed.
Lifelimited components cannot be altered or permanently marked in any manner without compromising
the part integrity. Part tagging or other record keeping system is required.
Related component records must be updated each time component is removed from service.
(2) Service life shown for the basic (no dash number) part numbers apply to all dash numbered versions
unless otherwise indicated.
(3) With no cargo hook attached: No retirement life assigned (Ref. Sec. 051000, Component Overhaul or
Recommended Replacement Schedule).
With cargo hook attached and no separate log: 1800 hours.
With cargo hook attached and with separate log: 1800 hours of external load operating time when logged
separately.
(For 369D/E/F/FF helicopters with 369A5364 or 369D25351 sprag assembly, Refer to AD 901902.)
(4) Inspect in accordance with Main Rotor Strap Pack Lamination Inspection at 100hour intervals, or 25hour
intervals if 2 laminates (369D/E/F/FF 500N) or 1 laminate (600N) have failed in any one leg or tongue
area of any strap assembly. A single cracked laminate between the shoes at the outboard end of a strap
pack is cause for rejection of the hub assembly
369D/E/F/FF 500N: (Ref. Sec. 622000, Main Rotor Strap Pack Lamination Inspection).
600N: (Ref. Sec. 622060, Main Rotor Strap Pack Lamination Inspection).
(For 369D/E/F/FF helicopters, refer to AD 890201.)
(5) The 369D21100513, 515, 516, 517 and 523 main rotor blades are not interchangeable with any earlier
configuration blades (Basic, 505 or 509); however, the 505 and 509 blades are interchangeable and
the 513 and 515 blades are interchangeable. The 505 and 509 configuration blades may be modified
to the 513M configuration, which is fully compatible with the 513 blade. (For information concerning
modification, contact MDHI Customer Service Department.)
(6) For the 369D/E helicopters, the 369D21120501, 503 main rotor blade has all the same inspections and
interchangeability as the 369D21100517 main rotor blade.
For the 369F/FF 500N helicopters, the 369D21121501, 503 main rotor blade has all the same
inspections and interchangeability as the 369D21102517 main rotor blade.
For the 600N helicopters, the 369D21121501, 503 main rotor blade has all the same inspections and
interchangeability as the 369D21102523 main rotor blade.
(7) Used with 369H90123 Rotor Brake Kit.
Page 12
Revision 42
04-00-00
FAA APPROVED
MAINTENANCE MANUAL
CSP-HMI-2
(8) Inspect main rotor drive shaft every 300 hours (Ref. Sec. 631000, Main Rotor Drive Shaft Inspection
(300 Hour)) (Reference AD 812601).
(9) Failsafe device, P/N 369D25530 bolt and 369D25531 socket, must be used at both ends of tail rotor
driveshaft in accordance with Tail Rotor Drive Shaft Installation with Bendix Couplings (Reference AD
862007).
(10) For helicopters equipped with a cargo hook, inspect overrunning clutch sprag assembly P/N 369D25351,
clutch inner race P/N 369A5353 and outer race 369A5352 every 300 hours (Ref. C.O.M., Sec. 631010,
Overrunning Clutch Sprag Inspection (300 Hour)). To establish time in service, either clutch total time with
hook attached or a separate and permanent log of external load operating time per CFR 91.417, may be
used.
(For 369D/E/F/FF helicopters with 369A5364 or 369D25351 sprag assembly, Refer to AD 901902.)
(11) Inspect main rotor blade root fittings and main rotor leadlag link assemblies every 25 hours in accordance
with Main Rotor Blade Upper and Lower Root Fitting Attach Lug and LeadLag Link Attach Lug Inspection
(25 Hour) and every 100 hours in accordance with Main Rotor Blade Upper and Lower Root, Fitting Attach
Lug and LeadLag Link Attach Lug Inspection (100 Hour) (Ref. Sec. 621000) (Reference AD 950313).
(12) Tip plates, tip weights (where applicable) and attaching hardware have no retirement life and may be
reused on replacement horizontal stabilizers.
(13) 421087903 and 905 require addition of tip plates, tip weights and attaching hardware before
installation.
(14) Inspect the three upper slot bridges for cracks (Ref. Sec. 052000).
(15) Inspect main rotor drive shaft every 300 hours (Ref. Sec. 631000, Main Rotor Drive Shaft Inspection
(300 Hour)).
(16) Inspect for deterioration every 600 hours up to a total time of 4200 hours and every 300 hours thereafter
until deterioration is sufficient to retire assembly
369D/E/FF 500N: (Ref. Sec. 622000, Main Rotor Damper and Attachments Inspection)
600N: (Ref. Sec. 622060, Main Rotor Damper and Attachments Inspection).
(17) For helicopters equipped with a cargo hook, inspect overrunning clutch sprag assembly P/N 369F5456,
clutch inner race P/N 369F5455 and outer race 369F5453 every 300 hours. To establish time in service,
either clutch total time with hook attached or a separate and permanent log of external load operating time
may be used.
(18) 500N711311 tube assembly, fan pitch is an OnCondition part and replaces the 500N71133 tube
assembly.
(19) Interim hours: life extension testing in progress.
(20) Inspect upper and lower blade root fittings every 100 hours in accordance with Main Rotor Blade Upper
and Lower Root, Fitting Attach Lug and LeadLag Link Attach Lug Inspection (100 Hour) (Ref. Sec.
621000)
(For 369D/E/F/FF 500N helicopters, Reference AD 961009).
(21) Main rotor blades, P/N 369D21102517 with S/N 1976 thru 2100, 2106 thru 2115 are not to be installed on
600N helicopter (Reference Service Bulletin SB600N007R2) (Reference AD 981526).
(22) Inspect main rotor blades with 600 or more hours of operation every 25 hours of helicopter operation with a
10X magnifying glass for cracking of the lower surface of the blade emanating from the root fitting and
doubler at the inboard end of the blade and to detect debonding between the blade root end fitting and
doubler if missing or cracked adhesive or paint is observed. (Reference Service Bulletins SB369D195R3,
SB369E088R3, SB369F075R3, SB500N015R3) (Reference AD 981526).
(23) Perform Main Rotor Blade Upper and Lower Root, Fitting Attach Lug and LeadLag Link Attach Lug
Inspection (25 Hour) up to a total time of 500 hours and every 15 hours thereafter and every 100 hours in
accordance with Main Rotor Blade Upper and Lower Root Fitting, Attach Lug and LeadLag Link Attach
Lug Inspection (100 Hour) (Ref. Sec. 621000) until retirement of 369H1203BSC and 21 LeadLag
Link Assembly. (Reference AD 950313).
(24) Inspect clutch retainer and bearing carrier for evidence of spinning and/or wear (Ref. Sec. 052020).
FAA APPROVED
04-00-00
Page 13
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MAINTENANCE MANUAL
CSP-HMI-2
(25) The 600N3500503 tailboom may be reworked to a 600N3500505 tailboom, and the 600N3500513
tailboom may be reworked to a 600N3500515 tailboom by modifying the attachment fittings to allsteel
fittings.
(26) (Ref. Sec. 052000) Using a flashlight and 10X magnifying glass, inspect horizontal stabilizer mounting
brackets for cracks (pay particular attention to the forward inboard legs) (Ref. Tailboom Inspection).
(27) Sockets must be inspected for cracks every eight hours after the initial 100 hour inspection.
(28) Log all landings: Brace life is limited to 35400 logged landings or 5900 hours flight time if landing are not
logged (assumed six landings per one hour of flight time).
(29) Log all landings: Strut life is limited to 4170 logged landings or 696 hours flight time if landing are not
(30) Log all landings: Foot life is limited to 23780 logged landings or 3900 hours flight time if landing are not
(31) The following main rotor blades have a finite life of 2,500 hours or 15,000 torque events*, whichever occurs
first;
P/N 369D21100517 with S/N H664, H665, H667, H669, H671, H672, H674, H676, H679, H680, H683 thru
H724, H726 thru H999 and J000 thru J039, J041 thru J055 and
P/N 369D21102517 with S/N 1976 thru 2100, 2106 thru 2115.
* TORQUE EVENT (TE) A TE is recorded for every transition from forward flight to a hover (Reference
Service Bulletins SB369D195R3, SB369E088R3, SB369F075R3, SB500N015R3).
(32) RIN = (200 x Hrs.) + (52 x TE).
(33) RIN = (160 x Hrs.) + (24 x TE).
(34) RIN = (153 x Hrs.) + (3 x TE).
(35) RIN = (50 x Hrs.) + (3 x TE).
(36) RIN = (768 x Hrs.) + (11 x TE).
(37) After accumulation of 750 flight hours and 13,720 TE, perform Main Rotor Blade Torque Event Inspection
(Ref. Sec. 621000) every 35 flight hours or 200 TEs (whichever occurs first).
(38) The 369D21640501, 503, 505, 507 tail rotor blades are twoway interchangeable with the 369D21613
tail rotor blades in sets of two only.
The 369D21641501, 503, 505, 507 tail rotor blades are twoway interchangeable with the 369D21615
tail rotor blades in sets of two only (installed on the same inboard or outboard hub).
The 369D21642501, 503, 505, 507 tail rotor blades are twoway interchangeable with the 369D21606
tail rotor blades in sets of two only.
(39) The 369H1203BSC, 11, 21, 31, 51 and 61 lead lag link assemblies can only be installed using the
369H1235BSC bearing.
(40) The 369H120353 lead lag link assembly can only be installed using the 369H12351 bearing.
(41) The 369N260811 Control Support Bracket must be removed from 600N helicopters equipped with YSAS
(Ref. SB600N040).
(42) RIN = (29 x Hrs.) + (1 x TE).
(43) The tensiontorsion straps have a 5 year calendar life that starts the day the package is opened (Ref. Sect
642530). If the date the package was opened is unknown, the 5 year calendar life is based on the
manufacturing cure date.
For straps installed before 06 March 2008 on model 500N helicopters serial numbers LN001 thru LN105
and Model 600N helicopters serial numbers RN003 thru RN074, the initial calendar replacement is based
on the cure date on the strap. Refer to Table 2 to find the expiration date.
(44) 500N53115 straps previously installed on MD900 helicopters are life limited to 2,500 hours when installed
on 500N and 600N series helicopters.
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04-00-00
FAA APPROVED
MAINTENANCE MANUAL
CSP-HMI-2
Table 2. TensionTorsion Strap Expiration Date

Manufacturers Cure Date
Expiration Date
Before 03/1999
09/2008
03/1999 thru 02/2001
03/2009
03/2001 thru 02/2005
03/2010
03/2005 thru 02/2008
Cure Date Plus 5 Years
FAA APPROVED
04-00-00
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04-00-00
FAA APPROVED
MAINTENANCE MANUAL
CSP-HMI-2
Section
040001
Airworthiness
Limitations
Supplements
CSP-HMI-2
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
Component
(1)
Part Number
(2)
Finite Life
Hours (RIN)
(1)
Mandatory
Inspection
Hours
Main Rotor System

Drive shaft, main rotor
600N5510
14000 (1,000,000)
(3)
800
(4)
Tailboom
Tailboom assembly
600N3500503
NOTES:
(1) Lifelimited components interchanged between models or configurations must be restricted to the lowest
service life indicated for the models or configurations affected. Lifelimited components removed at
retirement are to be destroyed or conspicuously marked to prevent inadvertent return to service. Parts are
applicable only on models under which a service life is listed.
(2) Service life shown for the basic (no dash number) part numbers apply to all dash numbered versions
unless otherwise indicated.
(3) RIN = (50xHrs.) + (3xTE)
(4) The 600N3500503 tailboom may be reworked to a 600N3500505 tailboom by modifying the attachment
fittings to all steel fittings.
REVISION:
DATE
Initial Issue:
24 May 2000
FAA SIGNATURE AND DATE *
* FAA approval in behalf of UK CAA per letter, Winnert to Wang, Ref. 9/33/0649/A26479, Dated 2 May 2000.
04-00-01
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04-00-01
MAINTENANCE MANUAL
Chapter
05
Continued
Airworthiness
CSP-HMI-2
MAINTENANCE MANUAL
CSPHMI2
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . .

Table 1. Component Overhaul Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2. Component Recommended Replacement Schedule . . . . . . . . . . . . . . . . .
Table 3. Kamatics Component Overhaul Schedule . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
3
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
05 Contents
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Para/Figure/Table
Title
Page

Conditional Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.
Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.
Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.
Overtorque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5.
Sudden Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6.
Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7.
Conditional Inspection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Table 1. Conditional Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Page ii
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05 Contents
MAINTENANCE MANUAL
CSP-HMI-2
Section
050000
Continued
Airworthiness
MAINTENANCE MANUAL
CSP-HMI-2
CHECKS/INSPECTIONS
1. General Description of Inspections
The following Continued Airworthiness
Sections specify inspections and other mainte
nance required under the Federal Aviation
Regulations unless an alternative program has
been FAA approved.
NOTE: Because this manual pertains to MDHI

model 369D, 369E, 369FF, 500N and 600N
helicopters (including the basic 500MD con
figuration), it may contain inspection re
quirements applicable to specific equipment
not installed on individual helicopters.
When this situation is encountered, require
ments that are not applicable should be dis
regarded.
The inspection intervals designated herein are
the maximum allowable and should not be
exceeded. When unusual local conditions, such
as environmental conditions, utilization, etc.
dictate, it is the prerogative and responsibility
of the operator to increase the scope and
frequency of the inspections as necessary to
ensure safe operation. Each item shall conform
with the FAA Requirements, A.D.'s and
Manufacturer Bulletins and Letters. Over
flying the inspection interval, or any change
desired to the requirements of this chapter,
may be requested through the local aviation
regulatory authority.
A. Airworthiness Limitations
Refer to section 04-00-00 for mandatory
inspections and component mandatory
retirement schedule.
B. Continued Airworthiness
This section contains the requirements for
Component Overhaul/Recommended Replace
ment, 100-Hour or Annual Inspection Check
list, 300-Hour Inspection Checklist, Special
Inspection Schedule and Conditional Inspec
tions.
(1). COMPONENT OVERHAUL/RE

COMMENDED REPLACEMENT
(Ref. Sec. 05-10-00) is a schedule for
the overhaul and recommended replace
ment of components and/or assemblies
and scheduled maintenance checks.
(2). 100-HOUR OR ANNUAL INSPEC
TION CHECKLIST (Ref. Sec.
05-20-00) is a schedule of inspections
that must be accomplished every 100
hours of helicopter operation or on a
12-month (annual) basis.
An Annual Inspection is required on
this helicopter for continued airworthi
ness and may be accomplished in
combination with a 100-hour inspec
tion.
NOTE:
D To comply with the requirements of ser
vice bulletins which have been incorpo
rated into the appropriate maintenance
and inspection manuals, the latest
100-Hour or Annual Inspection must be
used.
D Refer to applicable Rolls-Royce Engine
Operation and Maintenance Manual (Ref.
Table 201, 01-00-00) for detailed require
ments on inspection of the engine.
(3). 300-HOUR INSPECTION CHECK
LIST (Ref. Sec. 05-20-10) is a schedule
of inspections that must be accom
plished every 300 hours of helicopter
operation.
(4). YEARLY INSPECTION CHECK
LIST (Ref. Sec. 05-20-15) is a schedule
of inspections that must be accom
plished on a yearly basis.
(5). SPECIAL INSPECTIONS (Ref. Sec.
05-20-20) consist of inspections that
are contingent upon elapsed flight time
or calendar time.
05-00-00
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MAINTENANCE MANUAL
CSP-HMI-2
(a). Special Inspections Hourly should

be referred to for additional inspec
tion requirements that must be
performed at specified periodic
hourly intervals.
(b). Special Inspections Calendar
should be referred to for additional
inspection requirements that must be
performed at specified periodic
calendar intervals.
(6). CONDITIONAL INSPECTIONS (Ref.
Sec. 05-50-00) includes inspection
requirements for unusual or other
specific conditions or circumstances
that might occur.
2. Documentation
A. Records of Aircraft Inspection
(1). Aviation regulatory agencies require
pilot's, mechanics, owners and opera
tors to be familiar with, and to main
tain records of aircraft maintenance,
inspections and repairs. This includes,
but is not limited to, Airworthiness
Directives, Manufacturers Notices,
Scheduled Inspections and Time/Cycle
limited-life components.
B. Additional Documentation
(1). Additional documentation is required to
be available, or inside the aircraft,
during operation. This documentation
includes: Airworthiness and Registra
tion Certificates, Rotorcraft Flight
Manual, Weight and Balance informa
tion and Radio Permits. It is important
that all required documentation be
reviewed and revised as necessary
during regular inspections, mainte
nance and operation of the helicopter.
3. Visual Inspection Criteria
Any time an area of the helicopter is visible
during an inspection or maintenance action,
the following Visual Inspection Criteria shall
be accomplished without requiring disassem
bly or removal of adjacent equipment unless
otherwise specified. It will normally apply to
those areas, surfaces, or items which become
visible by the removal or opening of access
doors, panels, fairings, or cowlings. It shall
Page 2
Revision 38
05-00-00
include a visual examination of the area,

component, detail, assembly, or installation
and its surrounding environment, as well as
any associated equipment within the immedi
ate vicinity, using any inspection aids consid
ered necessary.
A. General Visual Inspection
A visual inspection that will detect obvious
unsatisfactory conditions/discrepancies. This
type of inspection may require cleaning,
removal of fillets, fairings, access panels/doors,
etc.
(1). Metal parts (all metal parts, bodies, or
casings of units in systems and in
electrical, instrument, and radio
installations, ducting, tubing, rods, and
bellcranks). Inspect for the following:
(a). Cleanliness, external signs of dam
age, leaks, overheating, discharge, or
fluid contamination.
(b). Obstruction of drainage or vent holes.
(c). Correct seating and sealing of
fairings and serviceability of fasten
ers.
(d). Security of attachment, fasteners,
and connections.
(e). Distortion, dents, scores, chafing,
pulled or missing fasteners, rivets,
bolts, or screws.
(f). Signs of cracks or wear.
(g). Separation of bond.
(h). Failure of welds or spot welds.
(i). Deterioration of protective treatment
and corrosion.
(2). Composite, rubber, fabric, fiberglass,
and plastic parts (coverings, ducting,
flexible hoses, flexible mountings, seals,
insulation of electrical cables, windows,
etc.). Inspect for the following:
(a). Cleanliness, cracks, cuts, chafing,
kinking, twisting, crushing, or
contraction -(sufficient free length).
(b). Damage, delamination, or deteriora
tion.
(c). Crazing.
MAINTENANCE MANUAL
(d). Loss of flexibility (other than fabric
covered component).
(e). Overheating.
(f). Fluid saturation.
(3). Control System Components. Inspect
for the following:
(a). Correct alignment, no binding.
(b). Distortion, signs of bowing, scoring,
chafing, fraying, kinking, signs of
wear, flattening, cracks, or loose
fasteners.
(c). Deterioration of protective treatment
or corrosion.
(d). Electrical bonding correctly posi
tioned, undamaged, and secure.
(e). Attachments, end connections, and
locking devices secure.
(4). Electrical components (circuit protec
tion devices, wiring, connectors, plugs,
motors, generators, actuators, relays,
solenoids, and contacts). Inspect for the
following:
(a). Cleanliness, obvious damage, corro
sion, security of attachments and
connections.
CSP-HMI-2
(b). If protective covers are required to be

removed, check for cleanliness,
scoring, pitting or burning of con
tacts, brushes for condition, and
security of exposed contacts.
(c). Overheating.
(d). Fluid contamination.
NOTE: For detailed Wiring Inspection criteria,

refer to CSP-HMI-3, Section 96-00-00.
(5). Wire harness. Inspect for the following:
(a). Routing, contact with structure,
proper support and protection.
(b). Strain at termination points, free
movement of shock-mounted or
hinged equipment and proper slack
for equipment installation and
maintenance.
(6). Inside fuel cell areas. Inspect for the
following:
(a). Leaks, cleanliness, foreign objects,
cracks.
(b). Components for security and general
condition.
(c). Plumbing, and wiring for security,
and general condition.
(7). Markings, labels, and placards. Inspect
for the following:
(a). Legibility and security of attachment.
05-00-00
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Revision 38
05-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
051000
Continued
Airworthiness
MAINTENANCE MANUAL
CSP-HMI-2
COMPONENT OVERHAUL/RECOMMENDED REPLACEMENT
1. Component Overhaul or Recommended
Replacement Schedule
Table 1 is the Overhaul Schedule. The listed
components or assemblies should be removed
from the helicopter and overhauled at inter
vals specified.
Table 2 is the Recommended Replacement
Schedule. The listed components should be
removed from the helicopter and scrapped at
intervals specified.
Table 3 is the Kamatics Component Overhaul
Schedule. The listed shafts and couplings
should be removed from the rotorcraft and
overhauled at the interval specified. To be
eligible for the program, the shaft or coupling
must be serviceable before return to MDHI for
overhaul/exchange. Any shaft or coupling

removed for After Main Rotor Drive System
Sudden Stoppage - Level 2, conditional
inspection requirements (Ref. CSP-HMI-2,
05-50-00, Table 1) is not eligible for overhaul
or exchange.
Neither the assignment of an airworthiness
life to a component nor failure to assign an
airworthiness life constitutes a warranty of
any kind. The only warranty applicable to the
helicopter and any components is that
warranty included in the Purchase Agreement
for the helicopter or the component.
NOTE: Hours for the 369F Model helicopters

will be the same as the 369FF unless other
wise noted.
Table 1. Component Overhaul Schedule

Component (1)
Model
Part Number (2)
Hours
369D25100
369D25100
3000
4000
369D/E/FF 500N
600N
369F5100
369F5100
5000
3000
Main rotor swashplate assembly
369D/E/FF 500N
600N
369D27609
600N76303
2770
2700
(3)(9)
(4)(9)
Main rotor hub assembly
369D/E/FF 500N
600N
369D21200
600N1200
2770
2700
(7)(9)
(7)(9)
Landing gear damper
369D/E/FF 500N
369D26300
369D26301
600N6300
On Cond.
On Cond.
On Cond.
(6)
(6)
(6)
369A5350603
369A5350605
1800
1800
(5)
(5)
369D/E/FF 500/600N 369F5450
1800
(10)(11)
369D/E
369FF
369D25400
4800
3365
369D/E
369D25300
4800
369A4550
369D28550
1200
1200
Main rotor transmission assembly
369D/E/FF 500N
600N
Overrunning clutch assembly
Tail rotor transmission
Starter/Generator
369D/E/FF 500N
(8) 369D/E 500N

369FF 600N
(12)
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.
05-10-00
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CSP-HMI-2
MAINTENANCE MANUAL
(2) Service life shown for basic part number applied to all dashnumbered versions unless otherwise
indicated.
(3) Bearing assembly must be relubricated every 2 years or 2770 hours, whichever occurs first (Ref.
CSPCOM5, Sec. 623010).
(4) Bearing assembly must be relubricated every 2 years or 2700 hours, whichever occurs first (Ref.
CSPCOM5, Sec. 623060).
(5) Under some operating conditions, overrunning clutch splines may need to be regreased more often than at
the 100hour intervals and bearings may need to be regreased more often than at the 300hour intervals.
With no cargo hook attached, inspect and regrease splines every 100 hours and bearing every 300 hours
(Ref. Sec. 631000, Installation of Overrunning Clutch Subassembly and CSPCOM5, Ball Bearing
Inspection and Grease Repack).
With cargo hook attached, inspect sprag assembly, inner race and outer race every 300 hours or 300 hours
of actual hook time when logged separately as per FAR 91.417, regrease clutch splines every 100 hours
and bearing every 300 hours (Ref. Sec. 631000, Installation of Overrunning Clutch Subassembly and
CSPCOM5, Ball Bearing Inspection and Grease Repack).
(6) When inspected per Landing Gear Damper Inspection (Ref. Sec. 321000 for 369D/E/FF 500N, or Sec.
321060 for 600N).
(7) Use only main rotor hubs overhauled by MDHI or approved MDHI Licensees.
(8) Refer to data plate to determine start/generator manufacturer.
(9) The shelf life of bearings preserved with grease is limited to 4 years.
(10) Regrease overrunning clutch bearings every 300 hours (Ref. CSPCOM5, Sec. 631015).
(11) Interim hours: life extension testing in progress.
(12) The 369D25100 main rotor transmission overhaul time may be extended from a mandatory 3000 hour
overhaul time to a mandatory 4000 hour overhaul time, provided, the transmission is operated with Mobil
SHC626 since last overhaul.
The transmission shall not exceed 3000 hours if cargo hook time has reached a quantity of 750 hours.
Page 2
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05-10-00
MAINTENANCE MANUAL
CSP-HMI-2
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

Thrust bearing cone, upper
369D/E/FF 500N
369D/E/FF 500N
369D21255
369D21254
On Cond.
On Cond.
(3)(9)
(3)(9)
Thrust bearing cup, upper

Thrust bearing cone, upper
600N
600N
369D21255
369D21254
600
600
(5)(9)
(5)(9)
Thrust bearing cup, lower

Thrust bearing cone, lower
369D/E/FF 500N
369D/E/FF 500N
369D21257
369D21256
On Cond.
On Cond.
(3)(9)
(3)(9)
Thrust bearing cup, lower

Thrust bearing cone, lower
600N
600N
369D21257
369D21256
5400
5400
(4)(9)
(4)(9)
Bearings, oil cooler blower
369D/E/FF 500/600N 369H56553

369D/E/FF 500/600N 369H56555
1200
1200
Belt, oil cooler blower
369D/E/FF 500N
600N
369D25623
93920219
1200
1200
A21810064602
1000
Cyclic stick trim switch
(7) 369D/E/FF 500N
NOTES:
(1) Limitedlife or scheduled replacement components interchanged between models or configurations must
be restricted to the lowest service life indicated for the models or configurations affected. Limitedlife or
scheduled replacement components removed at retirement are to be destroyed or conspicuously marked
to prevent inadvertent return to service. Parts are applicable only on models under which a service life is
listed.
(2) Service life shown for basic part number applied to all dashnumbered versions unless otherwise
indicated.
(3) Bearing assembly must be relubricated every 2 years or 2770 hours, whichever occurs first (Ref. Sec.
643000, Tail Rotor Swashplate Bearing Regreasing).
622060, Main Rotor Hub Tapered Bearing Grease Repack, Inspection and Replacement).
622060, Main Rotor Hub Upper Bearing Grease Repack, Inspection and Replacement).
(6) Deleted
(7) Installed in 369D27133 grip assembly made by Guardian Electric Co., PN A21896671400 (Ref. Sec.
671020, Cyclic Stick Grip Switch Replacement (Standard Grip)).
642530, AntiTorque Fan Bearing Regreasing).
(9) The shelf life of bearings preserved with grease is limited to 4 years.
05-10-00
Page 3
Revision 37
MAINTENANCE MANUAL
CSP-HMI-2
Table 3. Kamatics Component Overhaul Schedule

Component
Part Number
Serial Number (3) Initial TBO Date
Next Overhaul
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
0517 thru 1017
2014
2024
(1)
Interconnect Shaft
500N5215
1018 thru 1550
2015
2025
(1)
Interconnect Shaft
500N5215
1551 thru 1667
2016
2026
(1)
Interconnect Shaft
500N5215
1668 thru 1777
2017
2027
(1)
Interconnect Shaft
500N5215
1776 thru 1824 (2)
2018
2028
(1)
Tail Rotor Driveshaft Coupling
369D25501BSC N/A
2010 2011
2021
(1)
369D255013
0001 thru 0493
2010 2011
2021
(1)
369D255019
0001 thru 0505
2010 2011
2021
(1)
369D255013
0494 thru 1087
2012
2022
(1)
369D255019
0506 thru 1011
2012
2022
(1)
369D255013
1088 thru 1581
2013
2023
(1)
369D255019
1012 thru 1517
2013
2023
(1)
369D255013
1582 thru 1972
2014
2024
(1)
369D255019
1518 thru 2023
2014
2024
(1)
369D255019
2024 thru 2523
2015
2025
(1)
369D255019
2524 thru 3024
2016
2026
(1)
369D255019
3025 thru 3525
2017
2027
(1)
369D255019
3526 thru 4025
2018
2028
(1)
369D255019
4026 thru 4525
2019
2029
(1)
369D255019
4526 thru 5025
2020
2030
(1)
369D255019
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
Revision 44
05-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
052000
Continued
Airworthiness
MAINTENANCE MANUAL
CSP-HMI-2
100HOUR OR ANNUAL INSPECTION CHECKLIST
NOTE:
1. 100Hour or Annual Inspection
D The Chap/Sect column of the following

table is for reference unless a specific in
spection requirement is called out. If
there is only two numbers in the column,
it refers to the Chapter. If there is three
numbers, it refers to the Section the in
spection is found.
D Refer to applicable Rolls-Royce engine in
spection check list for required engine
maintenance.
This check sheet is designed to be used when

performing 100-Hour or Annual inspections as
defined under FAR, Part 43, Appendix D. This
checklist, when completed, should be kept as a
permanent part of the helicopter's records.
Adherence to Maintenance Manual informa
tion is required, and the manual should be
consulted when using the checklist.
Table 1. 100Hour or Annual Inspection

Registration No.
Serial No.
Helicopter Hours
Torque Events
Model
Requirement
Chap/Sect
Initial
GENERAL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
Thoroughly clean helicopter and engine prior to start of inspection.

Remove trim panels, covers and access panels as necessary.
Ensure all placards and markings are installed.
Ensure compliance with component mandatory retirement schedule.
Calculate and record TEs or RINs, of all affected components, in Table 2.
Ensure compliance with component overhaul schedule.
Ensure compliance with all applicable airworthiness directives, service
bulletins and special inspections.
ALL
Review aircraft maintenance records for recorded discrepancies and correct

discrepancies as applicable.
ALL
Refer to related manufacturers publications for detailed requirements on

inspection of engine, starter/generator, battery and all installed STC
equipment.
20
525000
110000
040000
040000
051000
N/A
N/A
010000
EXTERIOR
ALL
Air intake for cleanliness and foreign matter.
Visible portion of engine compressor inlet for foreign object damage.
71
CAUTION: Ensure that compressor cover is installed to prevent FOD.

ALL
Engine air plenum chamber for:
71
53
Damage and cleanliness.
Wear and security of internal components.
Particle separator mounting structure for cracks or damage.
Form HOE005 (Rev 5/04)
05-20-00
Page 1
Revision 35
MAINTENANCE MANUAL
CSP-HMI-2
Table 1. 100Hour or Annual Inspection (Cont.)

Registration No.
Serial No.
Helicopter Hours
Torque Events
Model
ALL
Requirement
Chap/Sect
Fuselage upper surfaces for:

*
Initial
52
53
Damage and condition.
* Mast base drain holes clean and free of debris (blow air thru holes to
ensure no clogging).
* Engine air inlet fairing free from damage. No delamination noted. Bypass
door operationally checked. Seals free from damage.
* Engine air bypass door operationally checked. Seals free from damage.
Cable system checked for smooth operation.
ALL
* Engine access doors for proper operation of latches and closure,

distortion, damage, cracks and security.
Fuselage for:
*
71
52
52
53
Damage and condition.
* Compartment fresh air vents in doors and front of canopy for easy of
operation and security.
*
Fuel cell vent fairings free of obstructions and obvious damage.
* Pilots and passenger/cargo compartment doors for condition of door

glass, vents and proper operation of latching and locking mechanisms.
* Door hinges and pins for play or wear. Ensure door pin locking tab is
engaged with slot in frame.
* No evidence of oil leakage around fuselage drain holes.
369D/E/FF Sta. 142.0 tail rotor control bellcrank support for cracking or damage, use
bright light and mirror (Ref. Upper Fuselage and Tailboom Control Linkage
Inspection).
500/600N Antitorque fan inlet for:
ALL
Screen for cleanliness and damage.
Attaching hardware for security.
Interior of fan inlet for cleanliness and damage.
Driveshaft cover for damage.
Check for no gap between tailboom and fuselage at attach points.
Check tailboom skin around stabilizer fittings for cracks.
672010
53
53
* Tailboom attachmenttofuselage for security, evidence of corrosion or

cracks, loose rivets or buckling.
Page 2
Revision 39
05-20-00
MAINTENANCE MANUAL
CSP-HMI-2

Registration No.
Serial No.
Helicopter Hours
Torque Events
Model
Requirement
Chap/Sect
500/600N
* Thruster cones and tip cap (500N only) for damage and security. Inspect
for wear between thruster cones and tailboom at points of contact.
534030
535030
Initial
* 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:
*
500/600N
535010
Skin damage and loose rivets.
* Tip plates for damage. Check for secure attachments (Ref. Horizontal
Stabilizer and Tip Plates Inspection).
Horizontal stabilizer for:
*
Skin damage and loose rivets.
Mounting fittings for cracks and security.
* Stabilizer attach bolts for security.

369D/E/FF Vertical stabilizer for:
53
535010
* Damage to leading and trailing edges and damaged stressed side panels
(no repair of side panels permitted).
*
500/600N
* Tail skid for obvious damage and security (Ref. Vertical Stabilizer
Inspection).
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.
05-20-00
Page 3
Revision 40
MAINTENANCE MANUAL
CSP-HMI-2

Registration No.
Serial No.
Helicopter Hours
Torque Events
Model
Requirement
Chap/Sect
Initial
LANDING GEAR
ALL
Landing gear skid tubes and fairings for:

*
Wear and damage in excess of permissible limits.
Upper fairing fillets for freedom of movement and general condition.
32
* 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
ALL
ALL
Compartment heat and antiicing valve controls for:

*
Easy and correct operation and rigging.
Heating system heat diffusers for security.
Seat belts for condition and security.
Inertia reels for condition and proper extension/retraction.
21
25
Pilot/copilot controls for:
67
76
* Wear, looseness and general condition of control rods and rod end
bearings.
*
Quickrelease pins for condition.
Cyclic, collective and antitorque controls for free movement.
Cyclic trim actuators for security.
* Collective torque tube, support bracket and bungee support bracket for
evidence of cracks, gouges or other visible damage in attach lug and bungee
support bracket attach areas; gaps between bracket and cradle cap of
collective torque tube (use bright light and mirror).
*
N1 power controls for obvious damage.
* Check for minimum cyclic friction adjustment (resistance to turning spring

with fingers).
* Flight control system oneway lock (Uniloc) for oil leakage, condition and
security. Fluid reservoir 1/2 3/4 full; replenish if low.
Page 4
Revision 35
05-20-00
MAINTENANCE MANUAL
CSP-HMI-2

Registration No.
Serial No.
Helicopter Hours
Torque Events
Model
Requirement
Chap/Sect
Initial
NOTE: With main rotor blades stationary, some friction drag is felt in the cyclic. The collective also has some drag,
plus resistance of the collective bungee spring. Heavy drag is an indication of droop stop deformation caused
by droop stop pounding.
ALL
Engine N1 and N2 (N/A 600N) power controls for:

*
76
Free movement, full travel, security, obvious damage and proper rigging.
* Pilots and copilots throttle rigging checks at FULL, GROUND IDLE and
CUTOFF positions.
MAIN ROTOR
ALL
ALL
Main rotor mixer control pushpull rods, links, scissors and bellcranks for
excessive bearing play, bent rods or links, worn bushings and cracked
bellcranks or brackets; all rodends centered.
Main rotor pitch control rod assemblies, upper and lower rod end bearing for
evidence of axial play and for any extrusion, displacement or damage to the
bearing teflon liner. Check that all rodends are centered and security of
lockwire (Ref. Pitch Control Rod Inspection).
62
67
623000
623060
ALL
Swashplate for evidence of galling or corrosion of spherical bearing, and

seals for deterioration and evidence of grease leakage. Upper and lower dust
boots free from damage and security. Swashplate interrupters and magnetic
pickup secure.
ALL
Main rotor hub retention strap assemblies for breaks or cracks in strap pack
laminations. Check visible portions of both lead and lag legs of pack in each
pitch housing (Ref. Main Rotor Strap Pack Lamination Inspection). Refer to
040000 for strap pack lamination airworthiness requirements.
622000
622060
ALL
Outboard ends of main rotor hub retention strap assemblies for gaps
between pack laminates (Ref. Main Rotor Strap Pack Lamination Inspection).
622000
622060
ALL
* Main rotor hub feathering bearings for excessive wear (Ref. Main Rotor
Hub Inspection).
622000
622060
ALL
ALL
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.
Main rotor blade damper assemblies for obvious damage, security and
excessive play in blade and pitch housing bearings, bonding of elastomeric
material and corrosion (Ref. Main Rotor Damper and Attachments
Inspection).
Using bright light and 5X magnifying glass, inspect all main rotor hub
assembly leadlag links for corrosion, discoloration, pitting, intergranular
cracks or stress corrosion cracks. Any discoloration or pitting is evidence of
more than superficial corrosion, and the main rotor hub must be removed for
replacement of leadlag links (Ref. Main Rotor Hub Inspection).
05-20-00
62
622000
622060
622000
622060
Page 5
Revision 35
MAINTENANCE MANUAL
CSP-HMI-2

Registration No.
Serial No.
Helicopter Hours
Torque Events
Model
ALL
Requirement
Chap/Sect
Main rotor hub bearings for roughness by rotating main rotor assembly
several times by hand and listening for unusual noise (Ref. Main Rotor Hub
Inspection).
Initial
622000
622060
NOTE: Do not confuse with normal noload transmission and overrunning clutch noise.
ALL
ALL
Main rotor blade and damper attach pins tight and levers properly locked.
Entire trailing edge and tabs for nicks, scratches and cracks generating from
trailing edge (Ref. Main Rotor Blade Inspection).
62
621000
WARNING: Using a bright light and 5X to 10X magnifying glass, inspect root fitting,
attach lugs and doublers for cracks and security.

ALL
Inspect main rotor blade root fittings, attach lug and leadlag link attach lug
every 100 hours in accordance with Main Rotor Blade Upper and Lower Root
Fitting, Attach Lug and LeadLag Link Attach Lug Inspection (100 Hour). Pay
particular attention to the lower side of the root fitting.
621000
ALL
Using a bright light and 10X magnifying glass, inspect main rotor blade
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).
621000
ALL
Tip area of main rotor blades for evidence of corrosion; pay particular
attention to mating area of blade skintotip weight interface; verify integrity
of sealant coating (Ref. Main Rotor Blade Forward Tip Cap Inspection and
Corrosion Protection).
621000
ALL
Drain holes in main rotor blade aft tip cap and vent holes in lower skin for
clogging. Main rotor tip caps for security and evidence of corrosion.
62
369D/E/FF Main rotor hub fairing for cracks, damage and security.
500N
62
DRIVE TRAIN
ALL
Main transmission lubrication and cooling system for:
63
* Main transmission case and cooling installation for evidence of leakage

and security of attachment.
*
Oil cooler blower, mount, ducting and hardware for security and damage.
Oil lines for chafing damage.
* Clamps attached to oil lines for evidence of cushion wear or deterioration

(if noted, remove clamp and inspect tube under clamp for chafing damage).
* Pressure switch for security and deterioration; wiring for chafing.
369D/E/FF Tach generator for security and deterioration; wiring for chafing.
500N
ALL
Rotor brake for:
63
63
Pucks and disc for wear and general condition.
Hydraulic lines for security and leaks.
Master cylinder for leaks.
* Air in system (spongy feel at brake actuating handle when force is

applied).
Page 6
Revision 35
05-20-00
MAINTENANCE MANUAL
CSP-HMI-2

Registration No.
Serial No.
Helicopter Hours
Torque Events
Model
ALL
Requirement
Chap/Sect
Overrunning clutch for:

*
Initial
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
500N
splines.
ALL
500/600N
Enginetomain transmission drive shaft couplings and shaft for condition and
security of attachment.
Bendix couplings only: inspect shaft coupling diaphragms for scratches, nicks
or cracks (Ref. Main Transmission Drive Shaft Inspection (Bendix)).
* Main transmissiontofan transmission drive shaft for dents, bulkhead
chafing and obvious damage.
*
631000
63
InterConnect drive shaft for dents and obvious damage.
* Free movement of control rod thru interconnect drive shaft.

369D/E
Bendix couplings only: Check tail rotor blade tip movement in excess of 0.75
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
63
631510
Evidence of buckling, dents, bulkhead chafing and obvious damage.
* Align aft coupling index stripe with corresponding tail rotor transmission
stripe and verify that bulkheadtodrive shaft index stripes align (Ref. Tail
Rotor Drive Shaft Twist Inspection).
ANTITORQUE
Tail Rotor System
369D/E/FF Tail rotor transmission for:
*
632510
Corrosion, excessive oil leakage, cracks and other damage.
* Check torque of mounting nuts (also tailboom extension hardware on

369FF helicopters) (Ref. Tail Rotor Transmission Installation).
369D/E/FF Tail rotor and pitch control assembly for:
*
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.
64
* 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.
05-20-00
Page 7
Revision 39
MAINTENANCE MANUAL
CSP-HMI-2

Registration No.
Serial No.
Helicopter Hours
Torque Events
Model
Requirement
Chap/Sect
369D/E/FF Drive fork for;

*
Initial
64
Elastomeric bearing elements for bond failure.
* Apply teetering force by hand (stoptostop) to rotor blades and inspect

elastomers for radialmolded ridges on each bearing face. Discontinuity in
molded ridges indicates bearing failure. There should by no apparent motion
between the cage and fork, observed motion indicates bond failure.
NOTE: Light swelling, pock marks and crumbs are surface conditions and do not indicate bearing failure.
369D/E
If equipped with conicaltype teetering bearings, torque check teeter bolt.

*
64
Conical bearings for axial or radial play (no play allowed).
369D/E/FF Tail rotor blades for:
641000
Evidence of damage, including leading edges, trailing edges, skin.
Open vent and drain holes.
Loose or damaged tip caps.
Rivets securing tip cap for installation and condition.
* Abrasion strips free of damage, no excessive erosion noted and no

separation in bond around edges or at tip end of blade (Ref. Tail Rotor Blade
Inspection).
* While holding hub stationary, check tail rotor blade pitch bearings for
leadlag play in excess of 0.250 inch (6.35 mm) at blade tip. If excess play is
found, remove blades, replace pitch bearings and inspect hubtopitch
bearing contact surface of hub (Ref. COM).
369D/E/FF Perform Tail Rotor Balance.
18
NOTARR AntiTorque System

500/600N
Rotate rotor system and check for unusual noises.
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.
64
NOTE: If any of these gaps for any blade exceeds the average gap of the other blades by more than 0.10 inch
(2.54 mm), remove and inspect the tensiontorsion strap for that blade.
500/600N
500/600N
Page 8
Revision 39
Perform Fan Blade Inspection (100Hour).

Fan Transmission for corrosion, excessive oil leakage, cracks, damage and
security on mounting frame. Drain line for cracks and security.
05-20-00
642530
63
MAINTENANCE MANUAL
CSP-HMI-2

Registration No.
Serial No.
Helicopter Hours
Torque Events
Model
500/600N
Requirement
Chap/Sect
Remove rotating cone and tip cap (500N) and inspect:
Initial
67
* Cables, cable ends and pulleys for condition and security. Perform
Forward and Center Cable Assembly Inspection and Sector Assembly and
Control Cable Inspection.
* Aft cable ends and turnbuckles for condition and security. Evidence of
corrosion pitting requires replacement.
* Rotating cone control tubes and cables for freedom of movement and
unusual sounds.
Reinstall rotating cone and tip cap (500N).
ELECTRICAL
NOTE: When possible, use auxiliary power source, not battery, during POWER ON inspection.
ALL
XMSN OIL TEMP, FUEL FILTER and CHIPS warning lights; electrical circuits
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
instrument light rheostat knob; verify CAUTION lights dim.
369D/E/FF Conduct operational check of automatic reignition system; igniter noise heard
500N
and reignition indicator light functions. Reset as required.
950000
95
PFM
CAUTION: Do not leave landing light ON for more that one minute during next check; lamp will overheat and
lamp life will be shortened.
ALL
Exterior lighting (landing, position and anticollision lights) for proper

operation; all switches OFF after check.
96
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
the touch; turn switch to OFF after check.
95
600N
Apply power to aircraft and disconnect CIT sensor (Ref. CIT (Compressor
Inlet Temperature) Sensor Replacement); Verify ECU FAIL light illuminates.
Reconnect CIT sensor.
760000
ALL
Clean battery and inspect for:
96
Connector pins for evidence of corrosion.
Leakage (if battery is leaking (wet), remove and replace battery).
Battery case for cracks in support flanges.
Dc wiring for chafing caused by wiring rubbing against battery case.
* Deep cycle charge (recondition) battery every 100 hours or on

conditional basis at operators discretion.
ALL
Functionally check and inspect all installed avionics, auxiliary or optional

systems and equipment. Do not actuate hoist guillotine or emergency floats.
05-20-00
97
Page 9
Revision 39
MAINTENANCE MANUAL
CSP-HMI-2

Registration No.
Serial No.
Helicopter Hours
Torque Events
Model
Requirement
Chap/Sect
Initial
ENGINE COMPARTMENT
ALL
Exhaust stack(s) and exhaust supports for cracks, defects and improper
attachment.
78
ALL
Engine compartment plumbing and electrical relay installation on left or right

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.
96
ALL
Entire engine for:
71
75
76
Loose bolts; loose or broken connections.
Accessories for security and broken or missing lockwire.
Fuel and oil lines for chafing and kinking.
Fuel drain line valve for leakage.
Oil cooler and cooler deflector for security and obvious damage.
Accessible areas for obvious damage; evidence of fuel and oil leaks.
* Engine mounts for cracks and play in mounting hardware at engine and
airframe (retorque any loose mounting bolts).
*
Fuel control and compressor exterior for condition and security.
369D/E/FF RPM governor lever control rod (replace if aluminum).

500N
761000
369D/E/FF Clean and lubricate drive splines of startergenerator drive shaft, and female
500N
splines in engine accessory gear case on dry spline installations.
369D/E/FF Antiice air tubes and compressor scroll for cracks or breaks at the antiice
500N
air valve and bleed port. If cracks exist, check engine for possible vibration
causes (Ref. Engine Antiicing System and applicable Allison Engine
Operation and Maintenance Manual).
96
751000
AFTER INSPECTION
ALL
ALL
ALL
Page 10
Revision 39
Touchup all damaged paint and exterior markings, as necessary.

Ensure all fluid levels are correct; service as required.
Perform operational check of particle separator filter (Ref. Scavenge Air
Operational Check).
05-20-00
20
12
711010
MAINTENANCE MANUAL
CSP-HMI-2

Registration No.
Serial No.
Helicopter Hours
Torque Events
Model
Requirement
Chap/Sect
ALL
Install or close all stressed panels, covers and trim panels removed or
opened for inspection. Check closure, fit and security. All loose equipment for
proper stowage.
525000
Initial
CAUTION: Helicopter must not be flown unless controls access panel and fuel cell access panels in cargo
compartment are securely installed. These are stressed panels.
POST INSPECTION RUN UP
See applicable Pilots Flight Manual for cockpit check and engine starting procedures. For troubleshooting
procedures, refer to applicable section of this manual.
100HOUR OR ANNUAL INSPECTION CERTIFICATION
It is certified that this helicopter has been thoroughly inspected as required by FAR, found to be airworthy, and
appropriate entries made in the helicopter log book. It is further certified that the helicopter conforms to FAA
specifications, that all FAA Airworthiness Directives and Manufacturers Service Notices and Maintenance
Manual data have been complied with, and the helicopter records are in proper order
Signature
Rating Type or Certificate No.
Date
2. Retirement Index Numbers Attachment

Table 2 is to be used for calculating and
recording the Retirement Index Number (RIN)
or Torque Events (TE) of components that are
affected by Torque Events (TE).
This record of RINs/TE's should be kept as a
permanent record.
Refer to Section 04-00-00 for components

requiring calculation of RIN's/TE's and
information pertaining to calculation of
RIN's/TE's.
Component must be scrapped when it reaches
1,000,000 RIN's or maximum TE's (Ref. Sec.
04-00-00).
Table 2. Permanent Record of Retirement Index Numbers/Torque Events

Component
Part No.
Serial No.
Hours
TEs
05-20-00
RINs
Signature
Page 11
Revision 39
MAINTENANCE MANUAL
CSP-HMI-2
Table 2. Permanent Record of Retirement Index Numbers/Torque Events

Component
Page 12
Revision 39
Part No.
Serial No.
Hours
05-20-00
TEs
RINs
Signature
MAINTENANCE MANUAL
CSP-HMI-2
Section
052010
Continued
Airworthiness
MAINTENANCE MANUAL
CSP-HMI-2
300HOUR INSPECTION CHECKLIST
NOTE:
1. 300Hour Inspection

spection is found.
maintenance.

performing scheduled inspections as defined
under FAR Part 91. This checklist, when
completed, should be kept as a permanent part
of the helicopter's records. Adherence to
Maintenance Manual information is required,
and the manual should be consulted when
using the checklist.
Table 1. 300Hour Inspection

Registration No.
Model
Serial No.
Helicopter Hours
Requirement
Chap/Sect
Initial
EXTERIOR
ALL
500/600N
Retorque tailboom attachment bolts.
53
Remove rotating cone and tip cap (500N) and inspect:
53
Cone rollers for condition and security.
* Four fasteners that attach 500N37601 upper input shaft to the

stationary thruster for play (replace pins and collars if any play is found).
* Three fasteners that attach 500N3759 support shaft assembly for play (if
play is found in top bolt, retorque to 10 15 inchpounds (1.13 1.69 Nm).
Replace pins and collars if any play is found in bottom fasteners).
Reinstall rotating cone and tip cap (500N).
369D/E/FF Remove engine inlet bypass door and inspect:
711010
.Latches, hinges and hardware for condition, wear and security.
.Cables, cable ends and pulleys for condition, corrosion and wear.
* Remove and replace the latch retention cotter pin (located inside the
attach U clamp) (Ref. Engine Air Inlet Bypass Door 300Hour Inspection).
369D/E/FF Check horizontal and vertical stabilizer attach bolts for proper torque (Ref.
Horizontal Stabilizer Tip Plate Installation and Vertical Stabilizer Installation).
535010
369D/E/FF Check lower surface of horizontal stabilizer for drain holes. Also check for
gaps between upper and lower doublers and stabilizer skin (Ref. Horizontal
Stabilizer and Tip Plates Inspection).
535010
500/600N
Control tubes and bellcranks in horizontal stabilizer for condition and security.
Form HOE006 (04/06)
05-20-10
53
Page 1
Revision 39
MAINTENANCE MANUAL
CSP-HMI-2
Table 1. 300Hour Inspection (Cont.)

Registration No.
Serial No.
Model
500/600N
Helicopter Hours
Requirement
Inspect S.A.S. system for:
*
Chap/Sect
Initial
67
Actuator for security and damage (no damage allowed).
* Wiring for condition and security (no wire chaffing, fraying or insulation
cracking allowed).
* Actuator mounting bracket for cracks, pay particular attention to area
around four rivet attach holes (no cracks allowed).
* Rate gyro and control box for security in mount and electrical connector
secure. Inspect mount for security and condition (no corrosion or cracks
allowed).
LANDING GEAR
ALL
Perform Landing Gear Inspection.
321000
ALL
Perform Cabin Entry Step Inspection.
321000
CABIN
ALL
Remove instrument console base covers and inspect antitorque pedal

crossover torque tube and bellcrank for cracks, damage and security.
67
ALL
Pushpull rods for excessive bearing play, wear and security.
67
ALL
Perform TunnelRouted Control Rod Inspection.
ALL
Check oil tank for security and evidence of leakage and damage.
671000
79
MAIN ROTOR
ALL
Perform Swashplate Inspection.
62
ALL
Perform LeadLag Bolt Inspection.
62
ALL
Perform Main Rotor Hub Droop Angle Check.
62
ALL
Perform Main Rotor Blade Inspection.
62
ALL
Inspect main rotor mast, mast base and mast base support structure for
evidence of cracks. Check with bright light and 5X magnifying glass. Visually
check mast support bolts for security and condition. Inspect internal bore for
chipping, orange peeling or flaking paint (Ref. Main Rotor Static Mast
Inspection and Repair).
ALL
Inspect hoisting eyebolts for cracks or corrosion.
369D/E/FF 369D25510 drive shaft only, perform Main Rotor Drive Shaft Inspection
500N
(300Hour).
633000
63
631000
DRIVE TRAIN
ALL
Remove, inspect and clean main transmission chip detectors.
369D/E/FF 369A5350 Overrunning Clutch: Perform Ball Bearing Inspection and Grease
500N
Repack (300 Hour).
ALL
369F5450 Overrunning Clutch: Perform Ball Bearing Grease Repack (300

Hour).
369D/E/FF Remove tail rotor drive shaft and check boom fairing and tailboom for
buckles, dents, bulkhead chafing and obvious damage.
Page 2
Revision 39
05-20-10
63
COM
COM
53
Form HOE006 (04/06)
MAINTENANCE MANUAL
CSP-HMI-2

Registration No.
Serial No.
Model
Helicopter Hours
Requirement
Chap/Sect
369D/E/FF Remove tailboom control rod and inspect for wear though hard anodized
surface (Ref. Tailboom Control Rod Replacement); inspect grommets for
wear and deterioration.
672010
369D/E/FF Check shaft damper for proper friction drag. Inspect damper for damage and
security (Ref. Tail Rotor Drive Shaft Damper Inspection).
631510
369D/E
Check forward and aft coupling bolt and socket for indication of contact,
Bendix couplings only (Ref. Tail Rotor Drive Shaft Inspection).
Initial
631510
ANTITORQUE
Tail Rotor System
369D/E/FF Remove, inspect and clean chip detectors.
63
369D/E/FF Check for contact between tail rotor bellcrank and tail rotor transmission
housing at extreme right pedal travel.
67
369D/E/FF Tail rotor assembly: Elastomeric teeter bearings for wear; bond between
concentric metal cones and elastomer rings of bearing assembly (Ref.
Elastomeric Bearing Inspection).
642000
369D/E/FF Remove blade stop for thorough inspection; in particular, check for cracks or
splits in stem area (Ref. Tail Rotor Blade Stop Inspection).
643000
NOTARR AntiTorque System

500/600N
Check balance weights for security. If any balance weight stud is found to be
loose, perform Fan Balance Stud Replacement.
64
500/600N
Remove, inspect and clean fan transmission chip detector.
63
500/600N
Remove tailboom:
Perform visual inspection of fan assembly for:
53
64
Cracks, nicks or corrosion.
Blades for cracks, nicks or impact damage.
* Check pitch horn counterweights for security. If counterweight(s) are

found loose, perform Pitch Horn Counterweight Set Screw Replacement
(Ref. Sec. 642530). NOTE: Access the forward counterweights through
the fan inlet (fan hub fairing must be removed).
* Gap between fan blade and tip seal and gap between fan blade and hub
(inboard end of the blade). If any of these gaps for any blade exceeds the
average gap of the other blades by more than 0.10 inch (2.54 mm)., remove
and inspect the tensiontorsion strap for that blade.
*
Fan liner for cracks, debonding or corrosion of liner material.
* Pseal for tears, deterioration and debonding.

Reinstall tailboom (on 600N only, install new tailboom mounting bolts).
ELECTRICAL
NOTE: When possible, use auxiliary power source during POWER ON inspection, not battery.
ALL
Perform Battery Temperature Sensing Switches Testing.
369D/E/FF Check TOT indicating system for proper calibration (Ref. TOT Indicating
500N
System Calibration).
Form HOE006 (04/06)
05-20-10
96
953000
Page 3
Revision 39
MAINTENANCE MANUAL
CSP-HMI-2

Registration No.
Serial No.
Model
Helicopter Hours
Requirement
Chap/Sect
Initial
ENGINE COMPARTMENT
ALL
ALL
Inspect starter/generator for:

*
Condition of brushes, electrical connections and commutator.
Screens for clogging.
Condition of Oring on drive spline.
Damper backplate and clutch for condition.
Perform Fuel Filter (Bypass) Caution Light Pressure Switch Test.
96
280000
280060
NOTE: Also, perform this operational check whenever low pressure fuel pump filter element is replaced for any
reason, or if contaminated.
Page 4
Revision 38
05-20-10
Form HOE006 (04/06)
MAINTENANCE MANUAL
CSP-HMI-2
Section
052015
Continued
Airworthiness
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSP-HMI-2
YEARLY INSPECTION CHECKLIST
NOTE:
1. Yearly Inspection

spection is found.

performing special inspections as defined
under FAR Part 91. This checklist, when
completed, should be kept as a permanent part
of the helicopter's records. Adherence to
using the checklist.
D Refer to applicable Allison engine inspec

tion check list for required engine mainte
nance.
Table 1. Yearly Inspection

Registration No.
Model
Serial No.
Helicopter Hours
Requirement
Chap/Sect
Initial
1 YEAR
EXTERIOR
ALL
Perform Pitot Static System Inspection.
951000
ALL
Check outside air temperature probe for security and obvious damage.
95
ALL
Particle separator for condition and servicing.
71
NOTE: If equipped with a Donaldson Particle Separator, ensure Orings for rubber boot are 711010
not deteriorated (Ref. Donaldson Particle Separator Inspection).
ALL
Perform engine air inlet Air Pressure Sensing Switch Calibration Check.
711010
711060
LANDING GEAR
369D/E/FF Perform Landing Gear Strut Inspection.
500N
321000
CABIN
ALL
ALL
ALL
First aid kit contents and security of attachment.
25
Fire extinguisher for charge pressure and security of attachment.
26
Inspect seats, interior trim, panels and covers for damage and security.
25
Inspect seat base structure for evidence of deformation.
Perform Tank Vent System Inspection.
280000
280060
369D/E/FF Inspect fuel vent system rollover valve for condition and operation (Ref. Tank
500N
Vent System Inspection).
280000
NOTE: The 369H8108505, 369H8108M, 369H8108501M,503M and 369D281081 rollover valves do not require a yearly inspection.
05-20-15
Page 1
Revision 29
MAINTENANCE MANUAL
CSP-HMI-2
Table 1. Yearly Inspection (Cont.)

Registration No.
Model
ALL
Serial No.
Helicopter Hours
Requirement
*
Actuate and visually inspect fuel shutoff valve for proper operation.
* Inspect fuel cell sending unit for electrical terminals and wiring for
security and condition.
*
Chap/Sect
280000
280060
Inspect wiring harness between sending unit and instrument cluster.
* Check FUEL LEVEL LOW caution light for proper operation (Ref. Fuel
Level Low Caution Light System Test).
600N
Aircraft WITHOUT airframe fuel filter option:

*
ALL
280060
Perform Fuel Transfer System Functional Check.
Inspect instrument plumbing and electrical wiring for chafing, damage and
security.
95
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
500N
instruments for seepage, chafing, cracking, damage and security.
95
ANTITORQUE
500/600N
Drain fan transmission. Flush with sufficient new oil to remove sludge
accumulation. Refill with new oil.
369D/E/FF Drain tail rotor transmission. Flush with sufficient new oil to remove sludge
accumulation. Refill with new oil.
12
12
FLIGHT CONTROLS
500/600N
Inspect forward thruster cable at Sta. 123.30 for crack in relieved area
between threads and swage.
67
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
ohmmeter.
96
ENGINE COMPARTMENT
ALL
Inspect firewall insulator panels for security and obvious damage.
53
ALL
Inspect overrunning clutch firewall seal and engine compressor firewall

(plenum chamber) seal for proper sealing and good condition.
63
71
Page 2
Revision 43
05-20-15
Initial
MAINTENANCE MANUAL
CSP-HMI-2
Table 1. Yearly Inspection (Cont.)

Registration No.
Model
Serial No.
Helicopter Hours
Requirement
Chap/Sect
Initial
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
have been in storage.
COM
500/600N
Clean, inspect and relubricate (repack) fan support and pitch plate bearings
that have been in storage.
64
369D/E/FF Clean, inspect and relubricate (repack) tail rotor swashplate (duplex)
bearings that have been in storage.
05-20-15
64
Page 3
Revision 31
CSP-HMI-2
MAINTENANCE MANUAL
Page 4
Revision 43
05-20-15
MAINTENANCE MANUAL
CSP-HMI-2
Section
052020
Continued
Airworthiness
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSP-HMI-2
SPECIAL INSPECTIONS
1. Special Inspection Hourly and Calendar
This table is a schedule of time-phase inspec
tions that are contingent upon elapsed flight
time or calendar time. These inspections
require a Log Book entry. Adherence to
using this checklist.
NOTE:
spection is found.
maintenance.
Table 1. Special Inspections Hourly

Model
What to Inspect
Chap/Sect
AFTER INSTALLATION OF NEW 369F5100 MAIN ROTOR TRANSMISSION

ALL
Perform transmission runin (Ref. Main Transmission RunIn Procedure)
632025
2 10 HOURS AFTER INSTALLATION OF TAIL ROTOR TRANSMISSION

369D/E/FF Using drag torque previously recorded, apply a torque load of 75 95 inchpounds
(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).
632510
EVERY 10 HOURS or BEFORE FIRST FLIGHT OF EVERY DAY

600N
Effectivity: RN003RN059 (Ref. SB600N039), Perform Tailboom Attach Fitting

Inspection (Ref. EAD 20012451) (Not required if TB600N007R1 has been
accomplished).
533030
EVERY 15 HOURS
369D/E/FF Effectivity: 369H1203BSC or 369H120321 leadlag link assemblies with at least
500 hours, perform Main Rotor Blade Upper and Lower Root Fitting Attach Lug and
LeadLag Link Attach Lug Inspection (25 Hour) and every 100 hours in accordance
with Main Rotor Blade Upper and Lower Root Fitting Attach Lug and LeadLag Link
Attach Lug Inspection (100 Hour) until retirement of 369H1203BSC or21 LeadLag
Link Assembly. (Reference AD 950313).
621000
25 HOURS AFTER REPLACING TAIL ROTOR DRIVE FORK HINGE BOLT

369D/E/FF Check rotational torque of bolt by applying 125 inchpounds (14.12 Nm) with torque
wrench. If 125 inchpounds (14.12 Nm) torque does not rotate bolt, preload is correct
(Ref. COM, Hub and Fork Assembly).
642010
642020
25 HOURS AFTER INSTALLATION OF OIL COOLER BLOWER

ALL
With two pounds of force applied, check belt tension for 0.17 to 0.20 inch (4.32 5.08
mm) deflection. Check pulley (Ref. Cooling Blower Belt Tension Check and
Adjustment). Check oil cooler blower driven pulley retaining nut for minimum torque of
160 inchpounds (18.08 Nm). If loss of torque is noted, remove pulley nut and
inspect pulley shaft and splines for condition. Reinstall nut and torque to 160 190
inchpounds (18.08 21.47 Nm) plus drag torque.
05-20-20
63
Page 1
Revision 43
MAINTENANCE MANUAL
CSP-HMI-2
Table 1. Special Inspections Hourly (Cont.)

Model
What to Inspect
Chap/Sect
EVERY 25 HOURS WITH 2 FAILED LAMINATES IN MAIN ROTOR STRAP ASSEMBLY

369D/E/FF Inspect in accordance with Main Rotor Strap Pack Lamination Inspection at 25hour
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).
622000
EVERY 25 HOURS WITH 1 FAILED LAMINATES IN MAIN ROTOR STRAP ASSEMBLY

600N
Inspect in accordance with Main Rotor Strap Pack Lamination Inspection at 25hour
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).
622060
EVERY 25 HOURS
NOTE: This inspection does not apply to 369D21100516, 517, 523 and 369D21102503, 517, 523 main
rotor blades or the 369H120351 and 61 leadlag links.
369D/E/FF Visually inspect exposed portion of all installed main rotor blade upper and lower root
fitting attach lugs and main rotor hub leadlag link attach lugs for broken or cracked
lugs, corrosion or other damage to the lug areas (Ref. Main Rotor Blade Upper and
Lower Root Fitting Attach Lug and LeadLag Link Attach Lug Inspection (25Hour)).
621000
EVERY 50 HOURS
369D/E/FF Effectivity: On models equipped with Rotorcraft Litter Kit: visually inspect litter doors
500N
for condition and security of quickrelease fasteners. Rubber gasket between window
glass and door for proper sealing.
CSP026
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.
AntiTorque Fan Liner (Felt Metal Seal) Inspection).
642530
EVERY 100 HOURS

ALL
If installed, floats and associated components for condition and security.
32
ALL
Effectivity: With 369F5450501 overrunning clutch installed, remove clutch assembly

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.
63
EVERY 300 HOURS

600N
Replace tailboom attach bolts with new bolts, scrap removed bolts
(Ref. Tailboom Installation).
Inspect radius blocks and tailboom attach points for corrosion and cracks
(Ref Tailboom Inspection).
534030
EVERY 300 HOURS OR ONE YEAR (Whichever occurs first)

ALL
Page 2
Revision 43
Effectivity: For 369D25100 main transmission serviced with MILL23699 oil, drain
main transmission oil system; Flush with sufficient new oil to remove sludge
accumulation. Replace filter and refill with new oil.
05-20-20
12
MAINTENANCE MANUAL
CSP-HMI-2

Model
500/600N
What to Inspect
Effectivity: Forward and center cable couplings; Using a bright light and 10X
magnifying glass, inspect inner coupling male and female connectors for corrosion
pitting or cracks; none allowed.
Chap/Sect
672030
EVERY 300 HOURS OR TWO YEARS (Whichever occurs first)

600N
Main rotor upper thrust bearing assembly must be relubricated every 2 years or 300
hours, whichever occurs first (Ref. Main Rotor Hub Upper Bearing Grease Repack,
Inspection and Replacement).
622060
EVERY 300 HOURS

ALL
Effectivity: 369D21400503 (369D/E/FF 500/600N) or M50452 (369D/E/FF 500N)

leadlag dampers with at least 4200 hours, inspect for deterioration until deterioration
is sufficient to retire assembly (Ref. Main Rotor Damper and Attachments Inspection
and Main Rotor Damper Weight Loading and Extension Check).
622000
622060
NOTE: The following inspection does not apply to 369D25100505 and 507 transmissions.
369D/E/FF Visually inspect upper surface of main transmission output shaft assembly (ring gear
carrier) for bulging or raised surfaces. Using 10X magnifying glass, inspect upper
surface of shaft for cracks. (Ref. COM, Output Drive Shaft Visual Inspection)
632000
369D/E
500/600N
282500
Replace antiice/airframe fuel filter element (if installed) (Ref. AntiIce Fuel Filter
Replacement).
ALL
Mist eliminator and access door for proper installation (attaching hardware for
security).
71
ALL
Hoist installation (if installed) for condition and security.
25
EVERY 600 HOURS OR ONE YEAR (Whichever occurs first)

ALL
Effectivity: 369D25100 main transmission serviced with Mobil SHC 626 oil and
369F5100 main transmission, drain main transmission oil system; Flush with sufficient
new oil to remove sludge accumulation. Replace filter and refill with new oil.
369D/E/FF Effectivity: 369F5510 Main Rotor Drive Shaft, perform 369F5510 Main Rotor Drive
500N
Shaft Inspection (Ref. 600N5510 and 369F5510 Main Rotor Drive Shaft Inspection).
600N
Effectivity: 600N5510 Main Rotor Drive Shaft, perform 600N5510 Main Rotor Drive
Shaft Inspection (Ref. 600N5510 and 369F5510 Main Rotor Drive Shaft Inspection).
12
631000
631000
EVERY 600 HOURS

ALL
Cyclic control system for excessive slack or free play. Cyclic control stick, at grip, for
play in excess of 3/8 inch (9.53 mm) (Ref. Main Rotor Flight Control System 600Hour
Inspection).
671000
ALL
Effectivity: 369D21400503 (369D/E/FF 500/600N) or M50452 (369D/E/FF 500N)

leadlag dampers with less than 4200 hours, inspect for deterioration until
deterioration is sufficient to retire assembly (Ref. Main Rotor Damper and Attachments
Inspection and Main Rotor Damper Weight Loading and Extension Check).
622000
622060
Using a dial indicator, measure the rotation of the fan pitch control clevis mounted on
the fan pitch control tube. If clevis rotation is more than 0.025 in. (0.635 mm), inspect
splines on fan pitch control tube (Ref. Fan Pitch Control Tube Inspection) and splines
in tube support (Ref. Tube Support Inspection).
632530
672030
500/600N
05-20-20
Page 3
Revision 38
MAINTENANCE MANUAL
CSP-HMI-2

Model
What to Inspect
Chap/Sect
EVERY 1200 HOURS

ALL
500/600N
Test battery over temperature sensor unit for proper operation and accuracy (Ref.
Battery Temperature Sensing Equipment Operational Check).
Perform visual inspection, using a 10x magnifying glass, on horizontal stabilizer
mounting brackets (pay particular attention to the forward inboard legs).
960500
53
500N
Regrease YSAS actuator (Ref. YSAS Actuator Regrease Procedure).
672030
600N
Perform Forward Upper Longeron Inspection (L153, R153).
533030
EVERY 1200 HOURS OR 2 YEARS (WHICHEVER OCCURS FIRST)

500/600N
Clean, inspect and relubricate (repack) fan support and pitch plate bearings (Ref.
AntiTorque Fan Bearing Regreasing).
642530
500/600N
Perform AntiTorque Fan Inspection.
642530
500/600N
Check pitch bearing retainer for cracks or damage.
64

600N
Main rotor lower thrust bearing assembly must be relubricated every 2 years or 2700
hours, whichever occurs first.
622060
600N
Clean, inspect and relubricate (repack) main rotor swashplate bearings.
623060

369D/E/FF Clean, inspect and relubricate (repack) main rotor swashplate bearings and main rotor
500N
hub tapered bearings (Ref. Main Rotor Hub Tapered Bearing Replacement).
622000
369D/E/FF Clean, inspect and relubricate (repack) tail rotor swashplate bearings (Ref. Tail Rotor
Swashplate Bearing Regreasing).
643000
EVERY 6,000 HOURS

DELETED
AT 6000 HOURS AND EVERY 100 HOURS THEREAFTER
600N
Remove tunnel control boot. Inspect interface between 369H2564 tunnel beams and
369D225087 web for cracks (Ref. Control Tunnel (FS 78.50) Beam Inspection).
533030
600N
Effectivity: (RN003RN077 with TB600N007 completed, and RN078 and subs)

Perform Forward Upper Longeron Inspection (L137, R137).
533030
AT 15,000 HOURS AND EVERY 1500 HOURS THEREAFTER

600N
Page 4
Revision 43
Effectivity: (RN003RN077 with TB600N007 completed, and RN078 and subs)

Perform Lower Longeron Inspection (L158, R158).
05-20-20
533030
MAINTENANCE MANUAL
CSP-HMI-2
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
operating in a corrosive environment, a TriFlow wash be preformed on the main
rotor hub and strap pack assembly (Ref. Main Rotor Hub Corrosion Prevention
(TriFlow Wash Procedure)).
204000
(DAILY) AFTER FINAL SHUTDOWN IN CORROSIVE ENVIRONMENT

500N
It is recommended that after shutdown from the last flight of the day, for helicopters
operating in a corrosive environment, the splitter bungee spring be sprayed with
TriFlow.
20
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
condition. Continue inflation to 5.5 psi (0.3867 kg/cm2) and check that chamber
pressure relief valves operate. Pressuretest float compartments (Ref. Float
Compartments Pressure Test).
328200
AFTER COMPRESSOR WATER WASH/RINSE WITH PARTICLE SEPARATOR INSTALLED

ALL
During engine run after compressor water wash with particle separator installed, it is
recommended that scavenge air switch be switched on to remove any moisture that
has accumulated in the solenoid air valve.
RFM
BEFORE OPERATION OF BREEZE HOIST SYSTEM

ALL
Prior to daily hoisting operations: unreel and inspect entire length of hoist cable for
broken strands (cluster of 7 wires), excessive broken wires, corrosion, and security of
attachment to cable drums and swivel hook. Replace cable if broken strand or
excessive broken wires are noted. (Refer to hoist manufacturers handbook, Table
201.)
01
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, retorque after every flight until bolts retain torque.
05-20-20
783000
Page 5
Revision 38
CSP-HMI-2
MAINTENANCE MANUAL
Page 6
Revision 36
05-20-20
MAINTENANCE MANUAL
CSP-HMI-2
Section
055000
Continued
Airworthiness
MAINTENANCE MANUAL
CSP-HMI-2
CONDITIONAL INSPECTIONS
1. General
This section contains the unscheduled or
conditional inspections. You must do the
necessary Maintenance Manual specific
inspections and procedures shown in Table 1 to
make sure there is continued airworthiness of
the helicopter.
Rotorcraft and components involved in
accidents or incidents must be inspected
and/or tested as required to make sure they
are in a condition of safe operation and
conform to type design. Accident or incident
parts are exposed to extreme forces, heat or
immersion that can have a serious effect on
structural integrity. In some cases, even
though inspection indicates the part is
acceptable, the part must be removed from
service and scrapped.
Aircraft and component records must be clear
and contain the necessary details to establish
a complete parts history. Without a complete
documented parts history, inspection of a part
per CSP-HMI-2 is not sufficient to determine
if the part is acceptable for installation. This is
especially critical for life-limited components,
flight safety critical aircraft parts (FSCAP)
and primary load structures.
Damage from accidents and incidents are
wide-ranging. The conditional inspection
requirements in CSP-HMI-2, Chapter 05
cannot fully relate to the accident or incident
that occurred. If you are not sure what
inspections and/or tests are required to make
sure the rotorcraft or parts are in a condition
of safe operation and conform to type design,
do the following. Record all information
regarding the accident or incident and contact
the MDHI Field Service Department for the
necessary inspection/tests and maintenance
procedures.
If there is an incident with your helicopter not
shown in this section, record all information
regarding the incident and speak to the Field
Service Department at MDHI, Mesa, Arizona.
Telephone 1-800-388-3378 or (480) 346-6387.
DATAFAX: (480) 346-6813 for inspections and
maintenance procedures you need to do.
It is possible you will need to do more than one

of the inspections or procedures shown in
Table 1 of this section. Do all inspections that
are applicable.
NOTE: Refer to the applicable Rolls-Royce En

gine Operation and Maintenance Manual
(Ref. Section 01-00-00, Table 201) for de
tailed requirements on inspection of the en
gine for specific or unique conditions compa
rable to those listed.
WARNING
D All components, assemblies, or parts
that are removed for overhaul or re
pair must be identified with the
cause for removal.
D All other components, assemblies, or
parts that need to be replaced, must
be discarded.
2. Hard Landing
A hard landing is an incident or accident in
which the helicopter hits the ground with
sufficient force to cause:
D main rotor blade to hit the tailboom or upper
fairings or cowlings.
D permanent deformation of the landing gear
more than permitted limits.
D the lower fuselage, lower tailboom surface,
tailrotor, or thruster to touch the ground.
Use the schedule of inspections in Table 1,
Conditional Inspections, After Hard Landing if
you think a hard landing has occurred.
3. Overspeed
Overspeed is an incident in which the rotor
speed (NR) is more than the limits shown in
the applicable Rotorcraft Flight Manual. Use
the schedule of inspections in Table 1, Condi
tional Inspections, After Main Rotor Over
speed when an overspeed has occurred.
05-50-00
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CSP-HMI-2
MAINTENANCE MANUAL
4. Overtorque
Overtorque is an incident in which the main
transmission torque loads are more than the
permitted limits. Use the schedule of inspec
tions in Table 1, Conditional Inspections, After
Main Transmission Overtorque Beyond
Transient Limits when an overtorque has
occurred.
5. Sudden Stoppage
Sudden stoppage is a rapid deceleration of the
main rotor, rotor drive system, tail rotor, or
anti-torque fan.
Sudden stoppage of the main rotor and rotor
drive system is caused when the main rotor
blades hit the ground, water, snow, thick
vegetation, or other object of sufficient mass to
cause deceleration. Sudden stoppage of the
main rotor and rotor drive system can also
occur during a hard landing if the blades hit
the fuselage or the tailboom. Use the schedule
of inspections in Table 1, Conditional Inspec
tions, After Main Rotor Blade/Drive System
Sudden Stoppage when sudden stoppage of the
main rotor has occurred.
Sudden stoppage of the tail rotor is caused
when the tail rotor blades hit the ground,
Page 2
Revision 44
05-50-00
water, snow, thick vegetation, or other object of

sufficient mass to cause deceleration. Use the
schedule of inspections in Table 1, Conditional
Inspections, After Tail Rotor Blade Strike
when sudden stoppage of the tail rotor has
occurred.
6. Lightning Strike
When you think there has been a lightening
strike on the helicopter, use the schedule of
inspections in Table 1, Conditional Inspec
tions, After Lightening Strike inspection
procedures.
7. Conditional Inspection Table
D Inspections in this table are for MDHI
369D/E/FF and 500/60N helicopters only.
The first column of the table denotes which
model helicopter the inspections are
applicable to.
D The second column of the table has a short
description of the necessary inspection or
procedure.
D The third column of the table shows, if
applicable, the manual or section that has
the specific inspection or procedure.
MAINTENANCE MANUAL
CSP-HMI-2
Table 1. Conditional Inspections

Model
Requirement
Chap/Sect
AFTER HARD LANDING

WARNING: Any component, assembly or detailed part that is removed for overhaul must be identified as
to the reason for removal. Components that require replacement must be discarded.
ALL
Main rotor blades for bending, cracks or wrinkles.
62
ALL
Main rotor blade droop stops for damage.
62
ALL
Main rotor hub assembly and strap pack assembly for evidence of damage.
62
ALL
Accessible areas of main rotor mast assembly and transmission attachment area for
damage.
63
ALL
Perform Landing Gear Inspection. Forward and aft rub plates for condition.
321000
ALL
Perform Tailboom Inspection; retorque mount bolts.
534000
534030
ALL
Inspect tailboom attachment area for damage.
53
Inspect stationary thruster attachment flange for damage; retorque mount bolts.
53
500/600N
369D/E/FF Tail rotor drive shaft and damper, tail rotor transmission and tail rotor for distortion,
loose mounting or attaching parts, buckling, breaks or other damage. Tail rotor drive
shaft for contact with bulkheads.
63
64
500/600N
Main transmissiontofan transmission drive shaft, fan transmission, fan drive shaft,
fan and fan control rod for distortion, loose mounting or attaching parts, buckling,
breaks or other damage. Drive shafts for contact with bulkheads.
Fan control rod for freedom of movement.
63
67
ALL
Perform Engine Mounts and Fittings Inspection. Inspect mounting pads and firewall for
damage and distortion. Inspect all suspected parts by magnetic particle or
dyepenetrant methods, as applicable (Ref. CSPSRM6).
71
ALL
All flight and engine control system pushpull tubes, links, bellcranks and bearings for
bends, cracks, security and free movement.
67
ALL
Tunnel area Aframe for distortion, buckling or any other damage.
53
ALL
Fuselage fittings for bends and cracks.
53
ALL
Main transmission chip detectors for metal particles.
63
Main transmission mounting flanges for cracks.

ALL
Perform Main Transmission Drive Shaft Inspection.
ALL
All engine accessories for cracked flanges, loose bolts and nuts, connections and
general condition.
79
ALL
Engine accessory drive housing for cracks.
79
ALL
Engine chip detectors for metal particles.
79
ALL
Engine oil tank, supports, tubing and hoses for leaks, cracks and security.
79
ALL
Fuel cells, supports, tubing and hoses for leaks, cracks and security.
28
ALL
Armor for security of attachment, buckling and distortion.
ALL
Rotor brake installation for security of attachment and disc alignment.
05-50-00
631000
CSP014
63
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CSP-HMI-2
MAINTENANCE MANUAL
Table 1. Conditional Inspections (Cont.)
Model
Requirement
Chap/Sect
AFTER MAIN ROTOR OVERSPEED

to the reason for removal. Components that require replacement must be scrapped.
If overspeed is between 523 and 549 (369D/E) or 508 and 533 (369FF, 500N) rpm, or 106 and 112 percent
(600N):
ALL
Main rotor blades for visible damage and distortion; main rotor blade tip caps for
security; all bond lines for evidence of separation; root doublers and attachment
fittings for security. Replace any blade with visible bond line separation.
62
Main rotor blade dampers for security.

369D/E/FF Tail rotor blades and hub for visible damage, free movement and security.
64
500/600N
NOTAR fan blades and hub for visible damage, free movement and security.
64
Main rotor hub and strap pack assembly for evidence of damage.
62
ALL
If overspeed is over 549 (369D/E) or 533 (369FF, 500N) rpm, or 112 percent (600N):
ALL
Remove main rotor hub assembly for overhaul inspection.
ALL
Remove and scrap main rotor blades.
62
Inspect antitorque fan assembly.
64
500/600N
369D/E/FF Remove tail rotor hub assembly for overhaul inspection.
MDHI
64
AFTER MAIN TRANSMISSION OVERTORQUE BEYOND TRANSIENT LIMITS

ALL
Main transmission for freedom of movement.
63
ALL
Main transmission chip detectors for metal particles. Reinspect after 8 hours of
operation.
63
AFTER AIRSPEED 10% BEYOND VNE LIMIT

ALL
Main rotor blades for visible damage and distortion; main rotor blade tip caps for
security; all bond lines for evidence of separation; root doublers and attachment
fittings for security. Replace any blade with visible bond line separation.
62
Main rotor hub assembly and strap pack assembly for evidence of damage.
Main rotor blade dampers for security.
369D/E/FF Tail rotor blades and hub for visible damage, freedom of movement and security.
64
369D/E/FF Horizontal stabilizer for skin damage and loose rivets.
53
Tip plates and vertical stabilizer for damage to leading and trailing edges and
damaged stressed side panels (no repair of side panels permitted).
Retorque stabilizer attach bolts.
500/600N
Horizontal stabilizer for skin damage and loose rivets.

600N Damage to gurney flap.
Vertical stabilizers for damage to leading and trailing edges and damaged side panels.
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53
MAINTENANCE MANUAL
CSP-HMI-2

Model
Requirement
Chap/Sect
ALL
Tailboom for visible deformation, loose or missing rivets, cracks and security; attaching
points to fuselage for cracks and security.
53
ALL
Canopy glass for security
53
AFTER MAIN ROTOR BLADE/DRIVE SYSTEM SUDDEN STOPPAGE

Sudden stoppage of the main rotor and rotor drive system is any rapid deceleration of the main rotor drive
system. This may be caused by contact of one or more of the main rotor blades with the ground, water, snow,
dense vegetation or any other object of sufficient mass to cause deceleration or impact damage to the main
rotor blades.
A main rotor blade strike in which one or more of the main rotor blades exceed the repair limits in the
maintenance manual is defined as sudden stoppage.
Sudden stoppage of the main rotor may also occur simultaneously with hard landing in which the blades contact
the upper fuselage structure or the tailboom.
The inspection requirements, After Main Rotor Drive System Sudden Stoppage Level 1, is to be used when
sudden stoppage of the main rotor drive system has occurred.
After Main Rotor Drive System Sudden Stoppage Level 1
ALL
Perform inspection of main rotor blades. Pay particular attention to the upper and
lower root fittings and attach lug areas. If inspection determines that one or more
blades have separation of the trailing edge bond, due to leading edge impact, the
blade is bent or shows evidence of a significant impact, and the damage occurred with
the engine running, perform the additional inspection in After Main Rotor Drive System
Sudden Stoppage Level 2.
62
ALL
Perform inspection of the main rotor hub and leadlag link attach lugs. If the leadlag
lug is broken or the pitch housing striker strip shows evidence of contact with the main
rotor hub and damage occurred the the engine running, perform the additional
inspection in After Main Rotor Drive System Sudden Stoppage Level 2.
62
ALL
Perform Main Rotor Strap Pack Lamination Inspection.
622000
622060
ALL
Perform Main Rotor Blade and Damper Attach Pin Disassembly and Special
Inspection. If a pin is found cracked or bent and damage occurred with the engine
running, perform the additional inspection in After Main Rotor Drive System Sudden
Stoppage Level 2.
621000
ALL
Perform Main rotor Damper and Attachments Inspection. If damage to a damper is

suspected, perform Main Rotor Damper Weight Loading and Extension Check.
622000
622060
ALL
Perform Main Rotor Drive Shaft Inspection. If main rotor drive shaft is rejected for
broken shaft splines, straightness or sheared shaft, perform the additional inspection
in After Main Rotor Drive System Sudden Stoppage Level 2.
631000
ALL
Inspect overrunning clutch sprag assembly (Ref. Detailed Inspection after Cleaning).
COM
CAUTION: Kamatic couplings are a balanced unit and cannot be disassembled.

ALL
Perform a visual inspection of all power train drive shafts and couplings for distortion,
breaks, cracks, contact with bulkheads and other damage.
63
ALL
Perform a visual inspection of the oil cooler blower assembly.
63
05-50-00
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MAINTENANCE MANUAL
CSP-HMI-2

Model
Requirement
Chap/Sect
ALL
Check main rotor transmission for freedom of movement. Visually check main rotor
transmission mounting flanges for cracks. Inspect main rotor transmission chip
detectors for metal accumulation. Reinspect chip detectors after eight hours of
helicopter operation.
63
ALL
Perform visual inspection of main rotor flight controls.
67
ALL
Perform visual inspection of the antitorque system.
64
ALL
Perform visual inspection of engine mounts for security, cracks or misalignment.
71
ALL
Perform visual inspection of the engine control linkage for bends, breaks and proper
alignment.
76
ALL
Inspect engine per the special inspection requirements in the appropriate Allison
Operation and Maintenance Manual.
01
After Main Rotor Drive System Sudden Stoppage Level 2

being removed due to Main Rotor Sudden Stoppage Level 2. Components that require replacement
must be scrapped.
ALL
Overhaul main rotor hub.
62
ALL
Remove and scrap main rotor drive shaft.
63
ALL
Overhaul main transmission assembly (Ref. COM).
63
ALL
Remove and scrap enginetotransmission drive shaft.
63
ALL
Overhaul overrunning clutch assembly (Ref. COM).
63
AFTER TAIL ROTOR BLADE STRIKE

After tail rotor blade strike, inspect the following:
369D/E/FF If equipped with Bendix couplings, remove and scrap couplings.
63
369D/E/FF Tail rotor blades for dents, nicks, scratches or separation of skin.
64
369D/E/FF Tail rotor flapping hinge bolt for damage.
64
369D/E/FF Tail rotor transmission for radial play and runout of output shaft, cracks in mounting
flanges, and chip detector for metal particles.
63
Remove for overhaul tail rotor transmission if damage is indicated.

369D/E/FF If equipped with Kamatics couplings:
Perform Tail Rotor Drive Shaft Twist Inspection. Misaligned or missing stripes require
removal and scrapping of drive shaft and Kamatics couplings, and an overhaul
inspection of tail rotor transmission (Ref. COM).
369D/E/FF Remove tail rotor drive shaft and inspect couplings for distortion and cracks; damper,
damper bracket and bulkheads for damage.
631510
632510
632520
63
NOTE: If damage in excess of allowable limits due to blade strike is noted in above areas, continue with following
inspections:
369D/E/FF Tail rotor drive fork, pitch links, swashplate, hub and pitch control bearing housing for
obvious damage.
Page 6
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64
MAINTENANCE MANUAL
CSP-HMI-2

Model
Requirement
369D/E/FF Upper fuselage and boom tail rotor control linkage.
Chap/Sect
67
If tail rotor control rod is damaged, ensure that all rod bulkhead grommets are in
place.
369D/E/FF Aft frame of tailboom for cracks and boom skin for loosened or popped rivets.
53
369D/E/FF Main transmission chip detectors and transmission lube pump oil filter for metal
particles.
63
369D/E/FF Main rotor hub assembly and strap pack assembly for evidence of damage.
62
AFTER TAILBOOM STRIKE

If one or more main rotor blades strike tailboom while blades are rotating, inspect following:
ALL
Perform Main Rotor Blade Inspection.
621000
ALL
If excessive damage requires replacement of main rotor blade(s), inspect complete

main rotor and scissors assembly, including droop stop mechanism and strap packs,
for evidence of damage.
62
369D/E/FF Remove and inspect tail rotor drive shaft for impact damage, buckling or twisting;
couplings for cracks and distortion; damper, damper bracket and bulkheads for
damage.
63
369D/E/FF If excessive damage requires replacement of tail rotor drive shaft, replace couplings
and perform overhaul inspection of tail rotor transmission (Ref. COM).
63
CAUTION: Any tailboom damage is significant (Ref. CSPSRM6).

ALL
Perform Tailboom Inspection. Dyecheck or remove and scrap tailboom attach bolts.
534000
534030
ALL
Structure forward of tailboom attachment for evidence of sheet metal yielding or

buckling. Pay particular attention for signs of buckling at right side forward of tailboom
attachment (Ref. CSPSRM6).
53
ALL
Perform Upper Fuselage and Tailboom Control Linkage Inspection.
67
ALL
Perform Horizontal Stabilizer Inspection.
535010
535030
Perform Vertical Stabilizer Inspection.

369D/E/FF Tail rotor assembly.
64
369D/E/FF Tail rotor transmission for radial play and runout of output shaft; cracks in mounted
flanges and chip detector for metal particles.
64
ALL
Main rotor brake, if installed, for condition and alignment of brake disc, calipers and
63
If tailboom strike occurred during POWER ON condition, also inspect the following:
ALL
Remove and inspect main rotor drive shaft, main transmission drive shaft and
couplings for distortion, breaks, cracks and other damage.
63
ALL
Main transmission chip detectors and transmission lube system oil filter for metal
particles. Reinspect chip detectors and oil filter after 8 hours of engine operation.
Visually check transmission mounting flanges for cracks.
63
05-50-00
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MAINTENANCE MANUAL
CSP-HMI-2

Model
ALL
Requirement
Chap/Sect
Engine air inlet and plenum chamber for foreign objects; motor engine and check for
unusual noise.
71
76
Engine mounts for security, cracks or distortion.

Engine control linkage for bends, breaks and proper operation.
500/600N
ALL
Inspect stationary thruster attachment flange for damage; retorque mount bolts.
53
Inspect tailboom attachment area for damage; retorque mount bolts.
53
AFTER CHIP DETECTOR LIGHT COMES ON

ALL
Remove chip detector leads, in turn, to determine which chip detector caused indicator
to light.
63
71
Remove and inspect applicable chip detector for metal accumulation.

ALL
If an engine chip detector caused indicator to light, refer to applicable Allison Engine
ALL
If main transmission chip detector caused indicator to light, perform Main

Transmission Filter Replacement.
ALL
If chips measure no longer than 0.125 inch (3.175 mm), drain and refill main and/or
fan transmission with new oil. Recheck applicable chip detectors after 4 hours of flight.
01
632100
12
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 scavenge oil filter is installed or if a scavenge oil filter is installed and indicates a bypass has occurred.
ALL
Remove, flush and reinstall oil tank.
12
79
Flush all lines, fittings and associated components.

Remove and reverse flush or replace engine oil cooler.
CAUTION: Failure to bleed fuel system can result in unexpected engine flameout or power loss.
ALL
Bleed fuel system.
28
ALL
Remove and install new scavenge oil filter element (if installed).
79
AFTER ENGINE FLAMEOUT CAUSED BY FUEL EXHAUSTION

ALL
Bleed fuel system to remove any entrapped air.
28
AFTER ENGINE SHUTDOWN USING EMERGENCY FUEL SHUTOFF VALVE

ALL
Bleed fuel system to remove any entrapped air.
28
AFTER MAIN TRANSMISSION CHANGE BECAUSE OF INTERNAL TRANSMISSION FAILURE

ALL
Reverse flush or replace transmission oil cooler, all lines, fittings and associated
components.
63
AFTER FUEL FILTER CAUTION LIGHT COMES ON

ALL
Check FUEL FILTER caution light and circuit for discrepancies.
95
ALL
Perform Fuel Filter (Bypass) Caution Light Pressure Switch Test.
280000
Page 8
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05-50-00
MAINTENANCE MANUAL
CSP-HMI-2

Model
ALL
Requirement
Remove and install new enginedriven fuel pump filter.
Chap/Sect
01
Remove and clean gas producer fuel control filter.

Clean and flush all lines and fittings.
Check bypass valve per applicable Allison Engine Operation and Maintenance
Manual.
369D/E
500N
ALL
Inspect start pump inlet screen for contamination when large amounts of foreign
material are found in the engine driven fuel pump filter (or optional airframe fuel filter, if
installed).
Perform Fuel Cell Inspection.
28
280000
AFTER NEW OR REPLACEMENT MAIN ROTOR HUB IS INSTALLED

ALL
Perform Main Rotor Hub Droop Angle Check.
622000
BEFORE INSTALLATION OF NEW BATTERY

ALL
Perform Battery Charging Deep Cycling Procedure. Repeat deep cycling procedure
once to ensure complete stabilization of battery.
960500
AFTER MAIN TRANSMISSION DRIVE SHAFT IS REMOVED (ENGINE INSTALLED)

ALL
Check overrunning clutch for correct oil level.
12
AFTER COOLER BLOWER IS REMOVED

ALL
Perform Cooling Blower Inspection (Disassembled). Check belt tension and clearance
after installation.
63
WHEN MAIN ROTOR DRIVE SHAFT IS REMOVED

ALL
Perform Main Rotor Drive Shaft Inspection.
631000
AFTER LIGHTNING STRIKE

If lightning strike is evident on helicopter exterior:
ALL
Inspect the fuselage interior and exterior, landing gear, rotor systems and ground wire
connection for burn marks, cracks, pitting or other signs of high temperature stress, to
determine the lightning entry and exit points.
ALL
Trace the path of the lightning strike to the extent possible using a magnetometer.
ALL
Check the magnetic compass for accuracy (the degree of inaccuracy may serve as an
indicator of the severity of the strike).
95
ALL
Inspect all wiring.
96
ALL
Inspect antenna(s) for burns and pitting.
97
ALL
Inspect all electrically operated components and lighting systems for damage.
96
ALL
Inspect communications and navigation equipment for damage.
97
ALL
If the preceding inspections reveal major damage has occurred, proceed as follows:
Bench test all avionics and electrical system and components.
Perform a continuity check on all wiring and cables.
Perform a Voltage Standing Wave Ratio (VSWR) check on all antennas, antenna
cables and connectors.
96
97
05-50-00
25
32
53
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MAINTENANCE MANUAL
CSP-HMI-2

Model
ALL
Requirement
Chap/Sect
Perform specific inspection/replacements as required.
500/600N
Check fan transmission and interconnecting drive shafts for magnetism and/or burns.
63
500/600N
If previous drive train items show magnetism, overhaul fan transmission.
500/600N
Inspect antitorque fan and components for evidence of arcing and magnetism;
replace any part showing evidence of arcing or magnetism.
64
500/600N
Inspect bellcrank and control rod for any indications of arcing. Scrap parts with
indications of arcing.
67
500/600N
Inspect thruster cables, bellcranks and control tubes for any indications of arcing.
Scrap parts with indications of arcing.
67
500/600N
Inspect thruster rollers for any indications of arcing. Scrap parts with indications of
arcing.
53
ALL
Check oil cooler blower assembly and overrunning clutch for residual magnetism;
replace as necessary.
ALL
Inspect oil cooler assembly for damage; replace as necessary.
ALL
If previous drive train items show magnetism, overhaul transmission.
ALL
If overrunning clutch assembly shows magnetism, remove engine and overrunning

clutch and overhaul.
ALL
Perform a ground run operational check on the aircraft. Functionally check the flight
control system, and all avionics, electrical, lighting, communication, and navigation
systems.
ALL
Repair any damage and replace damaged components as required.
COM
67
96
97
If lightning strike is evident on main rotor system:

ALL
Inspect blades for damage such as burns, pitting, skin separation, etc. If damage is
evident, scrap damaged blade(s).
62
ALL
Remove hub assembly and return for overhaul.
62
ALL
Inspect all bearings in the fixed and rotating control system located on the main rotor
mast.
62
ALL
Remove transmission assembly and overhaul.
63
ALL
Inspect main rotor mast and drive shaft for evidence of burns.
63
ALL
Check drive shafts for residual magnetism. If magnetized or damaged, scrap drive
shafts and remove engine for overhaul.
63
71
If lightning strike is evident on tail rotor system:

369D/E/FF Inspect blades for damage such as burns, pitting, skin separation, etc. If damage is
evident, scrap damaged blade(s).
369D/E/FF Overhaul tail rotor assembly.
64
COM
369D/E/FF Scrap pitch change links and pitch change assembly.
64
369D/E/FF Inspect bellcrank and control rod for any indications of arcing. Scrap parts with
indications of arcing.
67
369D/E/FF Overhaul tail rotor gearbox.

369D/E/FF Inspect tail rotor drive shaft and drive shaft damper for magnetism and/or burns.
Page 10
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05-50-00
COM
63
MAINTENANCE MANUAL
CSP-HMI-2

Model
Requirement
Chap/Sect
369D/E/FF Check oil cooler blower assembly, overrunning clutch and tail rotor drive shaft
couplings for residual magnetism; replace as necessary.
63
369D/E/FF Inspect oil cooler assembly for damage; replace as necessary.
63
369D/E/FF If previous drive train items show magnetism, overhaul transmission.
COM
369D/E/FF If overrunning clutch assembly shows magnetism, remove engine and overrunning
clutch and overhaul.
71
COM
369D/E/FF Inspect engine mounts and fitting for damage. Replace as necessary.
71
AFTER 369F5100 MAIN TRANSMISSION LUBRICATION PUMP IMPENDING BYPASS INDICATOR POPS
ALL
Refer to Troubleshooting Power Train System
630000
WHENEVER ENGINE IS REMOVED

ALL
Remove fire blanket from above engine and inspect airframe above engine for
evidence of cracks.
05-50-00
53
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MAINTENANCE MANUAL
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MAINTENANCE MANUAL
Chapter
06
Dimensions and
Areas
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
06-00-00 Dimensions and Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1.
Principal Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.
Airframe Stations Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Para/Figure/Table
Title
Page ii
Revision 34
06 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
060000
Dimensions and
Areas
MAINTENANCE MANUAL
CSP-HMI-2
DIMENSIONS AND AREAS

1. Principal Dimensions
(Ref. Figure 201 for Model 369D,
Figure 202 for Model 369E,
Figure 203 369FF,
Figure 204 for 500N and
Figure 205 for 600N)
2. Airframe Stations Locations
cm) forward of the fuselage nose for

Models 369E/FF. WL 0.00 is tangential
to bottom of fuselage at STA 90.61.
Canted stations start at WL 0.00 unless
otherwise specified. The canted station
is not the same distance from STA 0.00
over its length, and should be referred
to in association with a waterline
reference.
(1). Reference is occasionally made to

Fuselage Station (STA or FS), Fuselage
Station Plug (P. STA or FSP) and
Waterline (WL) throughout the manual.
P. STA or FSP refers to the stretched
area or longer fuselage section of the
600N as compared to the 500 Series
Helicopter. Fuselage Station and
Waterline are the same as those
referred to in the other 500 Series
publications. To assist in locating
components being discussed, station
diagrams are provided (Ref. Figure 206
for Model 369D, Figure 207 for Models
369E/FF, Figure 208 for 500N and
Figure 209 for 600N). Station and
Waterline references are also necessary
for weight and balance procedures (Ref.
Sec. 08-10-00).
(3). For the 600 Series Helicopter, all

dimensions are from three reference
points designated as STA 0.00, P. STA
0.00 and WL 0.00 for the fuselage/engi
neering station references. STA 0.00 is
15.00 inches (38.1 cm) forward of the
fuselage nose. P. STA 0.00 is located at
the forward lower edge of the mid door
(also designated as canted STA 78.50).
All references outside of the designated
P. STA areas are labeled STA or FS.
Waterline 0.00 is tangential to bottom
of fuselage at fuselage station STA
90.61. Canted stations start at water
line 0.00 unless otherwise specified.
The canted station is not the same
distance from WL 0.00 over its length,
and should be referred to in association
with a waterline reference.
(2). For the 500 Series Helicopters, all

dimensions are from two reference
points designated as STA 0.00 and WL
0.00. STA 0.00 is 28.00 inches (71.12
cm) forward of the fuselage nose for
Model 369D, and 15.00 inches (38.10
(4). Measurements from a station repre

sented by a rib, frame, or bulkhead that
is not accessible may be taken by noting
flange bend direction and compensating
on the correct side of visible external
skin attachment rivet line.
06-00-00
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Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
8.2 FT.
(2.5 M)
7.2 FT
(2.2M)
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.
(10.19 M) TO ALL VERTICAL DIMENSIONS.
0.76 FT
(0.23 M)
26.41 FT (8.06 M)
6.45 FT.
(1.97 M)
5.46 FT.
(1.67 M)
4.57 FT.
(1.39 M)
13.205 FT. (4.028

M)
31.31 FT. (9.55

M)
6.002 FT. (1.831
M)
7.67 FT.
(2.34 M)
30.84 FT. (9.41

22.53 FT. (6.72
M)
M) 15.208 FT. (4.64
M)
8.9 FT.
(2.7 M)
4.58 FT.
(1.40 M)
6.3 FT.
(1.9 M)
1.58 FT. (0.48 M)
2.29 FT. (0.70 M)
21.21 FT. (6.50 M)

23.5 FT. (7.2
M)
Figure 201. Principal Dimensions Model 369D

Page 202
Revision 23
06-00-00
G06-0001B
MAINTENANCE MANUAL
CSP-HMI-2
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
IS INSTALLED, ADD 0.87 FT. (0.27 M) TO
ALL VERTICAL DIMENSIONS.
8.72 FT.
(2.66 M)
7.65 FT.
(2.33 M)
1.27 FT.
(0.39 M)
30.81 FT. (9.40 M)
6.43 FT. (1.96 M)
23.88 FT. (7.28 M)
8.15 FT.
(2.49 M)
8.4 FT.
(2.6 M)
6.77 FT.
(2.06 M)
4.58 FT.
(1.40 M)
22.42 FT. (6.84 M)
2.0 FT. (0.61 M)
24.71 FT. (7.54 M)

G06-0002B
Figure 202. Principal Dimensions Models 369E
06-00-00
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
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)
5.43 FT.
(1.66 M)
4.57 FT.
(1.40 M)
6.45 FT.
(1.97 M)
27.35 FT.
(8.34 M)
32.06 FT. (9.78 M)

23.88 FT. (7.28 M)
6.8 FT. (2.1 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)
G06-0003C
Figure 203. Principal Dimensions Model 369FF

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Revision 44
06-00-00
MAINTENANCE MANUAL
CSP-HMI-2
GENERAL NOTES:
TYPICAL ATTITUDE OF CARGO DECK: 4.7 DEGREES
NOSE UP.
2. IF EXTENDED LANDING GEAR IS INSTALLED, ADD
0.87 FT. (0.27 M) TO ALL VERTICAL DIMENSIONS.
8.8 FT.
(2.7 M)
7.7 FT.
(2.3 M)
27.35 FT.
(8.34 M)
6.3 FT.
(1.9 M)
4.6 FT.
(1.4 M)
6.5 FT.
(2.0 M)
31.39 FT. (9.6

M)
24.9 FT. (7.6

M)
7.7 FT.
(2.3 M)
6.9 FT.
(2.1 M)
1.4 FT.
(0.4 M)
G06-0006B
Figure 204. Principal Dimensions Model 500N
06-00-00
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Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
27.5 FT
DIA
(8.4 M)
6.6 FT
(2.0 M)
8.8 FT
(2.7 M)
4.6 FT
(1.4 M)
36.9 FT
(11.3 M)
29.6 FT
(9.0 M)
9.7 FT
(2.9 M)
9.2 FT
(2.8 M)
9.8 FT
(3.0 M)
7.8 FT
(2.4 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.
Figure 205. Principal Dimensions Model 600N (Sheet 1 of 2)

Page 206
Revision 39
06-00-00
6G06-043D
MAINTENANCE MANUAL
CSP-HMI-2
48 INCHES
(122 CM)
48 INCHES
(122 CM)
25 INCHES
(63 CM)
62 INCHES
(157 CM)
72 INCHES
(183 CM)
6G06-038
Figure 205. Principal Dimensions Model 600N (Sheet 2 of 2)
06-00-00
Page 207
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
STA
164.87
STA
146.62
CANT STA
78.50
CANT STA
CL
124.00
MAST
STA
155.75
STA
137.50
STA
185.89
STA
174.00
CANT STA
197.78
STA
28.00
CORNER
PILOT'S
SEAT
WL 21.50
WL
38.64
WL
22.75
WL
14.19
WL
49.37
WL 45.36
CL BEAM
WL
JACKING
32.00
POINT
STA 96.89
WL 11.98
WL
34.50
WL
13.10
WL
0.00
WL
0.00
STA
STA
44.65
56.85
STA
STA
50.50
64.37
STA
0.00
STA
STA
STA
STA
84.79 96.42 108.04 119.6
CANT STA STA
STA
STA 7 STA
78.50
90.61 102.23 113.8 124.00
5
STA
137.50
WL
96.91
WL
55.34
WL
54.17
CANT STA
209.78
CANT STA
CANT STA
219.96
197.78
CANT STA
242.14
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.
CANT STA
264.32
CANT STA
273.00
CANT STA
281.12
FRAME BASE
WL
26.67
G06-0004B
Figure 206. Station Diagram Model 369D

Page 208
Revision 23
06-00-00
MAINTENANCE MANUAL
CSP-HMI-2
CANT STA
78.50
STA
108.50
CANT STA
124.00
CL
MAST
STA
146.62
STA
137.50
STA
155.75
STA
164.87
STA
174.00
STA
185.89
CANT STA
197.78
WL 76.70
WL 66.00
STA
15.00
WL
49.37
WL 45.36
CL BEAM
CORNER
PILOT'S
SEAT
WL 21.50
WL 34.50
WL 32.00
WL
11.98
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
44.65 56.85
STA
STA
50.50
64.37
STA
0.00
STA
STA STA STA
84.79 96.42 108.04 119.67
STA
STA
STA
90.61 102.23
124.00
STA
CANT
113.8
STA 78.50
5
STA
137.50
WL 102.17
WL 96.91
STA 289.12
(369FF)
WL 55.34
WL 54.17
CANT STA
209.78
CANT STA
CANT
219.96
STA
197.78
NOTE:
CANT STA
242.14
CANT STA
264.32
CANT STA
273.00
369FF
ONLY
WL 26.67
WL 25.46 (369E)
WL 22.36 (369FF)
CANT STA
281.12
FRAME BASE
G06-0005B
Figure 207. Station Diagram Models 369E/FF
06-00-00
Page 209
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
STA
129.00
STA
132.90
STA
124.75
CL
MAST
STA
146.62
STA
137.50
STA
155.75
STA
168.20
STA
174.00
CANT
STA
159.97
WL 66.00
STA
15.00
WL 60.00
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
0.00
STA STA
STA 96.42
STA
84.79 STA 108.04 119.6
56.85
STA CANT STA STA 102.23 STA 7 STA
STA
90.61
78.50
64.37
50.50
STA 113.8 124.00
5
STA
44.65
NOTE:
STA
137.50
AFT JACKING
POINT STA 275.40,
BL 0.00, WL 41.00
Figure 208. Station Diagram Model 500N

Page 210
Revision 23
06-00-00
STA
315.00
G06-0007B
MAINTENANCE MANUAL
NOTE 2
CSP-HMI-2
CL
NOTE 3
20
40
60
80
STA
15.00
STA
100.00
120
140
160
180
200
220
240
260
280
300
320
340
WL
83.00
WL
14.00
WL
0.00
MID
JACK POINT
FORWARD
JACK POINT
P.STA
18.76
STA
96.90
STA
124.00
STA
168.66
AFT
JACK POINT
STA
338.36
STA
303.30
30 IN.
STA
78.50
STA
0.00
(NOTE 1)
P.ST
A
0.00
P.ST
A
30.00
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.
6G06-004BA
Figure 209. Fuselage Station Diagram Model 600N
06-00-00
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MAINTENANCE MANUAL
CSP-HMI-2
L137, R137
L153, R153
L167, R167
L166, R166
L158, R158
G06-0008
Item No.
Name
Permits Access To
Qty.
Type
L137
Plug
Left forward upper longeron
Button Plug
R137
Plug
Right forward upper longeron
Button Plug
L153
Plug
Left upper longeron
Button Plug
R153
Plug
Right upper longeron
Button Plug
L158
Plug
Left lower longeron
Button Plug
R158
Plug
Right lower longeron
Button Plug
L166
Plug
Left lower attach fitting
Button Plug
R166
Plug
Right lower attach fitting
Button Plug
L167
Plug
Left upper attach fitting
Button Plug
R167
Plug
Right upper attach fitting
Button Plug
Figure 210. Aft Empenage Access Plugs Model 600N
Page 212
Revision 34
06-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Chapter
07
Lifting and Jacking
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
07-00-00 Lifting and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1.
Component Weights for Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 201. Approximate Maximum Hoisting Weights of Components 369D/E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 202. Approximate Maximum Hoisting Weights of Components 369FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 203. Approximate Maximum Hoisting Weights of Components 500N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 204. Approximate Maximum Hoisting Weights of Components 600N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201
201
201
201
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
07 Contents
Page i
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page ii
Revision 43
07 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
070000
Lifting and Jacking
MAINTENANCE MANUAL
CSP-HMI-2
LIFTING AND JACKING

1. Component Weights for Hoisting
(Ref. Table 201 thru Table 204) The maximum
weights for large components that may require
hoisting are listed.
Use hoist with minimum 3500
pound (1589 kg) capacity when
hoisting complete helicopter. Use hoisting
equipment with minimum 20% overrate to
hoist heavier components of helicopter (Ref.
Table 201 thru Table 204 for approximate
weights).
CAUTION
Table 201. Approximate Maximum Hoisting

Weights of Components 369D/E
Item
Wgt
Lb/kg
Tailboom
18/8
Main rotor hub
85/39
Main transmission (wet) (369D25100)

Main transmission (wet) (369F5100)
105/48
140/64
Engine (builtup) C20B

Engine (builtup) C20R/2
192/87
207/94
Helicopter (less main rotor hub,

swashplate, scissors and rotor blades)
1153/523
Helicopter (complete)
1361/618

Weights of Components 369FF
Item
Wgt
Lb/kg
Tailboom
23/10
Main rotor hub
92/42

105/48
140/64
Engine (builtup)
271/123

1369/622
1589/721

Weights of Components 500N
Item
Wgt
Lb/kg
Tailboom (w/o empennage, thruster)
35/16
Main rotor hub
92/42

105/48
140/64
Engine (builtup)
207/94

1314/597
1542/700

Weights of Components 600N
Item
Wgt
Lb/kg
Tailboom (w/o empennage, thruster)
55/25
Main rotor hub (with dampers, pins)
107/49
Main transmission (wet)
140/64
Engine (builtup) C47
292/133

1830/830
2100/953
2. Helicopter Hoisting
(Ref. Figure 201)
Item
ST201
N/A
Special Tools
(Ref. Section 910000)
Nomenclature
Hoisting adapter
Cable or Rope
(1). Remove dome fairing (N/A 600N) from

main rotor hub and install hoisting
adapter (ST201) on hub so that hoisting
eyebolts fit into slots on hoisting
adapter.
07-00-00
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Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
(2). Install quick release pins.

(3). Attach cable from overhead hoist to
adapter eye.
(4). Secure a line to tailboom. Have assis
tant hold line to keep helicopter from
swinging.
(5). Hoist slowly and smoothly to maintain
steady lifting force.
3. Helicopter Sling Lifting
Follow below procedures for sling lifting the
helicopter.
Item
Special Tools
Nomenclature
ST201
Hoisting adapter
Sling-lift helicopter only when

CAUTION other means of recovery are not
available. Ensure recovery helicopter has
adequate capabilities, performance and fuel
to accomplish sling-lift recovery. Ensure re
covery crew has experience level to assure
optimum performance at assigned positions.
Do not attempt lifting or lowering during
adverse wind or weather conditions.
A. Helicopter Preparations
Prepare helicopter to be lifted before attempt
ing lift to avoid damage or loss of equipment
during flight.
(1). Remove dome fairing from main rotor
hub (N/A 600N).
(7). Secure tail rotor hub to Sta. 284

bellcrank with strap or rope (369D/E/
FF only).
(8). Position one person to support tail of
helicopter.
(9). Position one person to accomplish
hookup to recovery helicopter.
(10). Position one person in view of recovery
helicopter to act as ground guide during
hookup.
B. Helicopter Lifting
Tail of helicopter may come
WARNING down sharply if helicopter is

lifted abruptly.
Avoid dragging helicopter dur
ing lift before ground clearance
is obtained. Dragging helicopter may cause
extensive damage.
CAUTION
(1). Carefully lift helicopter. Ensure that

person at tail of helicopter is familiar
with above warning.
(2). Transport recovery crew and removed
equipment to landing site before
recovery helicopter with lifted helicop
ter arrives.
C. Helicopter Landing
(1). Indicate wind direction with smoke
cannister.
(2). Ground guide recovery helicopter to
hover into wind before lowering begins.
CAUTION
Do not attempt lowering if heli

copter is spinning.
(3). Lower helicopter.

(2). Remove main rotor blades (Ref. Sec.
62-10-00).
(3). Replace and secure blade damper bolts
and attaching pins.
(4). Tape elastomeric damper to pitch
housing.
(5). Install hoisting adapter (ST201).
(6). Attach lifting straps or swivel-equipped
cable slings that clear lead by 10 feet
(3.048 M) to hoisting adapter.
Page 202
Revision 23
07-00-00
(4). Restrain and support tail of helicopter

as it contacts ground.
Ground guide must signal re
covery helicopter to move to one
side before dropping sling or helicopter win
dow damage may occur.
CAUTION
(5). Signal recovery helicopter to drop sling.

(6). Remove sling and hoist adapter.
(7). Inspect recovered helicopter to deter
mine condition.
MAINTENANCE MANUAL
(8). Inspect main rotor blades prior to
installation for damage caused during
removal and transportation (Ref. Sec.
62-10-00).
4. Helicopter Jacking
(Ref. Figure 201) Provisions for jacking
helicopter are provided by two (369D/E/FF 500N) or four (600N) forward (side) jacking
point fittings and an aft jacking pad. The aft
jack pad locations differ for the 369D/E/FF and
the 500/600N helicopters.
Item
ST202
ST203
ST204
Special Tools
Nomenclature
Jack fittings
Hydraulic jack: 1-5 ton (900-4500 kg)
Hydraulic jack: 80 inch (203 cm) leg
CSP-HMI-2
(1). Install jack fittings (ST202) in fuselage

jacking points. Secure jack fittings with
locking pins located in fuel cell access
doors.
NOTE: When jacking the 600N helicopter, only

use the forward and aft jacking points.
(2). Place suitable jacks (ST203 or ST204)
under jack fittings and AFT jacking
pad.
NOTE: If helicopter is jacked from one side

only, in next step, a cushioned saddle-type
support should be placed under tailboom at
aft jacking pad location for extra stability.
(3). Raise helicopter to desired height.
07-00-00
Page 203
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CSP-HMI-2
MAINTENANCE MANUAL
HUB FAIRING
SUPPORT
HOISTING EYEBOLTS
(3 PLACES)
HOISTING
ADAPTER
QUICK RELEASE PINS

(3 PLACES)
HOISTING
NOTE: HUB SUPPORT

REMOVED FOR CLARITY.
G07-0001-1
Figure 201. Hoisting and Jacking Helicopter (Sheet 1 of 3)

Page 204
Revision 23
07-00-00
MAINTENANCE MANUAL
CSP-HMI-2
AFT JACKING PAD

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

(STA 275.4) (500N)
JACK FITTING
JACKING
G07-0001-2A
07-00-00
Page 205
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
NOTE
HOISTING
ADAPTER
NOTE
NOTE
HOISTING
RELEASE PIN
(3 PLACES)
LOCKPIN
HOISTING EYE
BOLT
(3 PLACES)
JACK FITTING
HOISTING
VIEW ROTATED
AFT JACKING PAD

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

ACCORDING TO C/G OF HELICOPTER.

Page 206
Revision 23
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6G07-005
MAINTENANCE MANUAL
CSP-HMI-2
Chapter
08
Leveling/Weight and
Balance
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 201. Balance Diagram - Model 369D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 202. Balance Diagram - Model 369E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 203. Balance Diagram - Model 369FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 204. Balance Diagram - Model 500N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 205. Balance Diagram - Model 600N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 206. Weight and Balance Report Form (Sheet 1 of 2) . . . . . . . . . . . . . . . . .
Figure 207. Surplus and Missing Items Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 208. Basic Weight and Balance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 209. Example 1 (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
08 Contents
206
207
208
209
210
211
212
214
215
216
Page i
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page ii
Revision 43
08 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
080000
Leveling
MAINTENANCE MANUAL
CSP-HMI-2
LEVELING
1. Helicopter Leveling
(Ref. Figure 201) Leveling is accomplished by
positioning helicopter to align a plumb bob
with register marks on the target plate on
cargo compartment floor.
Item
Special Tools
Nomenclature
N/A
Plumb bob (commercially available)
N/A
Twine
N/A
Electronic weighing kit
ST202
Jack fittings
ST203
NOTE: Access to plumb line support bracket

and target plate on floor of passenger/cargo
compartment requires removal of trim on
right side of controls tunnel, and floor carpet
in aft compartment (Ref. Chap. 25).
(1). Suspend plumb line from bracket on

right side of controls tunnel at Sta.
92.64, BL+ 6.20.
(2). Adjust plumb line swing to leveling
target plate on floor of passenger/cargo
compartment.
(3). With weight of helicopter supported by
load cells of electronic weighing kit or
jacks (ST203), as applicable, adjust
appropriate jack until plumb line is
centered (Ref. Sec. 07-00-00, Helicop
ter Jacking).
(a). Adjust side jacks to level helicopter
laterally.
(b). Adjust tailboom jack to level helicop
ter longitudinally.
(c). Recheck lateral and longitudinal
levels until plumb bob exactly aligns
with marks on target plate.
(4). After leveling helicopter, remove plumb
bob, reinstall trim and carpet, and close
compartment door.
08-00-00
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MAINTENANCE MANUAL
CSP-HMI-2
AFT JACKING PAD

(STA 275.4) (500N)
AFT JACKING PAD

(STA 197.2) (369D/E/FF)
PLUMB LINE
SUPPORT CLIP
RIGHT EDGE OF
CONTROL TUNNEL
LOCKPIN
PLUMB LINE
JACK FITTING
TARGET PLATE
LEVELING
JACKING
G08-0001B
Figure 201. Leveling Helicopter (Sheet 1 of 2)

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08-00-00
MAINTENANCE MANUAL
CSP-HMI-2
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)
08-00-00
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CSP-HMI-2
MAINTENANCE MANUAL
Page 204
Revision 43
08-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
081000
Weight and Balance
MAINTENANCE MANUAL
CSP-HMI-2
WEIGHT AND BALANCE

1. General Weight and Balance Information
(1). Removal or addition of fuel or equip
ment results in changes to weight and
balance of a helicopter, and the permis
sible useful load is affected accordingly.
These changes must be investigated to
eliminate possible adverse effects on
the helicopter's flight characteristics.
(2). Basic weight and corresponding center
of gravity is determined by weighing
the helicopter without crew and
payload; however, basic weight does
include trapped and unusable fuel, full
operating fluids, lubricants, etc., and
installed equipment.
(3). 369D/E/FF - 500N - The longitudinal
reference datum is located 100 inches
(254 cm) forward of the main rotor
centerline. The lateral reference datum
is located along the longitudinal
centerline of the helicopter. The vertical
reference datum is located at a point
100 inches (254 cm) below the center of
the main rotor blades.
(4). 600N - The Weight and Balance
longitudinal reference datum is located
100 inches (254 cm) forward of the
main rotor centerline or 15 inches (38.1
cm) aft of the aircraft nose. The Weight
and Balance (longitudinal) Reference
Datum is different from the Fuselage/
Engineering Reference Datum (Ref.
Section 06-00-00). The lateral refer
ence datum is located along the longitu
dinal centerline of the helicopter. The
vertical reference datum is located at a
point 83 inches (210.8 cm) below the
center of the main rotor blades.
(5). Refer to the following for balance
diagrams
Figure 201 for Model 369D
Figure 202 for Model 369E
Figure 203 for Model 369FF
Figure 204 for Model 500N
Figure 205 for Model 600N.
NOTE: Weight and balance information for op

tional equipment is found in the Initial In
stallation section for the optional equip
ment.
Parameter
Wt
lb/kg
Certified Gross Weight (369D/E)
3000/1362
Certified Gross Weight (369FF)
3100/1407
Certified Gross Weight (500N)
3350/1521
Certified Gross Weight (600N)
4100/1860
Cargo Deck Capacity

(369D/E/FF 500N)
1300/590
Cargo Deck Capacity (600N)
1350/613
Cargo Deck Capacity not to exceed 115 pounds per

square foot.
Certified Gross Weights are for weightonskids.
A. Approved Center of Gravity Limits

(Ref. PFM)
B. Terminology
Following are terms with definitions, used
when determining helicopter weight and
balance:
(1). Arm: The distance in inches from the
longitudinal (longitudinal arm) and
lateral (lateral arm) reference datum of
a part to the center of gravity (CG) of
the part.
NOTE: When viewing helicopter from rear,

items to left of lateral reference datum (cen
ter line of helicopter) will be expressed as
having negative (-) lateral arm, and those
items to right of reference datum, a positive
(+) lateral arm.
(2). Center of gravity (CG): A point on a
part where the part will be perfectly
balanced. Center of gravity is measured
in inches from a known reference. It
can be determined using the following
formula:
08-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
CG(in)
Moment (inlb)
Weight (lb)
CAUTION
(3). Moment: Product of weight of a part

and its arm, either longitudinal or
lateral, and is expressed in inchpounds (in-lb).
Longitudinal moment = weight x
longitudinal arm;
Lateral moment = weight x lateral arm.
(4). Reaction point: A fixed point on helicop
ter where weight of helicopter counter
acts on a weighing device. The main
reaction points are;
(a). ALL: Long. Sta. 96.9.
(b). 369D/E/FF - 500N: Lat. Sta. 25.6.
D The controls access panel (aft side of Sta.

78.5 bulkhead) and the fuel cell access
panels must be installed before jacking
helicopter.
D 369D/E/FF - 500N: There are two meth
ods approved for weighing the helicopter.
The preferred method is by using elec
tronic weighing equipment. If equipment
for electronic weighing is unavailable, the
second approved method, mechanical
scales, may be used.
D 600N: There is one method approved for
weighing the helicopter. The method is by
using electronic weighing equipment.
A. Helicopter Weighing Preparation
The following items are required and should be
readily available prior to preparing and
weighing the helicopter, using the electronic
weighing method.
Item
Special Tools
Nomenclature
ST202
Jack fittings
(c). 600N: Lat. Sta. 26.0.

(d). 369D/E/FF: Tail reaction point is at
Long. Sta. 197.2, Lat. Sta. 0.0.
NOTE:
(e). 500N: Tail reaction point is at Long.
Sta. 275.4, Lat. Sta. 0.0.
(f). 600N: Tail reaction point is at Long.
Sta. 303.3, Lat. Sta. 0.0.
2. Helicopter Weighing
Forms
D Weigh helicopter without fuel if possible.

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
will remain. If fuel is pumped out using
start pump, 3.7 pounds (1.68 kg) of
trapped (unusable) fuel at 93.5 inch
(237.5 cm) arm will remain.
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
trapped (unusable) fuel at 93.5 inch
(237.5 cm) arm will remain.
Form
No.
Figure
No.
Weight and Balance Report
765B
206
(1). If defueling is not possible, ensure that

fuel cell is full.
Surplus and Missing Items
1702
207
(a). Fluid weights at 70 ambient are:
Basic Weight and Balance

Record
885
208
Nomenclature
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08-10-00
Fuel (Jet A)
6.75 Lb (3.06 kg) per U.S. gallon
MAINTENANCE MANUAL
CSP-HMI-2
Fuel (JP-4)
B. Preparation for Weighing Electronic

Method
Fuel (JP-5)
Item
Special Tools
Nomenclature
N/A
N/A
N/A
ST203
ST204
Electronic weighing kit/Platform Scales

Roll-away table (with weighing platform)
Plumb Bob
Fuel (JP-8)
PRC Fuel (No 3)
Lubricating Oil
(2). De-fuel helicopter (Ref. Sec. 12-00-00).
(3). Select weighing area that is enclosed
and draft-free, with hard-surfaced
floor.
(4). Ensure that helicopter and weighing
area is cleared of all tools and debris.
(5). 369D/E/FF - 500N: Verify that five
main rotor blades are uniformly spaced
(72 degrees apart).
600N: Verify that six main rotor blades
are uniformly spaced (60 degrees
apart).
(6). Check lubricant level at engine oil tank,
main rotor gear box and tail rotor or fan
gearbox sight gages. Add lubricant as
necessary where less than full indica
tion is noted (Ref. Sec. 12-00-00).
(7). Record weight, arm and moment of
surplus equipment on board helicopter
at time of weighing, which will not be
part of basic helicopter weight (Ref.
Figure 206).
(8). Record weight, arm and moment of
missing equipment, to be installed after
weighing and prior to flight, that will
become part of basic helicopter weight
(Ref. Figure 206).
(9). Install two fuselage jack fittings
(ST202) for main weighing points at
Longitudinal Sta. 96.9 and Lateral Sta.
25.6. Secure fittings with pip pins.
(1). Position hydraulic jack (ST203) under

each of main jacking points at Sta. 96.9,
left and right sides of helicopter.
(2). Position third hydraulic jack (ST203 or
ST204), on roll-away table if needed,
and attached load cell at aft jacking
point of helicopter.
(3). Attach electronic weighing kit load cell
to each jack, and to weighing kit control
unit.
(4). Turn electronic weighing kit power ON
and allow warm up time as specified in
electronic weighing kit operation
manual.
(5). Calibrate and zero-in each load cell
prior to applying aircraft load (Ref.
Electronic Weighing Kit operation
manual).
On the 600N helicopter, never
exceed aft (tailboom) jack load of
500 Lbs (227 kg).
CAUTION
(6). Exercise load cells by jacking all three

jacks simultaneously until load is
supported by load cells at all jack point
stations. Do not check helicopter level
at this time.
(7). Lower helicopter to floor so that no load
is supported by load cells.
(8). Repeat above steps (exercise load cells
and lower helicopter) twice.
(9). Recheck calibration and zero of each
load cell.
08-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
C. Helicopter Weighing Electronic Method
(Ref. Figure 209, example 1(b)). This

reading represents calibration correc
tion for each load cell. Depending on
sign shown on control unit (+ or -),
reading will have to be added to or
subtracted from reading in step (3).
above to obtain corrected weight for
each cell (Ref. Figure 209, example
1(c)).
When preparations have been made (Ref.

Helicopter Weighing Preparation and Prepara
tion for Weighing - Electronic Method), weigh
helicopter as follows:
Item
Special Tools
Nomenclature
N/A
N/A
ST203
ST204
ST205
Spirit level
Plumb Bob
Inclinometer
(1). Operate three hydraulic jacks (ST203

and/or ST204) simultaneously until
entire load is supported by load cells.
(6). Add corrected readings for all three

cells to determine total unadjusted net
weight of helicopter (Ref. Figure 209,
example 1(c).
D. Preparation for Weighing Mechanical
Scales Method (369D/E/FF 500N Only)
When preparing to weigh helicopter using
mechanical scales, complete preliminary
procedure (Ref. Helicopter Weighing Prepara
tion), then perform the following:
NOTE: If conditions permit, helicopter may be

leveled using plumb bob instead of spirit
level (Ref. Sec. 08-00-00).
(2). After landing gear skids are clear of
floor, level helicopter as follows:
(a). Remove main rotor hub fairing (Ref.
Sec. 62-20-00) (N/A 600N).
(b). Check lateral level by placing spirit
level on main rotor mast, with axis of
spirit level 90 degrees to longitudinal
axis of helicopter. Adjust left or right
jack at main jack points, as required,
to center bubble in spirit level.
(c). Place protractor or inclinometer
(ST205) on main rotor mast so that
its axis is parallel to longitudinal axis
of helicopter. Adjust jack at aft
jacking point until protractor or
inclinometer shows 3 degrees forward
tilt.
(d). Reinstall hub fairing (N/A 600N).
(3). Record reading shown on weighing kit
control unit for each load cell (Ref.
Figure 209, example 1(a)).
Item
N/A
N/A
N/A
ST202
ST203
ST204
Special Tools
Nomenclature
Roll-away table (with weighing platform)
Beam platform scales (two), 1000 lb. (450
kg) capacity with current calibration
Platform scale, 300 lb. (135 kg) capacity
with current calibration
Jack fittings
(1). Check 1,000 lb. (450 kg) capacity scales

for zero.
(2). Place 300 lb. (135 kg) capacity scale on
roll-away table with weighing platform,
and check zero on scale.
(3). Hoist helicopter so that main landing
gear skids are sufficiently clear of floor
to enable 1,000 lb. (450 kg) capacity
beam platform scales to be rolled under
main skids on left and right sides.
(4). Lower helicopter to floor by bleeding off

jacks, and clear load cells.
(4). Roll 1,000 lb. (450 kg) capacity beam

platform scales under main skids and
position so main jack fittings (ST202) at
Sta. 96.9 are on centerline of scale.
(5). Record reading on control unit for each

load cell under NO LOAD condition
(5). Place jack (ST203) on 300 lb. (135 kg)

capacity platform scale (67). Position
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08-10-00
MAINTENANCE MANUAL
roll-away table so that jack and 300
pound capacity scale are directly below
AFT jacking point.
(6). Lower helicopter so its weight is
supported by scales.
(7). Place jack on each 1,000 lb. (450 kg)
capacity platform scale, inboard of main
skids and directly below main jacking
points at Sta. 96.9.
E. Weighing Procedures Mechanical
Scales Method (369D/E/FF 500N Only)
Once preparations have been completed (Ref.
Helicopter Weighing Preparation and Prepara
tion for Weighing - Mechanical Scales Meth
od), weigh helicopter as follows:
(1). Operate jacks (ST203 and/or ST204)
simultaneously until helicopter is
supported only by jacks at right and left
Sta. 96.9 and AFT reaction points.
NOTE: If conditions permit, helicopter may be

leveled using plumb bob instead of spirit
level (Ref. Sec. 08-00-00).
(2). With main skids clear of 1,000 lb. (450
kg) capacity platform scales, level
helicopter (Ref. Helicopter Weighting Electronic Method).
(3). Record weight shown on scale at each
reaction point (Ref. Figure 209, exam
ple 1(a)).
(4). Simultaneously bleed off hydraulic
jacks until helicopter skids contact
1,000 lb. (450 kg) platform scales, and
total weight of helicopter is supported
by scales and AFT jack point.
(5). Remove jacks from 1,000 lb. (450 kg)
capacity platform scales.
(6). Hoist helicopter until scales at right
and left sides and jack at aft reaction
point can be rolled clear of helicopter
(Ref. Sec. 07-00-00).
CSP-HMI-2
weight at each reaction point (Ref.

Figure 209, example 1(b)).
(9). Subtract total tare weight for the three
reaction points obtained in step h above
from weight recorded in step c above to
obtain total unadjusted net weight of
helicopter (Ref. Figure 209, example
1(c)).
F. Longitudinal CG Determination for
Unadjusted Net Weight (369D/E/FF 500N
Only)
(1). Multiply net weight obtained at each
jacking point by its longitudinal arm, to
obtain a moment (Ref. Figure 209,
example 1(d)).
(2). Add three moments determined in step
(1). to calculate total moment (Ref.
Figure 209, example 1(e)).
(3). Divide total moment obtained in step
(2). by total unadjusted net weight, to
determine longitudinal CG (Ref.
Figure 209, example 1(f)).
G. Lateral CG Determination for Unadjusted
Net Weight
NOTE: Lateral CG is not critical with normal

internal loading. Certain optional equip
ment, such as an external cargo hook, may
induce lateral CG outside lateral CG limits,
if weight and CG control is not provided.
However, the Initial Installation section for
each optional equipment installation pro
vides complete instructions on lateral CG
control, to ensure operation within ap
proved limits.
(1). Multiply net weight for each jacking
point by its lateral reaction point
(369D/E/FF - 500N: left main, -25.6;
right main, +25.6; and aft, zero)
(600N: left main, -26.0; right main,
+26.0; and aft, zero) to obtain moment
for each jacking point (Ref. Figure 209,
example 1(g)).
(7). Lower helicopter to floor.
(2). Add three moments determined in step

(1). above to calculate total moment
(Ref. Figure 209, example 1(h)).
(8). Weigh each jack on same scale jack

occupied during helicopter weighing to
get the tare weight. Record the tare
(3). Divide total moment by total unad

justed net weight to determine lateral
CG (Ref. Figure 209, example 1(i)).
08-10-00
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CSP-HMI-2
MAINTENANCE MANUAL
H. Basic Weight and CG Determination

Using unadjusted net weight and longitudinal
moment, determine basic weight and CG of
helicopter (Ref. Figure 209, example 1).
(1). Add total weight and moment of
missing equipment to unadjusted net
weight and moment of helicopter.
(2). Subtract total weight and moment of
surplus equipment from weight and
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Revision 23
08-10-00
moment of helicopter determined in

step (1). above.
(3). Enter total basic weight, CG and
moment in Basic Weight and Balance
Record (Ref. Figure 208).
NOTE: Any changes that will affect basic

weight and CG of helicopter must be re
corded on Basic Weight and Balance Record
(Ref. Figure 208), and revised basic weight
and CG of helicopter must be calculated
(Ref. PFM for preflight weight and balance
requirements).
MAINTENANCE MANUAL
CSP-HMI-2
STA.
STA.
78.5 ROTOR CL 124.0
STA.
100.0
CG OF COPILOT/PASSENGER
STA.
28.0
CARGO
COMPARTMENT
STA.
174.0
+13
+12.1
-13
-12.1
REFERENCE DATUM
CG OF PILOT
STA.
73.3
TWO-PLACE COCKPIT
(OPTIONAL)
STA.
105.0
STA.
78.5 ROTOR CL
STA.
100.0
CG OF RIGHT SIDE
FWD PASSENGER
STA.
124.0
CARGO
COMPARTMENT
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
STA.
28.0
STA. 71.50
STA.
73.5
THREE-PLACE COCKPIT
(STANDARD)
STA.
105.0
PERMISSIBLE CG LIMITS
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
OIL TANK (RH SIDE)
SLING POINT
LEVELING PLUMB
STA. 92.6
FIREWALL
JIG POINT
AFT JACKING POINT
STA. 197.2 BL 0.00
3
STA. 174.0
BDH
STA.
284.0
ENGINE SECTION
REFERENCE
DATUM
BATTERY
STA.
78.5
STA.
124.0
FUEL CELL
COMPARTMENT
JIG POINT
MAIN JACKING POINT
STA. 96.9 BL 25.6
G08-1001
Figure 201. Balance Diagram Model 369D
08-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
STA.
78.5
STA.
15.00
STA.
ROTOR L 124.0
STA.
C
100.0
CARGO
COMPARTMENT
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.
73.3
STA.
78.5
CG OF RIGHT SIDE
FWD PASSENGER
STA.
15.00
STA.
105.0
STA.
124.0
ROTOR CL
STA.
100.0
CARGO
COMPARTMENT
STA.
174.0
+15.5
+12.2
REFERENCE DATUM
0.0
-12.2
-13.0
THREE-PLACE COCKPIT
(WITH SINGLE CONTROLS)
CG OF FWD PASSENGER
CG OF PILOT
STA. 71.5
CG OF AFT PASSENGERS
STA.
73.5
STA.
15.00
STA.
105.0
STA. STA.
99.0 107.4
20
40
60
SLING POINT
80
100
120
140
160
180
200
OIL TANK (RH SIDE)
220
240
260
280
300
LEVELING PLUMB
STA. 92.6
FIREWALL
JIG POINT
AFT JACKING POINT
STA. 197.2 BL 0.00
3
STA. 174.0
BDH
REFERENCE
DATUM
BATTERY
STA.
78.5
STA.
124.0
ENGINE SECTION
FUEL CELL
COMPARTMENT
STA.
284.0
JIG POINT
MAIN JACKING POINT
STA. 96.9 BL 25.6
G08-1002
Figure 202. Balance Diagram Model 369E

Page 208
Revision 23
08-10-00
MAINTENANCE MANUAL
STA.
STA.
78.5 ROTOR LC 124.0
STA.
100.0
CSP-HMI-2
CARGO COMPARTMENT
STA.
15.00
STA.
174.0
+15.5
+12.2
REFERENCE DATUM
0.0
-12.2
-13.0
TWO-PLACE COCKPIT
(WITH DUAL CONTROLS)
CG OF PILOT
STA.
73.3
STA.
105.0
STA.
78.5
CG OF RIGHT SIDE
FWD PASSENGER
STA.
15.00
STA.
124.0
ROTOR L
C
STA.
100.0
CARGO COMPARTMENT
STA.
174.0
+15.5
+12.2
REFERENCE DATUM
0.0
-12.2
-13.0
THREE-PLACE COCKPIT
(WITH SINGLE CONTROLS)
CG OF AFT PASSENGERS
CG OF FWD PASSENGER
CG OF PILOT
STA. 71.5
STA.
73.5
STA.
15.00
STA.
105.0
STA.
99.0
STA.
107.4
20
40
60
80
100
120
140
160
180
200
220
240
260
280
SLING POINT
LEVELING PLUMB
STA. 92.6
JIG POINT
AFT JACKING POINT
STA. 197.2 BL 0.00
STA.
284.0
STA. 174.0
BDH
BATTERY
320
FIREWALL
REFERENCE
DATUM
300
OIL TANK (RH SIDE)
STA.
78.5
STA.
124.0
ENGINE SECTION
FUEL CELL
COMPARTMENT
JIG POINT
MAIN JACKING POINT
STA. 96.9 BL 25.6
G081003
Figure 203. Balance Diagram Model 369FF
08-10-00
Page 209
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
STA
78.5
ROTOR
CL
STA
124.0
CARGO COMPARTMENT
CG OF COPILOT/
PASSENGER
STA
15.0
STA
100.0
STA
168.8
+ 15.5
+ 12.2
REFERENCE
DATUM
0.0
- 12.2
- 13.0
TWO-PLACE COCKPIT
WITH DUAL CONTROLS
CG OF PILOT
STA
105.0
STA
73.5
ROTOR
CL
STA
78.5
STA
124.0
STA
100.0
CG OF COPILOT/
PASSENGER
STA
15.0
CARGO COMPARTMENT
STA
168.8
+ 15.5
CG OF CENTER
PASSENGER
+ 12.2
+ 0.8
0.0
REFERENCE
DATUM
- 12.2
- 13.0
CG OF PILOT
STA
15.0
STA
100.0
STA
28.0
20
STA
73.5
STA
71.5
40
60
80
100
120
140
THREE-PLACE COCKPIT
WITH SINGLE CONTROLS
STA
105.0
160
180
200
220
240
260
280
300
320
3
LEVELING PLUMB
STA 92.6
OIL TANK - RH SIDE
REFERENCE DATUM
FIREWALL
ENGINE SECTION
JIG POINT
AFT JACKING POINT
STA 275.4
FUEL CELL
COMPARTMENT
STA
78.5
STA
124.0
JIG POINT
FWD JACKING POINT
STA 96.9
G08-1007
Figure 204. Balance Diagram Model 500N

Page 210
Revision 23
08-10-00
MAINTENANCE MANUAL
CG OF PILOT OR
COPILOT/PASSENGER
0.00
- 15.0
7PLACE SEATING,
TWOPLACE COCKPIT WITH DUAL CONTROLS,
AFTFACING MIDCABIN SEAT
+ 12.2
MID SEAT
+ 15.0
- 13.0
CSP-HMI-2
0.00 REFERENCE DATUM

- 12.2
STA
70.4
8PLACE SEATING,
THREEPLACE COCKPIT WITH SINGLE CONTROLS,
FWDFACING MIDCABIN SEAT
MID SEAT
STA
41.50
0.00
STA
77.1
STA
43.50
0.00 REFERENCE DATUM
STA
105.0
PASSENGER/CARGO
COMPARTMENT
THIS DIMENSION 15 INCHES

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

REFERENCE DATUM
ENGINE SECTION
FUEL CELL
COMPARTMENT
AFT JACKING
POINT STA 303.3
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
08-10-00
Page 211
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2
WEIGHT AND BALANCE REPORT

MODEL ___________
WEIGHED
BY
CONFIGURATION
MODEL
SERIAL NO.
REGISTRATION NO.
LONGITUDINAL
ARM
(INCHES)
LATERAL
ARM
(INCHES)
LEFT MAIN
96.9
26.0
RIGHT MAIN
96.9
+26.0
303.3
0.0
WEIGHING
POINTS
SCALE READING
(LBS)
TARE OR
CALIBRATION
CORRECTION
(LBS)
NET
WEIGHT
(LBS)
DATE
TAIL
LONGITUDINAL
MOMENT
(INCHLBS)
LATERAL
MOMENT
(INCHLBS)
TOTAL UNADJUSTED NET WEIGHT

TOTAL WEIGHT OF SURPLUS EQUIPMENT (SEE TABLE 1)
TOTAL WEIGHT OF MISSING EQUIPMENT (SEE TABLE 1)
TOTAL BASIC WEIGHT
FUEL/OIL ABOARD AT TIME OF WEIGHING:
EMPTY
FULL
FUEL
ENGINE OIL
MAIN GEAR BOX
TAIL GEAR BOX
FORM 765B (REV 483)
Page 1 of
Figure 206. Weight and Balance Report Form (Sheet 1 of 2)
Page 212
Revision 23
08-10-00
McDonnell Douglas
Helicopter Company
MAINTENANCE MANUAL
MODEL
SERIAL NO.
CSP-HMI-2
REGISTRATION NO.
DATE
EXAMPLES OF FORWARD, AFT AND LATERAL LOADING

WEIGHT
(LBS)
EXAMPLE 1, FORWARD
LONG.
ARM
(IN.)
LONG.
MOMENT
(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.
EXAMPLE 2, AFT
WEIGHT
(LBS)
LONG.
ARM
(IN.)
LONG.
MOMENT
(IN. LB.)
WEIGHT
(LBS)
LATERAL
ARM
(IN.)
LATERAL
MOMENT
(IN. LB.)
BASIC WEIGHT
PILOT
GROSS WEIGHT (ZERO FUEL) AFT C.G.

APPROVED AFT C.G. LIMIT FOR EXAMPLE 2 GROSS WEIGHT
INCHES.
EXAMPLE 3, LATERAL
BASIC WEIGHT
PILOT
GROSS WEIGHT (ZERO FUEL) LATERAL C.G.

APPROVED LATERAL C.G. FOR EXAMPLE 3 GROSS WEIGHT
INCHES.
*SEE FLIGHT MANUAL, SECTION 6, FOR C.G. LIMITS AT GROSS WEIGHT
Figure 206. Weight and Balance Report Form (Sheet 2 of 2)
08-10-00
Page 213
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
TABLE 1 SURPLUS AND MISSING EQUIPMENT

MODEL
SERIAL NO.
REGISTRATION NO.
WEIGHT
EQUIPMENT ITEM
DATE
ARM INCHES
MOMENT IN/LBS
LBS
LONG
( 1.3 )
( 96.9 )
1.3
96.9
( 15.9 )
( 97.4 )
ONE QT. ENGINE OIL
2.1
133.4
280
UNUSABLE FUEL
12.0
93.0
1116
FLIGHT MANUAL
1.8
85.0
153
SURPLUS EQUIPMENT TOTAL:

JACK PADS (2)
MISSING EQUIPMENT TOTAL:
FORM 1702 (REV 483)
Page
LATR
(
LONG
)
Revision 23
of
08-10-00
126
Figure 207. Surplus and Missing Items Report

Page 214
LATR
( 126 )
( 1549
McDonnell Douglas
Helicopter Company
IN
OUT
ITEM NO.
08-10-00
FORM 885 ( REV 2/82 )
BASIC WEIGHT DELIVERY
DESCRIPTION OF ARTICLE OR MODIFICATION
SERIAL NUMBER
1 ENTER CONSTANT USED BELOW LINE
DATE
AIRCRAFT MODEL
BASIC WEIGHT AND BALANCE RECORD
WEIGHT
LONG
ARM
ADDED (+)
IN .LB.
MOMENT1
LONG
ARM
IN .LB.
MOMENT1
REMOVED ()
WEIGHT
WEIGHT CHANGE
REGISTRATION NUMBER
( CONTINUOUS HISTORY OF CHANGES IN STRUCTURE OR EQUIPMENT AFFECTING WEIGHT AND BALANCE )

OF
109.0
1510.0
164561
IN .LB.
MOMENT
MD HELICOPTERS INC
LONG
ARM
WEIGHT
RUNNING TOTAL
BASIC AIRCRAFT
PAGE
MAINTENANCE MANUAL
CSP-HMI-2
G081006A
Figure 208. Basic Weight and Balance Record
Page 215
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
Determining total unadjusted net weight and longitudinal CG - 369D/E/FF

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

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

(a)
(b)
(c)
Scale
Reading
(lbs)
Tare or
Calibration
Correction
(lbs)
Net
Weight
(lbs)
Longitudinal
Arm
(inches)
Lateral
Arm
(inches)
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
3764.7
1634.6
111.8
(f)
-.3
(i)
182811.5
(e)
-5172
(h)
Weighing
Points
(d)
Figure 209. Example 1 (Sheet 1 of 2)

Page 216
Revision 23
08-10-00
(g)
Longitudinal Longitudinal
Moment
Moment
(inch-lb)
(inch-lb)
MAINTENANCE MANUAL
CSP-HMI-2
Determining total unadjusted net weight, longitudinal and lateral CG - 600N

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

Weighing
Points
Scale
Reading
(lbs)
Tare or
Calibration
Correction
(lbs)
Net Weight
(lbs)
Arm
(in.)
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
195.9
197.2
38631
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
1482.4
110.1
163224
Total Basic Weight
Determining basic weight and the longitudinal and lateral CG - 600N

Scale
Reading
(lbs.)
Tare or
Calibration
Correction
(lbs.)
Net Weight
(lbs.)
Longitudin
al Arm
(inches)
Lateral
Arm
(inches)
Longitudin
al Moment
(inch-lbs.)
Lateral
Moment
(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
31756
1909.3
108.2
-.5
206621
-879
Total Weight of Missing Equipment

(Ref. Figure 207)
+15.9
97.4
1549
Total Weight of Surplus Equipment

(Ref. Figure 207)
-1.3
96.9
-126
1923.9
108.1
-.5
208044
-879
Weighing
Points
Total Basic Weight
Figure 209. Example 1 (Sheet 2 of 2)
08-10-00
Page 217
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
Page 218
Revision 43
08-10-00
MAINTENANCE MANUAL
Chapter
09
Towing
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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
09 Contents
Page i
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page ii
Revision 43
09 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
090000
Towing
MAINTENANCE MANUAL
CSP-HMI-2
TOWING
1. Ground Handling Wheels
NOTE: At regular intervals, check wheel tire

pressure and repack wheel bearings (Ref.
Sec. 32-40-00/32-40-60).
A. Standard Ground Handling Wheels
(Ref. Figure 201) Standard ground handling
wheels, available as a special tool for helicop
ters not equipped with floats, are used for
moving helicopter by hand and for towing
helicopter. The wheels are manually lowered
with a detachable jack handle and are held in
the down position (helicopter raised on wheels)
by a mechanical lock. The wheels for the
369D/E/FF - 500N helicopters are equipped
with tow bar attach fitting.
Excessive lead-lag load applied

to the main rotor blades during
ground handling can result in damage to the
elastomeric damper buns and failure of the
damper assembly. Operators and mainte
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.
CAUTION
(1). Attach ground handling wheels (ST101

or ST104) as shown (Ref. Figure 201),
and hold tail up while lowering the
wheels (raising helicopter) with
detachable jack handle (ST102 or
ST103).
(2). Manually move helicopter on ground
handling wheels by balancing at
tailboom and pushing on rear fuselage
portion of airframe.
Except under extreme emergen
cy conditions, do not tow heli
copter at speeds over 5 mph (8 KmH). Do not
allow front ends of skid tubes to drag on
ground. Avoid sudden stops and starts, and
short turns which could cause helicopter to
turn over. Allow inside wheel to turn (not
pivot) while helicopter is being turned. Safe
minimum turning radius is approximately
20 ft. (6 M).
CAUTION
B. Special Ground Handling Wheels
(FloatEquipped Helicopters, 369D/E/FF
500N)
Special ground handling wheels are available
for towing helicopters equipped with utility or
emergency floats (Ref. Sec. 32-40-00).
NOTE: If tow bar is not equipped to keep front

2. Helicopter Towing and Manual Moving
(369D/E/FF 500N)
end of skid tubes from dragging, have an as

sistant balance helicopter at tailboom.
(3). Tow helicopter on ground handling
wheels by attaching suitable tow bar to
tow bar fittings.
Item
Special Tools
Nomenclature
ST101
Ground handling wheels
ST102
Handle-jack assembly, ground handling

(straight)
ST103
Handle-jack assembly, ground handling

(offset)
Item
Special Tools
Nomenclature
ST104
Ground handling wheels (one side)
ST101
3. Helicopter Manual Moving (600N)

(Ref. Figure 202)
09-00-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2

CAUTION
(1). Ensure all stress panels are installed

on helicopter before jacking.
D The ground handling wheel set can be at
tached to the skids facing either direction
for ease of jacking.
D Ensure all four ground handling attach
points are engaged in ground handling
wheel set.
(2). Attach ground handling wheels (ST101)
and hold tail up while lowering the
wheels (raising helicopter).
(3). Manually move helicopter on ground
handling wheels by balancing at
tailboom and pushing on rear fuselage
portion of airframe.
20 ft. (6 M).
CAUTION
4. Helicopter Towing (600N)

(Ref. Figure 202) The tow bar is equipped with
caster wheels and is designed for use with the
Revision 23
Item
Special Tools
Nomenclature
ST101
ST105

Tow bar (600N)

CAUTION
NOTE:
Page 202
ground handling wheel set, allowing the

helicopter to be moved by one person.
09-00-00
(1). Ensure all stress panels are installed

on helicopter before jacking.
(2). Raise helicopter with ground handling
wheel set (ST101).
(3). Position tow bar (ST105), with caster
wheels, straddling front of skid tube
assembly.
(4). Attach nylon straps under skid tube
and ratchet skid tube into rubber cups
on tow bar.
20 ft. (6 M).
CAUTION
MAINTENANCE MANUAL
CSP-HMI-2
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)
09-00-00
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
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)

Page 204
Revision 23
09-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Chapter
10
Parking and Mooring
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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
10 Contents
Page i
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page ii
Revision 43
10 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
101000
Parking and Mooring
MAINTENANCE MANUAL
CSP-HMI-2
PARKING AND MOORING

1. Helicopter Parking
(c). Secure blade sock tiedown cord for

blade located above tailboom to
tailboom. Secure other blade sock
tiedown cords to fuselage jack fittings
(ST202).
To park helicopter for short intervals, perform

following steps (1). thru (4). For longer
duration parking, also perform steps (5). and
(6).
Item
Special Tools
Nomenclature
ST202
ST2002
ST2004
ST2005
Jack fittings
Blade socks
Air inlet fairing cover
Engine exhaust cover
To prevent rotor damage from

blade flapping (droop stop
pounding) as a result of air turbulence from
other aircraft landing, taking off or taxiing,
or sudden wind gusts, rotor blades should be
secured whenever helicopter is parked.
(4). Secure six-bladed main rotor blades as

follows:
When securing blade sock tie
down cords, take up slack but do
not apply bending loads on blades.
CAUTION
(a). Position blades so that three blades

are on each side of helicopter (Ref.
Figure 201).
(b). Install blade socks (ST2002) on all
blades.
CAUTION
(1). Locate helicopter slightly more than

blade clearance from nearby objects on
most level ground available.
(2). Apply friction to lock cyclic and collec
tive sticks so that friction control knobs
are positioned as follows: neutral for
cyclic stick and full down for collective
stick.
NOTE: If not already accomplished, apply
(c). Secure blade sock tiedown cords to

fuselage jack fittings or cabin steps.
(5). Install air inlet fairing cover (ST2004)
on air inlet front fairing (Ref.
Figure 201).
(6). Install engine exhaust cover (ST2005)
on exhaust tailpipe (Ref. Figure 201).
2. Helicopter Mooring
Whenever severe storm conditions or wind
velocities higher than 40 knots are forecast,
helicopter should be hangared or evacuated to
a safer area. If these precautions are not
possible, moor helicopter as follows.
paint mark on edge of guide to locate neu

tral position for future reference (Ref. Sec.
67-10-00).
(3). Secure five-bladed main rotor blades as
follows:
When securing blade sock tie
down cords, take up slack but do
not apply bending loads on blades.
CAUTION
(a). Turn blades until one blade is

directly above tailboom (Ref.
Figure 201).
(b). Install blade socks (ST2002) on all
blades.
Item
Special Tools
Nomenclature
N/A
N/A
ST202
ST2001
ST2004
ST2005
Stakes or ground anchors (two)

Cable or rope
Jack fittings
Pitot tube cover
(1). Park helicopter (Ref. Helicopter

Parking) or remove main rotor blades
(Ref. Sec. 62-10-00) and install air
10-10-00
Page 201
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
inlet fairing cover (ST2004) and engine

exhaust (ST2005) covers.
(2). Install pitot tube cover (ST2001).
(3). Fill fuel tank (if possible) (Ref. Sec.
12-00-00).
Page 202
Revision 23
10-10-00
(4). Apply friction to lock cyclic and collec

tive sticks (Ref. Helicopter Parking).
(5). Secure helicopter to ground by attach
ing restraining lines (cable or rope)
between jack fittings (ST202) and
stakes or ground anchors (Ref.
Figure 201).
MAINTENANCE MANUAL
CSP-HMI-2
G101001
Figure 201. Parking and Mooring (Sheet 1 of 2)
10-10-00
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
BLADE SOCK
(6 PLACES)
CABLE OR
MANILA ROPE
(6 PLACES)
MOORING ANCHOR
(4 PLACES)
ENGINE EXHAUST
COVER
ZIPPER
AIR INLET
FAIRING
COVER
PITOT TUBE
COVER
DOOR
ACCESS
LATCH
PITOT TUBE
TIE CORD
COVER INSTALLATION
FUEL CELL
ACCESS DOOR
LOCKPIN
LOCKPIN
STOWAGE
JACK FITTING
FUESELAGE
STRUCTURE
JACK FITTING
TO BLADE SOCK
TO MOORING
ANCHOR
ENGINE AIR INLET

FAIRING COVER
INSTALLATION
TO BLADE
SOCK
JACK FITTING INSTALLATION

(TYPICAL - 2 PLACES)
Figure 201. Parking and Mooring (Sheet 2 of 2)

Page 204
Revision 23
10-10-00
f60039
MAINTENANCE MANUAL
CSP-HMI-2
Section
102000
Storage
MAINTENANCE MANUAL
CSP-HMI-2
STORAGE
1. Preservation and Storage
A helicopter to be placed in storage or non-op
erational status must have adequate inspec
tion, maintenance and preservation to avoid
unnecessary deterioration of airframe and
components of equipment. Extent of preventive
maintenance that is to be performed depends
on anticipated time in storage. Following
paragraphs describe what should be performed
in helicopter: for flyable storage; for up to 45
days in storage; and for up to 6 months in
storage.
2. Flyable Storage (No Time Limit)
A. Inspection Before Storage
(1). Perform Daily Pre-Flight Check (Ref.
appropriate PFM or RFM).
(2). Ensure that fuel cells are full (topped
off), and that oil in engine oil tank and
main, fan and tail rotor transmissions
is at FULL level (Ref. Sec. 12-00-00).
B. Storage
To maintain a flyable storage condition,
perform the following:
(2). Perform ground runup at least once
every five days (Ref. applicable PFM or
RFM, Table 201, Sec. 01-00-00).
(a). Start engine. After idle stabilizes,
accelerate engine to 100 percent N2,
collective full down. Operate until oil
temperature is in normal operating
range and ammeter indicates battery
is fully charged.
(b). Shut down engine.
(c). Drain fuel cell sump (Ref. Sec.
12-00-00). (Replenish fuel as neces
sary.)
(d). Ensure that fuel shutoff valve is
closed (Ref. Sec. 28-00-00).
(e). Open movable air vents in each door

of cargo compartment. Position
opening in each air vent downward.
Close all other vents.
(f). Install covers and equipment used to
park and moor helicopter.
(g). Install a static ground.
C. Return to Service
(1). Remove covers and equipment used to
3. Storage Up to 45 Days
A. Inspection During Storage
(1). Where local average humidity exceeds
40 percent, carefully inspect helicopter
every 15 days for corrosion. Perform
corrosion control as necessary (Ref. Sec.
20-40-00). When inspecting for
corrosion, pay particular attention to
those areas where moisture deposits do
not evaporate rapidly.
(2). Where local average humidity is 40
percent or less, inspect for corrosion
every 30 days.
(3). If interior temperature of fuselage
exceeds 160F (71C), ventilate helicop
ter by opening all doors and vents. If
necessary, promote air circulation by
use of fans or other forced air equip
ment.
(4). Ensure that fuel cells are full (topped
off) and that rotor transmissions are at
FULL level.
(5). Drain fuel cell sump daily. (Replenish
fuel as necessary.)
(6). Check fuel and oil systems periodically
for leakage. Replenish as necessary.
B. Storage
(1). Perform engine preservation according
to applicable Allison Engine Operation
10-20-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
and Maintenance Manual (Ref. Table

201, Sec. 01-00-00) and current engine
service letters.
(2). Remove battery (Ref. Sec. 96-05-00)
and store in cool, dry area.
(3). If necessary, clean battery compartment
(Ref. Sec. 20-20-00).
(4). Ensure that fuel shutoff valve is closed
(Ref. Sec. 28-00-00).
(5). Clean entire helicopter.
(6). Inspect all drain holes (blades, fuselage,
etc.) for obstructions and clear where
necessary.
(7). Open movable air vents in each door of
cargo compartment; position opening in
each air vent downward. Close all other
air vents.
(8). Park and moor helicopter.

4. Storage Up to 6 Months
A. Inspection During Storage
(1). Perform same inspection as for 45 days
of storage.
(2). Check main rotor, tail rotor and fan
blades for damage every 15 days (Ref.
Chap. 62 and 64).
(3). Check areas around mooring attach
ments for damage every 15 days.
B. Storage
Item
CM201
CM210
CM729
Consumable Materials
Nomenclature
Protective coating
Corrosive preventive
Tape, masking, pressure sensitive
Item
ST2001
Special Tools
Nomenclature
Pitot tube cover
(9). Install a static ground.

(10). Remove from area any objects that are
likely to strike helicopter during high
wind conditions.
(1). Check that battery area is clean; then
install and connect battery (Ref. Sec.
96-05-00).
(2). Check that fuel cells are full (Ref. Sec.
12-00-00).
(3). Remove covers and equipment used to
(4). Inspect areas around mooring attach
ments for damage. Repair damage as
necessary.
(5). Clean helicopter, as necessary.
(6). Check that all drain holes in helicopter
are free of obstructions.
(7). Perform engine depreservation accord
ing to applicable Allison Engine
Operation and Maintenance Manual
(Ref. Table 201, Sec. 01-00-00) and
current applicable engine service
letters.
Page 202
Revision 23
10-20-00
(1). Perform engine preservation according

to applicable Allison Engine Operation
and Maintenance Manual (Ref. Table
201, Sec. 01-00-00) and current
applicable engine service letters.
(2). Drain engine oil system (Ref. Sec.
12-00-00) and fill engine oil tank with
corrosion preventive (CM210).
(3). Remove battery (Ref. Sec. 96-05-00)
and store it in cool, dry area.
(4). Clean battery compartment, if neces
sary.
(5). Ensure that fuel shutoff valve is closed
(Ref. Sec. 28-00-00).
(6). Seal static source openings in engine
inlet fairing with masking tape
(CM729) and cover pitot tube with pitot
tube cover (ST2001).
(7). Clean entire helicopter.
(8). Inspect all drain holes (blades, fuselage,
etc) for obstructions and clear them
where necessary.
MAINTENANCE MANUAL
(9). Spray or brush on the canopy and all
windows a 0.008 inch (0.203 mm)
thickness of protective coating (CM201).
Cover and overlap all edges.
(10). Inspect all external access doors for
close fit. If doors are likely to admit
moisture, seal edges with masking tape
(CM729).
(11). Park and moor helicopter.
(12). Install a static ground.
(13). Remove any objects from area that are
likely to strike helicopter during high
wind conditions.
(1). Carefully lift protective coating along
edges and peel it from canopy and
windows.
CSP-HMI-2
(2). Remove masking tape from all external

access doors.
Do not use steam or unautho
rized cleaning compounds to
clean helicopter as damage to equipment
may result.
CAUTION
(3). Drain corrosion preventive from oil

tank and replenish with correct oil (Ref.
Sec. 12-00-00).
(4). Perform same procedures as for return
to service after 45 days of storage.
NOTE: Depreservation of engine fuel system

can usually be accomplished by making a
normal start. (Ref. applicable Allison En
gine Operation and Maintenance Manual,
Table 201, Sec. 01-00-00 and current appli
cable engine service letters for engine de
preservation procedures.)
10-20-00
Page 203
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
Page 204
Revision 44
10-20-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
103000
Blade Folding
MAINTENANCE MANUAL
CSP-HMI-2
BLADE FOLDING
1. Main Rotor Blades Storage Rack
Description
(1). Verify that front and rear support

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
on Model 369 helicopters during ground
handling operations. The storage rack
consists of fore and aft units which,
when installed, provide blade protection
for helicopters that cannot be placed in
hangers or evacuated during adverse
weather conditions.
(2). The aft blade storage rack supports
three blades and consists of a plywood
blade rack which incorporates shock
(bungee) cords and nylon-webbing
harness straps with buckles, pull tabs,
and a grommet. The aft storage rack is
installed on the tailboom at Sta. 197.78,
just above the jack fitting. A decal on
the aft side of the storage rack facili
tates proper fore and aft positioning on
the tailboom. The harness grommet
engages the jack fitting and holds the
storage rack in position when the
harness straps are tightened and
secured. Shock cords secure the blades.
(3). The forward blade storage rack sup
ports two blades and consists of a
plywood blade rack which incorporates
shock cords, blade clamp (top blade
only), rack support tubes, and landing
gear clamps. The storage rack is
installed forward of the fuselage so that
the blade clamp support is positioned
left of the helicopter centerline. The
rack support tubes are secured with
clamps to the landing gear just aft of
the skid tip lights. Shock cords secure
the blades.
2. Main Rotor Blades Storage Rack
Inspection
(3). Verify that no support tubing is bent.

(4). Verify that plywood of rear support is
not split, cushions not torn, or nylon
webbing harness not missing its buckle.
3. Main Rotor Blades Folding and Unfolding
The following paragraphs provide instruction
for operation of the main rotor blade storage
rack: For the unpinning of the main rotor
blades; for folding, unfolding, and repining of
the blades. Adjustment and testing of main
rotor flight controls, necessary after the blades
have been re-pinned, is also covered here.
(Ref. Sec. 20-40-00 for information about
adjustment and corrosion protection of main
rotor blade attaching pins.)
If main rotor blades are to re
main folded for a considerable
length of time, main rotor hub must be cov
ered with a suitable weather-resistant cov
er.
CAUTION
NOTE: A mechanic's assistant is needed for

blade folding and unfolding.
A. Helicopter Location for Blade Folding
(1). Locate helicopter slightly more than
rotor span from other aircraft or
vehicles.
(2). Park helicopter on the most level
ground available so that the load is
balanced as much as possible.
B. Main Rotor Blades Folddown Preparation
Item
ST2003
ST2004
ST2005
Special Tools
Nomenclature
Main rotor blade storage rack
(Ref. Figure 201)
10-30-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
(1). Inspect rack (Ref. Main Rotor Blades

Storage Rack Inspection).
(2). Position main rotor so that one blade is
directly above and parallel to helicopter
tailboom.
(3). Lock cyclic control stick (by applying
friction) in the following positions:
(a). Set collective pitch to mid position.
(b). Set longitudinal cyclic to full aft
position.
(c). Set lateral cyclic to two thirds of total
stick travel from full left toward full
right.
During blade folding, continual
ly monitor stick positions to
make sure no change occurs. Serious blade
damage may result from improper stick
placement.
CAUTION
(4). Disconnect wires or antennas (as

applicable) at tailboom attach fitting,
and coil them.
(5). Cover (ST2004 and ST2005) engine air
inlet and exhaust openings to prevent
entry of foreign objects during blade
folding.
During blade folding, use blade
support pole (ST2003). Prevent
scratching of blade by attaching pins or
bolts. Avoid brushing of blades against one
another or against any other surface. Lift
blade near tip to remove load on blade at
taching pins.
CAUTION
C. Aft Main Rotor Blades Folding
Item
Special Tools
Nomenclature
ST2003
(1). Install aft storage rack (ST2003) to

helicopter.
Revision 23
(b). Attach and secure straps. Adjust

strap pull tabs so that harness
grommet engages jack fitting on
tailboom.
(2). Install trailing rotor blade to aft storage
rack.
(a). Into center cushioned support step of
rear blade support assembly, position
trailing rotor blade (blade that is
directly above and parallel to tail
boom).
Blade movement must be re
strained in the following steps
to prevent damage since, with damper dis
engaged, the blade is free to pivot on blade
attaching pin.
CAUTION
(b). Remove bolt or (alternatively)

attaching pin from damper arm of
trailing rotor blade, and move
damper away from blade; replace bolt
(or attaching pin) in damper arm.
NOTE: It is not necessary to remove a blade at

taching pin in order to fold the first blade.
(c). Secure blade in support assembly
with shock cord fastener.
(3). Install remaining blades to aft storage
rack.
attaching pin.
CAUTION
NOTE: The right blade goes to the top hold

down position, and the left blade to the bot
tom holddown position.
(Ref. Figure 201)
Page 202
(a). Position rear blade support assembly

on tailboom at Sta. 197.78, with its
lower step on left side of helicopter.
10-30-00
(a). Remove bolt or (alternatively)

rotor blade, and move damper away
from blade; replace bolt (or attaching
pin) in damper arm.
(b). Unlock (but do not remove) blade
attaching pin that secures leading
edge of blade to main rotor hub.
MAINTENANCE MANUAL
(c). Unlock and remove blade attaching
pin that secures trailing edge of blade
to lead-lag link, and position cam
handle vertically above pin.
(d). Instruct mechanic's assistant using
blade-support pole (ST2003) to guide
rotor blade to its proper position on
rear support assembly.
(e). Secure blade in support assembly
(f). Reinstall blade attaching pin its
original position in lead-lag link of
main rotor hub.
D. Forward Main Rotor Blades Folding
(Ref. Figure 201)
Item
ST2003
Special Tools
Nomenclature
(1). Install forward storage rack (ST2003)

to helicopter.
(a). Position blade storage rack so that
top holddown position on rack is
approximately 15 degrees left of
helicopter centerline.
(b). Attach U-bolt clamp subassemblies
to forward ends of each landing gear
skid. Secure with hardware provided.
Ensure that each U-bolt is attached
ahead of curved portion of skid (but
aft of skid tip light) to assure ground
clearance.
NOTE: Top adjustment holes in support tubes

are for extended landing gear; bottom holes
are for standard landing gear.
(c). Attach lower ends of support tubes to
U-bolt clamp brackets. Attach short
tube to left skid. Secure with hard
ware provided.
CSP-HMI-2
(d). Attach upper ends of support tubes to

double blade support. Adjust tube
length to proper height as required
for extended or standard landing
gear. Secure with hardware provided.
(2). Install left forward blade to forward
storage rack. Observe that one blade is
directly above the left side of the front
blade support assembly. Secure that
blade in support with shock cord
fastener and hinged clamp fastener
support.
NOTE: It is not necessary to remove blade at

taching pins from the main rotor assembly
or damper arm in order to secure this blade.
(3). Install right forward blade to forward
storage rack.
attaching pin.
CAUTION
(a). Remove bolt or (alternatively)

right forward blade and move damp
er away from rotor blade; replace bolt
(or attaching pin) in damper arm.
(b). Unlock and remove blade attaching
pin that secures trailing edge of blade
to lead-lag link, and position cam
handle vertically above pin.
(c). Instruct mechanic's assistant using
blade support pole to guide rotor
blade to its proper position on right
side of double blade front support.
(d). Secure blade in support assembly
(e). Reinstall blade attaching pin into its
original position in lead-lag link of
main rotor hub.
10-30-00
Page 203
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
G103000
Figure 201. Folding and Stowing Main Rotor Blades

Page 204
Revision 23
10-30-00
MAINTENANCE MANUAL
E. Main Rotor Blades Unfolding Preparation
Item
Special Tools
Nomenclature
ST2003
ST2004
ST2005

CSP-HMI-2
(1). Begin with the trailing blade, the one

supported by the center support step of
the rear blade support assembly.
attaching pin.
CAUTION
(a). Set collective pitch to mid position.
(a). Remove damper arm bolt or (alterna

tively) attaching pin from damper
arm clevis. Extend and align damper
arm with bolt hole in trailing edge of
blade. Insert bolt or attaching pin,
but: If pin is used, do not lock pin at
this time; if bolt is used, tighten to
torque of 30 - 60 inch-pounds (3.39
- 6.78 Nm) and insert cotter pin.
(b). Set longitudinal cyclic to full aft

position.
(b). Remove shock cord fastener and

release blade from support.
Before unfolding the main rotor blades,

perform the following steps:
(1). Lock cyclic control stick, by applying
friction, in the following positions:
(c). Set lateral cyclic to two thirds of total

stick travel from full left toward full
right.
During blade unfolding, contin
CAUTION ually monitor stick positions to
make sure no change occurs. Serious blade
damage may result from improper stick
placement.
(2). Cover (ST2004 and ST2005) engine air
inlet and exhaust openings to prevent
entry of foreign objects during blade
folding.
During blade unfolding, use
CAUTION blade support pole (ST2003).
Prevent scratching of blade by attaching
pins or bolts. Avoid brushing of blades
against one another or against any other
surface. Lift blade near tip to remove load
on attaching pin.
F. Aft Main Rotor Blades Unfolding
(Ref. Figure 201)
Item
Special Tools
Nomenclature
ST2003
NOTE: Only the damper arm attaching bolt (or

pin) was removed from this blade during
folding, not a lead-lag link attaching pin.
(2). For the remaining aft secured rotor
blades, proceed as follows:
attaching pin.
CAUTION
(a). Remove shock cord fastener and

(b). Instruct mechanic's assistant using
blade support pole (ST2003) to lift
and rotate blade forward to align
trailing edge of blade and attachment
hole in lead-lag link of main rotor
hub (remove attaching pin from
lead-lag link to allow hole align
ment). Re-insert attaching pin (but
do not lock at this time).
(c). Remove damper arm bolt or (alterna
blade. Insert bolt or attaching pin
torque of 30 - 60 inch-pounds (3.39
10-30-00
Page 205
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
G. Forward Main Rotor Blades Unfolding

(Ref. Figure 201)
H. Main Rotor Blades Storage Rack Removal

and Storage
(Ref. Figure 201)
Item
ST2003
Special Tools
Nomenclature
(1). Begin with the blade stowed on the left

side of the double blade front support
assembly. No attaching pins were
removed from this blade for storage.
Release hinged clamp fastener support
and shock cord fastener. Alignment is
not necessary.
(2). For remaining forward rotor blade,
proceed as follows:
attaching pin.
CAUTION
(1). Remove covers from engine exhaust

and air inlet fairing.
(2). Unbuckle nylon webbing harness of
rear blade support assembly to disen
gage aft blade storage rack from
tailboom. Further disassembly is not
required.
(3). Loosen or remove wing nuts to disen
gage U-bolt clamp subassemblies from
front end of landing gear skid assembly.
Remove forward blade storage rack
from helicopter.
(4). Store blade storage racks.
(5). Reconnect any wires or antennas
disconnected for blade folding.
(a). Remove shock cord fastener and

4. Main Rotor Flight Controls Adjustment

and Testing
(b). Instruct mechanic's assistant using

blade support pole (ST2003) to lift
and rotate blade aft to align trailing
edge of blade and attachment hole in
lead-lag link of main rotor hub
(remove attaching pin from lead-lag
link to allow hole alignment). Re-in
sert attaching pin (but do not lock at
this time).
(Ref. Figure 201) Perform the following steps

after main rotor blades have been unfolded
and repined.
(c). Remove damper arm bolt or (alterna

blade. Insert bolt or attaching pin,
torque of 30 - 60 inch pounds (3.39
Page 206
Revision 23
10-30-00
(1). Lock all attaching pins and check that

locking force required to close pin
handle is 25 - 35 pounds force (111.2
- 155.7 N) (Ref. Sec. 62-10-00 Main
Rotor Blade and Damper Attach Pin
Installation and Adjustment, Sec.
62-10-00).
NOTE: Blade attaching pin handle is posi

tioned behind retainer clip as shown.
(2). Loosen friction on cyclic and collective
sticks and check movement of controls
through complete range of travel.
MAINTENANCE MANUAL
Chapter
11
Placards and
Markings
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
11-00-00 Placards and Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

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

1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.
Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 201. Exterior Placards and Markings (Sheet 1 of 4) . . . . . . . . . . . . . . . . . .
Figure 202. Interior Placards and Markings (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . .
Figure 203. Instrument Panel Placards and Markings (Sheet 1 of 2) . . . . . . . . .
11 Contents
201
202
206
210
Page i
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page ii
Revision 43
11 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
110000
Placards and
Markings
MAINTENANCE MANUAL
CSP-HMI-2

1. General
(Ref. Figure 201 thru Figure 204 for placards
and markings most common to 369D/E/FF 500N Model Helicopters). Nomenclature
corresponds to that used in the IPC. (Ref.
Illustrated Parts Catalog for each decal part
number and the quantity required.)
The following illustrations cover different
areas of decal placement on the helicopter:
(1). Exterior - Figure 201.
(2). Interior - Figure 202.
(3). Instrument panels - Figure 203.
(4). Optional equipment (various exterior
and interior locations) - Figure 204.
2. Decal Application
(1). Where a decal overlaps or covers drain
holes, access doors, etc., the decal shall
be cut out to provide proper draining or
ease of opening or removing of doors,
plates, etc.
(2). Where a decal is applied over a skin lap
(one skin overlapping another), the
decal must be cut so that it lies flat and
makes a positive bond.
(3). Seal edges of all exterior decals, and
only those interior decals in the engine
compartment and cargo compartment
aft of the transmission, with epoxy
adhesive. Edge sealing to be a mini
mum of 1/32 inch (0.8mm) and a
maximum of 1/8 inch (3mm) around
perimeter of decal.
11-00-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
3
500E
A
2
4
21
(NOTE 1)
ROTATING
SWASHPLATE
INNER
HANDLE
SCISSORS
CRANK
6
8
12
OUTER
HANDLE
TO
LOCK
DETAIL A-A
CARGO
FLOOR
TO
OPEN
CAUTION
1
1
7
5
500E
10
EXT. LH DOOR SHOWN
RH OPPOSITE
15
13
14
JACK PAD
16
17
OIL CAP
(REF)
18
N9011F
1
SHIP
CL
19
FAIRING
16
AIR
DUCT
(REF)
HEATER
DUCT
(REF)
NOTES:
1. EFFECTIVE ON S/N:
369D;
001 AND SUBS.
369E;
001 - 300
369FF;
001 - 054
2. EFFECTIVE ON S/N:
369E;
301 AND SUBS
369FF;
055 AND SUBS
500N;
001 AND SUBS
20
21
(NOTE 2)
FUEL CAP
(REF)
12 1
1
G11-0000-1B
Figure 201. Placards Exterior (Sheet 1 of 5)

Page 202
Revision 23
11-00-00
MAINTENANCE MANUAL
CSP-HMI-2
22
23
24
25
27
26
G11-0000-2
11-00-00
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
CAUTION
PUSH
1.
DISCONNECT ELECTRICAL WIRING

BEFORE REMOVING BOOM
PUSH
2.
ELECTRICAL
DISCONNECT
3.
500D / 500E / 530F / 520N
TO
LOCK
CAUTION
INSTALL THIS SIDE

TOWARD BLADES
4.
SAFELOCK
INNER HANDLE
IN POSITION
SHOWN BEFORE
FLIGHT
LOCKED
MAIN ROTOR
5.
LOCKED
TO
OPEN
6.
7.
LOCK BEFORE FLIGHT,

LH & RH
FULL
CAP. 0.4 U.S. PTS.

SEE FLT MANUAL
AND LOG BOOK
FOR OIL USAGE
8.
OPEN AND LOCK,

OUTER, LH & RH
JIG POINT
STA 92.64
CHECK LEVEL
ADD
TAIL ROTOR
TRANSMISSION OIL
9.
CHECK LEVEL
ATTACH JACK PAD
10. OIL LEVEL PLUG
THRU
11. JIG POINT
THRU
12. JACK PAD
THRU
DANGER
13. DANGER
THRU
LEFT-HAND
LETTERS AND NUMERALS
14. RADIO CALL

Page 204
Revision 23
11-00-00
RIGHT-HAND
LETTERS AND NUMERALS
G1100003A
MAINTENANCE MANUAL
CSP-HMI-2
STATIC LINE
DRAIN VALVE
PUSH BOTTOM UP
THRU
16. STATIC LINE
15. RADIO CALL
OIL
17. OIL
18. NON SELF-SEALING FUEL CELLS

FUEL 62.1 GALLONS
STATIC PORT
KEEP HOLES AND
SURFACE CLEAN
19. STATIC PORT
TORQUE SCREWS
TO 2025 INLB
22. HUB FAIRING

SCREW TORQUE
18. SELF-SEALING FUEL CELLS

FUEL 60.0 GALLONS
MCDONNELL DOUGLAS
HELICOPTER CO. MESA, AZ
MODEL NO. 369
SERIAL NO.
TYPE CERT NO. H3WE
PROD CERT NO. 410
20. GROUND SYMBOL
CAP. 12.0 U.S. PTS.

SEE FLT MANUAL
AND LOG BOOK
FOR OIL USAGE
23. MAIN ROTOR

TRANSMISSION OIL
21. MODEL IDENTIFICATION
WARNING
DO NOT SUPPORT
GEAR BOX WEIGHT FROM
DRIVE SHAFT COUPLING
24. TAIL ROTOR
GEARBOX WARNING
ENGINE VENT
27. ENGINE VENT
25. FUEL DRAIN
26. OIL DRAIN

G11-0000-4
11-00-00
Page 205
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
28
30
30
2
29
31
32
33
1
28. CAUTION-CABLE
30. MODEL MUMBER
29. CAUTION-JACK LOAD
31. NO PUSH INFORMATION
32. LIGHT ACCESS
33. TRANSMISSION CHECK
G11-0000-5

Page 206
Revision 23
11-00-00
MAINTENANCE MANUAL
CSP-HMI-2
11
5
8
10
9
7
2
ROTATED
13
14
15
G11-0002-1
Figure 202. Placards Interior (Sheet 1 of 5)
11-00-00
Page 207
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
18
17
16
20
18
20
19
16
17
17
17
G11-0002-2

Page 208
Revision 23
11-00-00
MAINTENANCE MANUAL
CSP-HMI-2
26
28
AFT BULKHEAD
ACCESS COVER
21
12
( NOTE 2 )
25
24
23
27
22
( NOTE 1 )
ROTATE
D
NOTES:
1. NOT APPLICABLE TO 369D, SHIP
NO. 605 AND SUBSEQUENT,
2. NOT APPLICABLE TO 369E/FF - 500N.
ROTATE
D
G11-0002-3A
11-00-00
Page 209
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
CONTROLS ACCESS DOOR
VOLTAGE REGULATOR
CAUTION
LAT TRIM
ONLY QUALIFIED PERSONNEL

WILL ADJUST THIS ASSEMBLY
1.
VOLTAGE REGULATOR
(369D;
S/N 002 AND
SUBS.)
(369E;
S/N 001 THRU
383 )
(369FF;
S/N 001 THRU
075)
2.
LATERAL TRIM
5.
OUTSIDE AIR TEMPERATURE
3.
T
H
R
O
T
T
L
E
IF MOISTURE VISIBLE
AND O.A.T. BELOW 5o C
USE ANTI-ICE
REPLACE DOOR BEFORE FLIGHT
4.
LONGITUDINAL TRIM
7.
THROTTLE OPEN
24 VOLT DC
8.
FRICTION INCREASE
OFF
CAUTION
ACTIVATE BOOST
PUMP BEFORE AND
DURING DRAINING
FUEL SAMPLE
CABIN
HEAT
FUEL ACCESS DOOR
9.
OPEN
WARNING

AND JACKING AIRCRAFT
ON
LEVEL HERE
10. FUEL ACCESS DOOR
DAMPER CHARGED RECOMMENDED

SERVICE BETWEEN 125 o F TO 10 o F
SEE HANDBOOK OF MAINTENANCE
INSTRUCTIONS.

SERVICE BETWEEN 70Fo TO -40o F
INSTRUCTIONS.

SERVICE BETWEEN 90Fo TO -25o F
INSTRUCTIONS.
24 VOLTS DC
CLOSE
BYP
DOOR
LEVEL HERE

WARNING - REPLACE DOOR
BEFORE FLIGHT
FRICTION
INCREASE
OPEN
6.
WARNING
LONG TRIM
11. BYPASS DOOR

ENGINE ANTI-ICE
WARNING
UNIT CHARGED WITH HIGH PRES SURE GAS. REFER TO HANDBOOK
MAINTENANCE INSTRUCTIONS OR
RETURN TO MANUFACTURER ON
EVIDENCE OF LEAKAGE OR
MALFUNCTION.
14. DAMPER WARNING
12. FUEL SAMPLING

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

S/N 001 THRU
S/N 001 THRU
CAUTION
CAUTION
USE ONLY WITH

STANDARD LANDING
GEAR OR IN TWO
FORWARD POSITIONS
OR EXTENDED
LANDING GEAR
USE ONLY IN TWO

AFT POSITIONS OR
EXTENDED LANDING
GEAR. DO NOT USE
WITH STANDARD
LANDING GEAR.
WHITE
DAMPER
ONLY
BLACK
DAMPER
ONLY
15. DAMPER CAUTION
13. DAMPER SERVICE
G11-0002-4A

Page 210
Revision 23
11-00-00
MAINTENANCE MANUAL
CSP-HMI-2
DANGER
WHEN EXITING, WALK AWAY FROM THE
HELICOPTER, KEEP HANDS AND HEAD LOW,
DO NOT WALK TO THE REAR.
CAUTION - TO ASSURE PROPER RESTRAINT. ADJUST SHOULDER

HARNESS SLIDE SO HARNESS IS SNUG AGAINST TORSO
WHILE SEATED UPRIGHT. FULL BACK IN THE SEAT
16. CAUTION - SHOULDER HARNESS
17. EXIT
TO
OPEN
CAUTION
SAFELOCK
HANDLE IN
POSITION
SHOWN BEFORE
FLIGHT
LONG RANGE TANK CONN

19. LONG RANGE TANK CONNECTION
TO
LOCK
20. LOOK BEFORE EXIT
18. DOOR INSTRUCTIONS
TANK
COOLER
ENGINE OIL DRAINS
PULL & TURN

90 o TO DRAIN
ENGINE LUBE OIL
OIL TANK OUTLET

23. OIL TANK OUTLET
21. ENGINE OIL DRAINS
OIL TANK INLET

25. DECAL. OIL TANK INLET
22. OIL DRAINS

(369D:
605)
OIL TANK VENT

24. OIL TANK VENT
S/N 002
M/R
XMSN
OIL
COOLER
DRAIN
26. MAIN ROTOR TRANSMISSION

OIL COOLER DRAIN
FULL
WARNING
FAILURE TO PROPERLY INSTALL,ALIGN
AND TORQUE,FUEL,OIL AND AIR TUBES
AND FITTINGS COULD RESULT IN AN
ADD 1 PINT
27. ,OIL LEVEL
ENGINE FAILURE.REFER TO THE APPLI

CABLE MANUAL FOR PROPER INSTAL4
ATION AND TORQUE PROCEDURES
28. WARNING
G11-0002-5A
11-00-00
Page 211
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
BATTERY
12
140 F
150 F
3
6
XMSN
OIL
PRESS
ENGINE
OUT
XMSN
OIL
TEMP
GEN
OUT
ENGINE
CHIPS
XMSN
CHIPS
XMSN
CHIPS
20
140
PRESS
TO
TEST
FUEL
FILTER
FUEL
LOW
120
40
100
60
80
ALTITUDE
0
10
120
20
110
100
30
40
80
50
70
60
10 12
TQI
FLIGHT COMPLIANCE
90
CAUTION
CYCLE
CYFSWWP
TO TRIM
TO NEUTRAL
BRINGHTEVKKD
ADJUPLVVCM
TMRUE
THIS HELICOPTER MUST BE OPERATED IN COMPLIANCE WITH THE OPERATING

LIMITATIONS SPECIFIED IN THE F.A.A. APPROVED ROTORCRAFT FLIGHT MANUAL.
1.
90 100
80
70
60
120
TORQUE
50
40
10
PSI
20
30
10
20
30
100
80
RADIO CALL
2.
100
PERCENT40
70 RPM
50
50
150
60
P PULL
U
TO
S CLOSE
ON
H
UTILITY
START
PUMP
PWR
PRESS
AMPS
PULL
FOR
AIR
OFF
RADIO CALL
GYRO
CFM
POS
ANTI-COLL
LT
PNL
F
OFF
MID FRONT SEAT IS

NOT TO BE OCCUPIED
IN FALLING AND/ OR
BLOWING SNOW
ON
BRT
TRIM
ENG OUT
PRESS TO
RESET
REIGN
NAV/COM
ARMED
ADF
AUTO REIGN
TEST
XPDR
3.
SNOW WARNING
EMERG FLOATS
PRESS TO TEST
SEARCHLIGHT
CONT
EXT
PWR
AUTO
BATTERY
CAUTION
-CYCLIC
FORCES TO
BE TRIMMED TO
NEUTRAL DURING
STARTUP AND SHUTDOWN
4.
O
F
F
CARGO
HOOK
CIGAR LIGHTER
PA
PRESS TO
TEST
HOIST
PWR
CTR
OFF
PRESS TO TEST
RADIO
PWR COMM 1
XMIT
SYS
COMM 2
SLIM-LINE INSTRUMENT PANEL (369D)
CYCLIC STICK POSITION WARNING

G11-0001-1A
Figure 203. Placards Instrument Panels (Sheet 1 of 2)

Page 212
Revision 23
11-00-00
MAINTENANCE MANUAL
CSP-HMI-2
RADIO CALL
THIS HELICOPTER MUST BE OPERATED IN COMPLIANCE WITH THE OPERATING

LIMITATIONS SPECIFIED IN THE F.A.A. APPROVED ROTORCRAFT FLIGHT MANUAL.
1.
FLIGHT COMPLIANCE
80
2.
VNE
130 KTS. I.A.S.
WITH LESS THAN
35 LBS. FUEL
90 100
120
TORQUE
70
60
20
140
10
PSI 20
50
1
2
120
40 30
40
ALTITUDE
60
100
10
8 TQI 12
RADIO CALL
80
6
4
3.
LOW FUEL WARNING
0
20
100
80
10
120
110
10
30
30
5
80
90
60
100
PERCENT
40
RPM50
70
20
70 60
40
50
CAUTION CYCLIC FORCES TO BE

TRIMMED TO NEUTRAL DURING
100
50
150
PRESS
AMPS
4.
PULL
FOR
AIR
START RECOMMENDATIONS
OAT oC -32 TO -18 -18 TO 7 7 TO 46
N1 7 o/o
12
13
15
5
T-INSTRUMENT PANEL (369MD)
5.
START RECOMMENDATIONS
RADIO CALL
1.
FUEL
VALVE
EXT
START PUMP
O
F
F
EXT PWR
OFF
SCAV
GEN
AIR
OFF
OFF
ANTI-COLL
LT
OFF
POS
LTS
OFF
PITOT
HTR
OFF
UTIL
ANTI-ICE PWR
OFF
RADIO CALL
PULL
FOR
AIR
OFF
OVSPD FAULT
TEST
TEST
OFF
OFF
THIS HELICOPTER MUST

BE OPERATED IN COMPLIANCE WITH OPERATING
2.
LIMITATIONS SPECIFIED
IN THE F.A.A. APPROVED
ROTORCRAFT FLT MANUAL.
FLIGHT COMPLIANCE
CAUTION CYCLIC FORCES TO BE

TRIMMED TO NEUTRAL DURING
2
3.
V NE 50 KTS MAX WHEN

TORQUE EXCEEDS 48.9 CONT.
4.
WARNING HIGH TORQUE. 369 FF
T-INSTRUMENT PANEL (369E/FF - 500N)

G11-0001-2A
Figure 203. Placards Instrument Panels (Sheet 2 of 2)
11-00-00
Page 213
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
ANTI-ICE
FUEL
FILTER
6
14
ENGINE OIL
SCAVENGE FILTER
PARTICLE SEPARATOR
8
HEATED
PITOT
TUBE
15
CARGO HOOK
CARGO HOOK
G11-0003-1
Figure 204. Placards Optional Equipment (Sheet 1 of 4)

Page 214
Revision 23
11-00-00
MAINTENANCE MANUAL
CSP-HMI-2
FOUR BLADE TAIL ROTOR

AUTOMATIC ENGINE RE-IGNITION
G11-0003-2
11-00-00
Page 215
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
12
12
1
1
13
EMERGENCY FLOATS
UTILITY FLOATS
10
10
SWITCH INSTALLATION
(SLIMLINE PANEL)
G11-0003-3

Page 216
Revision 23
11-00-00
MAINTENANCE MANUAL
FILTER BYPASS CONTROL

PULL HANDLE FWD
EXTERNAL LOAD LIMIT

2000 POUNDS
1. PARTICLE
SEPARATOR
2.
CSP-HMI-2
CARGO HOOK
EMERGENCY
RELEASE
HOOK
RELEASE
3.
4.
CARGO HOOK
FOR GROUND
TEMP. OF 5 C OR
LESS MAX. ALT.
12,000 FT.
ANTIICE
AIRFRAME
FUEL FILTER
INSTL
FOR GROUND
TEMP. OF 5 C OR
LESS. MAX. ALT.
12,000 FT.
FOR GROUND
TEMP. GREATER
THAN 5 C MAX.
ALT. 14,000 FT.
FOR GROUND
TEMP. GREATER
THAN 5 C MAX.
ALT. 14,000 FT.
ANTIICE
FUEL FILTER
INSTL
CAUTION: SPRING LOADED, DO NOT PUSH
5. FOURBLADED TAIL ROTOR
AUTOREIGNITION
ARM
OFF
PRESS TO RESET
7. AUTOMATIC
ENGINE REIGNITION
6. ANTIICE FUEL FILTER

WARNING
PITOT MAY BE HOT
DO NOT TOUCH
WARNING
EMERGENCY FLOATS
PRESS TO TEST
FLOAT LDG LT
9. LANDING
LIGHT FLOAT
8. HEATED
PITOT TUBE
FLOAT INFLATION ABOVE 81 KNOTS IAS

AT LESS THAN 6000 FEET ALTITUDE,
77 KNOTS IAS AT 6000 FEET AND ABOVE,
IS PROHIBITED
11. WARNING
10. AUXILIARY
ELECTRICAL PANEL
EMERGENCY FLOATS
NIGHT FLIGHT OVER

WATER BEYOND
AUTOROTATION CAPABILITY
TO GROUND PROHIBITED
12. NIGHT FLIGHT
RESTRICTION
(ALSO EMERGENCY
FLOATS)
MINIMUM FLOAT
OPERATIONAL
PRESSURE IS
2.0 PSIG
13. MIN. OPERATIONAL
PRESSURE
UTILITY FLOATS
WARNING
USE CORRECT LOAD
RINGS, RINGS WITH
INTERNAL DIM.
GREATER THAN
1.5 INCHES
CAN SLIP OFF
Facet
FILTER PRODUCTS DIVISION

GREENSBORO, NC 27409
A. INSPECT RED BUTTON ON BOTTOM

OF BOWL FOR INDICATION OF FILTER
BYPASS.
B. IF RED BUTTON IS NOT SHOWING
PROCEED WITH PREFLIGHT.
C. RED BUTTON SHOWING, RESET
BUTTON ONCE AND RUN ENGINE.
D. IF RED BUTTON REAPPEARS,
DISCONTINUE OPERATIONS AND IN
VESTIGATE REASON FOR FILTER
BYPASS INDICATION.
14.
ENGINE OIL SCAVENGE

FILTER (MODEL D
AND E WITH A C20/R2
ENGINE CONVERSION
15. CARGO HOOK

P/N 171491 THRU 5
G11-0003-4B
11-00-00
Page 217
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
Page 218
Revision 44
11-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
114000
Placards and
Markings (600N)
MAINTENANCE MANUAL
CSP-HMI-2

1. General
(Ref. Figure 201 thru Figure 203 for placards
and markings most common to Model 600N
helicopters). Nomenclature corresponds to that
used in the IPC. (Ref. Illustrated Parts Catalog
for each decal part number and the quantity
required.)
The following illustrations cover different
areas of decal placement on the helicopter:
(1). Exterior - Figure 201.
(2). Interior - Figure 202.
(3). Instrument panels - Figure 203.
2. Decal Application
(1). Where a decal overlaps or covers drain
holes, access doors, etc., the decal shall
be cut out to provide proper draining or

ease of opening or removing of doors,
plates, etc.
(2). Where a decal is applied over a skin lap
(one skin overlapping another), the
decal must be cut so that it lies flat and
makes a positive bond.
(3). Seal edges of all exterior decals, and
only those interior decals in the engine
compartment and cargo compartment
aft of the transmission, with epoxy
adhesive. Edge sealing to be a mini
mum of 1/32 inch (0.8mm) and a
maximum of 1/8 inch (3mm) around
perimeter of decal.
11-40-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
2
1
2
8
3
1
2
4
10
1
1
3
1
4
1
0
1
3
1
4
2
2
1
1
3
1
2
4
2
3
10
1
6
3
1
5
1
2
1
4
1
3
1
0
1
4
2
0
LOOKING
5
INBOARD
(LH SHOWN, RH OPP)
1
3
2
7
2
6
INSIDE ENGINE DOOR
(LH SHOWN, RH OPP)
2
9
2
8
2
5
LOOKING INBOARD
(LH SHOWN, RH OPP)
6G11-010-1B
Figure 201. Exterior Placards and Markings (Sheet 1 of 4)

Page 202
Revision 23
11-40-00
MAINTENANCE MANUAL
1
9
CSP-HMI-2
1
7
TOP VIEW
18 (4 PLCS)
3
0
BOTTOM VIEW
6G11-010-2
11-40-00
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
TO
LOCK
1.
MCDONNELL DOUGLAS LOGO
2.
LOCKED
4.
CAUTION
LOCKED
WARNING
SAFELOCK
INNER HANDLE
IN POSITION
SHOWN BEFORE
FLIGHT

7.
TO
OPEN
NO PUSH
3.

6.
5.
600N IDENTIFICATION
PUSH
WARNING
8.
DOOR
INSTRUCTIONS
OIL
PUSH
LOCK BEFORE FLIGHT

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

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

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

SEE FLT MANUAL
AND LOG BOOK FOR
OIL USAGE
ATTACH JACK PAD

14. ATTACH JACK PAD
15. PLATE IDENTIFICATION
SERVICED
WITH
MOBIL
SHC
626
18. FUEL DRAIN
19. OIL USAGE
16. GROUND SYMBOL
17. MAIN ROTOR

TRANSMISSION OIL
CAUTION
DISCONNECT ELECTRICAL WIRING
BEFORE REMOVING BOOM
20. ELECTRICAL DISCONNECT
CAUTION
21. CAUTION - CABLE
22. LIGHT ACCESS
23. TRANSMISSION CHECK
24. CAUTION-JACK LOAD
6G11-010-3B

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CSP-HMI-2
L
O
C
K
25. DECAL ARROW
26. DECAL ARROW
27. DECAL, LOCK
O
P
E
N
28. DECAL, OPEN
STATIC PORT
KEEP HOLES AND
SURFACE CLEAN
LOCKED
29. DECAL, LOCKED
ENGINE VENT
30. DECAL, ENGINE VENT
31. DECAL, STATIC PORT
6G11-010-4A
11-40-00
Page 205
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
4
0
2
7
1
5
1
0
2
9
4
0
2
8
1
5
1
6
1
3
28
2
0
4
4 7
1
5
1
6
2
8
4
5
4
6
43 (4 PLCS)
44 (OPP)
7 (4 PLCS)
9
1
1
1
2
FS
113.85
1
9
FORWARD
DAMPER
FS
119.67
1
4
1
3
AFT
DAMPER
VIEW ROTATED
1
7
LOOKING
OUTBOARD
LOOKING DOWN
PLAN VIEW OF CARGO FLOOR
4
INTERIOR
PANEL
1
6 CONVENIENCE
1
7
1
8
LOOKING
OUTBOARD
PANEL
1
8
4
VIEW LOOKING FORWARD

FROM CABIN INTERIOR
6G11-011-1B
Figure 202. Interior Placards and Markings (Sheet 1 of 4)

Page 206
Revision 23
11-40-00
MAINTENANCE MANUAL
CSP-HMI-2
3
6
2
1
2
5
2
2
2
3
2
4
37
VIEW LOOKING OUTBOARD

(UNDER CO-PILOTS SEAT)
4
VIEW LOOKING AFT
TRANSMISSION
COVER
2
6
42
41
35
VIEW ROTATED
32
34
39
LBL
6.00
5
CL
RBL
6.00
RIGHT FORWARD LOOKING AFT
VIEW LOOKING FWD AT

CANT STA 78.50
33
6G11-011-2A
11-40-00
Page 207
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
OFF
CLOSE
BYP
DOOR
IF MOISTURE VISIBLE
AND O.A.T. BELOW 5o C
USE ANTI-ICE
2.
CABIN
HEAT
OPEN
3.
OUTSIDE AIR
TEMPERATURE
5.
4.
CABIN HEAT AND

ENGINE ANTI-ICE

WARNING-REPLACE DOOR
BEFORE FLIGHT
NO SMOKING/SEAT BELT
FUEL ACCESS DOOR
WARNING

AND JACKING AIRCRAFT
LEVEL HERE
6.
WARNING
24 VOLT DC
ON
1.
24 VOLT DC
7.
FUEL ACCESS DOOR
LONG TRIM
LAT TRIM
8.
9.
LONGITUDINAL TRIM
LATERAL TRIM
LEVEL HERE
10. EXIT INSTRUCTIONS
11. FORWARD DAMPER

WARNING
12. AFT DAMPER

WARNING
CAUTION - TO ASSURE PROPER RESTRAINT. ADJUST SHOULDER

HARNESS SLIDE SO HARNESS IS SNUG AGAINST TORSO
WHILE SEATED UPRIGHT. FULL BACK IN THE SEAT
FRICTION
INCREASE
T
H
R
O
T
T
L
E
OPEN
13. THROTTLE
OPEN
TO
OPEN
TO
OPEN
TO
LOCK
TO
LOCK
16. CAUTION SHOULDER HARNESS
14. FRICTION INCREASE
DANGER
WHEN EXITING, WALK AWAY FROM THE
HELICOPTER, KEEP HANDS AND HEAD LOW,
DO NOT WALK TO THE REAR.
15. EXIT
TANK
COOLER
ENGINE OIL DRAINS
22. ENGINE OIL DRAINS
17. DOOR
INSTRUCTIONS
LONG RANGE TANK CONN

19. LONG RANGE TANK CONNECTION
CAUTION
WARNING
SAFELOCK
HANDLE IN
POSITION
SHOWN BEFORE
FLIGHT

M/R
XMSN
OIL
COOLER
DRAIN
OIL TANK OUTLET
20. WARNING
OIL TANK VENT

24. OIL TANK VENT

18. LOCK BEFORE EXIT
23. OIL TANK OUTLET
21. MAIN ROTOR

TRANSMISSION OIL
COOLER DRAIN
OIL TANK INLET

25. OIL TANK INLET
6G11-011-3

Page 208
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MAINTENANCE MANUAL
CSP-HMI-2
FULL
ADD 1 PINT
27. ARROW
28. EXIT COCKPIT
29. OPEN FIRST
26. OIL LEVEL
32. DECAL, E1
33. DECAL, E4
34. DECAL, E8
35. DECAL, E12
36. DECAL, E13
AIRCRAFT LIMITA
TIONS
XXXXXXXXXXXXXXXXX
47. DECAL, AIRCRAFT LIMITATIONS
41. DECAL, TB-502
39. DECAL, TB-5
42. DECAL, TB-501
37. DECAL, K309

40. DECAL, EMERGENCY EXIT
O
P
E
N
43. DECAL ARROW
44. DECAL ARROW
45. OPEN DECAL
L
O
C
K
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
11-40-00
Page 209
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MAINTENANCE MANUAL
CSP-HMI-2
VNE CARD HOLDER
OVSPD
TEST
OFF
FAULT
TEST
OFF
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
Revision 23
11-40-00
MAINTENANCE MANUAL
CSP-HMI-2
VNE CARD HOLDER
1. RADIO CALL
2. CYCLIC FORCES
6G11-012-2
3. HELICOPTER LIMITATIONS
Figure 203. Instrument Panel Placards and Markings (Sheet 2 of 2)
11-40-00
Page 211
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
Page 212
Revision 44
11-40-00
MAINTENANCE MANUAL
Chapter
12
Servicing
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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
12 Contents
Page i
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MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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
Page ii
Revision 32
12 Contents
MAINTENANCE MANUAL
CSP-HMI-2
Section
120000
Helicopter Servicing
MAINTENANCE MANUAL
CSP-HMI-2
HELICOPTER SERVICING
SERVICING
1. Servicing (General)
Servicing of helicopter includes replenishment
of fuel, changing or replenishment of oil and
other such maintenance functions.
For locations of servicing points of standard
equipment Refer to Figure 301. For optional
equipment servicing points Refer to
Figure 302. For lubrication points Refer to
Figure 304.
NOTE: The servicing intervals designated

herein are the maximum allowable and
should not be exceeded. When unusual local
conditions such as environmental condi
tions, utilization, etc., dictate, it is the pre
rogative and responsibility of the operator to
increase the scope and frequency of the in
spections as necessary to ensure safe opera
tion.
2. Servicing (Special)
Whenever helicopter operation has taken place
over or around salt water environments and
other environments found to be corrosive, the
following wash procedures must be performed.
A. Main Rotor Hub Wash Procedure
(Ref. Main Rotor Hub Corrosion Prevention
Tri-Flow Wash Procedure, Sec. 20-40-00)
B. Main Rotor Blades Washing and Waxing
(Ref. Main Rotor Blades Corrosion Arresting,
Sec. 20-40-00)
C. Engine Compressor Wash
(Ref. Chap. 71 and applicable Allison Engine
Operation and Maintenance Manual, Table
201, Sec. 01-00-00)
3. Fuel System Servicing
Fuel Cell Capacities 369D/E/FF 500N
NonselfSealing . . . . . 64.0 U.S. Gal. (242 Liters)
Usable Fuel . . . . . . 62.7U.S. Gal. (237 Liters)
SelfSealing . . . . . . . . . 62.0 U.S. Gal. (234 Liters)
Usable Fuel . . . . . . 60.7 U.S. Gal. (229 Liters)
Fuel Cell Capacities 600N

Total Fuel . . . . . . . . . . . . 116.2 U.S. Gal. (440 Liters)
Usable Fuel . . . . . . . . . . 114.6 U.S. Gal. (434 Liters)
A. Fuel System Servicing Precautions

Comply with following precautions when
servicing fuel system.
Turn off electrical switches
WARNING and disconnect any external

power from helicopter. Electrically
ground helicopter prior to refueling or
defueling. Static discharge spark in
presence of fuel vapors can cause fire
or an explosion.
(1). Refueling vehicle should be parked a
minimum of 20 ft. (6 M) from helicopter
during fueling operation.
(2). Before starting fueling operation,
always ground fueling nozzle or fuel
truck to GROUND HERE receptacle or
to another bare metal location.
B. Approved Fuels
Service the helicopter with one of the autho
rized fuels listed in the applicable Allison
Engine Operation and Maintenance Manual
(Ref. Table 201, Sec. 01-00-00). For operation
under emergency conditions where authorized
fuel is not available, or for operation under
cold weather conditions, refer to same manual.
C. Fuel System Filling
The fuel system has two fuel cells that are
interconnected for simultaneous flow and
venting. Fuel system filler is on right side of
helicopter.
(1). Refuel helicopter with correct fuel as
soon after landing as possible to
prevent moisture condensation and to
keep helicopter as heavy as possible in
case of winds.
(2). Keep fueling nozzle free of all foreign
matter.
(3). Check filler cap for security after
fueling.
12-00-00
Page 301
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
D. Fuel System Draining

Fuel draining should be accomplished with
helicopter as level as possible.
(1). Fuel system may be defueled in either
of two ways:
To avoid possible damage to fuel
pump, do not operate fuel pump
with fuel tanks drained.
CAUTION
(a). Defuel through filler port using a

pump.
(b). Open system drain valves on fuselage
underside and in engine compart
ment.
(2). Fuel supply line drain valves are spring
loaded type and open by pushing valve
and attached drain line.
(3). Fuel cells drain valve is spring-loaded
closed and is opened by pressing
internal plunger.
E. Fuel System Bleeding
(Ref. Chap. 28 and applicable Allison Engine
Operation and Maintenance Manual, Table
201, Sec. 01-00-00) Purge entrapped air from
the fuel system, if necessary.
F. Engine Fuel Filter Replacement
(Ref. Applicable Allison Engine Operation and
Maintenance Manual, Table 201, Sec.
01-00-00)
4. Engine Oil System Servicing
Oil Tank Capacity . . . . 3.0 U.S. Qt. (2.84 Liter)
A. Approved Lubricants
rized oils listed.
For operation under emergency conditions
where different oils must be mixed, or for
operation under cold weather conditions, use
alternate lubricants (Ref. applicable Allison
Engine Operation and Maintenance Manual,
Table 201, Sec. 01-00-00).
Page 302
Revision 23
12-00-00
NOTE: If the type of engine oil or the oil group

is changed, remove and inspect the oil filter
each 25 hours of engine operation (Ref.
applicable Allison Engine Operation and
Maintenance Manual for further informa
tion).
B. Engine Oil Changing
Maintenance Manual, Table 201, Sec.
01-00-00)
C. Engine Oil System Filling
The engine oil tank filler is on the right side of
the helicopter. A liquid level sight gauge for
checking oil level in tank is visible through a
transparent window near the filler.
NOTE:
D Before adding oil, the oil container must
be shaken to ensure proper mixture of the
anti-foaming additive.
D If sight gauge does not permit positive de
termination, remove filler cap and visual
ly check the oil level.
(1). Check oil level within 15 minutes of
engine shutdown; replenish if low.
(2). If engine oil level is low after helicopter
has set for more than 15 minutes;
(a). Run engine for at least 1 minute at
ground idle.
Ensure engine oil pressure is at
tained when starting engine
(Ref. applicable Pilot's Flight Manual).
CAUTION
(b). Shut down engine, check oil level,

replenish if low.
NOTE:
D Motoring engine can draw oil from the oil
tank to the gearbox, giving low oil level
indications.
D If engine oil level indicates a low condi
tion after setting overnight, engine check
valve may be leaking oil from tank to en
gine gearcase.
(3). Ensure oil tank filler cap is securely
tightened immediately after servicing.
D. Engine Oil System Draining (Helicopters
With Sta. 137.50 Bulkhead Drain Ports
Installed)
(1). Open engine access doors.
MAINTENANCE MANUAL
CSP-HMI-2
(2). Place suitable container under engine

oil tank drain and remove engine oil
tank filler cap.
(1). Drain oil from engine, oil tank and oil

cooler (Ref. Engine Oil System Drain
ing).
(3). Remove engine oil tank drain cap.
(2). Replace engine oil filter(s) (Ref. Appli

cable Allison Operation and Mainte
nance Manual).
(4). After draining oil from tank, reinstall

engine oil tank drain cap and filler cap.
(5). To drain residual oil from engine
accessory gearbox drain, remove wire
lead and lower chip detector. Use
suitable container to catch oil. Check
that detector O-ring is serviceable
(replace as required); reinstall detector;
torque to 50 - 60 inch-pounds (5.65 6.78 Nm); lockwire and reconnect wire
lead.
E. Engine Oil System Draining (Helicopters
with Drain Valve Installed)
(1). Remove interior trim and aft bulkhead
right access cover.
(2). Place a suitable container under
overboard oil drain line where it exits
fuselage underside at firewall.
(3). Remove cap from engine oil tank filler.
Pull out knurled spring-loaded button
to open valve in engine oil drain line
just below engine oil cooler (Ref.
Figure 301). Rotate button and valve
poppet so that locking pin rests on
shoulders of pin slot.
(4). After draining oil from tank, reinstall
filler cap and close oil drain valve;
ensure that poppet pin is in stop slot.
(5). Reinstall access cover and interior trim.
(6). To drain residual oil from engine
accessory gearbox drain, remove wire
lead and lower chip detector (Ref. Sec.
79-00-00). Use suitable container to
catch oil. Check that detector O-ring is
serviceable (replace as required);
reinstall detector, torque to 50 - 60
inch-pounds (5.65 - 6.78 Nm) and
reconnect wire lead.
F. Engine Oil System Flushing
The following procedure is for flushing oil that
has been contaminated or when changing the
type of oil.
(3). Refill engine oil system (Ref. Engine Oil

System Filling).
(4). Operate engine for five minutes and
repeat above procedures.
5. Main Rotor Transmission Servicing
rized oils listed (Ref. Sec. 91-00-00).
NOTE: Mobil oil SHC 626 can be formulated

such that it may have two different colors.
The oil can still be mixed with no adverse af
fects.
Main Transmission Capacities
369D25100 . . . . . . . . . . 12.0 U.S. Pt. (5.67 Liter)
369F5100 . . . . . . . . . . . 14.0 U.S. Pt. (6.62 Liter)
A. Main Rotor Transmission Filling

Transmission (gearbox) oil should be replaced
with new oil whenever it is drained. A liquid
level sight gauge for checking main rotor
transmission oil level is located on the
right-hand side and visible through the clear
panel of the main transmission interior cover.
NOTE:
D Replacement of oil pump filter (Ref. Sec.
63-21-00) is required after oil is drained
from main rotor transmission and at in
tervals specified (Ref. Sec. 05-20-20).
D If oil was drained from transmission cool
er, ground-operate helicopter for 15 min
utes after replenishing oil (Ref. applicable
PFM, Table 201, Sec. 01-00-00). Recheck
oil level at liquid level sight gauge and re
plenish as necessary. This purges air from
oil cooling system and ensures that entire
oil cooling system is full.
(1). Replenish with correct oil until oil level
is at FULL on sight gauge by lifting
breather-filler cap and inserting spout
of oil can into opening.
(2). Check that spring-loaded cap closes
when oil can spout is removed. Replace
trim cover.
12-00-00
Page 303
Revision 24
MAINTENANCE MANUAL
CSP-HMI-2
BATTERY ELECTROLYTE
WATER
MAIN XMSN FILLER
MIL-L-23699/SHC 626
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
NITROGEN/MIL-H-5606
PF
FUEL SYSTEM FILLER

JP4/JP5
ENGINE OIL TANK FILLER

MIL-L-23699
PF
PF
NOTE 2
FAN GEARBOX
DRAIN (500/600N)
FAN XMSN FILLER

MIL-L-23699/SHC 626
PF
NOTES 1, 2
NOTE 1
TRANS. OIL
COOLER DRAIN
ENGINE OIL
COOLER DRAIN
ENGINE OIL
TANK DRAIN
OIL DRAINS FOR MAIN TRANSMISSION, ENGINE OIL COOLERS,

ENGINE OIL TANK AND FAN GEARBOX
NOTES:
1. DO NOT MIX OILS.
2. REFER TO APPLICABLE ALLISON OPERATION MAINTENANCE
MANUAL FOR FREQUENCY OF OIL CHANGE, AUTHORIZED
FUELS AND OILS AND SERVICE CHECKS.
FAN TRANSMISSION
FREQUENCY SYMBOL
BREATHER FILLER
MIL-L-23699/SHC 626
DAILY . . . . . . . . . . . 1.
PF
NOTE 1
PF PREFLIGHT . . . . . . . 1.
100 HOURS . . . . . . . 1.
2.
YEARLY . . . . . . . . . . 1.
300 HRS / YEARLY . . 2.
600HRS / YEARLY . . 3.
TAIL ROTOR
TRANSMISSION
3.
ON CONDITION . . . . 1.
REQUIREMENTS
INSPECT PRIOR TO FIRST FLIGHT OF THE DAY
INSPECT PRIOR TO EACH FLIGHT
REMOVE BATTERY AND SERVICE PER THE MANUFACTURER'S
MAINTENANCE MANUAL
INSPECT AND REPLENISH ONE-WAY LOCK RESERVOIR AS
APPLICABLE
DRAIN AND REFILL T/R GEARBOX, FAN TRANSMISSION
DRAIN AND REFILL 369D25100 M/R G/B SERVICED WITH MIL-L-23699;
REPLACE OIL FILTER ELEMENT
DRAIN AND REFILL 369D25100 M/R G/B SERVICED WITH MOBIL SHC626
OR 369F5100 M/R G/B; REPLACE OIL FILTER ELEMENT
REPLACE ENGINE FUEL FILTER (5 MICRON)
ON CONDITION OR EVERY 9 MONTHS IF ON SHELF
G12-0001C
Figure 301. Servicing Points Standard Equipment

Page 304
Revision 34
12-00-00
MAINTENANCE MANUAL
CSP-HMI-2
ROTOR BRAKE RES

ERVOIR MIL-H-5606
MIST ELIMINATOR
PARTICLE SEPARATOR
ANTI-ICE FILTER
SCAVENGE OIL FILTER

NOTE
NOTE:
APPLICABLE TO ALL ALLISON 250C20R/2 AND C47 ENGINES.
OPTIONAL EQUIPMENT FOR ALLISON 250C20B, C30 ENGINES.
REFER TO ALLISON OPERATION AND MAINTENANCE MANUAL
FOR FILTER ELEMENT REPLACEMENT SCHEDULE.
FREQUENCY SYMBOL
REQUIREMENT
100 HOURS . . . . . . . . . 1.
CHECK ROTOR BRAKE RESERVOIR FOR

PROPER LEVEL; REPLENISH IF LOW.
. . . . . . . . . . . . . . . . . . . 2.
REMOVE AND CLEAN THE MIST

ELIMINATOR.
NOTE . . . . . . . . . . . . . 3.
REPLACE SCAVENGE OIL FILTER ELEMENT.
300 HOURS . . . . . . . . . 4.
REPLACE ANTI-ICE FILTER ELEMENT.
. . . . . . . . . . . . . . . . . . . 5.
SPEC:
MIL-L-23699
MOBIL SHC 626
REMOVE AND CLEAN PARTICLE

SEPARATOR ASSEMBLY.
SERVICING MATERIAL
MATERIAL:
REF:
LUBRICATING OILS
TABLE 1, 91-00-00
ITEMS CM125 & CM126
JET A/JP4/JP5/JP8
ENGINE FUEL, TURBINE
TABLE 201, 01-00-00

ALLISON OPERATION AND MAINTENANCE
MS36300 OR 0-B-41
DISTILLED WATER
ANY SOURCE ACCEPTABLE
DRY NITROGEN
OR EQUIVALENT
ANY SOURCE ACCEPTABLE
MANUAL
G12-0002B
Figure 302. Servicing Points Optional Equipment
12-00-00
Page 305
Revision 26
MAINTENANCE MANUAL
CSP-HMI-2
B. Main Rotor Transmission Draining
Item
Special Tools
Nomenclature
ST301
Main transmission drain hose
(1). Remove main rotor transmission cooler

drain cap and drain oil into suitable
container.
(2). Remove main rotor transmission drain
access covers, wire leads and chip
detectors.
(3). Using main rotor transmission drain
hose (ST301), drain oil into suitable
container.
(4). If damaged, replace O-rings used with
chip detectors and self-closing valves.
(5). If removed, reinstall self-closing valve.
Torque valve to 50 - 60 inch-pounds
(5.65 - 6.78 Nm) and chip detector to
40 - 50 inch-pounds (4.52 - 5.65
Nm). Lockwire valve to gearbox and
detector to valve. Reconnect wire leads.
(6). Reinstall main rotor transmission
access covers.
C. Main Rotor Transmission Oil System
Flushing
type of oil.
(1). Drain oil from transmission and oil
cooler (Ref. Main Rotor Transmission
Draining).
(2). Replace transmission oil filter (Ref. Sec.
63-21-00, Main Transmission Filter
Replacement).
(3). Refill transmission oil system (Ref.
Main Rotor Transmission Filling).
(4). Operate aircraft for five minutes, shut
down and repeat steps (1). thru (3).
Page 306
Revision 24
12-00-00
6. Tail Rotor Transmission Servicing

rized oils listed (Ref. Table 1, Sec. 91-00-00).

fects.
Tail Rotor Transmission Capacity
369D25300 . . . . . . . . . . 0.530 U.S. Pt. (0.250 Liter)
369D25400 . . . . . . . . . . 0.530 U.S. Pt. (0.250 Liter)
A. Tail Rotor Transmission Filling

Tail rotor transmission oil should be replaced
with new oil whenever it is drained. A liquid
level sight gauge for checking oil level is
located on the transmission housing.
(1). Check oil level.
(2). Remove lockwire and unscrew brea
ther-filler cap.
(3). Fill with proper oil by pouring oil into
transmission until oil level shows
FULL on sight gauge.
(4). Check that filler O-ring is serviceable
(replace if necessary). Reinstall brea
ther-filler and torque to 45 - 55
inch-pounds (5.08 - 6.21 Nm) with
breather hole aft (Ref. Sec. 63-25-10)
at completion of torquing. Secure with
lockwire.
B. Tail Rotor Transmission Draining
(1). Position suitable container under tail
rotor transmission drain.
(2). Remove wire lead, lockwire, chip
detector and self-closing valve (Ref.
Sec. 63-25-10).
(3). If damaged, replace O-rings used with
chip detector and self-closing valve.
(4). After oil drains, install self-closing
valve. Torque valve to 50 - 60 inchpounds (5.65 - 6.78 Nm) and chip
detector to 40 - 50 inch-pounds (4.52
- 5.65 Nm). Lockwire valve to gearbox
and detector to valve; reconnect wire
leads.
C. Tail Rotor Transmission Flushing
type of oil.
MAINTENANCE MANUAL
(1). Drain oil from tail rotor transmission
(Ref. Tail Rotor Transmission Drain
ing).
(2). Refill tail rotor transmission (Ref. Tail
Rotor Rotor Transmission Filling).
down and repeat steps (1). and (2).
7. AntiTorque Fan Transmission Servicing
rized oils listed (Ref. Sec. 91-00-00).

fects.
Fan Transmission Capacity . . . . 8 U.S. Oz. (236 cc)
A. AntiTorque Fan Transmission Filling

Anti-torque fan transmission oil should be
replaced with new oil whenever it is drained. A
liquid level sight gage for checking oil level is
located on the transmission housing.
(1). Check oil level.
(2). If servicing is required, remove fan
inlet screen and fan hub transmission
fairing.
(3). Remove lockwire and remove filler
plug.
(4). Fill by pouring oil into transmission
filler plug hole, until oil level shows
FULL on sight gauge.
(5). Check that plug O-ring is serviceable
(replace as required). Reinstall filler
plug and torque to 45 - 55 inchpounds (5.08 - 6.21 Nm). Secure with
lockwire.
B. AntiTorque Fan Transmission Draining
(1). Remove fan inlet screen and transmis
sion fairing.
(2). Cut lockwire and remove fan transmis
sion filler plug.
(3). Open engine access doors and place
suitable container under the fan
CSP-HMI-2
transmission drain and remove cap.

(Ref. Figure 301).
(4). After draining oil from transmission,
reinstall drain cap.
C. AntiTorque Fan Transmission Flushing
type of oil.
(1). Drain oil from fan transmission (Ref.
Anti-Torque Fan Transmission Drain
ing).
(2). Refill fan transmission (Ref. AntiTorque Fan Transmission Filling).
down and repeat steps (1). and (2).
8. OneWay Lock Control System Servicing
rized hydraulic oils listed (Ref. Sec. 91-00-00).
OneWay Lock Capacity . . . . 0.67 U.S. Oz. (20 cc)
(1). To check oil level, remove control access

cover.
NOTE: Reservoir should be 1/2 to 3/4 full.

(2). If oil level in reservoir is low, lift filler
cap and add oil as needed.
(3). Reinstall pilot's seat cover.
NOTE: If oil level is consistently low, one-way

lock should be repaired to stop oil leakage
(Ref. Component Overhaul Manual).
9. Overrunning Clutch Servicing and Oil
Leak Analysis
(Ref. Figure 303) When oil leakage or seepage
is noticed at oil seals or assembly joint lines of
overrunning clutch, clutch requires further
inspection and investigation as follows.

fects.
Overrunning Clutch Capacities
369A535011, 21, 31 . . . . . . 1.52 U.S. Oz. (45cc)
369A535041, 51 . . . . . . . . . 1.01 U.S. Oz. (30 cc)
369F5450 . . . . . . . . . . . . . . . . 3.64 U.S. Oz. (110 cc)
12-00-00
Page 307
Revision 24
MAINTENANCE MANUAL
CSP-HMI-2
Item
Nomenclature
CM112
Anti-seize compound high temperature
CM125
Oil
CM126
Oil, turbine
(b). Read scale to determine oil level and

servicing required. Full oil level is
indicated by oil level of 2 7/8 inches
(7.30 cm) on scale. Minimum allow
able quantity (13 cc) is 7/8 inch
(22.23 mm) on scale. Recheck reading
a minimum of three times.
If oil quantity is less than 7/8
inch (22.23 cm) on scale, the
clutch subassembly must be removed and
inspected for evidence of overheating (Ref.
CSP-DEF-5).
CAUTION
CAUTION
D Checking clutch oil level requires removal
of main rotor transmission drive shaft.
Use care not to stress drive shaft dia
phragms (early type) or flexible couplings
(current type) during removal and instal
lation. Deflection in these areas are lim
ited due to material hardness.
D The 369F5450 clutch is only to be serviced
with Mobil SHC 626 oil (CM125).
D The 369A5350 clutch is only to be ser
viced with MIL-L-23699 oil (CM126).
(1). Remove trim and blower access door.
(2). Remove main rotor transmission drive
shaft (Ref. Sec. 63-10-00). Carefully
slide shaft from drive couplings; do not
strike shaft against any object.
(3). Remove coupling bolt and O-ring from
end of clutch.
(4). Check that the three drain holes in
clutch housing are clean and free of
obstruction. Oil leakage may indicate
engine power output seal leakage if
clutch oil level is checked and within
limits.
(5). For a 369A5350 Clutch:
(a). Using a clean 6 inch (15 cm) machi
nists scale, 1/2 inch (12.7 mm) width,
slowly insert scale into center of
clutch output shaft until scale
bottoms. Scale must be inserted 4 7/8
inches (12.38 cm).
NOTE: Trim edge of scale as required to reduce

width of scale and allow scale to bottom in
clutch.
Page 308
Revision 26
12-00-00
(6). For a 369F5450 clutch, there is two

methods for checking the oil level:
(a). First Method: Full oil level is indi
cated by oil level of 3 1/8 inches (9.84
cm) on a 6 inch (15 cm) machinists
scale, 1/2 inch (12.7 mm) width,
inserted into clutch exactly 5 inches
(12.7 cm). Minimum allowable
quantity (60 cc) is 5/8 inch (15.88
mm) on scale. Recheck reading a
minimum of three times.
(b). Second Method: Full oil level is
indicated by oil level of 4 5/8 inches
(11.77 cm) on a 12 inch (30 cm)
machinists scale, 1/2 inch (12.7 mm)
width, inserted to bottom of inner
race. Minimum allowable quantity
(60 cc) is 2 1/8 inch (5.40 cm) on
scale. Recheck reading a minimum of
three times.
If oil quantity is less than 5/8
inch (15.88 mm) on scale for the
first method or 2 1/8 inches (5.40 cm) for the
second method, the clutch subassembly
must be removed and inspected for evidence
of overheating.
CAUTION
(7). Service clutch with lubricating oil

(CM125 or CM126). If oil level readings
indicate less than full level. Do not
overfill. Recheck oil level as in previous
step.
NOTE: Always check oil level after installing

clutch in the helicopter.
MAINTENANCE MANUAL
CSP-HMI-2
CLUTCH OUTPUT SHAFT
CLUTCH CENTERLINE
CLUTCH
SCALE
MINIMUM OIL LEVEL

7/8 IN. (22.23 MM)
FULL OIL LEVEL

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

LEVELS - SCALE INDICATIONS
MAIN TRANSMISSION
DRIVE SHAFT
COUPLING BOLT
CLUTCH CENTERLINE
SCALE
3 1/8 IN.
(9.84 CM)
CLUTCH CENT
ERLINE
5/8 IN.
(15.88 MM)
SCALE
4 5/8 IN.
(11.77 CM)
2 1/8 IN.
(5.40 CM)
ENGINE
FULL OIL LEVEL

110 CC
MINIMUM OIL LEVEL
60 CC
ENGINE
FULL OIL LEVEL

110 CC
MINIMUM OIL LEVEL
60 CC
6 INCH (15 CM) SCALE METHOD
12 INCH (30 CM) SCALE METHOD
369F5450 CLUTCH
OIL LEVELS - SCALE INDICATIONS
G12-3001B
Figure 303. Checking Oil Level Overrunning Clutch
12-00-00
Page 309
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
(8). If coupling shimming was disturbed,

shim coupling so that there is
0.035-0.055 inch (0.889-1.397 mm)
O-ring gap. (Ref. Sec. 63-10-00 for
clutch installation and shimming
requirement details.)
When installing clutch coupling
bolt in next step, installation
torque on the bolt must not be less than 250
- 300 inch-pounds (28.25 - 33.90 Nm)
plus drag torque. Torquing to lower value
reduces clutch bearing clamp-up and may
result in bearing race spinning.
CAUTION
(9). Coat bolt threads with oil (CM112).

Install coupling bolt and O-ring (Drag
torque for bolt self-locking serviceabili
ty is 25 inch-pounds (2.82 Nm)
minimum, 200 inch-pounds (22.60
Nm) maximum). Torque bolt to 250 300 inch-pounds (28.25 - 33.90 Nm)
plus actual drag torque.
(10). Position main rotor transmission drive
shaft between drive couplings. Install
four bolts and washers each end of
drive shaft and torque bolts to 50 - 75
inch-pounds (5.65 - 8.47 Nm).
(11). Reinstall blower access door and trim.
C. Component Lubrication Chart

(Ref. Figure 304 for required lubrication
points, lubricants to be used, and lubrication
intervals.)
Use extreme care when apply
ing any type of lubrication
(grease, oil, dry-film, etc) in vicinity of te
flon bearings. Most lubricants allow a dirtretaining film to form or have other detri
mental effects that can cause rapid
deterioration of bearing surface.
CAUTION
D. Tail Rotor Swashplate Dual Bearings

Repack
Check ball bearing for excessive loss of grease
and serviceability and relubricate (repack)
(Ref. Sec. 64-30-00).
E. Main Rotor Swashplate Bearing Repack
Check seals for evidence of deterioration and
grease leakage. Inspect bearing assembly for
serviceability and repack (Ref. COM, Sec.
62-30-10).
F. Main Rotor Hub Tapered Bearings
Clean, inspect, and relubricate (repack). (Ref.
Sec. 62-20--00).
G. Ground Handling Wheels Bearing Repack
10. Miscellaneous Component Servicing

A. Rotor Brake Servicing
(Ref. Sec. 63-22-00 for information on adding
hydraulic fluid to the rotor brake master
cylinder and bleeding the hydraulic system.)
B. Landing Gear Damper Servicing
Servicing of the landing gear damper is
performed by overhauling the damper assem
bly, or if equipped with schrader valve,
servicing with nitrogen if it does not meet the
minimum extension requirements (Ref.
32-10-00).
Page 310
Revision 32
12-00-00
Item
CM111
Nomenclature
Grease, aircraft
At regular intervals, repack wheel bearings

with grease (CM111).
11. Overrunning Clutch Subassembly Bearing
Repack
For 369A5350 overrunning clutch, repack
bearing per CSP-COM-5, Sec. 63-10-10.
For 369F5450 overrunning clutch, repack
bearing per CSP-COM-5, Sec. 63-10-15.
MAINTENANCE MANUAL
12. Component Fluid Leak Analysis
A. Main Rotor Transmission or AntiTorque
Transmission Oil Leaks
Oil leakage, seepage, or capillary wetting at oil
seals or assembly joint lines of main or
anti-torque transmissions are permissible if
leakage rate does not exceed 2 cc per hour (one
drop per minute). An acceptable alternate rate
of leakage from either transmission is, if oil
loss is not more than from the full to the add
mark on the sight gauge within 25 flight hours
(Repair leaks according to instructions in
Component Overhaul Manual).
NOTE:
D On gearbox oil seals with less than 2
hours of operation, some seepage or wet
ting of adjacent surfaces is normal until
seal is wetted and worn-in (seated). If
seepage continues at rate of one drop per
minute or less, seal may be continued in
service. Check transmission oil level and
observe seepage rate after every 2 hours
of operation. Shorter inspection periods
may be required if seal leakage appears to
be increasing.
D If excessive gearbox oil seepage occurs,
check breather filler for proper installa
tion and operation (Ref. Component Over
haul Manual for cleaning procedures).
B. Engine Oil Leaks
Maintenance Manual (Ref. Table 201, Sec.
CSP-HMI-2
01-00-00) for definition of permissible engine

oil leakage.
C. Landing Gear Damper Hydraulic Fluid
Leak
Hydraulic fluid leakage from any of landing
gear dampers is not permissible. If leakage is
present, damper assembly should be over
hauled (Ref. Component Overhaul Manual) as
required and a serviceable unit installed. If
leaking landing gear damper is not replaced
when leakage is noticed, continuation of
damper in service can result in unequal and/or
unacceptable dampening and/or ground
resonance.
NOTE: It is normal for a thin hydraulic oil film

to remain on damper piston as a result of
wiping contact with piston seal. Newly in
stalled dampers may also have slight oil
seepage from oil trapped in end cap threads
during damper assembly. Neither of these
should be considered damper leakage or
cause for damper replacement.
D. OneWay Lock Hydraulic Fluid Leak
Hydraulic fluid leakage from any part of
one-way lock is not permissible. When leakage
is observed, assembly should be overhauled
(Ref. Component Overhaul Manual) as
required and a serviceable unit installed. If
leaking one-way lock is not replaced when
leakage occurs, continuation in service may
result in mechanical malfunction that could be
hazardous to flight safety.
12-00-00
Page 311
Revision 32
MAINTENANCE MANUAL
CSP-HMI-2
(NOTE 2)
(NOTE 5)
(NOTE 3)
(NOTE 4)
(NOTE 3)
(NOTE 1)
SYMBOL
SPECIFICATION
300 HOURS
NOTES:
1. T/R SWASHPLATE DUPLEX BEARINGS
2. M/R SWASHPLATE BEARING
3. M/R HUB TAPERED BEARINGS
4. OVERRUNNING CLUTCH ASSEMBLY UPPER BEARINGS
5. YSAS ACTUATOR
1200 HOURS
2770 HOURS OR 2 YEARS
HAND PACK
G120003A
SPECIAL TOOL RECOMMENDED
Figure 304. Lubrication Chart

Page 312
Revision 23
12-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Chapter
18
Vibration and Noise
Analysis
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
C. Tracking Tip Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
D. Main Rotor System Balancing Equipment Installation . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401. Blade Tracking Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Main Rotor Balancing Equipment Installation . . . . . . . . . . . . . . . . . . 404
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Blade Tracking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Figure 501. Typical Track Conditions and Adjustments . . . . . . . . . . . . . . . . . . . . . 501
A. Blade Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
B. Pitch Control Link Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
C. Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
D. Main Rotor Ground Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
E. Hover Track Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Figure 502. Main Rotor Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
F. Forward Flight Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
2. Main Rotor Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
3.
4.
Main Rotor System Balance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505

Main Rotor Autorotation RPM Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
5.
Main Rotor Hub Balancing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 501. Summary Procedure for Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . .
Table 502. Autorotation Rpm Chart (369D/E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 503. Autorotation Rpm Chart (369FF/500N) . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 503. Main Rotor Hub Balancing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 504. Main Rotor Hub Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
506
507
508
508
509
510
18-10-60 Main Rotor Track and Balance (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1.
Main Rotor Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
18 Contents
Page i
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 501. Summary Procedure for Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . .
Table 502. Autorotation Percentage Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 503. Main Rotor System Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 504. Main Rotor Track at Hover (Pitch Change Link Adjustment) . . . . .
Figure 505. Main Rotor System Balance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 506. Main Rotor Tracking at 100 - 130 KIAS
(Inner Tab Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Mid Tab Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Outer Tab Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
505
506
506
507
508
509
510
511
512
18-20-00 Tail Rotor Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1.
Tail Rotor Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Page ii
Revision 23
18 Contents
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 201. Tail Rotor Assembly Balancing (Two-Bladed Tail Rotor) . . . . . . . . .
Table 201. Tail Rotor Balance Weight - Value Chart . . . . . . . . . . . . . . . . . . . . . . . .
Figure 202. Short Method Tail Rotor Balancing (Four-Bladed Tail Rotor) . . . . .
Figure 203. Long Method Tail Rotor Balancing (Inboard Blade) . . . . . . . . . . . . . .
Figure 204. Long Method Tail Rotor Balancing (Outboard Blade) . . . . . . . . . . . .
203
204
205
205
206
206
18-20-30 NOTARr Anti-Torque System Fan Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1.
Fan Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.
Fan Balance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 201. Preferred Hardware for Balancing Fan Assembly . . . . . . . . . . . . . . . .
Figure 201. Fan Balancing Stud Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 202. Fan Balance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 203. Fan Balancing Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . .
18 Contents
201
202
203
204
205
Page iii
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page iv
Revision 43
18 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
181000
Main Rotor Track
and Balance
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR TRACK AND BALANCE

1. Main Rotor Blade Tracking
Main rotor blade track is observed by means of
reflective tip caps temporarily installed on
each blade and a high-intensity strobe light.
Blade track is determined by observing the
apparent tip cap pattern created by strobe
light pulses synchronized with the rotating
blades. Strobe light electrical power is supplied
by the helicopter electrical system.
Immediately investigate the
WARNING cause of a sudden onset of

excessive or unusual main rotor vibra
tion prior to continued flight. Under no
circumstance should main rotor track
ing be attempted to correct the prob
lem until a thorough inspection of the
main rotor blades, hub assembly and
strap pack assembly has been per
formed.
When working near engine air
inlet, comply with all precau
tions to prevent entry of foreign material.
Carefully observe precautions in the Track
ing and Balancing Manual relating to the
placement and security of equipment (espe
cially cables) fastened to the exterior of the
helicopter.
CAUTION
NOTE: Refer to Table 201 to isolate ground or

in-flight blade tracking problems.
(1). Tracking must be accomplished in the
following sequence of six steps:
(a). Verification of proper blade phasing
(Ref. Main Rotor Blade Phasing
Check and/or Adjustment, Sec.
62-20-00).
(b). Ground tracking (Ref. Main Rotor
Ground Tracking).
(c). Verification of proper rotor balance
(Ref. Main Rotor System Balance
Procedure).
(d). Hover verification (Ref. Hover Track
Verification).
(e). Forward flight tracking (Ref. For

ward Flight Tracking).
(f). Autorotation rpm adjustment (Ref.
Main Rotor Autorotation RPM
Check).
(2). No attempt should be made to verify or
adjust blade track without first check
ing and adjusting blade phasing, a
function of main rotor damper adjust
ment (Ref. Sec. 62-20-00).
Understand the blade tracking
sequence and related adjust
ments before attempting blade track proce
dures.
CAUTION
If main rotor hub balance is suspect, balance ro

tor hub prior to performing blade track.
A. Main Rotor Hub Balancing

Main rotor hub balancing is accomplished by
adding or removing weight (flat washers) as
required at the lead-lag bolts (Ref. Main Rotor
Hub Balancing Procedure). Analysis of main
rotor hub balance is accomplished using
instrumentation that measures and localizes
vibrations due to main rotor hub imbalance.
Data provided by the instrumentation is
plotted on a chart designed to indicate how
much weight must be added or removed from
the lead-lag bolt. No other means of balancing
is to be used.
B. Main Rotor System Balancing
Main rotor system balancing is accomplished
by adjusting the turnbuckle on the elastomeric
damper. Analysis of main rotor system balance
is accomplished using instrumentation that
measures and localizes vibrations due to main
rotor imbalance (Ref. Main Rotor System
Balance Procedure). Data provided by the
instrumentation is plotted on a chart designed
to indicate how much rotor blade shall be
shifted in leading or lagging direction by
adjusting turnbuckle. No other means of
balancing is to be used. Never add weight to,
subtract weight from or redistribute weight on
the main rotor blades. Do not attempt the
blade balancing procedure without first
tracking the blades (Ref. Blade Tracking
Procedure).
18-10-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
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.
Excessive diving or climbing of

blade from low speed ground track
to high speed ground track.
Excessive torque and erratic high

speed ground tracking.
Turning turnbuckle wrong direction. Adjust correctly.

Pitch link bearing worn. Trim tab
bent excessively.
Replace bearing. Zero trim tabs.
Trim tab bent excessively.
Zero trim tabs.
Pitch link control not coordinated

with trim tab bend (Intermixing
control input).
Set pitch link to 6.25 in. (15.875 cm)

nominal and zero trim tabs.
Damage to blade or tabs.
Inspect for damage.
Pitch change links too long.
Set to nominal 6.25 in. (15.875 cm).
Worn pitch bearing housing

bearings.
Replace bearings.
Missing pitch bearing liner.
Replace bearing.
Broken or loose feathering studs.
Repair or replace studs.
Binding rotating scissor crank at

lower main rotor hub shoe.
Repair or replace crank.
Play between longitudinal pitch

mixer bellcrank and collective pitch
mixer bellcrank.
Rebond collective pitch mixer

bearings and install shims between
longitudinal pitch mixer bellcrank and
collective pitch mixer bellcrank
bearings (Ref. Sec. 623000).
Tilted tracking images, no blade in

track.
Retrack blades.

with trim tab bend (intermixing
control input), with climbing or
diving blades within acceptable
track limits.
Set pitch link to nominal 6.25 in.

(15.875 cm) and zero trim tabs.
INFLIGHT TRACKING
Blade track changes with power
and control changes.
Helicopter has rough feeling with

some vibration while appearing to
be in track.
Page 202
Revision 31
18-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Isolating Tracking Problems (Cont.)

Symptom
Blades very erratic in response to
tab bends.
Probable Cause
Tab bent too much in wrong area.
Corrective Action
Correct by limiting bending.
Blade erosion, but within chordwise Track erratic blade to other blades.
limits.
Tab bent too many degrees in one
area.
Limit tab bending to smaller degree

over larger area.
Blades climb or dive excessively at

high speeds.
Too much tab bending in outboard

tab areas.
Remove outboard bending and

increase inboard bending.
Ground track off at low speed and

stick shake at 103% N2.
Excessive tab bending and pitch

Zero trim tabs and set pitch links to
link control not coordinated with tab nominal 6.25 in. (15.875 cm)
bend (intermixing control input).
Helicopter in track but has stick

shake.
Blade out of phase.
Check phasing.
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

cruise.
Overcenter adjustment set too low.
Adjust.
Trim tab bent down excessively.
Adjust.
Light collective stick climb and

cruise.
Overcenter adjustment set too

high.
Adjust.
Trim tabs bent up excessively.
Adjust.
Bungee spring adjusted too short.
Adjust to nominal.
Heavy collective lift-off light flight.
Light collective lift-off heavy flight. Bungee spring adjusted too long.
Adjust to nominal.
18-10-00
Page 203
Revision 37
CSP-HMI-2
MAINTENANCE MANUAL
Page 204
Revision 37
18-10-00
MAINTENANCE MANUAL
CSP-HMI-2

REMOVAL/INSTALLATION
1. Main Rotor System Tracking Equipment
Installation
A. Interrupter Installation
(Ref. Figure 401)
(Ref. Figure 401 and Figure 402) Equipment

needed to track main rotor blades consists of
the main rotor tracking and tail rotor vibration
analyzer equipment, tracking and balancing
equipment and the tip cap assembly. Instruc
tions for equipment installation are contained
in Chadwick-Helmuth Operation and Service
Instruction Handbook.
inlet, comply with precautions
to prevent entry of foreign material. During
main rotor balancing the helicopter will be
airborne. Carefully observe precautions in
the Tracking and Balancing Manual relat
ing to the placement and security of equip
ment (especially cables) fastened to the ex
terior of the helicopter.
CAUTION
NOTE: Main rotor tracking tip caps manufac

tured by the same firm that manufactures
the tracking and balance equipment, are
components of the tracking and balancing
equipment and may be used instead of tip
cap assembly. In procedures that follow, use
of tip cap assembly is presumed. If tip caps
from the balancing equipment are used, re
fer to the Tracking and Balancing Manual
for tip cap data.
Item
Special Tools
Nomenclature
ST901
Tip cap assembly
ST903
Balancer/analyzer instrument kit
Item
Nomenclature
CM116
Grease, aircraft and instrument
(1). The helicopter is equipped with five

main rotor blade tracking interrupters
located immediately inboard of each
pitch control link attach clevis on the
rotating swashplate.
(2). The interrupter installation incorpo
rates a double interrupter which may
be used for both tracking and balanc
ing.
(3). Each interrupter insert is attached to
the interrupter body at a different
position (left, center, or right). The
interrupters create five equally spaced
horizontal reflective images, as viewed
by the technician, when the main rotor
blade tips are illuminated with the test
strobe light.
(4). Interrupter blade spacing separates the
image of each main rotor blade tip cap
by approximately 0.25 inch (6.35 mm).
This staggered relationship allows the
technician to view the stopped image of
each blade in order of rotation.
(5). The number one blade is seen on the
extreme left, number two blade is seen
second from left, and so on through
number five which is seen on the
extreme right.
(6). On current configuration helicopters,
the pulse of the double interrupter is so
short that it appears as a single pulse
to the strobe light amplifier. The second
pulse created by the double interrupter
is used during main rotor balancing.
(7). If counterweights are installed, coat the
two interrupter bolts passing through
the swashplate counterweights with
grease (CM116) before installation.
Torque nuts to 30 - 60 inch-pounds
(3.39 - 6.78 Nm).
18-10-00
Page 401
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
(8). Torque the three remaining interrupter

nuts to 15 - 20 inch-pounds (1.69 2.26 Nm).
B. Magnetic Pickup Installation
C. Tracking Tip Cap Installation
(Ref. Figure 401)

(1). The helicopter is originally equipped
with a magnetic pickup support bracket
installed with shim washers to prevent
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).
(2). To preclude rocking movement of
magnetic pickup support bracket when
installed on stationary swashplate,
check clearance between swashplate
and lower flange of bracket. If gap
exists, tap bent tip of lower flange
(typical both sides of bracket) until bent
tip touches swashplate.
(3). Reinstall by forcing bracket until
elongated bracket holes align with hole
in stationary swashplate.
(4). Install the magnetic pickup and cable
as instructed in the Chadwick-Hel
muth Operation and Service Instruc
tion Handbook.
(5). After final adjustment, torque the
adjustment nut to 15 - 20 inchpounds (1.69 - 2.26 Nm) and ensure
the cable is routed and tied down in
such a manner as not to be dislodged or
interfere with control components at
their extremes of travel.
Page 402
Revision 44
(6). Ensure the interrupter passing closest

over either early or current configura
tion magnetic pickup, clears pickup by
not less than 0.030 inch (0.762 mm).
18-10-00
(Ref. Figure 401)

with five tip caps that must be removed
and replaced with five tracking tip caps
(ST901).
(2). When blade tracking has been accom
plished or verified, the tracking tip caps
must be removed and original tip caps
installed.
(3). Torque the screw that secures the tip
cap to 15 - 20 inch-pounds (1.69 2.26 Nm).
NOTE: When installing tip cap targets, posi

tion double interrupter over magnetic pick
up. The blade positioned forward is number
5. By rotating rotor head in operating direc
tion, the next blade pointing forward will be
4, then 3, 2 and 1.
D. Main Rotor System Balancing Equipment
Installation
(Ref. Figure 401 and Figure 402) and Chad
wick-Helmuth Operation and Service Instruc
tion Handbook to install that portion of the
balancing equipment (ST903) needed to
balance the main rotor.
MAINTENANCE MANUAL
CSP-HMI-2
1
PLACE DOUBLE INTERRUPTER
OVER MAGNETIC PICKUP AND
THEN ATTACH TIP TARGET
NUMBERS EXACTLY AS SHOWN
ROTATION
2
TAPE
3
4
TRACKING TARGET
(NOTE 1)
TIP CAP
INTERRUPTER
(NOTE 4)
(NOTE 5)
TRACKING TIP CAP INSTALLATION
SUPPORT
BRACKET
NOTE 2
DOUBLE
ROTATION OF INTERRUPTER
(NOTE 4)
HUB
(NOTE 6)
SCISSORS
LINK
ADJUSTMENT
JAMNUT
ROTATING
SWASHPLATE
TEST EQUIPMENT
CABLE RECEPTACLE
PICKUP INSTALLATION (ROTATED)
PROTECTIVE CAP
SPACER
INTERRUPTER
(NOTE 4)
(NOTE 5)
INTERRUPTER
(NOTE 3)
STATIONARY
SWASHPLATE
0.030-0.070 IN.
(0.762-1.778 MM)
GAP TYP.
INTERRUPTER-TO-MAGNETIC PICKUP GAP

MAGNETIC PICKUP
INTERRUPTER
(NOTE 4)
(NOTE 6)
INTERRUPTER
(NOTE 4)
(NOTE 6)
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 CSP-IPC-4 FOR
PART NO.
5. TORQUE NUT TO 30-60 IN-LBS.
G18-1000C
Figure 401. Blade Tracking Equipment
18-10-00
Page 403
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
TAPE CABLE TO RIGHT HAND INBOARD

SIDE OF INLET HOUSING AND ROUTE
FORWARD ALONG FUSELAGE AS
SHOWN. CABLE MUST CLEAR AL
EXTREME MOVEMENTS OF CONTROLS.
VELOMETER/ACCELEROMETER
LOCATION FOR MAIN ROTOR
BALANCING
MAGNETIC PICKUP CABLE AND

CABLE MAY BE ROUTED
THROUGH VENT DOOR
KIT LOCATION
FOR MAIN ROTOR
BALANCING
INTERRUPTER
(TYP)
TORQUE NUT AFTER

SECURING GAP AND
SAFETY WIRE
ENGINE AIR INLET

FAIRING (LEFT
HAND SIDE)
0.030-0.070 IN.
(0.762-1.778 MM)
GAP (TYP)
MAGNETIC PICKUP
VIEW LOOKING DOWN
MAGNETIC PICKUP INSTALLATION

TAPE
BALANCING
VIEW LOOKING INBOARD
ACCELEROMETER INSTALLATION
G18-2005
Figure 402. Main Rotor Balancing Equipment Installation

Page 404
Revision 23
18-10-00
MAINTENANCE MANUAL
CSP-HMI-2

ADJUSTMENT/TEST
1. Blade Tracking Procedure
TIP PATH
PLANE
Table 501 is a summary of the sequence of

required procedures for blade tracking.
(1). Install strobe light, blade tip cap
reflectors and related equipment.
(2). Use 1/2 inch (12.7 mm) diameter
tracking tip cap reflector as a guide for
estimating track accuracy. For example:
(a). A tip cap reflector image displace
ment of 1/2 diameter up, or down,
indicates blade tip is approximately
1/4 inch (6.35 mm) out of track.
(b). One full reflector diameter indicates
IMAGE A:
IN TRACK
(3). Accomplish blade phasing (Ref. Sec.

62-20-00) when installing new rotor
blades or if ground rock or stick shake
is noted. This must be accomplished
prior to starting tracking procedure.
NOTE: Final rotor system balance cannot be

accomplished until blades are in track.
(4). Ground tracking is basically track-ob
servation and adjustment of idle and
flight rpm. Improper track at idle rpm
is corrected by adjusting length of pitch
control links connecting rotating
swashplate and blade pitch housing.
Ground track at flat pitch and flight
rpm is corrected by blade tab adjust
ment.
(5). Hover track verification is essentially
an observation to check for track
variations between high rpm (flat pitch)
ground track check and hovering.
NOTE: Track adjustments are not made on ba

sis of track observations during hovering.
However, track variations should be noted
and recorded for use during check of track in
forward flight.
2
1
IMAGE B:
MM) HIGH
ONE BLADE APPROX. 1/2 IN. (12.7
2
1
IMAGE C:
MM) HIGH
ONE BLADE APPROX. 1/2 IN. (12.7

ONE BLADE APPROX. 1 IN. (25.4
G18-1001A
CORRECTIVE ACTION
NOTE: Rocking or stick shake caused by a cor

rectly tracking rotor indicates improper
blade phasing.
ALL BLADES
CONDITION
GROUND IDLE RPM
HIGH RPM AND

FWD FLIGHT
IMAGE A
NONE REQUIRED
NONE REQUIRED
IMAGE B
SHORTEN PITCH CONTROL

ROD (2ND BLADE)
MOVE TAB DOWNWARD

(2ND BLADE) MOVE TAB
UPWARD (3RD BLADE)
IMAGE C

ROD (2ND BLADE):
LENGTHEN CONTROL ROD
(3RD BLADE)
MOVE TAB DOWNWARD

(2ND BLADE): MOVE TAB
UPWARD (3RD BLADE)
NOTE: Chordwise spacing of tracking images

are not an accurate indication of blade
phasing. Do not adjust blade phasing in an
attempt to equalize spacing. Slight tilting of
magnetic interrupters or balance of the main
rotor system can move the image
Figure 501. Typical Track Conditions and

Adjustments
(6). Forward flight track is corrected only
by making blade tab adjustments.
Forward flight tracking requires track
observation during following airspeeds
and maneuvers: Flight at 0-100 knots.
Forty-five degree banked turns at
80-100 knots. Flight at 100-155 knots.
(7). Check for proper balance of rotor
system prior to checking autorotation.
(8). Obtaining correct autorotation rpm
consists of checking main rotor rpm
18-10-00
Page 501
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
during stabilized autorotation flight

and adjusting rpm to specified limits as
necessary. Autorotation rpm check
must be accomplished to ensure that
track adjustments do not alter rotor
performance necessary for safe poweroff landings.
A. Blade Track Adjustment
Although adjustment of pitch control links
affects blade track at all rotor speeds, they
should be adjusted only when necessary to
establish acceptable track at ground idle
speed; blade tabs are used for all other track
corrections.
NOTE: Blade tab and/or track can make the

collective heavy or light.
B. Pitch Control Link Adjustment
Repeat this adjustment procedure as necessary
to establish ground idle track:
(1). To lower a blade tip, shorten pitch
control link assembly. To raise a blade
tip, lengthen pitch control link assem
bly. One-sixth of a turn of link (one flat)
raises or lowers blade tip approximately
1/4 inch (6.35 mm).
Center each rod end or (fitting
CAUTION wear) results. Make sure there
is no binding in full up travel position.
(2). After adjusting pitch control link
length, center each rod end in its fitting
and hold while tightening jam nuts;
safety with lockwire.
C. Blade Tab Adjustment
(Ref. Figure 502) Once ground idle track is
obtained, all remaining tracking correction is
accomplished by very slight bending of various
blade tab zones with tab bending tool (ST902).
Different zones of tabs are used to adjust blade
track at different airspeeds. In general, tab
zone A is used for high rpm, flat pitch ground
tracking (369D/E - 103% N2, 369FF/500N 100% N2) and zones C, D, and sometimes E,
are used for tracking at higher airspeeds. Zone
B is used to supplement zone A track correc
tion when maximum tab (5 degrees) has been
applied to zone A; if necessary, zone B may
also be used for correction in 0-110 knot
airspeed range.
Page 502
Revision 34
18-10-00
Item
ST902
Special Tools
Nomenclature
Main rotor blade fixture and tab bending
tool
Minimize bending and restrict

adjustments to very small incre
ments so that bonded trailing edge joint be
tween upper and lower skins is not dam
aged. Tabs must never be displaced more
than five degrees above or below neutral po
sition (parallel to chordline).
CAUTION
(1). To lower blade tip that tends to climb

during ground tracking at high rpm or
during forward flight, bend appropriate
tab section slightly downward; to raise
tip of blade that tends to descend, bend
tab slightly upward. If only slight track
correction is necessary, limit tab
bending to width of bending tool. If
more correction is necessary, bend a
slightly wider section of tab. Use small
adjustments to avoid excessive rebend
ing of tabs.
NOTE: Tab zones on same blade can require

bending in opposite directions. For example,
after bending tab zone A downward to get
good tracking at 60-90 knots, it might be
come necessary to bend tab zone D or E up
ward to correct track at redline airspeed. In
any case, do not use larger tab corrections
than are actually necessary.
(2). Each time blade tabs are adjusted,
recheck ground idle track and readjust
if necessary.
(3). After completion of forward flight
tracking, balance and check autorota
tion rpm.
D. Main Rotor Ground Tracking
(Ref. Figure 502) For best results, tracking
should be performed under calm air conditions.
Wind velocity should not exceed six knots
during adjustments. Accurate adjustment of
initial ground track is very important. In most
instances, forward flight tracking problems
can be avoided or greatly reduced by setting
initial track as nearly perfect as possible.
Tolerances specified in following instructions
MAINTENANCE MANUAL
should be considered maximum permissible
deviation rather than desired goal.
NOTE: If main rotor hub or a pitch control rod

end bearing has been replaced, adjust pitch
control link(s) before proceeding with
ground tracking.
(1). Before tracking blades that are not new,
check that normally straight (not to be
used) tab areas are in neutral position
(centered on chordline) and straight.
NOTE: On new (untracked) blades, check that

all tab areas are straight and in neutral po
sition (centered on chordline 0 0.5).
(2). Load helicopter to a gross weight of
approximately 2350 pounds (1066 kg);
then ground idle (approximately
64-65% N1).
CSP-HMI-2
blade tab zone A until high rpm ground

track is within tolerance.
E. Hover Track Verification
(Ref. Figure 502)
(1). Hover track verification must be
performed after ground tracking and
before forward flight tracking. Verifica
tion is only a check of hover track. Do
not adjust pitch control links or blade
tabs because of track images observed
during hovering. Tab adjustments often
cause variation between ground track
and hovering track. A large track
variation may indicate that one or more
blades is beyond its chordwise balance
tolerance, but this can only be deter
mined during forward flight tracking.
Perform hover track verification as
follows.
NOTE: Collective pitch stick may be heavy af

(3). Observe tracking tip cap reflector image
by directing strobe light beam toward
blade tip path and sweeping beam
slowly back and forth until reflector
images are clearly seen. Tracking image
should appear directly in front of
helicopter or slightly off helicopter
centerline.
(4). If blades are in track, tip cap reflector
image pattern should resemble image A
(Ref. Figure 501), (no blade tip more
than 1/4 of one tracking reflector
diameter, 1/8 inch (3.175 mm) above or
below adjacent reflectors). If blades are
in track, proceed with (5). below. If
blades are out of track, adjust pitch
control links and repeat step (3). above.
(5). With collective pitch stick full down,
increase engine speed to 103% N2 369D/E, 100% N2 - 369FF/500N and
observe tip cap reflector image to see if
blade track is changed from ground idle
track. When all five blades are in track
within 1/4 of one reflector diameter, 1/8
inch (3.175 mm), ground track is
correct; proceed with hover verification.
When a blade is out of track, adjust
ter tracking reflectors are mounted on blade

tips. This condition is not unusual and may
be disregarded.
(2). Verify helicopter gross weight of
2000-2500 pounds (908-1135 kg).
increase N2 to 103% - 369D/E, 100% 369FF/500N.
(4). Observe tracking reflector images to
verify that ground track is within
limits.
(5). With helicopter in a stable hover,
observe reflector images. If one or more
blades are out of track, record condi
tion(s) for reference during forward
flight tracking.
(6). Proceed with forward flight tracking.
Use of the tracking strobe
WARNING light in night flight is not
recommended. Such use can result in

pilot disorientation or loss of vision
with resultant damage to the helicop
ter and personal injury.
18-10-00
Page 503
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR BLADE

(TOP VIEW)
BLADE STATIONS
93
99
105
65 IN.
(165 CM)
59 IN.
(150 CM)
369D/E
TAB ZONES
NOT USED
(NOTE 1)
11
1
11
7
53 IN.
(135 CM)
124
47 IN.
(119 CM)
130
41 IN.
(104 CM)
142
34 IN.
(86 CM) 28 IN.
(71 CM)
D
C
B
HIGH RPM GROUND
TRACKING AND UP TO
110 KNOTS IN FLIGHT
MEDIUM SPEED
FLIGHT TRACKING
130-145 KNOTS
(103 % N2)
110-130 KNOTS
HIGH SPEED
IN FLIGHT
FLIGHT TRACKING
(103 % N2)
130-145 KNOTS
(103 % N2)
BLADE STATIONS
93
99
105
71 IN.
(180 CM)
369FF/500N
TAB ZONES
NOT USED
(NOTE 1)
11
1
11
7
65 IN.
(165 CM) 59 IN.
(150 CM)
124
53 IN.
(135 CM)
130
47 IN.
(119 CM)
TO END OF
BLADE NOT USED
(NOTE 1)
148
40 IN.
(102 CM 34 IN.
(86 CM)
164
16 IN.
(41 CM)
A
C
NOTE 2
HIGH RPM GROUND

MEDIUM SPEED
TRACKING AND UP TO
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)
SHOCK CORD
(OR EQUIVALENT)
16 IN.
(41 CM)
NOTE 2
MAIN ROTOR BLADE

(TOP VIEW)
158
TO END OF
BLADE NOT USED
(NOTE 1)
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
IN ZONE D.
POINTER
TAB BENDING TOOLS
BENDER
G18-1002C
Figure 502. Main Rotor Blade Tab Adjustment

Page 504
Revision 23
18-10-00
MAINTENANCE MANUAL
F. Forward Flight Tracking
(Ref. Figure 502) Forward flight tracking
should be performed whenever vertical flight
vibrations indicate that blades may be out of
track.
2000-2500 pounds (907-1134 kg).
(2). Perform flight tracking from hover up
to 110 knots at 103% N2 - 369D/E,
100% N2 - 369FF/500N. If flight track
varies from hover track more than 1/2
inch (12.7 mm), bend tab zone A (five
degrees maximum) to limit variation to
tab zone B (five degrees maximum).
2. Main Rotor Blade Tab Adjustment
(1). Check autorotation rpm; rpm must not
be less than 480.
Do not attempt to adjust chord
CAUTION wise balance of a blade found to
be faulty when performing banked turns.
Chordwise balance corrections must be ac
complished by manufacturer (MDHI).
(2). Perform a series of 45 degree banked
turns at 100 knots and observe track
change from level flight. If any blade
climbs or dives more than one inch out
of track with others, chordwise balance
(center of gravity) of that blade is
beyond its tolerance and blade must be
replaced. (Hover track variations of this
type that do not repeat during bankedturn maneuver may be disregarded.)
(3). Perform flight tracking at 110-155
knots and 103% N2 - 369D/E, 100% N2
- 369FF/500N. If necessary, adjust tab
zone B (five degrees maximum) to limit
track variation to 1/2 inch (12.7 mm) or
less and to minimize excessive vertical
(one-per revolution) vibration. If
variation is excessive, bend tab zone C
or D (five degrees maximum).
CSP-HMI-2
NOTE: When determining whether blade track

is acceptable, overall vibration level of heli
copter should be determining factor. Some
combinations of rotor blades might produce
higher five-per-revolution vibration as
blade tips are brought into close track; in
such cases, lowest vibration level is pre
ferred, even though observed blade track
may be beyond specified tolerances.
(4). After flight tracking is completed,
perform a Main Rotor System Balance
Procedure and Main Rotor Autorotation
RPM Check.
3. Main Rotor System Balance Procedure
Balance the main rotor system according to
instructions in the Tracking and Balancing
Manual. Since vibration reduction is accom
plished by slight adjustment in phasing, the
instruction outline in the Tracking and
Balancing Manual must be closely followed for
best results. Safety damper turnbuckle after
completing phasing balance adjustments.
4. Main Rotor Autorotation RPM Check
(Ref. Table 502 for 369D/E and Table 503
369FF and 500N). An autorotation rpm check
is required after each blade tracking operation
and whenever rpm is outside limits listed.
Check rotor rpm and make adjustments as
follows.
CAUTION
D All autorotation rpm adjustments shall
be made at the main rotor pitch control
links only. Do not re-adjust mixer control
rods after rigging is accomplished. Fail
ure to observe this precaution may result
in serious damage to rotor system and
controls. Do not adjust control rod end be
yond witness hole.
D Tracking targets reduce blade to tailboom
clearance, performing autorotations to
the ground could result in boom strikes.
NOTE: Change length of all five pitch control

links as necessary to adjust autorotation
rpm. Be sure to lengthen or shorten all five
links exactly same amount or blade track is
changed. One flat (1/6 turn) of control link
body causes approximately four rpm change
in autorotation rpm.
18-10-00
Page 505
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
(1). Autorotation Rpm Check: Load 369D/E

helicopter to a gross weight of 2250
pounds (1021 kg): 2350 pounds (1066
kg) for 369FF and 500N. Perform a
practice autorotative descent (Ref.
PFM), taking care not to allow rpm to
exceed rotor speed limitations. During
autorotation take careful note of
stabilized autorotation rpm at one of
gross weight/density altitude combina
tions. After landing, compare observed
rpm with values (Ref. Tables 502 and
503). If observed rpm is within limits in
table, rpm setting is correct. If limits
were exceeded, make corrective adjust
ments according to (2). below, until rpm
is within limits.
NOTE: After autorotation rpm adjustments are

satisfactorily accomplished, remove track
ing equipment before returning helicopter
to service. Be sure to correctly tighten and
safety all bolts after they are reinstalled.
(2). Autorotation Rpm Adjustment: Change
length of all five pitch control links as
required to adjust autorotation rpm.
Make certain all five links are short
ened or lengthened exactly the same
amount or blade track will be altered.
CAUTION
D Do not readjust mixer control rods after

rigging has once been accomplished. Fail
ure to observe this precaution can result
in serious damage to rotor system and
controls.
5. Main Rotor Hub Balancing Procedure

Balance the main rotor hub according to the
following instructions.
Revision 24
Item
ST903
Special Tools
Nomenclature
NOTE:
D If swashplate has weights removed, there
should be three AN970-3 washers at the
green pitch housing bolt.
D In some instances, main rotor hub bal
ance may not be achieved without addi
tion of swashplate weights (Ref. Sec.
62-30-00,
Counterweight
and
Interrupter Installation)
(1). Remove main rotor blades.
(2). Remove main rotor dampers.
(3). Hook up Phazor. Refer to ChadwickHelmuth Operation and Service
Instruction Handbook (ST903).
(4). Run engine at 103% N2 - 369D/E, 100
N2 - 369FF/500N.
(5). Record IPS reading and direction on
main rotor balance chart (Ref.
Figure 503).
(6). Plot IPS reading and direction on main
rotor balance chart (Ref. Figure 503).
D Do not adjust (lengthen) pitch control link

rodend threads beyond witness holes in
rods.
Page 506
Item
CM420
Nomenclature
Sealant
18-10-00
(7). Analyze chart for weight location and

amount requirements.
The maximum allowable bal
ance weight per lead-lag bolt on
the main rotor hub assembly is 150 grams.
CAUTION
(8). Install weights as follows: (Ref.

Figure 504).
(a). Engage head of screw, inside lead-lag
bolt, with Phillips screwdriver, then
loosen locknut with 1/4 inch wrench.
(b). Hold screw in place with screwdriver
while adding or removing flat wash
ers as required, then reinstall
locknut.
MAINTENANCE MANUAL
(9). Repeat steps (4). thru (8). until reading
is 0.15 IPS, or less.
(10). After balance has been established
satisfactorily, torque MS21042L08
locknuts to 20 - 35 inch-pounds (2.26
- 3.95 Nm) or MS21042L3 locknuts to
30 - 60 inch-pounds (3.39 - 6.78 Nm)
as applicable. Coat screw threads, nuts
and washers with sealant (CM420). (To
prevent imbalance, do not use excessive
amount of sealant.)
NOTE: Intermixing of P/N 369D21400-503 and
M50452 main rotor blade damper assem
blies in a shipset is not permitted. All damp
ers in shipset must be of same type and part
number.
CSP-HMI-2
(11). Reinstall main rotor blades (Ref. Sec.

62-10-00).
NOTE: If main rotor dampers require more

than four flats adjustment, re-phase main
rotor dampers (Ref. 62-20-00, Main Rotor
Damper Phasing Procedure).
(12). Perform main rotor system balance.
(13). Track main rotor blades (Ref. Blade
Tracking Procedure).
Table 501. Summary Procedure for Blade Tracking

Satisfactory
Result
Unsatisfactory
Result
(1) Observe ground track.
Go to step (2).
Ref. Corrective
Action.
Adjust pitch control links and blade

tabs as required. Repeat track
observation.
(2) Perform hover verification.
Go to step (3).
Ref. Corrective
Action.
Record track verification and proceed

with forward flight tracking.
(3) Perform forward flight tracking.
Go to step (4).
Ref. Corrective
Action.
Adjust blade tabs and repeat forward

flight tracking.
(4) Perform autorotation rpm

check.
Go to step (5).
Ref. Corrective
Action.
Adjust autorotation rpm and repeat

rpm check.
Step
Corrective Action
(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.
18-10-00
Page 507
Revision 24
MAINTENANCE MANUAL
CSP-HMI-2
Table 502. Autorotation Rpm Chart (369D/E)

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

Stabilized Autorotation Rpm at Density Chart
Gross Wt
lb/kg
Sea Level
1000 Ft
2000 Ft
3000 Ft
4000 Ft
5000 Ft
2216/1005
459-469
465-475
471-481
477-487
483-493
489-499
2316/1051
466-476
472-482
478-488
484-494
490-500
496-506
2416/1096
473-483
479-489
485-495
491-501
497-507
---
2516/1189
480-490
486-496
492-502
498-508
---
---
NOTES:
(1) Chart values based upon 15C (59F) outside air temperature. At sea level, 8C (14F) temperature
change is equal to 1000 feet (305 M) of change in density altitude.
(2) Perform autorotation rpm checks at gross weight/density altitude combinations for which rpm values are
given. Blank spaces indicate that application of collective pitch may be necessary to avoid rotor
overspeed.
Page 508
Revision 23
18-10-00
MAINTENANCE MANUAL
CSP-HMI-2
60 GRAMS
BLUE
4
GRN
2
40
40
20
YEL
3
12
0
20
40
1
1
60 GRAMS
20
1.0
.9
.8
10
40
.7
.6
.5
YEL
3
2
20
TGT
WHITE
5
.4
40
.3
.2
20
.1 .1 .2 .3 .4 .5 .6 .7 .8
.1
9
0
.9 1.0
60 GRAMS
.2
.3
40
.4
.5
20
RED
1
20
.6
8
BLUE
4
.7
0
.8
.9
40
1.0
60 GRAMS
20
40
RED
1
6
40
20
GRN
2
HELICOPTER S/N
RUN NO.
40
TGT
WHITE
5
HUB S/N
IPS
CLOCK
ANGLE
20
(1) RED
60 GRAMS
G18-1003A
BALANCE WEIGHT AND LOCATION

(2) GREEN (3) YELLOW
(4) BLUE
(5) WHITE
Figure 503. Main Rotor Hub Balancing Chart
18-10-00
Page 509
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
A
MS21042L08 NUT
(NOTE 2)
NOTE 1
369D29935 MAIN ROTOR

HUB BALANCE WEIGHT
SUPPORT WASHER
AN960C8, AN960C8L WASHERS

AS REQUIRED TO BALANCE
(NOTE 5)
369D21220 LEAD-LAG BOLT
369D29934 WASHER
NAS602-64P, -72P OR -76P

SCREW
369A1219 NUT AND
MS24665-300 COTTER PIN
(NOTE 4)
369D21300-501
LINK ASSY PITCH HOUSING
A-A
SERIAL NO. 0260D AND SUBS

MS21042L3 LOCKNUT
(NOTE 3)
NOTE 1
AN960C10, AN960C10L WASHERS

AS REQUIRED TO BALANCE
(NOTE 5)
AN970-3 WASHER
369A1220 LEAD-LAG BOLT
HS1555 WASHER
HS1554 WASHER
369A1219 NUT AND

MS24665-300 COTTER PIN
(NOTE 4)
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
BOLT ON THE MAIN ROTOR HUB ASSEMBLY IS 150 GRAMS.
NAS603-56 OR -64
SCREW
A-A
SERIAL NO. 003D THRU 0259D
Figure 504. Main Rotor Hub Balancing

Page 510
Revision 39
18-10-00
G18-1004B
MAINTENANCE MANUAL
CSP-HMI-2
Section
181060
Main Rotor Track
and Balance (600N)
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR TRACK AND BALANCE (600N)

1. Main Rotor Blade Tracking
Immediately investigate the
WARNING cause of a sudden onset of

excessive or unusual main rotor vibra
tion prior to continued flight. Under no
circumstance should main rotor track
ing be attempted to correct the prob
lem until a thorough inspection of the
main rotor blades, hub assembly and
strap pack assembly has been per
formed.
NOTE: Ref. Table 201 to isolate ground or inflight blade tracking problems.
Main rotor blade track is observed by means of
reflective tip caps temporarily installed on
each blade and a high-intensity strobe light.
Blade track is determined by observing the
apparent tip cap pattern created by strobe
light pulses synchronized with the rotating
blades. Strobe light electrical power is supplied
by the helicopter electrical system.
a. Tracking must be accomplished in the follow
ing sequence of six steps:
1). Verification of proper blade phasing
(Ref. Main Rotor System Balance Procedure).
2). Ground tracking
(Ref. Main Rotor Ground Tracking).
3). Verification of proper rotor balance
(Ref. Main Rotor System Balance Procedure).
4). Hover verification
(Ref. Hover Track Verification).
5). Forward flight tracking
(Ref. Forward Flight Tracking).
6). Autorotation rpm adjustment
(Ref. Main Rotor Autorotation RPM Check).
b. No attempt should be made to verify or adjust
blade track without first checking and adjust
ing blade phasing, a function of main rotor
damper adjustment.
CAUTION
D Understand the blade tracking sequence
and related adjustments before attempt
ing blade track procedures.
D If main rotor hub balance is suspect, bal
ance rotor hub prior to performing blade
track.
2. Main Rotor System Balancing
Main rotor hub balancing is accomplished by
adding or removing weight (flat washers) as
required at the lead-lag bolts (Ref. Main Rotor
Hub Balancing Procedure). Analysis of main
rotor hub balance is accomplished using
instrumentation that measures and localizes
vibrations due to main rotor hub imbalance.
Data provided by the instrumentation is
plotted on a chart designed to indicate how
much weight must be added or removed from
the lead-lag bolt. No other means of balancing
is to be used.
3. Balancing Equipment and Balance Spare
Kit
Item
ST903
Special Tools
Nomenclature
The balancing equipment (ST903) contains all

equipment needed to analyze main rotor
balance.
inlet, comply with all precau
tions to prevent entry of foreign material.
Carefully observe precautions in the Track
ing and Balancing Manual relating to the
placement and security of equipment (espe
cially cables) fastened to the exterior of the
helicopter.
CAUTION
18-10-60
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Isolating Tracking Problems

Symptom
Probable Cause
Corrective Action
GROUND TRACKING
Turning P/C link wrong direction.
Adjust correctly.
Pitch link bearing worn. Trim tab

bent excessively.
Replace bearing. Zero trim tabs.
Trim tab bent excessively.
Zero trim tabs.

with trim tab bend (Intermixing
control input).
Set pitch link to nominal 6.25 inches

Damage to blade or tabs.
Inspect for damage.
Pitch change links too long or

collective rigging too high.
Set to nominal 6.25 inches (15.88

cm). Check collective rigging.
Worn pitch bearing housing

bearings.
Replace bearings.
Missing pitch bearing liner.
Replace bearing.
Broken or loose feathering studs.
Repair or replace studs.
Binding rotating scissor crank at

lower main rotor hub shoe.
Repair or replace crank.
Play between longitudinal pitch

mixer bellcrank and collective pitch
mixer bellcrank.
Rebond collective pitch mixer

bearings (Ref. Sec. 623060).
Helicopter has rough feeling with

some vibration while appearing to
be in track.
Tilted tracking images, no blade in

track.
Retrack blades.

with trim tab bend (intermixing
control input), with climbing or
diving blades within acceptable
track limits.

Blades very erratic in response to

tab bends.
Tab bent too much in wrong area.
Correct by limiting bending.
Rotor does not follow adjustments.
Excessive diving or climbing of

blade from low speed ground track
to high speed ground track.
Excessive torque and erratic high

speed ground tracking.
INFLIGHT TRACKING
Blade track changes with power
and control changes.
Blades climb or dive excessively at

high speeds.
Page 202
Revision 31
Blade erosion, but within chordwise Track erratic blade to other blades.
limits.
Tab bent too many degrees in one
area.
Limit tab bending to smaller degree

over larger area.
Too much tab bending in outboard

tab areas.
Remove outboard bending and

increase inboard bending.
18-10-60
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Isolating Tracking Problems (Cont.)

Symptom
Probable Cause
Corrective Action
Ground track off at low speed and

stick shake at 100% N2.
Excessive tab bending and pitch

link control not coordinated with tab (15.88 cm) and zero trim tabs.
bend (intermixing control input).
Helicopter in track but has stick

shake.
Blade out of phase.
Check phasing.
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

cruise.
Overcenter adjustment set too low.
Adjust.
Trim tab bent down excessively.
Adjust.
Light collective stick climb and

cruise.
Overcenter adjustment set too

high.
Adjust.
Trim tabs bent up excessively.
Adjust.
Bungee spring adjusted too short.
Adjust to nominal.
Heavy collective lift-off light flight.
Light collective lift-off heavy flight. Bungee spring adjusted too long.
Adjust to nominal.
18-10-60
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Revision 31
CSP-HMI-2
MAINTENANCE MANUAL
Page 204
Revision 44
18-10-60
MAINTENANCE MANUAL
CSP-HMI-2

1. Main Rotor System Tracking Equipment
Installation
(Ref. Figure 401 and Figure 402) Equipment
needed to track main rotor blades consists of
the tracking and balancing equipment (ST903)
and the tip cap assemblies (ST901). Instruc
tions for equipment installation are contained
in Chadwick-Helmuth Operation and Service
Instruction Handbook.
Item
Special Tools
Nomenclature
ST901
Tip cap assembly
ST903
NOTE: Main rotor tracking tip caps manufac

tured by the same firm that manufactures
the tracking and balance equipment, are
components of the tracking and balancing
equipment and may be used instead of tip
cap assembly (ST901). In procedures that
follow, use of tip cap assembly is presumed.
If tip caps from the balancing equipment are
used, refer to the Tracking and Balancing
Manual for tip cap data.
A. Interrupter Installation
(1). The helicopter is equipped with a main
rotor blade tracking interrupter located
on the rotating swashplate.
(2). The interrupter creates six equally
spaced horizontal reflective images, as
viewed by the technician, when the
main rotor blade tips are illuminated
with the test strobe light.
(3). The balance analyzer separates the
image of each main rotor blade tip cap
by approximately 0.25 inch (6.35 mm).
This staggered relationship allows the
technician to view the stopped image of
each blade in order of rotation.
(4). The number one blade is seen on the

extreme left, number two blade is seen
second from left, and so on thru number
six which is seen on the extreme right.
(5). Additional interrupters can be added to
be compatible with the older balance/
analyzer instrument kits.
(6). Torque the interrupter as shown in
Figure 401.
B. Magnetic Pickup Installation
with a magnetic pickup support bracket
installed with shim washers to prevent
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).
(2). To preclude rocking movement of
magnetic pickup support bracket when
installed on stationary swashplate,
check clearance between swashplate
and lower flange of bracket. If gap
exists, tap bent tip of lower flange
(typical both sides of bracket) until bent
tip touches swashplate.
(3). Reinstall by forcing bracket until
elongated bracket holes align with hole
(4). Install the magnetic pickup and cable
as instructed in the Chadwick-Hel
muth Operation and Service Instruc
tion Handbook.
(5). After final adjustment, torque the
adjustment nut to 15 - 20 inchpounds (1.69 - 2.26 Nm) and ensure
the cable is routed and tied down in
such a manner as not to be dislodged or
interfere with control components at
their extremes of travel.
(6). Ensure the interrupter passing closest
over magnetic pickup, clears pickup by
not less than 0.030 inch (0.76 mm).
18-10-60
Page 401
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
PLACE DOUBLE INTERRUPTER

OVER MAGNETIC PICKUP AND
THEN ATTACH TIP TARGET
NUMBERS EXACTLY AS SHOWN.
ROTATION
TAPE
TRACKING TARGET
(NOTE 1)
SCISSORS
CRANK
TIP CAP
ROTATION
OF HUB
TRACKING TIP CAP

INSTALLATION
INTERRUPTER
(NOTE 4)
(NOTE 6)
SCISSORS LINK
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.
MAGNETIC PICKUP
6G18-014-1A
Figure 401. Blade Tracking Equipment Main Rotor Components (Sheet 1 of 2)

Page 402
Revision 44
18-10-60
MAINTENANCE MANUAL
INTERRUPTER
(NOTE 3)
0.030-0.070 IN.
(0.762-1.778 MM)
GAP (TYP)
SUPPORT
BRACKET
CSP-HMI-2
NOTE 2
ADJUSTMENT
JAMNUT
PROTECTIVE CAP
TEST EQUIPMENT
CABLE RECEPTACLE
PICKUP INSTALLATION
INTERRUPTER-TO-MAGNETIC PICKUP GAP
6G18-014-2
Figure 401. Blade Tracking Equipment Main Rotor Components (Sheet 2 of 2)

C. Tracking Tip Cap Installation
with six tip caps that must be removed
and replaced with six tracking tip caps
(ST901).
(2). When blade tracking has been accom
plished or verified, the tracking tip caps
must be removed and original tip caps
installed.
(3). Torque the screws that secures the tip
cap to 15 - 20 inch-pounds (1.69 2.26 Nm).
NOTE: Position interrupter over magnetic

pickup. The blade positioned forward is
number 6. By rotating rotor head in operat
ing direction, the next blade pointing for
ward will be 5 then 4, 3, 2 and 1.
D. Main Rotor System Balancing Equipment

Installation
Refer to Chadwick-Helmuth Operation and
Service Instruction Handbook to install that
portion of the balancing equipment (ST903)
needed to balance the main rotor.
inlet, comply with precautions
to prevent entry of foreign material. During
main rotor balancing the helicopter will be
airborne. Carefully observe precautions in
the Tracking and Balancing Manual relat
ing to the placement and security of equip
ment (especially cables) fastened to the ex
terior of the helicopter.
CAUTION
18-10-60
Page 403
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
INTERRUPTER
(TYP)
VIEW LOOKING DOWN
TORQUE NUT AFTER

SECURING GAP AND
SAFETY WIRE
0.030-0.070 IN.
(0.762-1.778 MM)
GAP (TYP)
MAGNETIC
PICKUP
ENGINE AIR INLET FAIRING

(LEFT HAND SIDE)
MAGNETIC PICKUP INSTALLATION

ACCELEROMETER/VELOMETER
BALANCING
VIEW LOOKING
INBOARD
TAPE
ACCELEROMETER INSTALLATION
Figure 402. Main Rotor Balancing Equipment Installation

Page 404
Revision 23
18-10-60
MAINTENANCE MANUAL
CSP-HMI-2

ADJUSTMENT/TEST
1. Blade Tracking Procedure
TIP PATH PLANE
Table 501 is a summary of the sequence of

required procedures for blade tracking.
(1). Install strobe light, blade tip cap
reflectors and related equipment.
(2). Use 1/2 inch (12.7 mm) diameter
tracking tip cap reflector as a guide for
estimating track accuracy. For example:
IMAGE A: ALL BLADES IN TRACK
IMAGE B: ONE BLADE APPROX. 1/2 IN. (12.7 MM) HIGH
(a). A tip cap reflector image displace

ment of 1/2 diameter up, or down,
indicates blade tip is approximately
(b). One full reflector diameter indicates
IMAGE C: ONE BLADE APPROX. 1/2 IN. (12.7 MM) HIGH

ONE BLADE APPROX. 1 IN. (25.4 MM) LOW
6G18-016A
CORRECTIVE ACTION
NOTE: Rocking or stick shake caused by a cor

rectly tracking rotor indicates improper
blade phasing.
(3). Accomplish blade phasing (Ref. Sec.
62-20-60) when installing new rotor
blades or if ground rock or stick shake
is noted. This must be accomplished
prior to starting tracking procedure.
NOTE: Final rotor system balance cannot be

accomplished until blades are in track.
(4). Ground tracking is basically track-ob
servation and adjustment of idle and
flight rpm. Improper track at idle rpm
is corrected by adjusting length of pitch
control links connecting rotating
swashplate and blade pitch housing.
Ground track at flat pitch and flight
rpm is corrected by blade tab adjust
ment.
(5). Hover track verification is essentially
an observation to check for track
variations between high rpm (flat pitch)
ground track check and hovering.
NOTE: Track adjustments are not made on ba

sis of track observations during hovering.
However, track variations should be noted
and recorded for use during check of track in
forward flight.
CONDITION
GROUND IDLE RPM
HIGH RPM AND

FWD FLIGHT
IMAGE A
NONE REQUIRED
NONE REQUIRED
IMAGE B

ROD (2ND BLADE)
MOVE TAB DOWNWARD

(2ND BLADE) MOVE TAB
UPWARD (3RD BLADE)
IMAGE C

ROD (2ND BLADE):
LENGTHEN CONTROL ROD
(3RD BLADE)
MOVE TAB DOWNWARD

(2ND BLADE): MOVE TAB
UPWARD (3RD BLADE)
NOTE: Chordwise spacing of tracking images

are not an accurate indication of blade phas
ing. Do not adjust blade phasing in an at
tempt to equalize spacing. Slight tilting of
magnetic interrupters or balance of the
main rotor system can move the image
Figure 501. Typical Track Conditions and
Adjustments
(6). Forward flight track is corrected only
by making blade tab adjustments.
Forward flight tracking requires track
observation during following airspeeds
and maneuvers: Flight at 0-100 knots.
Forty-five degree banked turns at
80-100 knots. Flight at 100-155 knots.
(7). Check for proper balance of rotor
system prior to checking autorotation.
(8). Obtaining correct autorotation rpm
consists of checking main rotor rpm
18-10-60
Page 501
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
during stabilized autorotation flight

and adjusting rpm to specified limits as
necessary. Autorotation rpm check
must be accomplished to ensure that
track adjustments do not alter rotor
performance necessary for safe poweroff landings.
sometimes E, are used for tracking at higher

airspeeds. Zone B is used to supplement zone
A track correction when maximum tab (5
degrees) has been applied to zone A; if
necessary, zone B may also be used for
correction in 0-110 knot airspeed range.
A. Blade Track Adjustment

Although adjustment of pitch control links
affects blade track at all rotor speeds, they
should be adjusted only when necessary to
establish acceptable track at ground idle
speed; blade tabs are used for all other track
corrections.
NOTE: Blade tab and/or track can make the

collective heavy or light.
B. Pitch Control Link Adjustment
Repeat this adjustment procedure as necessary
to establish ground idle track:
(1). To lower a blade tip, shorten pitch
control link assembly. To raise a blade
tip, lengthen pitch control link assem
bly. One-sixth of a turn of link (one flat)
raises or lowers blade tip approximately
1/4 inch (6.35 mm).
Center each rod end or pitch
case and/or swashplate wear
will result. Ensure there is no binding in full
up travel position.
CAUTION
(2). After adjusting pitch control link

length, center each rod end in its fitting
and hold while tightening jam nuts;
safety with lockwire.
C. Blade Tab Adjustment
(Ref. Figure 502) Once ground idle track is
obtained, all remaining tracking correction is
accomplished by very slight bending of various
blade tab zones with tab bending tool (ST902).
Different zones of tabs are used to adjust blade
track at different airspeeds. In general, tab
zone A is used for high-rpm, flat pitch ground
tracking (100% N2) and zones C, D, and
Page 502
Revision 34
18-10-60
Item
ST902
Special Tools
Nomenclature
Main rotor blade fixture and tab bending
tool
Minimize bending and restrict

adjustments to very small incre
ments so that bonded trailing edge joint be
tween upper and lower skins is not dam
aged. Tabs must never be displaced more
than five degrees above or below neutral po
sition (parallel to chordline).
CAUTION
(1). To lower blade tip that tends to climb

during ground tracking at high rpm or
during forward flight, bend appropriate
tab section slightly downward; to raise
tip of blade that tends to descend, bend
tab slightly upward. If only slight track
correction is necessary, limit tab
bending to width of bending tool. If
more correction is necessary, bend a
slightly wider section of tab. Use small
adjustments to avoid excessive rebend
ing of tabs.
NOTE: Tab zones on same blade can require

bending in opposite directions. For example,
after bending tab zone A downward to get
good tracking at 60-90 knots, it might be
come necessary to bend tab zone D or E (Ref.
Figure 502) upward to correct track at red
line airspeed. In any case, do not use larger
tab corrections than are actually necessary.
(2). Each time blade tabs are adjusted,
recheck ground idle track and readjust
if necessary.
(3). After completion of forward flight
tracking, balance and check autorota
tion rpm.
MAINTENANCE MANUAL
MAIN ROTOR
BLADE (TOP VIEW)
BLADE STATIONS
93
99
105
71 IN.
(180 CM)
NOT USED
(NOTE 1)
TAB ZONES
111
65 IN.
(165 CM)
117
59 IN.
(150 CM)
CSP-HMI-2
124
53 IN.
(135 CM)
130
47 IN.
(119 CM)
148
40 IN.
(102 CM 34 IN.
(86 CM)
16 IN.
(41 CM)
A
C
NOTE 2
HIGH RPM GROUND

MEDIUM SPEED
TRACKING AND UP TO
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)
SHOCK CORD
(OR EQUIVALENT)
164
TO END OF
BLADE NOT USED
(NOTE 1)
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
IN ZONE D.
POINTER
TAB BENDING TOOLS
BENDER
6G18-017A
Figure 502. Adjustment Main Rotor Blade Tab

D. Main Rotor Ground Tracking
For best results, tracking should be performed
under calm air conditions. Wind velocity
should not exceed six knots during adjust
ments. Accurate adjustment of initial ground
track is very important. In most instances,
forward flight tracking problems can be
avoided or greatly reduced by setting initial
track as nearly perfect as possible. Tolerances
specified in following instructions should be
considered maximum permissible deviation
rather than desired goal.
NOTE: If main rotor hub or a pitch control rod

end bearing has been replaced, adjust pitch
control link(s) before proceeding with
ground tracking.
(1). Before tracking blades that are not new,
check that normally straight (not to be
used) tab areas are in neutral position
(centered on chordline) and straight.
NOTE: On new (untracked) blades, check that

all tab areas are straight and in neutral po
sition (centered on chordline 0.0 0.5).
(2). Load helicopter to a gross weight of
approximately 2350 pounds (1066.9 kg);
then ground idle (approximately
64-65% N1) with collective pitch stick
full down.
(3). Observe tracking tip cap reflector image
by directing strobe light beam toward
blade tip path and sweeping beam
slowly back and forth until reflector
images are clearly seen. Tracking image
should appear directly in front of
helicopter or slightly off helicopter
centerline.
(4). If blades are in track, tip cap reflector
image pattern should resemble image
A, (Ref. Figure 501) (no blade tip more
than 1/4 of one tracking reflector
diameter, 1/8 inch (3.175 mm), above or
below adjacent reflectors). If blades are
in track, proceed with step (5). below. If
18-10-60
Page 503
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
blades are out of track, adjust pitch

control links and repeat step (3). above.
increase engine speed to 100% N2 and
observe tip cap reflector image to see if
blade track is changed from ground idle
track. When all six blades are in track
within 1/4 of one reflector diameter,
ground track is correct; proceed with
hover verification. When a blade is out
of track, adjust blade tab zone A until
high rpm ground track is within
tolerance.
E. Hover Track Verification
(Ref. Figure 504)
NOTE: Collective pitch stick may be ``heavy af

ter tracking reflectors are mounted on blade
tips. This condition is not unusual and may
be disregarded.
2000-2500 pounds (908-1135 kg).
increase N2 to 100%.
(4). Observe tracking reflector images to
verify that ground track is within
limits.
(5). With helicopter in a stable hover,
observe reflector images. If one or more
blades are out of track, record condi
tion(s) for reference during forward
flight tracking.
(6). Proceed with forward flight tracking.
Revision 23
recommended. Such use can result in

pilot disorientation or loss of vision
with resultant damage to the helicop
ter and personal injury.
F. Forward Flight Tracking
(Ref. Figure 502 and Figure 506 thru
Figure 508) Forward flight tracking should be
performed whenever vertical flight vibrations
indicate that blades may be out of track.
2000-2500 pounds (908-1135 kg).
NOTE: When bending trim tabs, do not bend

more than 1.5 between six inch sections.
(1). Hover track verification must be

performed after ground tracking and
before forward flight tracking. Verifica
tion is only a check of hover track. Do
not adjust pitch control links or blade
tabs because of track images observed
during hovering. Tab adjustments often
cause variation between ground track
and hovering track. A large track
variation may indicate that one or more
blades is beyond its chordwise balance
tolerance, but this can only be deter
mined during forward flight tracking.
Perform hover track verification as
follows.
Page 504
Use of the tracking strobe
WARNING light in night flight is not
18-10-60
(2). Perform flight tracking from hover up

to 110 knots at 100% N2. If flight track
varies from hover track more than 1/2
inch (12.7 mm), bend tab zone A (five
degrees maximum) to limit variation to
tab zone B (five degrees maximum).
(3). Check autorotation percentage; per
centage must not be less than 480
(90%).
Do not attempt to adjust chord
wise balance of a blade found to
be faulty when performing banked turns.
Chordwise balance corrections must be ac
complished by manufacturer (MDHI).
CAUTION
(4). Perform a series of 45 degree banked

turns at 100 knots and observe track
change from level flight. If any blade
climbs or dives more than one inch
(2.54 cm) out of track with others,
chordwise balance (center of gravity) of
that blade is beyond its tolerance and
blade must be replaced or balanced by
an MDHI Field Representative. (Hover
track variations of this type that do not
repeat during banked-turn maneuver
may be disregarded.)
(5). Perform flight tracking at 100% N2. If
necessary, adjust tab zone B (five
degrees maximum) to limit track
variation to 1/2 inch (12.7 mm) or less
and to minimize excessive vertical
(one-per revolution) vibration. If
variation is excessive, bend tab zone C
or D (five degrees maximum).
MAINTENANCE MANUAL
CSP-HMI-2
NOTE: When determining whether blade track
NOTE: Change length of all six pitch control
is acceptable, overall vibration level of heli

copter should be determining factor. Some
combinations of rotor blades might produce
higher six-per-revolution vibration as
blade tips are brought into close track; in
such cases, lowest vibration level is pre
ferred, even though observed blade track
may be beyond specified tolerances.
links as necessary to adjust autorotation

percentage. Be sure to lengthen or shorten
all six links exactly same amount or blade
track is changed. One flat (1/6-turn) of con
trol link body causes approximately one per
cent change in autorotation percent.
(6). After flight tracking is completed,

perform a Main Rotor System Balance
Procedure and Main Rotor Autorotation
RPM Check.
2. Main Rotor System Balance Procedure
Balance the main rotor system according to
instructions in the Chadwick-Helmuth
Operation and Service Instruction Handbook.
ance weight per lead-lag bolt on
the main rotor hub assembly is 143 grams.
CAUTION
3. Main Rotor Autorotation Percentage

Check
(Ref. Table 502) An autorotation percentage
check is required after each blade tracking
operation and whenever rpm is outside limits
listed. Check rotor rpm and make adjustments
as follows.
CAUTION
D All autorotation percentage adjustments
shall be made at the main rotor pitch con
trol links only. Do not re-adjust mixer
control rods after rigging is accomplished.
Failure to observe this precaution may re
sult in serious damage to rotor system
and controls. Do not adjust control rod
end beyond witness hole.
D Tracking targets reduce blade to tailboom
clearance, performing autorotations to
the ground could result in boom strikes.
(1). Autorotation Percentage Check (Ref.

Table 502) Load helicopter to a gross
weight of 2800 25 pounds (1270 11
kg). Perform a practice autorotative
descent (Ref. RFM), taking care not to
allow percentage to exceed rotor speed
limitations. During autorotation, take
careful note of stabilized autorotation
percentage at one of the gross weight/
density altitude combinations. After
landing, compare observed percentage
with values. If observed percentage is
within limits in table, percentage
setting is correct. If limits were exceed
ed, make corrective adjustments
according to Autorotation Percentage
Adjustment, until percentage is within
limits.
(2). Autorotation Percentage Adjustment:
Change length of all six pitch control
links as required to adjust autorotation
percentage. Make certain all six links
are shortened or lengthened exactly the
same amount or blade track will be
altered.
NOTE: After autorotation percentage adjust

ments are satisfactorily accomplished, re
move tracking equipment before returning
helicopter to service. Be sure to correctly
tighten and safety all bolts after they are re
installed.
18-10-60
Page 505
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
Table 501. Summary Procedure for Blade Tracking

Satisfactory
Result
Step
Unsatisfactory
Result
Corrective Action
(1) Observe ground track.
Go to step (2). Ref. Corrective

Action.
Adjust pitch control rods and blade tabs

as required. Repeat track observation.
(2) Perform hover verification.

Action.
Record track verification and proceed with

forward flight tracking.
(3) Perform forward flight

tracking.

Action.
Adjust blade tabs and repeat forward

flight tracking.
(4) Perform autorotation

percentage check.

Action.
Adjust autorotation percentage and

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
lb/kg
Sea Level
1000 Ft
(305 M)
2000 Ft
(610 M)
3000 Ft
(915 M)
4000 Ft
(1220 M)
5000 Ft
(1525 M)
2500/1134
93.8 95.8
94.6 96.6
95.4 97.4
96.3 98.3
97.1 99.1
98.0 100.0
2600/1179
95.6 97.6
96.4 98.4
97.3 99.3
98.1 100.1
99.0 101.0
99.9 101.9
2700/1224
97.4 99.4
98.2 100.2
99.1 101.1
100.0 102.0
100.9 102.9
101.8 103.8
2800/1270
99.2 101.2
100.0 102.0
100.9 102.9
101.8 103.8
102.7 104.7
103.6 105.6
2900/1315
101.0 103.0
101.8 103.8
102.7 104.7
103.6 105.6
104.6 106.4
3000/1361
102.7 104.7
103.6 105.6
104.5 106.4
105.4 106.4
NOTE: Perform autorotation percentage checks at gross weight/density altitude combinations for which percentage values are given. Blank spaces indicate that application of collective pitch may be necessary to avoid rotor
overspeed.
Page 506
Revision 23
18-10-60
MAINTENANCE MANUAL
MAIN ROTOR
BALANCE WEIGHTS
(NOTE)
CSP-HMI-2
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
18-10-60
Page 507
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
ROTATION
BLUE
MD600N HOVER PITCH LINK ADJUSTMENT

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

VELOCIMETER ON CONSOLE.
ADJUST PITCH CHANGE LINK IN FLATS. 1 FLAT=1/6 TURN
OF PITCH CHANGE BARREL.
BLADE SEQUENCE IS SHOWN WITH SINGLE INTERRUPTER
ATTACHED TO DRIVE LINK OF ROTATING SWASHPLATE.
TAKE READINGS FROM VERTICAL VELOCIMETER MOUNTED
ON INSTRUMENT PEDESTAL POINTING DOWN.
ADJUST PITCH CHANGE LINK BEFORE BALANCING AT HOVER.
2.
3.
MAG P/U
4.
RED
5.
GREEN
BLACK
ADJUSTMENT IN FLATS
OF PITCH LINKS
BLADE ORIENTATION WITH
DRIVE LINK INTERRUPTER
AIRCRAFT VIEWED FROM ABOVE
IPS
CLOCK
MOVE
GREEN
UP
MOVE
RED
UP
O 12:00
11:00
1:00
1 1/2
ADJUST
MOVE
YELLOW
UP
O
2:00
.6
O
1 1/2
1 1/2
.8
10:00
MOVE
WHITE
UP
MOVE
BLACK
UP
1 1/2
1 1/2
MOVE
BLACK
UP
1 1/2
.4
.2
.8
.6
9:00
.4
.2
3:00
1 1/2
3
1 1/2
8:00
0
4:00
0
1 1/2
1 1/2 7:00
MOVE
BLUE
UP
MOVE
GREEN
UP
5:00
6:00 0
1 1/2
3
3
MOVE
WHITE
UP
3
1 1/2
MOVE
BLUE
UP
3
MOVE
YELLOW
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
Revision 23
18-10-60
MAINTENANCE MANUAL
CSP-HMI-2
ROTATION
BLUE
WHITE
YELLOW
MD600N HOVER BALANCE CHART

1.
2.
3.
RED
GREEN
BLACK
4.
TAKE READINGS AT IGE HOVER AFTER PCL TRACK.

USE WEIGHT, IN GRAMS, AT HUB LOCATION.
LATERAL VELOCIMETER READINGS USING VELOCIMETER
AT LEADING SIDE OF CONTROLS COVER POINTING TO
LEFT OF AIRCRAFT.

OVER MAGNETIC PICKUP
AIRCRAFT VIEWED FROM
ABOVE
IPS
CLOCK
ADJUST
G18-1007
Figure 505. Main Rotor System Balance Chart
18-10-60
Page 509
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
ROTATIO
N
MD600N VERTICAL TAB CHART 100-130 KIAS
BLUE
1.
2.
3.
VELO.
WHITE
4.
YELLOW
RED
TAKE READINGS AT 100-130 KIAS.

TAB MEASUREMENTS ARE IN 0.001 IN. (0.0254 MM).
TAKE READINGS FROM VERTICAL VELOCIMETER MOUNTED ON
INSTRUMENT PEDESTAL POINTING DOWN.
GREEN
BLACK
1.
2.
3.

INNER TAB TWO WIDTHS OF BENDER (STA. 97 - 111)

MIDDLE TAB TWO WIDTHS OF BENDER (STA. 111 - 130)
OUTER TAB ONE WIDTH OF BENDER (STA. 130 - 142)
AIRCRAFT VIEWED FROM

ABOVE
IPS
CLOCK
ADJUST
NOTE:
ARROWS INDICATE DIRECTION POINT SHOULD GO
WHEN ADJUSTMENT TO NOTED BLADE IS MADE.
G181006A
Figure 506. Main Rotor Tracking at 100 130 KIAS (Inner Tab Adjustment)
Page 510
Revision 37
18-10-60
MAINTENANCE MANUAL
CSP-HMI-2
ROTATION

BLUE
1.
2.
3.
VELO.
WHITE
YELLOW

TAB MEASUREMENTS ARE IN .001 INCH.
4.
RED
GREEN
BLACK
NO BEND
AREA
TAB BENDER TWO WIDTHS
1.
2.
3.

UNDER TAB TWO WIDTHS OF BENDER (STA 97 - 111)

MIDDLE TAB TWO WIDTHS OF BENDER (STA 111 - 130)
OUTER TAB ONE WIDTH OF BENDER (STA 130 - 142)
WHITE
.010
RED
.005
BLACK
.005
IPS
CLOCK
ADJUST
1.0 IPS 12:00
BLUE
11:00
0
.005
1:00
.8
RED
.6
.010
10:00
WHITE
.010
.005
.005
2:00
.4
.2
.005
0
9:00
.2
.4
.8
.6
.005
1.0 IPS
.005
8:00
4:00
.010
7:00
YELLOW
0
5:00
6:00
.005
.010
BLUE
GREEN
.005
GREEN
.005
BLACK
.005
YELLOW
.010
6G18-100
Figure 507. Main Rotor Tracking at 100 130 KIAS (Mid Tab Adjustment)
18-10-60
Page 511
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
ROTATION

BLUE
VELO.
WHITE
1.
2.
3.
YELLOW

TAB MEASUREMENTS ARE IN .001 INCH
4.
RED
GREEN
BLACK
ONE WIDTH OF TOOL

1.
2.
3.

IPS
CLOCK
UNDER TAB TWO WIDTHS OF BENDER (STA. 97 TO 111)

MIDDLE TAB TWO WIDTHS OF BENDER (STA. 111 TO 130)
OUTER TAB ONE WIDTH OF BENDER
(STA. 130 TO 142)
.016
.016
.008
.008
RED
UP
ADJUST
BLACK
UP
WHITE
UP
RED
.008
12:00
.008
11:00
1:00
2:00
.008
1.0 IPS
10:00
BLUE
UP
.8
1.0 IPS
.008
GREEN
.8
.6
.4
9:00
.2
.2
.4
.016
.6
3:00
.016
.008
1.0 IPS
.008
WHITE
UP
NO BEND
AREA
8:00
4:00
.005
5:00
7:00
.008
6:00
.008
YELLOW
UP
.008
YELLOW
UP
BLACK
UP
.008
.016
.016
BLUE
UP
GREEN
UP
6G18-101
Figure 508. Main Rotor Tracking at 100 130 KIAS (Outer Tab Adjustment)
Page 512
Revision 23
18-10-60
MAINTENANCE MANUAL
CSP-HMI-2
Section
182000
Tail Rotor Balance
MAINTENANCE MANUAL
CSP-HMI-2
TAIL ROTOR BALANCE

1. Tail Rotor Balancing
Item
Special Tools
Nomenclature
ST903
Balancing is accomplished by use of a balanc

ing kit (ST903). The carrying case of this kit
contains all instrumentation, balance charts
and miscellaneous items needed to balance the
tail rotor. Also included is a track and balance
handbook for use with the equipment to
correct balance when such can be obtained by
addition or subtraction of weight at pitch-arm
studs or at blade tips.
Since vibration reduction by weight adjust
ment is dependent on proper mechanical
condition of the tail rotor and tail rotor drive
system, troubleshooting information (Ref.
Chap. 64) should be used with balancing kit
instructions. Acceptance criteria for balance
and vibration are contained in the balancing
kit and on each balance chart. Main rotor and
tail rotor balancing spare kit contains spare
screws, washers and tip weights.
NOTE: If tail rotor balance is difficult to

achieve and horizontal stabilizer resonance
is noted refer to 421-087-505 Horizontal
Stabilizer Tab Weight Installation.
A. Balance at Blade Tip
When balancing procedures indicate that
weight should be added to a tip, it is prefer
able, if possible, to instead remove an equiva
lent amount from the opposite tip to keep
overall weight to a minimum. Installation of
tip weights is not mandatory. However, open
screw holes are not permitted; screws must be
installed. Shorter than normal screws may be
used for balance if minimal thread engage
ment of 5/16 inch (7.9375 mm) exists.
(1). Remove tip-weight screws and weights
(Ref. Figure 201). Select balancing
hardware indicated by balancing
procedure. Tail rotor balance spare kit

contains extra tip weights and screws.
(2). Install combination of weights required.
Maximum weight permitted is thirtyfour grams at each tip (Ref. Table 201).
Torque screws to 21 - 24 inch-pounds
(2.37 - 2.71 Nm).
B. Balance at Blade Pitch Arm
(Ref. Figure 201) Weight increase at light pitch
arm may be obtained by removal of equivalent
washer weight from opposite pitch arm.
Always remove washers from opposite pitch
arm, if installed, and subtract from weight to
be added before adding more weight. For
washer data, refer to Table 201. Main rotor
and tail rotor balancing spare kit contains
extra washers. Maximum washer weight
allowed at either pitch arm bolt is 26.91 grams
(23 washers).
NOTE:
D A tail rotor out-of-balance condition that
cannot be corrected by standard balanc
ing procedures may be an indication of ex
cessive play in tail rotor hub components.
D There is possibility of slight weight varia
tion between pitch control links.
(1). If tail rotor has maximum balance
washer weight allowed on one pitch
arm, compare the two links.
(2). If pitch link opposite the weight
requirement appears larger, exchange
one link for the other and repeat
vibration analysis.
(3). If, as a result of parts peculiarity,
maximum allowable weight at one pitch
arm does not correct assembly balance,
tail rotor hub may be shifted in fork
and hub-to-fork shimming adjusted, if
maximum allowable play in fork
bearings is not exceeded. This is done
by transferring fork-to-hub spacing
shims from balance weighted side to
opposite side of hub, according to hub
and fork assembly procedures (Ref.
COM).
18-20-00
Page 201
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
(a). Chordwise weight shift resulting

from each 0.001 inch (0.0254 mm) of
spacing thickness transferred
reduces weight requirement at
weighted pitch arm by one
HS306-227L balance washer.
(b). Transferring one 369A1717-53
spacing shim, 0.010 inch (0.254 mm)
thickness, allows initial removal of
10 thin washers from pitch arm and
thereby allows more flexibility for
further balance correction during
vibration analysis.
(4). It should be noted that spanwise
balance is probably affected by any
chordwise shift of fork.
(5). If maximum allowable play in fork
bearings is exceeded, bearings must be
replaced (Ref. COM).
(6). Replacement or adjustment of parts
requires balancing of tail rotor follow
ing re-assembly.
C. Short Method Balance Check
(Ref. Figure 201 and Figure 202) Use tail rotor
vibration analyzer (ST903) throughout this
procedure.
(1). Mount accelerometer into tail rotor
gearbox breather plug as noted in
Chadwick-Helmuth Operation and
Service Handbook.
(2). Connect accelerometer and balancer DC
power cables as noted in the ChadwickHelmuth Operation and Service
Handbook.
(3). Apply a retro-reflective target material
on blade root fitting. For four-bladed
tail rotor, one blade of the outboard tail
rotor assembly.
(6). Initially balance the tail rotor until

vibration level is 0.1 IPS (0.85 MIL) or
less as follows:
(a). Add weights to blade tips only. For
four-bladed tail rotor, divide weights
as necessary between the two lower
blades to make the total weight
vector in the downward direction.
NOTE: If more than 15 grams of tip weight (in

cluding screw) is necessary on any one
blade, use the ``long method'' balance proce
dure.
(7). After initial balance, reset RPM TUNE
dial, according to Chadwick-Helmuth
Handbook for final balancing. Direct
strobe at tail rotor and adjust per
Chadwick-Helmuth instructions for
VERIFY TUNE. Apply the same
method used for initial balance to
balance until vibration level is 0.1 IPS
(0.85 MIL) or less.
D. Long Method Balance Check
(FourBladed Tail Rotor)
(Ref. Figure 203 and Figure 204) A long
method balance check must be accomplished
each time hubs and fork of four-bladed tail
rotor are reassembled. Use tail rotor vibration
analyzer (ST903) throughout the procedure.
First runup of tail rotor assem
bly should be accomplished in a
cautious manner, increasing tail rotor rpm
slowly so that vibrations from out-of-ba
lance tail rotor assembly will not cause dam
age.
CAUTION
NOTE: Prior to performing long method bal

ance check, ensure hub is centered on fork
and elastomeric bearings are preloaded cor
rectly.
(4). Connect cables and instruments and

adjust settings as noted in ChadwickHelmuth Handbook.
(1). With outboard blade removed, balance

inboard blade by adjusting tip weights
and washers at pitch arm bolt to
achieve 0.10 IPS (0.85 MIL) or less
vibration level at 2100 rpm (input shaft
of transmission). This corresponds to
tail rotor rpm of 2168.
(5). Direct strobe at tail rotor and adjust

per Chadwick-Helmuth instructions for
VERIFY TUNE.
(2). Install outboard blade and hub assem

bly; check balance of outboard blades by
adjusting weights to obtain 0.10 IPS
Page 202
Revision 23
18-20-00
MAINTENANCE MANUAL
(0.85 MIL) vibration or less, using same
method as used for inboard blade
balancing, except as shown in
Figure 204.
2. Horizontal Stabilizer Tuning
Installation of tab weight is optional on the
421-087 -505 horizontal stabilizer if difficulty
in tail rotor balance and horizontal stabilizer
tab resonance vibration is encountered.
(1). With helicopter on flat smooth surface,
operate engine at 102%-105% N2 and
observe horizontal stabilizer tab.
(2). If tab resonance vibration occurs,
remove the horizontal stabilizer
CSP-HMI-2
assembly and balance the tail rotor

assembly.
(3). After balancing the tail rotor assembly,
reinstall the horizontal stabilizer.
(4). Run engine at 102%-105% N2 and
observe horizontal stabilizer tab.
(5). If tab resonance occurs and tail rotor
balance is no longer acceptable, install
tab weight to horizontal stabilizer right
tab (Ref. Sec. 53-50-10, Horizontal
Stabilizer Tab Weight Installation).
(6). If needed, a one ounce weight may also
be installed on left tab.
(7). A maximum of two ounces may be
installed on each tab.
18-20-00
Page 203
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
FOR TAIL ROTOR BALANCING.
INSTALL ON BREATHER PLUG
OF TAIL ROTOR GEAR BOX
TAPE
SECURE UNDER LATCH

REFLECTIVE
TAPE
KIT LOCATION FOR TAIL

ROTOR BALANCING
28VDC POWER CABLE

TO AUXILIARY OUTPUT
RECEPTACLE
BALANCE WASHERS
RETAINING NUT
PITCH ARM BOLT

CABLE
SPRING WASHER
(NOTE 1)
BREATHER/FILLER
PITCH CONTROL
LINK
PITCH ARM
BALANCE WASH
ER INSTALLATION
TIP WEIGHT
NOTE 3
WEIGHT INSTALLA
TION 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).
Figure 201. Tail Rotor Assembly Balancing (TwoBladed Tail Rotor)

Page 204
Revision 34
18-20-00
G18-2000B
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Tail Rotor Balance Weight Value Chart

At Blade Tip (4)
At Blade Pitch Arm (3)
Screw (5)
Washer (1)(2)
Part Number
Length
(in./mm)
Weight
(Grams)
Part Number
Thickness
(in./mm)
Weight
(Grams)
OD
(in./mm)
NAS13520812P
0.75/19.05
2.22
HS306227L
0.016/0.4064
1.17
0.800/20.32
NAS13520814P
0.875/22.23
2.44
Weight
Thickness
(In./mm)
Weight
(Grams)
369A16223
0.016/0.4064
0.29
369A16225
0.036/0.9144
1.76
NOTES:
(1) Used on balance bolt.
(2) Maximum of 23 washers is permitted on each balance bolt.
(3) Minimum of two threads must extend past nut securing balance washers on balance bolt.
(4) Maximum weight, including screws, is 34 grams.
(5) Minimum screw thread engagement is 5/16 inch (7.9375 mm).
TOTAL
WEIGHT
VECTOR
TOTAL
WEIGHT
VECTOR
WEIGHT
TOTAL
WEIGHT
VECTOR
SMALLER
WEIGHT
EQUAL
WEIGHT
EQUAL
WEIGHT
OR
LARGE WEIGHT
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 (FourBladed Tail Rotor)
18-20-00
Page 205
Revision 39
MAINTENANCE MANUAL
CSP-HMI-2
BALANCE
WASHERS (NOTE 1)
SHIMS
(NOTE 2)
NOTES:
1. MAXIMUM ALLOWABLE NUMBER OF WASHERS AT
PITCH ARM BOLT IS 23. WHENEVER THIS LIMIT IS
REACHED AND REQUIRED BALANCE CANNOT BE
MET, SHIFT THE CENTER OF THE HUB BY
TRANSFERRING SHIMS, THICKNESS OF 0.010 IN.
(0.254 MM), FROM WEIGHTED PITCH ARM SIDE TO
THE OPPOSITE SIDE AS SHOWN AND 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
THE OPPOSITE SIDE.
SHIM
G18-2002A
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.
Figure 204. Long Method Tail Rotor Balancing (Outboard Blade)
Page 206
Revision 23
18-20-00
G18-2003A
MAINTENANCE MANUAL
CSP-HMI-2
Section
182030
NOTARr
AntiTorque System
Fan Balance
MAINTENANCE MANUAL
CSP-HMI-2
NOTARR ANTITORQUE SYSTEM FAN BALANCE

1. Fan Balancing
The NOTARr anti-torque system uses a
fan-driven air circulation system within the
tailboom to control the directional heading of
the helicopter. The rudder pedals in the cockpit
control the blade angle of the fan assembly.
The fan assembly operates at a constant speed
of 5388 RPM at 100% N2.
Balancing is accomplished by use of a balanc
ing kit. The carrying case of this kit contains
all instrumentation, balance charts and
miscellaneous items needed to balance the fan
assembly. Also included is a track and balance
handbook for use with the equipment to
correct balance when such can be obtained by
addition or subtraction of weight at studs on
the fan assembly.
Since vibration reduction by weight adjust
ment is dependent on proper mechanical
condition of fan drive system, troubleshooting
information (Ref. Chap. 64) should be used
with balancing kit instructions. Acceptance
criteria for balance and vibration are con
tained in the balancing kit and on each
balance chart.
2. Fan Balance Check
(Ref. Figure 201)
(4). Install velometer on bracket located at

the 6:00 o'clock position (Ref.
Figure 203).
(5). Install magnetic pick-up and velometer
wiring (Ref. Figure 203).
Wiring must be secured to pre
vent them from being ingested
into the fan assembly during run-up.
CAUTION
(6). Position the anti-torque pedals at

neutral during fan balancing.
NOTE: The neutral position is 62% from full

left or approximately one inch of right pedal
from pedals centered. This pedal position
produces minimum fan pitch and closes the
thruster.
WARNING
D Damage could occur if the antitorque pedals are not kept at neutral
while the helicopter is operating
with the fan/hub transmission fair
ing removed.
D Operators and authorized observers
should remain in the designated
areas during balancing operations.
D Wearing loose clothing or having ma
terials in shirt pockets during opera
tions can result in injury to person
nel and/or damage to aircraft.
Item
Special Tools
Nomenclature
(7). Run helicopter to establish N2 speed of

100% percent.
ST903
(8). Observe vibration reading.
NOTE: Use the vibration analyzer (ST903)

throughout this procedure.
(1). Remove fan inlet screen.
(2). Remove upper portion of the fan/hub
transmission fairing.
(3). Number balancing studs as shown in
Figure 201 using a permanent marker.
(a). If vibration reading is greater than

0.2 ips, shut down helicopter and
proceed with step (9).
(b). If vibration level is 0.2 ips or less,
proceed with step (11).
(9). Add hardware to the balancing studs in
any combination as required using
Table 201 and Figure 202. Torque nuts
on studs to 30 - 40 inch pounds (3.39
- 4.52 Nm).
18-20-30
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
Do not over torque the nuts on

the balancing studs. An overtorqued nut may cause the stud locking col
lar to become loose the next time the nut is
removed.
(10). Repeat steps (6). thru (9). until fan
dynamic balance is 0.2 ips or less.
CAUTION
(11). Remove balancing equipment wiring

and attachments.
(12). Install the fan/hub transmission fairing
and fan inlet screen.
Table 201. Preferred Hardware for Balancing Fan Assembly

Washer
Aluminum
Weight (grams)
Stainless
Steel
AN960KD416L
Thickness
(in/mm)
ID
(in/mm)
OD
(in/mm)
Aluminum
Stainless
Steel
0.016 / 0.406
0.265 / 6.731 0.500 / 12.700
AN960C416L
0.016 / 0.406
0.265 / 6.731 0.500 / 12.700
AN960KD416
AN960C416
0.063 /1.600
0.265 / 6.731 0.500 / 12.700
0.407
1.144
HS306325L
HS306225L
0.016 / 0.406
0.263 / 6.680 0.528 / 13.411
0.121
0.339
HS306325
HS306225
0.032 / 0.813
0.263 / 6.680 0.528 / 13.411
0.241
0.677
HS306325H
HS306225H
0.063 / 1.600
0.263 / 6.680 0.528 / 13.411
0.482
1.355
HS306326L
HS306226L
0.016 / 0.406
0.263 / 6.680 0.619 / 15.723
0.181
0.507
HS306326
HS306226
0.032 / 0.813
0.263 / 6.680 0.619 / 15.723
0.361
1.015
HS306326H
HS306226H
0.063 / 1.600
0.263 / 6.680 0.619 / 15.723
0.723
2.029
HS306327L
HS306227L
0.016 / 0.406
0.263 / 6.680 0.800 / 20.320
0.329
0.922
HS306327
HS306227
0.032 / 0.813
0.263 / 6.680 0.800 / 20.320
0.657
1.844
HS306327H
HS306227H
0.063 / 1.600
0.263 / 6.680 0.800 / 20.320
1.314
3.689
NOTE: Maximum washer stackup thickness = 0.20 inch (5.08 mm).
Page 202
Revision 23
18-20-30
0.103
0.572
MAINTENANCE MANUAL
CSP-HMI-2
FAN ROTATION
MAGNETIC PICKUP
INTERRUPTER
1
13
2
12
3
11
4
10
5
9
6
8
7
BALANCING STUD
(13 PLCS)
VIEW LOOKING AFT
G18-2006
Figure 201. Fan Balancing Stud Numbering
18-20-30
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
12
350
11
340
360
IPS GRAMS
1.0 5.60
10
20
1
30
330
.9 5.04
#4
320
#3
40
.8 4.48
.7 3.92
310
50
#2
#5
.6 3.36
10
300
2
60
.5 2.80
.4 2.24
290
70
.3 1.68
#6
.2 1.12
280
80
#1
.1 .56
270
90
#7
260
100
# 13
110
250
#8
240
120
# 12
8
230
4
130
220
# 11
#9
# 10
210
150
200
160
190
180
140
170
G18-2007
Figure 202. Fan Balance Chart

Page 204
Revision 23
18-20-30
MAINTENANCE MANUAL
CSP-HMI-2
MAGNETIC PICK-UP/
VELOMETER CABLES
28 VDC POWER CABLE
TO AUXILIARY OUTPUT
RECEPTACLE
KIT LOCATION FOR

FAN BALANCING
GAP 0.060 IN. (1.524 MM)
MAGNETIC PICK-UP
FAN / HUB
TRANSMISSION
FAIRING
VELOMETER
BALANCING STUD
(13 PLCS)
G18-2008A
Figure 203. Fan Balancing Equipment Installation
18-20-30
Page 205
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
Page 206
Revision 44
18-20-30
MAINTENANCE MANUAL
CSP-HMI-2
Chapter
20
Standard Practices
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
20-10-00 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Torque Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Application of Torque Wrench Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Bearings Installation, Staking or Swaging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Control Tube Jam Nut Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Standard Hardware Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 201. Recommended Standard Torques for Tension-Type Fasteners . . . . .
Table 202. Recommended Standard Torques for Shear-Type Fasteners . . . . . . .
Table 203. Locking (Drag) Torque for Self-Locking Fasteners . . . . . . . . . . . . . . .
201
201
201
201
202
202
203
204
205
20-20-00 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Fuselage Interior Trim and Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Airframe Exterior and Rotor Blades Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Transparent Plastic Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Engine Compressor Contamination Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Cleaning Of Engine Air Inlet Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201
201
201
201
201
202
202
20-30-00 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Paint Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Paint Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Paint Touchup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A. Touchup - Small Sanded Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Touchup - Flaking or Dried Paint or Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Touchup - Primer Not Adhering to Metal Finish . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Touchup - Glass Fiber Laminate Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E. Touchup - Polycarbonate Plastic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F. Touchup - ABS Thermoplastic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Main Rotor Blade Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A. Main Rotor Blade Paint Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Main Rotor Blade Paint Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Tail Rotor Blade Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A. Tail Rotor Blade Paint Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Tail Rotor Blade Paint Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201
201
201
201
201
201
201
202
202
202
203
203
203
204
204
204
20-40-00 Corrosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
20 Contents
Page i
Revision 41
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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
20-90-00 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
Page ii
Revision 41
20 Contents
MAINTENANCE MANUAL
CSP-HMI-2
Section
201000
Torque
MAINTENANCE MANUAL
CSP-HMI-2
TORQUE
1. Torque Wrenches
Torque wrenches should be of good quality and
calibration should be verified at regular
intervals to verify accuracy. Torque wrench
accuracy at room temperature, 70F (22 C)
must be within following limits.
(1). From zero through 19 percent of torque
wrench range, error may not exceed 7
percent of load applied.
(2). From 20 thru 79 percent of torque
percent load applied.
(3). From 80 to 100 percent of torque
percent of load applied.
2. Application of Torque Wrench Loads
(Ref. Table 201 thru Table 203) Recommended
tightening torque values and minimum drag
torque values for fine and coarse thread nuts,
and minimum breakaway torque for used
self-locking bolts or screws are listed in
Table 201 and Table 202. Requirements
governing application of torque loads follow.
These requirements apply throughout this
manual except where otherwise specifically
indicated.
(1). Values apply to cadmium-plated bolts,
cadmium-plated nuts coated with
molybdenum disulfide (MoS2).
(2). Manufacturer applied lubricant must
not be removed nor additional lubricant
added.
(3). Bolts, nuts and surfaces they bear on
must be clean, dry and free of lubricant
except as stated in requirement above.
(4). Turning (drag) torque required to
install self-locking nut or bolt up to
point of final tightening must always be
added to final torque value specified or
the maintenance instruction, as
applicable.
(5). Torque values specified in this manual

are special torque values that apply
instead of those listed.
(6). If adapters are used such that adapter
and torque wrench are not at right
angles (90 degrees) to each other,
wrench or indicator reading must be
corrected.
(7). Any re-use of self-locking nuts over 3/8
inch is governed by values listed in
Table 203.
(8). Castellated nuts aretorqued to the
minimum side of the recommended
torque range. Continue to tighten the
nut until the hole of the cotter pin lines
up with the castellation without
exceeding the maximum specified
torque.
(9). Bolt must not be rotated during
application of torque to mating nut.
3. Bearings Installation, Staking or Swaging
Force
The following procedure explains how to
convert from a given `Force` which is required
to perform a task to a proper hydraulic
pressure reading.
(1). Determine the diameter of the ram
(staking or swaging contact surface) on
the hydraulic press to be used.
NOTE: The hydraulic press to be used must

have a pressure gauge.
(2). Divide the ram diameter by two to get
the radius.
(3). Multiply 3.14159 (pi) times the Radius
squared (R2). This will give the area of
the ram.
(4). Divide the force required for the task by
the area of the ram. This gives the
actual PSI reading for the hydraulic
press pressure gauge needed to perform
the task.
20-10-00
Page 201
Revision 38
MAINTENANCE MANUAL
CSP-HMI-2
EXAMPLE:
5. Standard Hardware Torque Values
Ram Diameter = 2.65 in. (6.731 cm)

Ram Radius (R) = 1.325 in. (3.366 cm)
The following tables list torque values for

standard hardware by part number.
Radius squared (R2) = 1.756 in.2 (8.548 cm2)
NOTE: If unsure of hardware type, refer to
R2 X 3.1416 = 5.517 in. (26.854 cm) (Area of

ram)
Force required = 7500-8500 lbs. (3402-3856
kg) (variable)
7500-8500 lbs. (3402-3856 kg) / 5.517 in.
(26.854 cm) = 1359-1540 PSI (9370-10618
kPa)
PSI required =1359 PSI (9370 kPa) Min.
1540 PSI (10618 kPa) Max.
Force needed/(R2) X 3.1416 = Pressure Gauge
Reading
4. Control Tube Jam Nut Torquing
(1). Tighten jam nuts against control rods
by holding rodend with wrench.
NOTE: Do not tighten with rodend against fit

ting.
(2). Ensure rodends are not preloaded after
torquing jam nuts.
Page 202
Revision 38
20-10-00
CSP-IPC-4.
(1). Table 201 lists self-locking tensiontype fastener torque values.
(2). Table 202 lists shear-type fastener
torque values.
(3). Table 203 lists maximum and minimum
self-locking fastener drag (run-on)
torque values.
Table 203 lists self-locking
(run-on) torque values, i.e.;
torque required to overcome the friction of
the self-locking feature of fastener threads
prior to clamp-up and final tightening. Any
self-locking fastener that can be run down
with the fingers after the locking feature en
gages must be replaced. Determine final
torque value by adding the run-on torque to
the specified final clamping torque. Final
clamping torque values are listed in
Table 201 and Table 202.
CAUTION
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Recommended Standard Torques for TensionType Fasteners

Diameter
inch
(mm)
Thread
Size
(Fine)
Recommended
Torque
in. lb (Nm)
Maximum
Allowable
in. lb (Nm)
Thread
Size
(Coarse)
Recommended
Torque
in. lb (Nm)
Maximum
Allowable
in. lb (Nm)
0.1640
(4.1656)
8 36
12 15
(1.13 1.36)
20
(2.26)
8 32
12 15
(1.36 1.69)
20
(2.26)
0.1900
(4.8260)
10 32
20 25
(2.26 2.82)
40
(4.52)
10 24
20 25
(2.26 2.82)
35
(3.95)
0.250
(6.350)
1/4 28
50 70
(5.65 7.91)
100
(11.30)
1/4 20
40 50
(4.52 5.65)
75
(8.47)
0.3125
(7.9375)
5/16 24
100 140
(11.30 15.82)
225
(25.42)
5/16 18
80 90
(9.04 10.17)
160
(18.08)
0.3750
(9.5250)
3/8 24
160 190
(18.08 21.47)
390
(44.06)
3/8 16
160 185
(18.08 20.90)
275
(31.07)
0.4375
(11.1125)
7/16 20
450 500
(50.84 56.49)
840
(94.91)
7/16 14
235 255
(26.55 28.81)
475
(53.67)
0.50
(12.70)
1/2 20
480 690
(54.23 77.96)
1100
(124.3)
1/2 13
400 480
(45.19 54.23)
880
(90.39)
0.5625
(14.2875)
9/16 18
800 1000
(90.39 112.98)
1600
(180.8)
9/16 12
500 700
(56.49 79.09)
1100
(124.3)
0.6250
(15.8750)
5/8 18
1100 1300
(124.3 146.9)
2400
(271.2)
5/8 11
700 900
(79.09 101.69)
1500
(169.5)
0.750
(19.050)
3/4 16
2300 2500
(259.9 282.5)
5000
(565.0)
3/4 10
1150 1600
(129.95 180.8)
2500
(282.5)
0.8750
(22.2250)
7/8 14
2500 3000
(282.5 339.0)
7000
(791.0)
7/8 9
2200 3000
(248.6 339.0)
4600
(542.4)
1.00
(25.40)
1 12
3700 5500
(418.1 621.5)
10000
(1130.0)
18
3700 5000
(418.1 565.0)
7600
(858.8)
1.1250
(28.5750)
11/8 12
5000 7000
(565.0 791.0)
15000
(1695.0)
11/8 8
5500 6500
(621.5 734.5)
12000
(1356.0)
1.250
(31.750)
11/4 12
9000 11000
(1017.0 1243.0)
25000
(2825.0)
11/4 8
6500 8000
(734.5 904.0)
16000
(1469.0)
20-10-00
Page 203
Revision 38
MAINTENANCE MANUAL
CSP-HMI-2
Table 202. Recommended Standard Torques for ShearType Fasteners

Diameter
inch
(mm)
Thread
Size
(Fine)
Recommended
Torque
in. lb (Nm)
Maximum
Allowable
in. lb (Nm)
Thread
Size
(Coarse)
Recommended
Torque
in. lb (Nm)
Maximum
Allowable
in. lb (Nm)
0.1640
(4.1656)
8 36
79
(0.79 1.02)
12
(1.36)
8 32
79
(0.79 1.02)
12
(1.36)
0.1900
(4.8260)
10 32
12 15
(1.36 1.69)
25
(2.82)
10 24
12 15
(1.36 1.69)
21
(2.37)
0.250
(6.350)
1/4 28
30 40
(3.39 4.52)
60
(6.78)
1/4 20
25 30
(2.82 3.39)
45
(5.08)
0.3125
(7.9375)
5/16 24
60 85
(6.78 9.60)
140
(15.82)
5/16 18
48 55
(5.42 6.21)
100
(11.30)
0.3750
(9.5250)
3/8 24
95 110
(10.73 12.43)
240
(27.12)
3/8 16
95 110
(10.73 12.43)
170
(19.21)
0.4375
(11.1125)
7/16 20
270 300
(30.51 33.90)
500
(56.49)
7/16 14
140 155
(15.82 17.51)
280
(31.64)
0.50
(12.70)
1/2 20
290 410
(32.77 46.32)
660
74.57)
1/2 13
240 290
(27.12 32.77)
520
(58.75)
0.5625
(14.2875)
9/16 18
480 600
(54.23 67.79)
960
(108.47)
9/16 12
300 420
(33.90 47.45)
650
(73.44)
0.6250
(15.8750)
5/8 18
660 780
(74.57 88.13)
1400
(158.2)
5/8 11
420 540
(47.45 61.01)
900
(101.69)
0.750
(19.050)
3/4 16
1300 1500
(146.9 169.5)
3000
(339.0)
3/4 10
700 950
(79.09 107.34)
1500
(169.5)
0.8750
(22.2250)
7/8 14
1500 1800
(169.5 203.4)
4200
(474.6)
7/8 9
1300 1800
(146.9 203.4)
2700
(305.1)
1.00
(25.40)
1 12
2200 3300
(248.6 372.9)
6000
(678.0)
18
2200 3000
(248.6 339.0)
4500
(508.5)
1.1250
(28.5750)
11/8 12
3000 4200
(339.0 474.6)
9000
(1017.0)
11/8 8
3300 4000
(372.9 452.0)
7200
(813.6)
1.250
(31.750)
11/4 12
5400 6600
(610.2 745.8)
15000
(1695.0)
11/4 8
4000 5000
(452.0 565.0)
10000
(1130.0)
Page 204
Revision 38
20-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Table 203. Locking (Drag) Torque for SelfLocking Fasteners

Diameter
inch
(mm)
Thread
Size
(Fine)
Maximum
in. lb
(Nm)
Minimum
in. lb
(Nm)
Thread
Size
(Coarse)
Maximum
in. lb
(Nm)
Minimum
in. lb
(Nm)
0.1640
(4.1656)
836
15
(1.7)
1.50
(0.17)
8 32
15
(1.7)
1.50
(0.17)
0.1900
(4.8260)
10 32
18
(2.03)
2.0
(0.23)
10 24
18
(2.03)
2.0
(0.23)
0.250
(6.350)
1/4 28
30
(3.39)
3.50
(0.40)
1/4 20
30
(3.39)
4.50
(0.51)
0.3125
(7.9375)
5/16 24
60
(6.78)
6.50
(0.73)
5/16 18
60
(6.78)
7.50
(0.85)
0.3750
(9.5250)
3/8 24
80
(9.04)
9.50
(1.07)
3/8 18
80
(9.04)
12.0
(1.36)
0.4375
(11.1125)
7/16 20
100
(11.3)
14.0
(1.58)
7/16 14
100
(11.3)
16.50
(1.86)
0.50
(12.70)
1/2 20
150
(16.95)
18.0
(2.03)
1/2 13
150
(16.95)
24.0
(2.71)
0.5625
(14.2875)
9/16 18
200
(22.60)
24.0
(2.71)
9/16 12
200
(22.60)
30.0
(3.39)
0.6250
(15.8750)
5/8 18
300
(33.90)
32.0
(3.62)
5/8 11
300
(33.90)
40.0
(4.52)
0.750
(19.050)
3/4 16
400
(45.19)
50.0
(5.65)
3/4 10
400
(45.19)
60.0
(6.78)
0.8750
(22.2250)
7/8 14
600
(67.79)
70.0
(7.91)
7/8 9
600
(67.79)
82.0
(9.27)
1.00
(25.40)
1 12
800
(90.39)
90.0
(10.17)
18
800
(90.39)
110.0
(12.43)
1.1250
(28.5750)
11/8 12
900
(101.69)
117.0
(13.22)
1.250
(31.750)
11/4 12
1000
(112.98)
143.0
(16.16)
20-10-00
Page 205
Revision 38
CSP-HMI-2
MAINTENANCE MANUAL
Page 206
Revision 38
20-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
202000
Cleaning
MAINTENANCE MANUAL
CSP-HMI-2
CLEANING
1. Cleaning
Item
Nomenclature
CM234
Solvent, dry-cleaning
General cleaning of oil and dirt deposits from

the helicopter and its components must be
accomplished by using dry-cleaning solvent
(CM234), standard commercial grade kerosene
or a solution of detergent soap and water.
Exceptions that must be observed are specified
in the following cleaning paragraphs.
Some commercial cleaning

CAUTION agents, such as readily avail
able household cleaners, contain chemicals
that can cause corrosive action and/or leave
residue that can result in corrosion. Exam
ples of cleaning agents that are not to be
used are ``Fantastic and ``409 type clean
ers, or locally made strong soap cleaners.
2. Fuselage Interior Trim and Upholstery
Cleaning
(1). Clean dirt or dust accumulations from
floors and other metal surfaces with
vacuum cleaner or small hand brush.
(2). Sponge soiled upholstery and trim
panels with a mild soap and lukewarm
water solution. Avoid complete soaking
of upholstery and trim panels. Wipe
solution residue from upholstery with
cloth dampened by clean water.
(3). Remove imbedded grease or dirt from
upholstery and carpeting by sponging
or wiping with an upholstery cleaning
solvent recommended for the `àpplica
ble fabric (nylon, vinyl, leather, etc).
NOTE: If necessary, seat upholstery may be

thoroughly dry-cleaned with solvent. When
complete dry-cleaning is performed, uphol
stery must be re-flameproofed.
3. Airframe Exterior and Rotor Blades

Cleaning
Item
CM234
Nomenclature
Use care to prevent scratching

of aluminum skin when clean
ing main rotor blades. Never use volatile
solvents or abrasive materials. Never apply
bending loads to blades or blade tabs during
cleaning.
CAUTION
NOTE: Avoid directing soapy or clean water

concentrations toward engine air intake
area and instrument static source ports in
aft fairing.
(1). Wash helicopter exterior, including
fiberglass components and rotor blades,
when necessary, using solution of clean
water and mild soap.
(2). Clean surfaces stained with fuel or oil
by wiping with soft cloth dampened by
solvent (CM234), followed by washing
with clean water and mild soap.
(3). Rinse washed areas with water and dry
with soft cloth.
4. Transparent Plastic Cleaning
(1). Clean outside surfaces of plastic panels
by rinsing with clean water and
rubbing lightly with palm of hand.
(2). Use mild soap and water solution or
aircraft type plastic cleaner to remove
oil spots and similar residue.
Never attempt to dry plastic
panels with cloth. To do so
causes any abrasive particles lying on plas
tic to scratch or dull surface. Wiping with
dry cloth also builds up an electrostatic
charge that attracts dust particles from air.
CAUTION
(3). After dirt is removed from surface of

plastic, rinse with clean water and let
air-dry or dry with soft, damp chamois.
20-20-00
Page 201
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
(4). Clean inside surfaces of plastic panels

by using aircraft type plastic cleaner
and tissue quality paper wipers.
6. Cleaning Of Engine Air Inlet Screens

(1). Remove engine air inlet and engine
cooling air screen (Ref. Chap. 71).
5. Engine Compressor Contamination

Removal
(2). Clean screens with soft brush to remove

dirt accumulations.
(Ref. Chap. 71 and the applicable Allison

Engine Operation and Maintenance Manual,
Table 201, Sec. 01-00-00)
(3). Immerse screen in solution of detergent

and allow to soak approximately 15
minutes. Flush out clear water. Allow
screen to drain and air-dry thoroughly.
Page 202
Revision 23
20-20-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
203000
Painting
MAINTENANCE MANUAL
CSP-HMI-2
PAINTING
1. Paint Finish
Polyurethane paint is used for the helicopter
exterior finish. The primary interior finish is
acrylic paint. A base coat of primer is used on
most helicopter structure.
2. Paint Removal
Item
Nomenclature
CM229
Paint remover
CM230
Paint remover
Use paint remover (CM229 or CM230) when it

becomes necessary to remove finish paint
coatings. Ordinarily, use of paint remover
should be limited to stripping of paint from
parts that require magnetic-particle or
fluorescent-penetrant inspection and to parts
that require removal of excessive paint
buildup. When possible, use high-pressure
water spray to rinse off paint remover and
paint particles and to neutralize paint
remover. Solvent type paint remover usually
does not remove primer coating; acid type
solvent removes primer.
If paint remover is used in vicin
ity of drive shaft couplings, be
sure couplings are completely masked and
covered. If paint remover contacts coupling
diaphragms, rust spots will develop and cou
pling replacement is required. If acid type
paint remover is used, comply with all spe
cial safety precautions listed on container.
CAUTION
3. Paint Touchup
Following procedures apply to application of
both polyurethane and acrylic paints.
Item
CM305
CM318
CM320
(1). Apply applicable chemical surface

treatment (Ref. Sec. 20-40-00) if metal
protection is not adequate. If chemical
surface treatment is undamaged, or has
already been applied, wipe surface
clean with thinner (CM320) and wipe
dry immediately.
(2). Apply coat of primer (CM318). Feather
primer coating onto surrounding color
coat. Allow primer to air-dry for 30
minutes.
(3). Apply lacquer (CM305) color coats to
match original finish color.
B. Touchup Flaking or Dried Paint or
Primer
Item
CM801
Nomenclature
Abrasive paper, silicon carbide
(1). Sand non-adherent surface to smooth

featheredge with surrounding area,
using 320-grit or finer abrasive paper
(CM801), and wet or dry sanding
method. Do not sand beyond point
where chemical film protection begins
to show through primer.
(2). Touchup sanded area [Ref. Touchup Small Sanded Area).
C. Touchup Primer Not Adhering to Metal
Finish
A. Touchup Small Sanded Areas

The following procedure is for rework of
scratches, nicks, gouges and other small
blemishes.
Nomenclature
Lacquer, acrylic
Primer
Thinner, lacquer
Item
CM801
Nomenclature
20-30-00
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CSP-HMI-2
MAINTENANCE MANUAL
(1). Use 320-grit or finer abrasive paper

(CM801) and wet or dry sanding
method to sand through chemical film
to bare metal. Feather surrounding
surface with bare surface.
(2). Re-treat bare metal with applicable
chemical film (Ref. Sec. 20-40-00)
using brush application.
(4). Lightly sand surface with 320-grit

abrasive paper (CM801). Normal grain
appearance does not require further
filling or sanding.
(5). Apply primer and color finish (CM305)
[Ref. Touchup - Small Sanded Areas).
E. Touchup Polycarbonate Plastic Parts
(3). Touchup re-treated surface [Ref.

Touchup - Small Sanded Areas).
D. Touchup Glass Fiber Laminate Parts
Item
CM217
CM219
CM305
CM316
CM801
Nomenclature
Isopropyl alcohol
Methyl-ethyl-ketone
Lacquer, acrylic
Epoxy coating / Thinner
(1). Remove all gloss from area requiring

finish with 100-grit or coarser abrasive
paper (CM801) until there is a uniform
dull condition.
MEK solvent is flammable.
WARNING Use only in well-ventilated
area and away from heat and flame.
(2). Wipe surface clean with 1:1 mixture of
MEK (CM219) and isopropyl alcohol
(CM217).
(3). Squeeze one coat of Poly-EP (CM316),
thinned as required with thinner, into
fiberglass pores until surface of fibers is
smooth.
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Revision 23
20-30-00
Item
Nomenclature
CM220
CM217
CM305
CM317
Naphtha aliphatic
Isopropyl alcohol
Lacquer, acrylic
Resin primer / Thinner
(1). Wipe surface clean with a 1:1 mixture

of naphtha (CM220) and isopropyl
alcohol (CM217). Mix equal parts (1:1)
of primer resin (CM317) and thinner.
Apply one coat to surface and allow to
air-dry minimum of 3 hours. Apply
epoxy primer and color finish (CM305)
F. Touchup ABS Thermoplastic Parts
Item
Nomenclature
CM305
Lacquer, acrylic
Clean surface with mild soap and water. Dry

thoroughly. Apply one coat of lacquer (CM305)
MAINTENANCE MANUAL
4. Main Rotor Blade Paint
The following procedures is to be used whenev
er the main rotor blades require either
repainting or paint touch-up.
NOTE:
CSP-HMI-2
CAUTION
D When sanding paint from the main rotor
blade, take care to not damage rivet heads
and sealant.
D Do not sand through the paint and primer
into the base metal.
D Repaint main rotor blades only in sets to

maintain rotor balance. Never completely
repaint only one main rotor blade
installed on helicopter.
(4). Using 320 grit, or finer, abrasive paper

method, sand areas that require
painting.
D New main rotor blades have the inboard

24 inches (610 mm) painted gloss white.
This aids in inspection of the blade.
(5). Using a soft cloth, dampened in

isopropyl alcohol (CM217), thoroughly
clean main rotor blade.
D At owner-operators convenience, in-ser

vice main rotor blades may have the in
board 24 inches (610 mm) painted gloss
white.
(6). Inspect sanded areas for damage.
Item
Nomenclature
CM206
Chemical coating
CM217
Isopropyl alcohol
CM304
Enamel, epoxy
CM318
Primer
CM729
CM801
A. Main Rotor Blade Paint Removal

(1). Position main rotor blade on a bench of
sufficient length to provide support.
(2). Inspect main rotor blade (Ref. Sec.
62-10-00, Main Rotor Blade Inspec
tion).
When removing paint from
main rotor blade, do not use any
paint remover. Bonding agents used in
manufacture of the blade may be damaged
by the chemicals causing the blade to be un
serviceable.
CAUTION
(3). Apply tape (CM729) to all bushings,

bearing, data plates and the abrasion
strip.
B. Main Rotor Blade Paint Application
NOTE: If inboard 24 inches (610 mm) of main

rotor blade is to be painted white, paint is to
be applied to the entire circumference of the
blade. There is to be no ridges in the paint
when completed.
(1). Inspect main rotor blade (Ref. Sec.
62-10-00, Main Rotor Blade Inspec
tion).
(2). Ensure all bushings, bearing, data
plates and the abrasion strip are
protected from paint with tape
(CM729).
clean main rotor blade.
(4). Treat any bare metal areas of main
rotor blade with chemical coating
(CM206).
NOTE: Mix primer (CM318) according to

manufacturer's recommendations.
(5). Allow mixed primer to stand for 15 to
30 minutes prior to use.
NOTE:
D Working life of mixed primer is four hours
maximum.
D Primer allowed to stand for more than
two hours must be stirred or shaken be
fore use.
D Addition of freshly mixed primer to re
plenish an older mixture is not permitted.
20-30-00
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Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
(6). Apply primer (CM318) to sanded areas,

feather into surrounding color coat.
(7). Allow to air-dry for one hour minimum.
NOTE: Mix paint (CM304) according to

(8). Allow mixed paint to stand for 20
minutes minimum prior to use.
NOTE:
D Working life of mixed paint is four hours
maximum.
(9). Apply paint (CM318) to primed areas.
Feather-edge paint while applying.
(10). Allow to air-dry for eight hours
minimum.
(11). Remove protective tape from main rotor
blade.
NOTE: Main rotor assembly may need to be rebalanced after painting.

5. Tail Rotor Blade Paint
The following procedures is to be used whenev
er the tail rotor blades require either repaint
ing or paint touch-up.
NOTE: Repaint tail rotor blades only in sets to

maintain rotor balance. Never completely
repaint only one tail rotor blade installed on
helicopter.
Item
Nomenclature
CM206
CM217
CM304
CM318
CM729
CM801
Chemical coating
Isopropyl alcohol
Enamel, epoxy
Primer
A. Tail Rotor Blade Paint Removal

(1). Inspect tail rotor blade (Ref. Sec.
64-10-00, Tail Rotor Blade Inspection).
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Revision 34
20-30-00
When removing paint from tail

rotor blade, do not use any paint
remover. Bonding agents used in manufac
ture of the blade may be damaged by the
chemicals causing the blade to be unservice
able.
CAUTION
(2). Apply tape (CM729) to all bushings,

data plates and the abrasion strip.
(3). Plug root end of tail rotor blade to
ensure no paint enters.
CAUTION
D When sanding paint from the tail rotor
blade, take care to not damage rivet heads
and sealant.
D Do not sand through the paint and primer
into the base metal.
(4). Using 320 grit, or finer, abrasive paper
method, sand areas that require
painting.
clean tail rotor blade.
(6). Inspect sanded areas for damage.
B. Tail Rotor Blade Paint Application
(1). Inspect tail rotor blade (Ref. Sec.
64-10-00, Tail Rotor Blade Inspection).
(2). Ensure all bushings, data plates and
the abrasion strip are protected from
paint with tape (CM729).
(3). Ensure root end of tail rotor blade is
plugged to prevent entry of paint.
clean tail rotor blade.
(5). Treat any bare metal areas of tail rotor
blade with chemical coating (CM206).
NOTE: Mix primer (CM318) according to

(6). Allow mixed primer to stand for 15 to
30 minutes prior to use.
MAINTENANCE MANUAL
NOTE:
D Working life of mixed primer is four hours
maximum.
D Primer allowed to stand for more than
two hours must be stirred or shaken be
fore use.
(7). Apply primer (CM318) to sanded areas,
feather into surrounding color coat.
CSP-HMI-2
NOTE:
D Working life of mixed paint is four hours
maximum.
(10). Apply paint (CM318) to primed areas.
Feather-edge paint while applying.
(11). Allow to air-dry for eight hours
minimum.
(8). Allow to air-dry for one hour minimum.
NOTE: Mix paint (CM304) according to

(9). Allow mixed paint to stand for 20
minutes minimum prior to use.
(12). Remove protective tape from tail rotor

blade.
NOTE: Tail rotor assembly may need to be rebalanced after painting.
20-30-00
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CSP-HMI-2
MAINTENANCE MANUAL
Page 206
Revision 34
20-30-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
204000
Corrosion
Prevention
MAINTENANCE MANUAL
CSP-HMI-2
CORROSION PREVENTION
1. Corrosion Control
The airframe is fabricated primarily of
aluminum and some magnesium alloys, with
selective use of stainless steel and titanium,
and should be checked regularly for any signs
of corrosion, especially at points of dissimilar
and overlapping metal contact. Corrosion of
dissimilar metals is the result of several
conditions; lack of sufficient insulation in
areas of metal contact, tears or punctures in
metal itself, and areas where protective
finishes have been scuffed, scratched, chipped
or worn away. Perform corrosion control
according to MDHI Corrosion Control Manual
(CSP-A-3) and instructions in the following
paragraphs.
Do not apply potassium hydrox
ide to or near bolts, fasteners,
seams, or faying surfaces. Immediately af
ter completing the magnesium and alumi
num test (Ref. NOTE below), wash the
tested area with water to prevent burns and
continued action on the material.
CAUTION
(1). Coat contacting surfaces with layer of

sealing compound (CM425), in addition
to primer (CM318).
CAUTION
Do not use steel washers.
(2). Use 5056S aluminum alloy washers

under boltheads and nuts that would
otherwise contact magnesium. If 5056S
aluminum is not available, use 5052S
alloy washers.
(3). Apply primer on attaching hardware
before installation.
3. Sealing Compound Application
Use sealing compound (CM425) to replace
loose or missing sealant on exterior surfaces.
Sealant is used to fill seams and joints that
might trap water. Apply sealant as follows:
Item
CM425
Nomenclature
Sealing compound
NOTE: To differentiate between aluminum and

magnesium alloy, apply one drop of ordinary
potassium hydroxide (dropped from a glass
rod) to the surface of the metal being tested.
If the alloy is aluminum, a foaming or boil
ing action of the liquid, accompanied by a
black discoloration of the metal, will imme
diately occur. If the alloy is magnesium, no
reaction will be evidenced.
2. Magnesium Alloys Insulation Against
Corrosion
To prevent galvanic corrosion between
magnesium and any dissimilar metals:
Item
Nomenclature
CM318
Primer
CM425
Sealing compound
(1). Check that seam or joint is clean and

free of foreign matter and moisture.
(2). Apply sealant with putty knife or
similar tool.
(3). Force sealant well down into seam to
eliminate any air pockets.
(4). Fillet sealant to give joint or seam a
smooth appearance.
4. Main Rotor Hub Corrosion Prevention
(TriFlow Wash Procedure)
The following procedure will help prevent
corrosion of main rotor hub components,
especially on helicopters operated in marine
environments. The procedure should be
accomplished following the last flight each day
for helicopters operated in marine or other
corrosive environments, and at each 25-hour
inspection (Ref. Chap. 05), or more often if
desired, for helicopters not operated in
corrosive environments.
20-40-00
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MAINTENANCE MANUAL
CSP-HMI-2
Item
Nomenclature
CM104
Lubricant, spray
CM227
Washing compound with wax
(5). Wash remainder of helicopter exterior

using fresh water spray.
(6). Wash main rotor blades with Zip Wax
(CM227) or equivalent, mixed per
manufacturer's instructions.
5. Main Rotor Blades Corrosion Arresting
Use care when working
WARNING around turning rotor blades.

Stay low. Remain on right side of heli
copter to avoid tail rotor blades.
NOTE: Perform the first step below prior to en

gine shutdown, following the last flight of
the day if possible. When the rotor stops
turning, the laminates of the strap-pack
spread apart slightly. Contaminates col
lected on the edges of the strap-pack assem
bly can enter the area between the lami
nates as they spread apart. If the rotor
continues turning until the contaminants
are washed away, centrifugal force will keep
the laminates compressed and not allow the
corrosive substances to enter the area be
tween the laminates.
The following procedure will help prevent

corrosion of main rotor blades. The procedure
should be accomplished following the last
flight each day on helicopters operated in
marine or other corrosive environments, and
weekly for helicopters not operated in corrosive
environments.
Item
Nomenclature
CM227
CM228

Surface cleaner
Wear rubber gloves when us
WARNING ing phosphoric solution in

next step.
(1). Bring engine to ground idle (64-65 %

Nl); set SCAV AIR to ON (Ref. applica
ble PFM, Table 201, Sec. 01-00-00).
Perform the following:
(a). Spray fine fresh water mist on main
rotor blades.
(b). Direct a strong stream of fresh water
into main rotor hub and control
system at main rotor hub.
(c). Spray entire rotor hub with lubricant
(CM104).
(2). Shut down engine and allow rotor
blades stop turning.
NOTE: In the next step, spray directly between

individual laminates.
(3). Lift main rotor blades to separate strap
pack laminates and spray strap-packs
with lubricant.
(4). Perform engine water wash (Ref. Chap.
71).
Page 202
Revision 23
20-40-00
(1). Wipe down main rotor blades with

surface cleaner (CM228).
(2). Rinse main rotor blades immediately
with water and dry. (Ref. Sec. 20-20-00
for additional information on cleaning
main rotor blades.)
(3). Wax main rotor blades with Zip Wax
(CM227) or equivalent, mixed per
A. Main Rotor Blade and Damper Attach
Pins Corrosion Prevention
If helicopter is subject to salt-laden atmo
sphere, lubricate mating surfaces of barrel nut
and cam handle at each periodic inspection,
using corrosion preventive oil (CM120) (Ref.
Chap. 62).
Item
Nomenclature
CM120
Oil, corrosion preventive
MAINTENANCE MANUAL
6. Magnesium Alloy Exterior Surface
Touchup Treatment
Item
Nomenclature
CM207
Chromic acid solution
CM320
Thinner, lacquer
(1). Wash affected area with solution of

mild soap and clean fresh water. Rinse
area with clean water and wipe dry
using clean soft lint-free cloth.
(2). Use thinner (CM320) on damaged area
to remove any grease and old paint.
(3). Apply chromic acid solution (CM207) by
swabbing exposed area for 10 to 30
minutes.
(4). Using clean cloth soaked in clean, fresh
water, thoroughly rinse area where
solution was applied. Allow area to
thoroughly dry.
(5). Apply paint finish touchup (Ref. Sec.
20-30-00).
7. Aluminum Alloy Exterior Surface Touchup
Treatment
Item
Nomenclature
CM206
Chemical coating
NOTE: If there is any question of whether or

not the protective coating is removed, it
should always be assumed that bare metal
is exposed.
(1). Wash affected area with solution of
mild soap and fresh water. Rinse area
with clean water and wipe dry with
clean soft lint-free cloth.
CSP-HMI-2
(2). Using swab, liberally apply chemical

film (CM206). Allow solution to remain
on surface for 1 to 3 minutes, or until
surface becomes amber to brown in
color.
(3). Rinse treated surface thoroughly with
clean water. After rinsing, wipe off
excess moisture with clean lint-free
cloth. If dry compressed air is available,
blow any moisture from joints or
crevices and allow to dry completely at
room temperature for approximately 1
hour.
20-30-00).
8. Steel Alloy Exterior Surface Touchup
Treatment
Item
Nomenclature
CM228
Surface cleaner
CM801
(1). Remove loose paint and corrosion

products by scraping area with sharp
phenolic scraper, brushing with heavy
fiber brush and light sanding with
320-grit or finer abrasive paper
(CM801).
(2). Wash off area with mild soap and clean
fresh water; rinse thoroughly.
(3). Treat surface with surface cleaner
(CM228).
(4). Allow solution to remain on surface for
approximately 5 minutes. Keep sur
faces wet.
(5). Rinse thoroughly with clean water. Dry
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
surface with solution.

20-30-00).
20-40-00
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MAINTENANCE MANUAL
CSP-HMI-2
9. Splitter Bungee Spring Corrosion Control

(500N)
It is recommended that after shutdown from
the last flight of the day, for helicopters
operating in a corrosive environment, the
splitter bungee spring be sprayed with
Tri-Flow.
Item
CM104
Nomenclature
Lubricant, spray
(1). After helicopter shut-down, insert

absorbent cloth into area around
splitter bungee spring.
(2). Liberally spray spring with lubricant
(CM104) until spring inner coils are
coated.
(3). Remove absorbant cloth from around
spring.
(4). Wipe excess spray from aircraft.
Table 201. AntiCorrosion Chemical Finishes Aluminum

Process
Applicable Specification
Normal Coating Thickness and Color
Dow #1 (Chrome Pickel)
MILM3171, Type I
Removes metal. Iridescent yellow or red;

gray coatings are unacceptable.
Dow #7 (Dichromate
Treatment)
MILM3171, Type III
No dimensional change. Wrought or

extruded parts chestnut brown; castings
light brown to black; AZ91CT6 and
AZ92AT6 alloys gray.
Dow #17 (Anodize)
MILM45202, Type I light coat
Class C: 0.00020.0003 inch

(0.005080.00762 mm); light green.
Type II heavy coat
Class D: 0.00020.0035 inch

(0.005080.08890 mm); dark green.
MILM3171, Type VI
No dimensional change; gray to black.
Dow #19 (Chromic Acid

Brushon Treatment)
Page 204
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20-40-00
CSP-HMI-2
MAINTENANCE MANUAL
Section
209000
Nondestructive
Inspection
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSP-HMI-2
NONDESTRUCTIVE INSPECTION
1. Nondestructive Inspection Methods
missing fasteners, security of parts,

corrosion, and damage.
A. Visual Inspection
(3). Treat any corrosion found during

preliminary inspection.
(Ref. Figure 201)

(1). Select applicable visual inspection aids
from the following list:
(4). Clean the areas or surface of parts to be

inspected.
(a). A flashlight with the correct explo

sive atmosphere rating, beam spread,
efficiency, and brightness for the
inspection being performed.
(a). Remove any contaminates that

might hinder surface indications.
(b). An inspection mirror on a ball joint

for use in viewing an area that is not
in the normal line of sight.
(5). Using optical aids as required, inspect

area as follows:
(b). Do not remove protective finishes.
(c). A 2-10 power magnifying glass to

expose defects that cannot be seen by
the unaided eye.
(a). Examine surface for cracks using a

flashlight, and confirm with a
magnifying glass.
(d). A borescope to allow remote visual

inspection of internal surfaces or
otherwise inaccessible areas.
(b). Examine surface for other disconti

nuities, such as: discoloration from
overheating; buckled, bulging, dented
skin; cracked, chafed, split, or dented
tubing; chafed electrical wiring;
delaminating of composites; and
damaged protective finishes.
(2). Perform a preliminary inspection of

overall general area for cleanliness,
presence of foreign objects, deformed or
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
20-90-00
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MAINTENANCE MANUAL
CSP-HMI-2
B. Dye Penetrant Inspection
Item
Nomenclature
CM234
CM805
Dye penetrant kit
(1). Using cleaning solvent (CM234), clean

area to be inspected.
NOTE:
D Manufacturers instructions on Dye Pene
trant Kit take precedence over the follow
ing steps.
D Parts to be inspected must be dry and
heated to at least 70F (21.1C) but not
over 130F (54.4C).
(2). Apply penetrant from dye penetrant kit
(CM805) by brushing, spraying or by
dipping. Allow to stand for a minimum
of 2 minutes.
(3). Remove excess penetrant with remover
(available with dye penetrant kit
(CM805)), or by cleaning with plain
water. Allow part to dry.
(4). Apply a light even layer of developer
from dye penetrant kit (CM805) by
brushing, spraying or by dipping. When
dipping, avoid excess quantity.
(5). Penetrant, which has penetrated into
cracks (or other openings) in the surface
of the part will be drawn out by the
developer resulting in a bright red
indication.
(6). If part is serviceable or repairable,
clean part free of penetrant and
developer with cleaning solvent
(CM234).
C. Coin Tap Inspection
Revision 40
CM234
The coin tap method of inspection is used

evaluate composite structures. The coin tap is
limited to detecting shallow defects.
When inspecting cored structure, two sided
access is required. When multiple laminates
are installed over core, the core bond-line
cannot be evaluated.
The sound of an acceptable part can vary
considerably and the entire area must be
tapped in order to detect any variance.
Compare the sound of the suspected area with
the sound of a known acceptable area.
An acceptable area will have a slightly sharper
or crisper sounding response. A dead or flat
sound is unacceptable, and requires a more
thorough type of NDI.
Any suspect areas must be in
spected by person(s) qualified in
the appropriate NDI. Contact MDHI cogni
zant engineering for recommended NDI pro
cedures and applications.
CAUTION
(1). Thoroughly clean area to be inspected

with cleaning solvent (CM234).
(2). Perform a visual inspection for any
raised or blistered appearing areas.
NOTE: Tap the entire area to be inspected in

cluding any surrounding area of like
construction.
(3). Using a coin, light hammer, or other
suitable blunt object, lightly tap the
surface of the part to be inspected.
D. Fluorescent Penetrant Inspection
Refer to the appropriate manufacturer's
related instructions for type of equipment and
materials being used.
E. Magnetic Particle Inspection
Refer to the appropriate manufacturer's
related instructions for type of equipment and
materials being used.
(Ref. Figure 202)

Page 202
Item
Nomenclature
20-90-00
MAINTENANCE MANUAL
CSP-HMI-2
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
This procedure includes general information
on material, equipment and procedures for the
detection of surface cracks.
(a). Personnel doing nondestructive tests

must be qualified and certified in of
NAS 410 or ASNT SNT-TC-1A or
equivalent. Personnel making must
be certified to Level 2 minimum.
The Eddy Current test instruments induce an

Eddy Current into a conductive medium and
detect the change in the induced eddy current
field which is produced by a defect.
(b). The test facilities written procedure

approved by the Level 3 technician
must be followed.
Related Publications
(Ref. Section 010000 (Table 201)
Specification
Publication Title
NAS410

ASNTSNTTC1
ASTM E 1316
Standard Terminology for Nondestructive
Examinations
(1). Personnel Qualification and Certifica

tion.
(2). Equipment
Refer to equipment manufacturer's
instructions for type of material
inspected.
(a). Electronic - Electronic - All electron
ic equipment must be calibrated
annually or after repair. Records
must be kept and made available
when requested. All calibration must
be made to a national standard. The
equipment must be approved for the
type of part examined. Maintain a
3:1 signal to noise ratio during
inspection.
20-90-00
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CSP-HMI-2
MAINTENANCE MANUAL
(b). Probes - Must be correct for the part

shape, depth of penetration, and
frequency range for material ex
amined, and sensitivity to sense the
defect. Test probes must not give
interference during movement.
Probes must be identified with the
manufacturer's part number and
frequency range.
(c). Standards - Reference calibration
standards can be actual parts (with
natural defects) or from test blocks.
All calibration standards must be
calibrated and certified.
1). Reference standards must be of an
alloy of the same base material
and temper or approximately the
same electrical conductivity,
surface texture, shape, and defect
location as the part to be in
spected.
2). Only the reference standards
calibrated and certified must be
used for the specific component
examined. All calibration stan
dards must be kept to a national
standard. Records must be kept
and made available when reques
ted.
(3). Surface preparation - All surface
contamination that could cause an
interference with the inspection must
be removed. Methods of cleaning must
not damage surface finish or damage to
the part.
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Revision 40
20-90-00
(4). Standardization
(a). Standardization must be done in
accordance with the manufacture
recommendations.
(b). Calibration scan must be done
before, during and after the inspec
tion. If the after calibration shows
test equipment is not accurate, do a
calibration of the equipment and do
another inspection on all components
examined since last acceptable
calibration.
(5). Regulatory Requirements

The Eddy Current Inspection of
components must be done with the
test facilities local aviation regulato
ry authority and approved proce
dures.
(6). Test Facilities
(a). Approved facilities must use the
same or equivalent equipment.
(b). Analysis of all indications must be
made in accordance with the test
facilities approved procedures and
with defects.
(c). Parts with defects must be removed
from service in accordance with the
facilities approved procedures.
(d). Records must be completed in
accordance with the facilities ap
proved procedures.
MAINTENANCE MANUAL
Chapter
21
Environmental
Control System
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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
21 Contents
Page i
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 901. Weight and Balance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 902. Engine Air Bleed Line Installation (250-C20B) . . . . . . . . . . . . . . . . .
Figure 903. Engine Air Bleed Line Installation (250-C20R/2) . . . . . . . . . . . . . . .
Figure 904. Engine Air Bleed Line Installation (250-C30) . . . . . . . . . . . . . . . . . . .
Figure 905. Heating Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 906. Duct, Hose and Convenience Panel Installation (Sheet 1 of 2) . . . .
Page ii
Revision 23
21 Contents
904
904
905
906
907
908
909
MAINTENANCE MANUAL
CSP-HMI-2
Section
211000
Ventilation Systems
MAINTENANCE MANUAL
CSP-HMI-2
VENTILATION SYSTEMS
1. Environmental Systems
The cabin ventilation system consists of a
ventilation valve, control cable and snapvents
installed in the door windows. The ventilation
valve contains a moveable vane operated by a
push-pull cable mounted in the right center of
the instrument panel. The control cable locks
the vane in any selected position, controlling
airflow. Fresh air forced through an opening in
the lower front canopy passes through the
valve and is directed into the cabin.
Adjustable snapvents are installed in each
door window. The snapvents can be opened
and rotated to face the airstream to supple
ment fresh air intake, or in the trail position,
provide a vent-air exhaust outlet.
Before high speed flight; ensure
that all snapvents are posi
tioned up, aft or down with outs in the trail
position. Door damage and vibrations could
occur if vent cutouts face the airstream.
CAUTION
NOTE:
D The following maintenance procedures
cover round or pointed nose helicopters.
Whenever reference is given to diffuser
type valve this is for round nose military
D model, and likewise the Y type is for
civil models.
D For round nose model with diffuser or Y
type valve, refer to Figure 202. For
pointed nose Y type valve, refer to
Figure 201.
2. Cabin Vent Control Cable Replacement
A. Cabin Vent Control Cable Removal
(4). Remove control cable nut from plunger

housing and pull entire control cable
out aft through instrument panel
mounting hole.
B. Cabin Vent Control Cable Installation
(1). Route replacement control cable
through instrument panel and secure in
place using lockwasher and control
cable nut.
(2). Secure control cable sleeve to valve
bracket with clip.
(3). Position shaft arm so that vane assem
bly is fully closed.
(4). Insert control cable wire through hole
in swivel and move control knob to fully
closed position.
(5). Tighten swivel on control cable wire
and install cotter pin.
(6). Check swivel for free rotation by
actuating control knob through full
stroke. Inspect valve assembly for
complete closure of inlet opening when
control knob is pushed forward against
cable panel fitting stop. Check valve
door for looseness on shaft and defor
mation; valve door must be flat; a firm,
snug fit is required in the inlet.
(7). Reinstall right side fairing on instru
ment panel.
3. Cabin Ventilating Valve Replacement
A. Cabin Ventilating Valve Removal
(1). Remove left and right side fairing from
instrument panel; then remove ducts
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

ment panel.
(3). Remove control cable clip and discon

nect control cable from swivel on valve
shaft.
(3). Disconnect control cable from swivel in

valve shaft. Remove clip and separate
control cable from support bracket.
(4). Drill out rivets and remove valve

assembly from helicopter canopy panel.
21-10-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
B. Cabin Ventilation Valve Installation

(1). Position ventilating valve on canopy
panel and align rivet holes. Attach
valve to canopy panel with rivets
spaced at 90 degrees.
NOTE: If rivet holes are elongated or oversize,

install next larger rivets.
(2). Secure control cable sleeve to valve
bracket with clip.
(3). Install swivel assembly loosely in arm
of shaft.
(4). Position shaft arm so that vane assem
bly is fully closed.
(5). Insert control cable wire into swivel
assembly and move control knob to
fully closed position.
(6). Tighten swivel assembly on control
cable wire; install cotter pin.
(7). Operate valve through several openclose cycles to assure ease of operation
and to determine that valve locks in
any position when control knob is
released.
(8). Install ducts on rear of valve; then
install instrument panel left and right
side fairings.
4. Cabin Ventilation Valve Disassembly
(1). Remove screws and separate vane
assembly from shaft.
(2). Remove cotter pins and slide shaft from
valve body.
5. Cabin Ventilating Valve Reassembly
(3). Position vane assembly on shaft and

secure with screws using loctite
(CM431).
(4). Install washer on end of shaft and
insert cotter pin.
(5). Operate valve several times to assure
freedom of operation and positive
closing.
6. Cabin Ventilating Valve Inspection
(1). Inspect for cracks, secure attachment to
canopy panel and separation of bonded
joints.
NOTE: Very small, widely separated spots or

voids in plastic joints are not separation but
air pockets produced during solvent bonding
at manufacture.
(2). Inspect for bent shaft or vane assembly
and excessive shaft wear in pivot areas.
(3). Inspect seal on vane assembly for wear.
7. Cabin Ventilating Valve Repair
Item
Nomenclature
CM418
Cement, epoxy
(1). Patch polycarbonate valve body cracks

and repair seam separations according
to repair methods specified for polycar
bonate plastic (Ref. Sec. 20-30-00).
(2). Replace unserviceable seal if installed,
using cement (CM418) according to
container instructions.
8. SnapVent Replacement
Item
Nomenclature
CM431
Sealing, locking and retaining compound
(1). Install cotter pin in hole at control arm

end of shaft. Install washer on shaft to
bear on cotter pin.
(2). Insert shaft in body of valve.
Page 202
Revision 23
21-10-00
A. SnapVent Removal
(1). Push snapvent outward in window
(open position).
(2). Grasp open side of snapvent and gently
squeeze it into an elliptical shape.
(3). Slip snapvent out of window hole at
about a 30 degree angle to surface of
window.
MAINTENANCE MANUAL
B. SnapVent Installation
CSP-HMI-2
(2). Slip snapvent flange into window hole

at an angle of about 30 degrees to
surface of window. Be sure ends of wire
stiffener are inside window pole.
(1). Hold open end of replacement snapvent

and gently squeeze it into an elliptical
shape.
CONTROL KNOB
INSTRUMENT
PANEL
CONTROL CABLE NUT
VENT VALVE CONTROL
CABLE
AIR DUCT
DOOR WINDOW
SNAP VANT
CABIN VENT VALVE

K
BRACKET
CANOPY PANEL
CLIP
SHAFT
OUTSIDE (RAM) AIR IN
SIDE (EXAUST) AIR
RIVET
SWIVEL ASSEMBLY
VENTILATING VALE
VANE
SEAL
VANE ASSEMBLY
G21-1001
Figure 201. Ventilating System Pointed Nose
21-10-00
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
OUTSIDE (RAM) AIR

INSIDE (EXHAUST) AIR
DOOR WINDOW
SNAP VANT
CONTROL KNOB
NOTE
CONTROL CABLE NUT

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

LOCKWASHER
CONTROL KNOB
CLIP
CONTROL CABLE
SWIVEL
ASSEMBLY
SPRING PIN
VALVE ASSEMBLY
DEFFUSOR
SHAFT
CANOPY PANEL
RIVET
VALVE PLATE
NOTE:
369D INSTRUMENT PANEL SHOWN,
500MD CONFIGURATION VALVE IS
INSTALLED WITH A T-SHAPED
OPEN PANEL.
COLLAR
TUBE
G21-1002
Figure 202. Ventilating System Round Nose

Page 204
Revision 23
21-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
214000
Heating System
MAINTENANCE MANUAL
CSP-HMI-2
HEATING SYSTEM
1. Heating System Description and
Operation
(1). The heating system mixes cold air
supplied by the oil cooler blower and
hot air extracted from the engine
compressor scroll. Cabin air tempera
ture is mechanically controlled with a
handle in the crew compartment that
positions a cable operated mixing valve.
The system distributes temperature
controlled air via a muffler and ducts to
strategically located cabin outlets.
(2). The heat control valve is mounted on
the forward left side of the firewall
bulkhead. The valve consists of a
housing that contains air control ports
for mixing hot and cold air. A 90 inlet
elbow attaches the valve to the com
pressor bleed air tube through the
firewall bulkhead. The valve housing
inlet contains a stainless steel bleed air
flow control ball valve that is rotated by
an attached drive pulley. A nozzle on
the inlet body injects hot air down
stream of cold air. A fitting supports the
cold air control vane and drive pulley
that is rotated by a drive belt. Hot air is
mixed with cold air at a variable ratio.
Because engine bleed air temperature
is approximately 500F (260C), cold air
is never completely shut off while the
system is in use.
(3). The duct system and the direct air flow
muffler are forward of the firewall and
enclosed behind the heating system

access cover. Air is Ducted overhead
from the muffler into the cargo/pas
senger and crew compartments. Six
fan-shaped diffusers distribute air
throughout the cabin.
(4). The muffler consists of a laminated
fiberglass housing, perforated alumi
num core, and a one inch layer of
fiberglass wool around the core.
(5). Air outlets are also provided for the
cargo/passenger compartment through
an overhead duct diffuser valve
mounted in the passenger convenience
panel. Diffuser valve airflow can be
adjusted as required.
(a). The -519 heating system adds
ducting to provide two floor-heated
air outlets.
(b). The -521 heating system provides
ducting for one floor-heated air
outlet.
(6). The control handle, control cable and
conduit assembly are incorporated in
the left side of the duct attached to the
overhead canopy structure. Moving the
control handle forward opens the heat
control valve. Control handle travel is
approximately 2-3/4 inches (6.985 cm)
from open to closed. Cable routing is
along the left side of the main rotor
mast support structure and down to the
firewall mounted control valve.
21-40-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
2. Heating System Fault Isolation

(Ref. Table 201)
Table 201. Troubleshooting Heating System
Symptom
Probable Trouble
Corrective Action
Control valve pulley drive belt

broken
Replace faulty parts and adjust

valve.
Pulley shaft retaining pin sheared

or control cable spring pin sheared

valve.
Heat valve ball binding in housing
Shim between valve housing and

elbow fitting.
Heat control valve internally

defective
Replace valve.
Heat control clevis improperly

adjusted for length
Adjust control cable clevis.
Cracked, broken or disconnected

ducting in system
Replace defective ducts.
Movement of heat valve does not

shut off hot air
Same troubles as above

valve.
Movement of heat valve control

lever very difficult
Control cable crushed or one or

more routing bend radii less than 3
inch (7.62 cm) minimum
Check cable operation with clevis

detached from pulley arm.
Heat valve control lever does not

remain in selected position
Cable sleeve (sheath) damage

causing preload springback
Replace defective parts.
Air excessively hot at diffusers (*)
Improper cold air mixing
Adjust valve.
Actuation of heat valve control

lever produces no heated air at
outlets
(*) CAUTION: Do not operate engine until this condition is corrected. Canopy plastic or ducting may be badly
damaged if operation is continued.
3. Heat Control Valve Replacement

(Ref. Figure 201)
A. Heat Control Valve Removal
(1). Remove interior trim and left aft
bulkhead access cover.
(2). Remove cotter pin, washer, and pin
attaching clevis to heat control valve.
(3). If particle separator is installed, loosen
and back off tube coupling nut of
369H90149-51 tube assembly at end
connected to elbow assembly.
Page 202
Revision 23
21-40-00
(4). In left side of engine compartment,

disconnect the hot bleed air line at the
heat control valve elbow fitting.
(5). Loosen the elbow tube nut and remove
elbow fitting and gasket.
(6). Remove hardware attaching the upper
and lower end of control valve assembly
to the canted firewall.
(7). Remove clamp securing cool air duct to
valve.
(8). Remove attaching hardware connecting
the muffler and valve. Remove heat
control valve and gasket.
MAINTENANCE MANUAL
CSP-HMI-2
STRAP
(TYP)
GROMMET
CABLE
AFT AIR DUCTS
FWD AIR DUCTS
AIR DIFFUSERS
AIR DIFFUSERS
MUFFLER
BOLT
COLD AIR
CONNECTOR HOSE
INDEX FOR COLD AIR

VANE ALIGNMENT IN
OPEN POSITION
CABLE ASSEMBLY
CLAMP
WASHER
NUT
CLAMP
SPACER
GASKET
NUT
CONTROL VALVE
ASSEMBLY
WASHER
1/8 IN. (3.175MM) DRILL
ROTATED
BOL
T
NOTE
JAM NUT
RIGGING PIN HOLES

(OPEN POSITION)
NOTE:
GASKET
INSTALLED ON AIRCRAFT WITH
NUT
AIR PARTICLE SEPARATOR.
COTTER
PIN
CLEVIS
NUT
BLEED AIR LINE
BOLT
PIN
WASHER
BLEED AIR
FITTING
ELBOW
G21-4001A
Figure 201. Heating Valve and Cable Installation
21-40-00
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
B. Heat Control Valve Installation
Item
Nomenclature
CM113
Anti-seize compound low temperature
4. Heat Control Valve Cable Replacement

(Ref. Figure 202)
A. Heat Control Valve Cable Removal
(1). Remove left half of engine air inlet
forward fairing, interior trim and left
aft bulkhead access cover.
(1). Install control valve assembly on

forward left side of firewall with bolts,
washers and nuts, but do not tighten.
(2). Remove seven screws attaching heat

duct outer box to heat duct and canopy
frame.
NOTE: Use anti-seize compound (CM113) on
(3). Remove clamps, straps, and grommets

that attach cable to structure along its
full length. Remove cotter pin and
clevis pin from clevis at heater control
valve arm.
threaded fittings.
(2). For helicopters equipped with particle
separator kit, re-engage tube coupling
nut of the 369H90149-51 tube assem
bly with elbow assembly, and tighten
fasteners.
(3). In left side of engine compartment,
install elbow, nut and new gasket.
Tighten retaining hardware on heating
valve.
B. Heat Control Valve Cable Installation
Item
Nomenclature
CM430
Sealant, solvent resistant
(4). Connect control valve flange to muffler,

using new gasket and four nuts,
washers, and bolts.
(1). Route the cable assembly into position.

Check that grommet is in place on
cable.
(5). Install cool air connector hose on

control valve inlet and secure with
clamps.
(2). Install clamps and straps that attach

cable to structure. Install grommet at
structure fairing that cable passes
through using adhesive (CM430).
(6). Position control handle fully forward.

Position lever on control valve to open,
and insert a 1/8 inch (3.175 mm)
rigging pin through lever and into valve
boss.
(7). Loosen jam nut on control cable and
adjust clevis so attach holes align with
hole in valve lever. Install pin through
clevis and valve lever, and safety with
cotter pin.
NOTE: The clamp nearest to the valve should

not be tightened until after travel is
checked.
(3). Attach heat duct outer box to heat duct
and canopy frame with seven screws.
(4). For adjustment of clevis refer to initial
installation.
(8). Tighten clevis jam nut. Remove rigging

pin from valve lever.
(5). When assured that cable will operate

the valve freely through full range of
travel, tighten the clamp nearest the
valve.
(9). Move control handle full aft and

forward several times to check ease of
heat control operation.
(6). Reinstall aft bulkhead access cover,

interior trim, and left half of engine
inlet fairing.
(10). Reinstall left aft bulkhead cover and

interior trim.
Page 204
Revision 23
21-40-00
(7). After installation, adjust handle to be

parallel to windshield glass.
MAINTENANCE MANUAL
CSP-HMI-2
CANOPY FRAME
RIGID TUBING
CANOPY CENTER
FRAME TRIM AND
HEAT DUCT - LOWER
SPRING PLUNGER
CABLE SUPPORT BLOCK
(3 PLCS) (NOTE)
2 PLCS
SET SCREW
WASHER
(NOTE)
CONTROL HANDLE
HANDLE SHAFT
OUTER BOX
HEAT DUCT/TRIM
6 PLCS
CANOPY CLIP
INCREASE HEAT
CONTROL HANDLE
INSTALLATION
HEAT DUCT MOUNTING

SCREW
DIFFUSER
ASSEMBLY
DIFFUSER ASSEMBLY
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
(Ref. Figure 202)
(1). With the helicopter on the ground,
(a). Inspect heat valve control lever and
cable for freedom of operation.
(b). Remove interior trim and left aft
bulkhead access cover in cargo
compartment. Inspect cable for
condition and security.
(c). Inspect cable clevis for security of
jam nut and cotter pin.
(d). Inspect security of heat control valve
to firewall; check pulley belt for
condition.
(e). Inspect flexible fiberglass hose for
tears and deformation due to failure
of inner supporting wire or short
radius bends.
(f). Inspect rubber hose for tears and

evidence of deterioration.
(g). Inspect all ducts and muffler for
security of attachment and coupling
hardware and any duct section or
muffler damage that would allow
heated air leaks. Inspect diffuser
outlets for condition of cemented
joints or distribution ducts.
(h). In engine compartment, inspect tube
connecting engine air bleed fitting to
control valve for cracks and security
of hex nuts.
(2). Perform an operational check (Ref.
Heating System Operational Check).
A. Heat Control Valve Inspection
(1). Inspect timing belt for deterioration,
stretching, worn teeth, or evidence of
slipping.
(2). Inspect valve housing for deep dents
and cracks, mating flanges and connect
21-40-00
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Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
ing area for bends or dents which would

prevent tight connections, bearing
bosses for galling and excessive wear,
and interior seat and ball valve for
galling.
(3). Inspect pulley shafts for galling and
evidence of wear.
(4). Inspect ball valve and retainer for
cracks, galling and evidence of wear;
cold air vane for flatness and evidence
of excessive edge wear.
B. Heat Control Valve Cable Inspection
(1). Inspect cables for kinks, crushed sleeve,
and corrosion.
(2). Remove hardware (nut, washer, bolt)

attaching elbow to valve housing and
remove elbow and shims if installed.
(3). The O-ring, wave washer, retainer, ball
valve and coupling are now free for
removal.
(4). Cut lockwire and remove three screws
from valve lever and drive pulley.
Remove timing belt.
(5). Remove pin from drive pulley. Remove
shaft from valve housing; inner and
outer washers will fall free.
(2). Clean all corrosion from cable.
(6). Remove screws attaching cold air valve

vane to shaft. Remove plate spring and
spacers. Remove vane.
(3). If cable is kinked or crushed, locate

problem and repair or replace cable as
required.
(7). Remove pulley, shaft, and washers from

valve housing.
6. Heating System Operational Check

(1). Perform an operational check of the
heating system as follows:
(2). Move CABIN HEAT control handle full
forward to open heat valve. Control
handle should not creep away from ON
position.
(3). Remove left aft bulkhead access cover.
(4). Check that valve is full open position by
inserting a 1/8 inch (3.175 mm) drill
shank (or rod) into the drive pulley
alignment hole (Ref. Figure 201). The
drill shank should pass through the
pulley and enter a mating alignment
hole in the valve housing inlet body.
(5). Check the cold air vane drive pulley
alignment mark. The mark should align
with a similar mark on the cold air
vane housing.
7. Heat Control Valve Disassembly
(Ref. Figure 203)
(1). Rotate ball valve lever fully counter
clockwise to position the ball valve
open.
Page 206
Revision 23
21-40-00
(8). Remove pin from driven pulley to

complete disassembly.
8. Heat Control Valve Repair
(1). Repair small dents in valve housing by
bumping out and burnishing. Repair
warped flanges by straightening on a
surface plate. No weld repairs are
permitted.
(2). No repairs are permitted on moving
parts, ball valve, retainer, coupling, or
shafts which are cracked, bent or badly
worn.
(3). Place valve housing upside down on a
suitable workbench (Ref. Figure 204).
Find the thickness of shims required
between valve body and elbow fittings
as follows.
(a). Measure diameter of the ball valve
using an outside micrometer. Record
as dimension A.
(b). Place ball valve in housing and use a
depth micrometer to measure dis
tance from housing flange to top of
ball. Record as dimension B.
MAINTENANCE MANUAL
CSP-HMI-2
VANE
SCREW
SPACER
SPRING
SHAFT
HOUSING
WASHER
PIN
BOLT
DRIVEN PULLEY
WASHER
WASHER
DRIVE PULLEY
BELT
BLEED AIR
FITTING
SHIM (AR)
ROTATED
(NOTE)
SCREW
PIN
RETAINER
BALL
LEVER
WASHER
O-RING
WASHER
COUPLING
SHAFT
NUT
WASHER
ELBOW
NOTE:
USED ON AIRCRAFT WITH
PARTICLE SEPARATOR.
G21-4003
Figure 203. Heater Control Valve Assembly
21-40-00
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MAINTENANCE MANUAL
CSP-HMI-2
(c). Multiply dimension A by 0.933; then

subtract the result from 1.627 in.
(4.1356 cm). Record as dimension C.
position ball valve in housing to engage

coupling (ball valve in open position).
(6). Install new O-ring in elbow flange
groove.
Example:
Ball dia. A = 1.441 in. (3.6601 cm)
1.441 in. (3.6601 cm) x 0.933 = 1.344
in. (3.4138 cm)
1.627 - 1.344 in. (3.4138 cm) = 0.283
in. (7.1882 mm) (dim. C)
(d). Compare dimension B with dimen
sion C. If B is greater than C, no
shims are required. If C is greater
than B, add shims 369H8007 until B
is equal to or greater, 0.010 in. (0.254
mm) max., than C.
Example:
B = 0.270 in. (6.858 mm) and C =
0.283 in. (7.1882 mm)
(e). Add a 0.015 in. (0.381 mm) shim to
dimension B. B now equals 0.285 in.
(7.239 mm), or 0.002 in. (0.0508 mm)
more than dimension C, and is a
correct total shim thickness for use.
(4). Install washer (Ref. Figure 203) on ball
valve shaft; then insert this assembly
into valve housing boss.
(5). Install coupling on shaft (check that the
ball drive lug is chamfered); then
(7). Install retainer and washer in housing

on ball valve.
NOTE: A 1/2 inch (12.7 mm) wood dowel may

be inserted through top of assembly to tem
porarily hold these parts in position.
(8). Install shim(s) of thickness determined
in above steps; then install elbow on
valve housing flange with four bolts
and nuts. Washers are installed under
both the bolt head and the nut. Use
care to avoid nicking or cutting the
O-ring during mating.
The flanges of the valve housing
and elbow should mate without
the use of undue force. If flanges do not mate
easily, the internal parts of the valve may be
misaligned. Investigate before tightening
bolts.
CAUTION
(9). Install washer and ball valve so that

rigging pin holes in pulley and in valve
housing boss are aligned (ball valve in
open position).
(10). Install pin through ball valve pulley
and shaft.
DEPTH MICROMETER
DIMENSION B (FLANGE-TO-BALL)
VALVE HOUSING
DIMENSION A (BALL DIAMETER)
BALL VALVE
NOTE:
FIND DIMENSION C AS FOLLOWS:
C = 1.627 IN. (4.1356 CM) - A X 0.993).
REFER TO TEXT FOR USAGE.
BALL VALVE SUPPORT
G21-4004A
Figure 204. Control Valve Shim Thickness Determination

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21-40-00
MAINTENANCE MANUAL
(11). Remove wood dowel if used to align
internal parts; then rotate pulley
through full travel several times to
assure ease of operation and positive
closing of ball valve. A valve torque
check, step (18). below, is made after
the timing belt is installed.
(12). Install cold air pulley and washer on
shaft.
(20). Reinstall and actuator belt pulley on

ball valve using three screws (Ref.
Figure 201). Note that the screw
located 180 degrees from the rigging
pinhole is 1/8 inch (3.175 mm) longer
than the others. Remove rigging pin
installed in step (10). above. Safety
screws to each other with lockwire.
9. Heating System Muffler and Ducts Repair
(13). Install cold air pulley and shaft assem

bly into valve housing.
(14). Attach cold air vane to shaft using two
screws.
(15). Rotate ball valve pulley fully counter
clockwise to full stop.
(16). Rotate cold air pulley so that the vane
is 45 degrees from fully closed, or align
yellow rigging marks, if present.
(17). Install a serviceable timing belt
between pulleys while maintaining
valve position located in steps (15).and
(16). above.
(18). Check valve operation by applying 6 11 inch-ounces (0.0423 - 0.0777 Nm)
of torque on the ball valve shaft. If the
ball valve does not operate within this
range, change thickness of shims
between the valve elbow and housing as
required. Shims are provided inch 0.015
inch (0.381 mm), 0.010 in. (0.254 mm),
and 0.005 inch (0.127 mm) thicknesses.
NOTE: Final total shim thickness should not

exceed dimension C (step (c).) by more than
0.10 inch (2.54 mm).
(19). If rigging marks have not been applied,
paint a yellow index mark, 1/16 inch
(1.59 mm) wide, on pulley and housing
(Ref. Figure 201).
CSP-HMI-2
Item
CM432
CM433
Nomenclature
Dichloromethane
Ethylene chloride
Repair of heat system ducting will depend

upon the type of material used in the section
that requires repair. Rubber hose or flexible
fiberglass hose that is torn, flattened, or
deteriorated must be replaced. When removing
ducting for repair or replacement, use illustra
tion as a guide (Ref. Figure 205).
(1). Repair rigid fiberglass or muffler
according to the fiberglass repair
procedures outlined in the SRM, except
use fire-retardant resin.
(2). Repair rigid polycarbonate plastic
sections by bonding a patch according
to the criteria and methods specified for
acrylic plastic in FAA AC 43.13-1B,
Aircraft Inspection and Repair for
Standard Sheet Metal Repair. Use
dichloromethane (CM432) or ethylene
dichloride (CM433) as the bonding
agent.
(3). Repair small areas of rib or seam
separation in plastic sections by
injecting ethylene dichloride (CM433)
into the void area and clamping
together under light pressure.
21-40-00
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Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
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
FLEX LINES OR STRUCTURE.
DIFFUSER
ASSEMBLY
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
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21-40-00
MAINTENANCE MANUAL
CSP-HMI-2
HEATING SYSTEM
INITIAL INSTALLATION
1. Heating System Initial Installation
Procedures in this section may be performed at
the operator's discretion and are applicable to
369D/E/FF model helicopters.
A. Preparation for Installation
Item
Nomenclature
CM702
Lockwire CRES
(1). Remove engine (Ref. Chap. 71).

(a). 250-C20B - 250-C20R/2: (Ref.
Figure 902 or Figure 903)
1). Remove existing plugs and install
tee and elbow.
Tee and elbow must be installed
so that no interference will exist
between hose assembly and existing bleed
air tube.
CAUTION
assembly (Sta. 31.50); retain washers

for use when installing diffuser assem
blies.
(4). Remove attaching hardware and outer
box from heat duct and canopy frame.
(5). Remove rubber plug from left side of
convenience panel.
(6). Remove cap from cool air manifold duct.
B. Heating Valve Initial Installation
(1). Using hardware, install heating valve,
but do not tighten.
(2). On aircraft equipped with engine air
particle separator only, engage tube
coupling nut of 369H90149-51 tube
assembly and tighten fasteners.
(3). Install elbow, nut and gasket from aft
side of firewall. Tighten heating valve
attaching hardware.
(4). Reinstall engine (Ref. Chap. 71).
(a). 250-C20B - 250-C20R/2: (Ref.
Figure 902 or Figure 903)
2). Install hose assembly and tube

assembly. Do not reinstall engine
at this time.
1). Connect tube assembly to elbow

using nut and gasket. Torque both
connecting nuts onto tube assem
bly to 350 inch-pounds (39.54
Nm).
(b). 250-C30: (Ref. Figure 904)

1). Remove existing plate and install
fitting, using engine supplied
washers and bolts. Safety with
lockwire (CM702).
2). Install engine bleed assembly to
fitting, and secure tube assembly
by connecting one end of the strap
to the inlet bell with bolt, nut and
washers, but do not tighten. Attach
clamp to bleed assembly. Secure to
strap with attaching hardware.
Tighten nut.
(2). Remove interior trim panels and aft
bulkhead access.
(3). Remove left and right hand guide
assemblies from forward end of duct
(b). 250-C30: (Ref. Figure 904)

1). Connect engine bleed assembly to
elbow. Torque connecting nut to
350 inch-pounds (39.54 Nm).
C. Ducting Installation (517)
(Ref. Figure 906)
Item
Nomenclature
CM411
CM821
Adhesive, epoxy
Gasket material
21-40-00
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Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
(1). Using clamps, install air hose between

heating valve and cold air manifold
duct (Ref. Figure 905).
NOTE: Ensure that heater hose does not con

tact transmission oil lines or structure.
(2). Install muffler assembly with gasket

and hardware; attach hose to muffler
with clamp.
(8). Install aft valve assembly (23) in

convenience panel (24) and connect
valve to duct (3) with hose (25) and
clamps (26).
(3). Remove protective cap from existing

duct assembly (1). Install grommets (2)
with cement (CM411) to prevent
chafing.
(9). Install diffuser assemblies (Ref.

Figure 202); add washers as necessary
to obtain diffuser to duct fit.
D. Ducting Installation (519)
(4). Route heater hose (9) and secure to oil

flex line (10) with clamps (11, 12),
bracket (13), and attaching hardware
(14, 15, and 16).
(Ref. Figure 906)
(5). Position standoff (17) on inboard side of

channel (18) as shown. Drill two #40
holes and deburr. Attach standoff to
channel using two rivets (19).
Item
Nomenclature
CM318
CM702
Primer
Lockwire CRES
(6). Install clamp (20) around hose and

secure to standoff, using attaching
hardware (21 and 22). Install Scotch
Foam (CM821) as required to prevent
chafing.
(7). Connect duct (3) to duct assembly (1),
and hose (5). Attach duct (3) to bulk
head using attaching hardware (6, 7,
and 8). Attach hose (5) to duct with
clamp (4).
369D292479-1 OUTLET
INSTALLATION SAME
FOR 369D292479-2
NAS1329A08-75 RIVNUT
NAS1402-2 SCREW
AN960-8 WASHER
PICK UP EXISTING RIVET
LOCATION
(1). Perform installation as described (Ref.

Ducting Installation (-517), steps (1).
thru (4). and (6).) except that duct (27),
replaces duct (3) and that hose (5) is not
secured to duct (27) at this time.
(2). Install splitter duct (28) with attaching
hardware (29, 30) and valve (23) into
convenience panel (24).
0.188 IN. (4.7752 MM)

HOLE IN PANEL
369A2544-3
NAS1402-2 SCREW
FITTING
AN960-8 WASHER
(OPPOSITE SIDE)
0.40 IN. (10.16 MM)
TRUE HOLE LOCATION
REIDENTIFY AS 369H90020-5
CONVENIENCE PANEL, TO BE
MADE FROM 369D26553-21 PANEL
1.38 IN. (3.5052 CM)

2.75 IN. (6.985 CM)
DRILL 0.020-0.023 IN.
(0.508-0.584 MM) HOLE
NAS1303-4 BOLT
MS21042-3 NUT
AN960KD10 WASHER
PICK UP EXISTING
RIVET LOCATION
Figure 901. Outlet Installation and Convenience Panel Modification

Page 902
Revision 23
21-40-00
1.00 IN.
(2.54 CM)
0.30 IN.
(7.62 MM)
369D292480
SPLITTER DUCT
G21-4006A
MAINTENANCE MANUAL
(3). Attach hose (25) to valve (23) with
clamp (26), and hose (31) to splitter
duct (28) with lockwire (CM702).
(4). Attach hose (25) to lower outlet on duct
(27) with clamp (26), and second hose
(31) to upper outlet on duct (27) with
lockwire.
(5). Mount convenience panel (24) with
attached duct, valve, and hose to
bulkhead with with attaching hardware
(32, 33).
(6). Measure distance between splitter duct
outlets. Using this dimension, position
ducts (34, 35) and outlet ducts (36)
parallel to each other on bulkhead.
Match drill six 0.221-0.226 inch
(5.6134-5.7404 mm) holes common to
duct clips to bulkhead. Remove ducts.
Deburr and apply primer (CM318) to
bare metal surfaces. Install rivnuts
(37). Reconnect ducts (34, 35) to splitter
duct (28) and attach ducts to bulkhead
with screws (38) and washers (39).
(7). Install outlets (36) on ducts (34, 35).
Match drill holes through outlet duct
clips into bulkhead (Ref. Figure 901).
Remove outlets. Deburr and apply
primer to bare metal. Install rivnuts
(37) were applicable. Install outlets
with attaching hardware (38, 39, 40, 41,
and 42).
(8). Attach hose (5) to duct (27) with clamp
(4).
E. Modification of Existing 517 to 519
Configuration
(Ref. Figure 906)
(1). The -517 heating system may be
modified by replacing duct (3) with duct
(27), modifying the convenience panel,
as illustrated, and by installing addi
tional hose (31), splitter duct (28), ducts
(34 and 35), outlets (36), and associated
hardware.
(2). Follow installation instructions (Ref.
Ducting Installation (-519).
CSP-HMI-2
F. Ducting Installation (521)

(Ref. Figure 906)
Item
Nomenclature
CM318
Primer
(1). Perform installation as described (Ref.

Ducting Installation (-519), steps (1).
thru (5). except replace splitter duct
(28) with duct (43) (Ref. Figure 905).
(2). Position duct (35) and outlet duct (36)
on bulkhead. Match drill three
0.221-0.226 inch (5.6134-5.7404 mm)
holes common to clips into bulkhead.
Remove outlet duct (36) and duct (35).
Deburr and apply primer (CM318) to
bare metal surfaces. Install rivnuts
(37).
(3). Connect duct (43) to duct (35) and
secure to bulkhead and convenience
panel with attaching hardware (29, 30,
38, 39, 40, 41, and 42).
(4). Attach hose (5) to duct (27) with clamp
(4).
G. Cabin Heat Control Cable Initial
Installation
(Ref. Figure 201)
Item
Nomenclature
CM425
Sealing compound
(1). Remove clevis and jam nut assembly;

install grommet on cable, remove
existing plug button in canted frame
structure, and route cable through hole
in structure and hole in structure
fairing.
(2). Remove clamps from duct assembly and
secure control handle and rigid portion
of control cable assembly with clamps.
(3). Tie control cable to existing tubing and
cables with straps.
21-40-00
Page 903
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
(4). Secure grommet in structure and seal

hole at structure fairing that cable
passes through, using adhesive
(CM425).
(5). Secure lower end of cable assembly to
structure with clamp and attaching
hardware.
NOTE: Do not tighten clamp until after travel
(c). Tighten clevis jam nut. Remove

rigging pin from valve lever.
(d). Move pilot's heat control handle full
aft and forward several times to
check ease of heat control operation.
(e). Tighten clamp nearest clevis end of
control cable.
is checked.
(6). Install heat duct outer box to heat duct
and canopy frame with seven screws.
(f). Reinstall aft bulkhead access cover,

interior trim, and left half of engine
inlet fairing.
(7). Install jam nut and clevis as follows;

(a). Position heat control handle full
forward. Position lever on heat
control valve to open and insert a 1/8
inch (0.125 mm) rigging pin through
lever and valve boss.
(b). Loosen jam nut on control cable and
adjust clevis so attach holes align
with hole in valve lever. Install pin
through clevis and valve lever. Install
washer and secure pin with cotter
pin.
(g). After installation, adjust control

handle to be parallel with windshield
glass.
H. Weight and Balance
Weight and balance changes resulting from
installation of heating system equipment are
listed in Table 901. After installation of
heating system equipment, incorporate
changes in helicopter weight and balance
record (Ref. Sec. 08-10-00).
Table 901. Weight and Balance Data

Configuration
Weight
Pounds (kg)
Arm
Inches (cm)
Moment
inlb (kg cm)
369H90020517
Added
+8.2
Removed
Change
(+3.719)
106.7
0.0
(271.02)
+874.9
(+1007.990)
+8.2
(+3.719)
106.7
(271.02)
+874.9
(+1007.990)
+8.6
(+3.901)
110.1
(27965)
+946.9
(+1090.942)
369H90020519
Added
Removed
Change
Page 904
Revision 23
0.0
+8.6
(+3.901)
21-40-00
110.1
(27965)
+946.9
(+1090.942)
MAINTENANCE MANUAL
CSP-HMI-2
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 (250C20B)
21-40-00
Page 905
Revision 23
CSP-HMI-2
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)
Figure 903. Engine Air Bleed Line Installation (250C20R/2)

Page 906
Revision 23
21-40-00
G21-4008
MAINTENANCE MANUAL
CSP-HMI-2
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 (250C30)
21-40-00
Page 907
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
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
Revision 23
21-40-00
MAINTENANCE MANUAL
CSP-HMI-2
8
5
7
6
-517 (REF)
27
14
1
1
15
21
22
15
10
16
15
14
13
20
19
17
16
SCOTCH FOAM
15
12
18
G21-4011
Figure 906. Duct, Hose and Convenience Panel Installation (Sheet 1 of 2)
21-40-00
Page 909
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
32
33
31
27
28
25
37
26
26
24
43
23
42
41
34
30
41
29
42
38 39
42
35
41
37
40
39
36
38
36
41
36
40
G27-4012
Figure 906. Duct, Hose and Convenience Panel Installation (Sheet 2 of 2)

Page 910
Revision 23
21-40-00
MAINTENANCE MANUAL
CSP-HMI-2
Legend (Ref. Figure 906)

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

CONVENIENCE PANEL
HOSE
CLAMP
DUCT
SPLITTER DUCT
SCREW
WASHER
HOSE
SCREW
WASHER
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DUCT
OUTLET
RIVNUT
SCREW
WASHER
BOLT
WASHER
NUT
DUCT
21-40-00
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Revision 23
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Revision 44
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MAINTENANCE MANUAL
Chapter
25
Equipment/
Furnishings
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 201. Upholstered Seat Installation (369D) . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 202. Upholstered Seat Installation (369E/FF - 500/600N) . . . . . . . . . . . .
Figure 203. Mid and Aft Seating Configuration (600N) . . . . . . . . . . . . . . . . . . . . . .
Figure 204. Mid and Aft Bench Seat Assembly Installation (600N) . . . . . . . . . . .
Figure 205. Upholstered Passenger Individual Seat Installation (369D) . . . . . .
Figure 206. Mid-Cabin Business Seat Installation (600N) . . . . . . . . . . . . . . . . . . .
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203
204
205
206
207
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
Table 901. 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) . . . . . . . . . . . . . . . . . . . . . .

Figure 201. Seat Belt/Inertia Reel Installation (Sam Browne Style)
(369D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 202. Seat Belt/Inertia Reel Installation (Yoke Style) (369D) . . . . . . . . . . .
Figure 203. Seat Belt/Inertia Reel Installation (Yoke Style)
(369E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.
201
202
203
204
Crew Seat Belt/Harness Replacement With Manual Lock Option

(369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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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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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
H. Weight and Balance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 903. Seat Belt and Seat Assemblies Installation
(369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 904. Shoulder Straps and Fittings Installation
(369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
906
906
907
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 201. Miscellaneous Furnishings (369D) (Sheet 1 of 2) . . . . . . . . . . . . . . . .
Figure 202. Miscellaneous Furnishings (369E/FF - 500/600N)
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 203. Passenger Step Assembly (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202
203
205
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 101. Troubleshooting - Cargo Hook Installation . . . . . . . . . . . . . . . . . . . . . .
Table 102. Wire Chart, 369D/E/FF Right or Left Hand Command. . . . . . . . . . . .
Table 103. Wire Chart, 369E/FF T-Panel with Center Electrical Console,
R/H Command. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 101. Cargo Hook - Wiring Diagrams (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . .
101
102
102
103
104
1.
Cargo Hook Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

A. Cargo Hook Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
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MAINTENANCE MANUAL

Para/Figure/Table
Title
B. Cargo Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 401. Manual Release Cable Routing - Interior . . . . . . . . . . . . . . . . . . . . . . .
Figure 402. Manual Release Cable and Electrical Wire Harness Routing Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 403. Cargo Hook Electrical Equipment Installation . . . . . . . . . . . . . . . . . .
Figure 404. Hook and Pad - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 405. Cargo Hook Manual Release Lever - Installation . . . . . . . . . . . . . . .
Figure 406. Cargo Hook Release for 600N Helicopters . . . . . . . . . . . . . . . . . . . . . .
Page
401
403
404
405
406
407
408
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Cargo Hook Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2.
3.
4.
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Exterior Components Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Interior Components Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Cargo Hook Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A. Preparation for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Helicopter Equipment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Modification of Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
901
901
901
901
901
D. Cargo Hook Provisions Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E. Electrical Components and Wiring Installation (Left and Right Hand
Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 901. Cargo Hook Relay Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 901. Fuselage Skin Cutouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
901
902
902
903
F. Cargo Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 902. Relay and Bracket Installation Pilots Floor (369D/E/FF) . . . . . . . . .
Table 902. VNE Card Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G. Helicopter Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 903. Cargo Hook Switch Installations - Stick Grip . . . . . . . . . . . . . . . . . . . .
H. Weight and Balance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
904
905
906
906
906
907
907
25-60-00 Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Emergency First Aid Kit Contents Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 201. Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201
201
201
202
25-63-00 Hoist Passenger/Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Hoist Passenger/Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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25 Contents
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 201. Troubleshooting Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 204. Wiring Diagram - Hoist System (L/H Command) . . . . . . . . . . . . . . .
Figure 205. Wiring Diagram - Hoist System (R/H Command) . . . . . . . . . . . . . . .
Figure 206. Schematic Diagram - Hoist System Winch . . . . . . . . . . . . . . . . . . . . .
213
214
214
215
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
25 Contents
Page vii
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CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page viii
Revision 43
25 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
250000
Equipment/
Furnishings
MAINTENANCE MANUAL
CSP-HMI-2
EQUIPMENT/FURNISHINGS
1. Interior Furnishings Description
Standard furnishings on the 369D/E/FF 500/600N Helicopters include seats in the crew
and passenger compartments, seat belts,
interior trim, floor trim and covering, and
other miscellaneous furnishing items.
A. Upholstered Seat Furnishings
Configuration
The helicopters are equipped with the basic
interior furnishings configuration. This
includes upholstered seats with a bench type
in the passenger compartment and three
individual seats in the crew compartment. The
center crew seat is removed for the dual
controls option. Seat belts are provided at all
seat locations. Interior trim finish is provided
throughout interior cabin enclosure.
The 600N helicopter comes equipped with a
mid position bench seat. At this position in the
passenger compartment, the mid seat can be
positioned in either the forward or aft facing
configuration.
B. Mesh Seat Furnishings Configuration
The helicopters are equipped with a basic
interior furnishings configuration. This
includes two mesh seats and seat backs in the
crew compartment and two stowable mesh
seats in the passenger/cargo compartment.
Seat belts are provided at all seat locations.
Interior trim is provided for the passenger
convenience panel, transmission, passenger aft
bulkhead, inboard collective pitch stick, and
cyclic controls.
C. Crew Upholstered Seating
The crew compartment on all models with
single controls has a three-place seating
arrangement. A two-place seating arrange
ment is provided for optional dual controls.
Crew compartment seats consist of left and
right side seat cushions and, if applicable, a
center seat cushion. Each seat has a seat back
cushion. Crew compartment seat structure is
an integral part of the helicopter fuselage.
D. Crew Mesh Seating

The crew compartment is equipped with
two-part seats. Each two-part seat consists of
a seat back and a seat bottom constructed of
aluminum tubing frames with a nylon mesh
covering and rubber pads cemented to the
frame mounting plates. The seat backs are
mounted on the Station 78.50 canted frame.
Seat bottoms are secured on top of the pilot's
seat structure.
E. Passenger Upholstered Bench Seating
Passenger compartment seating is provided by
a bench type tubular steel structure furnished
with upholstered cushions. The bench seat is
adjustable fore and aft as well as up and down,
and may be folded or quickly removed when
cargo space is required. All seat cushions are
either upholstered and trimmed with vinyl, or
may be all vinyl. Velcro strip fasteners secure
seat cushions in place.
F. Mid Bench Seat (600N)
The mid bench seat provides additional three
abreast seating in the passenger area. This
seat can be positioned in either the forward or
aft facing configuration. The seat belt/harness
system is completely attached to the seat
structure for quick removal and installation of
the entire bench seat assembly.
G. Upholstered Passenger Individual Seat
Individual seat installations are also available
for the passenger compartment. The seat
frames are secured to the bulkhead attach
fittings with ball-lock pins. When each seat is
folded, the flat surface of the seat back serves
as a barrier for cargo. Ref. P/N 369D290037 in
the optional equipment list for a further
description of individual passenger seat
installations (Ref. Table 202, Sec. 01-00).
H. Passenger Mesh Seating
Two passenger seats are installed in the aft
compartment of the helicopter. The seats are of
welded tubular aluminum structure with
nylon mesh covers. The seats may be folded for
clear cargo space and, if desired, are easily
removed by means of quick disconnect
attachments.
25-00-00
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Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
I. Seat Belts and Shoulder Harnesses

(369D/E/FF 500N)
In the standard installation, Sam Browne type
seat belts with shoulder harness straps are
installed at each seat position. Seat belts and
shoulder straps are fabricated from nylon
webbing with sewn-in buckles and attach
fittings. Lengths of seat belts and shoulder
straps are not adjustable. Inertia reels are
provided to take up slack and allow free
movement of the seat occupant.
Comfort clips are available for helicopters
equipped with Sam Browne type seat belt
assemblies. The comfort clip is designed to
maintain proper strap tension and relieve
excessive pressure of the inertia reel shoulder
harness on the crew or passengers during
flight.
After each seat belt and shoulder harness
assembly is fastened and adjusted for individu
al comfort and safety, the comfort clip is moved
from its original position next to the buckle
and relocated by sliding up on the harness
strap as close as possible to the inertia reel.
The clip prevents any further retraction of the
strap into the inertia reel, thus keeping a
constant yet comfortable tension of the
harness strap against the user. After each
flight, the comfort clip is to be returned to its
original location.
J. Seat Belts and Shoulder Harness (600N)
The crew seats in the helicopter utilize a
four-point restraint harness that combines the
lap seat belts with double shoulder straps for
greater occupant security and comfort. Both
mid and aft passenger seats are equipped with
a three-point restraint system. The lap seat
belt and shoulder strap are joined at the end
into a single unit for ease of attachment and
convenience. In one motion, the lap and
shoulder belts together can be attached to the
seat buckle. All seat belt/harness systems are
equipped with an automatic locking inertia
reel mechanism.
Page 2
Revision 23
25-00-00
K. Interior Trim
Interior trim used in the crew compartment
and the passenger compartment is of thermo
plastic material contoured to cover interior
structure. Trim panels and covers provide
interior finish, compartment insulation and
mounting surfaces for convenience items, and
certain optional equipment. Trim panels and
covers are attached with Velcro fasteners and
with upholstery screws with rivnuts or isolator
nut mounts on the fuselage structure.
L. Floor Trim and Covering
Interior floor trim and covering consists of
fire-resistant carpeting and two foot fairing
trim assemblies. The lower part of Sta. 78.50
bulkhead and access doors are also covered
with fire-resistant carpeting.
M. Miscellaneous Furnishings
Miscellaneous furnishings include a stowage
compartment, heat duct, VNE card holder, foot
rest assembly, helicopter checklist, operational
record holder, ashtrays, and LH/RH passenger
step assemblies. The stowage compartment is
under the right floor access door (Ref. Sec.
52-50). The compartment has a uniformly-dis
tributed load capacity of 50 pounds maximum
when optional avionics equipment is not
installed in the crew area underfloor compart
ment. The heat duct provides interior trim for
the canopy frame and mounting surface for the
magnetic compass (Ref. Sec. 95-20). The VNE
card holder is located on the left side of the
instrument panel. The helicopter checklist is
stored with the magnetic compass card in the
map case. The operational record holder is
attached to the outboard side of the right
instrument panel fairing. Ashtrays and
cigarette lighters are provided in the lower
portion of the instrument panel and on the
back side of the station 78.50 canted bulkhead.
The removable passenger steps are attached to
the helicopter side jacking points.
MAINTENANCE MANUAL
CSP-HMI-2
Section
251000
Upholstered Seats
MAINTENANCE MANUAL
CSP-HMI-2
UPHOLSTERED SEATS
1. Upholstered Crew Seat Replacement
(Ref. Figure 201, Figure 202 and Figure 204)
Upholstered Seats for the 369D/E/FF 500/600N Helicopters are the same. The
addition of the mid position bench seat is
unique to the Model 600N.
(1). Clear seats of seat belts and shoulder
straps.
(2). Lift seat cushions away from fuselage
seat structure to release Velcro strip
and fasteners.
(3). To replace, position seat cushions so
that Velcro fastener strips mate. Apply
slight pressure to secure seat cushions
in place.
2. Upholstered Passenger Aft Bench Seat
Replacement
(Ref. Figure 201 or Figure 202)
straps.
(2). Release seat quick-disconnect fittings
at bulkhead, then at floor points.
NOTE: For height adjustment, install ball-lock

pins in desired position at support legs and
bulkhead fittings. For fore and aft adjust
ment, move and secure seat back at desired
position on lower frame.
(3). To replace, position bench seat so that
quick-disconnect fittings align with
floor and bulkhead attach points.
(4). Lock seat in place, first at floor fittings
then at bulkhead fittings.
3. Mid Bench Seat Assembly Replacement
(600N)
(Ref. Figure 204)
A. Mid Bench Seat Removal

(1). Remove quick release pins that attach
seat support fittings to floor rails.
(2). Remove seat assembly.
B. Mid Bench Seat Installation
(1). Install seat assembly in aircraft.
(2). Align seat support fittings with floor
rails.
(3). Install quick release pins to secure seat
assembly to floor.
4. Upholstered Passenger Individual Seat
Replacement
(Ref. Figure 205)
(1). Clear seat of seat belts and shoulder
straps.
(2). Remove ball-lock pins from bulkhead
attach fittings.
(3). To replace, position seats so that
quick-disconnect pins align with
bulkhead attach points and lock seats
in place.
5. Upholstered Seat Inspection
(1). Inspect upholstery material for cuts,
loose stitching or other unserviceable
condition.
(2). Inspect Velcro fastener strips for
security of attachment and condition.
(3). On passenger seat structure, inspect
quick-disconnect mechanisms for
proper operation or damage that may
prevent positive locking.
A. Upholstered Seat Cleaning
(Ref. Sec. 20-20-00, Fuselage Interior Trim
and Upholstery Cleaning)
25-10-00
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Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
6. Upholstered Seat Repair
Item
CM219
CM405
Nomenclature
Methyl-ethyl-ketone
Adhesive
(1). Lapstitch frayed or worn upholstery.


NOTE: Loosened Velcro strips may be reacti

vated for adhesion by wiping original adhe
sive film with MEK (CM219).
(2). Replace unserviceable Velcro fastener
strips. Install new Velcro strips to mate.
Bond in place with adhesive (CM405).
(3). Make minor welded or riveted sleevetype repairs on tubular structure
according to FAA AC 43.13-1B Inspec
tion and Repair for Standard Sheet
Metal Repair.
7. Optional Mid Business Seat Replacement
(600N)
(Ref. Figure 206) This option replaces the
standard mid bench seat with two fore and aft
Page 202
Revision 44
25-10-00
adjustable seats attached through four seat

tracks that allow seat location adjustment over
a 10 inch span when seats are facing forward.
NOTE:
D With the seats in the full aft position and
facing forward, the rear passenger seats
become unusable for passenger seating.
D The seats are removable and may be
placed in the aft facing position.
D In the aft facing position, only two seat
locations are available.
A. Business Seat Removal
(1). Remove quick release pins that attach
seat support fittings to floor rails.
(2). Remove seat assembly.
B. Business Seat Installation
(1). Install seat on tracks with forward
guide pin in track cutout first.
(2). Once seat guide pin is in track, slide
seat forward until 2 rear guide pins are
in the track cutouts.
(3). When installing seat facing aft, tilt
seat-back full forward during
installation.
MAINTENANCE MANUAL
CSP-HMI-2
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
NOTE 2
NYLON
MESH
RELEASE PIN
FORE AND AFT

ADJUSTMENT
HOLES
SUPPORT LEG AND

HEIGHT ADJUSTMENT
FLOOR STRUCTURE
SEAT BACK
CUSHION
HIGH SHOULDER BEAM

NOTE 1

(TYP)
NOTES:
1. SHOWN WITHOUT CUSHION
FOR CLARITY.
2. CENTER CUSHIONS AND SEAT
BELTS ONLY FOR 3-PLACE
SEATING.
SEAT BOTTOM
CUSHION
CREW COMPARTMENT
SEAT STRUCTURE
G25-1000
Figure 201. Upholstered Seat Installation (369D)
25-10-00
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Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
SEAT BACK CUSHION
VELCRO STRIP
FASTENER (TYP)
CUSHION SUPPORT
AFT SUPPORT FITTING
AND HEIGHT ADJUSTMENT
SEAT BOTTOM CUSHION
SEAT BACK
CUSHION
FLOOR STRUCTURE
LOWER FRAME
SEAT BOTTOM
CUSHION
LOCKPIN
RELEASE PIN
SUPPORT LEG AND
HEIGHT ADJUSTMENT
LOW SHOULDER BEAM

(TYP)
SEAT STRUCTURE
CREW COMPARTMENT
G25-1001
Figure 202. Upholstered Seat Installation (369E/FF 500/600N)

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25-10-00
MAINTENANCE MANUAL
CSP-HMI-2
FWD FACING
AFT FACING
OPTIONAL MID-CABIN BENCH SEAT ORIENTATION

6G25-069
Figure 203. Mid and Aft Seating Configuration (600N)
25-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
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
Figure 204. Mid and Aft Bench Seat Assembly Installation (600N)
Page 206
Revision 24
25-10-00
6G25-061
MAINTENANCE MANUAL
CSP-HMI-2
SEAT BACK
ASSY
SEAT BACK CUSHION
VINYL END PIECES
(TYP)
SEAT BOTTOM CUSHION
FABRIC
SEAT BOTTOM
ASSY
UPPER SURFACE
OF FLOOR
SEAT STRUCTURE
TOP OF CARPET
VINYL END PIECES

(TYP)
SEATS-ERECTED POSITION
SEAT FOLDED
POSITION RH. SIDE
SEAT FOLDED POSI

TION L.H. SIDE
G25-1002
Figure 205. Upholstered Passenger Individual Seat Installation (369D)
25-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
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
FORE AND AFT SEAT

ADJUSTMENT HANDLE
(HANDLE SHOWN RAISED)
TRACK CUTOUT
G25-1006
Figure 206. MidCabin Business Seat Installation (600N)

Page 208
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25-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
251500
Mesh Seats
MAINTENANCE MANUAL
CSP-HMI-2
MESH SEATS
1. Crew/Passenger Mesh Seats
(Ref. Figure 201 thru Figure 203) The typical
mesh seat installation consists of lightweight
nylon mesh-covered seats installed in the crew
and passenger compartments. For description
of the various installations, consult the
Optional Equipment List (Ref. Table 202,
01-00-00). Some installations have a benchtype passenger seat, some have individual
passenger seats, and others have no passenger
seats at all. Installations differ depending on
whether the helicopter has a high shoulder
beam or a low shoulder beam, and various seat
colors.
2. Crew Mesh Seat Replacement
(Ref. Figure 201)
NOTE: Identify and retain all components and

hardware removed from the helicopter.
(1). Remove or clear area of seat belts and
shoulder straps.
(2). Remove installing hardware and lift
seat bottoms and seat backs from the
helicopter.
(3). To replace, install seat backs and seat
bottoms with attaching hardware.
(4). When removed, reinstall seat belt and
shoulder harness.
3. Passenger Mesh Seat Replacement
NOTE: Identify and retain all components and

hardware removed from helicopter.
(1). Remove or clear area of seat belts and
shoulder straps.
(2). Release seat quick-disconnects at aft
fittings, then at floor points.
(3). Lift seats from helicopter.
(4). To replace, attach horizontal support
legs to aft attach fittings with lockpins.
(5). Insert vertical legs into floor structure

and secure.
(6). If removed, reinstall seat belts and
shoulder harness.
4. Passenger Mesh Seat Adjustment
(1). (Ref. Figure 203) The height of the
bench seat may be adjusted by install
ing the ball lock pins in any of the three
holes in the vertical support legs, and
by installing the ball lock pins that
support the horizontal legs in any of the
three holes in each aft support fitting.
(2). For the fore and aft adjustment of the
bench seat, insert the seat back legs
into either pair of holes in the seat
frame.
(3). (Ref. Figure 202) The height of the
individual seats may be adjusted by
inserting lock pins into any of three
pairs of holes in the aft support fittings
to secure the horizontal legs of the seat.
(4). The individual seats may be folded up
out of the way to permit cargo storage
by first releasing the quick-disconnects
at the forward legs and folding the legs
aft. The seat back is then folded
forward at the upper hinge point. As
the seat is swung up at the aft fitting,
the seat back and the seat bottom are
rotated forward and down at the lower
hinge point.
5. Crew Mesh Seat Inspection
(1). Inspect upholstery material for cuts or
other unserviceable conditions.
(2). Check rubber pads cemented to each
mounting plate.
6. Passenger Mesh Seat Inspection
(1). Inspect upholstery material for cuts or
other unserviceable conditions.
(2). Inspect quick-disconnect mechanisms
for proper operation and for damage
that may prevent positive locking.
25-15-00
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MAINTENANCE MANUAL
CSP-HMI-2
CREW SEATS BACK

LOWER LEGS
CREW SEATS FORWARD

LOWER LEGS
CREW SEATS BACK UPPER

LEGS, HIGH SHOULDER BEAM
(NOTE)
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

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25-15-00
MAINTENANCE MANUAL
CSP-HMI-2
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
25-15-00
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MAINTENANCE MANUAL
CSP-HMI-2
7. Mesh Seats Cleaning
(1). Lap stitch frayed or torn nylon web

bing, or replace if damaged beyond
repair.

(2). Install new rubber pads.
8. Mesh Seats Repair
(3). Clean seat mounting plate with clean

cloth dampened with solvent (CM234).
Item
Nomenclature
CM234
CM405
Adhesive
(4). Apply cement (CM405) and attach pad

to seat mounting plate.
(5). Replace damaged nutplates.
(6). Minor weld repairs may be performed
Metal Repair.
Repair of seats is limited to the following:
SEAT BACK
AFT SUPPORT FITTING AND

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

HEIGHT ADJUSTMENT
RELEASE PIN
G25-1005
Figure 203. Passenger Bench Mesh Seat Adjustment
Page 204
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25-15-00
MAINTENANCE MANUAL
CSP-HMI-2
MESH SEATS
1. Mesh Seat Initial Installation
(2). Install ball lock pins.
Procedures in this section are for initial

installation of 369H90040-BSC, -501, and
-503 mesh seat installations on Model 369D
helicopters with to replace the existing cushion
seats.
(3). With release pins raised and locked,

insert the two vertical legs into keyhole
fitting slots in floor.
A. Model Applicability
To determine the applicability of the mesh seat
installation for use on each model helicopter,
consult the Optional Equipment List (Ref.
Table 202, 01-00-00).
B. Preparation for Installation
(1). Check all electrical switches for OFF
position. Ensure that BATTERY-OFFEXT switch is OFF.
(2). Identify all components and hardware
to be removed for access to work areas.
Protect components from damage and
foreign matter until reinstalled.
C. Helicopter Equipment Removal
Prior to installing the mesh seats, a limited
number of items must be removed from the
helicopter to accommodate seat installation.
straps.
(2). Lift crew compartment seat cushions
away from fuselage seat structure to
release Velcro strips and fasteners.
Remove seats from helicopter (Ref. Sec.
25-10-00).
(3). In passenger compartment, release
existing seat quick-disconnect fittings
at aft bulkhead, then at floor points.
Remove existing installed seats from
helicopter.
D. Passenger Compartment Bench Seat
Installation
(Ref. Figure 203)
(1). Position bench seat horizontal support
legs in aft support fittings.
NOTE: For height adjustment, install ball lock

fittings in any of the three attachment
holes, in the vertical support legs, and in the
aft support fittings. For fore and aft adjust
ment, insert the seat back lower legs in ei
ther pair of holes in lower frame.
(4). Move vertical support legs to right in
keyhole fittings and unlock release pins
in legs. The pins will drop to bottom of
slots and secure support legs to fittings
in floor.
E. Passenger Compartment Individual Seat
Installation
(Ref. Figure 202)
NOTE: Installation procedures for left and

right seats are identical.
(1). Position passenger seat horizontal
support legs in aft support fittings.
(2). Install ball lockpins.
(3). Depress pushbutton quick disconnects
at front legs of seat.
(4). Insert legs into keyhole fittings in floor.
Move legs outboard and release push
buttons to secure legs in place.
F. Crew Compartment Mesh Seat
Installation
(Ref. Figure 201) Installation includes
installing a shim under the inboard forward
leg of the left crew seat.
(1). Position mesh seat back halves in crew
compartment.
(2). Attach upper ends of seat backs to
canted stations with screws and
washers.
(3). Attach lower legs to helicopter seat
structure with screws.
25-15-00
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MAINTENANCE MANUAL
CSP-HMI-2
(4). Position lower halves of mesh seats on

helicopter seat structure.
(5). Insert shim under inboard forward leg
of left seat. Attach leg to seat structure
with bolt and washer.
(6). Attach remaining forward legs of seats
to seat structure with bolts and wash
ers.
G. Helicopter Equipment Installation
After installation of mesh seats, a limited
number of items must be replaced in the
helicopter.
(1). Install seat belts and shoulder harness

in crew compartment (Ref. Sec.
25-20-00, Seat Belt/Inertia Reel
Replacement).
(2). Install seat belts and shoulder harness
in passenger compartment.
H. Weight and Balance Data
Weight and balance data resulting from -BSC,
-501 and -503 mesh seat installations are
listed in Table 901. After installation, incorpo
rate changes in helicopter weight and balance
records (Ref. Sec. 08-10-00).

Configuration
Weight
Pounds (kg)
Arm
Inches (cm)
Moment
inlb (kg cm)
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
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25-15-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
252000
Seat Belts/Inertia
Reel
MAINTENANCE MANUAL
CSP-HMI-2
SEAT BELTS/INERTIA REEL

1. Seat Belts/Inertia Reel Description and
Operation (369D/E/FF 500N)
Inertia reel-type seat belt/harness equipment
consists of a shoulder harness, an inertia reel,
and a two-piece adjustable seat belt for both
the pilot and copilot.
The shoulder harnesses and seat belts are of
nylon web material with sewn-in length
adjusters and end adapters for attachment of
the harnesses to the seat belts. Inertia reels,
furnished as part of the harnesses, are
mounted on the Sta. 78.50 canted frame. The
reels permit the pilot and copilot freedom for
slow, deliberate shoulder movement, but lock
with any sudden forward movement. Full
extension or retraction of the straps on the
spring-loaded reels is approximately 25 inches
(63.5 cm).
Some installations have a handle: with the
handle up, the inertia reel operates normally;
with the handle down, the inertia reel is locked
up to restrain movement.
2. Seat Belts/Inertia Reel Description and
Operation (600N)
The crew seats utilize a four-point restraint
harness. This harness combines the lap seat
belts with double shoulder straps attached to
an inertia reel mechanism. Both mid and aft
passenger seats are equipped with a threepoint restraint system. The lap seat belt and
shoulder strap are joined at the end into a

single unit for ease of attachment and conve
nience. In one motion, the lap and shoulder
belts together can be attached to the seat
buckle.
3. Crew Seat Belt/Harness Cleaning
The harness and seat belt may be cleaned
using a soft-bristle brush and a mild solution
of warm water and laundry detergent.
4. Seat Belt/Inertia Reel Replacement
(369D/E/FF 500N)
(1). For access to seat belt attach fittings,
remove crew compartment seats.
(2). Remove inertia reel, with harness, from
canted bulkhead lateral beam by
removing four bolts.
(3). Install replacement harness by securing
inertia reel, with harness, to canted
bulkhead lateral beam.
(4). Install replacement seat belts and
shoulder straps as shown. Place snap
end fittings up or down to eliminate any
twist in seat belt.
(5). Tongue portion of center passenger lap
belt must be installed on right side and
buckle portion on left side as shown.
25-20-00
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MAINTENANCE MANUAL
CSP-HMI-2
FITTING
INERTIA REEL
SNAP END
FITTING
SEAT BACK
SEAT BELT FITTING

ATTACHMENT
NOTE 1
INERTIA REEL
INERTIA REEL
FLOOR STRUCTURE
NOTE 2
HARNESS MUST UNREEL

IN DIRECTION SHOWN
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
Revision 23
25-20-00
MAINTENANCE MANUAL
CSP-HMI-2
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
NOTE:
SLIDE BAR
HARNESS LENGTH ADJUSTER.
ADAPTER
(NOTE)
SNAP END FITTING

(HOOK UP)
SNAP END FITTING

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

(HOOK DOWN)
ADAPTER
(NOTE)
HARNESS MUST UNREEL

IN DIRECTION SHOWN
41 3
90 LIMITS OF CUTOUT
IN ALUM. HOUSING
BUCKLE
ADAPTER
LATCH
FITTING
ADAPTER
(NOTE)
NYLON WEBBING
SEAT BELT
SNAP END FITTING
INERTIA REEL
PILOT AND COPILOT SEAT BELT AND SHOULDER HARNESS ASSEMBLY
G25-2003
Figure 202. Seat Belt/Inertia Reel Installation (Yoke Style) (369D)
25-20-00
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
INERTIA REEL (2)
SEAT BACK CUSHION

VELCRO STRIP
FASTENER (TYP)
SUPPORT CUSHION
AFT SUPPORT
FITTING AND HEIGHT
ADJUSTMENT
SEAT BOTTOM CUSHION
INERTIA REEL (2)
LOCK PIN
SEAT BACK
CUSHION
LOWER FRAME
RELEASE PIN
SUPPORT LEG AND
HEIGHT ADJUSTMENT
SEAT BOTTOM
CUSHION
FLOOR STRUCTURE
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
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25-20-00
MAINTENANCE MANUAL
CSP-HMI-2
5. Crew Seat Belt/Harness Replacement With

Manual Lock Option (369D/E/FF 500N)
(2). Remove inertia reel, with harness, from

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

type end fittings from bulkhead
structure fittings.
(4). Install inertia reel, with harness, to

fiberglass mount with ferrule nut and
four bolts, nuts and washers.
CONTROL HEAD ROTATED

90 CW FOR CLARITY
UPPER FERRULE NUT
AUTOMATIC
INERTIA
REEL ASSY
CABLE
MANUAL LOCK
LOWER
FERULE
NUT
ADJUSTER
(TYP)
TAB RELEASE
(TYP)
CONTROL ASSY
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)

WIDE WEBBING LAP BELT ASSY
(0101936-1 ASSY)
END FITTING
LINK
LATCH
ADJUSTER
G25-2006A
Figure 204. Webbed Shoulder Harness and Seat Belt Installation with Manual
Inertia Reel Lock (369D)
25-20-00
Page 205
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
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
(Ref. Pull tests of seat belts and shoulder strap
harnesses shall be accomplished in accordance
with FAA AC 43.13-1B, Aircraft Inspection
and Repair for Standard Sheet Metal Repair
and TSO C22.
7. Seat Belt/Inertia Reel Inspection
Ensure center passenger lap
WARNING belt is installed with tongue

portion to the right of the seat and
buckle portion to the left. (Quick re
lease of the lap belt and shoulder strap
may be impaired if the assembly is im
properly installed.) If tongue and
buckle portions are reversed, remove
and reinstall in correct positions and
document reinstallation in Compliance
Record of Helicopter Log Book.
(1). Pull seat belt or shoulder strap out of
inertia reel to full extended length.
Ensure harness strap cannot be pulled
out of inertia reel. With tension re
Page 206
Revision 44
25-20-00
leased, harness strap should automati

cally reel back into reel. Exert a sudden
forward pull on seat belt or shoulder
strap to ensure inertia reel locks.
(2). Inspect inertia reels, snap end fittings,
adjusters, links, buckles, latches and
belt attachment fittings for cracks,
wear, corrosion and deformation. Check
for freedom from binding, ease of
adjustment and operation as applicable.
If doubt exists as to strength, perform
pull test (Ref. Seat Belts/Inertia Reel
Testing).
(3). Inspect shoulder harnesses and seat
belts for worn, frayed or deteriorated
condition, and loose stitching.
(4). (Manual Lock Option) Check mechani
cal inertia lock mechanism for proper
operation, with handle up and with
handle down. Inspect fiberglass mounts
for cracking and separation. Inspect
laminates for debonding.
MAINTENANCE MANUAL
8. Seat Belt/Inertia Reel Repair
(1). Replace seat belts and shoulder straps
if fabric is frayed, worn, deteriorated,
stitching is loose, or if enertia reels are
destroyed or do not function properly.
(2). Polish minor nicks and scratches.
Restore protective finish to aluminum
parts as required.
(3). Repair fiberglass mounts (Ref. Sec.
25-30-00, Boltaron Trim Panels
Repair).
9. Seat Belt/Restraint Harness, Crew Seat,
Replacement (600N)
(Ref. Figure 206)
A. Seat Belt/Restraint Harness Removal
(1). Release end fittings to remove lap seat
belts.
CSP-HMI-2
(2). Remove hardware that attaches inertia

reel to mounting surface.
(3). Remove complete seat belt restraint
harness from seat.
B. Seat Belt/Restraint Harness Installation
(1). Position lap seat belt and shoulder
harness into seat assembly.
(2). Engage end fittings attaching lap seat
belts.
(3). Install hardware attaching inertia reel
to mounting surface.
(4). Ensure proper engagement and release
of seat buckle and inertia reel mecha
nism.
ADJUSTOR
ADJUSTOR
SHOULDER
HARNESS
END FITTING
LAP
SEAT BELT
SHOULDER
HARNESS
ADJUSTOR
ADJUSTOR
LAP
SEAT BELT
END FITTING
BUCKLE
6G25-070
Figure 206. Seat Belt/Restraint Harness Installation, Crew Seat (600N)
25-20-00
Page 207
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
10. Seat Belt/Restraint Harness, Mid

Passenger Seat, Replacement (600N)
11. Seat Belt/Restraint Harness, Aft

Passenger Seat, Replacement (600N)
(Ref. Figure 207) These three individual seat

belt harnesses are completely contained in the
seat assembly and attach to the seat frame.
This feature aids in the quick removal and
installation of the mid bench seat assembly.
(Ref. Figure 207)

reel end of harness to seat back.
(2). Release end fitting that attaches lap
seat belt to seat frame.
(3). Release end fitting that attaches buckle
end of harness to seat frame.
(4). Remove seat belt/restraint harness.
(1). Position seat belt/restraint harness into
seat assembly.
(2). Engage end fitting attaching buckle end
of harness to seat frame.
(3). Engage end fitting attaching lap belt to
seat frame.

reel end of harness to mounting
surface.
(2). Release end fitting that attaches lap
belt to mounting surface.
(3). Release end fitting that attaches buckle
end of harness to mounting surface.
(4). Remove seat belt/restraint harness.
(1). Position seat belt/restraint harness into
seat assembly.
(2). Engage end fitting attaching buckle end
of harness to mounting surface.
(3). Engage end fitting attaching lap belt to
mounting surface.

end of harness to seat back.

end of harness to mounting surface.

nism.

nism.
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25-20-00
MAINTENANCE MANUAL
MID SEAT
CSP-HMI-2
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)
25-20-00
Page 209
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MAINTENANCE MANUAL
CSP-HMI-2
12. Comfort Clip Installation and Decal

Application (369D/E/FF 500N)
(Ref. Figure 208 and Figure 209) The comfort
clip is designed to maintain proper strap
tension and relieve excessive pressure of the
inertia reel shoulder harness on the pilot or
passenger during flight. It is available for
installation on helicopters equipped with Sam
Browne style seat belt assemblies.
(1). Pry open slot on underside of clip.
position as close as possible next to

inertia reel.
(4). After each flight, reposition comfort clip
on harness strap at original position
next to buckle.
(5). Clean panel or door frame where decal
is to be applied. Decals will not adhere
to a greasy or soapy film.
(2). Insert harness strap in slot.
(6). Mark location(s) of decal per the

illustrations.
(3). After seat belt and shoulder harness

assembly is fastened and adjusted for
individual comfort and safety, slide
comfort clip up on harness strap and
(7). Peel backing off decal and position. Use

a cloth to squeeze all bubbles from
under the decal, working from the
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
Revision 23
25-20-00
MAINTENANCE MANUAL
CSP-HMI-2
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)
25-20-00
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CSP-HMI-2
MAINTENANCE MANUAL
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Revision 44
25-20-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
252100
Seating/Belts (Four
on the Floor)
MAINTENANCE MANUAL
CSP-HMI-2
SEATING/BELTS (FOUR ON THE FLOOR)

1. General
NOTE: This option has an aircraft effectivity

limit. Refer to CSP-IPC-4 for effectivity.
The four on the floor seating and belt installa
tion is designed for maximum use of the
passenger compartment for transportation of
personnel. The installation consists of four
floor-installed seat assemblies with seat belts
and shoulder straps at each position. The two
aft-facing seat positions include head and
back restraint panels mounted on Cant. Sta.
78.50 structure.
The shoulder strap is adjusted to cross the
passenger's chest from outboard shoulder to
center of lap where it joins the seat belt
assembly. Seat belts are adjusted by individual
passengers for a close and comfortable fit.
(3). Remove seat belt assemblies and

shoulder straps by unsnapping hooks at
structure-mounted fittings.
B. Seating/Belt Installation
(1). Install seat assemblies by placing seat
in position and inserting tabbed rivets
into holes in floor stiffeners (Ref.
Figure 903).
(2). Install restraint panels by securing
each panel at bracket assemblies with
four screws and washers (Ref.
Figure 902).
(3). Install seat belt assemblies and
shoulder straps by snapping hooks to
structure-mounted fittings.
The installation for the early configuration is

designed for use with a high shoulder beam.
The current configuration installation is used
for a low shoulder beam.
3. Seating/Belt Inspection
NOTE: Shoulder straps for aft-facing passen
4. Seating/Belt Cleaning
gers are installed on early configuration he

licopters only.
2. Seating/Belt Replacement
A. Seating/Belt Removal
(1). Remove seat assemblies by lifting
tabbed rivets from holes in floor
stiffeners (two per seat), then lift seat
up (Ref. Figure 903).
(2). Remove restraint panels by removing
four screws and washers from each
panel bracket assembly (Ref.
Figure 902).
(Ref. Sec. 25-20-00, Seat Belt/Inertia Reel

Inspection)
(Ref. Sec. 20-20-00, Fuselage Interior Trim or

Upholstery Cleaning or 25-20-00, Crew Seat
Belt/Harness Cleaning)
5. Seating/Belt Repair
(1). Repair minor tears and cuts to the seat
and restraint panel coverings (Ref. Sec.
25-20-00, Seat Belt/Inertia Reel
Repair).
(2). Replace unserviceable seats and
restraint panels.
(3). Seat belts or shoulder straps that show
signs of wear, deterioration, fraying, or
loose stitching must be replaced.
25-21-00
Page 201
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
Page 202
Revision 44
25-21-00
MAINTENANCE MANUAL
CSP-HMI-2
SEATING/BELTS (FOUR ON THE FLOOR)

1. Seating/Belts (Four on the Floor) Initial
Installation
(3). Remove passenger compartment carpet

floor covering.
NOTE: This option has an aircraft effectivity
(4). Remove aft trim panel from Cant. Sta.

78.50 and disconnect cigarette lighter
wiring.
limit. Refer to CSP-IPC-4 for effectivity.

Consult the optional equipment table (Ref.
Table 202, Sec. 01-00-00) for model applicabil
ity for seating/belts (369H90035) installations.
The -501 and -503 installations are covered in
the following paragraphs.
Item
Nomenclature
CM318
Primer
(1). Ensure all electrical switches are set to

OFF position. Recheck master switch
for OFF position.
(2). Identify all components and attaching
hardware to be removed for access to
work areas. Protect components from
damage and foreign matter until
reinstalled.
(5). Remove bulkhead trim panels or

insulation blankets at Sta. 124.00 in
area of WL 40.00 and BL 20.00 right
and left seats.
(6). (369D only) Remove crew compartment
outboard seat backs.
C. Seating and Belts Installation General
Installation of the seating and belts for four
includes procedures for installing restraint
panels on Cant. Sta. 78.50, seat assemblies,
shoulder straps, and seat belt assemblies.
Item
Nomenclature
CM318
Primer
NOTE:
(3). After drilling or cutting, remove burrs

and metal particles. Apply a thin coat of
primer (CM318) to all bare metal areas.
D Use Cleco clamps and fasteners as re

quired to facilitate rivet installation, and
install rivets with wet primer (CM318).
NOTE: An application of color-matched paint
D Rivets are equally spaced and are normal

ly positioned twice the diameter of the riv
et shank from the outside edge of the ma
terial, edge joggle, or flange radius.
may be applied to primer painted reworked

areas and to installed hardware.
B. Removal of Existing Equipment
Prior to installing the seating and belts for
four, a limited number of items must be
removed from the helicopter passenger
compartment to accommodate installation.
(1). Remove passenger compartment seats
by releasing quick-disconnects on
seating structure at floor and firewall
fittings.
(2). Remove existing passenger compart
ment seat belt and shoulder strap
assemblies.
D. Cant. Sta. 78.50 Brackets, Fittings and

Restraint Panels Installation
(1). On Cant. Sta. 78.50, WL 22.45, remove
four existing bracket rivets in area of
LBL 8.25 and four rivets in area of LBL
19.25.
(2). Position bracket assemblies to match
holes in removed rivet pattern. Locate
and drill four 0.1285 inch (3.2639 mm)
holes in each bracket.
25-21-00
Page 901
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
LBL 15.50
BRACKET ASSEMBLY
LBL 8.50
BRACKET
ASSEMBLY
0.50 IN. (12.7 MM) (TYP)

RIVET (2)
RIVET (2)
CANT. STA 78.50

0.75 IN. (19.05 MM)
0.83 IN. (21.082 MM)
LH SHOWN
RH OPPOSITE
0.50 IN. (12.7 MM)
RIVET (4)
0.42 IN. (10.668 MM)
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.
RESTRAINT PANEL
ASSEMBLY
LBL
15.50
LH
LBL
8.50
LH
PICK UP EXISTING RIVETS

LBL
20.75
BL
0.00
LBL
19.25
RBL
8.50
RH
LBL
17.00
LH SHOWN
RH OPPOSITE
LBL
11.30
LBL
8.25
LBL
6.00
RESTRAINT PANEL
ASSEMBLY
BRACKET ASSEMBLY
BRACKET
ASSEMBLY
RESTRAINT PANEL
ASSEMBLY
WL 45.36
BRACKET
ASSEMBLY
WL 45.30
BRACKET ASSEMBLY
FITTING
SUPPORT
FITTING SUPPORT
TRIM
PANEL
SHOULDER STRAP
SHOULDER
STRAP
WL 28.44
BRACKET
ASSEMBLY
WL 22.45
SEAT AS
SEMBLY
WL 21.50
BRACKET ASSEMBLY
LBL 20.75 LH
RBL 20.75 RH
BRACKET AS
LBL 19.25 LH
RBL 19.25 RH
SEMBLY
LBL 17.00 LH
RBL 17.00 RH
LBL 11.30 LH
RBL 11.30 RH
LBL 8.25 LH
RBL 8.25 RH
CANT. STA 78.50
RESTRAINT PANELS BRACKET
LOCATION HIGH BULKHEAD
SECTION
WL 13.10
D-D
G25-2008A
Figure 901. Restraint Panel Assemblies and Hardware Installation (369D)

Page 902
Revision 23
25-21-00
MAINTENANCE MANUAL
CSP-HMI-2
LBL 19.50
BRACKET ASSEMBLY
BRACKET
ASSEMBLY
LBL 8.50
0.50 IN. (12.7 MM) (TYP)

RIVET (2)
RIVET (2)
CANT. STA 78.50

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

0.50 IN. (12.7 MM)
LH SHOWN
RH OPPOSITE
RIVET (4)
RIVET (4)
CANT. STA 78.50
BRACKET ASSEMBLY
BRACKET ASSEMBLY
NOTES: DRILL 0.217-0.229 IN.

(5.5118-5.8166 MM) HOLES (4) IN EACH
RESTRAINT PANEL ASSEMBLY; LOCATE
FROM BRACKETS. DRILL HOLES IN TRIM
PANEL ASSEMBLIES AS APPLICABLE.
LBL
19.50
LH
LBL
8.50
LH
PICK UP EXISTING RIVETS

LBL
20.75
BL
0.00
RBL
8.50
RH
LBL
19.25
LBL
17.00
LH SHOWN
RH OPPOSITE
LBL
11.30
LBL
8.25
LBL
6.00
RBL
19.50
RH
RESTRAINT PANEL
ASSEMBLY
RESTRAINT PANEL
ASSEMBLY
RESTRAINT PANEL
ASSEMBLY
BRACKET
ASSEMBLY
BRACKET
ASSEMBLY
BRACKET ASSEMBLY
WL 37.85
TRIM
PANEL
WL 28.44
BRACKET
ASSEMBLY
WL 22.45
LBL 20.75 LH
LBL 19.25 LH
LBL 17.00 LH
LBL 11.30 LH
LBL 8.25 LH
WL 21.50
BRACKET ASSEMBLY
BRACKET AS
SEMBLY
RESTRAINT PANELS BRACKET

LOCATION HIGH BULKHEAD
RBL 20.75 RH
RBL 19.25 RH
RBL 17.00 RH
RBL 11.30 RH
RBL 8.25 RH
SEAT
ASSEMBLY
CANT. STA 78.50
WL 13.10
SECTION
D-D
G25-2007A
Figure 902. Restraint Panel Assemblies and Hardware Installation (369E/FF 500N)
25-21-00
Page 903
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
(3). Hold brackets in position with Cleco

fasteners and drill four 0.1285 inch
(3.2639 mm) holes through upper flange
of each bracket and through Cant. Sta.
78.50 web.
(8). (369D only) Install shoulder strap

fittings for aft-facing passenger seat as
follow:
(4). Install bracket assemblies with 16

rivets.
(a). On left side of Cant. Sta. 78.50

bulkhead frame, locate four existing
nutplates in area of WL 41.06 and BL
24.74.
(5). Repeat last four steps to install two

bracket assemblies to opposite side.
(b). Attach shoulder strap fitting with

four screws.
(6). (369D only) Install bracket assemblies

as follows:
(c). On right side of Cant. Sta. 78.50

bulkhead frame, locate four existing
nutplates in area of WL 41.06 and BL
24.74.
(a). On WL 45.33, position bracket

assembly at LBL 15.50 and drill two
0.1285 inch diameter holes through
bracket and Cant. Sta. 78.50 channel.
(d). Attach shoulder strap fitting with

four screws.
(b). Install bracket assembly with two

blind rivets.
(e). Attach L/H fitting to nutplates in L/H

tee using four screws.
(c). On WL 45.33 L/H, position bracket

assembly at LBL 8.50 and drill two
0.1285 inch diameter holes through
bracket and Cant. Sta. 78.50 channel.
(f). Attach R/H fitting to nutplates in

R/H tee using four screws.
(d). Install bracket assembly with two

blind rivets.
(e). Repeat last four steps to install two
bracket assemblies R/H opposite.
(7). (369E/FF only) Install bracket assem
blies as follows:
(a). On WL 37.85, position bracket
assembly at LBL 19.50 L/H. Drill two
0.1285 inch (3.2639 mm) holes
through bracket and Sta. 78.50
channel.
(b). Install bracket assembly with two
blind rivets.
(c). On WL 37.85, position bracket
assembly at LBL 8.50 L/H. Drill two
0.1285 inch (3.2639 mm) holes
through bracket and Cant. Sta. 78.50
channel.
(g). Cut out slots in removed passenger

compartment forward trim panels to
accommodate lugs of shoulder strap
fittings.
(9). Drill four 0.217-0.229 inch
(5.5118-5.8166 mm) holes in forward
trim panel, and four holes in each
restraint panel. Locate holes from
bracket assemblies and install as in
steps (1). thru (8).
(10). Reinstall forward trim panel (connect
cigarette lighter wiring).
(11). Install passenger compartment carpet
floor covering.
(12). (369D only) Install fitting cap to L/H
and R/H shoulder strap fittings with
two screws each side.
(13). Install restraint panel to L/H side over
trim panel with four washers and
screws.
(d). Install bracket assembly with two

blind rivets.
(14). Install restraint panel to R/H side over

trim panel with four washers and
screws.
(e). Repeat last four steps to install R/H

bracket assemblies.
(15). Reinstall crew compartment seat back

assemblies.
Page 904
Revision 23
25-21-00
MAINTENANCE MANUAL
E. Seat Assemblies Installation
(Ref. Figure 903)
NOTE: Seat assemblies are position-inter

changeable.
(1). Position seat assemblies on floor
structure to locations specified.
(2). Secure seats in position by pressing
tabbed rivets into holes in floor stiffen
ers.
F. Aft Seat Belt Assemblies and Shoulder
Straps Installation
(Ref. Figure 903)
(1). On both left and right sides of Cant.
Sta. 128.00 locate four existing nut
plates in areas of WL 40.0 and BL 20.0.
(2). Attach a shoulder strap support fitting
on each side, using four washers and
screws for each fitting.
(3). Cut out slots in removed trim panels or
insulation blankets to accommodate
lugs of new support fittings.
(4). Reinstall trim panels or insulation
blankets.
(5). Connect a shoulder strap to each
fitting.
NOTE: Adjust shoulder strap to cross passen

ger's chest from outboard shoulder to inner
center of lap.
(6). Locate the three existing cargo floor
seat belt fittings on the passenger
compartment floor at Sta. 124.00.
CSP-HMI-2
NOTE: All seat belt assemblies are to be in

stalled as shown and as noted on cloth iden
tification labels attached to each seat belt
assembly. The two center belts are installed
with hooks down.
(7). Connect adjustable portion of seat belt
assembly to the R/H fitting and nonad
justable portion to center fitting.
assembly to L/H fitting and nonadjust
able portion to center fitting.
G. Forward Seat Belt Assemblies and
Shoulder Straps Installation
(Ref. Figure 904)
(1). (369D only) Connect a shoulder strap to
each shoulder strap fitting on Cant.
Sta. 78.50.
NOTE: Adjust shoulder strap to cross passen

ger's chest from outboard shoulder to inner
center lap area.
(2). Locate the four tiedown fitting holes on
the first floor stiffener aft of Cant. Sta.
78.50.
(3). Install a cargo tiedown fitting in each
floor stiffener hole.
assembly to the L/H fitting and the
nonadjustable portion to the L/H center
fitting.
assembly to the R/H fitting and the
nonadjustable portion to the R/H center
fitting.
25-21-00
Page 905
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2

(Ref. Table 901) After installation, incorporate
changes to helicopter weight and balance
records as instructed (Ref. Sec. 08-10-00).
Configuration
Weight
Pounds (kg)
Arm
Inches (cm)
Moment
inlb (kg cm)
369H90035501
Added
+30.2
(+13.698)
+93.5
(+237.49)
+2824
(+3253.6)
Removed
32.7
(14.832)
+108.6
(+275.84)
3551
(4091.2)
+31.2
(+14.152)
+92.1
(+233.93)
+2874
(+3311.2)
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)
369H90035503
Added
Removed
Page 906
Revision 23
25-21-00
MAINTENANCE MANUAL
CSP-HMI-2
NUT
GROMMET
RIVET
CARGO TIE-DOWN FITTING
(4 PLCS)
STA. 78.50
BELT ASSEMBLY
RIVET TAB (TYP 4 PLCS)
STA. 124.00
BELT ASSEMBLY
SEAT AS
SEMBLY (4
PLCS)
4.0 IN.
(10.16 CM)
4.0 IN.
(10.16 CM)
EXISTING CARGO FLOOR

SEAT BELT FITTINGS
(3 PLCS)
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)
25-21-00
Page 907
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
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 (4 REQ'D)
SCREW (2 REQ'D)
LOW BULKHEAD
STA. 78.50 SHOULDER STRAP FITTING
SHOULDER STRAP
(TYP)
SHOULDER STRAP
(TYP)
STA. 78.50
WL 28.44
STA. 78.50 SHOULDER STRAP AND FITTINGS
WL 32.00
STA. 124.00
STA. 124.00 SHOULDER STRAP AND FITTINGS
PICK UP EXISTING NUTPLATES LO

NOTE:
CATED ON CANT. STA. 78.50 BULKHEAD FRAME
AND CANT. STA. 124 BULKHEAD FRAME.
Figure 904. Shoulder Straps and Fittings Installation (369D/E/FF 500N)

Page 908
Revision 23
25-21-00
G25-2009
MAINTENANCE MANUAL
CSP-HMI-2
Section
253000
Interior Trim
MAINTENANCE MANUAL
CSP-HMI-2
INTERIOR TRIM
1. Interior Trim
Trim panels, covers, and applicable attaching
devices are found in the following locations:
(1). Models 369D/E/FF - 500N crew
compartment (Ref. Figure 201).
(2). Models 369D/E/FF - 500N passenger
compartment (Ref. Figure 202).
(3). Model 369D crew and passenger
compartments - R/H command helicop
ters with center console (Ref.
Figure 203).
(4). Floor trim covering and applicable
methods of attachment (Ref.
Figure 204).
A. Cyclic Stick Control Cover
(Ref. Figure 201) A cyclic stick control cover
protects the cyclic control linkage from objects
that might jam or foul control linkage. The
cover extends between the pilot's and copilot's
cyclic sticks at the seat bulkhead and covers
the cyclic control linkage. Cyclic stick openings
in the cover are protected by boot assemblies
(dust covers) secured to the cover with Velcro
hook and pile fasteners. The cyclic sticks pass
through elastic ringed openings in the dust
covers.
B. Copilots Inboard Collective Pitch Stick
Cover
The inboard collective pitch stick cover on L/H
command helicopters provides access to the
underseat flight controls linkage and forms a
protective guard for the collective friction
mechanism on the inboard collective pitch
stick. A sliding protective cover at the collec
tive pitch stick slotted opening guards against
foreign object entry.
A. Cyclic Stick Control Cover Replacement

(L/H Command)
(Ref. Figure 201)
(1). Remove four upper attaching cover
screws. Remove velcro attached boot
assemblies from cover. Tip cover
forward to remove two lower attaching
screws.
(2). Remove cover from cyclic stick assem
bly and slip boot assemblies over cyclic
stick grips.
(3). To replace, slip boot assemblies over
cyclic stick grips and position cover in
place. Attach boot assemblies to cover
with the velcro fasteners.
(4). Tip cover forward and install two lower
attaching screws. Install four upper
attaching screws.
B. Copilots Collective Pitch Stick Cover
Replacement (L/H Command)
(Ref. Figure 201)
(1). Remove crew seats.
(2). Remove attaching hardware. While
carefully removing cover, ensure sliding
protective cover remains fixed to
collective pitch stick. Partial removal of
the cyclic stick control cover may be
required.
NOTE: Electrical wires from passenger com
(3). Spread sliding cover at collective stick

and remove. If necessary, remove nylon
grommet on stick (Ref. Sec. 67-10-00,
Pilot's Collective Pitch Stick Replace
ment).
partment cigarette lighter, optional utility

light, and running time meter must be dis
connected before removing and reconnected
before installing associated trim panel or
cover (Ref. Chap. 96).
(4). To replace, install nylon grommet on

collective stick. Spread sliding cover at
collective stick hole and fit over nylon
grommet.
2. Interior Trim Replacement
25-30-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
VELCRO FASTENER
CONTROL TUNNEL PAN

EL (NOTES 1, 5)
CAP
(NOTE 2)
VELCRO
FASTEN
ER
4 PLCS
MAP CASE
TRIM COVER
(NOTE 4)
SHOULDER BEAM PANEL

6 PLCS
MAP POCKET
LH BOOT
AS
SEMBLY
RH BOOT
AS
SEMBLY
CYCLIC STICK CONTROL COVER

LID
3 PLCS
VELCRO
FASTEN
ER
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)
Figure 201. Crew Compartment Interior Trim (Sheet 1 of 2)

Page 202
Revision 23
25-30-00
G25-3001-1
MAINTENANCE MANUAL
CSP-HMI-2
VELCRO FASTENER
ASSIST STRAP
CANTED BULKHEAD PAN

EL (RIGHT SIDE)
3 PLCS
2 PLCS
2 PLCS
DOOR PANEL
UPPER SIDE PANEL
ASSIST HANDLE
NOTE 6
VELCRO FASTENER
LOWER INSTRUMENT
HOUSING PANEL
4 PLCS
8 PLCS
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
MIRROR IMAGE OPPOSITE).
8. DOOR MAIN TRIM PANELS NOT SHOWN.
OUTBOARD AFT PANEL

G25-3001-2
Figure 201. Crew Compartment Interior Trim (Sheet 2 of 2)
25-30-00
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
VELCRO FASTEN
ER (8 PLCS)
VELCRO FASTENER
COVER
(2 PLCS)
SCREW
(4 PLCS)
SCREW
(2 PLCS)
STANDOFF
(2 PLCS)
BRACKET
HIGH FORWARD BULKHEAD PAN

EL (LOOKING FORWARD)
STANDOFF
(2 PLCS)
VELCRO FASTENER
BRACKET
SCREW
(2 PLCS)
LOW FORWARD BULKHEAD PAN

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

ER (NOTES 1, 2)
NOTES:
1. NOT USED WITH OPTIONAL ROTOR BRAKE EQUIPMENT.
2. FOR INFORMATION ON OPTIONAL EQUIPMENT USED ON
THIS PANEL, REFER TO OPTIONAL EQUIPMENT LIST
(REF. SEC. 01-00-00).
WASHER
(12 PLCS)
BULKHEAD PANEL
POCKET
LITERATURE POCKET
Figure 202. Passenger Compartment Interior Trim (Sheet 1 of 2)

Page 204
Revision 23
25-30-00
G25-3002-1
MAINTENANCE MANUAL
CSP-HMI-2
SCREW
(16 PLCS)
SCREW
(5 PLCS)
CURRENT CONFIGURATION
EARLY CONFIGURATION
UPPER AFT BULKHEAD PANEL

(LEFT SIDE)
OIL LEVEL
CHECK COVER
PLUG BOTTOM
(BOTH SIDES)
5 PLCS
LOWER AFT BULKHEAD PANEL

VELCRO FASTENER
MAIN TRANSMISSION
ACCESS PANEL
8 PLCS
VELCRO FASTENER
TRANSMISSION PANEL
DOOR STRUCTURE
5 PLCS
STRUCTURE
DOOR PANEL
(LEFT SIDE)
ISOLATOR NUT MOUNT INSTALLA

TION (TYP)
G25-3002-2
Figure 202. Passenger Compartment Interior Trim (Sheet 2 of 2)
25-30-00
Page 205
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
(5). Position cover over collective stick and

start upper end of sliding cover into
cover tracks.
(6). Slowly lower cover and guide remainder
of sliding cover upward in cover tracks.
(7). Secure with screws and washers.
(8). Install crew seats.
(Ref. Figure 203) At installation, tuck bottom

edge of lower curtain under support.
Curtains must not fold inward
through full travel of the collec
tive stick. Folding inward may result in en
tanglement with collective stick friction
gear mechanism.
CAUTION
D. Transmission Panel
(Ref. Figure 203) Remove low or high bulkhead
convenience panel before removing transmis
sion panel.
E. Log Book Holder (Optional for R/H
Command)
(Ref. Figure 203)
Item
Nomenclature
CM217
CM432
CM433
Isopropyl alcohol
Dichloromethane
Ethylene chloride
ble-faced tape or bonded with adhesive, and

should not be removed unless replacement
or repair is required.
(1). Tear away carpeting (if bonded) and
clean surface with wire brush. Bond
replacement carpeting using adhesive
(CM718).
(2). Lift carpeting (if taped) away from floor
and remove double-faced tape. Apply
new double-faced tape (CM718) and
press replacement carpeting in position.
3. Interior Trim Inspection
(1). Inspect interior trim for tears, cuts,
breaks, or other evidence of unservice
able condition.
(2). Inspect trim panels and covers for
loose, damaged, or missing Velcro
fasteners, as applicable.
(3). Inspect fuselage structure for loose,
damaged, or missing Velcro fasteners,
rivnuts or isolator nut mounts, as
applicable.
(4). Inspect carpeting for cuts, tears, or
other unserviceable condition.
(5). Inspect foot fairings, floor trim, and
access doors for cuts, breaks or cracks.
(1). Remove upper two screws and loosen

the bottom screws.
(2). Lift holder up and out.
(3). Repair cracks or separation by cleaning
with isopropyl alcohol (CM217); then
apply ethylene dichloride (CM433) or
dichloromethane (CM432) to patch or
mate surfaces.
(4). Join immediately with light pressure to
cement joint.
Revision 23
Item
CM405
CM718
Nomenclature
Adhesive
Tape, double-faced
NOTE: Carpeting is secured in place with dou
C. Inboard Collective Pitch Stick Cover

Replacement (R/H Command)
Page 206
F. Carpeting
25-30-00
(6). Inspect Velcro fasteners on access flap

for security of attachment or other
damage.
(7). (L/H command helicopters) Inspect
sliding cover of copilot's collective pitch
stick cover for freedom of movement in
cover tracks. Inspect stowage lid for
condition and positive fastening.
A. Interior Trim Cleaning
MAINTENANCE MANUAL
CSP-HMI-2
TRANSMISSION PAN
EL INSTALLATION
PLUG BUTTON
(BOTH SIDES)
OIL LEVEL
CHECK COVER
MAIN TRANSMISSION
ACCESS PANEL
CHIP DETECTOR
COVER PLUG
TRANSMISSION
PANEL
AFT BULKHEAD INSTALLATION
UPPER BULKHEAD PAN
EL (RIGHT HAND)
UPPER BULKHEAD PANEL

(LEFT HAND)
CHECKLIST
MAGNETIC
COMPASS
CARD
LOWER BULKHEAD PANEL
SEAT FITTING COVER
LOGBOOK HOLDER
CONVENIENCE PANEL
INSTALLATION
LOGBOOK HOLDER
INSTALLATION
PLUGS
CONVENIENCE PANEL
ISOLATOR NUT MOUNT

INSTALLATION
BLANK COVER
CONVENIENCE
PANEL COVER
TRIM PANEL
NUT MOUNT
G25-3003-1
Figure 203. Crew and Passenger Compartment Interior Trim R/H Command (Sheet 1 of 2)
25-30-00
Page 207
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
CIRCUIT BREAKER
PANEL
ASH RECEIVER AND

CIGARETTE LIGHTER
PANEL
STICK COVER
SUPPORT
TUBE CLAMP
SUPPORT
TUBE AS
SEMBLY
PILOT COLLECTIVE PITCH

STICK COVER ASSEMBLY
FLEXIBLE CLOSURE
ASSEMBLY
LOWER CURTAIN
PILOT'S INBOARD COLLECTIVE
PITCH STICK COVER
UPPER CURTAIN
CURTAIN STOP
SLIDER
COTTER PIN
FASTENER STUD
FASTENER BUTTON
EXPLODED VIEW
(ROTATED)
PILOT'S CYCLIC
STICK GUARD
CYCLIC CONTROLS
CENTER GUARD
CYCLIC STICK GUARDS

(ROTATED)
COPILOT'S CYCLIC
STICK GUARD
G25-3003-2
Figure 203. Crew and Passenger Compartments Interior Trim R/H Command (Sheet 2 of 2)
Page 208
Revision 23
25-30-00
MAINTENANCE MANUAL
4. Interior Trim and Carpeting General
Repair
CSP-HMI-2
(1). Remove damaged panel.

(2). Stop-drill end(s) of crack.
Item
Nomenclature
CM219
Methyl-ethyl-ketone
CM405
Adhesive
CM718
Tape, double-faced
(1). Remove and replace broken or missing

rivnuts or isolator nut mounts, as
applicable.
(2). Bond loose insulation material on
underside of trim panel or cover using
adhesive (CM405).
(3). Repair cut or torn floor trim or carpet
ing with new application of doublefaced tape (CM718) or adhesive
(CM405), as applicable.

NOTE: Loosened Velcro fasteners may be reac

tivated for adhesion by wiping original
adhesive with MEK (CM219).
(4). Replace unserviceable Velcro fasteners
on access flap using adhesive (89).
(3). Deburr stop drill(s) and clean any

jagged area of crack.
(4). Cut patch from fiberglass cloth to
overlap damaged area or crack, mini
mum 1 inch (2.54 cm) in all directions.
(5). Cut second patch to overlap first,
minimum 1/2 inch (12.7 mm) in all
directions. If required, cut third patch
to overlap second, minimum 1/2 inch
(12.7 mm) in all directions.
(6). Abrade surface of panel in area to be
patched with emery cloth (CM804).
(7). Clean surface by wiping with cloth,
dampened not saturated, with
1,1,1-trichloroethane (CM222) or
(8). Place panel in horizontal position. Tape
around area to be repaired with
masking tape, to catch residual resin.
(9). Apply glass cloth (CM501) to panel one
ply at a time.
5. Boltaron Trim Panels Repair

A. Fiberglass Patch Method
(Ref. Figure 205)
Item
Nomenclature
CM222
1,1,1-Trichloroethane
CM228
Surface cleaner
CM501
Fiberglass cloth
CM505
Polyester laminating resin
CM804
Emery cloth, fine
(10). Apply resin (CM505) to material with a

brush or squeegee.
(11). Continue adding material and resin
until desired thickness has been
achieved.
NOTE: Heat lamp should be placed a minimum

of 12 inches from fiberglass repair area.
(12). Allow repair to cure, minimum 45
minutes, at 265 10F (129 5C). Or
alternatively, heat lamp may be used
(minimum 2 hours).
25-30-00
Page 209
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
NAUGAHYDE
HANDLE (2)
FLOOR CARPETING
STA. 78.50
BULKHEAD
FOOTWELL PANEL
ASSEMBLY
ACCESS DOOR
CARPETING
DOUBLE
FACE TAPE
FLOOR STRUCTURE
RIGHT SIDE TRIM
CARPETING
ACCESS FLAP
CARPETING
FLOOR ACCESS DOOR

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

CARPETING
FLOOR STRUCTURE
FLOOR CARPETING
CENTER TRIM
CARPETING
BULKHEAD TRIM (NOTE)
NOTE:
CARPETING IN THIS AREA
IS BONDED IN PLACE.
FLOOR PAN
DOUBLE
FACE TAPE
G25-3004A
Figure 204. Floor Trim and Covering

Page 210
Revision 23
25-30-00
MAINTENANCE MANUAL
B. Solvent Bonding Patch Method
(Ref. Figure 205)
Item
Nomenclature
CM220
CM435
Naphtha aliphatic
Tetrahydrofuran

jagged area of crack.
(4). Select a piece of boltaron material with
same contour as patch area. Plating
surfaces must provide a snug fit. Patch
material to overlap damaged area a
minimum of 1 inch (2.54 cm) in all
directions.
(5). Clean mating surfaces with aliphatic
naphtha (CM220). Ensure surfaces are
free from oil, grease or other contami
nates.
(6). Assemble patch with mating surface of
patch in contact with panel but without
application of pressure.
Tetrahydrofuran bonding
WARNING solvent is a flammable liq

uid. Care must be exercised in handl
ing.
Solvent shall be applied careful
ly so no excess material will run
over other surfaces and mar the finish.
CAUTION
NOTE: On larger parts, solvent shall be applied

evenly to mating surfaces with brush.
(7). Inject tetrahydrofuran (CM435)
between mating surfaces by means of
syringe or eye dropper.
(8). Assemble mating surfaces as quickly as
possible by firmly pressing together.
(9). Apply clamps to assembly immediately
after solvent application. Use sufficient
pressure to force out air bubbles.
CSP-HMI-2
(10). After forcing out bubbles, adjust clamps

to minimum pressure required to hold
parts together.
(11). If solvent has evaporated at or near
edge of patch, apply more solvent
between mating surfaces using syringe
or eye dropper.
(12). Leave clamps in place for a minimum of
20 minutes.
(13). Allow the panel to cure for 24 hours
prior to reinstallation.
C. Epoxy Adhesive Patch Method
(Ref. Figure 205)
Item
Nomenclature
CM228
CM411
CM804
Surface cleaner
Adhesive, epoxy
Emery cloth, fine

jagged area of cracks.
(4). Select a piece of boltaron material with
same contour as patch area. Mating
surfaces must provide a snug fit. Patch
to overlap damaged area a minimum of
1 inch (2.54 cm) in all directions.
(5). Lightly abrade mating surfaces with
emery cloth (CM804) and clean with
(6). Air dry for 30 minutes at ambient
temperature. Apply adhesive (CM411)
within 2 hours of drying.
(7). Thoroughly mix equal parts of adhesive
by weight. Color should be uniform
green. Use unwaxed disposable contain
er and wooden tongue depressor or
metal spatula for mixing. Pot life of
mixed adhesive is 45 minutes at
ambient temperature.
25-30-00
Page 211
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
FIBERGLASS PATCH METHOD A

0.50 IN.
(12.7 MM)
1.0 IN.
(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.
PATCH
PANEL
RIVETS
STOP DRILL
2 X O.D.
+0.030 IN.
(0.762 MM)
BOND AND RIVET PATCH METHOD D

2 X O.D.
+0.030 IN.
(0.762 MM)
WASHER
(NOTE)
NOTE: USE AN960 WASHER, OF PROPER SIZE TO FIT RIVET DIAMETER, TO

PRECLUDE RIVET TAIL FROM PULLING THROUGH BOLTARON PANEL.
4-6 X O.D.
G25-3005A
Figure 205. Boltaron Panel Repair

Page 212
Revision 23
25-30-00
MAINTENANCE MANUAL
(8). Spread thin uniform layer (0.002-0.010
inch) (0.0508-0.254 mm) of adhesive
lightly on mating surfaces and clamp
lightly together.
(9). Wipe excess adhesive from bond line.
(10). The clamps are to remain in place for 8
hours minimum at ambient tempera
ture or 2 hours at 160 10F (72
5C).
(11). Allow panel to cure for 24 hours prior to
installation.
D. Bond and Rivet Patch Method
(Ref. Figure 205) The following procedure may
be used in conjunction with one of the above
bonding procedures (Ref. Solvent Bonding
Patch Method or Epoxy Adhesive Patch
Method). If cracks are excessive and/or a piece
of boltaron is not available that fits contour in
repair area, rivets may be used to help secure
patch to panel.
Item
Nomenclature
CM220
Naphtha aliphatic
CM228
Surface cleaner
CM411
Adhesive, epoxy
CM435
Tetrahydrofuran
CM804
Emery cloth, fine
(1). Cut patch to proper size.

(2). Determine rivet spacing.
(a). Rivet spacing to be 4-6 times rivet
diameter.
(b). Minimum edge distance to be 2 times
rivet diameter 0.030 inch (0.762
mm).
Example :For #4 rivet, minimum
edge distance is 0.028 inch (0.7112
mm). Rivet diameter 0.125 inch
(3.175 mm) X 2 + 0.030 inch (0.762
mm) = 0.280 inch (7.112 mm).
CSP-HMI-2
(3). Lay out rivet pattern on patch and drill

holes. Position patch on panel and drill
holes.
(4). Deburr all holes on both sides of patch
and panel.
(5). Countersink holes on patch if using
MS20426A4 rivets.
(6). Comply with the following procedures if
using Solvent Bonding Patch Method
(tetrahydrofuran).
(a). Clean mating surfaces with naphtha
aliphatic (CM220). Ensure surfaces
are free from oil, grease or other
contaminates.
(b). Set patch in place. Use a minimum
amount of clecos required to hold
patch in contact with panel without
applying too much pressure.
Tetrahydrofura bonding sol
WARNING vent is a flammable liquid.

Care must be exercised in handling.
Solvent shall be applied careful

ly so no excess material will run
over other surfaces and mar the finish.
CAUTION
NOTE: On larger parts, solvent shall be applied

evenly to mating surfaces with brush.
(c). Inject tetrahydrofuran (CM435)
between mating surfaces by means of
(d). Assemble mating surfaces as quickly
as possible by firmly pressing togeth
er.
(e). Apply clamps to assembly immedi
ately after solvent application, with
sufficient pressure to force out air
bubbles.
(f). After forcing out bubbles, adjust
clamps to minimum pressure re
quired to hold parts together.
(g). If solvent has evaporated at or near
edge of patch, apply more solvent
between mating surfaces using
(h). Leave clamps in place for a minimum
of 20 minutes.
25-30-00
Page 213
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
NOTE: If gap exists between patch and panel

prior to installing rivets, inject tetrahydro
furan between mating surfaces in immedi
ate area of each rivet hole that has a gap us
ing a syringe or eye dropper.
(i). Rivet patch to panel.
(j). Allow panel to cure for a minimum of
24 hours prior to installation.
(7). Comply with the following procedures if
using the Epoxy Adhesive Patch
Method.
(a). Lightly abrade mating surfaces with
emery cloth (CM804) and clean with
(b). Air dry for 30 minutes at ambient
temperature. Apply adhesive
(CM411) within 2 hours of drying.
Page 214
Revision 23
25-30-00
(c). Thoroughly mix equal parts, of

adhesive by weight. Color should be
uniform green. Use unwaxed dispos
able container and wooden tongue
depressor or metal spatula for
mixing. Pot life of mixed adhesive is
45 minutes at ambient temperature.
(d). Spread a thin uniform layer,
0.002-0.010 inch (0.0508-0.254 mm),
of adhesive on mating surfaces. Try
to keep adhesive out of the rivet
holes.
(e). Install the patch on the panel with
clecos.
(f). Rivet the patch to the panel.
(g). Wipe excess adhesive from bond line
and from around the rivets.
(h). Allow the panel to cure for 24 hours
prior to installation.
MAINTENANCE MANUAL
CSP-HMI-2
Section
254000
Miscellaneous
Furnishings
MAINTENANCE MANUAL
CSP-HMI-2
MISCELLANEOUS FURNISHINGS
1. Crew Compartment Miscellaneous
Furnishings Replacement
Methods for removal and installation are
obvious for most miscellaneous furnishing
items. Some maintenance instructions are
provided in the following procedures.
Crew compartment furnishings for the 600N
Helicopter are the same as for the 369D/E/FF
- 500N Helicopters.
A. Stowage Box
Access to stowage box is thru crew compart
ment right side floor access door (Ref. Sec.
52-50-00).
Item
Nomenclature
CM117
Grease
NOTE: Helicopters equipped with certain op

tional communications and avionics instal
lations do not have stowage box installed.
When installing replacement stowage box,
cover screwheads with tape (CM717).
B. Heat Duct
The heat duct consists of an upper and lower
section with a magnetic compass mounted on
the lower section just above the instrument
panel. The anti-icing control (Ref. Sec.
75-10-00) and cabin heat control (Ref. Sec.
21-40-00) mount on the upper section of the
heat duct. Removal of magnetic compass is not
required for removal of heat duct. However,
wiring to the light must be disconnected at the
splices.
C. Foot Rest (L/H Command)
For access to foot rest attaching hardware,
remove stowage box. Position replacement foot
rest on floor support bulkhead and install
attaching hardware. When necessary, use
additional thin aluminum washers to shim
between foot rest and bulkhead for correct

four-point contact.
D. Ash Receiver and Cigarette Lighter Panel
(1). The cigarette lighter panel may be
removed by releasing four turnlock
fasteners.
(2). Disassembly of the cigarette lighter and
panel for maintenance purposes is
shown in the figure.
2. Passenger Compartment Miscellaneous
Furnishings Replacement
obvious for most miscellaneous furnishing
items. Some maintenance instructions are
provided in the following procedures.
Passenger compartment furnishings for the
600N Helicopter are the same as for the
369D/E/FF - 500N Helicopters except, where
applicable, panels and ducting is 30 inches
longer.
A. Convenience Panel Replacement (R/H
Command)
(1). Remove attachment screws. Lower
panel and disconnect any wiring and
heat valve connectors before removing
panel.
(2). Reinstall using reverse procedure.
3. Passenger Step Assembly Description
(Ref. Figure 203) Due to the extended fuselage
of the 600N Helicopter, the addition of an
elongated passenger step is unique to this
aircraft. The step is secured at two positions
on each side of the fuselage, as compared to
one position on the 369D/E/FF - 500N
Helicopters. The step is available in either a
high or low step configuration depending on
the landing gear option installed.
4. Passenger Step Assembly Inspection
(1). Inspect step attach point(s) for security
of installation and general condition.
25-40-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
(2). Inspect no skid surface of step for

general condition. Replace or reattach if
worn excessively.
5. Passenger Step Assembly Replacement
(1). To replace worn or lost safety-walk

tape, carefully scrape away damaged
tape. Remove all residual adhesive by
wiping with naphtha (CM220) wetted
cloth.
A. Passenger Step Assembly Removal

(1). Gain access to passenger step assembly
attaching hardware under floor cover
ing of passenger/cargo compartment.
(2). Remove quick release pin(s) that secure
step assembly in mounting hole(s).
(2). Install new tape (CM724) and press

firmly into place. Expel air bubbles by
pressing down tape from center out to
the edges.
7. Miscellaneous Furnishings Inspection
(3). Remove step assembly.

B. Passenger Step Assembly Installation
(1). Align and insert passenger step
assembly into mounting hole(s) in
fuselage.
(2). Insert quick release pin(s) to secure
step assembly.
(3). Secure floor covering in passenger/cargo
compartment.
(1). Inspect for cracks, breaks or other

unserviceable condition.
(2). Inspect helicopter checklist and
magnetic compass card for condition
and legibility.
(3). Inspect for loose, damaged or missing
rivnuts and other attaching hardware
as applicable.
6. Passenger Step Assembly Repair

The passenger step has black, non-slip,
pressure-sensitive, safety-walk tape applied
to the upper surface of the step plate.
Item
CM220
CM724
Nomenclature
Naphtha aliphatic
Tape, non-slip
Page 202
Revision 44
25-40-00
8. Miscellaneous Furnishings Repair

(1). Repair cracks or breaks in thermoplas
tic material (Ref. Sec. 20-30-00,
Boltaron Trim Panels Repair).
(2). Perform minor weld and rivet repairs
Metal Repair.
MAINTENANCE MANUAL
CSP-HMI-2
SWIVEL BRACKET
VNE CARD
VNE CARD HOLDER
OUTER BOX
ANTI-ICING CONTROL
6 PLCS
UPPER SECTION
CABIN HEAT CONTROL
(NOTE 1)
LOCKING PIN
LOWER SECTION
END CAP
JACKING
FITTING
4 PLCS
MAGNETIC COMPASS
HEAT DUCT AND

MAGNETIC COMPASS
10 PLCS
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)
25-40-00
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
MAP POCKET
MAP CASE TRIM

COVER
HELICOPTER
CHECK LIST
MAGNETIC
COMPASS CARD
COMPASS CARD AND CHECK LIST
2 PLCS
ASHTRAY
BONDED
(2 PLCS)
CIGARETTE LIGHTER
RECORD HOLDER
ASHTRAY PASSENGER COMPARTMENT
FLOOR SUPPORT
BULKHEAD
ASHTRAY
HOLDER
BULKHEAD COVER
(NOTE 2)
LIGHTER
4 PLCS
ASHTRAY CREW COMPARTMENT
FOOT REST
NOTES: (CONT)
2. NOTE USED WHEN STROBE LIGHTS
POWER SUPPLY OF NIGHT LIGHTING
SYSTEM IS INSTALLED.
Figure 201. Miscellaneous Furnishings (369D) (Sheet 2 of 2)

Page 204
Revision 23
25-40-00
G25-4001-2A
MAINTENANCE MANUAL
CSP-HMI-2
SWIVEL BRACKET
VNE CARD
COVER
VNE CARD HOLDER
ANTI-ICING CONTROL
UPPER SECTION
6 PLCS
10 PLCS
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)
25-40-00
Page 205
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
MAP CASE TRIM

COVER
HELICOPTER
CHECK LIST
MAGNETIC COMPASS CARD
MAP POCKET
COMPASS CARD AND CHECK LIST
BONDED
(2 PLCS)
RECORD HOLDER
FLOOR SUPPORT BULKHEAD
LIGHTER
BULKHEAD COVER
(NOTE)
FOOT REST
ASHTRAY
NOTE: NOT USED WHEN STROBE LIGHTS POWER

SUPPLY OF NIGHT LIGHTING SYSTEM IS INSTALLED.
ASHTRAY CREW COMPARTMENT

G25-4002-2A
Figure 202. Miscellaneous Furnishings (369E/FF 500/600N) (Sheet 2 of 2)

Page 206
Revision 23
25-40-00
MAINTENANCE MANUAL
CSP-HMI-2
QUICK
RELEASE PIN
4 PLCS
(TYP)
6G25-080
Figure 203. Passenger Step Assembly (600N)
25-40-00
Page 207
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
Page 208
Revision 44
25-40-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
255000
Cargo Hook
MAINTENANCE MANUAL
CSP-HMI-2
CARGO HOOK
FAULT ISOLATION
1. Cargo Hook Description
The cargo hook provides a means of transport
ing external cargo. The cargo hook installation
consists of a cargo hook assembly, electrical
hook release equipment and backup emergen
cy manual release equipment. The cargo hook
assembly is externally attached to the center
beam of the helicopter at Station 99.325. The
cargo hook operational rating (external load
limit) is 2000 pounds.
The cargo hook and swivel assembly are
mounted on the helicopter center beam by four
bolts at Station 99.325. The swivel assembly
allows the cargo hook to swing in any direction
through a 30-degree arc.
2. Cargo Hook Operation
The cargo hook is normally operated electrical
ly by pressing the CARGO HOOK switch on
the pilot's cyclic stick grip (Ref. Figure 403).
Actuation of the CARGO HOOK switch
energizes a solenoid in the cargo hook. The
maximum electrical current required to
operate the cargo hook solenoid is 14 amperes
at 28 Vdc. however, the solenoid is designed to
operate with voltage as low as 23 Vdc. Actua
tion of the cargo hook solenoid releases the
hook (load beam).
In the event of an electrical malfunction, the
hook can be released (opened) by pulling a
manual release cable lever attached to the
pilot's cyclic stick (Ref. Figure 401). The
manual release cable releases (opens) the
cargo hook in the same manner as the electri
cally operated solenoid. The hook can be
released for testing or by cargo personnel by
turning (clockwise) a cargo hook release knob
located on the left side of the hook body.

Regardless of the method used to release the
hook, the hook will return to the closed
(retracted) position.
3. Cargo Hook Fault Isolation
(Ref. Table 101) Cargo hook system malfunc
tions might be caused by any one of several
general conditions which are easily corrected.
Before starting specific troubleshooting
procedures, make the following checks and
take indicated action for troubleshooting
procedures.
(1). Refer to applicable wiring diagram and
check for loose or damaged wires and/or
terminals and connectors; reconnect or
replace as required.
(2). Check for damaged interconnect wires
and/or equipment (Ref. Chap. 96).
(3). Check for loose or defective terminal
board connections; repair or replace as
required.
(4). Check for loose ground wires.
(5). Make certain circuit breaker is pushed
to full in (closed) position.
(6). Check system power source.
4. Wiring Diagrams
(Ref. Figure 101) Wiring diagrams of the
various cargo hook electrical system circuits
have been illustrated. Wire charts are provided
in Table 102 and Table 103. For helicopter
electrical system interface information refer to
DC Electrical Load Distribution (Ref. Chap.
96).
25-50-00
Page 101
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
Table 101. Troubleshooting Cargo Hook Installation

Symptom
Probable Cause
Corrective Action
NOTE: Following procedures are to be performed with electrical system power on and CARGO HOOK circuit
breaker (CB603) closed.
Hook release operates manually (by
lever) but fails to operate electrically
(by HOOK RELEASE switch).
Hook release operates electrically

(by HOOK RELEASE switch) but
fails to operate manually (by lever).
Defective hook ground
Replace hook assembly.
Defective ground
Secure ground wire.
Defective HOOK RELEASE switch
Replace switch.
Defective CARGO HOOK circuit

breaker (CB603)
Replace circuit breaker (CB603).
Manual release cable housing

adjusted incorrectly at lever.
Reset adjustment nut at leverend

of cable housing.
Defective hook assembly
Replace hook assembly.
Table 102. Wire Chart, 369D/E/FF Right or Left Hand Command.

From
To
Wire No.*
Terminal
Termination
Terminal
Termination
M532A20
TB118D
MPCM20MH2**
K104X1
Solder
TB119B
MPCM20MH2**
K104X1
Solder
M531A16
TB31D
AYH11H1**
K104D2
Solder
M523A20N
J104X2***
Solder
E24
MS25036103
M522C16
K104D1***
Solder
TB34A
AYH14H1**
M520AA16
SP92B
32447
TB31C
AYH14H1**
J616q
Crimp
TB31C
AYH14H1**
CB6032
MS25036106
SP92A
32447
CB6032
MS25036106
P616q
TB118C
MPCM20MH2**
TB31D
AYH14H1**
TB118A
MPCM20MH2**
TB31D
AYH14H1**
TB119A
MPCM20MH2**
TB31D
AYH14H1**
M520A16
M520B20
*(Ref. Figure 101 sheets 1 & 2) for applicable wiring diagrams.

**Burndy Corp., Norwalk, Conn.
***K312X2, _D1 for helicopters equipped with 369D24153 Tee console.
Page 102
Revision 23
25-50-00
MAINTENANCE MANUAL
CSP-HMI-2
Table 103. Wire Chart, 369E/FF TPanel with Center Electrical Console, R/H Command.
From
To
Wire No.*
Terminal
Termination
Terminal
Termination
M520AA16
K104X2
Solder
E24
MS25036103
M532A20
K104X1
Solder
TB18F
M39029/22192
M531A16
K104D2
Solder
TB31C
M39029/22193
M531B16
K104D1
Solder
TB38B
M39029/22193
M520B20
TB31E
M39029/22193
TB18E
M39029/22192
M523C20N
J605C
MS3193A1616A
E20
M7928/124
M520A16
CB1182
M7928/141
P616 Q
M39029/31228
M520AA16
J616 Q
M39029/32247
TB31
M39029/22193
*(Ref. Figure 101 sheet 3) for applicable wiring diagram.
25-50-00
Page 103
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
P605J
TB1-18
TB3-4
A
M522D16
B
C
M523A20
M522C16
TB3-1
M523B16N
E20
M531A16
K104
M520B20
SP92
M520AA16
M523BB20
CARGO HOOK
D3
D1
D2
X1
C1
C2
C3
CB603
1
CR3
369D STANDARD CYCLIC STICK GRIP

3-1149, 1151-1184
B1
B3
B2
X2
A1
A2
A3
HOOK RELEASE
SWITCH (S114)
15A
P130J
10-20
M523A20N
E24
M522A20
A
B
9-20
M521E20
P605J
TB1-18
TB3-4
A
M522D16
A
B
C
M522C16
M523A20
TB3-1
M523B16N
M520A16
E20
M531A16
K104
CARGO HOOK
D1
D3
C1
C3
D
C
D2
M520B20
SP92
M520AA16
X1
C2
CB603
1
CR3
B1
369D OPTIONAL CYCLIC STICK GRIP

RIGHT OF LEFT HAND COMMAND
B3
B2
X2
A1
A2
A3
HOOK RELEASE
SWITCH (S4)
15A
P130J
10-20
E24
M523A20N
M520A16
M520C20
E
A
9-20
M522A20
P605J
A
M522D16
B
C
M522C16
M523A20
TB3-1
M523B16N
E20
M531A16
K104
M520B20
M520AA16
M523BB20
CARGO HOOK
NOTE 1
TB1-19
TB3-4
D1
D3
C1
C3
D2
J616P
q
X1
369D RIGHT HAND COMMAND
CYCLIC STICK GRIP
3-1149, 1151-1184
E24
NOTES:
1. 369D294402 CENTER ELECTRICAL CONSOLE:
-703 WITH ARMAMENT PANEL
-701 WITHOUT ARMAMENT PANEL
2. 369D294500 CENTER ELECTRICAL CONSOLE
WITH VHF-FM RADIO SET AND ASW EQUIPPED
HELICOPTERS.
C2
CB603
1
CR3
B1
B3
B2
X2
A1
A2
A3
HOOK RELEASE
SWITCH
WHT/VIO
OR BLUE
M523A20N
WHT/GRAY
OR GRAY
P109J
B
A
Revision 23
25-50-00
M520A16
P109J
D
E
M521F20
M520F20
TB1-19
M521F20
M520F20
C
D
NOTE 2
Figure 101. Cargo Hook Wiring Diagrams (Sheet 1 of 4)

Page 104
2
15A
G25-5005-1
MAINTENANCE MANUAL
J130P
CARGO HOOK RE
LEASE SWITCH
TB1-12
10 OR BLU
M522A20
9 OR GRY
M521E20
S4
CSP-HMI-2
J109-A (REF)
A
B
C
D
J109-B (REF)
M520B20
M532A20
M520AA16
C
D
D1
D3
C1
C3
D2
X1
C2
CB603
B2
B3
E24
M520A16
15A
X2
A3
A1
M531A16
CR3
B1
J9P
TB3-1
K104
A2
M523A20N
CARGO HOOK RELEASE

P605J
TB3-4
M522C16
M522D16
M523BB20N
369D CYCLIC STICK GRIP

LEFT OR RIGHT HAND COMMAND
1150, 1185-1204
E20
M523B16N
WHT
TB1-12
C
A3
A2
M523A20
X2
B1
E24
K312
A1
BLK
B3
B2
D
B
M520B20
CR3
C1
C3
C2
J9P
X1
D1
D3
D2
M531A16
D C
M520AA16
TB3-1
CB603
1
M531B16
J605P
A
B
C
M522D16
A
TB3-4
HOOK RELEASE
SWITCH (PILOT'S)
S4
M523C20N
369E/FF CYCLIC STICK GRIP

LEFT OR RIGHT HAND COMMAND
M520A16
J130P
A
B
E20
CARGO HOOK
ASSEMBLY
2
15A
HOOK RELEASE
SWITCH (CO-PILOT'S)
S4
M522A20
M521E20
J109P
A
B
M522C20
M521G20
G25-5005-2
25-50-00
Page 105
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
REF
15A 2
M520A16
PILOT
S4
TB3-1
P616J
CB118
M520AA16
M531A16
J109P
TB1-8
M520B20
X1
M532A20
CR3
X2
A2
M522C20
M521G20
A
B
CO-PILOT
S4
J130P
M522A20
M521E20
A
B
M523A20N
E24
A1
A3
B1
16 AWG BUS WIRE
B2
C2
B3
C1
C3
D1
TB3-8
M531B16
D2
D3
M522D16
M523B16N
M523C20N
J605P
A
B
C
K104
HOOK
369E/FF RIGHT HAND COM
MAND CONFIGURATION
E20
G25-5005-3

CB603
15A
1
2
M1015A16
M1015C16
X1
M1020A16N
M1021A20N
B
C
X2
E36
M1015B16
M1105A22
M1107A22
K201
HOOK RELAY
B
E37
M1179A22N
Y
Z
S4
HOOK
9
10
P130
J130
B
A
B
A
W
1M1106B22
1M1106A22
HOOK ASSY
J/P605
P/J1202
D
2M1106B22
2M1106A22
J109
P109
B
A
B
A
9
10
S4
HOOK
(RIGHT COLLECTIVE GRIP)

T
TB200-4
(LEFT COLLECTIVE GRIP)

N
P
R
S
EFFECTIVE 369E 384 & SUBS

AND 369FF 076 & SUBS
TB200-4

Page 106
Revision 23
25-50-00
G25-5005-4
MAINTENANCE MANUAL
CSP-HMI-2
CARGO HOOK
1. Cargo Hook Replacement
A. Cargo Hook Removal
Remove the cargo hook assembly including the
cargo hook manual release cable and electri
cal harness as follows:
(1). Remove cotter pin (Ref. Figure 405),
washer, and slotted bushing from
manual release lever on pilot's cyclic
stick.
(2). Loosen locking nut securing adjustment
nut shaft to release lever bracket.
(3). Remove screws (Ref. Figure 401), nuts,
washers, and clamps securing manual
release cable to cyclic stick.
(4). Remove adjustment nut shaft (Ref.
Figure 405) from release lever bracket.
(5). Loosen dust cover from pilot's cyclic
stick control trim cover (Ref. Sec.
25-30-00).
(6). Remove passenger/cargo compartment
left foot fairing trim (Ref. Sec.
25-30-00).
(7). Carefully push manual release cable
(Ref. Figure 401) down through grom
mets in pilot's floor and fuselage skin.
Do not pull on cable housing.
(8). Remove cargo hook electrical harness
plug from receptacle in fuselage; install
protective caps on receptacle and plug.
(9). Remove clamps (Ref. Figure 402)
securing cable and harness to clips on
fuselage underside.
(10). Remove four bolts (Ref. Figure 404)
securing cargo hook base to attach
holes in fuselage keel.
B. Cargo Hook Installation
Installation of the cargo hook kit consists of
attaching the hook, and electrical/manual
release cables on the underside of the helicop
ter, routing and securing the manual release
cable, installation and adjustment of the

manual release lever as follows:
(1). Secure base of cargo hook assembly
(Ref. Figure 404) to fuselage underside
with bolts and washers.
(2). Remove protective cap from cargo hook
electrical receptacle (J605); check that
BATTERY switch is in OFF position
and connect plug (P605) to receptacle.
(3). Insert free end of hook manual release
cable through elongated hole adjacent
to electrical receptacle (Ref.
Figure 402). Push manual release cable
up into fuselage and insert cable
through hole in pilot's floor.
(4). Loosely attach harness and manual
release cable using clamps (Ref.
Figure 402) screws, washers, and nuts.
Adjust harness and cable to allow
sufficient slack for hook to swing 30
degrees conically from centerline
without creating strain on harness and
cable. Arrange harness and cable to
form smooth flow to cutouts in fuselage
skin; tighten clamps. Install tie straps
approximately as shown (Ref.
Figure 402).
NOTE: The 600N helicopters equipped with

emergency floats require the manual re
lease handle to be mounted on the collective
stick (Ref. Figure 406).
(5). Loosely attach manual release cable to
cyclic stick with clamps, screws,
washers, and nuts (Ref. Figure 401).
(6). Engage approximately half of the
threads on the manual release cable
adjustment nut shaft into the bracket
portion of the manual release lever
assembly (Ref. Figure 405).
(7). Engage swaged ball on release cable in
lever bushing (Ref. Figure 405). Secure
bushing with washer and cotter pin.
(8). Attach manual release lever assembly
to cyclic stick with clamp and screws.
Adjust cable and/or release lever as
shown (Ref. Figure 405).
25-50-00
Page 401
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
(9). Tighten three sets of clamps securing

(10). Perform adjustment/test of cargo hook
installation.
(11). Readjust cable lever (Ref. Figure 405)
as required to obtain smooth consistent
release of hook.
NOTE: The manual release lever clamp may be
loosened and the lever assembly moved on
cyclic stick to simplify adjustment, provid
ing the 2.250 0.250 inch (5.715 0.635 cm)
dimension limit is maintained (Ref.
Figure 405).
Page 402
Revision 23
25-50-00
(12). Install grommet (Ref. Figure 401) in

crew compartment floor cutout.
(13). Install grommet (Ref. Figure 402) in
elongated hole in fuselage lower skin
and doubler.
(14). Safetywire manual release lever clamp
screws with lockwire (Ref. Figure 405).
MAINTENANCE MANUAL
CLAMP
CSP-HMI-2
CLAMP
SCREW
NUT
HOOK RELEASE DECAL (NOT REQUIRED
WITH OPTIONAL EQUIPMENT GRIP)
WASHER
CLAMP INSTALLATION
(TYP - THREE PLACES)
CARGO HOOK
EMERGENCY RE
LEASE 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
25-50-00
Page 403
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
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
FLOOR
ELECTRICAL WIRE HARNESS

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

RELEASE CABLE AND ELECTRICAL
WIRE HARNESS
WASHER
CLAMP (ELECTRICAL)
CLIP
NOTES:
1. LEFT HAND COMMAND ILLUSTRATED. RIGHT HAND COMMAND
DIMENSIONS THE SAME EXCEPT ON OPPOSITE SIDE.
2. EXISTING RIVET LOCATION AT STATION 84.79.
3. P4 HUCK RIVET MAY BE USED INSTEAD AT STATION 84.79.
4. HARNESS AND CABLE TIED TOGETHER MIDWAY BETWEEN
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
ON CABLE AND HARNESS.
CLAMP
(MANUAL)
NUT
SCREW
RIVET (NOTES 1, 2)
CLAMP ATTACHMENT
(TYPICAL)
Figure 402. Manual Release Cable and Electrical Wire Harness Routing Exterior
Page 404
Revision 23
25-50-00
G25-5001
MAINTENANCE MANUAL
CSP-HMI-2
CARGO HOOK RELEASE

CIRCUIT BREAKER
369D LEFT-HAND
COMMAND CONFIGURATION
CARGO HOOK RELEASE
CIRCUIT BREAKER
369E/FF TEE PANEL

LEFT-HAND COMMAND CONFIGURATION
HOOK RELEASE DECAL
CIRCUIT BREAKER PANEL
CARGO HOOK RE
LEASE SWITCH
CARGO HOOK RELEASE
CIRCUIT BREAKER
RIGHT-HAND COMMAND
WITH CENTER ELECTRICAL
CONSOLE CONFIGURATION
REMOVE PLUG BUTTON

AND INSTALL CARGO
HOOK RELEASE SWITCH
STANDARD GRIP
HOOK RELEASE DECAL
CARGO HOOK RELEASE

SWITCH
OPTIONAL
EQUIPMENT GRIP
OPTIONAL
T GRIP
HOOK RELEASE SWITCH

PILOT'S CYCLIC STICK GRIP
G25-5002
Figure 403. Cargo Hook Electrical Equipment Installation
25-50-00
Page 405
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
DECAL
DECAL
FUSELAGE LOWER
SKIN SURFACE
NEOPRENE PAD
0.090 X 1.75 X 4.0 IN.
(0.229 X 4.445 X
10.16 CM) (NOTE)
NEOPRENE PAD
0.090 X 1.75 X 1.75
IN. (0.229 X 4.445 X
4.445 CM) (NOTE)
WASHER (4 PLACES)
BOLT (4 PLACES)
EXTERNAL RELEASE
(TURN CLOCKWISE)
ELECTRICAL WIRE
HARNESS
SWIVEL
STA 99.325
KEEPER
1.62 0.12 IN.
(4.1148 0.3048 CM)

HOOK (LOAD BEAM)
1.00 0.12 IN.

(2.54 0.3048 CM)
1.12 0.12 IN.

(2.8448 0.3048 CM)
LONGITUDINAL
CENTERLINE OF
4-HOLE LAYOUT
FWD
1.88 0.12 IN. (4.7752 0.3048 CM)
2.00 0.12 IN.

(5.08 0.3048 CM)
3.75 0.12 IN.

(9.525 0.3048 CM)
(2 PLCS)
NOTE:
PADS PREVENT FUSELAGE SKIN DAMAGE
AT HOOK CONTACT POINTS.
LATERAL CENTERLINE
OF 4-HOLE LAYOUT
G25-5003A
Figure 404. Hook and Pad Installation

Page 406
Revision 23
25-50-00
MAINTENANCE MANUAL
CSP-HMI-2
20 (NOTE 2)
CARGO HOOK MANUAL RE
LEASE LEVER ASSEMBLY
SLOTTED BUSHING
(NOTE 5)
CARGO HOOK
RELEASE CABLE
2.250 0.250
INCHES
POSITIONING LEVER ON STICK
CLAMP
LOCKWIRE
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)
NOTES:
1. CABLE BALL TERMINAL RETAINED IN SLOTTED BUSHING OF RELEASE LEVER.
2. APPROXIMATE ANGULAR POSITION OF LEVER REQUIRED FOR
CONVENIENCE AND RELEASE OF CARGO HOOK.
3. CABLE BALL TERMINAL AFT TRAVEL SHOULD BE APPROXIMATELY
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
POSITION OF LEVER ASSEMBLY ON CYCLIC STICK.
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.
WASHER
ADJUSTMENT
NUT (NOTE 4)
RELEASE
BRACKET
LOOKING INBOARD FROM
LEFT SIDE OF HELICOPTER
G25-5004
Figure 405. Cargo Hook Manual Release Lever Installation
25-50-00
Page 407
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
CARGO HOOK MECHANI

CAL RELEASE
CARGO HOOK ELEC

TRICAL 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 emer
gency float installation, stc# sr00471la.
60-052-1
Figure 406. Cargo Hook Release for 600N Helicopters

Page 408
Revision 23
25-50-00
MAINTENANCE MANUAL
CSP-HMI-2
CARGO HOOK
INSPECTION/CHECK
1. Cargo Hook Operational Check
Perform the following operational check
procedure whenever it is necessary to verify
that the cargo hook system is operating
properly:
(1). Place battery switch in BATTERY
position.
(2). Check that CARGO HOOK/HOOK
circuit breaker is pressed to full in
position (Ref. Figure 402).
NOTE: Cargo load rings (or equivalent check

tool) with a maximum cross-section thick
ness of 3/4 inch can be used for testing or for
cargo transport operations.
(3). Push cargo load ring forward into hook
throat (Ref. Figure 404); keeper should
permit easy entrance to hook throat.
(4). Pull aft and downward on load ring;
hook must remain in locked position.
(5). Rotate external release knob located on
left side of cargo hook body, while
pulling downward on load ring; hook
(load beam) bar should drop and release
load ring.
(6). Reinsert load ring in hook throat. Pull
CARGO HOOK EMERGENCY RE
LEASE (manual release) lever on pilot's
cyclic stick while load ring is being
pulled downward; hook (load beam)
should release load ring. Reinsert load
ring and move pilot's cyclic stick to all
extreme positions; CARGO HOOK
EMERGENCY RELEASE lever must
not move from hook-engaged position
and hook load beam must remain in
locked position.
(7). Press CARGO HOOK switch on pilot's
cyclic stick grip (Ref. Figure 403) while
load ring is being pulled downward;
hook load beam should release load
ring.
Cargo hook must remain

while
moving
through all positions of extreme travel
fore and aft as well as side-to-side.
WARNING closed
(8). Grasp load ring and pull downward

while moving cargo hook manually full
travel side-to-side. Ensure hook (load
beam) remains in locked position.
2. Adjustment
Adjust the manual release cable so that the
2.250 0.250 inch (5.715 0.635 cm) dimension
shown (Ref. Figure 405) is maintained.
3. Exterior Components Inspection
On cargo hooks, manufac
WARNING tured by Breeze-Eastern,
Model 2A20B, P/N 17149-1 thru -5, en

sure Warning Plate P/N 13830-1 is at
tached to the manual release side of the
cargo hook. If Warning Plate is not
installed, contact Breeze-Eastern for
Warning Plate and installation instruc
tions.
(1). Make certain that neoprene pads (Ref.
Figure 404) are securely bonded to skin.
Check pads for excessive wear.
(2). Verify security of four bolts attaching
hook assembly to fuselage (Ref.
Figure 404); examine hook assembly for
damage or excessive wear. Check that
hook body swivels freely in all direc
tions.
(3). Verify security of clips and clamps
attaching electrical wire harness and
manual release cable housing to
fuselage (Ref. Figure 402).
(4). Verify presence and security of grom
met (Ref. Figure 401) through which
manual release cable passes at fuselage
skin.
(5). Check electrical wire harness for cuts,
wear, and skinned insulation.
(6). Examine manual release cable housing
for nicks, cuts, kinks, dents, or general
damage that would restrict movement
of cable within housing.
25-50-00
Page 601
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
4. Interior Components Inspection

(1). Verify security of electrical receptacle
(J605) at fuselage connection (Ref.
Figure 401).
(2). Examine electrical wire harness for
cuts, wear, or skinned insulation.
(3). Check manual release cable housing for
nicks, cuts, kinks, dents, or general
damage that would restrict movement
of cable within housing.
(4). Verify presence and security of grom
met where manual release cable passes
through pilot's floor (Ref. Figure 401).
(5). Check security of manual release cable
housing adjustment nut; verify that
release lever freely returns to hook-en
gaged position (Ref. Figure 405).
Page 602
Revision 23
25-50-00
NOTE: The 600N helicopters equipped with

emergency floats require the manual re
lease handle to be mounted on the collective
stick (Ref. Figure 406)
(6). Verify security of clamps attaching
manual release cable housing to pilot's
cyclic stick (Ref. Figure 401); check for
damage to manual release cable
housing that might restrict movement
of cable.
(7). Check security of manual release lever
attachment to pilot's cyclic stick (Ref.
Figure 405).
(8). Examine decals (Ref. Figure 403) for
secure attachment and legibility.
(9). Examine cargo hook circuit wiring for
damage and/or loose connections.
(10). Verify secure installation of CARGO
HOOK circuit breaker and HOOK
RELEASE push-button switch (Ref.
Figure 403).
MAINTENANCE MANUAL
CSP-HMI-2
CARGO HOOK
1. Cargo Hook Initial Installation
the operator's discretion and are applicable to
369D/E/FF - 500N helicopters. These instruc
tions provide for the installation of the cargo
hook assembly.
Preparation for installation of the cargo hook
assembly includes the following:
(1). Identify all components, including
attaching hardware, or components to
be removed for access to work areas.
contamination until installed.
(2). Check that all electrical switches are in
OFF position.
(3). Make certain BATT-OFF-EXT switch
is in OFF position.
B. Helicopter Equipment Removal
(Ref. Figure 404) Prior to installing the cargo
hook, a limited number of items must be
removed from the helicopter to accommodate
cargo hook installation.
NOTE: Fuselage cutouts for left and right hand

command are as illustrated (Ref.
Figure 901). Use applicable dimensions ac
cording to the model helicopter being modi
fied.
(1). Make cutouts in three places as
illustrated (Ref. Figure 901).
Item
Nomenclature
CM318
Primer
(2). Deburr cutouts and apply thin coat of

primer (CM318) to exposed bare metal.
D. Cargo Hook Provisions Installation
(Ref. Figure 404) The following procedure
involves installation of the cargo hook provi
sions exclusive of the cargo hook assembly kit.
To complete installation of the cargo hook
system, both cargo hook provisions, and the
cargo hook assembly kit installations must be
accomplished. Hook provision equipment
omitted in the following procedure is included
in the cargo hook installation procedure.
Install cargo hook provisions as follows:
(1). Remove plug button from cargo switch

hole in stick grip; discard plug button.
left support fairing.
seat.
(4). Remove cyclic stick control cover.
(5). Remove pilot's floor left covering.
(6). Remove pilot's floor left access door.
C. Modification of Helicopter
Modification of the helicopter consists of
cutouts in the pilot's floor and fuselage lower
skin to accommodate routing of the cargo hook
manual control cable and electrical harness.
Item
Nomenclature
CM206
CM228
CM230
CM318
CM418
Chemical coating
Surface cleaner
Paint remover
Primer
Cement, epoxy
NOTE: The cargo hook and provision kits are

supplied with as many parts assembled as
practical, however, some parts might re
quire assembly at installation. The operator
should omit those steps which may have al
ready been accomplished.
(1). Install cargo hook neoprene pads as
follows:
25-50-00
Page 901
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
(a). Remove paint from fuselage skin in

pad installation areas as shown; use
paint remover (CM230).
(b). Clean metal in areas where paint as
removed; use surface cleaner
(CM228).
(c). Bond neoprene pads to skin at
locations shown; use adhesive
(CM418).
(2). Prime and touch-up border areas
around pads as follows:
(a). Wash affected area with solution of
mild soap and fresh water. Rinse
area with clean water and wipe dry
with clean lint-free cloth.
(b). Using swab, liberally apply chemical
film (CM206).
(c). Allow solution to remain on surface
for 1 to 3 minutes, or until surface
becomes amber to brown in color.
NOTE: Avoid letting chemical mixture dry on

surface. If it has dried, re-wet surface with
solution.
(d). Rinse treated surface with clean
water. After rinsing, wipe off excess
moisture with clean lint-free cloth.
Allow area to dry completely at room
temperature for 1 hour.
(e). Wipe surface clean with thinner and
dry off immediately.
(f). Apply primer (CM318) and allow to
dry for 30 minutes.
(g). Apply lacquer to match original
factory finish color.
NOTE: Installation of the cargo hook manual

release lever assembly and clamp assem
blies is accomplished during installation of
the cargo hook kit.
Page 902
Revision 23
25-50-00
E. Electrical Components and Wiring

Installation (Left and Right Hand
Command)
Item
CM404
CM614
CM704
Nomenclature
Adhesive, epoxy
Sleeving, heat-shrink
Tie strap, nylon
NOTE: The order and manner of installation

for left or right hand command is the same.
Refer to dimensions given in applicable fig
ures, for model of helicopter being modified.
(1). Make certain BATTERY switch is in
OFF position.
(2). Disconnect battery connector.
(3). Connect cargo hook switch to existing
wires according to stick grip and model
helicopter being modified. Insulate
wires and contacts on switch with
sleeving (CM614). Ref. Table 901 and
applicable wiring diagrams (Ref.
Figure 101).
(4). Install switch guard on switch. Apply
small amount of adhesive (CM404) to
O.D. of switch.
(5). Install switch in grip. Allow minimum
cure time of 24 hours 30 minutes.
(6). Install relay on bracket with screws,
Table 901. Cargo Hook Relay Installation
Relay
Model
Location
Remarks
K104
369A2519
Bulkhead
Slim console
K312
E/FF
369H2500
Bulkhead
TPanel
(7). Locate existing mounting holes accord

ing to model of helicopter being modi
fied. (Ref. Table 902 and Figure 902).
Using relay bracket as a template,
mark and drill attachment hole(s)
0.165-0.177 inch (4.191-4.4958 mm) in
bulkhead as required.
MAINTENANCE MANUAL
CSP-HMI-2
STA.
64.365
CREW
COMPARTMENT
DOOR
10.00 LBL
PILOT'S FLOOR
CHANNEL
GROMMET
5.00 0.25 IN.

(12.7 0.635 CM)
4.25 IN.
(10.795 CM)
PILOT'S FLOOR
0.555-0.562 IN.
(14.0970-14.2748 MM)
HOLE
3.00 0.25 IN.

(7.62 0.625 CM)
GROMMET
10.00 RBL
CLIP
CHANNEL
0.555-0.562 IN.
(14.0970-14.2748 MM)
HOLE
0.88 IN.
(22.352 MM)
0.88 IN.
(22.352 MM)
CUTOUT (RIGHT-HAND COMMAND)

CUTOUT (LEFT-HAND COMMAND)
GROMMET
LONGERON
GROMMET
12.05 LBL
0.68 X 1.18 IN.

(17.272 X
29.972 MM)
(NOTE 1)
STIFFENER
0.68 X 1.18 IN.
(17.272 X
29.972 MM)
(NOTE 1)
0.890-0.901 IN.
(22.60622.8854 MM)
(NOTE 2)
12.05 RBL
0.890-0.901 IN.
(22.60622.8854 MM)
(NOTE 2)
STIFFENER
LONGERON
0.38 IN.
(9.652 MM)
DOUBLER
DOUBLER INSTALLATION
(LEFT-HAND COMMAND)
0.38 IN.
(9.652 MM)
DOUBLER
DOUBLER INSTALLATION
(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
25-50-00
Page 903
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
(8). Attach relay bracket to bulkhead with

screws, washers and nuts. Identify
relay as indicated (Ref. Table 902),
using a suitable contrasting permanent
ink.
(9). On left hand command helicopters,
remove edgelighted panel from lower
switch and circuit breaker panel: loosen
lower circuit breaker panel. Remove
hole cover button; install circuit
breaker (CB603) (Ref. Figure 402).
(10). On right hand command helicopters
with center electrical console, remove
edgelighted panel from circuit breaker
panel located on the pilot's collective
pitch stick cover; loosen circuit breaker
panel remove hole cover button; install
circuit breaker (Ref. Figure 402).
(11). On right or left hand command helicop
ters with standard cyclic stick grip,
install module and cover on TB3.
(12). Install cargo hook circuit wiring; see
applicable wiring diagram (Ref.
Figure 101). For wire termination and
terminal hardware, refer to Table 102.
(13). Install cargo hook electrical connector
with washer and connector nut. Install
protective cap on receptacle if cargo
hook kit is not being installed concur
rent with provisions.
(14). Secure cargo hook circuit wiring with
tie-straps (CM704) as required. Check
that wires and terminals are not
stressed.
(15). Check all wiring for correct installation
and security of attachment.
(16). Connect battery connector.
F. Cargo Hook Installation
Item
CM429
CM702
CM704
Nomenclature
Sealing compound, silicone
Lockwire CRES
Tie strap, nylon
The cargo hook installation consists of

attaching the hook and emergency electrical/
Page 904
Revision 23
25-50-00
manual release cables on the underside of the

helicopter, routing and securing the manual
release cable, and installation and adjustment
of the manual release lever.
(1). Secure base of cargo hook assembly to
fuselage underside with bolts and
washers (Ref. Figure 404).
(2). If installed, remove protective cap from
cargo hook electrical receptacle (J605);
check that BATTERY switch is in OFF
position and connect plug (P605) to
receptacle.
(3). Insert free end of hook manual release
cable through elongated hole adjacent
to electrical receptacle; push manual
release cable up into fuselage and
insert cable through hole in pilot's floor
(Ref. Figure 401).
(4). Install electrical harness and manual
release cable clamp (provision) clips
with rivets (Ref. Figure 402).
(5). Loosely attach harness and cable
clamps with screws, washers and nuts;
adjust harness and cable to allow
sufficient slack for hook to swing 30
degrees conically from centerline
without creating strain on harness and
cable. Arrange harness and cable to
form smooth flow to cutouts in fuselage
skin; tighten clamps. Install tie straps
(CM704) approximately as shown (Ref.
Figure 402).
(6). Loosely attach manual release cable to
cyclic stick with clamps, screws,
(7). Engage swaged ball on release cable in
lever bushing; secure bushing with
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
(9). Tighten three sets of clamps securing
(10). Check that hook does not release when
cyclic stick is moved to extremes in all
directions.
MAINTENANCE MANUAL
SCREW
CSP-HMI-2
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
(369E/FF - 500N)
WASHER
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)
25-50-00
Page 905
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
(11). Pull manual release lever; check that

hook load beam opens. Repeat opera
tion several times to ensure proper
release of hook.
(12). Re-adjust cable/lever as required to
obtain smooth consistent release of
hook.
NOTE: The manual release lever clamp may be

loosened and the lever assembly moved on
cyclic stick to simplify adjustment, provid
ing the 2.250 0.250 inch (5.715 0.635 cm)
dimension limit is maintained (Ref.
Figure 405).
(13). Install grommet in crew compartment
floor cutout (Ref. Figure 401). Fill any
voids between grommet and cable. Use
sealant (CM429).
(14). Install grommet in elongated hole in
fuselage lower skin and doubler (Ref.
Figure 402). Fill any voids between
grommet and manual release cable. Use
sealant (CM429).
(16). Install HOOK RELEASE decal on left

or right hand cyclic stick grip (Ref.
Figure 403).
(17). Install CARGO HOOK EMERGENCY
RELEASE decal on cyclic stick (Ref.
Figure 405).
(18). Install EXTERNAL LOAD LIMIT 2000
POUNDS decal (Ref. Figure 404).
Table 902. VNE Card Installation
Part Number
Model
Effectivity
369D29571
17, 19
003 523
21, 23
D/E
D 524 & Subs

E 001 & Subs
369D292588
FF
001 & Subs
(19). Replace VNE card on instrument panel

as applicable (Ref. to Table 903).
G. Helicopter Equipment Installation
Reinstall equipment initially removed in
reverse order of removal.
NOTE: At completion of installation, perform
(15). Safety manual release lever clamp

screws with lockwire (CM702), (Ref.
Figure 405).
an operational check of cargo hook installa

tion.
Table 903. Cargo Hook Switch Installations Stick Grip

Part Number
Model
Remarks
369H90153BSC
D/E/FF
For models equipped with emergency floats, left or right hand

command (Ref. Figure 403).
D/E/FF
For models equipped with hoist, left or right hand command

(Ref. Figure 403).
369D27133
D/E/FF
Standard grip, left hand command (Ref. Figure 403).
369D297846BSC
Center electrical console, T grip right hand command (Ref.

Figure 403).

Figure 403).
369H92805

Figure 403).
Page 906
Revision 23
25-50-00
MAINTENANCE MANUAL
installation of the cargo hook are listed in
CSP-HMI-2
Table 904. After installation of the cargo hook

incorporate changes in helicopter weight and
balance record as instructed.

Weight
Pounds (kg)
Added
+6.3
(+2.858)
Arm
Inches (cm)
+87.0
(+220.98)
25-50-00
Moment
inlb (kg cm)
+548.1
(+631.48)
Page 907
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
Page 908
Revision 44
25-50-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
256000
Emergency First Aid
Kit
MAINTENANCE MANUAL
CSP-HMI-2
EMERGENCY FIRST AID KIT

1. Emergency First Aid Kit
(Ref. Figure 201)
(1). The Emergency First Aid Kit uses a
plastic case that meets Federal Aviation
Regulation (FAR) 27.8530 requirements
for fire protection. The kit is installed
on the lower right front of the seat
structure in the crew compartment and
centered at right buttline 20.75 just
above the pilot's floor mold line. It
attaches to the station bulkhead with
two parallel velcro pile strips, 1 x 8
inches (2.54 x 20.32 cm), bonded two
inches (5.08 cm) apart in the horizontal
position. Two matching velcro hook
strips are bonded across the width of
the case back.
(2). The kit is easily detached from its
velcro tape mount by a firm pull on the
handle. The case is opened by off-set
ting the snap fastener.
(3). Kit contents include a direction sheet

and the following eight packaged items:
adhesive and plain bandage compres
ses, iodine, swabs, ammonia inhalants,
burn ointment, tourniquet, forceps, and
scissors. The contents of the kit meet or
exceed the requirements of Federal
Aviation Authority (FAA) Specification
121, Appendix A for aircraft with a
passenger capacity of five persons or
less.
2. Emergency First Aid Kit Contents Check
Periodically check kit contents to ensure an
adequate supply of medical items. Purchase
individual items locally. To purchase a
replacement kit, contact:
MD Helicopters Inc.,
5000 East McDowell Road,
Mesa, AZ 85205,
Att: New Parts Sales.
25-60-00
Page 201
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
G25-6010
Figure 201. Emergency First Aid Kit

Page 202
Revision 23
25-60-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
256300
Hoist
Passenger/Cargo
MAINTENANCE MANUAL
CSP-HMI-2
HOIST PASSENGER/CARGO
1. Hoist Passenger/Cargo
(Ref. Figure 201)
(1). The hoist configuration is installed on
the right side of L/H command helicop
ters. The configuration for R/H com
mand is identical except that the hoist
is installed on the opposite (left) side of
the helicopter. The passenger/cargo
hoist assembly consists of an electrical
ly-operated winch mounted on a
support tube, a hoist operator's safety
harness, a passenger door (hold open)
retainer assembly, a passenger door sill
antichafing bar assembly, a control
pendant, and associated electrical
equipment. The hoist provides a means
for lifting and lowering personnel or
objects weighing up to 300 pounds (136
kg). The hoist system employs light
weight, readily-attachable and -de
tachable exterior-mounted equipment
without using passenger or cargo space
in the helicopter. For safety purposes, a
guillotine-type cable cutting device is
incorporated in the hoist winch assem
bly. The hoist function is identical when
operated from either side of the helicop
ter.
NOTE: When the hoist is installed on L/H com

mand helicopters equipped with emergency
floats, the floats must be in a stowed condi
tion during hoisting operations. Emergency
floats must be removed from R/H command
before conducting hoisting operations.
(2). (Ref. Figure 202) The weatherproof
winch consists of a 28 Vdc motor that
drives a cable drum to which a 110 foot
(33.5 M) stainless steel cable with a
swivel hook is attached. The winch is
equipped with an automatic brake
system; up (full-in) and down (full out)
limit stop switches; and an explosive,
electrically-activated guillotine-type
cable cutter for cutting the cable in an
emergency. The hoist assembly is
mounted on a support tube attached

with quick-release pins to three fittings
located on the exterior of the fuselage
on either side and above the passenger/
cargo door. The support tube positions
the winch to allow raising and lowering
the cable between the side of the
fuselage and landing gear skid. Two
modified mounting brackets are used to
accommodate installation of the winch
on the support tube. The winch incorpo
rates a disc-type brake, housed on the
end of the hoist drum, which consists of
spring-loaded friction plates and an
actuating solenoid. The solenoid is
energized to release the brake at the
same time the motor is energized. Once
the control pendant switch is released
to the off position, the brake solenoid is
deenergized and the brake sets,
preventing any possibility of uncon
trolled cable payout. Cable up (full-in)
and down (full out) limit switches are
incorporated in the winch brake
system. When either limit switch is in
the closed position, the brake solenoid
is energized, releasing the brake discs
and allowing the winch drum to rotate.
Conversely, when either limit switch is
in the open position the brake solenoid
is deenergized and the winch brake
automatically sets and stops the winch.
(3). (Ref. Figure 203) The passenger/cargo
door retainer assembly consists of a
tubular housing attached with four
clamps securing the housing horizontal
ly across the canted bulkhead in the
passenger/cargo compartment. With the
passenger/cargo door in full open
position, a smaller tube stowed inside
the tubular housing extends in a
telescoping effect and engages a bracket
located on the outboard frame of the
door, thus retaining the door in an open
position. The telescoping tube can be
used in either end of the tubular
housing to hold the left or right passen
ger/cargo door open as required.
25-63-00
Page 201
Revision 23
CSP-HMI-2
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
HOIST CABLE ANTI-CHAFING BAR
RIGHT-HAND COMMAND HELICOPTERS

CIRCUIT BREAKER PANELS
G25-6001-1
Figure 201. Hoist System Components (Sheet 1 of 3)

Page 202
Revision 23
25-63-00
MAINTENANCE MANUAL
CSP-HMI-2
WINCH
HANGER
AFT BRACKET
FWD BRACKT
HOOK
WINCH SUP
PORT TUBE
BEARING PIN
FITTING
LINK ASSY
FITTING
ELECTRICAL PLUG
HOIST SUPPORT AND ATTACH

MENTS (ROTATED)
SAFETY PIN
FITTING
CABLE ANTI-SNAG PROVISIONS

(ROTATED)
G25-6001-2
25-63-00
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
WINCH CONTROL
SWITCH
PENDANT
CABLE CUTTER
SWITCH
WARNING
CONTROL PENDANT CABLE CUTTER

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

Page 204
Revision 23
25-63-00
G25-6001-3
MAINTENANCE MANUAL
(4). (Ref. Figure 201) An antichafing bar,
installed just below the passenger/cargo
door sill, prevents the hoist cable from
cutting the door frame during hoisting
operations. A hoist operator's safety
harness. provided with the hoist, is
connected to the seat belt anchor fitting
on the side of the passenger/cargo
compartment opposite the side where
the hoist is installed.
(5). The hoist system electrical equipment
consists of a hand held electrical
pendant control for use in the passen
ger/cargo or crew compartments to
operate the winch, an emergency cable
cutter switch on the pilot's cyclic stick,
circuit breaker equipment, and asso
ciated electrical wiring. The pendant
control contains a three position switch,
spring loaded to the off position, for
raising and lowering the swivel hook,
and a guarded switch for cutting the
cable at the winch in an emergency. The
pilot's cyclic stick cable cutter switch
allows the pilot to cut the hoist cable
independent of the pendant control. The
circuit breakers are mounted on the
lower switch and circuit breaker panel
in L/H command, and on the circuit
breaker panel located aft of the pilot's
collective stick on R/H command. The
cable cutter circuits are independently
protected by a separate lower-amper
age circuit breaker located adjacent to
the hoist power circuit breaker. Electri
cal wiring, plugs, receptacles, and
terminals interconnect the various
electrical components.
(6). Differences in hoist installations and
electrical circuitry for L/H and R/H
command is described in subsequent
text and illustrations. Refer to man
ufacturer's publications (Ref. Table 201,
Sec. 01-00-00, BL-16600 Series 300 Lb
Capacity Hoist Operating lnstructions Hoist Winch Assembly, Breeze Corpora
tion, Inc)) for additional hoist, hook,
cable, and parts information.
CSP-HMI-2
2. Preparation for Hoisting Operations

To avoid inadvertent firing of
cable cutter, ensure cable cutter
electrical circuits are not energized.
CAUTION
(1). Connect external electrical power to

helicopter.
(2). Place BATTERY switch in EXT posi
tion.
(3). Open passenger/cargo door; extend and
secure door (hold-open) retainer tube.
(4). Using hoist system control pendant,
exercise winch by paying out 3 or 4 feet
of cable under approximately 15 pounds
(6.8 kg) tension, pulling cable straight
down to avoid rubbing cable on cable
bellmouth. Reverse control and reel
cable in. Check that cable winds on
winch drum evenly and that winch
operation is smooth and consistent.
Make certain winch stops automatically
when top of swivel hook pushes against
winch bumper pad.
(5). If installed, remove cable cutter jumper
wire (Ref. Figure 202).
Cable cutter jumper wire
WARNING must be removed to allow
cable cutter electrical circuit to be

completed by switch control, providing
instantaneous in-flight cable cutting
capability should such emergency ac
tion be required.
(6). If winch has not been used for an
extended period of time, or if cable has
been replaced, perform an operational
check (Ref. Hoist System Operational
Check).
(7). Check that winch support tube attach
safety pins are secure and fully seated.
(8). Check that winch electrical connector
plug is secure on receptacle on side of
fuselage.
(9). Connect hoist system operator's safety
harness to seat belt fitting on opposite
side of passenger/cargo compartment
from where winch is installed.
25-63-00
Page 205
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
WINCH
HOIST SUP
PORT 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
FILL-IN (UP)
LIMIT SWITCH
CABLE CUTTER
(GUILLOTINE)
INDENT
BELLMOUTH
PROTECTIVE
ELECTRICAL
JUMPER
(REF. WARNING)
BUMPER RING
RUBBER BUMPER
PAD
1/8 IN. (3.175 MM)

DIA. CABLE
GROUND WIRE
(WHITE, BLUE
OR WHITE/BLUE)
ELECTRICAL
WIRING
POSITIVE WIRE (BLACK,
GREEN, OR WHITE/GREEN)
(REF. CAUTION)
CABLE CUTTER
REPLACEMENT
WARNING: REMOVE JUMPER WIRE AFTER

SYSTEM INSTALLATION OR MAINTENANCE
(REFER TO TEXT)
CAUTION: CONNECT POSITIVE WIRE ONLY
(BLACK, GREEN, OR WHITE/GREEN) TO POS
ITIVE (+) POST OF CABLE CUTTER.
G25-6002-1A
Figure 202. Winch Cable, Cable Cutter, and Swivel Hook Replacement (Sheet 1 of 2)
Page 206
Revision 23
25-63-00
MAINTENANCE MANUAL
CSP-HMI-2
RUBBER BUMPER
KEYWAY
HOOK HOUSING
CABLE
SWIVEL HOOK
SOCKET
SWAGED BALL
END FITTING
SAFETY KEEPER
CABLE-TO-HOOK
ATTACHMENT
FIRST DRUM GROOVE
ROLLER WHEEL
TOP COVER
FULL-OUT (DOWN
LIMIT SWITCH)
(NOTE 1)
CABLE END
ALLEN HEAD SETSCREW
NUT, WASHER
(4 PLCS) (NOTE 1)
HOOK HANGER
(NOTE 2)
CABLE WINDING
(ON DRUM)
DRUM
CABLE DRUM FLANGE
CABLE GUIDE ASSEMBLY

DRUM CABLE END
ANCHOR HOLE
CABLE-TODRUM ATTACH
MENT
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)
25-63-00
Page 207
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
(10). Place BATTERY switch in OFF posi

tion.
(11). Remove external electrical power from
helicopter.
3. Hoist System Troubleshooting
(Ref. Table 201) Wiring diagrams are provided
for the hoist systems used on L/H command
(Ref. Figure 204) and R/H command helicop
ters (Ref. Figure 205). A schematic diagram of
the winch is also provided (Ref. Figure 206).
(Ref. Chap. 96 for interfacing schematics and
wiring diagrams)
4. Cyclic Stick Grip and Cyclic Stick Cable
Cutter Switch (S600) Replacement
(Ref. Sec. 67-10-20)
5. Hoist Assembly Replacement
A. Hoist Assembly Removal
(1). Check that cable is fully retracted on
winch drum.
(2). Check that BATTERY switch is in OFF
position.
(3). Install safety jumper wire on cable
cutter electrical terminals (Ref.
Figure 202).
Protective jumper wire should
remain on cable cutter electrical
terminals until winch is reinstalled for use.
CAUTION
(4). Disconnect winch electrical plug (Ref.

Figure 201) from receptacle on fuselage;
install protective cap on receptacle.
(5). Support winch; remove three quick-dis
connect safety pins securing winch
support tube to fittings on fuselage.
(6). Remove winch and support tube from
fuselage.
(7). Remove cotter pin, washer, and bearing
pin securing link assembly to winch
support tube.
Page 208
Revision 23
25-63-00
NOTE: If support tube fittings are to be re

moved from fuselage, make certain nylon
screws are installed in attachment holes.
(8). Remove bolts securing winch to support
tube brackets.
B. Hoist Assembly Installation
Item
Nomenclature
CM703
Tie strap
NOTE: If
support tube fittings (Ref.

Figure 201) were removed from fuselage, re
move nylon screws installed in support fit
ting attachment holes on fuselage.
(1). If required, install winch support tube

attach fittings on fuselage using screws
and washers.
(2). Attach winch to support tube using
bolts, washers, and nuts. Torque bolts
to 70 - 100 inch-pounds (7.91 - 11.30
Nm).
(3). Attach link assembly to support tube
using bearing pin, washer, and cotter
pin.
(4). Attach winch support tube to fuselage
fittings using quick-disconnect pins.
NOTE: Install pins in positions shown.

Check that all electrical power
is OFF to eliminate possibility
of inadvertent firing of cable cutter.
CAUTION
(5). Remove protective cap from electrical

receptacle on side of fuselage. Connect
winch electrical plug to fuselage
receptacle. Secure wire harness to
support tube using tie-straps (CM703).
Remove protective electri
jumper wire (Ref.
Figure 202) from cable cutter whenev
er winch is installed on helicopter.
Jumper wire will prevent operation of
cable cutter in an in-flight emergency.
WARNING cal
MAINTENANCE MANUAL
CSP-HMI-2
BRACKET ASSY
(RH)
TUBE
TUBE
RIGHT DOOR BRACKET

(ROTATED)
STRUCTURAL
REINFORCEMENT
BRACKET
CLAMP
DOUBLER ANGLE
CLAMP
RIGHT INBOARD
TUBE CLAMP
RIGHT OUTBOARD
TUBE CLAMP
G25-6003
Figure 203. Passenger/Cargo Door Retainer Installation
25-63-00
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Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
6. Winch Components Replacement

A. Winch Cable Replacement
(Ref. Replacement of the winch cable (Ref.
Figure 202) is required if cable is damaged,
worn excessively, or cable cutter has been fired
(Ref. Hoist Equipment Inspection for inspec
tion requirements and for cable replacement
criteria).
(1). Install hoist and support on helicopter
(Ref. Hoist Assembly Installation).
When electrical power is pres
ent, make certain cable cutter
electrical circuits remain deenergized to
eliminate the possibility of inadvertent ac
tuation of cable cutter. To avoid possibility of
cutting cable, install jumper wire between
cable cutter electrical terminals.
CAUTION
NOTE: An external power source should be

connected to the helicopter to prevent exces
sive battery discharge. Hoist uses up to 40
amperes electrical current during operation.
(2). Connect external electrical power
source to helicopter.
(3). Place BATTERY switch in EXT posi
tion.
(4). Using hoist pendant control (Ref.
Figure 201), reel off all cable from
winch drum as follows:
NOTE: Two persons can facilitate cable remov

al; one person to operate winch and a second
person to handle and coil cable.
(a). Operate winch and start reeling cable
off winch drum.
To prevent bellmouth wear,
cable should not be pulled
against side of bellmouth on cable guide.
CAUTION
(b). As cable unwinds, maintain straight

downward tension, approximately 15
pounds (6.8 kg); lay or coil cable in a
clean clear area. Position cable so
that cable will not kink or tangle, to
facilitate rewinding.
Page 210
Revision 23
25-63-00
(c). Continue unwinding cable until down

(full-out) limit switch (Ref.
Figure 202) activates (opens) and
allows brake to engage, thus stopping
cable payout.
NOTE: Three turns of cable will remain on
winch drum when down limit switch opens.
(d). Remove winch cable drum cover.
(e). Manually raise roller wheel, at top
right rear of winch drum, to close the
down limit switch (release brake) and
allow remaining cable to be reeled off
cable drum.
(f). Using control pendant, finish un
winding cable. Stop winch when
cable is fully unwound from drum.
(5). Remove winch cable from drum as
follows:
(a). Loosen Allen head setscrew securing
cable end in drum anchor hole.
Remove cable end from winch by
pulling cable down through cable
guide, cable cutter, and bumper
guide.
Anchor hole setscrew should be
CAUTION temporarily tightened to pre
vent fouling winch mechanism if winch is
inadvertently operated.
(b). Retighten setscrew in anchor hole.
(6). Remove swivel hook from cable (Ref.
Swivel Hook Replacement).
NOTE: Replacement cable must be 0.125 inch
(3.175 mm) diameter stainless steel, 19 by 7
cable strand, extra strength, antispin cable
with a minimum breaking strength of 1800
pounds. Make certain any replacement
cable, other than cable supplied by winch
manufacturer, is approximately 113 feet
(34.442 M) long, is equipped with a swaged
ball fitting, and is proof-tested to a mini
mum load of 1850 pounds (840 kg).
(7). Install swivel hook on replacement
cable (Ref. Swivel Hook Replacement).
(8). Attach new replacement cable to winch
as follows:
(a). Insert free end of replacement cable
up through bumper pad guide center,
bellmouth, switch, cable cutter, and
between cable rollers in the cable
guide assembly (Ref. Figure 202).
MAINTENANCE MANUAL
(b). Ensure cable guide assembly is
centered and aligned with first
groove on double helical screw shaft.
Facing cable guide mechanism, check
that guide will travel from right to
left when winding cable on drum.
(c). Secure cable to drum by loosening set
screw and inserting cable end into
drum cable anchor hole until cable
end bottoms, approximately 3/8 inch
(9.525 mm); tighten setscrew.
CSP-HMI-2
NOTE: The up limit switch should actuate be

fore excessive cable pressure is applied to
vertically compress bumper pad. Permanent
damage can result if rubber bumper pad is
stowed in a compressed state over an ex
tended period of time; rubber bumper will
remain in a compressed (set) state.
(d). Install cover on winch.
(10). Perform an operational check of hoist
system (Ref. Hoist System Operational
Check).
B. Swivel Hook Replacement
(d). Check that replacement cable is

positioned in first drum groove at
right when facing cable guide mecha
nism.
(9). Operate hoist and wind replacement
cable on winch as follows:
(a). Deactivate down limit switch by
manually raising teflon roller wheel
at top right rear of winch drum; use
control pendant to wind replacement
cable on winch. Release the down
limit switch after three turns of cable
are on drum.
(b). Maintain sufficient tension, approxi
mately 15 pounds (6.8 kg) on cable
while winding cable on drum; check
that cable winds straight, smooth,
and snug, without kinking against
cable windings on drum. Avoid cable
rubbing on side of bellmouth during
cable winding.
(c). Continue winding operation until
entire cable is wound on drum: check
that winch stops automatically when
top of swivel hook pushes against
winch rubber bumper pad. (Bumper
pad upward movement actuates
(opens) full-in (up) limit switch at
cable guide base.
(Ref. Figure 202)
Item
Nomenclature
CM114
Petrolatum
(1). Remove swivel hook assembly from

cable as follows:
(a). Remove rubber bumper covering
swivel hook housing by pulling
bumper upward off top of hook
housing.
(b). Remove cable swaged ball end fitting
from hook housing socket: pull cable
swaged ball fitting through rubber
bumper.
(2). Install swivel hook on cable as follows:
(a). Lubricate cable swaged ball end
fitting with petrolatum (CM114).
(b). Insert cable through top of rubber
bumper.
(c). Insert cable ball fitting in hook
housing keyway and socket.
CAUTION
Ensure hook rubber bumper

completely covers hook housing.
(d). Secure cable ball fitting in housing

socket by sliding rubber bumper
down over hook housing.
25-63-00
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Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
NOTE: Hook rubber bumper should completely

cover housing, and bumper base will overlap
inward around housing base by approxi
mately 1/16 inch when fully seated on hous
ing.
C. Cable Cutter Replacement
(GuillotineType)
(Ref. Figure 202)
Item
Nomenclature
CM425
Sealing compound
Setscrew mates with indent on cable

cutter.
(6). Connect one electrical terminal lug to
cable cutter terminal, leaving protective
short-circuiting jumper installed on
cable cutter. Then connect second wire
to remaining cable cutter terminal in
the same way.
Protective jumper wire should
remain connected to cable cutter
electrical terminals until hoist is to be used.
CAUTION
(7). Cover exposed electrical terminal areas

with sealing compound (CM425).
7. Hoist System Operational Check
Cable must be removed from winch (Ref.

Winch Cable Replacement) before guillotinetype cable cutter can be replaced. Replace a
spent cable cutter guillotine on winch as
follows:
The cable cutter contains an
WARNING explosive squib that is elec
trically fired. A protective short-cir

cuiting electrical jumper should re
main connected to cable cutter, not
installed on the winch, to eliminate
possibility of inadvertent accidental
firing.
(1). Disconnect two electrical wire terminal
lugs from spent cable cutter.
(2). Loosen two Allen head setscrews at side
of movable cable guide and remove
spent cable cutter from guide.
(3). Check that all electrical power is OFF.
Do not use an ohmmeter or
WARNING any other device containing

an internal voltage source which could
fire cable cutter.
(4). Using a voltmeter, check for zero
voltage between electrical wiring
terminal lugs; also check for zero
current between lugs with a milliamme
ter.
(5). Insert cylindrical end of new cable
cutter into winch movable cable guide,
with shorting jumper positioned
downward, and secure cable cutter to
guide with two Allen head setscrews.
Page 212
Revision 23
25-63-00
The following procedure is used to verify the

capability of the hoist system to function
correctly. The procedure should be performed
any time a malfunction is suspected, and prior
to normal use after repair.
jumper wire (Ref.
cable cutter in an in-flight emergency.
WARNING cal
(1). Open applicable passenger/cargo door;

extend door retainer tube to hold door
in full open position.
Avoid inadvertent operation of
cable cutter. Make certain cable
cutter switches are not actuated when hoist
system circuits are energized.
CAUTION
(2). Energize helicopter electrical system;

check that both HOIST PWR (power)
and CBL CTR (cable cutter) circuit
breakers are in closed position (Ref.
Figure 201).
(3). Using hoist system control pendant,
exercise hoist winch by paying out 3 to
4 feet (1.2 M) of cable under approxi
mately 15 pounds (6.8 kg) tension; pull
cable straight down to avoid cable
rubbing on cable bellmouth. Reverse
control and reel cable in. Check that
cable winds on winch drum evenly and
that winch operation is smooth and
consistent. Check that winch stops
automatically when top of swivel hook
MAINTENANCE MANUAL
rubber bumper pushes against winch
bumper pad.
(4). Test hoist lifting capability with 300
pound weight. Check that hoist oper
ates smoothly throughout hoisting and
lowering operations.
NOTE: Cable retraction rate should be approxi

mately 55-60 feet (16.8-18.3 M) per minute.
The full usable cable length should unwind
in approximately 95 seconds and rewind in
approximately 103 seconds.
(a). With helicopter hovering approxi
mately 100 feet (45.4 M) above test
weight, lower hoist hook between
fuselage and landing gear skid.
Continue lowering hook until hook
can be connected to test weight.
(b). Gradually maneuver helicopter to
remove cable slack and to center
hoist over test weight.
(c). Slowly elevate helicopter to raise test
weight approximately 20 feet (6.1 M)
from ground.
(d). Using pendant control, payout full
usable length of cable. Check that
hoist down limit switch stops winch
with three turns of cable on winch
drum. If required, adjust position at
which down limit switch activates.
CSP-HMI-2
(6). Stow door retainer tube; close passen

ger/cargo door.
8. Hoist Equipment Inspection
General inspection procedure for the hoist
system is as follows:
(1). Inspect components for security of
attachment, damage, deformation,
cracks, and excessive wear.
WARNING
D Human life might depend on cable
condition. Inspect full length of cable
carefully and thoroughly.
D Use heavy leather gloves to protect
hands from injury due to broken
cable strands.
Keep cable clean. Provide a
clean area to coil cable during
inspection. Dirt and oil grime will create an
abrasive wear on cable and winch compo
nents.
CAUTION
(2). Inspect cable for fraying, corrosion,

broken strands, and security of attach
ment to winch drum and cable ball
swivel hook attachment. General
criteria for cable replacement are as
follows:
(e). Reverse pendant control. Lift test

weight to within approximately 10
feet (3.0 M) of helicopter skid.
(a). Any single broken strand (cluster of 7

individual wires) requires cable
replacement.
(f). Lower helicopter and remove hoist

hook from test weight; raise hoist
hook and check that hoist winch
automatically stops when top of
swivel hook rubber bumper pushes
up against hoist bumper pad.
(b). Both ends of individual broken wires

should be tucked into cable to
prevent fouling when cable travels
through cable guides and nonfouling
mechanisms. Breaks of individual
wires are allowable, unless the
number is excessive as defined in
next criterion.
NOTE: Up limit switch should actuate before

excessive cable pressure is applied to verti
cally compress bumper pad (Ref.
Figure 202).
(g). Land helicopter; deenergize electrical
system.
(5). Stow pendant control.
(c). Generally, one individual broken wire

(two ends) for each foot of cable is
permissible, up to a total of 20
individual wire breaks for each 100
foot (30.5 M) length of cable. A
greater number of breaks requires
cable replacement.
25-63-00
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Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Troubleshooting Hoist System

Symptom
Probable Trouble
Winch will not raise or lower cable.
Improper lower cable travel limit.
Corrective Action
Tripped circuit breaker.
Reset circuit breaker.
Defective pendant control.
Repair pendant control.
Defective winch assembly.
Repair winch assembly.
Down (fullout) limit switch out of

adjustment.
Reset lower limit adjustment.
W3 BUS
A526A12
A527G12N
A527H20N
A527J20N
CYCLIC STICK
CABLE CUTTER
SWITCH S600
1
2
E19
3
4
5
6
7
P506AH12
CB600
1
2
40A
TB10
M535A12
P107C14-8S
RECEPTACLE
(MATES WITH
PT06P14-8P
WINCH PLUG)
(NOTE 4)
E5
JUMPER
AWG 20
2
7.5A
P130
TB1-16
CB601
1
M503B20
M503F20
13-20
14-20
SPARE
H
D
M504H20
CC8A20
CC9A20
E24
PENDENT CONTROL
CC10A20
CC2AA20
CC1AA20
NOTES:
1. THIS DIAGRAM IS TO BE USED WITH ELECTRICAL SYSTEM WIRING
DIAGRAMS IN CHAP. 96 FOR COMPLETE CIRCUIT IDENTIFICATION.
2. DASHED LINE ( - - ) ITEMS ARE PART OF HELICOPTER BASIC
ELECTRICAL SYSTEM.
3. COMPONENT TERMINAL NUMBERS ARE FOR REFERENCE AND MAY
NOT BE SHOWN ON COMPONENT.
4. REFER TO WINCH SCHEMATIC DIAGRAM FOR INTERNAL CONNECTIONS.
XJ2
A
B
D
Revision 23
25-63-00
HOIST
DOWN
CUTTER
C
MS3101E16S-1S
RECEPTACLE
Figure 204. Wiring Diagram Hoist System (L/H Command)

Page 214
UP
G25-6009
MAINTENANCE MANUAL
CSP-HMI-2
CB600
1
A526A12
A526A12
40A
J28
C
SPLICING PERMISSIBLE
HOIST (PWR) OR (ORD)

CB133
2
A526A12
40A
HOIST CUT (CTR)
CB134
1
2
7.5A
A527G12N
A527H20N
A527J20N
PT07C14-8S
RECEPTACLE
(MATES WITH
PT06P14-8P
WINCH PLUG)
(NOTE 4)
CYCLIC STICK
CABLE CUTTER
SWITCH S600
M503A20
SLAE ONLY
E9
CB601
TB1-40
P616
2
M503A20
7.5A
M503AA20
(NOTE 5)
A
B
TB1-19
M504K20
NOTE 6
P109
M521F20
M520F20
C
D
K504M20
H
SPARE
E24
CC10A20
0.040 IN. (1.016 MM)

369H90070-67 DECAL
D
CC8A20
CC9A20
CABLE CUTTER
SWITCH BUTTON
PENDANT CONTROL
GRIP
A
CABLE CUTTER SWITCH
GRIP
B
CC2AA20
CC1AA20
CYCLIC GRIP REWORK
UP
HOIST
DOWN
CUTTER
MS3101E16S-1S
RECEPTACLE
NOTES:
1. THIS DIAGRAM IS TO BE USED WITH ELECTRICAL SYSTEM WIRING DIAGRAM
IN CHAP. 96 FOR COMPLETE CIRCUIT IDENTIFICATION.
2. DASHED LINE ( - - ) ITEMS ARE PART OF HELICOPTER BASIC ELECTRICAL
SYSTEM.
3. COMPONENT TERMINAL NUMBERS ARE FOR REFERENCE AND MAY NOT BE
SHOWN ON COMPONENT.
4. REFER TO WINCH DIAGRAM FOR INTERNAL CONNECTIONS.
5. EXISTING WIRE, RELOCATED TO TB1-40A.
6. REMOVE EXISTING WIRE M520B20.
G25-6004A
Figure 205. Wiring Diagram Hoist System (R/H Command)
25-63-00
Page 215
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
FULL-IN
LIMIT SWITCHES
P28
(NOTE)
F
BRAKE
AWG 20 ORG OR WHT/ORG
DOWN
UP
G
AWG 12 WHT
AWG 12 RED OR WHT/RED

UP
DOWN
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
REFER TO HOIST SYSTEM INTERCONNECT WIRING

NOTE:
DIAGRAMS (REF CHAP. 96) FOR EXTERNAL CONNECTION.
REMOVE JUMPER WIRE AFTER INSTALLATION
WARNING:
OR MAINTENANCE (REF. TEXT).
Figure 206. Schematic Diagram Hoist System Winch

Page 216
Revision 23
25-63-00
G25-6005
MAINTENANCE MANUAL
CSP-HMI-2
HOIST PASSENGER/CARGO
1. Hoist Passenger/Cargo Initial Installation
The passenger/cargo hoist can be installed on
any L/H command or R/H command Model
369D helicopter. On L/H command, the hoist
winch is installed on the right side of the
fuselage. On R/H command, the hoist winch is
installed on the left side of the fuselage.
Subsequent procedures provide separate
instructions for electrical installations in L/H
command and R/H command to accommodate
differences in component location and wire
routing.
Installation instructions include procedures for
installing a passenger/cargo door retainer
assembly, a door sill antichafing bar assembly,
a winch and winch support tube assembly, and
the electrical wiring and components required
for operation of the hoist system.
The hoist passenger/cargo installations may be
performed at the discretion of the operator, or
the helicopter may be returned to the factory
for modification. The instructions which follow
are for the 369H90070-521 and -522 installa
tions only.
Instructions in the following paragraphs are
applicable to both left and right hoist installa
tions, except as noted.
(1). Identify all components that are to be
installed, along with those removed to
gain access to work areas. Protect
components from damage and contami
nation.
(2). Check that all electrical switches are in
OFF position.
CAUTION
(2). Remove left and right foot support

fairings in passenger/cargo compart
ment.
forward bulkhead trim panel (L/H
command) and controls access door.
(4). Remove fuel cell forward vent from
control tunnel (Ref. Sec. 28-00-00).
NOTE: Fuel vent must be removed to avoid

damage during structural modification hole
drilling operations.
(5). Remove crew compartment seat and
back cushions.
(6). Remove left (outboard) collective stick
cover.
(7). Remove crew compartment lower aft
trim panels (left and right).
(8). Remove crew compartment left or right
bulkhead panel and lower portion of
right upper side panel.
(9). Remove edgelighted panel face from
lower switch and circuit breaker panel
(Ref. Chap. 96). Loosen lower switch
and circuit breaker panel to accommo
date installation of additional circuit
breakers.
C. Helicopter Modification
(Ref. Figure 901) Modification of the helicopter
involves cutting a hole in the fuselage skin to
facilitate installation of an electrical receptacle
(J28) to receive a winch electrical plug, and a
hole in the lower left area of the canted
bulkhead and forward bulkhead trim panel to
facilitate installation of an electrical receptacle
(XJ2) to receive a control pendant plug.
Ensure BATTERY switch is in

OFF position.
B. Helicopter Equipment Removal

Remove following panels, access doors, and
equipment as applicable to accommodate
installation of the hoist system components:
(1). Remove battery (Ref. Chap. 96).
Item
CM318
Nomenclature
Primer
(1). Cut and deburr holes, remove chips,

and apply a thin coat of primer
(CM318) to exposed metal surfaces.
25-63-00
Page 901
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
(2). Fit forward bulkhead trim panel to

canted bulkhead; locate and cut hole in
trim panel to match XJ2 receptacle hole
in bulkhead. Remove trim panel to
accommodate installation of door
retainer assembly.
NOTE: Hoist electrical connector (J28) doubler

is located in the crew compartment, below
the aft lower corner of the upper canopy
windshield, and immediately forward of the
canted frame (Sta. 78.50) for either right
side (L/H command) or left side (R/H com
mand) hoist winch installation.
D. Electrical Equipment Installation (L/H
Command)
Install hoist kit electrical wire harness
assembly, general wiring, and components on
L/H command as follows:
Item
Nomenclature
CM614
CM703
Tie strap
CM807
Twine, nylon
CM815
Solder
Ensure wires and/or wire

bundles do not chafe or bind
control mechanisms.
CAUTION
NOTE: When providing ground contact for elec

trical components, clean the contacting sur
faces to bare metal (Ref. Chap. 96). Route
wire and wire bundles with existing wires
and bundles. Temporarily tie wires in place
with existing bundles until installation is
complete, then secure wires with nylon
twine (CM807), tie-straps (CM703), or
clamps as required.
(1). Install cyclic stick grip (Ref. Figure 201
and Sec. 67-10-20).
(2). From inside crew compartment,
temporarily install J28 receptacle
through hole provided in right side of
ship (Ref. Figure 901). Install washer
Page 902
Revision 23
25-63-00
(Ref. Figure 201) and receptacle nut

externally to retain J28 receptacle in
place.
NOTE: The J28 receptacle is temporarily in

stalled to provide a means of determining
wire length to receptacle.
(3). Install circuit breakers in positions
CB60l and CB600 respectively, on lower
switch and circuit breaker panel (Ref.
View A).
(4). (Ref. Figure 204) Install terminal on
circuit breaker jumper wire; install
jumper wire on contact 1 of CB60l.
(5). Install terminal on wire P506AH12 and
install on contact 1 of CB600 together
with jumper wire fabricated in previous
step. Route wire P506AH12 to contact 7
of BUSS W3; cut wire to length and
install terminal. Connect wire
P506AH12 to contact 7 of BUSS W3.
(6). Install terminal on wire M535A12 and
connect wire to contact 1 of TB10.
Route wire M535A12 to contact 2 of
CB600 and install terminal. Connect
wire M535A12 to contact 2 of CB600.
(7). Install terminal on wire M503B20 and
connect to contact 2 of CB601. Route
opposite end of wire M503B20 to
TB1-16, install pin and insert pin in
TB1-16, contact A.
(8). Connect terminal of wire A526A12 to
TB10, contact 1, and route wire below
floor through center beam, below crew
compartment right seat and up right
side aft of door frame to J28 receptacle.
NOTE: Temporarily tie wires in place. Do not

cut wires until all wires are adjusted and
tied in place.
(9). Insert pin of wire CC10A20 in TB1-16,
contact C. Connect terminal on shield
ing of wire CC10A20 to ground stud
E24. Do not tighten ground stud nut.
Route wire CC10A20 to J28 receptacle
and tie in place.
MAINTENANCE MANUAL
CSP-HMI-2
CUT HOLE IN SKIN TO

MATCH HOLE IN DOUBLER
HOIST ELECTRICAL CON
NECTOR DOUBLER
UPPER CANOPY
WINDSHIELD
E19
CREW COMPARTMENT
RIGHT DOOR FRAME
NOTE: LH COMMAND VERSION SHOWN. RH

COMMAND VERSION IS INSTALLED AT SAME
LOCATION OR LEFT SIDE OF HELICOPTER.
LH COMMAND HELICOPTER
CONFIGURATION, CUT
1.00 IN. (2.54 CM) HOLE IN SKIN
WINCH ELECTRICAL RECEPTACLE

(J28) CUTOUT LOCATION
(NOTE)
WL 21.50
XJ2
2.00 IN.
(5.08 CM)
0.970 IN.
(24.638 MM)
(TYP)
2.00 IN.
(5.08 CM)
2.00 IN.
(5.08 CM)
XJ2
1.50 IN.
(3.81 CM)
0.970 IN.
(24.638 MM)
(TYP)
VIEW LOOKING FORWARD, LOWER LEFT
CORNER OF CANTED BULKHEAD STA. 78.50
RH COMMAND HELICOPTER CON

FIGURATION, CUT
1.00 IN. (2.54 CM) HOLE IN SKIN
0.121-0.135 IN.
(3.0734-3.429 MM)
HOLE (4 PLCS)
PENDANT CONTROL ELECTRICAL

RECEPTACLE - CUTOUT LOCATION
G25-6006A
Figure 901. Helicopter Modification
25-63-00
Page 903
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MAINTENANCE MANUAL
CSP-HMI-2
(10). Install XJ2 receptacle.

(a). Insert XJ2 receptacle (Ref.
Figure 201) in hole provided in lower
left corner of canted bulkhead (Ref.
Figure 901). Using XJ2 receptacle
bracket as a template, mark and drill
four 0.121-0.133 inch (3.0734-3.3782
mm) attach holes. Protect attached
wires during drilling operation.
(b). Install XJ2 receptacle (Ref.
Figure 201) from forward side of
canted bulkhead, with screws,
washers, and nuts.
(11). Route wires CC1AA20 and CC2AA20
(Ref. Figure 203) from XJ2 receptacle to
TB1-16; install pin of wire CC1AA20 in
contact B and pin of wire CC2AA20 in
contact D. Connect terminal on shield
ing of wire CC2AA20 to ground stud
E24; tighten ground stud nut.
(12). Route wires CC8A20 and CC9A20 to
J28 receptacle and tie in place.
(13). Wire J28 receptacle.
(a). Cut and strip wires at J28 receptacle.
Ensure sufficient wire length to
provide a smooth right angle wire
flow to J28 receptacle.
(b). Install approximately 6 inches (15.24
cm) of 0.50 inch (12.7 mm) insulation
tubing (CM614) on wire bundle to
cover all wires extending from J28
receptacle.
(c). Ensure that all electrical contact
installations are correct and secure.
(d). Adjust wires at J28 receptacle and
make certain sufficient wire slack
remains to avoid stress on terminals
and contacts below floor and seat
areas. Use twine (CM807) and
tie-straps (CM703) to secure wires in
place.
Ensure wires do not chafe or
bind throughout full travel of
any control mechanism.
CAUTION
(14). Remove J28 receptacle from side of

ship. Install insulation sleeving
(CM614) and, using solder (CM815),
Page 904
Revision 23
25-63-00
connect wires A526A12, A527G12N,

A527H20N, A527J20N, CCl0A20,
CC8A20, and CC9A20 to J28 receptacle
contacts as indicated (Ref. Figure 203).
(15). Install J28 receptacle and secure with
washer and nut. Install protective cap
(Ref. Figure 201).
(16). Install ground stud on forward side of
canted bulkhead frame (Ref.
Figure 901). Identify ground stud as
E19.
(17). Install wires A527G12N, A527H20N,
and A527J20N, from J28 receptacle, on
ground stud E19. Adjust and trim
insulation tubing (CM614) to accommo
date ground wire connection as re
quired; heat shrink tubing.
(18). Replace existing cyclic stick grip with
part number 369H90129-505 (Ref. Sec.
67-10-20). Wire cyclic stick cable cutter
switch S600 as shown (Ref. Figure 204).
E. Electrical Equipment Installation (R/H
Command)
Install hoist kit electrical wire harness
assembly, general wiring, and components on
R/H command helicopters, as follows:
Item
Nomenclature
CM614
CM703
CM725
CM807
CM815
Tie strap
Tape, electrical, plastic
Twine, nylon
Solder
Ensure wires and/or wire

bundles do not chafe or bind
control mechanisms.
CAUTION
NOTE: When providing ground contact for elec

trical components, clean the contacting sur
faces to bare metal (Ref. Chap. 96). Route
wire and wire bundles with existing wires
and bundles. Temporarily tie wires in place
with existing bundles until installation is
complete, then secure wires with nylon
twine (CM807), tie-straps (CM703), or
clamps as required.
MAINTENANCE MANUAL
(1). From inside crew compartment,
temporarily install J28 electrical
receptacle (Ref. Figure 201) through
hole provided in left side of ship (Ref.
Figure 901). Install washer (Ref.
Figure 201) and receptacle nut exter
nally to retain J28 receptacle in place.
NOTE: The J28 receptacle is temporarily in

stalled to provide a means of determining
proper length of wires to be connected to re
ceptacle.
(2). On standard R/H command equipped
with 369H92143 circuit breaker panel,
install circuit breaker CB600 (Ref. View
B), and a circuit breaker CB601 in
circuit breaker panel located on the
pilot's collective pitch stick cover. Make
certain circuit breaker connections to
buss bar are secure.
(3). On SLAE-equipped R/H command with
369D294566 circuit breaker panel,
install circuit breaker CB133 and
circuit breaker CB134 in circuit breaker
panel located on the pilot's collective
pitch stick cover. Make certain circuit
breaker connections to buss bar are
secure.
(4). (Ref. Figure 205) Install terminal on
wire A526A12 and connect to contact 2
of CB600 on standard R/H command, or
to contact 2 of CB133 on SLAEequipped R/H command. Route opposite
end of wire A526A12 with existing wire
bundles to J28 receptacle and tempo
rarily tie in place.
(5). On standard R/H command, locate
existing wire M503A20, install terminal
on wire M503A20, and connect to
contact 2 of CB601. Locate existing wire
M503AA20, remove from TB16 contact
A, and relocate to TB1-40, contact A.
(6). On SLAE-equipped R/H command,
install pin on wire M503A20, insert pin
in contact A of TB1-40. Route wire
M503A20 to CB134; install terminal
and connect to contact 2 of CB134.
(7). Install pin on wire M504K20, insert in
contact B of TB1-19, and route opposite
end of wire M504K20 to TB1-40.
CSP-HMI-2
Install pin and insert pin in contact A of

TB1-40.
(8). Remove existing wire M520B20 from
TB1-19A. Wire end is left open insu
lated with tape (CM725), and secured to
basic electrical system tie-strap
(CM703). Install pin on wire K504M20
and insert in contact A of TB1-19.
Route wire K504M20 to TB1-40, install
pin, and insert pin in contact C of
TB1-40.
(9). Insert pin of wire CC10A20 in contact C
of TB1-40, route wire to J28 receptacle,
and temporarily tie in place. Connect
terminal on shielding of wire CC10A20
to ground stud E24. Do not tighten
ground stud nut.
(10). Install XJ2 receptacle.
(a). Insert XJ2 receptacle in hole pro
vided in lower left corner of canted
bulkhead (Ref. Figure 901). Using
XJ2 receptacle bracket as a template,
mark and drill four 0.121-0.133 inch
(3.0734-3.3782 mm) attach holes.
(b). Install XJ2 receptacle (Ref.
Figure 201) from forward side of
canted bulkhead, using screws,
washers, and nuts.
(11). Route wires CC1AA20 and CC2AA20
(Ref. Figure 205) from XJ2 receptacle to
TB1-40, install pin of wire CC1AA20 in
contact B, and pin of wire CC2AA20 in
contact D. Contact terminal on shield
ing of wire CC2AA20 to ground stud
E24; tighten ground stud nut.
(12). Route wires CC8A20 and CC9A20 to
J28 receptacle and temporarily tie in
place.
(13). Wire J28 receptacle.
(a). Cut and strip wires at J28 receptacle.
Ensure sufficient wire length to form
a smooth right angle wire flow to J28
receptacle.
(b). Install approximately 6 inches (15.24
cm) of 0.50 inch (12.7 mm) insulation
tubing (CM614) on wire bundle to
cover all wires extending from J28
receptacle.
25-63-00
Page 905
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
(c). Ensure that all hoist system electri

cal installations are correct and
secure.
(d). Adjust wires at J28 receptacle and
make certain sufficient wire slack
remains to avoid stress on terminals
and contacts below floor seat areas.
Use twine (CM807) and tie straps
(CM703) to secure wires in place.
Ensure wires do not chafe or
bind throughout full travel of
any control mechanism.
CAUTION
(14). Remove J28 receptacle from side of

ship. Install insulation sleeving
(CM614) and, using solder (CM815),
connect wires A526A12, A527G12N,
A527H20N, A527J20N, CC10A20,
CC8A20, CC9A20 to J28 receptacle
contacts as indicated (Ref. Figure 205).
(15). Install J28 receptacle and secure with
washer (Ref. Figure 201) and nut.
Install protective cap.
(16). Install ground stud on forward side of
canted bulkhead frame (Ref.
Figure 901). Identify stud as E19.
(17). Install wires A527G12N, A527H20N,
and A527J20N from J28 receptacle on
ground stud E19. Adjust and trim
insulation tubing (CM614) to accommo
date ground wire connection as re
quired; heat shrink tubing.
(18). (Ref. Figure 205) Check switch
MS25089-4AR (S600) on cyclic stick
grip to verify that button is flush with
guard. If it is not, the switch must be
reworked, as follows:
(a). Remove switch from grip (unsolder
wiring).
(b). Grind off end of switch button as
shown.
CAUTION
Do not allow file chips to get into

switch base.
(c). Install modified switch in grip and

resolder wiring as shown.
(d). Install decal 369H90070-67 to grip
as shown.
Page 906
Revision 23
25-63-00
F. Passenger/Cargo Door Retainer

Installation
The passenger/cargo door retainer installation
consists of a tubular assembly attached to the
aft side of Sta. 78.50 canted bulkhead with
four clamps. With the passenger/cargo doors in
the open position, a telescoping tube slides out
of the tubular assembly to engage a bracket
attached to the door frame, and thus retains
the door in an open position. Install the
passenger/cargo door retainer as follows:
(1). Install doubler angles.
(a). Locate doubler angles (Ref.
Figure 203) on forward side of Sta.
78.50 canted bulkhead, using two
existing 0.070 inch (1.778 mm)
tooling holes (Ref. Figure 902). Use
angles (Ref. Figure 203) as templates
and determine rivet hole locations on
Sta. 78.50 bulkhead.
(b). Drill rivet attach holes, 0.069-0.074
inch (1.7526-1.8796 mm).
(c). Attach angles to Sta. 78.50 bulkhead
using rivets.
(2). Install structural reinforcement
brackets.
(a). Position structural reinforcement
brackets on forward side of Sta. 78.50
canted bulkhead as shown (Ref.
Figure 902). Locate nine existing
rivets which must be removed prior
to installation of reinforcement
brackets. Remove rivets using drill
motor and appropriate drill bit.
(b). Use brackets as templates and
determine rivet hole locations on Sta.
78.50 bulkhead. Drill rivet attach
holes, 0.069-0.074 inch
(1.7526-1.8796 mm).
(c). Attach brackets to Sta. 78.50 canted
bulkhead using rivets.
(3). Drill eight 0.190-0.199 inch
(4.826-5.0546 mm) holes through Sta.
78.50 canted bulkhead and structural
reinforcement angles and brackets at
locations shown (Ref. Figure 902).
MAINTENANCE MANUAL
CSP-HMI-2
BL
6.50
CANTED BULKHEAD
(STA. 78.50)
EXISTING
TOOLING
HOLES
BL
22.60
9.375 IN.
(23.8125 CM)
11.44 IN.
(29.0576 CM)
DOUBLER
ANGLE
WL 34.36
REMOVE EXISTING
RIVETS (9 PLCS)
REINFORCEMENT
BRACKET
STRUCTURAL REINFORCEMENT LOCATION
WL 21.50
PASSENGER/CARGO
DOOR RETAINER TUBE
REINFORCEMENT
BRACKET
0.190-0.199 IN.
(4.826-5.0546 MM)
HOLE (8 PLCS)
WL 34.36
BL
22.60
DOUBLER
ANGLE
PASSENGER/CARGO DOOR RETAINER
TUBE ALIGNMENT AND ATTACHMENT
(VIEW LOOKING FORWARD - LEFT SIDE)
BL
6.50
G25-6007A
Figure 902. Passenger/Cargo Door Retainer Tube Installation
25-63-00
Page 907
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
NOTE: Drill retainer tube outboard clamp

holes first; install retainer tube and out
board clamps to ensure proper alignment for
marking and drilling inboard clamp holes.
(4). Install the retainer assembly (Ref.
Figure 203) on Sta. 78.50 canted
bulkhead, using clamps, washers,
spacers, screws, and nuts.
(5). Locate bracket on applicable passenger/
cargo door in such a manner as to allow
tube to engage bracket when door is in
open position. Install bracket on
passenger/cargo door frame using
rivnuts, washers, and screws.
G. Hoist Assembly
NOTE: Pendant assembly is shipped as

sembled with no additional assembly re
quired.
(1). Install hanger on winch, using screws,
lockwashers, and washers.
(2). Remove existing attach brackets from
winch. Install replacement brackets on
winch frame, using existing hardware.
H. Hoist Installation
The hoist system winch is mounted on a
support tube and attached with quick-release
safety pins to three fittings installed on either
side and above the passenger/cargo compart
ment door. The support tube positions the
winch to raise and lower the cable between the
side of the fuselage and the landing gear skid.
The winch and support can be installed for use
on either the left or right side of the helicopter
as applicable. Install the hoist system as
follows:
Item
Nomenclature
CM703
Tie strap
Revision 23
(2). Install support tube attachment fittings

(Ref. Figure 201) on fuselage using
screws and washers.
(3). Attach winch to support tube, using
bolts, washers, and nuts. Torque bolts
to 70 - 100 inch-pounds (7.91 - 11.30
Nm).
(4). Attach link assembly to support tube
using bearing pin, washer, and cotter
pin.
(5). Attach winch support tube to fuselage
fittings, using quick-disconnect pins.
NOTE: Install pins in position shown (Ref.
(Ref. Figure 201) The hoist assembly consists

of a winch assembly, pendant control assembly,
hook, hanger, and two attach brackets. To
assemble the hoist, proceed as follows:
Page 908
(1). Remove nylon screws installed in

support fitting attachment holes on
fuselage.
25-63-00
Figure 201).
Ensure all electrical power is
off, eliminating possibility of in
advertent firing of cable cutter.
CAUTION
(6). Remove protective cap from electrical

receptacle on side of fuselage. Connect
winch electrical plug to fuselage
receptacle. Secure wire harness to
support tube, using tie-straps (CM703).
jumper wire (Ref.
cable cutter in an emergency.
WARNING cal
(7). Install the hoist operator's body

harness (Ref. Figure 201).
(8). Install flush rivets in wheel fittings
after removing existing rivets from
locations shown (Ref. Figure 903).
NOTE: Do not install rivets if wheel fittings

have been previously equipped with flush
rivets.
(9). Install rivnuts at locations shown (Ref.
Figure 903). Secure clips (Ref.
Figure 201) to fuselage, using screws
and washers. Install bar assembly,
using screws, washers, and nuts.
(10). On R/H command, install landing gear
skid chafing bar assembly
(369D292556) as follows (Ref.
Figure 903):
MAINTENANCE MANUAL
(a). Remove bolts from inboard side of aft
abrasion strip (369H6102), and aft
bolt from inboard side of forward
abrasion strip (369H6102), on left
landing gear skid.
(b). Install screw (NAS603-8) in forward
attach hole of aft abrasion strip
(369H6102).
CSP-HMI-2
(2). Install edgelighted and circuit breaker

panels as applicable (Ref. Chap. 96).
(3). Install crew compartment left or right
bulkhead panel and lower portion of left
or right upper side panel as applicable.
(4). Install crew compartment lower aft
trim panels (left and right).
(c). Position chafing bar on inboard side

of left skid with bent end of bar aft,
and 3/8 inch (9.525 mm) recess hole
in chafing bar over aft abrasion strip
forward attach screw.
(5). Install left (outboard) collective stick

cover.
(d). Align chafing bar aft screwhole with

aft abrasion strip aft attach hole;
install screw (NAS603-8) to secure
aft portion of chafing bar.
(7). In passenger/cargo compartment,

install fuel cell forward vent in control
tunnel (Ref. Sec. 28-00-00).
(e). Hold chafing bar against skid; locate

bar forward screw hole over forward
abrasion strip aft attach hole; drill
0.190-0.200 inch (4.826-5.08 mm)
screw hole through chafing bar.
(f). Install screw (NAS603-8) to secure
forward end of chafing bar.
I. Helicopter Equipment Installation
Install equipment and panels as follows:
Remove all tools and foreign
materials from helicopter before
panel installations.
CAUTION
(1). Prior to closing access areas, check

integrity of entire hoist system installa
tion.
(6). Install seats and back cushions.
(8). In passenger/cargo compartment,

install controls access door and foot
support fairings.
NOTE: The forward bulkhead, Sta. 78.50, trim

panel is not installed during use of the hoist
system door retainer equipment.
(9). Install battery.
(10). Perform operational check of hoist
system (Ref. Hoist System Operational
Check).
J. Weight and Balance Data
(Ref. After installation of the hoist system,
incorporate changes in the helicopter weight
and balance records as instructed (Ref. Sec.
08-10-00).

Configuration
Weight
Pounds (kg)
Arm
inches (cm)
Moment
inlb (kg cm)
369H90070521
(R/H Command)
+42.3
(+19.187)
+98.0
(+248.92)
+4145
(+4775.5)
369H90070522
(L/H Command)
+39.3
(+17.826)
+98.7
(+250.70)
+3879
(+4469.1)
25-63-00
Page 909
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
WHEEL FITTING
REMOVE EXISTING RIVETS

(2 PLCS), INSTALL FLUSH
RIVETS
LANDING GEAR SKID

(INBOARD SIDE)
CABLE ANTI-SNAG PROVISIONS

(ROTATED)
FORWARD ABRASION
STRIP
AFT ABRASION
STRIP
LEFT SKID
(INBOARD SIDE)
CHAFING BAR
LEFT LANDING GEAR SKID CHAFING BAR PROVISION

(RH COMMAND HELICOPTERS WITH
CENTER ELECTRICAL CONSOLE ONLY)
INSTALL RIVETS
(2 PLCS)
1.12 IN.
(2.8448 CM)
STA.
96.92
STA.
85.69
JACK FITTING
0.47 IN.
(11.938 MM)
16.03 IN.
(40.7162 CM)
1.12 IN.
(2.8448 CM)
11.20 IN.
(28.448 CM)
STA.
112.92
DOOR SILL ANTI-CHAFING BAR PROVISIONS

G25-6008A
Figure 903. Cable Antichafing Bar Installation

Page 910
Revision 23
25-63-00
MAINTENANCE MANUAL
Chapter
26
Fire Protection
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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
26 Contents
Page i
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page ii
Revision 43
26 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
261000
Engine Fire
Detection System
MAINTENANCE MANUAL
CSP-HMI-2
FIRE DETECTION SYSTEM

1. Fire Detector System Description and
Operation
The fire detection system is located in the aft
section of the fuselage encircling the engine
bay area. The fire detector cable is looped
around the inboard structure of the engine
compartment. The fire detection system is held
in place by stainless steel positive locking
cable clips and clamps attached to the air
frame.
The detector consists of a pressure switch
connected to a small diameter tube. Inside the
tube is helium gas and a core material that
contains trapped hydrogen. The detector can
provide an output signal when heat is applied
to it in two ways. If the detector tube average
temperature exceeds a preset amount, the
helium gas pressure increase will trigger the
output signal. If there is a local hot spot on the
detector tube, the core will outgas hydrogen.
The release of hydrogen gas will cause a
pressure increase inside the tube, triggering
the output signal. Both of these processes are
reversible. When the tube cools, the output
signal ceases, the hydrogen is readsorbed into
the core, and the system is reset. The detector
core has a spiral groove cut into its outside
diameter, so that crushing, flattening, or
kinking of the detector tube will not prevent
gas pressure from reaching the pressure
switch. Loss of tube integrity through cracking
or breakage will make the detector inopera
tive, but the detector incorporates a built in
test for tube integrity.
2. Fire Detector System Troubleshooting
(Ref. Figure 201)
3. Fire Detection System Replacement

(Ref. Figure 202)
A. Fire Detection System Removal
(1). Disconnect wire harness from fire
detector unit.
(2). Remove hardware securing clamps from
cable and fire detector unit.
(3). Disconnect fire detection cable quick
release clips.
(4). Careful remove fire detection cable
from engine compartment.
(5). Replace any broken quick release clips.
B. Fire Detection System Installation
NOTE:
D Replace any damaged or broken quick re
lease clips.
D Do not exceed minimum bend radius
0.375 inch (9.53 mm) when installing fire
detection cable.
(1). Form fire detection cable to fit original
mounting locations.
(2). Secure fire detector cable in quick
release clips.
(3). Install clamps to fire detector unit
using previously removed hardware.
(4). Attach electrical connector to fire
detection cable connector.
26-10-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
J1201
TB201-1
89
FIR 002AA22
P19 VOICE/WARNING LRU

G
FIR 002AAA22
S
P/J 30
FIR 002A22
78
FIR 001A22
79
FIR 001F22
FIR 003A22
FIRE DETECTOR
6G26-095A
Figure 201. Fire Detection System Interconnect Data
Page 202
Revision 23
26-10-00
MAINTENANCE MANUAL
CSP-HMI-2
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
AN960C10L WASHER
MS3456KT14S-5S PLUG
M85049/52S14W BACKSHELL
MS9029/30-217 SOCKETS (X5)
LOOKING OUTBOARD
LEFT SIDE
6G26-094
Figure 202. Fire Detection System Installation
26-10-00
Page 203
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
Page 204
Revision 44
26-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
262000
Fire Extinguisher
MAINTENANCE MANUAL
CSP-HMI-2
FIRE EXTINGUISHER
1. Fire Extinguisher Description
(2). Remove fire extinguisher from mount

ing bracket.
(Ref. Figure 201) The early model helicopters

use the pressurized, dry chemical type of fire
extinguisher. The current models use a
liquified gas which discharges as a vapor at
high nozzle velocity (Halon 1211). The L/H and
R/H command fire extinguishers mount on the
forward door frame between the crew door and
the canopy. The fire extinguisher quickly
detaches from the mounting bracket by
unfastening the quick-release clasps. Note the
current fire extinguishers are equipped with
two straps for extra high vibration applica
tions.
(3). Remove safety pin from handle. Point

nozzle toward base of flame and
squeeze the handle.
2. Fire Extinguisher Operation

(1). Grasp fire extinguisher handle with one
hand. Use the thumb and forefinger of
the other hand to unfasten the quickrelease clasp.
3. Fire Extinguisher Servicing/Inspection

The fire extinguishers are equipped with a
pressure gage that indicates normal, charge,
and overcharge pressures.
(1). Dry chemical type - white area indi
cates normal operating range of 150 psi
(1034 kPa). Red area indicates
CHARGE or OVERCHARGE.
(2). Halon type - green area indicates
normal operating range of 125 psi (862
kPa). Red area indicates CHARGE or
OVERCHARGE.
Service the fire extinguishers in accordance
with manufacturer's instructions.
26-20-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
EARLY ASSEMBLY
CURRENT ASSEMBLY
G26-2001
Figure 201. Fire Extinguisher Installation (R/H Command)

Page 202
Revision 23
26-20-00
MAINTENANCE MANUAL
Chapter
28
Fuel System
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSPHMI2
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 101. Fuel Supply System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 101. Fuel System Wiring Diagram (Model 250-C20B/R2 Engines) . . . . .
Figure 102. Fuel Quantity System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . .
Figure 103. Fuel System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101
101
103
103
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
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
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3.
Title
Page
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
Start Pump Replacement (Model 250-C20B/R2 / 250-C30 Engine Installation) . 409
5.
A. Start Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

Table 401. Fuel Line Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Start Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Figure 404. Start Pump and Fuel Lines Installation (Sheet 1 of 4) . . . . . . . . . . . 411
6.
Fuel Quantity Transmitter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415

A. Fuel Quantity Transmitter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Fuel Quantity Transmitter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
7.
Fuel System Drain Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415

A. Fuel System Drain Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Fuel System Drain Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
8.
Fuel Cell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

A. Fuel Cell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Fuel Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
C. Fuel Cell Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Figure 405. Fuel Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Figure 406. Fuel Cell Support Lacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1.
Fuel Level Low Caution Light System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2.
Fuel Quantity Transmitter Calibration and Adjustment . . . . . . . . . . . . . . . . . . . . . . . 501

Figure 501. Fuel Quantity Transmitter Calibration (Sheet 1 of 2) . . . . . . . . . . . . 502
A. Fuel Level Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
B. Fuel Level Low Warning Light Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
3.
Fuel Quantity Transmitter Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
4.
Fuel Filter (Bypass) Caution Light Pressure Switch Test . . . . . . . . . . . . . . . . . . . . . . 506

Figure 502. Fuel Filter Caution Light Pressure Switch Test
(C20/C30 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
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Para/Figure/Table
Title
Page
Figure 503. Fuel Filter Caution Light Pressure Switch (C30 Engine) . . . . . . . . . 509
Figure 504. Fuel Filter Caution Light Pressure Switch (C20 Engines) . . . . . . . . 509
Figure 505. Fuel Filter Caution Light Pressure Switch (C20R/2 Engines
with CECO Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
1.
Fuel System General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2.
Fuel Shutoff Valve Control Cable Swage Test (369D/E) . . . . . . . . . . . . . . . . . . . . . . . . 601

Figure 601. Fuel 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
10. Fuel Cell Leak Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605

A. Soap Bubble Leak Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
B. Phenolphthalein Stain Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
C. Liquid Stand Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
11. Fuel Tank Pressure Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1.
Fuel Shutoff Valve Control Cable Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2.
Fuel Shutoff Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3.
Fuel Cell Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
4.
Uniroyal 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 PN369D296303, 369D296303-701 and
369A4245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
B. MIL-S-8802 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
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Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 101. Fuel Supply System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 102. Fuel Quantity System Wire Data List . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 101. Fuel Quantity System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . .
101
101
103
103

1.
Fuel Cell Cleaning - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.
Engineered Fabrics Corp. Fuel Cell Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.
Fuel Cell Handling, Storage and Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4.
Fuel Cell Preservation and Storage (Engineered Fabrics Corp. Cells) . . . . . . . . . . . 201
5.
Fuel System Air Bleed (Model 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
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Para/Figure/Table
3.
Title
Page
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
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
28 Contents
Page v
Revision 44
CSPHMI2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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
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
Page vi
Revision 44
28 Contents
MAINTENANCE MANUAL
CSPHMI2

Para/Figure/Table
Title
Page

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
D. Anti-Ice Fuel Filter Control Panel Installation: 600N98110-501 . . . . . . . . . . . . 902
E. Firewall Modifications and Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
F. Fuel Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 901. Anti-Ice Fuel Filter Modifications and Installation
(369D/E - 500N) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 902. Anti-Ice Fuel Filter Modifications and Installation (600N)
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 903. Anti-Ice Fuel Filter Wiring Diagram (369D S/N 0001 - 1204)
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 904. Anti-Ice Fuel Filter Wiring Diagram (369D S/N 1205 & Subs
and 369E S/N 001 - 383) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 905. Anti-Ice Fuel Filter Wiring Diagram (369E S/N 384 & Subs
and 500N S/N 001 & Subs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 906. Anti-Ice Fuel Filter Wiring Diagram (600N S/N 003 & Subs)
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
903
904
907
910
912
913
914
G. Post-Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 916

H. Furnishings, Panels and Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 916
28 Contents
Page vii
Revision 44
CSPHMI2
MAINTENANCE MANUAL

Para/Figure/Table
2.
Title
Page
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

Page viii
Revision 44
28 Contents
MAINTENANCE MANUAL
CSP-HMI-2
Section
280000
Fuel System
(369D/E/FF 500N)
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
1. Engine Fuel System
(1). Engine fuel system operational infor
mation is provided in the applicable
Allison Engine Operation and Mainte
nance Manuals (Ref. Sec. 01-00-00).
2. Fuel Cells
(1). The MDHS helicopter standard fuel
tank consists of two interconnected
non-self-sealing bladder cells having a
total capacity of 64 U.S. gallons (242.3
L), with 62 gallons (234.7 L) usable.
Alternate self-sealing cells may be
installed having a capacity of 62 U.S.
gallons (234.7 L), with 60.7 gallons
(229.7 L) usable. Bladder and self
sealing fuel cells are supplied by
Engineered Fabrics Corporation and
Uniroyal, Inc. (Ref. Sec. 01-00-00).
(2). Cells are located in separate fiberglass
lined bays below the passenger com
partment floor. Both cells are supported
by a system of airframe brackets,
hangers, grommets and nylon suspen
sion cords.
(3). Each fuel cell is equipped with an
access cover fitting, cover, forward and
aft vent crossover fittings, fuel intercon
nect fittings, internal baffles and baffle
support rods.
(4). The right fuel cell contains the male
portion of the cell interconnect fitting,
filler neck, cap and attached filler
shield.
(5). The left fuel cell contains the female
half of the cell interconnect fitting,
sump plate, sump/tank drain valve,
engine start fuel pump (C20 series
engine installation) or fuel inlet fitting
(C30 engine installation). The left cell
cover supports the fuel quantity
transmitter, manually actuated fuel
shutoff valve, fuel supply tubes, hoses
and attaching hardware.
(6). Fuel tank servicing is through the tank

filler neck on the right side of the
fuselage.
3. Fuel Quantity System
(1). The fuel quantity system is powered by
24 - 28 Vdc current and consists of a
float operated quantity transmitter
mounted on the left fuel cell cover and a
quantity indicator gauge and FUEL
LEVEL LOW caution light on the
instrument console. Early series
helicopters incorporate the gauge as
part of a three-pack instrument cluster.
Current helicopters feature an individ
ual quantity gauge. The system is
protected by the INSTR CLUSTER 5
ampere circuit breaker. Power is
supplied to the system from the DC bus
through the INSTR CLUSTER circuit
breaker, CB101. With power on and
approximately 35 or 70 pounds of fuel
remaining, depending on customer
requirements, the fuel quantity trans
mitter float arm contacts a spring wire
that completes a circuit to ground
through a transistor located on a circuit
board inside the transmitter assembly.
The transistor switches on the FUEL
LEVEL LOW caution light. Refueling
raises the float, breaks the transistor
circuit and switches off the FUEL
LEVEL LOW caution lamp. The float
operates a rheostat that controls
electrical current through the quantity
indicator circuit. Fuel level changes
alter transmitter resistance values that
effect the fuel quantity indicator needle
position.
4. Vent System
(1). Tank cells are vented to atmosphere
through bottom and side fuselage ports
by a system of interconnected hoses and
tubes attached to the forward and aft
ends of each fuel cell. A fuel vent
emergency shutoff valve automatically
closes to prevent fuel loss through the
vent system when a 45 helicopter pitch
or roll angle limit is exceeded.
28-00-00
Page 1
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
5. Fuel Shutoff Valve Control

(1). A red fuel shutoff control knob labeled
FUEL, PULL TO CLOSE is located on
the instrument panel face. The flexible
cable and housing is routed aft under
the floor to the shutoff valve lever on
the left fuel cell access cover.
6. Fuel Shutoff Valve
(1). The cable actuated, mechanically
detented fuel shutoff valve is located on
the left fuel cell access cover. Valve
lever arm travel from full open to closed
is 90.
7. Start Pump
NOTE: Helicopters with C30 engines are not

equipped with a start pump. Fuel is drawn
from the tank by the engine-driven fuel
pump.
(1). Helicopters with C20 series engines are
equipped with a submerged, single
stage centrifugal, 24 - 28 Vdc, 4.5
ampere, negative ground, electric start
pump bolted to the sump plate in the
left fuel cell. Pump delivery volume at
sea level is 300 lbs/hr (136 kg/hr),
nominal at 10 psi (68.95 kPa), mini
mum. Delivery at 20,000 feet (6100 M)
is 120 lbs/hr (54.48 kg/hr), nominal at
11 psi (75.84 kPa), minimum. The start
pump is controlled by a 7.5 ampere
circuit breaker/switch on the instru
ment panel.
(2). 369F - Maintenance Fuel Pump
Helicopters with C30 engines are not
equipped with a start pump. An
optional maintenance fuel pump with
the same specifications as the C20
series engine submerged start pump
can be installed. The maintenance fuel
pump is used to bleed or purge fuel
lines after maintenance and is not used
during engine operation. The mainte
nance fuel pump is controlled by a 7.5
ampere circuit breaker/switch on the
instrument panel.
8. Fuel Filter Caution Light Pressure Switch
(1). A differential pressure switch is
installed across the engine fuel pump
Page 2
Revision 44
28-00-00
filter pressure AF (after filter) and BF

(before filter) ports just upstream of the
engine fuel pump. The switch is
sensitive to a preset differential
pressure. An increase in BF pressure
with a concurrent decrease in AF
pressure due to partial or complete
filter blockage may intermittently or
completely close the switch depending
on the nature of the filtered material.
Switch contacts complete an electrical
circuit through a case ground that
switches on the FUEL FILTER
caution lamp, a part of the instrument
console caution and warning light
array.
9. Drain System and Drain Valves
(1). One spring loaded plunger drain valve
is installed in the fuel tank sump plate.
Air in the fuel system will
WARNING cause a power reduction or

flameout. Do a fuel system vacuum leak
check and system air bleed after open
ing fuel system to atmosphere and
prior to releasing helicopter for flight.
NOTE: The tank sump drain valve is installed

in the tank sump mount plate on the bottom
of the left fuel cell. The valve is accessed
from under the helicopter.
(2). An additional drain valve and asso
ciated tubing is installed on helicopters
equipped with an optional anti-ice
(airframe) fuel filter.
10. Fuel Supply Lines
(1). The engine fuel supply lines consist of:
(a). A hose between the start pump (C20
engines) or fuel pickup fitting (C30
engines) to the fuel shutoff valve.
(b). A tube between the fuel shutoff valve
and firewall fitting.
(c). A hose from the firewall fitting to the
engine filter inlet port.
(d). Associated elbows, fittings and
unions.
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
FAULT ISOLATION
1. Fuel System Fault Isolation
Table 101. Fuel Supply System Fault Isolation
Symptom
Probable Trouble
Corrective Action
Fuel tank empty.
Refuel helicopter.
Defective start pump.
Replace start pump.
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 inlet screens.
Clean as required.
Twisted or kinked fuel supply

hose.
Repair as required.
Defective fuel shutoff valve.
Repair or replace fuel shutoff valve.
Fuel shutoff valve control

cable failed or disconnected.
Repair or replace control cable.
Clogged engine fuel filters.
Replace pump and gas producer fuel control

filters. Clean fuel control pneumatic (air)
circuits (refer to Allison Engine Operation and
Maintenance Manual). When installed, replace
antiice (airframe) filter. 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 with start pump ON
and adequate fuel on board.
Water/ice in fuel system.
Drain water out of tank and fuel supply system.
Engine power surge or

flameout with start pump OFF.
Same as above.
Air in fuel system.
Bleed fuel system.
Air leaking into system.
Vacuum leak check fuel supply system.
Start pump supplies

insufficient or no fuel to
engine.
FUEL FILTER warning light

on.
28-00-00
Page 101
Revision 29
MAINTENANCE MANUAL
CSP-HMI-2

Symptom
Probable Trouble
Bottom of fuselage stays wet

with fuel.
Loose or broken lines or

fittings.
Inspect and repair as required.
Fuel tank leak.
Remove, test and repair, or replace cells.
Transistor current leakage

FUEL LEVEL LOW caution
light stays on, glows or flickers through FUEL LEVEL LOW
with known quantity above low caution lamp.
level.
Defective fuel quantity
transmitter.
Erroneous fuel quantity gauge
readings.
Revision 19
Install resistor in transmitter circuit.
Remove, test, calibrate and repair or replace

fuel quantity transmitter.
Loose or defective wiring or

connections.
Inspect wiring and repair.
Defective gauge.
Remove, test and replace a defective gauge.
Defective fuel quantity

transmitter.
Remove, test, calibrate and repair or replace

transmitter.
NOTE: 369FF Helicopters are not equipped with a start pump.
Page 102
Corrective Action
28-00-00
MAINTENANCE MANUAL
CSP-HMI-2
P250J
P9J
CB11
1 8 2
START
PUMP
7.5A
START
PUMP
A
E8
B
B250
TB503-9
NOTE
A
D
NOTE
NOTE
DIMMER
INDICATO
P12 R LIGHTS
N
NOTE
TB6
START PUMP
ON LT
TB10
R1
SP24
C
NOTE
330
B
SB23
B
GND BUS
SW PNL
NOTE
XDS7
E33-A
G280012A
NOTE: EFFECTIVE ON 369E - 500N HELICOPTERS.
Figure 101. Fuel System Wiring Diagram (Model 250C20B/R2 Engines)
CB101
2
5A
C
J
REF SEC
98-00
FUEL QTY
M35
DS143
E31
DIMMER
IND LTS
FUEL QTY
SENDER
P9J
P251J
BLU
RED
BLK
E5
P12
R251
GND BUS
DS1
1
G280013
Figure 102. Fuel Quantity System Wiring Diagram
28-00-00
Page 103
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
28 VDC BUS
PNL
LTS
CB104
START
PUMP
CB118
IGN
INSTR
CLUSTER
CB101
S202
ENG
SEND
OIL
TEMP
IND
GND
RT30
1
ENG OIL
TEMP
SENDER
FLOA
T
GND
IGN
FUEL
QTY
IND
S203
J251P
SEND
FUEL LEVEL SENDER
B
R251
1K
D
E
P250
A
B
510
START
PUMP
P12
PRESS-TO-TEST
SWITCH XDS21
NC
C
NO
XDS21-S2
START
PUMP
ON LT
XDS21-S1
NO
C
NC
DIMMER
A
+28 VDC
IN
WARN
FUELLTLOW
FUEL
FILTER
B
K
A
L
N
B
S303
FUEL
FILTER
SWITCH
NOTES:
START PUMP
CIRCUITRY NOT EFFECTIVE ON 369FF
HELICOPTERS.
G28-0014A
Figure 103. Fuel System Schematic

Page 104
Revision 23
28-00-00
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
1. Fuel Cell Cleaning General
(1). Fuel cells are susceptible to fungus
growth after contact with contaminated
fuel. Fungus trapped in the fuel filters
indicates fuel tank contamination.
Remove, inspect, clean or replace filter
elements per applicable Allison Engine
Where installed, service anti-ice
(airframe) filter (Ref. Sec. 28-25-00).
(2). Periodic incorporation of an FAA
approved anti-fungal fuel additive will
kill and prevent new fungus growth.
2. Uniroyal Fuel Cell Cleaning
Steam cleaning may cause ir
reparable cell damage. Do not
use MEK, soap or commercial cleaning de
tergents to clean rubberized fabric fuel cells.
Some cleaning agents leave a residue that
will react with fuel to form materials that
can block fuel filters.
CAUTION
(1). Clean Uniroyal fuel cell interior/exter

ior surfaces with lint free cloth moist
ened with water, alcohol or kerosene.
No other cleaning materials should be
used.
3. Engineered Fabrics Corp. Fuel Cell
Cleaning
Do not steam clean Engineered
Fabrics Corp. fuel cells. Steam
cleaning may cause irreparable damage.
CAUTION
(1). Clean cell exterior and interior surfaces

with warm soapy water and clean lint
free cloth. Rinse away all soap residue
and wipe dry.
4. Fuel Cell Handling, Storage and Shipping

Do not use cell fittings as hand
holds. Do not store fuel cells un
crated or exposed to direct sunlight, ozone,
dirt, moisture, solvents, chemicals, or ex
tremes of heat and humidity.
CAUTION
(1). Store and ship cells in a suitable

protective container.
(a). Apply protective tape over all cell
machined fittings.
(b). Use packing material to keep the cell
from shifting in transit.
(c). Suspended self-sealing cells to
maintain cell shape.
5. Fuel Cell Preservation and Storage
(Uniroyal Cells)
CAUTION
D Uniroyal cells removed from service must
not be left dry for more than 10 days with
out the application of oil as a plasticizing
agent. The cell liner will loose pliability if
left dry for extended periods and subse
quent flexing may cause the material to
crack.
D Do not work on cell in ambient tempera
tures below 50F (10C).
(1). Before removing cell from airframe:
(a). Spray or wipe exposed internal and
external cell surfaces with SAE 10
petroleum based oil.
(b). Allow oil to soak into cell for 24 hours
to soften cell material prior to
handling or folding.
(c). Mop up puddled oil.
(Engineered Fabrics Corp. Cells)
NOTE: Engineered Fabrics Corp. VITHANE/R

fuel cells do not require oiling for preserva
tion.
28-00-00
Page 201
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
(1). Thoroughly clean cell with warm soapy

water. Wipe completely dry.
CAUTION
Do not work on cell in ambient

temperatures below 70F
(21C).
(a). Fold cell over protective wadding as
loosely as possible and with a mini
mum number of folds.
(b). Wrap the cell in a protective cover.
(c). Put cell in a suitable storage/ship
ping container. Use wadding as
required to prevent movement. Do
not stuff cell into an undersized
container.
(d). Store cell at 70F (21C) away from
sunlight and moisture.
7. Fuel System Air Bleed (Model 250C30
Engine Installation)
Fuel/air vapor discharged
WARNING during bleeding is a fire haz
ard. Prevent fuel vapor accumulation,

ignition and fire. Perform work in an
open, well ventilated area away from
all potential ignition sources. Attach
helicopter to an approved electrical
ground. Wear approved eye protection.
(1). Helicopters with C30 engines fuel
supply systems are not equipped with a
start pump. However, the helicopter
fuel system has an engine driven self
priming pump that will fill the fuel
system when the engine is motored
with the starter. Motor engine per the
appropriate Pilot's Flight Manual.
(2). Bleed air out of helicopter engine fuel
controls per Allison Engine Operation
and Maintenance Manual.
Page 202
Revision 19
28-00-00
NOTE: Check fuel supply system for leakage

with vacuum (Ref. Fuel System Vacuum
Leak Inspection).
8. Fuel System Air Bleed (Model
250C20B/R2 Engine Installation)

(1). Bleed air from helicopter fuel systems
as follows:
CAUTION
Do not operate start pump in an

empty fuel tank.
(2). Refuel helicopter as required.

(a). Connect battery.
(b). Open engine access doors.
(c). In crew compartment; push FUEL
shutoff valve knob in to open shutoff
valve.
(d). Set helicopter master switch to
BATTERY.
(e). Set START PUMP switch ON to
pressurize fuel system. Check; start
pump is operating.
NOTE: Refer to applicable Allison Engine Op

eration and Maintenance Manual for specif
ic engine fuel system air bleed information.
(f). Purge air from engine fuel system
per Allison Engine Operation and
Maintenance Manual.
(3). Set START PUMP and battery
switches OFF.
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
1. Fuel Shutoff Valve Control Cable
Replacement
A. Fuel Shutoff Valve Control Cable
Removal
(Ref. Figure 401)
(1). Thread cable assembly aft through

instrument panel or console, lockwash
er, jamnut and grommets to fuel shutoff
valve. Maintain a cable bend radius
greater than 3.5 inches (8.89 cm).
(1). Remove left fuel cell floor access panel.
(2). Secure forward end of cable with

lockwasher and jamnut.
(2). Disconnect control wire from fuel

shutoff valve swivel.
(3). Slip control cable wire through fuel

shutoff valve lever swivel.
(3). Remove control cable ty-raps and

clamps.
(4). Secure end of cable housing to cell cover

with a clamp, washer and screw.
(4). Remove instrument panel left fairing

and lower cover panels (instrument
panel mounted).
(5). Install remaining clamps and ty-raps.
(5). Completely back jamnut away from

cable plunger housing (Ref. Figure 401,
view A).
(6). Remove straps securing cable in nose
(instrument panel mounted) or remove
clamp in compartment under pilot's
seat (console mounted).
NOTE: Attach a trace wire or cord to the valve

end of the cable before pulling assembly out
of the instrument panel. Trace will guide re
placement cable into correct position.
(7). Pull cable assembly out through
washer, jamnut and instrument panel.
B. Fuel Shutoff Valve Control Cable
Installation
(Ref. Figure 401)
Pulling detent knob out of cable
housing two or more inches may
result in loss of the detent ball.
CAUTION
(6). Rig cable with shutoff valve lever hard

against open stop. Adjust cable to get a
0.090-0.150 inch (2.286-3.810 mm) gap
between bottom of control knob and
cable housing end fitting. Tighten cable
swivel pinch nut. Install cotter pin.
Control action must move valve
to full open against mechanical
stop without bottoming control knob on
cable housing. Control cable operation shall
be smooth with no binding.
CAUTION
(7). Pull valve control knob out with a

spring scale. Required valve actuation
force to be not more than 12 pounds
(53.38 N).
(8). Repair, adjust or replace valve control
system components to meet force limit.
(9). Reinstall left fuel cell floor access panel.
(10). Reinstall instrument panel left fairing
and lower cover panels (instrument
panel mounted).
28-00-00
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Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
DETENT RELEASE
DETENT RELEASE
CABLE PLUNGER
DETENT BALL
PLUNGER HOUSING
0.090-0.150 INCH
(2.286-3.810 MM)
PLUNGER HOUSING
SPRING
INSTRUMENT PANEL
CABLE PLUNGER
INSTRUMENT PANEL
NUT
CABLE RIGGING
HOLE
LOCKWASHER
OPEN
LEVER
CABLE HOUSING
CL VALVE
CONTROL KNOB ASSEMBLY
CLOSED
FUEL SHUTOFF VALVE ORIENTATION
AND LEVER POSITIONS
(LOOKING DOWN)
CABLE WIRE
CONSOLE-MOUNTED
CONTROL
INSTRUMENT
PANEL
END CLAMP
GROMMET
FUEL SHUTOFF
CABLE
CLAMP
STA. 78.50
STRAP
NYLON GROMMET
STA. 64.36
STRAP
BRACKET
CREW COMPARTMENT
FLOOR
FUEL SHUTOFF
CABLE
STRAP
STA. 50.50
G28-0001A
Figure 401. Fuel Shutoff Valve Cable Installation

Page 402
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28-00-00
MAINTENANCE MANUAL
2. Fuel Shutoff Valve Replacement
A. Fuel Shutoff Valve Removal
(Ref. Figure 402)
Avoid fuel vapor ignition
WARNING and fire. Use only nonspark

ing tools and explosion proof work
lights. Attach helicopter to an ap
proved electrical ground. Switch OFF
all electrical power. Disconnect exter
nal power and battery before opening
fuel system. Ensure work area is ade
quately ventilated.
CAUTION
D Air in fuel system may cause power
surges or flameout. Bleed off trapped air
after opening system at any point be
tween fuel tank and engine fuel nozzle.
D Prevent fuel system contamination. In
stall caps on the ends of hoses, tubes and
fittings as parts are removed. Bag and
identify small parts to prevent loss or
damage.
(1). Defuel helicopter. Drain remaining fuel
from tank sump drain valve into a
suitable container.
(2). Remove left fuel tank access panel from
passenger/cargo compartment floor.
(3). Unclamp fuel supply tube between fuel
shutoff valve and Sta. 124.00 bulkhead
elbow. Using backup wrench on bulk
head elbow so it will not rotate, discon
nect and remove tube.
(4). With 250-C20B/R2 Engine or 250-C30
Engine With Optional Maintenance
Fuel Pump: Unclamp start pump wire
harness and disconnect plug from cell
cover receptacle.
CSP-HMI-2
(5). Unplug fuel quantity transmitter

connector from cell cover receptacle.
(6). Unclamp and disconnect control cable
from fuel shutoff valve.
(7). Unfasten and remove Sta. 91.00 and
102.00 left fuel cell cover support
brackets.
CAUTION
D Do not strain or bend fuel quantity trans
mitter float arm.
D Handle fuel cell cover with care. Prying
cover from cell opening or rough handling
may damage seal or cell fitting.
(8). Remove fuel quantity transmitter
flange screws. Lift transmitter assem
bly out of cover opening.
(9). Unbolt cell access cover. Prop cover
open with suitably padded blocks.
(10). Using a backup wrench on valve,
separate fuel supply hose from fuel
shutoff valve.
(11). Remove fuel shutoff valve and attach
ing hardware.
B. Fuel Shutoff Valve Installation
(Ref. Figure 402)
NOTE: Fuel shutoff valve installation steps are

given in Fuel Cell Cover Installation proce
dures.
(Ref. Fuel Cell Cover Installation)
28-00-00
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Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
SCREW, TORQUE; 20-25 IN. LB

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

230-260 IN. LB (25.99 - 29.38 NM)
CONTROL
CABLE
CARGO
COMPARTMENT
FLOOR
ELECTRICAL CONNECTOR
FUEL SHUTOFF VALVE

SEAL WASHER
JAMNUT, TORQUE; 240-280 IN. LB
(27.12-31.64 NM)
HOSE NUT, TORQUE; 230-260 IN. LB
(25.99-29.38 NM)
FUEL INLET HOSE
FUEL QUANTITY
TRANSMITTER
ELECTRICAL
RECEPTACLE
ELECTRICAL
RECEPTACLE
START PUMP ELECTRICAL

WIRING HARNESS
NOTE:
REQUIRED AT LOCATION SHOWN.
Figure 402. Left Fuel Cell Cover Installation
Page 404
Revision 19
28-00-00
G28-0002A
MAINTENANCE MANUAL
3. Fuel Tank Vent System Component
Replacement

quately ventilated.
Prevent fuel system contamina
tion. Install caps on the ends of
hoses, tubes and fittings as parts are re
moved. Bag and identify small parts to pre
vent loss or damage.
CAUTION

suitable container.
Prevent spontaneous com
WARNING bustion or explosion. Never
use oxygen to purge or ventilate fuel
tank or fuel system components. Fuel,
either vapor or liquid, will violently
react with an oxygen rich atmosphere.
(2). Ventilate fuel tank with an inert gas,
such as nitrogen, or low pressure
compressed air applied through filler
neck.
A. Vent Tube/Emergency Valve Assembly
Removal
(Ref. Figure 403)
(1). Unbolt and remove right fuel cell access
cover.
(2). Remove right foot support, controls,
and fuel vent access panels.
(3). Remove right seat from crew compart
ment.
(4). Move collective pitch stick full down.
(5). In passenger/cargo compartment;
remove right and left fuel tank floor
access panels.
(6). Remove lockwire from vent connector
hoses and main rotor mast pan drain
tube.
CSP-HMI-2
(7). Remove vent tube/emergency valve

assembly attaching hardware. Remove
flexible tubing from lower vent tube tee.
(8). Rotate emergency shutoff valve inboard
and slip assembly down over landing
gear structure. Remove tube assembly
through controls access panel opening.
(9). Unclamp flexible tubing from side vent
fairing. Remove tubing through controls
access opening.
B. Forward Vent Crossover Fitting Removal
(Ref. Figure 403)
(1). Unbolt forward vent crossover fitting
flanges.
(2). Remove fitting, clamps, seals and
washers.
(3). Cover cell vent fittings and aft vent line
tube openings.
C. Aft Vent Crossover Fitting Removal
(Ref. Figure 403)
NOTE: Left and right fuel cell access covers

must be removed to get at aft vent crossover
U-tube attaching hardware.
(1). Remove left and right fuel cell floor
access panels.
(3). With 250-C20 Series Engines or
250-C30 Engine With Optional Mainte
nance Fuel Pump: Unclamp start pump
wire harness and disconnect plug from
cell cover receptacle.
brackets.
28-00-00
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Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
PAN
DRAIN TUBE
LOCKWIRE
CLIP
(2 PLACES)
BOLT
WASHER
LACING CORD
(TYPICAL)
WASHER
BOLT
CLAMP
WASHER
BOLT
WASHER
NUT
FROM AFT VENT
VENT TUBE
SIDE VENT FAIRING
SCREW
LOCKWIRE
(TYPICAL)
CONNECTOR HOSE
(NOTE 2)
WASHER
(4.06-5.20 NM)
WASHER
CLAMPS
SCREW
SUPPORT COIL
CLIP
WASHE
R
FUEL VENT
COVER
INTERCONNECT
FITTING
ANTI-SIPHON
HOLES
FLEXIBLE TUBING
(NOTE 1)
SEAL WASHER
STAND-OFF
WASHER (TYP)
SEAL WASHER
LOWER VENT FAIRING
FWD INTERCONNECT AND

EMERGENCY VALE ASSY
NOTES:
1. ROUTED THRU LANDING GEAR BRACE.
2. NOT TO BE PAINTED.
G28 0003 1B
Figure 403. Vent System (Sheet 1 of 2)

Page 406
Revision 19
28-00-00
MAINTENANCE MANUAL
VALVE CLOSED WHEN TILT
EXCEEDS 45 FROM VERTICAL
CSP-HMI-2
INTERCONNECT
CLAMP
OVERBOARD
VALVE SEAT
HOSE
SEAL
WASHER
VALVE
CELL
(REF)
TUBE
WEIGHT
FUEL VENT
IN
NUT, TORQUE; 40-60 IN. LB

(4.52-6.78 NM)
G28-0003-2B
EMERGENCY VENT
SHUTOFF VALVE
AFT INTERCONNECT
Figure 403. Vent System (Sheet 2 of 2)
CAUTION
mitter float arm.
D Do not damage cell cover bonded seal.
Handle fuel cell covers with care. Prying
covers from cell openings or rough handl
ing may damage seal or cell fitting.
(8). Unbolt and prop fuel cell access cover
(9). Use a backup wrench on valve and
shutoff valve. Move fuel cell cover to get
at remaining hardware.
(10). Reach back inside cells and remove
vent interconnect nuts. Separate aft
U-tube interconnect from cells.
(11). Unclamp and remove hose between
U-tube interconnect tee and straight
tube. Remove U-tube interconnect.
Discard sealwashers.
(12). Cap tube and cell openings.

(13). Inspect all vent system components
(Ref. Fuel Tank Vent System Inspec
tion).
D. Fuel Tank Vent System Installation
(Ref. Figure 403)
Item
CM124
Nomenclature
Kerosene

quately ventilated.
(1). Wipe forward and aft cell vent
fittings and crossover tube flanges
clean with kerosene (CM124) or
equivalent on a clean shop towel.
Wipe dry.
28-00-00
Page 407
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
NOTE: Do not lubricate fitting sealwashers.

Lubricants may cause seal cold flow and
subsequent leakage.
(2). Install new sealwashers on aft vent
tube ends. Insert tube ends through cell
fittings. Reach inside cell and install
nuts.
(3). Torque aft vent U-tube interconnect
(4). Install hose and clamps between
interconnect U-tube and straight tube.
(5). Position new sealwashers on cell
forward vent fittings. Slip vent tube
into cell fitting.
NOTE: Permatex Form-A-Gasket No.1 may be

used to hold metal stand-off washers in
place.
(6). Sandwich one AN960-10 washer on
each side of seal washer between vent
tube flanges and cell fittings. Align
washers with bolt holes. Install bolts
with one washer under each bolt head.
(7). Torque forward vent interconnect tube
flange bolts to 36 - 46 inch-pounds
(4.07 - 5.20 Nm).
(8). Connect powerplant supply tube to Sta.
124.00 bulkhead elbow. Loosely install
tube support clamps, screws, washers
and nuts. Using backup wrench on
bulkhead elbow so it will not rotate,
torque tube nut to 230 - 260 inchpounds (25.99 - 29.38 Nm).
(9). Install fuel cell covers (Ref. Fuel Cell
Cover Installation).
Page 408
Revision 19
28-00-00
E. Vent Tube/Emergency Valve Assembly

Installation
(Ref. Figure 403)
(1). Move collective pitch stick full down.
(2). Remove protective covers from fittings
and tubes.
(3). Work emergency valve and vent tube
assembly through landing gear brace
then into position in tunnel.
(4). Insert vent tube assembly in bottom
vent fairing.
(5). Loosely install vent tube support
clamps, washers and bolts.
(6). Install flexible tubing between side vent
fairing and vent tube assembly tee.
(7). Clamp flex tube ends in position with
two or three wraps of lockwire.
(8). Tighten vent tube assembly support
clamp and bracket fasteners.
(9). Install and secure remaining vent
system connector hoses with lockwire.
(10). Operate all flight controls through full
range of motion to ensure no interfer
ence exists between control linkages
and vent system. No interference is
allowed. Adjust vent system hardware
as required.
(11). Install fuel vent access panel.
(12). Install controls access and foot support
panels.
(13). Install crew seat.
MAINTENANCE MANUAL
4. Fuel Supply Lines Replacement
A. Fuel Supply Lines Removal
(Ref. Figure 404)
CSP-HMI-2
(4). Apply a torque alignment stripe to fuel

line tube, hose and fitting fasteners.
5. Start Pump Replacement (Model
250C20B/R2 / 250C30 Engine Installation)
NOTE: Use these start pump removal and

quately ventilated.
installation procedures for helicopters with

250-C30 engines equipped with optional
maintenance fuel pump.
CAUTION
damage.
suitable container.
(2). Disconnect, remove and cap fittings and
lines as required.
B. Fuel Supply Lines Installation
(Ref. Figure 404)
(1). Install and torque engine fuel supply
lines (Ref. Table 401).
NOTE: It may be necessary to install a peelable

shim washer between the Sta. 124.00 fire
wall and the bulkhead elbow washer to ob
tain the proper clocking angle and clearance
needed for line installation.
(2). Install Sta. 124.00 firewall elbow, with
jam nut on forward side of firewall, flat
of nut against stiffener, and washer
against elbow. Torque elbow to 145 155 inch-pounds (16.38 - 17.51 Nm).
Ensure elbow is clocked 12 - 16 to the
right from vertical after torquing.
(3). Connect flexible drain lines to drain
valves and clamp in place with lock
wire.
A. Start Pump Removal

(Ref. Figure 404)

quately ventilated.
hoses, tubes and fittings as the parts are re
CAUTION

suitable container.
(4). Unclamp start pump wire harness and
disconnect plug from cell cover recep
tacle.
brackets.
28-00-00
Page 409
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
Table 401. Fuel Line Torque Values

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

mitter float arm.
pressure port union threads. Install

O-ring on union. Install union in start
pump pressure port and torque to 280 305 inch-pounds (31.64 - 34.46 Nm).
D Handle fuel cell covers with care. Prying

ing may damage the cover seal or cell fit
ting.
(2). Attach fuel supply hose to start pump

pressure port union. Torque hose nut to
230 - 260 inch-pounds (25.99 - 29.38
Nm).
CAUTION

CAUTION
(10). Use a backup wrench on valve and

shutoff valve.
D Ensure start pump wire lead is wrapped

around or tie-wrapped to fuel supply hose
so that there is no possibility of its interf
ering with fuel quantity transmitter float
mechanism. Ensure electrical connec
tions will not be strained by G-induced
hose movements.
(11). Remove pump electrical receptacle from

cover. Remove fuel cell cover.
D Do not mark torque alignment stripes on

fuel cell internal hardware.

(12). Unbolt fuel pump from sump mount

plate. Remove fuel pump and hose.
NOTE: Use only MS3367 ty-raps inside fuel
(13). Remove hose and union from pump

pressure port.
(3). Tie-wrap or wrap pump wire around

supply hose. Secure wire with ty-raps
as required.
B. Start Pump Installation

(Ref. Figure 404)
Item
Nomenclature
CM114
Petrolatum
(1). Apply a thin coat of petrolatum

(CM114) to a new O-ring and pump
Page 410
Revision 19
28-00-00
tanks.
(4). Clean start pump and sump plate

mount contact surfaces to establish an
electrical bond per requirements of FAA
publication, EA-AC43.13-1A and 2A.
(5). Install start pump on sump plate with
bolts and washers. Torque bolts to 36 46 inch-pounds (4.07 - 5.20 Nm).
(6). Install fuel cell cover (Ref. Fuel Cell
Cover Installation).
MAINTENANCE MANUAL
CSP-HMI-2
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

(4.06-5.20 NM)
HOSE NUT, TORQUE;

230-260 IN. LB
(25.99-29.38 NM)
WASHER
UNION, TORQUE;
280-305 IN. LB
(31.64-34.46 NM)
FUEL PICKUP FITTING

START PUMP
HOSE NUT, TORQUE;

230-260 IN. LB
(25.99-29.38 NM)
O-RING
TANK SUMP PLATE
STRUCTURE

(4.06-5.20 NM)
UNION, TORQUE;
280-305 IN. LB
(31.64-34.46 NM)
FUEL CELL
WASHER
O-RING
O-RING
WASHER
TANK SUMP PLATE
TANK SUMP DRAIN VALVE,

TORQUE; 95-105 IN. LB
(10.73-11.86 NM)

(4.06-5.20 NM)
FUEL PICKUP INSTALLATION
(369FF)
O-RING
WASHER
TANK SUMP DRAIN VALVE,
(10.73-11.86 NM)

(4.06-5.20 NM)
START PUMP INSTALLATION

G28-0004-1C
Figure 404. Start Pump and Fuel Lines Installation (Sheet 1 of 4)
28-00-00
Page 411
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
TOP VIEW
FUEL HOSE
BATHTUB FITING
START PUMP WIRE

FLOAT ASSEMBLY
START PUMP
SIDE VIEW
NOTE:
WRAP WIRE AROUND FUEL INLET HOSE TO PREVENT
INTERFERENCE WITH FLOAT.
G28-0004-2

Page 412
Revision 19
28-00-00
MAINTENANCE MANUAL
CSP-HMI-2
TOP VIEW
FUEL HOSE
BATHTUB FITING
START PUMP WIRE
FLOAT ASSEMBLY
START PUMP
SIDE VIEW
NOTE:
G28-0004-3
28-00-00
Page 413
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
TOP VIEW
FUEL HOSE
BATHTUB FITING
START PUMP WIRE
FLOAT ASSEMBLY
START PUMP
SIDE VIEW
NOTE:

Page 414
Revision 19
28-00-00
G28-0004-4
MAINTENANCE MANUAL
6. Fuel Quantity Transmitter Replacement
A. Fuel Quantity Transmitter Removal
(Ref. Figure 404)

quately ventilated.
suitable container.
(2). Ventilate fuel tank with an inert gas
such as nitrogen or low pressure
neck.
Unclamp wire harness.
CSP-HMI-2
(7). Calibrate quantity transmitter as

required (Ref. Fuel Quantity Transmit
ter Calibration and Adjustment).
B. Fuel Quantity Transmitter Installation
(Ref. Figure 404)
Item
Nomenclature
CM124
Kerosene
(1). Wipe fuel quantity transmitter flange

and cell fitting clean with kerosene
(CM124) on a clean lint free cloth. Wipe
parts dry.
(2). Position fuel quantity transmitter and
flange gasket on cell with float inboard
and clear of obstructions.
(3). Install screws and washers. Progres
sively torque screws to 20 - 25 inchpounds (2.26 - 2.82 Nm). Lockwire
screws.
(4). Attach fuel quantity electrical connec
tor to receptacle. Lockwire connector.
(5). Perform a Fuel Quantity Transmitter
Functional Check.
(6). Install left fuel tank floor access panel
(Ref. Fuel Cell Cover Installation).
7. Fuel System Drain Valve Replacement
A. Fuel System Drain Valve Removal
CAUTION
mitter float arm.
stall a cover over quantity transmitter
cell opening. Bag small parts to prevent
loss or damage.
bly out of cover opening. Discard
gasket.
(6). Inspect fuel quantity transmitter as
required (Ref. Fuel Quantity Transmit
ter Inspection).

quately ventilated.
Helicopter must be defueled and
drained prior to removing tank
sump drain valve.
CAUTION
(1). Defuel helicopter, as required. Drain

remaining fuel from tank sump drain
valve into a suitable container.
28-00-00
Page 415
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2
(2). Remove lockwire from tank sump drain

valve.
(3). Using appropriate socket or wrench,
remove drain valve.
B. Fuel System Drain Valve Installation
Item
Nomenclature
CM114
CM124
CM702
Petrolatum
Kerosene
Lockwire CRES
(1). Replace drain valve O-ring packings.

Lubricate packings with kerosene
(CM124), petrolatum (CM114) or jet
fuel.
(2). Install and torque sump drain valve to
95 - 105 inch-pounds (10.73 - 11.86
Nm). Lockwire valve.
(4). Refuel helicopter.
(5). Check drain valve for leakage.
(6). Apply external power.
(7). In crew compartment; set battery
switch to EXT PWR position.
(8). Push fuel shutoff valve control knob in
to open valve.
(9). With 250-C20B/R2 Engine: Set START
PUMP switch ON to pressurize fuel
system.
8. Fuel Cell Replacement
CAUTION
D Do not work on Uniroyal fuel cell in ambi
ent temperatures below 50F (10C).
D Do not work on Engineering Fabric Corp.
fuel cell in ambient temperatures below
70F (21C).
Page 416
Revision 44
28-00-00
A. Fuel Cell Removal


quately ventilated.
CAUTION

suitable container.

(2). Ventilate fuel tank with low pressure
forced air or an inert gas such as
nitrogen through filler neck.
(3). Remove right and left fuel tank access
panels from passenger/cargo compart
ment floor.
NOTE: The following procedures are required

to access and separate the fuel cell intercon
nect fitting and vent system aft crossover
before either cell can be removed from its
bay.
shutoff valve and firewall Sta. 124.00
bulkhead elbow. Using a backup
wrench on bulkhead elbow so it will not
rotate, disconnect and remove tube.
Fuel Pump: Unclamp start pump wire
harness and disconnect plug from cell
cover receptacle.
MAINTENANCE MANUAL
brackets from airframe structure.
CAUTION
mitter float arm.
D Handle fuel cell covers with care. Prying
ing may damage the cover seal or cell fit
ting.
shutoff valve. Move fuel cell cover to get
at remaining hardware.
Fuel Pump: Unbolt start pump from
sump mount plate. Remove start pump,
hose and cell cover. Remove pump
electrical receptacle from cover.
(13). With 250-C30 Engine: Unbolt fuel inlet
fitting from sump plate. Remove fuel
inlet fitting, hose and cell cover.
(14). Unbolt and remove right fuel cell access
cover.
(15). Mop up any remaining fuel in both cells
with clean lint free cloth. Purge fuel
cells with dry, forced air or inert gas.
(16). Have an assistant hold the male end of
the cell interconnect fitting with the
special spanner wrench. Disassemble
fuel cell interconnect fitting (Ref.
Figure 405). Discard packing.
(17). Remove aft vent crossover U-tube nuts
from inside cells.
(18). Remove forward vent crossover tube
flange bolts and washers (Ref.
Figure 403).
CSP-HMI-2
NOTE: At this point either cell may be re

moved, as required.
(19). Remove left fuel cell as follows:
(a). Remove cell suspension cords (Ref.
Figure 406).
(b). Remove and discard forward and aft
vent sealwashers.
(c). Lift inboard and outboard cell clips at
each end of baffle support rod out of
airframe hangers (Ref. Figure 405).
(d). Inside cell, work baffle support rod
ends out of cell nipples (Ref.
Figure 405, detail B).
(e). Remove support rod and baffle.
Cells are thin-walled and frag
ile. Avoid snagging or dragging
cell over pointed or sharp edges. Do not
scratch or nick any of the cell's metal fit
tings.
CAUTION
(f). Collapse and fold cell lengthwise and

remove through floor access opening.
(20). Remove right fuel cell as follows:
(a). Remove fuel filler cap and shield.
Unclamp and remove filler from cell
filler neck.
(b). Remove cell suspension cords.
(c). Remove and discard forward and aft
vent sealwashers.
(d). Lift inboard and outboard cell clips at
each end of baffle support rod out of
airframe hangers.
(e). Inside cell, work baffle support rod
ends out of cell nipples.
(f). Remove support rod and baffle.
tings.
CAUTION
(g). Collapse and fold cell lengthwise and

28-00-00
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Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
B. Fuel Cell Installation
(6). Insert baffle rod ends in nipples.
Item
Nomenclature
CM114
CM124
CM809
Petrolatum
Kerosene
Nylon cord
Item
Special Tools
Nomenclature
ST802
Spanner wrench

quately ventilated.
NOTE:
D Discard used O-rings and sealwashers.
Apply a thin coat of petrolatum (CM114)
to all new O-rings except cell vent system
sealwashers and interconnect fitting gas
ket.
D Always test and inspect a repaired fuel
cell for leaks using soap bubble, phe
nolphthalein or liquid stand method be
fore installing the cell in the helicopter.
(1). Air-vacuum all debris from cell bays.
Ensure compartment liner will protect
cell from airframe points and edges.
Repair liner as required.
(2). Wipe left and right cell interconnect
fitting halves clean with kerosene
(CM124) on a clean lint free shop towel.
Wipe dry.
(3). Fold cell lengthwise and position in bay
through floor opening and unfold cell.
(4). Align cell openings with airframe
openings.
(5). Insert baffle support rods through
baffle tabs (Ref. Figure 405)..
Revision 19
(8). Wipe cell forward and aft vent fittings

and vent tube flanges clean with
kerosene (CM124) or equivalent on a
clean shop towel. Wipe dry.
NOTE: Do not lubricate fitting sealwashers.
Page 418
(7). Attach baffle external support hooks to

airframe hangers.
28-00-00
Lubricants may cause seal cold flow and

subsequent leakage.
(9). Install new sealwashers on aft vent
tube ends. Insert tube ends through cell
fittings and install nuts finger tight. Do
not torque at this time.
(10). Position new sealwashers on cell
forward vent fittings. Slip cell fitting
over vent tube.
NOTE: Permatex Form-A-Gasket No. 1 may

be used to hold stand-off washers in place.
(11). Sandwich one AN960-10 washer on
each side between vent tube flanges
and cell fittings. Align washers with
bolt holes. Install bolts with one washer
under each bolt head and engage
several threads to keep bolt in place. Do
not torque bolts at this time.
(12). Fasten fuel cell sump plate to airframe
with washers and bolts. Torque bolts to
36 - 46 inch-pounds (4.07 - 5.20
Nm). Lockwire bolts.
(13). Install a new O-ring on sump drain
valve. Install valve and torque to 95 105 inch-pounds (10.73 - 11.86 Nm).
Lockwire valve.
NOTE: Do not lubricate fuel cell interconnect

fitting gasket. Lubrication may cause seal
cold flow and subsequent leakage.
(14). Thread gasket and nut onto cell
interconnect fitting. While having an
assistant hold the opposite end of
fitting with spanner wrench (ST802)
tighten nut. Gap between nut and
female fitting shall not be more than
0.005 inch (0.127 mm) after tightening.
(15). Connect powerplant supply tube to
firewall Sta. 124.00 bulkhead elbow.
Loosely install tube support clamps,
MAINTENANCE MANUAL
screws, washers and nuts (Ref.
Figure 404, detail A). Using a backup
wrench on bulkhead elbow so it will not
rotate, torque tube nut to 230 - 260
inch-pounds (25.99 - 29.38 Nm).
(16). Torque aft vent U-tube interconnect
(17). Torque forward vent interconnect tube
flange bolts to 36 - 46 inch-pounds
(4.07 - 5.20 Nm) (Ref. Figure 403).
(18). Install nylon support lacing (CM809).
Anchor both ends of cord with a bowline
knot (Ref. Figure 406).
Fuel Pump: Install union in start pump
pressure port with a new O-ring
packing. Torque union to 280 - 305
inch-pounds (31.64 - 34.46 Nm) (Ref.
Figure 404, detail B). Attach fuel
supply hose to start pump pressure port
union. Torque hose nut to 230 - 260
inch-pounds (25.99 - 29.38 Nm).
Ensure start pump wire lead is
wrapped around or tie-wrapped
(using only MS3367 Ty-Raps) to fuel supply
hose so that there is no possibility of its in
terfering with fuel quantity transmitter
float mechanism. Ensure electrical connec
tions will not be strained by G-induced hose
movements.
CAUTION
(20). Wrap pump wire around supply hose or

secure wire with ty-raps as required.
(21). Clean start pump and sump plate
mount contact surfaces to establish an
electrical bond per requirements of FAA
(22). Install start pump on sump plate with
(23). With 250-C30 Engine: Attach fuel inlet
fitting to cell sump plate with bolts and
washers. Torque bolts to 36 - 46
CSP-HMI-2
(24). Install filler on right fuel cell filler neck

with clamp and fuel filler shield. Install
filler cap (Ref. Figure 405).
C. Fuel Cell Cover Installation
Item
Nomenclature
CM114
CM124
Petrolatum
Kerosene
(1). Inspect both cell cover seals for debond

ing, nicks or cuts and any other damage
having a leak producing potential.
Replace covers as required.
(2). Wipe fuel cell and cover sealing sur
faces clean with kerosene (CM124) on a
clean lint free cloth.
(3). Install right cell cover bolts and
washers (Ref. Figure 405). Progressive
ly torque cover bolts to 70 - 90 inchpounds (7.91 - 10.17 Nm) in a cross
pattern.
(4). Apply a coating of petrolatum (CM114)
to a new fuel shutoff valve/cover
sealwasher. Install valve on cell cover
with sealwasher next to valve body and
valve properly aligned to make connec
tion with valve control cable. Install
and torque valve jamnut to 240 - 280
inch-pounds (27.12 - 31.64 Nm) (Ref.
Figure 402).
Fuel Pump: Plug start pump wire
harness cell cover hole with a bulkhead
union, sealwasher inside cover and a
plain washer outside. Install jamnut
and torque to 120 - 150 inch-pounds
(13.56 - 16.95 Nm). Install cap outside
of cell. Torque cap to 120 - 150 inchpounds (13.56 - 16.95 Nm).
(6). Position cover over cell opening.
Connect fuel supply hose to fuel shutoff
valve. Torque hose nut to 230 - 260
inch-pounds (25.99 - 29.38 Nm).
Ensure hose will not be twisted when
cover is installed.
28-00-00
Page 419
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
0.005 IN. (0.127 MM) MAXIMUM GAP

BETWEEN NUT AND FITTING
NUT
CELL INTERCONNECT
FITTING
HELICOPTER
CL
GASKET
NIPPLE
BAFFLE
SUPPORT ROD
FUEL CELL INTERCONNECT
BOLT, TORQUE;
70-90 IN. LB
(7.91-10.17 NM)
GROMMET
FILLER
FUEL FILLER CAP
BAFFLE SUPPORT HOOK
RIGHT FUEL CELL

ACCESS COVER
FUEL FILLER SHIELD
BAFFLE SUPPORT ROD

(2) (TYP)
FUEL
CELL
FUEL TANK FILLER NECK
CLAMP
NYLON CELL
SUPPORT LACING
(TYP)
BAFFLE SUPPORT
(CROSS SECTION VIEW)
AFT VENT CELL

INTERCONNECT
TANK BAFFLE
(TYP)
STA. 124.00
BULKHEAD
NUT
CLAMP
(TYP)
CELL INTERCONNECT
FITTING
VENT TUBE
EMERGENCY
VALVE ASSY
LEFT FUEL CELL

ACCESS COVER
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 420
Revision 19
28-00-00
MAINTENANCE MANUAL
CSP-HMI-2
CELL TOP ATTACHMENT

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

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

Fuel Pump: Install start pump wiring
harness receptacle on fuel cell cover.
(8). Install three support brackets on Sta.
91.00 and 102.00 floor cross-members
with washers and screws. Torque
screws to 20 - 25 inch-pounds (2.26 2.82 Nm).
(9). Finger tighten fuel supply tube nut
onto fuel shutoff valve. Position control
cable and electrical harness clamps on
cover.
(10). Install cover bolts and washers. Install
drilled-head bolt one bolt hole inboard
of pump electrical receptacle. Progres
sively torque cover bolts to 70 - 90
inch-pounds (7.91 - 10.17 Nm) in a
cross pattern.
(11). Lockwire electrical receptacle nut to
drilled bolt.
(12). Inspect fuel quantity transmitter flange

gasket for condition. Replace gasket if
damaged or deteriorated. Position fuel
quantity transmitter in cell with float
inboard and clear of obstacles. Install
screws and washers. Progressively
torque screws to 20 - 25 inch-pounds
(2.26 - 2.82 Nm). Lockwire screws.
(13). Torque power plant fuel supply tube
nut to 230 - 260 inch-pounds (25.99 29.38 Nm). Tighten supply tube clamp
fasteners.
(14). Slip control cable through hole in fuel
(15). Rig cable control system (Ref. Fuel
Shutoff Valve Control Cable Installa
tion).
(16). Attach fuel quantity electrical connec
tor to receptacle. Lockwire connector.
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Revision 44
CSP-HMI-2
MAINTENANCE MANUAL

Fuel Pump: Attach start pump electri
cal connector to receptacle. Lockwire
connector.
NOTE: To ensure that the C30 engine installa

tion fuel system is free of leaks you must
perform a vacuum leak test.
(18). Perform a vacuum leak inspection on
all helicopter models.
Page 422
Revision 44
28-00-00

Fuel Pump: Perform a start pump
operation and system pressurization
check with a concurrent leak inspection
(Ref. Start Pump Operational Check
(Model 250-C20 Series Engines).
(21). Install left and right cell access panels
on cargo compartment floor.
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
ADJUSTMENT/TEST
1. Fuel Level Low Caution Light System Test
Item
Special Tools
Nomenclature
N/A
Inclinometer, Sperry Model 45
WARNING
D FUEL LEVEL LOW warning light-on
point, either 35 pounds for commer
cial helicopters or 70 pounds fuel re
maining for noncommercial ma
chines, must comply with the fuel
low level caution light calibration
specified in the Pilot's Flight Manual.
D A 70 pound fuel level low warning
light calibration is not approved for
commercial applications.
(1). Refuel to bring fuel quantity above 35
or 70 pound low level warning point, as
appropriate.
previously installed, replace quantity

transmitter and calibrate system.
(9). Ground fuel quantity transmitter
terminal D to airframe with a jumper
wire.
(10). FUEL LEVEL LOW caution lamp
should show a steady bright light.
(11). If the light is intermittent or does not
come on at all, disconnect all power and
run a continuity check on the warning
light and wiring between the INSTR
circuit breaker and transmitter.
(12). If the wiring and light check out,
remove and bench check the transmit
ter assembly (Ref. Fuel Quantity
Transmitter Calibration and Adjust
ment).
2. Fuel Quantity Transmitter Calibration and
Adjustment
(Ref. Figure 501)
(2). Plug in and switch on 24 - 28 Vdc

external power.
(3). Set battery switch to EXT PWR.
Item
Special Tools
Nomenclature
(4). Reset INSTR circuit breaker.
N/A
Test harness and No. 328 lamp
(5). Set caution and warning light dimmer

control on BRT.
(6). Test caution and warning light array.
Replace lamps as required.
(7). With known fuel quantity above 35 or
70 pounds, caution lamp must be off.
Check warning light to ensure it does
not glow or flicker. A glowing caution
lamp with fuel quantity above the low
level warning point indicates that
current is leaking past the low level
warning transistor (switch) through the
caution lamp. This problem is corrected
by installing a resistor in the transmit
ter warning light circuit (Ref. Fuel
System Repairs). If resistor has been
Prevent fuel vapor accumu
WARNING lation, ignition and fire. At
tach helicopter to an approved electri

cal ground. Switch OFF and disconnect
external power and battery before
opening fuel system. Perform work in
an open, well ventilated area away
from all potential ignition sources. Use
only nonsparking tools and explosion
proof work lights.
(1). Remove fuel quantity transmitter from
tank. Install a cover on cell opening.
(2). Fabricate a stand to support quantity
transmitter level about 11 inches (28
cm) above work table surface. Support
stand must allow access to float arm.
28-00-00
Page 501
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
NO. 328
LAMP
+
BLU
RED
Q
24 VDC
POWER
SUPPLY
-
BLK
BLK
P251
CONNECTOR
FUEL QUANTITY
TRANSMITTER
TEST CONNECTIONS
CONNECTOR
1.75 IN. (4.45 CM)

DIA (MAX.
SEALANT
ENVELOPE)
0.75 IN. (4.45 CM) MAX.
SEALANT ENVELOPE
FULL
FLOAT STOP (FULL)
SPRING
10.08 IN.
(25.60 CM)
RADIUS
BRACKET
FLOAT STOP
(EMPTY)
8.99-9.11 IN.
(22.84-23.134CM)
FLOAT
SPRING CONTACT
2.15 IN. (5.46 CM)
(NOTE 2)
GROUND TERMINAL
EMPTY
B
TRANSISTOR SWITCH
(ON UNDERSIDE)
TANK UNIT
CONNECTIONS
CALIBRATION 369A4245 (EARLY UNIT)

NOTES:
1. CAUTION LIGHT ON, 35 LBS REMAINING.
NOT APPROVED FOR COMMERCIAL
APPLICATION.
1.25 IN.
(3.175 CM)
(NOTE 1)
G2800071A
Figure 501. Fuel Quantity Transmitter Calibration (Sheet 1 of 2)

Page 502
Revision 19
28-00-00
MAINTENANCE MANUAL
CONNECTOR
CSP-HMI-2
0.62 IN.
(15.75 MM)
MOUNTING FLANGE
FLOAT STOP
(FULL)
FULL
BOTTOM OF FLOAT
SPRING
10.08 IN.
(25.60 CM)
RADIUS
FLOAT STOP
(EMPTY)
8.41-8.45 IN.
(21.36-21.46 CM)
2.13-2.17 IN.
(5.41-5.51 CM)
(NOTE 2)
SPRING CONTACT
(NOTE 1)
0.91-0.95 IN.
(23.11-24.13 MM)
FLOAT
NOTES:
NOT APPROVED FOR COMMERCIAL
EMPTY
CALIBRATION 369D296303 (CURRENT UNIT)
G28-0007-2A
Figure 501. Fuel Quantity Transmitter Calibration (Sheet 2 of 2)

A. Fuel Level Calibration
(1). Let float arm rest on lower stop.
(2). Set an ohmmeter on its low resistance
scale. Measure resistance across
connector pins B and H.
Part number 369A4245 (early) quantity
transmitter resistance must be 0 - 3
ohms.
P/N 369D296303 (current) units must
register 0.10 - 2.00 ohms.
(3). Bend float stop down to decrease, or up
to increase resistance.
(4). Raise float arm to contact upper stop.
(5). On 369A4245 (early) quantity transmit
ters only, measure resistance between
steel wire spring support bracket and
mounting flange. Resistance must be
greater than 2 megohms.
(6). On part Nos. 369A4245 (early) and

369D296303 (current) transmitters:
(a). Attach ohmmeter leads to connector
pins B and H.
(b). Raise float arm against upper stop.
(c). Indicated resistance shall be 88 - 95
ohms.
(d). Bend stop to adjust resistance value.
(e). Measure float travel between empty
and full stops. Ensure travel is
within limits (Ref. Figure 501).
(7). Disconnect ohmmeter.
B. Fuel Level Low Warning Light Calibration
(1). Fabricate test harness incorporating a
No. 328 lamp bulb and P251 female
connector half. Alternatively, fabricate
test wires with individual insulated
tubular pin connectors.
28-00-00
Page 503
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
(2). Attach test harness to transmitter

connector pins D and H and power
source.
(5). Check P/N 369D296303 and

369D296303-701 (current) transmitter
units as follows:
(a). Hold float arm between stops. Test
lamp must be off. A glowing lamp
indicates that current is leaking past
transistor (lamp switch).
(3). Switch on 24 Vdc power.

(4). Check P/N 369A4245 (early) transmit
ter units as follows:
The problem is corrected by installing

a 510 ohm resistor in the transmitter
caution light circuit (Ref. Fuel
System Repairs).
(a). Hold float arm between stops. Test

lamp must be off. A glowing lamp
indicates that current is leaking past
transistor (lamp switch). The prob
lem is corrected by installing a 510
ohm resistor in the transmitter
caution light circuit (Ref. Fuel
System Repairs). If resistor has been
previously installed, replace quantity
transmitter.
If resistor has been previously

installed, replace quantity transmit
ter.
(b). Lower float arm to just touch bracket
supported steel wire.
(c). Test lamp should come on.
(b). Lower float arm until it just contacts

bracket supported steel wire:
(d). Mark arm/float centerline position on

a ruler or stick where lamp comes on.
(c). Test lamp should come on.
(e). Lower float. Mark ruler at arm/float

centerline position with float bot
tomed on stop.
(d). Mark arm/float centerline position on

a ruler or stick at point where lamp
comes on.
(f). Measured distance between upper

and lower marks shall be:
(e). Lower float. Mark ruler at arm/float

centerline position with float bot
tomed on stop.
0.91 - 0.95 inch (23.11 - 24.39 mm)

for 35 pounds (nominal) fuel remain
ing.
WARNING
D FUEL LEVEL LOW warning light-on
point, either 35 pounds for commer
cial helicopters or 70 pounds fuel re
maining for noncommercial ma
chines, must comply with the fuel
low level caution light calibration
specified in the Pilot's Flight Manual.
D A 70 pound fuel level low warning
light calibration is not approved for
commercial applications.
(f). Distance between upper and lower
marks shall be:
1.25 inch (3.18 cm) for 35 pounds
(nominal) fuel remaining.
2.15 inch (5.46 cm) for 70 pounds
(nominal) fuel remaining.
Page 504
Revision 19
28-00-00
2.13 - 2.17 inch (5.41 - 5.51 cm) for

70 pounds (nominal) fuel remaining.
(6). Bend transmitter bracket spring wire to
adjust light-on position as required.
(7). Check that lamp operation and float
dimensions are within specified
tolerances.
(8). Disconnect electrical power and test
equipment.
3. Fuel Quantity Transmitter Functional
Check
Item
Special Tools
Nomenclature
N/A
Inclinometer, Sperry Model 45
MAINTENANCE MANUAL
Avoid fuel vapor accumula
WARNING tion, ignition and fire. Use

only non-sparking tools and explosion
proof work lights. Attach helicopter to
an approved electrical ground. Switch
OFF all electrical power. Disconnect
opening fuel system. Ensure work area
is adequately ventilated.
(1). Attach helicopter to an approved
electrical ground.
(2). Defuel and drain fuel tank.
(3). Locate inclinometer on rear deck
between Sta. 100 and 104.
(4). Jack and level helicopter or spot
helicopter on level ground.
(5). Jack helicopter to get a 2 nose down
attitude on the inclinometer. Stabilize
helicopter with blocks as required.
(6). Reset INST and PNL LT circuit
breakers.
(7). Apply external power. Set battery
switch to EXT PWR.
NOTE: All gauge readings are taken from the

centerline of the fuel quantity indicator
pointer.
(8). Check that fuel quantity gauge needle
points to empty, E with the pointer
centerline between the outer and inner
edge of the E graduation mark. Check
that FUEL LEVEL LOW warning
light is on.
NOTE: Do not bend float arm for adjustment of

fuel quantity indicating system.
(9). If adjustments are required; shut down
external electrical power, and remove
transmitter, bend float stops as re
quired and re-install transmitter.
(10). Pump seven gallons of fuel into tank.
(11). Apply external power. Set battery
switch to EXT PWR.
FUEL LEVEL LOW warning light
should be out, and gauge should
indicate approximately 45 pounds.
CSP-HMI-2
(12). Disconnect fuel supply hose from

engine.
(13). Have an assistant direct fuel hose into
a suitable 10 gallon (37.85 L) container.
Push fuel control valve knob in to open
fuel shutoff valve.
(14). (C20 Series Engines) Set fuel start
pump switch to START PUMP.
(15). (C30 Engine) Attach a siphon pump to
fuel supply hose to suck fuel out of
tank.
(16). Pump 0.5 - 1.5 gallons (1.89 - 5.68 L),
3.0 - 10.0 pounds (1.36 - 4.54 kg) out of
the fuel tank while observing fuel
gauge for erratic or hung movement.
Fuel quantity gauge needle shall range
between 34 - 42 pounds.
NOTE:
D (C20 Series Engines) A stuck needle on
a new, calibrated and tested gauge may be
due to transmitter float contact with the
start pump wire, pump or supply hose.
D (C30 Engine) Transmitter float interfer
ence may be caused by the supply hose or
sump pickup fitting.
(17). Loosen fuel quantity transmitter
mounting flange screws. Rotate
transmitter clockwise as far as it will
move and tighten screws. Check gauge
needle position.
(18). If float interference problem persists,
remove quantity transmitter and
determine action required to eliminate
problem; i.e. reposition transmitter
float arm, fuel supply hose and, or start
pump wire.
(19). Install transmitter and repeat function
al check.
(20). When 10 pounds (4.54 kg), 1.53 gallons
(5.79 L) has been pumped, needle
pointer should be aligned on center of
the 35 pound red dot mark and FUEL
LOW caution light should come on.
(21). Drain remaining fuel and observe that
gauge needle falls to empty (E) as tank
runs dry.
(22). Repeat adjustments as required.
Additional adjustments to float arm or
28-00-00
Page 505
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2
low level contact wire requires a

verification check and repetition of the
entire check procedure sequence.
(23). Connect fuel supply hose to engine inlet
port. Torque hose nut to 230 - 260
inch-pounds (25.99 - 29.38 Nm).
(24). Install quantity transmitter (Ref. Fuel
Quantity Transmitter Installation).
4. Fuel Filter (Bypass) Caution Light
Pressure Switch Test
WARNING
D Air in the fuel system will cause a
power reduction or flameout. Do a
fuel system vacuum leak check and
system air bleed after opening fuel
system to atmosphere and prior to
releasing helicopter for flight.
D (Model 250-C20 Series Engines) En
sure start pump is operating before
taking fuel samples from system sup
ply line drain valves.
(1). Set all switches; OFF. Disconnect
external electrical power. Disconnect
battery.
(4). Disconnect hose from from switch

bushing. Cap hose.
(5). Remove fuel pressure switch with
bushing intact from after filter (AF)
port adapter. Install an O-ring on a
suitable airtight plug and tighten into
adapter fitting.
(6). Bench test 369H8144 bypass pressure
switch as follows (denoted by three
housing screws):
(a). Assemble test equipment shown in
Figure 502. Connect tester to pres
sure switch lead and connect ground
test lead to one of three screws on the
housing body.
(b). Remove bushing and O-ring from
switch. Attach tubing to switch inlet
port as shown. Wipe switch complete
ly dry so any leakage can be detected
during the test.
(c). Add fuel to tube. Ohmmeter must
indicate switch contact closure as
fuel column height passes between
24.5 and 35.0 inches (62.23 and 88.90
cm).
(d). Check switch for leakage around
diaphragm. No leaks allowed.
Replace a leaking switch.
(e). Separate switch from test apparatus.
(3). Locate pressure switch on engine fuel

pump filter (Ref. Figure 503, Figure 504
or Figure 505). Disconnect bypass
switch wire knife splice.
(f). Install new O-ring and bushing on

switch. Torque switch bushing.
CAUTION
D Pressure switch is easily damaged. A
slight shearing force applied to half the
pressure switch can cause leakage and, or
operational failure. Always grip both
halves of pressure switch hex flats with
wrench when loosening or torquing at
taching hardware.
D Bypass pressure switch is not field repair
able. Do not disassemble switch. Return
faulty switches to vender for repair.
NOTE: For all torques in the following proce

dures, refer to Figure 503, Figure 504 or
Figure 505.
Page 506
Revision 19
28-00-00
(7). Bench test 369D28144 bypass pressure

switch as follows (denoted by six
housing screws):
test lead to one of six screws on the
housing body.
(b). Pressure Method:
1). Remove bushing and O-ring from
switch. Attach tubing to switch
port A as shown. Tubing has to be
airtight.
2). Add pressure to the tube. Ohmme
ter must indicate switch contact
closure as pressure passes between
8 - 9 psig (16.3 - 18.3 in. hg.).
MAINTENANCE MANUAL
3). Hold pressure for five minutes and
check for bleed-off. Any bleed-off
indicates a leak in the switch and
requires switch replacement.
4). Slowly release pressure. Ohmme
opening by 4 psig (8.1 in. hg).
(c). Vacuum Method:
1). Remove bushing and O-ring from
switch. Attach tubing to switch
port B as shown. Tubing has to be
airtight.
2). Add vacuum to the tube. Ohmme
closure as vacuum passes between
8 - 9 psig (16.3 - 18.3 in. hg.).
3). Hold vacuum for five minutes and
check for bleed-off. Any bleed-off
indicates a leak in the switch and
requires switch replacement.
4). Slowly release vacuum. Ohmmeter
must indicate switch contact
opening as vacuum reaches 4 psig
(8.1 in. hg).
(d). Separate switch from test apparatus.
(e). Install new O-ring and bushing on
switch. Torque switch bushing.
(8). (Model 250-C20B/R2 Series Engines)
Perform a switch operational check as
follows:
CSP-HMI-2
(e). Set battery switch to EXT PWR.

(f). Reset INSTR circuit breaker.
(g). Set caution and warning light
dimmer control on BRT.
(h). Test caution and warning light array.
Replace lamps as required.
(i). Connect a jumper wire between
switch body and airframe ground
E12.
(j). Set start pump switch; ON. FUEL
FILTER caution light should come
on. If FUEL FILTER caution light
fails to light but works when tested,
switch is probably faulty. Replace
switch and repeat operational test.
(k). Check switch diaphragm for leakage
through open port while pressurized.
Replace a leaky switch.
(l). Disconnect jumper wire between
pressure switch and ground. Set start
pump switch; OFF. Set battery
switch; OFF. Disconnect external
power and battery.
(m). Disconnect bypass hose from switch
bushing. Install an airtight cap on
hose.
(n). Remove plug from adapter fitting.
Install bypass switch assembly and a
new O-ring in adapter fitting. Torque
switch assembly.
(a). Uncap and attach bypass hose to

bushing. Torque hose nut.
(o). Remove plug from bypass hose.

Attach hose to switch bushing.
Torque hose nut.
(b). Install a suitable airtight plug and

O-ring in adapter fitting.
(p). Install insulating sleeve and connect

(c). Connect and insulate switch wire

knife splice.
(q). Bleed fuel system.
(d). Have an assistant hold switch clear

of adjacent structures. Connect
battery and external electrical power.
(r). Operate engine per Pilot's Flight

Manual and check fuel system for
correct operation. Shut down engine.
Inspect fuel system for leaks.
28-00-00
Page 507
Revision 29
MAINTENANCE MANUAL
CSP-HMI-2
PRESSURE METHOD:
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.
PORT A
NOTE 2
PORT B
OHMMETER
OR
CONTINUITY TESTER
VACUUM METHOD:
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.
369D28144 FUEL FILTER

PRESSURE SWITCH
36 INCH
SCALE
3/8 TYGON TUBING

(OR EQUIV.)
36 IN.
PORT A
NOTE 1
FUEL FILTER
PRESSURE SWITCH
PORT B
OHMMETER
OR
CONTINUITY TESTER
369H8144 FUEL FILTER

PRESSURE SWITCH
NOTES:
1. CONNECT GROUND TEST LEAD TO ONE OF
THREE SCREW HEADS ON THE HOUSING BODY.
2. CONNECT GROUND TEST LEAD TO ONE OF
SIX SCREW HEADS ON THE HOUSING BODY.
Figure 502. Fuel Filter Caution Light Pressure Switch Test (C20/C30 Engines)
Page 508
Revision 19
28-00-00
G28-0010B
MAINTENANCE MANUAL
CSP-HMI-2
ELBOW, TORQUE: 20-25 IN. LB

(2.26-2.82 NM)
BEFORE FILTER
PORT (BF)
FITTING, TORQUE; 40-50 IN. LB
(4.52-5.65 NM)
REDUCER, TORQUE; 20-25 IN. LB

(2.26-2.82 NM)
ENGINE FUEL
PUMP FILTER
FUEL FILTER PRESSURE SWITCH,

TORQUE; 40-50 IN. LB (4.52-5.65 NM)
BUSHING, TORQUE; 40-50 IN. LB
(4.52-5.65 NM)
ELBOW, TORQUE; 20-25 IN. LB

(2.26-2.82 NM)
HOSE
G28-0009A
Figure 503. Fuel Filter Caution Light Pressure Switch (C30 Engine)
O-RING
ENGINE FUEL
PUMP FILTER
AFTER FILTER
PORT (AF)
BEFORE
FILTER PORT
(BF)

(4.52-5.65 NM)
HOSE
(4.52-5.65 NM)
O-RING
ELBOW, TORQUE; 20-25 IN. LB
(2.26-2.82 NM) (2 PLS)

TORQUE; 40-50 IN. LB (4.52-5.65 NM)
O-RING
(4.52-5.65 NM)
G28-0008A
Figure 504. Fuel Filter Caution Light Pressure Switch (C20 Engines)
28-00-00
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Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
AFTER FILTER
PRESSURE TAP
BEFORE FILTER
PRESSURE TAP
FUEL PUMP
SEAL DRAIN
O-RING
(4.52-5.65 NM)
O-RING
TORQUE 20-25 IN. LB

(2.26-2.82 NM)
O-RING
(4.52-5.65 NM)
TORQUE; 40-50 IN. LB (4.52-5.65 NM)
O-RING
(4.52-5.65 NM)
(2.26-2.82 NM)
HOSE
G28-0027B
Figure 505. Fuel Filter Caution Light Pressure Switch (C20R/2 Engines with CECO Pump)
Page 510
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28-00-00
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
INSPECTION/CHECK
WARNING
D Avoid fuel vapor ignition and fire.
Use only nonsparking tools and ex
plosion proof work lights. Attach he
licopter to an approved electrical
ground. Switch OFF all electrical
power. Disconnect external power
and battery before opening fuel sys
tem. Ensure work area is adequately
ventilated.
D Air entering the airframe fuel supply
lines may cause a power reduction or
flameout. Fuel system vacuum leak
check and fuel air bleed procedures
must be performed after opening fuel
the supply system for any reason,
prior to releasing helicopter for
flight.
1. Fuel System General Inspection
(1). Remove right and left fuel tank floor
access panels.
(2). Inspect fuselage bottom skin for
evidence of fuel leakage. No leaks
allowed. Determine source and repair
as required.
(3). Inspect fuel lines, fittings, cell access
covers, fuel quantity unit, clamps and
attaching hardware for leakage,
corrosion and security. Inspect fire
sleeves for cuts, tears and punctures.
No leakage allowed. Repair or replace
components as required.
(4). Inspect electrical wiring and connectors
for corrosion and security. Replace or
repair wiring as required.
(5). If start pump wire is ty-rapped to start
pump line, inspect security and condi
tion of ty-raps.
2. Fuel Shutoff Valve Control Cable Swage
Test (369D/E)
(Ref. Figure 601)
Item
Nomenclature
CM309
Lacquer, green
N/A
Lockwire CRES
CM714
Tape, pressure sensitive
(1). Remove left instrument panel fairing.

Check for control cables marked (Jairen
Inc. 16722 PN 110262-15N) with a date
of (5/18) or later, and having a swage
less than 0.50 inch (12.70 mm) in
length. These cables are MDHS part
numbers 369A8137-503 and -603.
(a). Inspect cable casing for a green
stripe. The green stripe indicates
that cable has been previously pull
tested.
(2). Unpainted control cables, P/N
369A8137-503 and -603 fitting the
preceding description require a manda
tory 50 pound (222.4 N) pull test to
determine cable swage integrity.
(a). Unclamp cable from canopy or
instrument panel support structure
(Ref. Figure 401).
(b). Behind instrument panel; back cable
retaining nut completely off threaded
portion of casing.
(c). Wrap a 12 inch (30.48 cm) length of
two inch 5.08 cm) wide duct tape or
equivalent around cable casing about
0.50 inch (12.70 mm) behind casing
swage or instrument panel, whichev
er is furthest from front of instru
ment panel.
(d). Wrap one end of 0.042 lockwire
around cable and attach the other
end to the spring scale (Ref.
Figure 601).
28-00-00
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Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
INSTRUMENT PANEL
CLAMP
CABLE CASING
FRONT OF INSTRUMENT
PANEL
NOTCHED WASHER
TAPE
SWAGE
LOCKWIRE
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 ShutOff Control Cable, PN 369A8137503 Pull Test

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Revision 19
28-00-00
MAINTENANCE MANUAL
(e). Notch a 0.265 ID x 0.063 inch (6.73
ID x 1.60 mm) thick washer and
position over cable between tape and
back of instrument panel.
CSP-HMI-2
(5). Ensure shutoff valve control knob is

pushed in. Valve ball must be wide
open.
Sudden cable separation
(6). Pull control knob out to stop. Valve ball

should be closed.
injury. Be properly braced while pull

ing on the cable.
(7). Valves that can not be fully closed or

opened must be overhauled or replaced
prior to further flight.
WARNING may cause serious personal
(f). Apply a steady tension through the

spring scale up to 50 pounds (222.4
N). Relax the tension.
(g). Inspect cable casing swage for
separation.
(h). Replace separated/unserviceable
cable assemblies.
(i). If the swage held without apparent
damage, paint a green lacquer
(CM309) stripe around the swage/
casing joint.
(3). Install and secure cable hardware.
(4). Perform the following inspections and
checks on all model helicopters.
(a). Remove left fuel cell floor access
panel.
(b). Inspect fuel shutoff cable, nylon
grommets and attaching hardware
for condition and security.
(c). Operate cable and check for binding.
Cable bend radius to be 3.5 inches,
minimum.
(d). Push knob in and check for 0.090 0.150 inch (2.286 - 3.81 mm) gap
between bottom of plunger and top of
plunger housing (Ref. Figure 401).
3. Fuel Shutoff Valve Inspection
(1). Shut down and disconnect all electrical
power.
(2). In cargo/passenger compartment, open
left fuel cell access panel.
(3). Disconnect fuel supply tube from fuel
shutoff valve.
(4). Use an inspection mirror and flashlight
to check shutoff valve ball position.
(8). Disconnect control cable from valve.

(9). Inspect shutoff valve lever and cable
swivel hardware for corrosion and wear.
Check lever for smooth movement from
closed to open stops.
(10). Use a spring scale to check tension
required to move valve lever from full
open to closed. Design force require
ment is 1.5 - 3.5 pounds (6.7 - 15.6 N)
maximum.
(11). Inspect valve for evidence of external
leakage. External leakage not allowed.
(12). Check that lever detents at open and
closed positions. Repair or replace valve
as required.
(13). Connect and rig valve control cable.
Install cotter pin on cable swivel.
4. Fuel Quantity Transmitter Inspection
(2). Check 369D helicopters for potting
compound on top of transmitter. Apply
missing potting compound per repair
instructions. Check transmitter
electrical terminals and wire harness
where exposed for security and condi
tion.
(3). Where potting compound has been
installed, use a pointed probe and
bright light to inspect interface between
potting compound and flange plate for
voids, debonding and separations.
Inspect area around terminal fasteners
for voids. No separations or voids are
allowed.
(4). Remove and test unit as required.
(5). Repair or replace potting compound.
5. Tank Vent System Inspection
(1). Remove controls access door. Discon
nect hoses from forward and aft vent
crossover tubes.
28-00-00
Page 603
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
(2). Blow low-pressure compressed air

through vent system to verify passages
are clear.
(3). Check vent fairing passages for obstruc
tions and condition. Repair or replace
fairings as required.
(4). Inspect vent system hoses for deteriora
tion. Pinch or bend hoses and look for
surface cracks. Replace hose if cracks
are apparent.
(5). Inspect vent tubes for dents, cracks,
deformation or corrosion. Smooth
nonrestrictive dents are permissible
except at lower end which must fit flush
within vent fairing flared riser.
(6). Inspect crossover fittings for cracks,
dents or corrosion. Smooth nonrestric
tive dents are permissible.
Item
Special Tools
Nomenclature
ST801
Hand operated vacuum pump kit
Air entering the airframe
WARNING fuel supply lines may cause
a power reduction or flameout. Fuel

system vacuum leak check and fuel air
bleed procedures must be performed
after opening the fuel supply system
for any reason, prior to releasing heli
copter for flight.
(2). Pull FUEL shutoff valve knob out to
stop. Verify that fuel shutoff valve lever
is hard against its OFF stop.
(3). In engine compartment; remove the
upper drain plug from the fuel pump
filter bowl.
(7). Check that forward crossover anti-si

phon holes are open and clean.
(4). On C30 and C20R installations, remove

and plug the fuel vapor return line.
(8). With vent tube removed inspect vent

tube emergency shutoff valve for
condition. Valve should remain open
when held vertical. Valve should be
closed when held in the 45 from
vertical position. While held in the 45
position, blow in the valve assembly
and check that valve is closed (Do not
use compressed air). Valve shall open
when returned to the 25 position.
Replace obstructed valve assembly.
(5). Assemble vacuum pump (ST801) hoses,

filter port adapter, shutoff valve and
vacuum gauge.
6. Fuel System Vacuum Leak Inspection

Fuel is drawn out of the tank by the engine
driven fuel pump when the START PUMP is
switched OFF on Model 250-C20 Series
engine installations and at all times in Model
250-C30 engine installations. Water, ice, dirt,
fungus or a few pinhole leaks in the supply
system between the fuel tank sump pickup and
engine driven fuel pump may cause power
surges, deceleration and, or flameout. A
vacuum leak inspection will determine
whether or not air is being drawn into the
engine fuel supply system.
Page 604
Revision 28
28-00-00
(6). Install the vacuum gauge in the line

between the filter port adapter and
shutoff valve. Attach the vacuum pump
above the shutoff valve.
(7). Attach vacuum test vacuum pump to
engine fuel filter upper drain port.
Apply 8.0 Hg vacuum. Close vacuum
line shutoff valve.
(8). Fuel system shall hold vacuum between
8.0 and 7.5 Hg for two minutes.
NOTE: Vacuum loss exceeding 0.5 Hg in two

minutes indicates a leak in the system be
tween, and including, the fuel shutoff valve
and engine.
(9). If test is satisfactory, remove test
vacuum. Inspect and replace filter plug
O-ring as required. Install filter plug.
(10). On C30 and C20R installations,
reconnect and torque the fuel vapor
return line.
MAINTENANCE MANUAL
(11). Retorque fuel line connections (Ref.
Table 401) and where installed, anti-ice
(airframe) fuel filter fittings and line
nuts (Ref. Sec. 28-25-00). Repeat
vacuum test.
(12). If system continues to leak, disconnect
and install airtight caps on lines and
fitting ports in a progressive sequence
from fuel shutoff valve toward engine.
The fuel shutoff and drain valve
installations should be especially
suspect. Apply vacuum at each stage
until leak has been isolated. Replace
parts as required.
NOTE: If the vacuum held at 7.5 Hg or better,

airframe system seal is satisfactory and
leak is due to an engine fuel system prob
lem. Refer to the applicable Allison and Ben
dix manuals for additional information.
(13). Apply a torque stripe to all effected fuel
line fittings and nuts.
7. Start Pump Operational Check (Model
250C20 Series Engines or 250C30 Engine
With Optional Maintenance Fuel Pump)
(1). Remove fuel cell floor access panels.
CAUTION

empty fuel tank.

(3). Connect battery and external power.
(4). Set battery switch to EXT PWR.
(5). Push FUEL shutoff valve knob in to
open shutoff valve.
(6). Set START PUMP switch ON to
pressurize fuel system.
9. Fuel Cell Inspection
CAUTION
D Do not work on Uniroyal fuel cell in ambi
ent temperatures below 50F (10C).
D Do not work on Engineering Fabric Corp.
70F (21C).
D Do not remove fuel cells unless absolutely
required.
D The barrier can be invisibly torn, punc
tured or cracked by careless handling.
D Do not carry or move cell by its metal fit
tings.
D Never probe cell material with sharp
edged or pointed tools.
NOTE:
D Non-self-sealing and self-sealing cells
are primarily a 0.002 inch (0.051 mm)
thick nylon barrier membrane sand
wiched between lightweight construc
tions of either rubberized (Uniroyal) or
plasticized (Engineered Fabrics Corp.)
nylon fabric that protects and strength
ens the barrier.
D Self-sealing cells may have one or more
thin layers of natural rubber sandwiched
between the barrier and fabric plies.
(1). Apply protective tape to all machined
metal fittings.
(2). Perform cell inspection on a padded,
clean, craft paper covered surface.
(3). Inspect fuel cells per applicable man
ufacturers requirements.
10. Fuel Cell Leak Inspection
(7). Inspect all line connections for leaks.

(8). Shut down start pump.
(a). Repair leaks as required.
8. Drain Valve Inspection
(1). Inspect tank sump drain valve for
leakage and security. No leakage
allowed.
CSP-HMI-2
Item
Nomenclature
N/A
N/A
N/A
CM218
CM810
CM820
Ammonia
Cloth, cotton flannel
Phenolphthalein, crystalline
Alcohol, denatured
Leak detector, liquid
Cheesecloth
(2). Replace valve as required.
28-00-00
Page 605
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
Any one of three techniques can be used to find

leaks in non-self-sealing and self-sealing fuel
cells. The methods are listed in ascending
order of effectiveness and complexity in terms
of required equipment, materials, time, and
effort.
Soap bubble leak inspection.
Phenolphthalein stain inspection.
Liquid stand inspection.
NOTE: The soap bubble and phenolphthalein

inspections require the cell to be inflated
with air.
(1). Manufacture or supply the following
equipment necessary to do soap bubble
or phenolphthalein inspections:
(a). Rigid, airtight closures or plugs to
seal all cell openings. Fit one cover
plate with:
(b). An air pressurization inlet fitting.
(c). A manometer or an extremely
accurate and sensitive low pressure
air gauge.
A. Soap Bubble Leak Test Procedures
NOTE: Soap bubble test reliability is good for
B. Phenolphthalein Stain Inspection

Procedures
(1). Remove cell from helicopter.
(2). Lay cell out on a padded table. Install
all but one of the cell closures.
(3). Make phenolphthalein solution as
follows:
(a). Add 40 grams phenolphthalein
crystals to 1/2 gallon (1.9 L) of
denatured alcohol (CM218) and stir.
(b). Add 1/2 gallon (1.9 L) of water. Allow
to stand 30 minutes. Stir before
using.
(4). Pour commercial ammonia on an
absorbent cloth in a ratio of one
teaspoon (3 ml) per cubic foot of cell
capacity (minimum of 10 ml or 3.3
teaspoons).
(a). Place the ammonia saturated cloth
inside the cell and install the remain
ing cover.
(b). Inflate cell with air to 1/4 psi (1.7
kPa) maximum. Maintain 1/4 psi (1.7
kPa) pressure for 15 minutes mini
mum, before proceeding.
(c). Soak a large white cloth in the

phenolphthalein solution. Thoroughly
wring cloth out.

cell closures.
(d). Spread and smooth cloth onto cell. Do

not let cloth dry out.
(3). Inflate cell to 1/4 psi (1.7 kPa), maxi

mum.
(e). A red spot will appear on the cloth

where there is a leak in the cell wall.
Mark each leak.
bladder type non-self-sealing cells.
(4). Unless leak is immediately evident,

maintain 1/4 psi (1.7 kPa) pressure for
two hours to allow any air trapped in
cell exterior laps and seams to escape.
(5). Run soap solution around all patches,
lap joints, seams, fittings, creases,
abrasions and any other suspicious
areas. Bubbles will appear over a leak.
(6). Mark leak areas with a white or yellow
crayon.
(7). Repair cell as required.
Page 606
Revision 19
28-00-00
(f). Inspect the entire exterior surface of

the cell.
C. Liquid Stand Inspection
NOTE:
D Engineered Fabrics Corp. recommends
VITHANE\R cells be supported in a fix
ture for the liquid stand inspection.
D Uniroyal rubberized fabric cells do not re
quire support for this test.
MAINTENANCE MANUAL
(1). Remove cell from helicopter and place
on a clean, padded, kraft paper covered
table.
(2). Fabricate closure plates for each cell
opening as follows:
(a). The object is to completely fill the cell
and eliminate all air pockets.
(b). Equip one of the plates with liquid
filler and vent stand pipes at least six
inches (15 cm) tall.
(3). Fill the cell with Stoddard solvent,
Stanisol or Varsoline.
(4). Permit cell to stand undisturbed for 24
hours.
(5). Inspect paper to determine where cell is
leaking.
(6). Change paper as required. Drain, turn
over, refill and let cell stand for another
24 hours to ensure liquid has contacted
all cell surfaces.
Item
N/A
CSP-HMI-2
Special Tools
Nomenclature
Manometer
(1). Plug vent system.

(2). Remove left and right cell floor access
panels.
(3). Install manometer and air pressuriza
tion equipment.
(4). Apply 2 psi (14 kPa) air pressure for 10
minutes to precondition cells. This
forces trapped air from between fuel
cells and helicopter structure. If
necessary, repeat until cells adjust to
contour of cell bay.
(5). Apply 2 psi (14 kPa) air pressure for 15
minutes with no visible, less than 1/4
inch (6.35 mm) drop on manometer.
NOTE: If pressure drop occurs, check all vent

plugs, fittings and re-test cells.
(6). Repair or replace parts as necessary to

eliminate pressure drop.
11. Fuel Tank Pressure Leak Test
(7). Unplug vent system. Remove manome

ter and pressurization equipment.
Check installed fuel tanks and plumbing for

leaks as follows:
(8). Install left and right cell floor access

panels.
28-00-00
Page 607
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
Page 608
Revision 44
28-00-00
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
REPAIRS
1. Fuel Shutoff Valve Control Cable Repair
Item
Nomenclature
CM118
Grease
NOTE: Worn fuel shutoff valve control cables

are normally replaced as an assembly.
(1). The only authorized repair is replace
ment of a missing detent ball, as
follows:
(a). Disconnect cable from fuel shutoff
valve lever swivel.
(b). Pull plunger out until detent ball
hole is visible. Insert detent release
rod in plunger. Align notch in detent
release rod with plunger detent ball
hole.
(c). Apply grease (CM118) between
plunger and plunger housing.
(d). Insert detent ball in plunger hole.
Push release rod and plunger to full
open position.
(e). Rig fuel shutoff valve cable.
2. Fuel Shutoff Valve Repair
(1). Overhaul Dukes Inc. valves with repair
kit, part No. 1595-1000. No other
repairs are authorized.
(2). Electric pencil the letter M at the end of
the part number, i.e., 369A8104-5M.
3. Fuel Cell Repair
(1). MDHS cannot guarantee the currency,
completeness or technical accuracy of
fuel cell repair procedures provided
herein. Since cell repair materials,
techniques, and procedures may be
changed or deleted by the cell manufac
turers without notice to MDHS light
helicopter publications; we strongly
recommend that:
(a). Only personnel specifically trained to

inspect and repair the fuel cells
installed in 369/500 series helicopters
perform the work.
(b). Customers planning to do their own
fuel cell repairs order manuals from
the applicable cell manufacturer
before beginning repair tasks (Ref.
Sec. 01-00-00).
(c). Cell inspections, maintenance and
repair be only per the cell manufac
turers advice and instructions.
(2). Bladder or self sealing fuel cells are
supplied to MDHS by Uniroyal, Inc.,
and Engineered Fabrics Corporation.
Engineered Fabrics Corp., and
Uniroyal fuel cell construction
materials, inspection requirements, repair
methods and requirements, supplies and
materials are not compatible or inter
changeable.
CAUTION
(3). Cells manufactured by Uniroyal are an

assembly of nitrile rubber impregnated
woven nylon inner and outer coverings
with an impervious 0.002 inch (0.051
mm) thick, nylon barrier membrane
sandwiched between the coverings.
(4). Fuel cells produced by Engineered
Fabrics Corp. are constructed of
VITHANE/R polyurethane plastic
impregnated fabric.
4. Uniroyal SelfSealing and
NonSelfSealing Cell Repairs
Procedures in this section cover Uniroyal
self-sealing and non-self-sealing fuel cell
repairs as follows:
D Scuff Mark Repairs.
D Reinforcements, Hangers and Splice
Repairs.
D Loose Patch Repair.
D Patch Installation.
D Loose Edges and Lap Seam Repair.
28-00-00
Page 801
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
A. Scuff Mark Repair
D Blister Repairs.
Fuel cells are fragile. Do not at
CAUTION tempt to fold/unfold or handle
cells in temperatures below 50F (10C).
Cell material is easily cut, torn or punc
tured. Never use sharp edged or pointed
tools to probe damage or to puncture blis
ters. Puncturing the 0.002 inch (0.051 mm)
thick nylon fuel barrier of a non-self-seal
ing cell will cause the cell to leak. Punctur
ing the nylon barrier of a self-sealing cell
will allow fuel to activate the rubber sealing
agent that will swell over time and possibly
rupture the cell. In any case, cells with acti
vated seal compound are not repairable.
Barrier membrane can be invisibly torn by
rough handling or impact. Handle cells with
care and no more than necessary. Protect
metal fittings from damage.
NOTE: Accomplish fuel cell repair work in tem

peratures ranging from 60 - 80F (16 27C) and in less than 50% humidity.
(1). Fabric exposed by a scuff mark may be

buffed, cleaned, coated with cement and
allowed to air-dry for 8 hours.
(2). No patch is required unless fabric is
torn.
(3). Install patches where required (Ref.
Patch Installation).
B. Reinforcements, Hangers and Splice
Repairs
(1). Loose reinforcement edges, hangers or
lap splices must be lifted, buffed,
cleaned, cemented and cured under
pressure per applicable instructions
provided (Ref. Patch Installation).
C. Loose Patch Repair
(1). Replace loose patches with new patch
installations (Ref. Patch Installation).
(2). Where two opposing patches have been
installed over cell wall damage, unless
otherwise indicated by inspection,
replace only the loose patch.
Item
Nomenclature
N/A
Polyethylene plastic, sheet or roll
CM211
Solvent
CM219
Methyl-ethyl-ketone
CM603
Patching material
(1). Drain, remove and thoroughly dry cell

as soon as possible after determining
cell repair is required. Drying time may
be accelerated by keeping cell at 80F
(27C) and ventilating interior with dry,
low pressure air.
CM604
Patching material
(2). Inspect fuel cell.
CM605
Fuel cell repair kit
CM607
Cement
CM608
Cement
CM609
Repair kit
CM804
Emery cloth, fine
CM820
Cheesecloth
Item
Special Tools
Nomenclature
N/A
C-Clamp, 8 - 12 inch
N/A
Patch pressure plates, 1/2 inch thick

aluminum stock
N/A
Brayer
Page 802
Revision 19
28-00-00
D. Patch Installation
CAUTION
D Do not repair tears or holes over two in
ches long using cold patch repair. Do not
attempt to repair bonded fittings or cor
ners. Contact Uniroyal, Inc. when corner
or fitting damage is discovered or when
cell wall damage exceeds two inch (5.08
cm) length limit.
D Never expose a dry cell to high tempera
tures and, or direct sunlight for long peri
ods of time. If repairs will not be started
within ten days, prepare cell for storage.
NOTE: Damp air, especially in combination

with low temperatures, will cause water to
condense on cement applications. Water in
hibits patch adhesion.
MAINTENANCE MANUAL
(3). Both sides of a cell must be patched to
repair any one hole or tear.
(4). Thoroughly clean cell internal and
external repair areas with cheese cloth
(CM820) dampened with solvent
(CM211) or MEK (CM219).
(5). Collapse cell and expose external
damage area on a clean, flat working
surface.
(6). Use a greaseless silver pencil to outline
patch installation area two inches
beyond damage in all directions.
(7). Hand-buff an area 1/2 inch (12.7 mm)
larger than space occupied by patch
with fine emery cloth (CM804) to
provide a roughened substrate for
cement application. Do not cut through
cell fabric.
(8). Select a patch (CM604) of #5218
material for non-self-sealing cell
exterior, or Uniroyal #5241/5241
sandwich material for self-sealing cells.
Trim patch to extend two inches (5.08
cm) beyond edges and ends of damage
in all directions. Tilt scissors to bevel
patch edges away from cell surface.
Radius all patch corners.
(9). Hand-buff patch gummed surface with
fine emery cloth. Ensure entire patch
joint surface has been abraded.
(10). Repeat buffing procedures on cell
interior surface. Buff internal patch
(CM603) trimmed from Uniroyal
#5200/5187/5194 sandwich material.
Fuel cell and patch contact sur
faces must be perfectly clean
and dry prior to adhesive and patch applica
tion. Rubber and fabric particles, moisture,
and fuel or oil from fingers will prevent
proper patch/cell adhesive cure and may
subsequently provide a leak path. Wear
clean, lint free gloves to handle patch and
cell after preparing surfaces for cement and
patch application.
CAUTION
(11). Install exterior patch first. Wipe cell

exterior and patch faying surfaces with
clean cheesecloth dampened with
Uniroyal #3339 solvent or MEK.
CSP-HMI-2
(12). Continue to wipe cell and patch,

changing cheesecloth and applying
clean solvent as required, until no stain
or particles appear on cheesecloth pad
after the last wipe.
Use cement sparingly. Two,
thin, even coats provide better
adhesion than one thick coat.
CAUTION
(13). Position a sheet of polyethylene plastic

beneath cell damage to keep cement off
opposite cell wall.
NOTE: Determine cement adhesive tack with a

test specimen. Apply cement to a piece of
buffed, scrap patch material each time ce
ment is spread on cell and repair patch.
(14). Coat patch, test specimen, and fuel cell,
including edges of damage, with EC678
cement (CM607) or Uniroyal #3230
cement (CM608). Allow cement to dry
15 minutes before application of a
second coat. Allow second coat to dry 15
minutes.
(15). Press a bare knuckle into cement on
test specimen. Cement that tears away
from skin leaving a rough, finely
peaked imprint without transferring to
knuckle, is ready for patch installation.
(16). Wipe cement with cheesecloth moist
ened with solvent to reactivate adhesive
when required.
NOTE: A brayer or similar tool is required to

systematically roll patch into contact with
cell. Apply patch as follows:
(17). Center patch on repair area. Stick one
edge down and double check patch
alignment. If required, release adhesive
by flooding joint with solvent. Check
adhesive tack again before proceeding
with patch installation.
NOTE: The object of the next step is to get the

patch down without trapping any air under
it.
(18). Hold free edge of patch off cell. Follow
one line and roll tool back and forth
over patch. Advance toward loose end,
1/4 inch (6.35 mm) per pass until patch
is down and free of trapped air.
(19). An alternate technique is to lay
prepared patch on a perfectly clean
28-00-00
Page 803
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
sheet of polyethylene plastic about

twice the size of the patch. Locate
plastic sheet and patch over cell repair
area; then, slip sheet from under patch
as patch is rolled down, 1/4 inch (6.35
mm) at a time.
(20). Fabricate two smooth, flat, rigid, metal
plates with no sharp edges or corners.
Plates must be larger than cemented
repair area.
Excessive clamp pressure may
deform cell and, or squeeze ce
ment out of joint.
CAUTION
(21). Cover both sides of repair with sheet

polyethylene plastic or oiled paper large
enough to cover entire cemented area.
NOTE: Do not include opposite cell wall in

clamp up. Work through cell access opening
and arrange cell as necessary to clamp only
the wall with the patch installation.
(22). Sandwich repair area and barrier
material between pressure plates.
Install at least two C-clamps over
pressure plates. Equalize clamp
pressure.
(23). Do not disturb cell. Maintain pressure
for six hours, minimum, after which cell
is ready for internal patch installation.
(24). Remove clamps and plates.
(25). Clean patch and cell internal repair
area with solvent or MEK saturated
cheesecloth swabs.
(26). Apply two coats of cement, allowing 15
minutes drying time between coats.
Allow 15 minutes for second coat to set.
(27). Install and roll out patch.
(28). Position a barrier sheet under each
pressure plate. Clamp and cure instal
lation for a minimum of 24 hours at 60
- 80F (16 - 27C) before leak testing
and returning cell to service.
Page 804
Revision 19
28-00-00
E. Loose Edge and Lap Seam Repairs
CAUTION
Loose lap seams should be re

paired as soon as possible after
discovery.
NOTE: Loose lap seam edges not more than two

inches long on cell interior or exterior sur
faces may be repaired. Contact Uniroyal,
Inc. for repair data addressing lap seam sep
arations exceeding two inch (5.08 cm) length
limit. Seam separation repairs require buff
ing, cementing and a patch installation.
(1). Lift seam separation and buff flap and
cell faying surfaces with emery cloth
(CM804).
(2). Buff an area on exterior surface
extending 2 inch (5.08 cm) in all
directions from seam separation.
CAUTION
D Fuel cell and patch contact surfaces must
be perfectly clean and dry prior to adhe
sive and patch application. Rubber and
fabric particles, moisture, and fuel or oil
from fingers will prevent proper patch/
cell adhesive seal and may subsequently
provide a leak path. Wear clean, lint free
gloves to handle patch and cell after pre
paring surfaces for cement and patch
application.
D Careless application of compressed air be
tween lap joints may separate seam fur
ther.
(3). Either air-vacuum or blow buffing dust
out of separation with dry, low pressure
compressed air.
(4). Wipe inside and outside of repair area
clean with cheesecloth (CM820)
moistened with solvent (CM211) or
MEK (CM219). Continue wiping with
fresh solvent dampened cheesecloth as
required until no stain or particle
appears on the swab after the last wipe.
Allow area to dry.
CAUTION

MAINTENANCE MANUAL
(5). Apply two coats of EC678 cement
(CM607) or Uniroyal #3230 (CM608)
allowing 15 minutes between applica
tions. Allow second coat to dry 15
minutes.
(6). Roll separation together starting from
the bottom of the pocket toward the
open end, 1/4 inch (6.35 mm) per pass.
Ensure no air is trapped underneath.
(7). Cover repair with a sheet of polyethyl
ene plastic or oiled paper large enough
to cover entire cemented area.
repair area.
ment out of joint.
CAUTION
(9). Cover both sides of repair with polyeth

ylene plastic or oiled paper sheets large

the wall containing the seam repair.
(10). Sandwich cell wall repair area and
barrier material between pressure
plates. Install at least two C-clamps
over pressure plates. Equalize clamp
pressure.
is ready for patch installation.
(13). Use Uniroyal #5200/5187/5194 sand
wich patch material (CM603) on
non-self-sealing and self-sealing cell
interiors.
(14). Use Uniroyal #5241/5241 sandwich
patch material (CM604) on self-sealing
cell exterior surfaces or Uniroyal #5218
patch material on non-self-sealing cell
exterior surfaces.
CSP-HMI-2
(15). Prepare cell wall and patch for installa

tion (Ref. Patch Installation). Install
patch.
F. Blister Repair
(1). Blisters can occur on cell interior and
exterior surfaces. blisters are caused by
a separation of the cell laminates and
may contain air or a combination of air
and fuel.
NOTE: Exterior blisters that contain fuel indi

cate that the barrier has been penetrated.
Contact Uniroyal for repair information be
fore proceeding. Blisters inside cell measur
ing under one inch (2.54 cm) diameter are
acceptable and need not be disturbed.
(2). Buff surface of blister and area extend
ing two inch (5.08 cm) in all directions
from its edge.
Avoid damaging nylon barrier
membrane. Do not probe, cut, or
puncture blisters with tool perpendicular to
cell wall.
CAUTION
(3). Slit blister open with an X cut to expose

all of the delaminated surface. Lift flaps
and mop interior with clean cheesecloth
(CM820) and solvent (CM211) or MEK
(CM219). Buff underlying cell surface
and blister flaps with emery cloth
(CM804). Air-vacuum or blow away all
traces of buffing dust.
(4). Wipe inside and outside of repair area
clean with cheesecloth moistened with
solvent or MEK. Continue wiping with
fresh solvent dampened cheesecloth as
required until no stain or particle
appears on the swab after the last wipe.
Allow area to dry.
CAUTION

(5). Apply two coats of EC678 cement
(CM607) or Uniroyal #3230 (CM608)
minutes.
28-00-00
Page 805
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
(6). Roll blister together starting from the

bottom of each flap pocket toward the
open end, 1/4 inch (6.35 mm) per pass.
Ensure no air is trapped underneath.
repair area.
ment out of joint.
CAUTION
(8). Cover both sides of repair with polyeth

ylene plastic or oiled paper sheets large
5. Fuel Quantity Transmitter Repair
Item
CM220
CM425
CM815
Nomenclature
Naphtha aliphatic
Sealing compound
Solder
Item
N/A
Special Tools
Nomenclature
Solder gun
A. Resistor installation, Transmitters

PN 369D296303, 369D296303701 and
369A4245
(1). Remove transmitter from helicopter.

the wall containing the blister repair.
pressure.
(2). Remove potting compound from top of

transmitter to expose terminals and
circuit board.
(3). Solder resistor to transmitter circuit
with tin alloy solder (Ref. Figure 501).
(4). Perform FUEL LEVEL LOW Caution
Light System Test and Fuel Quantity
Transmitter Calibration and Adjust
ment procedures.
Naptha is a fire hazard. Per
WARNING form work in a well venti

is ready for patch installation; remove
clamps and plates.
(11). Use #5200/5187/5194 sandwich patch
material (CM603) on non-self-sealing
and self-sealing cell interiors.
(12). Use Uniroyal #5241/5241 sandwich
patch material (CM604) on self-sealing
cell exterior surfaces or Uniroyal #5218
patch material (51) on non-self-sealing
cell exterior surfaces.
tion per instructions (Ref. Patch
Installation). Install patch.
Page 806
Revision 19
28-00-00
lated area away from potential sources

of ignition.
NOTE: All transmitters with exposed wire ter

minals and, or circuit boards must be sealed
(potted) before they can be returned to ser
vice.
(5). Remove all grime and oily residue from
sealing compound application area with
naptha (CM220) and a soft bristle
brush. Blow away excess solvent with
dry low pressure compressed air.
(6). Ensure transmitter terminal connec
tions are clean, tight, free of corrosion
and dry.
(7). Heat soak transmitter assembly in an
oven set at 100F (38C), maximum for
one hour to vaporize trapped volatiles.
A heat gun may be used as an alternate
MAINTENANCE MANUAL
drying method. Pot transmitter electri
cal connections with sealing compound
(CM425).
B. MILS8802 Application
(1). Combine MIL-S-8802 sealing com
CSP-HMI-2
pound components per manufacturers

instructions.
(2). Apply to top of transmitter (Ref.
Figure 501).
(3). Cure material per instructions before
returning transmitter to service.
28-00-00
Page 807
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
Page 808
Revision 44
28-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
280060
Fuel System (600N)
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
1. Engine Fuel System
(1). Engine fuel system operational infor
mation is provided in the applicable
nance Manuals (Ref. Sec. 01-00-00).
2. Fuel Cells
(1). The MDHS helicopter standard fuel cell
consists of two interconnected crash-re
sistant non-self-sealing bladder type
cells having a total capacity of 116.2
U.S. gallons (439.9 Liter), with 114.6
U.S. gallons (433.8 Liter) usable.
(2). Bladder crash-resistant non-self
sealing fuel cells are supplied by
Engineered Fabrics Corporation (Ref.
Sec. 01-00-00).
(3). Cells are located in separate fiberglass
lined bays below the passenger com
partment floor. Both cells are supported
by a system of airframe brackets,
hangers, grommets and nylon suspen
sion cords.
(4). Each fuel cell is equipped with two
access covers, forward fuel vent aft fuel
vent forward vent crossover fittings and
fuel interconnect fittings.
(5). Each fuel cell contains two sump plates
and two fuel drain valves
(6). Each fuel cell is divided by an internal
lateral baffle which reduces fuel
sloshing during changes in flight
attitudes. The baffles have openings
across their face to allow fuel to pass
through them. This reduces the load on
the baffles and provides even fuel
distribution within the cell.
(7). Fuel tank servicing is through the cell
filler neck on the right side of the
fuselage. The right side fuel cell
contains the gravity filler port, filler
check valve, neck, cap and attachment
hardware.
(8). A check valve attaches to the filler neck

fitting. The check valve located within
the fuel cell. opens when the fuel cap is
removed by pulling a lanyard for
refueling and defueling operations. The
valve closes when the fuel cap is
secured to the filler neck fitting pre
venting fuel leakage.
(9). The left-rear cell cover supports the
manually actuated fuel shutoff valve,
fuel supply hose, motive flow hose, fuel
quantity probe wire harness and
attaching hardware.
3. Fuel Distribution
(1). The fuel distribution system supplies
fuel to the engine. The engine driven
fuel pump sucks fuel from the fuel cell.
(2). Fuel is supplied from the fuel cell
through supply lines located under the
passenger/cargo compartment floor and
within the fuel cell.
(3). The ejector pump is driven by pressur
ized fuel (motive flow) returning from
the engine driven fuel pump.
(4). The ejector pump scavenges fuel from
the forward portion of fuel cell and
transfer fuel to the aft portion of the
cell, thus motive flow.
4. Fuel Vent System
(1). Fuel cells are vented to the atmosphere
through the bottom and side fuselage
ports by a system of interconnected
hoses and tubes attached to the forward
inboard and aft inboard ends of each
fuel cell.
(2). The fuel vent float/rollover valves are
located internally at each inboard
upper corner of the fuel cell. The vent
float/rollover valve allows the fuel cell
to vent to the atmosphere during
aircraft fueling/defueling.
(3). Each vent float/rollover valve is
designed so that when not submerged
in fuel and with airflow through the
28-00-60
Page 1
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
valve between zero and the rated flow,

the valve remain open within 25
conical angle from vertical.
(4). The valve automatically closes when
the fuel level is at or above the float
actuation level to prevent fuel loss
through the vent system. The valve will
also close with changes in aircraft
ground attitudes from 25 to 180 with
fuel present.
(5). Flame arrestors located in the outlet
vent tube or standpipe prevents any
potential flames from reaching the vent
float/rollover valves and fuel cell.
5. Fuel Quantity System
(1). The fuel quantity system is powered by
24 - 28 Vdc current and consists of an
electromechanical fuel quantity
indicator, a signal conditioner, two
capacitance type fuel quantity probes
mounted in the left fuel cell, a float
switch located on the aft fuel quantity
probes, a FUEL LEVEL LOW caution
light on the instrument console and
interconnecting wire harness.
(2). The system is protected by a 5 ampere
circuit breaker. Power is supplied to the
system from the DC bus, through a
circuit breaker.
(3). The float switch provides a electrical
signal to the FUEL LEVEL LOW
caution light panel located on the
instrument panel. Refueling breaks the
float switch circuit and switches off the
FUEL LEVEL LOW caution lamp. The
switch is fixed to the aft fuel quantity
probe and is not adjustable.
the instrument panel face. The flexible

cable and housing is routed aft under
the floor to the shutoff valve lever on
the left fuel cell access cover.
7. Fuel Shutoff Valve
(1). The cable actuated, mechanically
detented fuel shutoff valve is located on
the left fuel cell access cover. Valve
lever arm travel from full open to closed
is 90.
8. Fuel Filter Caution Light Pressure Switch
installed across the engine fuel pump
filter pressure AF (after filter) and BF
(before filter) ports just upstream of the
engine fuel pump. The switch is
sensitive to a preset differential
pressure. An increase in BF pressure
with a concurrent decrease in AF
pressure due to partial or complete
filter blockage may intermittently or
completely close the switch depending
on the nature of the filtered material.
Switch contacts complete an electrical
circuit through a case ground that
switches on the FUEL FILTER
caution lamp, a part of the instrument
console caution and warning light
array.
9. Drain System and Drain Valves
(1). Two spring loaded plunger tank sump
drain valve are installed in each cell
sump mount plate on the bottom of the
left and right fuel cell. The valve is
accessed from under the helicopter.
10. Fuel Supply Lines
(1). The engine fuel supply lines consist of:
(4). Calibrating of the fuel system is

accomplished on the fuel quantity
indicator calibration switch. By holding
the switch in the empty or full calibra
tion positions a resistance is stored in
the gauge memory circuit.
6. Fuel Shutoff Valve Control
(1). A red fuel shutoff control knob labeled
FUEL, PULL TO CLOSE is located on
Page 2
Revision 19
28-00-60
(a). A fuel inlet hose between the inlet

screen to the fuel shutoff valve.
(b). A engine feed hose between the fuel
shutoff valve and firewall fitting.
(c). A hose from the firewall fitting to the
engine filter inlet port.
(d). A return flow hose from engine to the
firewall fitting.
MAINTENANCE MANUAL
CSP-HMI-2
(e). A motive flow hose assembly between

the firewall fitting and a flow check
valve on the left aft cell cover.
(g). A scavenge fuel cell hose from the

ejector pump to the bottom of aft cell
cover.
(f). A submerged motive flow hole from

aft cell cover to the ejector pump.
(h). Associated elbows, fittings and

unions.
28-00-60
Page 3
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
Page 4
Revision 44
28-00-60
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
FAULT ISOLATION
1. Fuel System Fault Isolation
Symptom
Insufficient or no fuel to engine.
FUEL FILTER warning light on.
Probable Trouble
Corrective Action
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

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

failed or disconnected.
Repair or replace control cable.
Clogged engine fuel filters.
Replace pump and gas producer fuel

control filters. Clean fuel control
pneumatic (air) circuits (refer to
Allison Engine Operation and
Maintenance Manual). When
installed, replace antiice (airframe)
filter (Ref. Sec. 282500). Bench
check FUEL FILTER caution light
pressure switch.
Fuel contamination.
Inspect and clean the fuel cell and

start pump inlet screens if large
amounts of foreign material are
found in the engine driven fuel pump
filter (or the optional airframe fuel
filter if installed).
Defective fuel filter pressure switch. Replace pressure switch.
Engine power surge or flameout.
Wiring fault.
Repair wiring.
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.
28-00-60
Page 101
Revision 29
MAINTENANCE MANUAL
CSP-HMI-2
Table 101. Fuel Supply System Fault Isolation (Cont)

Symptom
Probable Trouble
Corrective Action
Loose or broken lines or fittings.
Inspect and repair as required.
Fuel cell leak.
Remove, test and repair, or replace

cells.
Fuel cell interconnects leak
Replace cell interconnect Orings.
FUEL LEVEL LOW caution light

stays on, glows or flickers with
known quantity above low level.
Defective aft fuel quantity probe

low level switch.
Replace fuel quantity probe.
Erroneous fuel quantity gauge

readings.
Loose or defective wiring or

connections.
Loose or incorrect wiring at the fuel

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

gauge.
Defective forward or aft fuel

quantity probe.
Remove, test, calibrate and repair or

replace probe.
Bottom of fuselage stays wet with

fuel.
Page 102
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28-00-60
MAINTENANCE MANUAL
CSP-HMI-2
Table 102. Fuel Quantity System Wire Data List

Wire No.
From
Termination
To
Termination
Specification
FQ1A22WHT
J2511
HSD4123915
600N810771
87F5544
M2750022SP2T23
FQ1A22BLU
J2512
HSD4123915
600N810772
87F5544
M2750022SP2T23
FQ2A22WHT
J2513
HSD4123915
600N81077S
87F5547
M2750022SP2T23
FQ3A22WHT
600N81079S
87F5547
600N81077S
87F5547
M2750022SP3T23
FQ2A22BLU
J2514
HSD4123915
600N81077R
87F5546
M2750022SP2T23
FQ3A22BLU
600N81079R
87F5546
600N81077R
87F5546
M2750022SP3T23
FQ2A22ORN
J2515
HSD4123915
600N81077L
87F5548
M2750022SP2T23
FQ3A22ORN
600N81079L
87F5548
600N81077L
87F5548
M2750022SP3T23
JMPR
J2516
HSD4123915
OUTER SHLD
FQ4A22N
OUTER SHLD
OVERBRAID
600N81077
NOTE
M2750022SP2T23
FQ5A22N
OUTER SHLD
OVERBRAID
600N81079
NOTE
M2750022SP2T23
JMPR
J2512 SHLD
HSD4123830
J2515 SHLD
HDS4123915
JMPR
J2515 SHLD
HSD4123830
J2517 SHLD
HDS4123817
JMPR
P1A22 SHLD
HSD4123830
P2A22 SHLD
HDS4123817
J2518
SPARE
J2519
SPARE
J25110
SPARE
J25111
SPARE
J25112
SPARE
J25113
SPARE
NOTE: To 3 probe flange mount bolt.
MS27474P10F35P
J251
1
2
3
4
5
8
7
10
11
12
13
6
9
OUTER
SHIELD BRAID
OUTER
SHIELD BRAID
FQ1A22
WHT
BLU
ORN
WHT
BLU
TO LOW LEVEL SWITCH TERM.. 1 (#4 LUG)

TO LOW LEVEL SWITCH TERM.. 2 (#4 LUG)
TO PROBE TERM.. S (#8 LUG)
FQ2A22
TO PROBE TERM.. R (#6 LUG)
AFT PROBE
TO PROBE TERM.. L (#10 LUG)
FQ4A22
TO AFT PROBE FLANGE MOUNTING BOLT
OUTER SHIELD
BRAID
ORN
FQ3A22
BLU
WHT
FQ5A22
TO PROBE TERM.. L (#10 LUG)

TO PROBE TERM.. R (#6 LUG)
TO PROBE TERM.. S (#8 LUG)
FORWARD PROBE
TO FORWARD PROBE FLANGE MOUNTING BOLT

6G28-020A
Figure 101. Fuel Quantity System Wiring Diagram
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CSP-HMI-2
MAINTENANCE MANUAL
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28-00-60
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
1. Fuel Cell Cleaning General
(1). Fuel cells are susceptible to fungus
growth after contact with contaminated
fuel. Fungus trapped in the fuel filters
indicates fuel tank contamination.
Remove, inspect, clean or replace filter
elements per applicable Allison Engine
Where installed, service anti-ice
(airframe) filter (Ref. Sec. 28-25-00).
(2). Periodic incorporation of an FAA
approved anti-fungal fuel additive will
kill and prevent new fungus growth.
2. Engineered Fabrics Corp. Fuel Cell
Cleaning
Do not steam clean Engineered
CAUTION Fabrics Corp. fuel cells. Steam
cleaning may cause irreparable damage.
(1). Clean cell exterior and interior surfaces
with warm soapy water and clean lint
free cloth. Rinse away all soap residue
and wipe dry.
3. Fuel Cell Handling, Storage and Shipping
Do not use cell fittings as hand
CAUTION holds. Do not store fuel cells un
crated or exposed to direct sunlight, ozone,
dirt, moisture, solvents, chemicals, or ex
tremes of heat and humidity.
(1). Store and ship cells in a suitable
protective container.
(a). Apply protective tape over all cell
machined fittings.
(b). Use packing material to keep the cell
from shifting in transit.
(c). Suspended self-sealing cells to
maintain cell shape.
(Engineered Fabrics Corp. Cells)
(1). Thoroughly clean cell with warm soapy
water. Wipe completely dry.
(2). If a fuel cell that has previously

contained fuel is to be stored for longer
than three days, coat inside of cell with
a light coating of #10 weight, non-syn
thetic engine oil.
CAUTION
D Engineered Fabrics Corp. cells removed
from service must not be left dry for more
than 3 days without the application of oil
as a plasticizing agent. The cell liner will
loose pliability if left dry for extended pe
riods and subsequent flexing may cause
the material to crack.
D Do not work on fuel cell in ambient tem
peratures below 70F (21C).
(a). Fold cell over protective wadding as
loosely as possible and with a mini
mum number of folds.
(b). Wrap the cell in a protective cover.
(c). Put cell in a suitable storage/ship
ping container. Use wadding as
required to prevent movement. Do
not stuff cell into an undersized
container.
(d). Store cell at 70F (21C) away from
sunlight and moisture.
5. Fuel System Air Bleed (Model 250C47
Engine Installation)

(1). Helicopters with C47 engines and
standard fuel supply systems are not
equipped with a start pump.
(2). Helicopters equipped with an airframe
mounted fuel filter are equipped with
an airframe mounted fuel pump inside
the left fuel cell and can be primed
using the same procedure as helicopters
with the 250-C20 Series engines.
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MAINTENANCE MANUAL
CSP-HMI-2
(3). The standard helicopter fuel system

only has an engine driven self priming
pump that will fill the fuel system when
the engine is motored with the starter.
Motor engine per the appropriate Pilot's
Flight Manual.
(e). Open fuel shutoff valve.

(f). Open throttle to ground idle position.
(g). Squeeze primer bulb until fuel comes
out of fuel line.
NOTE: When reinstalling fuel lines, refer to ap
(4). Bleed air out of helicopter engine fuel

controls per Rolls-Royce Engine
propriate Rolls-Royce Operation and Main

tenance Manual for proper torques.
(h). Remove primer bulb assembly from
fuel line and reconnect fuel line to
HMU.
(5). If fuel system fails to bleed properly,

proceed as follows:
(a). Field fabricate a primer bulb assem
bly (Ref. Figure 201).
(i). Crank engine for approximately 15

seconds to verify fuel to fuel nozzle is
free of air in the system.
(b). Disconnect fuel line between CEFA

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

between HMU GEAR INLET and the
CEFA.
(l). Close throttle.

(m). Close fuel shutoff valve.
CLAMPS
BULB PRIMER 5/16

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

(FIELD FABRICATE)
6G28-076
Figure 201. Field Fabricated Fuel System Bleeding Tool
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MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
1. Fuel Shutoff Valve Control Cable
Replacement
A. Fuel Shutoff Valve Control Cable
Removal
(Ref. Figure 401)
(1). Remove left aft access panel from
(2). Disconnect control cable from fuel
shutoff valve swivel.
(3). Remove control cable ty-raps and
clamps.
(4). Remove instrument panel left fairing
and lower cover panels.
(5). Completely back jamnut away from
cable plunger housing (Ref. Figure 401,
view A).
NOTE: Attach a trace wire or cord to the valve

end of the cable before pulling assembly out
of the instrument panel. Trace will guide re
placement cable into correct position.
(6). Pull cable assembly out through
washer, jamnut and instrument panel.
B. Fuel Shutoff Valve Control Cable
Installation
(Ref. Figure 401)
Pulling detent knob out of cable
housing two or more inches may
result in loss of the detent ball.
CAUTION
(1). Thread cable assembly aft through

instrument panel, lockwasher, jamnut
and grommets to fuel shutoff valve.

Maintain a cable bend radius greater
than 3.5 inches (8.89 cm).
(2). Secure forward end of cable in instru
ment panel with lockwasher and
jamnut.
(3). Slip control cable wire through fuel
(4). Secure end of cable housing to cell cover
with a clamp, washer and screw.
(5). Install remaining clamps and ty-raps.
(6). Rig cable with shutoff valve lever hard
against open stop. Adjust cable to get a
0.090 - 0.150 inch (2.29 - 3.81 mm) gap
between bottom of control knob and
cable housing end fitting. Tighten cable
swivel pinch nut. Install cotter pin.
Control action must move valve
to full open against mechanical
stop without bottoming control knob on
cable housing. Control cable operation shall
be smooth with no binding.
CAUTION
(7). Pull valve control knob out with a

spring scale. Required valve actuation
force not to be more than 12 pounds
(5.443 kg).
(8). Repair, adjust or replace valve control
system components to meet force limit.
(9). Install left aft fuel cell access panel
from passenger/cargo compartment
floor.
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MAINTENANCE MANUAL
CSP-HMI-2
INSTRUMENT
PANEL
PLUNGER
HOUSING
CABLE
PLUNGER
DETENT
RELEASE
0.090-0.150 INCH
(2.29-3.81 MM)
SPRING
DETENT
BALL
DETENT
RELEASE
LOCKWASHE
R
CABLE
PLUNGER
PLUNGER
HOUSING
NUT
HOLE
INSTRUMENT
PANEL
CABLE
HOUSING
ENGINE FEED HOSE SHUTOFF
VALVE TO FIREWALL
CONTROL KNOB
ASSEMBLY
FUEL SHUTOFF
VALVE
MOTIVE FLOW HOSE
FIREWALL TO FUEL CELL
SUPPORT
BRACKET
FUEL SHUTOFF
CABLE
NUT
WASHER
WASHER
CLAMP
SCREW
SCREW
SCREW
SCREW
WASHER
CLAMP
CABLE
HOUSING
WASHER
WASHER
CLAMP
CLAMP
WASHER
BRACKET
GROMMET
NUT
PLUG STA
0.000
6G28-021A
Figure 401. Fuel Shutoff Valve Cable Installation

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MAINTENANCE MANUAL
2. Fuel Shutoff Valve Replacement

quately ventilated.
CAUTION
damage.
from cell sump drain valve into a
suitable container.
CSP-HMI-2

from fuel shutoff valve (Ref. Fuel
Shutoff Valve Control Cable Replace
ment).
Handle fuel cell cover with care.
Prying cover from cell opening
or rough handling may damage seal or cell
fitting.
CAUTION
(7). Unbolt cell access cover. Prop cover

separate engine feed fuel cell supply
hose from fuel shutoff valve.
(9). Remove fuel shutoff valve attaching
hardware.
B. Fuel Shutoff Valve Installation
(Ref. Figure 402)
Item
Nomenclature
CM114
Petrolatum
(2). Disconnect electrical power.

A. Fuel Shutoff Valve Removal
(Ref. Figure 402)
(1). Remove left aft fuel cell access panel
floor.
(2). Disconnect fuel quantity probe wire
harness connector from cell cover
receptacle.
102.00 left aft fuel cell cover support
brackets.
(1). Apply a coating of petrolatum (CM114)

to a new fuel shutoff valve/cover
sealwasher.
(2). Install fuel shutoff valve with seal
washer and nut. Use a backup wrench
on shutoff valve so it will not rotate.
Torque nut 240 - 280 inch-pounds
(27.12 - 31.64 Nm).
(3). Connect engine feed fuel supply hose to
fuel shutoff valve. Using a backup
wrench on valve, torque fuel supply
hose 230 - 260 inch-pounds (25.99 29.38 Nm).
(4). Disconnect motive flow fuel hose

assembly between Sta 124.00 bulkhead
and fuel cell access cover. Use backup
wrench on check valve so it will not
rotate.
(4). Start bolts onto aft fuel cell access

cover.
(5). Disconnect engine feed fuel supply hose

assembly between fuel shutoff valve
and Sta. 124.00 bulkhead. Use backup
wrench on fuel shutoff valve so it will
not rotate.
(6). Connect engine feed fuel supply hose

and Sta. 124.00 bulkhead. Torque hose
assembly 230 - 260 inch-pounds
(25.99 - 29.38 Nm).
(5). Install and fasten Sta. 91.00 and 102.00

left fuel cell cover support brackets.
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MAINTENANCE MANUAL
CSP-HMI-2
CAP
BULKHEAD
UNION
BOLT
ENGINE FEED HOSE

SHUTOFF VALVE TO FIREWALL
SHUTOFF
VALVE
SEALING
WASHER
MOTIVE FLOW HOSE

SEALING
WASHER
WASHER
SCREW
WASHER
SCREW
WASHER
REF.
CARGO FLOOR
STRUCTURE
NUT
REF.
CARGO FLOOR
STRUCTURE
WASHER
BRACKET
ASSEMBLY
BRACKET
ASSEMBLY
BOLT
WIRE
HARNESS
RECEPTACLE
WASHER
NUT
ACCESS COVER
FUEL INLET
HOSE ASSEMBLY
BOLT
WASHER
SEALING WASHER
WASHER
NUT
SEALING
WASHER
SUBMERGED
MOTIVE FLOW
HOSE ASSEMBLY
REF. CARGO
FLOOR STRUCTURE
BULKHEAD
ELBOW
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
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MAINTENANCE MANUAL
(7). Connect motive flow fuel hose assembly
between Sta 124.00 bulkhead and fuel
tank access cover. Torque hose assem
bly 55 - 65 inch-pounds (6.21 - 7.34
Nm).
(8). Connect fuel quantity transmitter
(9). Progressively torque fuel cell cover
bolts to 70 - 90 inch-pounds (7.91 10.17 Nm) in a cross pattern.
(10). Clamp and connect control cable to fuel
shutoff valve. Rig fuel shutoff valve
control cable (Ref. Fuel Shutoff Valve
Control Cable Replacement).
(11). Install left aft access passenger/cargo
compartment floor panel.
3. Fuel Cell Cover Replacement
CSP-HMI-2
(a). Remove right side floor panels from

(b). Remove bonding jumpers then
remove fuel cell access cover bolts
and washers.
(2). To remove left aft fuel cell access cover
(Ref. Figure 402):
(a). Remove left aft fuel cell access panel
floor.
(b). Unclamp and disconnect control
cable from fuel shutoff valve (Ref.
Figure 401).
(c). Disconnect engine feed fuel supply
hose assembly between fuel shutoff
valve and Sta. 124.00 bulkhead. Use
backup wrench on fuel shutoff valve
so it will not rotate.

quately ventilated.
(d). Disconnect motive flow fuel hose

assembly between Sta 124.00 bulk
head and fuel cell access cover.
CAUTION
(g). Remove cover bolts and washers.

Prop cover open with suitably padded
blocks.

damage.
suitable container.
A. Fuel Cell Cover Removal
(1). To remove right side fuel cell access
covers (Ref. Figure 406).
(e). Disconnect fuel quantity probe wire

harness connector from fuel cell cover
receptacle.
(f). Unfasten and remove Sta. 91.00 and
brackets.
(h). Using a backup wrench on valve,

hose from fuel shutoff valve and fuel
inlet from fuel cell access cover.
(i). Disconnect submerged motive flow
fuel hose assembly between fuel
check valve and ejector pump from
fuel cell access cover.
(j). Disconnect fuel cell scavenge hose
assembly from bottom of fuel cell
access cover bracket assembly to
ejector pump (Ref. Figure 404).
(k). Cut safety wire from fuel probe
electrical connector base nut and
remove connector from fuel cell
access cover.
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MAINTENANCE MANUAL
CSP-HMI-2
(l). If applicable, remove fuel cell scav

enge hose bracket assembly,bulkhead
union and fuel shutoff valve from fuel
cell cover.
B. Fuel Cell Cover Installation
Item
Nomenclature
CM114
Petrolatum
CM124
Kerosene
CM702
Lockwire CRES

(2). Inspect fuel cell cover seals for debond
Replace covers or left aft cover as
required.
(3). Install bonding jumper with right cell
access covers, bolts and washers (Ref.
Figure 406). Progressively torque cover
bolts to 70 - 90 inch-pounds (7.91 10.17 Nm) in a cross pattern.
(4). To install left aft fuel cell access cover
(Ref. Figure 402):
(a). Apply a coating of petrolatum
(CM114) to a new fuel shutoff valve/
cover sealwasher. Install valve on cell
cover with sealwasher next to valve
body and valve properly aligned to
make connection with valve control
cable. Install and torque valve
jamnut to 240 - 280 inch-pounds
(27.12 - 31.64 Nm).
(b). Apply a coating of petrolatum
(CM114) to sealwasher. Install check
valve and sealwasher to inside cover
and a plain washer outside. Install
jamnut and torque to 85 - 105
(c). Install bulkhead elbow to support
bracket. with washer and nut. Torque
Page 406
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28-00-60

(27.12 - 31.64 Nm).
(d). Install support bracket to cover with
bolts, washer, and sealwashers.
Apply a coating of petrolatum
(CM114) to sealwasher. Torque bolts
36 - 46 inch-pounds (4.06 - 5.19
Nm).
(e). Install bulkhead union to cover with
sealwasher next to union. Apply a
coating of petrolatum (CM114) to
sealwasher. Install washer and
jamnut. Torque jamnut to 120 - 150
inch-pounds (13.56 - 16.95 Nm).
Install cap outside of cell. Torque cap
to 110 - 130 inch-pounds (12.43 14.69 Nm).
(5). Place left forward fuel cell access cover
into position on fuel cell.
(6). Connect fuel quantity probe wire
harness connector to cell cover. Torque
connector jamnut and safetywire to
bulkhead union with (CM702) lockwire.
CAUTION
D On early aircraft, the fuel inlet hose and
the fuel cell scavenge hose have the same
size end fitting. Care must be taken to not
misconnect these two hoses (Ref.
Figure 404).
D The fuel inlet hose is the hose that runs
from the fuel inlet fitting at the bottom of
the fuel cell aft of the fuel cell baffle.
D The fuel cell scavenge hose is the hose
that runs forward over the fuel cell baffle.
(7). Install left hand fuel inlet hose assem
bly to access cover fuel shutoff valve.
Torque hose assembly 230 - 260
inch-pounds (25.99 - 29.38 Nm).
(8). Install submerged motive flow hose
assembly to access cover check valve.
Torque hose assembly 50 - 65 inchpounds (5.65 - 7.34 Nm).
(9). Install scavenge fuel cell hose assembly
to access cover bulkhead elbow. Torque
hose assembly 230 - 260 inch-pounds
(25.99 - 29.38 Nm).
MAINTENANCE MANUAL
(11). Install cover bolts and washers.
Progressively torque cover bolts to 70 90 inch-pounds (7.91 - 10.17 Nm) in
a cross pattern.
fuel shutoff valve. Torque hose nut to
230 - 260 inch-pounds (25.99 - 29.38
Nm).
(13). Connect fuel motive flow hose to access
cover/check valve. Torque hose nut (50
- 65 inch-pounds (5.65 - 7.34 Nm).
(14). Connect fuel quantity probe connector
to wire harness receptacle.
(16). Rig cable control system (Ref. Fuel
Shutoff Valve Control Cable Replace
ment).
(18). Install access panels on passenger
4. Fuel Supply Lines Replacement
quately ventilated.
CAUTION
damage.
CSP-HMI-2

suitable container.
(2). Cap fittings and lines as required.
A. Fuel Supply Lines Removal
floor.
assembly between Sta 124.00 bulkhead
and fuel cell access cover. Use backup
wrench so fittings will not rotate.
and Sta. 124.00 bulkhead. Use backup
wrench on fittings so they will not
rotate.
(4). Remove Sta. 91.00 and Sta.102.00 fuel
cell cover support brackets.
(5). Remove clamps and attaching hard
ware from passenger/cargo compart
ment floor.
(6). Remove engine feed fuel supply hose
and motive flow fuel hose assemblies.
(7). Remove Sta. 124.00 bulkhead unions.
B. Fuel Supply Lines Installation
(1). Install Sta. 124.00 firewall bulkhead
unions, with washer and jam nut on
forward side of firewall. Torque engine
feed fuel supply union nut to 240 - 280
inch-pounds (27.12 - 31.64 Nm).
Torque fuel return by-pass union to 85
- 105 inch-pounds (9.60- 11.86 Nm).
(2). Connect fuel cell engine feed supply
hose to fuel shutoff valve and bulkhead
union. Use a backup wrench on valve
and bulkhead union. Torque fuel supply
hose 230 - 260 inch-pounds (25.99 29.38 Nm).
(3). Connect motive flow fuel hose assembly
between Sta 124.00 bulkhead and fuel
tank access cover. Torque hose assem
bly 50 - 65 inch-pounds (5.65 - 7.34
Nm).
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MAINTENANCE MANUAL
CSP-HMI-2
NUT
WASHER
BULKHEAD
UNION
NUT
ENGINE FEED HOSE
SHUTOFF VALVE TO FIREWALL
WASHER
BULKHEAD
UNION
MOTIVE FLOW HOSE
SCREW
REF. STA 113.85
CARGO FLOOR
WASHE
R
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

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MAINTENANCE MANUAL
CSP-HMI-2
HOSE ASSEMBLY
BOLT
WASHER
SEALING WASHER
FUEL INLET
SUPPLY HOSE
ASSEMBLY
CHECK
VALVE
AFT FUEL
PROBE
NUT
SUBMERGED
MOTIVE FLOW
HOSE ASSEMBLY
WASHER
BOLT
BULKHEAD ELBOW
WASHER
BONDING
JUMPER
BOLT
BRACKET
ASSEMBLY
BOLT
WASHER
NUTPLATE
WASHERS
FUEL INLET
FITTING ASSEMBLY
WASHER
NUT
FUEL CELL SCAVENGE
HOSE ASSEMBLY
BRACKET ASSEMBLY
BOLT
NUTPLATE
EJECTOR
PUMP
WASHER
FUEL CELL
SCAVENGE
HOSE ASSEMBLY
EJECTOR
BRACKET ASSEMBLY
SPACER
SUBMERGED
MOTIVE FLOW
HOSE ASSEMBLY
CLAMP
O-RING
WASHER
BOLT
EJECTOR PUMP
ELBOW
REDUCER
BUSHING
NUT
FORWARD
FUEL PROBE
O-RING
6G28-024-2
Figure 404. Ejector Pump and Fuel Lines Installation
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MAINTENANCE MANUAL
CSP-HMI-2

(5). Apply chaffing tape between hose
assemblies and fuel cell cover assembly
to prevent chaffing.
(6). Secure engine feed hose assembly and
motive flow hose assembly underneath
passenger/cargo floor with clamps and
attaching hardware.
A. Fuel Cell Vent System Components

Removal
(Ref. Figure 405)
(1). Remove fuel vent cross over tube access
cover and Sta.78.50 chanted bulkhead
stress panel.
(2). Remove flame arrestor/tube assembly
with clamps and attaching hardware.
(7). Secure fuel cell to Sta. 91.00 and

Sta.102.00 cell cover support brackets.
(3). Disconnect hoses from vent cross-overtube and attaching hardware and
remove crossover tube.
(8). Install aft fuel cell access panel from


floor fuel cell access panels.
5. Fuel Cell Vent System Components

Replacement

quately ventilated.
CAUTION tion. Install caps on the ends of
suitable container.

(3). Ventilate fuel tank with an inert gas,
such as nitrogen, or low pressure
neck.
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28-00-60
(5). Disconnect hoses from aft fuel vent

valves, remove bonding jumper and
attaching hardware from vent tubes
and remove fuel vent tubes from under
cargo floor.
(6). Remove bonding jumper and fell cell
access covers as required.
(7). Remove retaining ring and spring from
fuel vent valve and remove fuel vent
valve from inside of fuel cell.
B. Fuel Cell Vent System Components
Installation
(Ref. Figure 405)
Item
Nomenclature
CM114
CM411
CM702
Petrolatum
Adhesive, epoxy
Lockwire CRES
(1). Coat O-rings with (CM114) lubricant

and install on vent valves.
(2). Insert vent valves thru cell from inside
and secure using springs and retainers.
(3). Bond prep aft vent fittings at bond
jumper location.
(4). Coat O-rings with lubricant (CM114)
and install on vent fittings.
MAINTENANCE MANUAL
CSP-HMI-2
BOLT
WASHER
SCREW
REF. FS 78.50
CANTED BULKHEAD
BONDING
JUMPER
WASHER
FLAME
ARRESTOR
BOLT
WASHER
(3 PLCS)
WASHER
(3 PLCS)
CLAMP
VENT
TUBE
WASHER
CLAMP
SCREW
WASHER
NUT
NUT
VENT
FITTING
TUBE ASSEMBLY
NUT
(3 PLCS)
CLAMP
SCREW
WASHER
NUT
CLAMP
(3 PLCS)
GROMMET
CONNECTOR
NUT
(2 PLCS)
CLAMP
(2 PLCS)
TUBE ASSEMBLY
WASHER
(2 PLCS)
CLAMP
(2 PLCS)
HOSE
(2 PLCS)
FLAME
ARRESTOR
(2 PLCS)
BOLT (2 PLCS)
0-RING
NUT
(2 PLCS)
RETAINING
RING (2 PLCS)
WASHER
(2 PLCS)
BOLT
WASHER
CLAMP
WASHER
BOLT
(2 PLCS)
WASHER
(2 PLCS)
CROSSOVER
ASSY
WASHER
(2 PLCS)
SPACER
(2 PLCS)
WASHER
(2 PLCS)
PIN (2 PLCS)
SPRING
RETAINER
0-RING
NUT
VENT VALVE
(2 PLCS)
Figure 405. Fuel Cell Vent System Components
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CSP-HMI-2
MAINTENANCE MANUAL
(5). Install aft vent fittings and bond

jumpers to vent valves with hardware.
Torque bolts to 36 - 46 inch-pounds
(4.0 - 5.2 Nm).
(6). Bond prep six vent tube clamp screw
holes on cargo deck.
(7). Install hoses to aft vent fittings with
lockwire (CM702), two wrap around
turns minimum.
(8). Slide vent tubes under cargo floor and
connect to hoses with lockwire
(CM702), two wrap around turns
minimum.
(9). Attach forward end of tube to cargo
floor with clamps.
(10). Install bonding jumpers at aft clamps.
(11). Install hoses on forward ends of vent
tubes and safety using lockwire
(CM702), two wrap around turns
minimum.
(12). Coat O-rings with lubricant (CM114)
and install on cross-over tube.
(13). Attach vent cross-over tube with
hardware to tops of vent valves. Torque
bolts to 36 - 46 inch-pounds (4.06 5.19 Nm).
(14). Bond prep two nutplate holes for
attaching cross-over tube.
(15). Install clamps on cross-over tube and
attach to airframe.
(21). Safety connector to cross-over tube

with lockwire (CM702).
(22). Tie-rap tube assembly to forward
bulkhead of Sta. 78.50.
(23). Route tube assembly to vent fairing and
bond using sealant (CM425).
(24). Bond prep fuel cell access covers.
(25). Install bonding jumpers and fell cell
access covers. Torque bolts 70 - 90
Install fuel vent access cover.
(26). Install passenger/cargo compartment
floor access panels.
6. Fuel Cell Replacement

quately ventilated.
CAUTION
D Do not work on cell in ambient tempera
tures below 70F (21C).
damage.
(16). Install grommet in Sta. 78.50 skin at

vent outlet using epoxy adhesive
(CM411).

suitable container.
(17). Attach connector to the flame arrestor

and safety with lockwire (CM702), two
wrap around turns minimum.
(18). Attach tube to flame arrestor and

safety with lockwire (CM702) two wrap
around turns minimum.
A. Fuel Cell Removal

(Ref. Figure 406)
NOTE: The following procedures are required
(19). Bond prep one of the three attaching

screw holes for the flame arrestor.
to access and separate the fuel cell intercon

nect fitting, vent system and gravity fill port
before either cell can be removed from its
bay.
(20). Install flame arrestor/tube assembly

with clamps.
(1). Remove forward fuel vent crossover

tube cover, right and left fuel cell access
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MAINTENANCE MANUAL
panels from passenger/cargo compart
ment floor.
(2). Disconnect fuel quantity probe wire
harness connector from fuel cell access
cover receptacle.
brackets from passenger/cargo floor
structure (Ref. Figure 402).
(5). Remove attaching hardware from Sta
102.230 and Sta 113.850 passenger/car
go compartment floor structure that
secures engine feed fuel supply hose
and motive flow firewall to fuel cell
hose to bottom of floor (Ref.
Figure 403).
between fuel shutoff valve and firewall
Sta. 124.00 bulkhead union. Using a
backup wrench on bulkhead union so it
will not rotate, disconnect and remove
engine feed fuel supply hose assembly
(Ref. Fuel Supply Line Replacement).
assembly between fuel cell access cover
and Sta 124.00 bulkhead. Using a
backup wrench on bulkhead union so it
will not rotate, disconnect and remove
motive flow fuel hose assembly.
Handle fuel cell covers with
CAUTION care. Prying covers from cell
openings or rough handling may damage
the cover seal or cell fitting.
(8). Unbolt and prop left aft fuel cell access
cover open with suitably padded blocks.
(9). Disconnect fuel inlet supply hose
between fuel shutoff valve fuel cell
access cover and fuel inlet support
bracket (Ref. Figure 402 and
Figure 404).
(10). Disconnect submerged motive flow fuel
hose assembly between fuel check valve
fuel cell access cover and ejector pump.
CSP-HMI-2
(11). Disconnect submerged fuel cell scav

enge hose assembly from bottom of fuel
cell access cover bracket assembly to
ejector pump (Ref. Figure 404).
(12). Cut safety wire from fuel probe electri
cal connector base nut and remove
connector from fuel cell access cover.
(13). Unbolt and remove right hand fuel cell
access cover(s) and bonding jumpers.
Remove left hand forward fuel cell
access cover.

(14). Mop up any remaining fuel in both cells
with clean lint free cloth. Purge fuel
cells with dry, forced air or inert gas
such as nitrogen through filler neck.
(15). Disconnect wire harness from forward
and aft fuel quantity probe and remove
wire harness (Ref. Fuel Quantity Probe
Replacement).
(16). Remove aft fuel quantity probes, fuel
inlet with fuel supply hose and bracket
assembly, forward fuel quantity probe,
ejector pump with submerged motive
flow fuel hose assembly and fuel cell
scavenge hose as a subassembly (Ref.
Figure 404 and Figure 407).
(17). Disconnect and remove fuel vent
system components necessary to
remove fuel cell (Ref. Fuel Cell Vent
System Component Replacement).
NOTE: At this point either cell may be re

moved, as required.
(18). Remove sump drain valve.
(19). Remove retaining ring and spring from
fuel cell interconnect fittings (Ref.
Figure 406).
(20). Remove cell suspension cords.
(21). For right fuel cell removal:
(a). Remove fuel filler neck fairing from
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Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
(b). Unclamp fuel gravity filler port from

fill valve, remove hose from fill valve
and disconnect lanyard.
tings.
CAUTION
(22). Collapse and fold cell lengthwise and

B. Fuel Cell Installation
(Ref. Figure 406)
Item
Nomenclature
CM114
CM220
CM702
CM809
Petrolatum
Naphtha aliphatic
Lockwire CRES
Nylon cord

quately ventilated.
NOTE: Discard used O-rings and sealwashers.

Apply a thin coat of petrolatum (CM114) to
all new O-rings except cell vent system
sealwashers.
(1). Air-vacuum all debris from cell bays.
Ensure compartment liner will protect
cell from airframe points and edges.
Repair liner as required.
(2). Bond prep fill valve with fuel cell
fitting. Coat O-rings with lubricant
(CM114) and install fill valve into right
fuel cell with O-ring, spring and
retaining ring. Ensure clocking of fill
valve with flat at top lines up with
shoulder on fuel cell fitting.
(3). Hook up fuel cell interconnect fittings
into left fuel cell. Ensure short end of
interconnects are facing into left fuel
Page 414
Revision 43
28-00-60
cell. Coat O-rings with lubricant

(CM114) and install O-ring, spring and
retaining ring.
tings. Avoid hard contact between cell and
fuselage structure when inserting.
CAUTION
(4). Fold cells lengthwise and position in

bay through floor opening. Unfold cell
and smooth out all creases.
(5). Align cell openings with airframe
openings. Hook up fuel cell cross over
interconnects into right fuel cell. Coat
O-rings with lubricant (CM114) and
install O-ring, spring and retaining
ring.
(6). Install a new O-ring on sump drain
valve. Install valve and torque to 95 105 inch-pounds (10.73 - 11.86 Nm).
Safety wire drain valve with lockwire
(CM702).
(7). For right fuel cell installation:
(a). Install rubber hose to fill valve and
filler neck, hose should be approxi
mately six an one half inches (16.5
cm) long. Secure hose to fill valve and
filler neck with clamps.
(b). Ensure lanyard on filler valve is
accessible with fill cap removed. Slip
lanyard on fuel cap onto ring of fill
valve. Install fuel cap.
(c). Connect lanyard of fill valve to
gravity filler port. Install hose and
clamp.
(8). Connect engine feed fuel supply hose
and motive flow fuel hose assembly to
Sta. 124.00 bulkhead union (Ref. Fuel
Supply Line Replacement).
(9). Install fuel vent system components
(Ref. Fuel Vent System Components
Replacement).
(10). Route suspension nylon cord (CM809)
thru grommet of fuel cell and thru
eyelets of fuselage. Tighten and tie cord
using a bowline knot. Cut excess cord
after knot to approximately 3 to 4
inches (7.6 cm to 10.2 cm) in length.
MAINTENANCE MANUAL
(11). Secure opposite end of cord using a
trucker's slip knot. Cut excess cord
after knot to approximately 3 to 4
inches (7.6 cm to 10.2 cm) in length.
(12). Forward fuel probe and ejector pump
subassembly installation (Ref. Ejector
Pump and Fuel Line Installation):
(a). Bond prep ejector pump bracket
assembly with forward fuel probe and
ejector pump assembly.
(b). Coat O-rings with lubricant (CM114)
and install reducer bushing with
O-rings into ejector pump. Torque to
50 - 65 inch-pounds (5.65 - 7.34
Nm).
(c). Coat O-rings with lubricant (CM114)
and install jamnut, bulkhead elbow
to reducer bushing. Torque jamnut to
85 - 105 inch-pounds (9.60 - 11.86
Nm).
(d). Install fuel cell scavenge hose to
ejector pump. Torque hose nut to 230
- 260 inch-pounds (25.99 - 28.81
Nm).
(e). Install submerged motive flow fuel
hose assembly to elbow and torque to
50 - 65 inch-pounds (5.65 - 7.34
Nm).
(f). Bond prep ejector pump in area of
clamp up and install forward fuel
quantity probe, ejector pump with
submerged motive flow hose assem
bly and fuel cell scavenge hose
assembly as a subassembly.
(g). Install ejector pump subassembly to
bracket assembly with clamps, bolts
and washers. Torque bolts to 36 - 46
(h). Connect wire harness to forward fuel
probe. Route submerged motive flow
fuel hose assembly, fuel cell scavenge
hose assembly and wire harness thru
fuel cell fabric retaining loops and
baffle (Ref. Fuel Quantity Probe
Replacement).
CSP-HMI-2
(13). Aft fuel probe and fuel supply inlet hose

installation (Ref. Ejector Pump and
Fuel Line Installation):
(a). Bond attachment holes on fuel cell
aft sump fitting assembly, bracket
assembly, aft fuel probe attachment
holes and fuel inlet fitting assembly.
(b). Install fuel inlet fitting assembly to
bracket assembly with four washers
each between fuel inlet fitting and
bracket assembly.
(c). Install aft fuel probe to bracket
assembly and fuel cell aft sump
fitting with bolts and two washers
under the head of each bolt, except
bolt with ground wire, only one
washer is required.
(d). Connect wire harness to aft fuel
probe. Attach bonding jumper to
outboard bolt of probe. Torque bolts
to 36 - 46 inch-pounds (4.06 - 5.19
Nm) (Ref. Fuel Quantity Probe
Replacement).
(14). Install attaching hardware from Sta
102.230 and Sta 113.850 passenger/car
go compartment floor structure that
secures engine feed fuel supply hose
and motive flow firewall to fuel cell
hose to bottom of floor (Ref.
Figure 403).
(15). Install right hand fuel cell access
covers, left hand forward and left hand
aft access cover (Ref. Fuel Cell Cover
Replacement).
(16). Connect fuel quantity probe wire
harness connector from fuel cell access
cover receptacle.
(17). Connect and clamp control cable from
fuel shutoff valve (Ref. Fuel Shutoff
Valve Control Cable Replacement).
(18). Install forward fuel vent crossover tube
cover, right and fuel cell access panels
floor.
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MAINTENANCE MANUAL
CSP-HMI-2
RETAINING
RING
SPRING
INTERCONNECT
SPRING
BL
0.000
CENTER BEAM
ASSEMBLY
RETAINING
RING
RETAINING
RING
O-RING
SPRING
RETAINING
RING
INTERCONNECT
SPRING
RIGHT
FUEL CELL
LEFT
FUEL CELL
O-RING
6G28-025-1
Figure 406. Fuel Cell Interconnect and Support Lacing (Sheet 1 of 3)

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Revision 19
28-00-60
MAINTENANCE MANUAL
START HERE
BOWLINE KNOT
CSP-HMI-2
END HERE
TRUCKER SLIPKNOT
BONDING
JUMPER
END HERE
TRUCKER SLIPKNOT
START HERE
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
28-00-60
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Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
TRUCKER SLIPKNOT
6G28-025-3
LEFT
BAFFLE
RIGHT
BAFFLE
GROMMET
(6 PLCS)
FLAPPER CHECK VALVE

IN CLOSED POSITION
FLAPPER CHECK VALVE

IN OPEN POSITION
Page 418
Revision 19
28-00-60
MAINTENANCE MANUAL
7. Fuel Filler Neck Gravity Fill Port
Replacement
(Ref. Figure 406)

quately ventilated.
CAUTION

drained prior to removing grav
ity fill port.

suitable container.
A. Fuel Filler Neck Gravity Fill Port Removal
(1). Remove fuel filler neck fairing from
(2). Unclamp fuel gravity filler port from fill
valve, remove hose from fill valve and
disconnect lanyard.
(3). Remove bolts and washers from filler
neck mounting flange and remove
gravity fill port.
(4). Insure lanyard on filler valve is

accessible with fill cap removed. Slip
lanyard on fuel cap onto ring of fill
valve. Install fuel cap.
(5). Connect lanyard of fill valve to gravity
filler port. Install hose and clamp.
8. Fuel System Drain Valve Replacement

quately ventilated.
drained prior to removing tank
sump drain valve.
CAUTION
(1). Defuel helicopter, as required. Drain

remaining fuel from tank sump drain
valve into a suitable container.
A. Fuel System Drain Valve Removal
(1). Remove lockwire from tank sump drain
valve.
(2). Using appropriate socket or wrench,
remove drain valve.
B. Fuel System Drain Valve Installation
B. Fuel Filler Neck Gravity Fill Port

Installation
(1). Bond prep attach points for bonding
jumper near fuel fill area. Attach
bonding jumper to fuel cell with screw
and washer. Attach opposite end of
bonding jumper to passenger/cargo
compartment flooring with screw,
washers and nut.
(2). Install bolts and washers from filler
neck mounting flange and install
gravity fill port.
(3). Install rubber hose to fill valve and
filler neck. Note, hose should be
approximately six an one half inches
long. Secure hose to fill valve and filler
neck with clamps.
CSP-HMI-2
Item
CM114
CM124
CM702
Nomenclature
Petrolatum
Kerosene
Lockwire CRES
(1). Replace drain valve O-ring packings.

Lubricate packings with kerosene
(CM124), petrolatum (CM114) or jet
fuel.
(2). Install and torque sump drain valve to
95 - 105 inch-pounds (10.73 - 11.86
Nm). Safety valve with lockwire
(CM702).
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MAINTENANCE MANUAL
CSP-HMI-2
B. Forward Fuel Quantity Probe Installation

(5). Check drain valve for leakage.
9. Fuel Quantity Probe Replacement

quately ventilated.
suitable container.
(Ref. Figure 407)

(1). Install fuel quantity probe ground wire
and attaching hardware. Torque bolts
to 36 - 46 inch-pounds (4.06 - 5.19
Nm).
(2). Connect wire harness connector ends to
forward fuel probe in the same locations
as removed.
(3). Bond prep fuel cell access cover.
(4). Install left forward fuel cell access
cover. Install bonding jumper to fuel
cell access cover. Torque bolts to 70 - 90
inch pounds (7.91 - 10.17 Nm).
panel from passenger/cargo compart
ment floor.
C. Aft Fuel Quantity Probe Removal
(Ref. Figure 407)
(3). Ventilate fuel tank with an inert gas

such as nitrogen or low pressure
neck.

floor.
A. Forward Fuel Quantity Probe Removal
(2). Remove left aft fuel cell access cover

(Ref. Fuel Cell Cover Replacement).
(Ref. Figure 407)

(1). Remove left forward fuel cell access
ment floor.
(3). Disconnect wire harness connector ends

from aft fuel probe.
(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

from forward fuel probe.
(c). Remove WHITE wire from terminal

S.
(a). Remove ORANGE wire from termi

nal L.
(b). Remove BLUE wire from terminal R.
(c). Remove WHITE wire from terminal
S.
(4). Remove GROUND wire from probe
mount flange, remaining attachment
hardware and remove probe.
Page 420
Revision 19
28-00-60
(d). Remove low level switch WHITE wire

from terminal 1.
(e). Remove low level switch BLUE wire
from terminal 2.
(f). Remove GROUND wire from probe
mount flange, remove remaining
attachment hardware and remove
probe.
MAINTENANCE MANUAL
CSP-HMI-2
REF. FUEL CELL

FABRIC LOOPS
FUEL CELL SCAVENGE

HOSE ASSEMBLY
EJECTOR
BRACKET
ASSEMBLY
SCAVENGE
HOSE ASSEMBLY
BOLT
SUBMERGED MOTIVE
FLOW HOSE
WASHER
WIRE HARNESS
BOLT
WASHER
EJECTOR
PUMP
FORWARD
FUEL PROBE
FUEL CELL FITTING
FORWARD FUEL PROBE
6G28-051-1A
Figure 407. Fuel Quantity Probes (Sheet 1 of 2)
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Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
AFT FUEL PROBE
BOLT
BOLT
WASHER
WASHER
GROUND
JUMPER
WASHE
R
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
(Ref. Figure 407)
(1). Install fuel quantity probe ground wire
and attaching hardware. Torque bolts
to 36 - 46 inch-pounds (4.06 - 5.19
Nm).
Page 422
Revision 19
28-00-60
(2). Connect wire harness connector ends to

forward fuel probe in the same locations
as removed.
(3). Install left aft fuel cell access cover
(Ref. Fuel Cell Cover Replacement).
ment floor.
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
ADJUSTMENT/TEST
1. Fuel Level Low Light/Fuel Quantity
Indicator System Test and Calibration
(5). Level the helicopter laterally across the

The following procedure is for calibrating the

fuel quantity system when the fuel cell, fuel
probes or fuel quantity indicator have been
replaced.
(6). Plug in and switch on 27.5 0.5 Vdc

external power. Set BAT master switch
to EXT PWR. Make sure the INST and
PNL LT circuit breakers are pushed in.
NOTE: All readings are taken from the center

Item
Special Tools
Nomenclature
ST203
ST205

Inclinometer
WARNING lation, ignition and fire. At
tach helicopter to an approved electri

cal ground. Switch OFF and disconnect
opening fuel system. Perform work in
an open, well ventilated area away
from all potential ignition sources. Use
only nonsparking tools and explosion
proof work lights.
(1). Attach helicopter to a approved electri
cal ground.
(2). Defuel and drain fuel cell sumps of all
fuel from all four sump drains with the
helicopter at normal ground attitude.
(3). Place an aircraft jack (ST203) under the
aft jacking point.
Do not apply more than 500 lb.
(227 kg) pressure on aft jacking
point, damage to tailboom and attachment
points will occur.
CAUTION
(4). Locate a inclinometer (ST205) on the

passenger/cargo compartment floor at
approximately fuselage Sta. 100.00 104.00. Raise the helicopter at Sta.
303.03 with jack (ST204) and P.Sta.
18.76 with jacks (ST203) to obtain a 3
degree nose down simulated flight
attitude as observed on the inclinome
ter scale.
line of the fuel quantity indicator pointer.

(7). Verify the FUEL LEVEL LOW light is
illuminated.
(8). Add 1.3 gals (4.92 Liter) of fuel from a
calibrated delivery system to the fuel
cell. This amount of fuel is trapped fuel
or unusable fuel. Calibrate empty.
(a). Calibrate zero on the fuel quantity
indicator by holding the fuel quantity
gauging system calibration switch in
the empty calibration position (down)
for a minimum of 5 - 10 seconds.
(b). Verify the the fuel quantity indicator
now reads empty. Empty is the E
with the pointer centerline between
the outer and inner edge of the E
graduation mark.
(9). Add 11.4 gals (44.3 Liter) of fuel from a
calibrated delivery system to the fuel
cell.
(10). Verify the FUEL LEVEL LOW light is
not illuminated.
(11). Wait 15 minutes and verify the FUEL
LEVEL LOW light is not illuminated. If
light illuminates:
(a). Inspect baffles for damage, tears,
punctures or delamination.
(b). Inspect flappers for proper seating.
Flappers should seat flush with
gravity or very light finger pressure
and should move freely.
(12). Fill the fuel cell and secure the fuel
filler cap.
(a). Calibrate full on the fuel quantity
indicator by holding the fuel quantity
gauging system calibration switch in
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Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
the full calibration position (up) for a

minimum of 5 seconds.
(b). Verify the the fuel quantity indicator
now reads approximately 759 pounds
(344.28 kg).
(13). Place the BAT master switch to OFF
position. Disconnect external power.
2. Fuel Filter (Bypass) Caution Light
Pressure Switch Test
(Ref. Figure 501)

NOTE: For all torques in the following proce

dures, refer to Engine Build-Up, Section
71-00-47.
(1). Set all switches; OFF. Disconnect
external electrical power. Disconnect
battery.
(3). Locate pressure switch on engine fuel
pump filter. Disconnect bypass switch
wire knife splice.
CAUTION
D Bypass pressure switch is not field repair

able. Do not disassemble switch. Return
faulty switches to vender for repair (Ref.
Sec. 01-00-00).
(4). Disconnect hose from fuel filter pres
sure switch. Install an airtight plug to
hose.
(5). Remove fuel pressure switch with
reducer bushing.
Revision 22
(7). Bench test 600N8131 bypass pressure

switch as follows (denoted by six
housing screws):
test lead to one of three screws on the
housing body.
(b). Remove reducer bushing and O-ring
from switch. Wipe switch completely
dry so any leakage can be detected
during the test.
(c). Apply 2.0 to 3.0 psig (13.8 - 20.68
Kpa) at port `À'' .
1). There shall be no evidence of
leakage. Replace a leaky switch.
2). When air pressure is applied,
switch shall be close when pres
sure at port `À'' is 2.1 - 2.9 psid,
pound per square inch differential
(4.3 - 5.9 in. Hg, inch of mercury).
3). When air pressure is bled off,
switch shall be open when pres
sure at port `À'' is 1.0 psid (2.0 in.
Hg).
(d). Remove test equipment.
D Pressure switch is easily damaged. A

slight shearing force applied to half the
pressure switch can cause leakage and, or
operational failure. Always grip both
halves of pressure switch hex flats with
wrench when loosening or torquing at
taching hardware.
Page 502
(6). With reducer bushing removed from tee

fitting, install an O-ring on a suitable
airtight plug and tighten into tee
fitting.
28-00-60
(8). Remove plug from tee fitting. Install

reducer bushing and bypass switch
assembly with new O-rings on reducer
bushing and bypass switch. Torque
switch assembly.
(9). Remove plug from bypass hose. Attach
hose to switch bushing. Torque hose
nut.
(10). Install insulating sleeve and connect
(11). Bleed fuel system.
(12). Operate engine per Pilot's Flight
Manual and check fuel system for
correct operation. Shut down engine.
Inspect fuel system for leaks.
MAINTENANCE MANUAL
CSP-HMI-2
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
LOOKING FORWARD
PORT B
OHMMETER
OR
CONTINUITY TESTER
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)
28-00-60
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Revision 21
CSP-HMI-2
MAINTENANCE MANUAL
Page 504
Revision 44
28-00-60
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
INSPECTION/CHECK
WARNING
ventilated.
D Air entering the airframe fuel supply
lines may cause a power reduction or
flameout. Fuel system vacuum leak
check and fuel air bleed procedures
must be performed after opening fuel
the supply system for any reason,
prior to releasing helicopter for
flight.
1. Fuel System General Inspection
(1). Remove all fuel tank floor access
panels.
(2). Inspect fuselage bottom skin for
evidence of fuel leakage. No leaks
allowed. Determine source and repair
as required.
(3). Inspect fuel lines, fittings, cell access
covers, fuel quantity unit, clamps and
attaching hardware for leakage,
corrosion and security. Inspect fire
sleeves for cuts, tears and punctures.
No leakage allowed. Repair or replace
(4). Inspect electrical wiring and connectors
for corrosion and security. Replace or
repair wiring as required.
2. Fuel Shutoff Valve Inspection

(1). Shut down and disconnect all electrical
power.
(a). In cargo/passenger compartment,
open left aft fuel cell access panel.
(b). Disconnect fuel supply tube from fuel
shutoff valve.
(c). Use an inspection mirror and flash
light to check shutoff valve ball
position.
(d). Ensure shutoff valve control knob is
pushed in. Valve ball must be wide
open.
(e). Pull control knob out to stop. Valve
ball should be closed.
(2). Valves that can not be fully closed or
opened must be overhauled or replaced
prior to further flight.
(3). Disconnect control cable from valve.
(a). Inspect shutoff valve lever and cable
swivel hardware for corrosion and
wear. Check lever for smooth move
ment from closed to open stops.
(b). Use a spring scale to check tension
required to move valve lever from full
open to closed. Design force require
ment is 1.5 - 3.5 pounds (6.7 - 15.6
N) maximum.
(c). Inspect valve for evidence of external
leakage. External leakage not
allowed.
(d). Check that lever detents at open and
closed positions. Repair or replace
valve as required.
(4). Connect and rig valve control cable.
Install cotter pin on cable swivel.
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MAINTENANCE MANUAL
CSP-HMI-2
3. Tank Vent System Inspection
hardware. Repair or replace vent

float/rollover valve as required.

quately ventilated.
CAUTION

suitable container.
4. Fuel Quantity Probe Inspection

(1). Inspect probe wire harness electrical
connector for serviceable conditional.
(2). Inspect for bent or broken pins, frayed
or broken wires. Repair or replace as
required,
5. Fuel System Vacuum Leak Inspection
(Ref. Figure 601) Water, ice, dirt, fungus or a
few pinhole leaks in the supply system
between the fuel tank sump pickup and engine
driven fuel pump may cause power surges,
deceleration and, or flameout. A vacuum leak
inspection will determine whether or not air is
being drawn into the engine fuel supply
system.
(3). Remove all four passenger/cargo access

panels.
(4). Remove fuel vent cross over tube access
cover and disconnect hoses from
forward vent crossover tubes.
(5). Blow low-pressure compressed air
through vent system to verify passages
are clear.
(6). Check vent fairing passages for obstruc
tions and condition. Repair or replace
fairings as required.
(7). Inspect vent system hoses for deteriora
tion. Pinch or bend hoses and look for
surface cracks. Replace hose if cracks
are apparent.
(8). Inspect vent tubes for dents, cracks,
deformation or corrosion. Smooth
nonrestrictive dents are permissible
except at lower vent end which must fit
flush within vent fairing flared riser.
(9). Inspect crossover fittings for cracks,
dents or corrosion. Smooth nonrestric
tive dents are permissible.
(10). Inspect fuel vent float/rollover valves
for serviceable condition, leakage and
corrosion. Inspect for loose or missing
Page 602
Revision 31
28-00-60
Item
Special Tools
Nomenclature
ST801
Hand operated vacuum pump kit
Air entering the airframe
WARNING fuel supply lines may cause
a power reduction or flameout. Fuel

system vacuum leak check and fuel air
bleed procedures must be performed
after opening the fuel supply system
for any reason, prior to releasing heli
copter for flight.
(2). Pull FUEL shutoff valve knob out to
stop. Verify that fuel shutoff valve lever
is hard against its OFF stop.
(3). In engine compartment; remove and
plug the motive fuel line at the CEFA.
(4). Assemble vacuum pump (ST801) hoses,
filter port adapter, shutoff valve and
vacuum gauge.
(a). Install the vacuum gauge in the line
between the filter port adapter and
shutoff valve. Attach the vacuum
pump above the shutoff valve.
MAINTENANCE MANUAL
CSP-HMI-2
MOTIVE FUEL LINE

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

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 fuel
filter upper drain port. Apply 8.0 Hg
vacuum. Close vacuum line shutoff
valve.
(6). Fuel system shall hold vacuum between
8.0 and 7.5 Hg for two minutes.
(7). If test is satisfactory, remove test
vacuum.
(8). Reconnect and torque the fuel vapor
return line.
NOTE: Vacuum loss exceeding 0.5 Hg in two

minutes indicates a leak in the system be
tween, and including, the fuel shutoff valve
and engine.
(9). Retorque fuel line connections and
where installed, anti-ice (airframe) fuel
filter fittings and line nuts (Ref. Sec.
28-25-00). Repeat vacuum test.
(10). If system continues to leak, disconnect
and install airtight caps on lines and
fitting ports in a progressive sequence
from fuel shutoff valve toward engine.
The fuel shutoff and drain valve

installations should be especially
suspect. Apply vacuum at each stage
until leak has been isolated. Replace
parts as required.
NOTE: If the vacuum held at 7.5 Hg or better,

airframe system seal is satisfactory and
leak is due to an engine fuel system prob
lem. Refer to the applicable Allison and Ben
dix manuals for additional information.
(11). Apply a torque stripe to all effected fuel
line fittings and nuts.
6. Drain Valve Inspection

check and fuel system air bleed after
opening fuel system to atmosphere and
(1). Inspect tank sump drain valves for
leakage and security. No leakage
allowed. Replace valve as required.
28-00-60
Page 603
Revision 31
CSP-HMI-2
MAINTENANCE MANUAL
7. Fuel Cell Inspection
8. Fuel Cell Leak Inspection
CAUTION
D Do not work on Engineered Fabric Corp.
70F (21C).
D Do not remove fuel cells unless absolutely
required.
D The barrier can be invisibly torn, punc
tured or cracked by careless handling.
D Do not carry or move cell by its metal fit
tings.
D Never probe cell material with sharp
edged or pointed tools.
Item
Nomenclature
N/A
N/A
N/A
CM218
CM810
CM820
Ammonia
Cloth, cotton flannel
Phenolphthalein, crystalline
Alcohol, denatured
Cheesecloth
Any one of three techniques can be used to find

leaks in non-self-sealing and self-sealing fuel
cells. The methods are listed in ascending
order of effectiveness and complexity in terms
of required equipment, materials, time, and
effort.
Soap bubble leak inspection.
Phenolphthalein stain inspection.
NOTE:
Liquid stand inspection.
D Non-self-sealing and self-sealing cells

are primarily a 0.002 inch (0.051 mm)
thick nylon barrier membrane sand
wiched between lightweight construc
tions of either rubberized (Uniroyal) or
plasticized (Engineered Fabrics Corp.)
nylon fabric that protects and strength
ens the barrier.
D Self-sealing cells may have one or more
thin layers of natural rubber sandwiched
between the barrier and fabric plies.
(1). Apply protective tape to all machined
metal fittings.
NOTE: The soap bubble and phenolphthalein

inspections require the cell to be inflated
with air.
(1). Manufacture or supply the following
equipment necessary to do soap bubble
or phenolphthalein inspections:
(a). Rigid, airtight closures or plugs to
seal all cell openings. Fit one cover
plate with:
(b). An air pressurization inlet fitting.
(c). A manometer or an extremely
accurate and sensitive low pressure
air gauge.
A. Soap Bubble Leak Test Procedures
NOTE: Soap bubble test reliability is good for

(2). Perform cell inspection on a padded,
clean, craft paper covered surface.
(3). Inspect fuel cells per applicable man
ufacturers requirements (Ref. Sec.
01-00-00).
Page 604
Revision 31
28-00-60
bladder type non-self-sealing cells.

cell closures.
(3). Inflate cell to 1/4 psi (1.7 kPa), maxi
mum.
MAINTENANCE MANUAL
(4). Unless leak is immediately evident,
maintain 1/4 psi (1.7 kPa) pressure for
two hours to allow any air trapped in
cell exterior laps and seams to escape.
(5). Run soap solution around all patches,
lap joints, seams, fittings, creases,
abrasions and any other suspicious
areas. Bubbles will appear over a leak.
(6). Mark leak areas with a white or yellow
crayon.
CSP-HMI-2
(f). Inspect the entire exterior surface of

the cell.
C. Liquid Stand Inspection
(1). Remove cell from helicopter and place
on a clean, padded, kraft paper covered
table.
(2). Fabricate closure plates for each cell
opening.
(a). The object is to completely fill the cell

and eliminate all air pockets. Equip
one of the plates with liquid filler and
vent stand pipes at least six inches
(15 cm) tall.

all but one of the cell closures.
(b). Fill the cell with Stoddard solvent,

Stanisol or Varsoline.
(3). Make phenolphthalein solution as

follows:
(c). Permit cell to stand undisturbed for

24 hours.
B. Phenolphthalein Stain Inspection

Procedures
(d). Inspect paper to determine where cell

is leaking.
(a). Add 40 grams phenolphthalein

crystals to 1/2 gallon (1.9 L) of
denatured alcohol (CM218) and stir.
(e). Change paper as required. Drain,

turn over, refill and let cell stand for
another 24 hours to ensure liquid has
contacted all cell surfaces.
(b). Add 1/2 gallon (1.9 L) of water. Allow

to stand 30 minutes. Stir before
using.
(4). Pour commercial ammonia on an
absorbent cloth in a ratio of one
teaspoon (3 ml) per cubic foot of cell
capacity (minimum of 10 ml or 3.3
teaspoons).
(f). Repair cell as required.

9. Fuel Tank Pressure Leak Test
(a). Place the ammonia saturated cloth

inside the cell and install the remain
ing cover.
Item
Special Tools
Nomenclature
N/A
Manometer
(b). Inflate cell with air to 1/4 psi (1.7

kPa) maximum. Maintain 1/4 psi (1.7
kPa) pressure for 15 minutes mini
mum, before proceeding.
NOTE: Always test and inspect a repaired fuel
(c). Soak a large white cloth in the

phenolphthalein solution. Thoroughly
wring cloth out.
(1). Use the following procedures to check

installed fuel tanks and plumbing for
leaks.
(d). Spread and smooth cloth onto cell. Do

not let cloth dry out.
(e). A red spot will appear on the cloth
where there is a leak in the cell wall.
Mark each leak.
cell for leaks using soap bubble, phenolph

thalein or liquid stand method before in
stalling the cell in the helicopter.
(a). Plug vent system.

(b). Remove cell floor access panels.
(c). Install manometer and air pressur
ization equipment.
28-00-60
Page 605
Revision 31
MAINTENANCE MANUAL
CSP-HMI-2
(d). Apply 2 psi (14 kPa) air pressure for

10 minutes to precondition cells. This
forces trapped air from between fuel
cells and helicopter structure. If
necessary, repeat until cells adjust to
contour of cell bay.
WARNING
ventilated.
(e). Apply 2 psi (14 kPa) air pressure for

15 minutes with no visible, less than
1/4 inch (6.35 mm), drop on manome
ter. If pressure drop occurs, check all
vent plugs, fittings and re-test cells.
Repair or replace parts as necessary
to eliminate pressure drop.
D Engine operation or helicopter flight

must be accomplished in accordance
with requirements and limitations
specified in the 600N Rotorcraft
Flight Manual and applicable sup
plements.
(f). Unplug vent system. Remove ma

nometer and pressurization equip
ment.
(g). Install cell floor access panels.
10. Fuel Transfer System Functional Check
NOTE: This check is only done on aircraft

CAUTION
without the airframe fuel filter option.

(Ref. Figure 602)
Item
ST803
Special Tools
Nomenclature
Fuel Transfer System Functional Tester
NOTE: Gross weight, fuel load and ambient

conditions are optional for this functional
check.
FUEL PRESSURE
SWITCH HOSE
FUEL PRESSURE SWITCH
UNION
CEFA BEFORE FILTER
PORT
CEFA
MOTIVE FLOW
SUPPLY HOSE
LOOKING FORWARD
6G28-078
Figure 602. Fuel Transfer System Functional Check

Page 606
Revision 43
28-00-60
MAINTENANCE MANUAL
CSP-HMI-2
A. Test Setup
CEFA
TESTER INLET
LINE
TESTER INLET
LINE
TESTER OUTLET
LINE
FLOW METER
MOTIVE FLOW
SUPPLY HOSE
6G28-079
Figure 603. Fuel Transfer Test Setup
28-00-60
Page 607
Revision 43
MAINTENANCE MANUAL
CSP-HMI-2
(1). Make sure fuel transfer system tester

calibration is current.
(2). Disconnect motive flow supply hose
from CEFA before filter port union.
(3). Connect inlet line of tester to CEFA
before filter port union.
lective to increase N1 speed. Reduce throttle

twist grip to decrease N1 speed.
(5). Record N1, pressure altitude, outside
air temperature, motive flow rate and
motive flow pressure.
(4). Torque tester fitting to 50 - 65 inchpounds (5.64 - 7.34 Nm).
(6). Use the calibration chart provided with

the fuel transfer system tester and
calculate the calibrated motive flow
rate.
(5). Connect motive flow supply hose to

outlet line of tester.
(7). The minimum calibrated motive flow

rate shall be 0.18 GPM.
(6). Torque motive flow supply hose fitting

to 50 - 65 inch-pounds (5.64 - 7.34
Nm).
(a). Check valve
B. Check Procedures
(1). Make sure test setup is complete.
(2). Ground run engine in accordance with
Rotorcraft Flight Manual.
(3). Operate the helicopter on the ground at
100 percent main rotor speed (Nr) with
collective down.
(4). Stabilize motive flow pressure from
42.0 PSIG minimum to 44.0 PSIG
maximum. N1 at approximately 81
percent.
NOTE: Motive flow pressure increases or de

creases with engine N1 speed. Increase col
Page 608
Revision 43
(8). If the calibrated motive flow rate is less

than 0.18 GPM, check the following
components for correct operation.
28-00-60
(b). Jet (ejector) pump

(c). Motive flow hoses
(9). Shut down engine ground run in
accordance with Rotorcraft Flight
Manual.
(10). Disconnect motive flow supply hose
from outlet line of tester.
(11). Disconnect inlet line of tester from
CEFA before filter port union.
(12). Connect motive flow supply hose to
CEFA before filter port union.
(13). Torque motive flow supply hose fitting
to 50 - 65 inch-pounds (5.64 - 7.34
Nm).
MAINTENANCE MANUAL
CSP-HMI-2
FUEL SYSTEM
REPAIRS
1. Fuel Shutoff Valve Control Cable Repair
Item
Nomenclature
CM118
Grease
NOTE: Worn fuel shutoff valve control cables

are normally replaced as an assembly.
(1). The only authorized repair is replace
ment of a missing detent ball, as
follows:
(a). Disconnect cable from fuel shutoff
valve lever swivel.
(b). Pull plunger out until detent ball
hole is visible. Insert detent release
rod in plunger. Align notch in detent
release rod with plunger detent ball
hole.
(c). Apply grease (CM118) between
plunger and plunger housing.
(d). Insert detent ball in plunger hole.
Push release rod and plunger to full
open position.
(e). Rig fuel shutoff valve cable.
2. Fuel Cell Repair
Item
Nomenclature
CM219
CM603
CM604
CM605
CM607
CM804
CM820
N/A
Methyl-ethyl-ketone
Patching material
Patching material
Cement
Emery cloth, fine
Cheesecloth
Polyethylene plastic, sheet or roll
NOTE: MDHS cannot guarantee the currency,

completeness or technical accuracy of fuel
cell repair procedures provided herein.
Since cell repair materials, techniques, and
procedures may be changed or deleted by
the cell manufacturers without notice to
MDHS light helicopter publications; we
strongly recommend that:
(1). Only specially trained personnel are
allowed to inspect and repair the fuel
cells installed in 369/500/600 series
helicopters.
(2). Customers planning to do their own
fuel cell repairs must order any re
quired manuals from the applicable cell
manufacturer before beginning repair
tasks (Ref. Sec. 01-00-00).
(a). Cell inspections, maintenance and
repair must be per the cell manufac
turers advice and instructions.
(3). Bladder or self sealing fuel cells are
supplied to MDHS by Engineered
Fabrics Corporation.
Use only approved inspection
requirements, repair methods,
materials and supplies designed for Engine
ered Fabrics Corp.
CAUTION
(4). Fuel cells produced by Engineered

Fabrics Corp. are constructed of Nitrile
polyurethane plastic impregnated
fabric.
3. Scuff Mark Repair
Fabric exposed by a scuff mark may be buffed,
cleaned, coated with cement and allowed to
air-dry for 8 hours. No patch is required
unless fabric is torn. Install patches where
required (Ref. Patch Installation).
4. Reinforcements, Hangers and Splice
Repairs
Loose reinforcement edges, hangers or lap
splices must be lifted, buffed, cleaned, cem
ented and cured under pressure per applicable
instructions (Ref. Patch Installation).
28-00-60
Page 801
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
5. Loose Patch Repair

Replace loose patches with new patch installa
tions (Ref. Patch Installation). Where two
opposing patches have been installed over cell
wall damage, unless otherwise indicated by
inspection, replace only the loose patch.
6. Patch Installation
(1). Drain, remove and thoroughly dry cell
as soon as possible after determining
cell repair is required. Drying time may
be accelerated by keeping cell at 80F
(27C) and ventilating interior with dry,
low pressure air.
(2). Inspect fuel cell.
Do not repair tears or holes over
CAUTION two inches (5.08 cm) long using
cold patch repair. Do not attempt to repair
bonded fittings or corners. Contact Engine
ered Fabrics Corporation when corner or fit
ting damage is discovered or when cell wall
damage exceeds two inch length limit.
(3). Accomplish fuel cell repair work in
temperatures ranging from 60 - 80F
(16 - 27C) and in less than 50%
humidity.
NOTE: Damp air, especially in combination

with low temperatures, will cause water to
condense on cement applications. Water in
hibits patch adhesion.
Never expose a dry cell to high
temperatures and, or direct sun
light for long periods of time. If repairs will
not be started within ten days, prepare cell
for storage.
CAUTION
(4). Both sides of a cell must be patched to

repair any one hole or tear.
(5). Thoroughly clean cell internal and
external repair areas with cheese cloth
(CM820) dampened with solvent MEK
(CM219).
(a). Collapse cell and expose external
damage area on a clean, flat working
surface.
Page 802
Revision 19
28-00-60
(b). Use a greaseless silver pencil to

outline patch installation area two
inches beyond damage in all direc
tions.
(6). Hand-buff an area 1/2 inch (12.7 mm)
larger than space occupied by patch
with fine emery cloth (CM804) to
provide a roughened substrate for
cement application. Do not cut through
cell fabric.
(7). Select a patch of #5218 material
(CM604) for cell exterior. Trim patch to
extend two inches beyond edges and
ends of damage in all directions. Tilt
scissors to bevel patch edges away from
cell surface. Radius all patch corners.
(8). Hand-buff patch gummed surface with
fine emery cloth. Ensure entire patch
joint surface has been abraded.
(9). Repeat buffing procedures on cell
interior surface. Buff internal patch
(CM603) trimmed from
#5200/5187/5194 sandwich material.
Fuel cell and patch contact sur
faces must be perfectly clean
and dry prior to adhesive and patch applica
tion. Rubber and fabric particles, moisture,
and fuel or oil from fingers will prevent
proper patch/cell adhesive cure and may
subsequently provide a leak path. Wear
clean, lint free gloves to handle patch and
cell after preparing surfaces for cement and
patch application.
CAUTION
(10). Install exterior patch first. Wipe cell

exterior and patch faying surfaces with
clean cheesecloth (CM820) dampened
with MEK (CM219).
(a). Continue to wipe cell and patch,
changing cheesecloth and applying
clean solvent as required, until no
stain or particles appear on cheese
cloth pad after the last wipe.
CAUTION
(11). Position a sheet of polyethylene plastic

beneath cell damage to keep cement off
opposite cell wall.
MAINTENANCE MANUAL

(12). Coat patch, test specimen, and fuel cell,
including edges of damage, with EC678
cement (CM607). Allow cement to dry
15 minutes before application of a
second coat. Allow second coat to dry 15
minutes.
(13). Press a bare knuckle into cement on
test specimen. Cement that tears away
from skin leaving a rough, finely
peaked imprint without transferring to
knuckle, is ready for patch installation.
NOTE: Wipe cement with cheesecloth moist

ened with solvent to reactivate adhesive
when required.
(14). A brayer or similar tool is required to
systematically roll patch into contact
with cell. Apply patch as follows:
(a). Center patch on repair area. Stick
one edge down and double check
patch alignment. If required, release
adhesive by flooding joint with
solvent. Check adhesive tack again
before proceeding with patch installa
tion.
NOTE: The object of the next step is to get the

patch down without trapping any air under
it.
(b). Hold free edge of patch off cell.
Follow one line and roll tool backand-forth over patch. Advance
toward loose end, 1/4 inch (6.35 mm)
per pass until patch is down and free
of trapped air.
(c). An alternate technique is to lay
prepared patch on a perfectly clean
sheet of polyethylene plastic about
twice the size of the patch. Locate
plastic sheet and patch over cell
repair area; then, slip sheet from
under patch as patch is rolled down,
1/4 inch (6.35 mm) at a time.
CSP-HMI-2

repair area.
ment out of joint.
CAUTION
(a). Cover both sides of repair with sheet

polyethylene plastic or oiled paper
large enough to cover entire cem
ented area.

the wall with the patch installation.
(b). Sandwich repair area and barrier
material between pressure plates.
Install at least two C-clamps over
pressure plates. Equalize clamp
pressure.
is ready for internal patch installation.
(18). Clean patch and cell internal repair
area with MEK saturated cheesecloth
swabs.
(a). Apply two coats of cement, allowing
15 minutes drying time between
coats. Allow 15 minutes for second
coat to set.
(b). Install and roll out patch.
(19). Position a barrier sheet under each
pressure plate. Clamp and cure instal
lation for a minimum of 24 hours at 60
- 80F (16 - 27C) before leak testing
and returning cell to service.
7. Loose Edge and Lap Seam Repairs
CAUTION
Loose lap seams should be re

paired as soon as possible after
discovery.
NOTE: Loose lap seam edges not more than two

inches long on cell interior or exterior sur
faces may be repaired. Seam separation re
pairs require buffing, cementing and a
patch installation.
28-00-60
Page 803
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
(1). Lift seam separation and buff flap and

cell faying surfaces with emery cloth
(CM804).
(a). Buff an area on exterior surface
extending 2 inches (5.08 cm) in all
directions from seam separation.
CAUTION
D Fuel cell and patch contact surfaces must
be perfectly clean and dry prior to adhe
sive and patch application. Rubber and
fabric particles, moisture, and fuel or oil
from fingers will prevent proper patch/
cell adhesive seal and may subsequently
provide a leak path. Wear clean, lint free
gloves to handle patch and cell after pre
paring surfaces for cement and patch
application.
D Careless application of compressed air be
tween lap joints may separate seam fur
ther.
(b). Either air-vacuum or blow buffing
dust out of separation with dry, low
pressure, compressed air.
(c). Wipe inside and outside of repair
area clean with cheesecloth (CM820)
moistened with MEK (CM219).
Continue wiping with fresh solvent
dampened cheesecloth as required
until no stain or particle appears on
the swab after the last wipe. Allow
area to dry.
Use cement sparingly. Two thin,
CAUTION even coats provide better adhe
sion than one thick coat.

(d). Apply two coats of EC678 cement
(CM607) allowing 15 minutes be
tween applications. Allow second coat
to dry 15 minutes.
(e). Roll separation together starting
from the bottom of the pocket toward
the open end, 1/4 inch (6.35 mm) per
pass. Ensure no air is trapped
underneath.
Page 804
Revision 19
28-00-60
(f). Cover repair with a sheet of polyeth

ylene plastic or oiled paper large
enough to cover entire cemented
area.
repair area.
ment out of joint.
CAUTION
(a). Cover both sides of repair with

sheets large enough to cover entire
cemented area.

the wall containing the seam repair.
pressure.
is ready for patch installation.
(a). Remove clamps and plates.
material on cell interiors.
(6). Use #5218 patch material on cell
exterior surfaces.
tion per (Ref. Patch Installation):
Install patch.
8. Blister Repair
Blisters can occur on cell interior and exterior
surfaces. blisters are caused by a separation of
the cell laminates and may contain air or a
combination of air and fuel.
NOTE: Exterior blisters that contain fuel indi

cate that the barrier has been penetrated.
Blisters inside cell measuring under one
inch diameter are acceptable and need not
be disturbed.
(1). Repair blisters as follows:
MAINTENANCE MANUAL
(a). Buff surface of blister and area
extending two inches (5.08 cm) in all
directions from its edge.
Avoid damaging nylon barrier
membrane. Do not probe, cut, or
puncture blisters with tool perpendicular to
cell wall.
CAUTION
(b). Slit blister open with an X cut to

expose all of the delaminated surface.
Lift flaps and mop interior with clean
cheesecloth (CM820) and MEK
(CM219). Buff underlying cell surface
and blister flaps with emery cloth
(CM804). Air-vacuum or blow away
all traces of buffing dust.
(c). Wipe inside and outside of repair
area clean with cheesecloth moist
ened with solvent or MEK. Continue
wiping with fresh solvent dampened
cheesecloth as required until no stain
or particle appears on the swab after
the last wipe. Allow area to dry.
CAUTION

(d). Apply two coats of EC678 cement
minutes.
(e). Roll blister together starting from the
bottom of each flap pocket toward the
open end, 1/4 inch (6.35 mm) per
pass. Ensure no air is trapped
underneath.
CSP-HMI-2

repair area.
ment out of joint.
CAUTION
(a). Cover both sides of repair with

sheets large enough to cover entire
cemented area.

the wall containing the blister repair.
pressure.
is ready for patch installation; remove
clamps and plates.
material on cell interiors.
(6). Use #5218 patch material on non-selfsealing cell exterior surfaces.
tion per instructions for Patch Installa
tion. Install patch.
(8). Heat soak transmitter assembly in an
oven set at 100F (38C), maximum for
one hour to vaporize trapped volatiles.
A heat gun may be used as an alternate
drying method. Pot transmitter electri
cal connections with sealing compound
MIL-S-8802 (CM425).
28-00-60
Page 805
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
Page 806
Revision 44
28-00-60
MAINTENANCE MANUAL
CSP-HMI-2
Section
282500
AntiIce / Airframe
Fuel Filter (369D/E
500/600N)
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSP-HMI-2
ANTIICE/AIRFRAME FUEL FILTER

Table 1. AntiIce/Airframe Fuel Filter Effectivity
Installation
Model & Production Number
Features
369H90022BSC
369D, 003 and subsequent
Helicopters equipped with slimline instrument panel.
369H90022503
369E, 001 and subsequent
Helicopters equipped with Tinstrument panel.
369H90022503
500N, 001 and subsequent
600N98110501
600N, 003 and subsequent
NOTE: Antiice / airframe fuel filter is not certified for installation on C30 engine installation.
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 refered to as an anti-ice
fuel filter.
1. Description
(1). The airframe mounted anti-ice fuel
filter is installed on the aft face of the
firewall upstream of the engine fuel
pump filter. The 10 micron, 500 square
inch disposable filter element strips ice
and other solids from the fuel before it
enters the engine fuel system.
2. Operation
(1). A flow pressure sensing switch in the
filter body furnished with all installa
tions closes when flow differential
pressure across the filter drops to a
preset level.
(2). On the 369H90022-BSC installation,
pressure switch contact closure directs
28Vdc current across the S2 contacts of
the FUEL FILTER relay K254 to
activate the RT170-277 time delay
relay (TDR). The TDR energizes relay
K254 after a two to five second delay,
closing switches S1, S2, and S3;
energizing the FUEL FILTER caution
light, start pump and START PUMP
ON light.
(3). On 369H90022-503, -505 and
600N98110-501 fuel filter installations,
pressure switch closure only advises the
pilot of an impending or total fuel filter

blockage by lighting the AIRFRAME
FILTER caution lamp in the caution/
warning panel. The pilot must manual
ly set the START PUMP switch ON to
pressurize the fuel system.
(4). On all installations, total filter blockage
forces a filter bypass valve in the filter
body open to second supply unfiltered
fuel to the engine.
(5). Pressing the FUEL FILTER caution
light/switch supplied with
369H90022-BSC installations resets
relay K254 and the time delay relay,
shuts down the start pump and START
PUMP ON light and switches off the
FUEL FILTER caution light.
(6). The caution light dimmer switch on the
lower left control panel of -BSC
installations controls only FUEL
FILTER caution light intensity with
DIM or BRT positions. FUEL FILTER
caution lamp test is executed with the
PRESS TO TST WARN LT switch on
the caution/warning light panel.
(7). On -503, -505 and -501 installations,
caution light intensities, including the
AIRFRAME FILTER light are
controlled through the WARN LT DIM
potentiometer on the pedestal switch
panel.
(8). Circuit protection is provided by the 7.5
ampere anti-ice FUEL FILTER circuit
breaker on the anti-ice fuel filter panel.
28-25-00
Page 1
Revision 39
CSP-HMI-2
MAINTENANCE MANUAL
Determine why a circuit break

er popped before pushing the re
set button (Ref. Table 101).
CAUTION
(9). A press-to-test button located on top of

the filter body is featured in all installa
tions. Pressing the button simulates a
blocked filter condition for power-on
ground test.
(10). On all installations, a filter bowl drain
valve plumbed into the drain manifold
provides for filter draining and fuel
sampling.
Page 2
Revision 20
28-25-00

Ensure start/boost pump is operating
before taking fuel samples from system
drain valves.
(11). Refer to Table 101 for anti-ice fuel filter
fault isolation information.
MAINTENANCE MANUAL
CSP-HMI-2

FAULT ISOLATION
fuel filter.
1. AntiIce Fuel Filter System Fault Isolation
Table 101. AntiIce Fuel Filter System Fault Isolation
Symptom
FUEL FILTER caution lamp
does not light.
Probable Trouble
Corrective Action
No power. Battery switch OFF. Supply power. Set battery switch to BATT or
EXT PWR position.
Circuit breaker reset button
pulled out. (369D/E 500N)
Press circuit breaker reset button.
Defective wiring or connection. Locate circuit defect and repair as required.

FUEL FILTER caution light on. System not reset.
START PUMP ON lamp fails

to light.
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.
No power. Battery switch OFF. Supply power. Set battery switch to BATT or
EXT PWR.
Circuit breaker reset button
pulled out. (369D/E 500N)
Press circuit breaker reset button.
Defective lamp.
Replace lamp.
Defective wiring.
Locate circuit defect and repair as required.
28-25-00
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CSP-HMI-2
MAINTENANCE MANUAL
Page 102
Revision 44
28-25-00
MAINTENANCE MANUAL
CSP-HMI-2

fuel filter.
1. AntiIce Fuel Filter Replacement
(Ref. Figure 201)
A. AntiIce Fuel Filter Removal
Prevent fuel vapor ignition.
WARNING Turn OFF and disconnect all

electrical power. Electrically ground
helicopter before opening fuel system.
(1). Disconnect battery and external power
(Ref. Sec. 96-05-10).
(a). Pull FUEL VALVE knob to close fuel
shut off valve.
(c). Drain fuel from filter bowl and
supply line drain valves.
(d). Unclamp and disconnect filter drain
tube.
(e). Remove fuel supply hose between
engine driven fuel pump and anti-ice
filter. Cap hose ends and fittings.
(f). Remove hose assembly between
anti-ice filter and firewall fitting.
Cap hose ends and fittings.
(g). Remove anti-ice filter electrical
connector.
B. AntiIce Fuel Filter Installation
Item
Nomenclature
CM113
(1). Attach assembled filter to bracket with

bolts, washers and spacers. Torque
bolts 50 - 70 inch-pounds (5.65 - 7.91
Nm). Install lockwire.
(a). Apply a thin coat of anti-seize
compound (CM113) to all male fuel
line fittings.
Do not twist hoses while torqu
ing hose nuts. Use a backup
wrench to stabilize hose.
CAUTION
(b). Install hose between filter and

engine. Install hose between filter
and firewall fitting. Torque hose nuts
230 - 260 inch-pounds (25.99 29.38 Nm).
(c). Connect wire harness connector to
fuel filter plug.
(d). Connect drain tube to filter drain
valve. Clamp tube to valve with
lockwire.

Ensure start pump is operating before
taking fuel samples from system drain
valves.
(h). Unbolt and remove filter body

assembly.
(e). Perform a fuel system vacuum leak

check (Ref. Fuel System Vacuum
Leak Check).
(i). Unscrew filter bowl from body, as

required.
(f). Bleed fuel system (Ref. Fuel System

Air Bleed).
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MAINTENANCE MANUAL
CSP-HMI-2
2. Fuel System Air Bleed

WARNING lation, ignition and fire. Per
form work in an open, well ventilated

area away from all potential ignition
sources. Attach helicopter to an ap
proved electrical ground. Wear ap
proved eye protection.
CAUTION

empty fuel tank.
NOTE: The object of fuel system bleeding is to

remove all air trapped in the fuel supply
system.
(1). Refuel helicopter as required.
(a). Connect battery.
(c). In crew compartment; push FUEL
shutoff valve knob in to open shutoff
valve.
Page 202
Revision 20
28-25-00
(d). Set helicopter master switch to

BATT.
(e). Set START PUMP switch ON to
pressurize fuel system. Check start
pump for operation.
(f). Loosen engine filter bowl plug. Let
fuel flow until a steady, bubble free,
uninterrupted fuel stream emerges
without any evidence of trapped air.
Tighten plug.
(2). Refer to applicable Allison Engine
specific engine fuel system air bleed
information.
(a). Purge air from engine fuel system
per Allison Engine Operation and
Maintenance Manual.
(3). Set START PUMP and battery
switches OFF.
(4). Reassemble drain system as required
and install lockwire.
MAINTENANCE MANUAL
CSP-HMI-2
BOLT
CONNECTOR
WASHER
TEST
BUTTON
CLAMP
NUT
NUT
BRACKET
O-RING
SCREW
REDUCER
FIREWALL
CLAMP
WASHE
RSCREW
WASHER
HOSE
NUT
FILTER
ELEMENT
WIRE
HARNESS
TUBE
NUT
BOWL
SHIM WASHER
(AS REQ'D)
WASHER
GASKET
NUT
FITTING
WASHER
O-RING
HOSE
ELBOW
HOSE
CLAMP
SCREW
SCREW
GASKET
CLAMP
WASHER
ANTI-ICE
DRAIN VALVE
NUT
BOLT
EFFECTIVITY: 369D/E - 500N
G28-2000-1B
Figure 201. AntiIce Fuel Filter (Sheet 1 of 3)
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MAINTENANCE MANUAL
CSP-HMI-2
CAUTION LIGHT
T-PEDESTAL
(369H90022-503, -505)
ANTI - ICE
FUEL FILTER
INSTL
FOR
SPACER
PLACARD
WASHER
SCREW
SCREW
RIVNUT
DIODE CR26
TIME-DELAY
RELAY
CAUTION LIGHT/
RELAY K254
CIRCUIT BREAKER
SCREW
COVER
SCREW
DIMMER SWITCH
SLIMLINE PEDESTAL
(369H90022-BSC)
G28-2000-2A

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28-25-00
MAINTENANCE MANUAL
CSP-HMI-2
B
A
B
FUEL HOSE
TO ENGINE
A
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
VIEW A - A
GROMMET
AIRFRAME FILTER
CAUTION LIGHT
VIEW B - B
G28-2000-3
EFFECTIVITY: 600N
28-25-00
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CSP-HMI-2
MAINTENANCE MANUAL
Page 206
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28-25-00
MAINTENANCE MANUAL
CSP-HMI-2

INSPECTION/CHECK
fuel filter.
1. AntiIce Fuel Filter System Inspection
A one time diode inspection and
polarity check is mandatory for
helicopters
equipped
with
a
369H90022-BSC anti-ice fuel filter instal
lation and, or 369H90118 auto-reignition
installation on helicopters delivered in
1979. The following procedures address only
the anti-ice fuel filter installation.
CAUTION
Item
Special Tools
Nomenclature
N/A
N/A
Ohmmeter
Voltmeter
(1). Determine ohmmeter lead polarity with

voltmeter.
(a). In crew compartment; remove cover
from anti-ice caution/warning light
panel.
(b). Find part number stamped on diode
C26 (Ref. Figure 201).
(c). Diodes, part numbers 1N3210 do not
require a polarity check.
(d). Replace diodes, part number
1N3210R with a new part number
1N3210 diode.
(e). If the diode is unidentifiable, test
diode to determine polarity.
1). Check for low forward resistance
with ohmmeter positive lead
attached to terminal end and
negative lead attached to stud end.
Reverse leads and check for very
high resistance.
(f). Replace diode with a new 1N3210
unit if polarity is reversed.
(g). Do an anti-ice fuel filter functional

check (Ref. Anti-Ice Fuel Filter
Installation Operational Check:
369H90022-BSC).
(2). Inspect wiring for damage and security.
Repair or replace damaged components.

valves.
(3). Inspect fuel system as follows:
(a). Apply external power to the helicop
ter.
(b). Open the engine compartment doors.
(c). Set battery switch to EXT PWR.
(d). Push FUEL VALVE knob in to open
fuel shutoff valve.
(e). Set START PUMP switch; ON.
Check start pump operation.
NOTE: Failure to drain in freezing tempera

tures may be due to ice buildup.
(f). Drain several ounces of fuel from
filter bowl into a suitable container.
Inspect sample for solids and water
contamination. Dismantle and clean
filter bowl as required. Replace filter
element.
(g). Inspect hose assemblies for evidence
of leakage, swelling or dampness,
kinks, cuts, twists, tears and fraying.
Check hose nut threads for damage.
Replace damaged parts.
(h). Disconnect drain tubes from drain
valves. Check each drain valve for
leakage. Replace damaged drain
valves.
(i). Inspect filter fuel line fittings for
leakage. Repair or replace parts as
required.
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CSP-HMI-2
MAINTENANCE MANUAL
(j). Connect drain tubes to drain valves.

Inspect drain tubes for security and
correct routing without fluid traps or
kinks.
(k). Inspect fuel filter press-to-test
button for security.
2. AntiIce Fuel Filter Installation
Operational Check: 369H90022BSC
NOTE: The system may be operated with a ful

ly charged battery that can provide more
than the 23.8 Vdc required to actuate sys
tem solenoids. If battery state is an un
known, use external power.
(1). Apply external power to the helicopter.
Set battery switch to EXT PWR.
(a). Reset PNL LT and FUEL ANTIICE circuit breakers.
(b). Press PRESS TO TST WRN LT on
Check entire caution/warning light
array. Replace lamps as required.
(c). Push FUEL VALVE knob in to open
fuel shutoff valve.
(d). Open the engine compartment doors.
(2). Press the red press-to-test button on
top of the filter body for five or more
seconds. Test results shall be as follows:
(a). FUEL FILTER caution light comes
on.
(b). START PUMP ON indicator light
comes on and start pump pressurizes
fuel system.
(3). Release the press-to-test button.
(a). FUEL FILTER and START PUMP
ON lights remain on and start pump
continues to operate.
(4). Press FUEL FILTER caution light to
reset system. Result shall be:
(a). FUEL FILTER caution light goes
out.
(b). START PUMP ON indicator light
goes out.
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28-25-00
(c). Start pump stops running.

(5). Inspect fuel system for leakage.
3. AntiIce Fuel Filter Installation
Operational Check: 369H90022503, 505
and 600N98110501
(1). Apply external power to the helicopter.
Set battery switch to EXT PWR.
(a). Reset PNL LT circuit breaker.
(b). Press PRESS TO TST WRN LT on
Check entire caution/warning light
array. Replace lamps as required.
(c). Push FUEL VALVE knob in to open
fuel shutoff valve.
(2). Set START PUMP switch ON.
(a). START PUMP ON indicator light
comes on and start pump pressurizes
fuel system.
(3). Open the engine compartment doors.
(4). Press the red press-to-test button on
top of airframe filter body. Result shall
be:
(a). AIRFRAME FILTER caution light
comes on.
(5). Release the press-to-test button.
(a). AIRFRAME FILTER caution light
goes out.
(6). Set START PUMP switch OFF.
(7). Inspect fuel system for leaks.
4. Fuel System Vacuum Leak Check
(1). Fuel is drawn out of the tank by the
engine driven fuel pump when the start
pump is switched off. Water, ice, dirt,
fungus, trapped air or a few pinhole
leaks in the supply system between the
fuel tank sump pickup and engine
combustion chamber nozzles may cause
power surges, deceleration and, or
flameout. A vacuum leak inspection will
determine whether or not air can be
drawn into the fuel system by the
engine driven fuel pump.
(2). An automotive vacuum test pump and
hardware that will provide 8 Hg
vacuum or better is required to do the
vacuum leak check.
MAINTENANCE MANUAL
(3). Assemble vacuum pump, hoses, filter
port adapter, shutoff valve and vacuum
gage as follows:
(a). Insert a vacuum gage in the vacuum
hose between the engine fuel filter
port adapter and vacuum shutoff
valve. Attach the vacuum pump to
the vacuum hose above the shutoff
valve.
(b). Plug vacuum hose and pull 5 - 10 Hg
vacuum. Apparatus should hold the
selected pressure indefinitely. Repair
leaky equipment before proceeding
with fuel system test.
CSP-HMI-2
(b). Fuel system shall hold vacuum

between 8 and 7.5 Hg for two min
utes.
(c). If test is satisfactory, remove test
apparatus. Inspect and replace filter
plug O-ring as required. Install filter
plug.
(6). Vacuum loss exceeding 0.5 Hg in two
minutes indicates a leak somewhere in
the system between the fuel shutoff
valve and engine.
(a). Torque fuel line connections (Ref.
Table 601). Repeat vacuum test.
(c). Open engine access doors.

(d). Remove left fuel cell floor access
panel.
(e). In crew compartment; pull FUEL
shutoff valve knob out to stop. Verify
that fuel shutoff valve lever on left
fuel cell access cover is hard against
its OFF stop. Rig control cable as
required.
(f). In engine compartment; remove the
upper drain plug from the fuel pump
filter bowl.
(4). Disconnect the fuel bleed return line at
Sta. 124.00 (if equipped) and cap off.
(5). Attach vacuum test apparatus to
engine fuel filter upper drain port.
(a). Apply 8 Hg vacuum. Close vacuum
line shutoff valve.
(b). If system continues to leak, discon

nect and install airtight caps or plugs
in tubes, hoses and fitting ports in a
progressive sequence from fuel
shutoff valve toward engine. The fuel
shutoff and drain valve installations
should be especially suspect. Apply
vacuum at each stage until leak has
been isolated. Replace parts as
required.
(c). Apply a torque stripe to all effected
fuel line fittings and nuts.
(d). If the airframe system vacuum held
at 7.5 Hg or better, system seal is
satisfactory and malfunction is
probably due to an engine system
leak. Refer to the applicable Allison
and Bendix manuals for additional
information.
Table 601. Fuel Supply System Torque Values

Item & Location
Torque Range
InchPounds (Nm)
Tube endnuts; fuel shutoff valve; Sta. 124.00 Blkhd elbow
230 260 (25.99 29.38)
Blkhd elbow jamnut; Sta. 124.00
145 155 (16.38 17.51)
Threeport elbow jamnuts
145 155 (16.38 17.51)
Antiice filter drain fitting bolt
185 200 (20.90 22.60)
Antiice filter in/out reducers
550 600 (62.14 67.79)
Hose endnuts; firewall/filter
230 260 (25.99 29.38)
Hose endnuts; filter/engine
230 260 (25.99 29.38)
Drain valves (all)
95 105 (10.73 11.86)
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MAINTENANCE MANUAL
CSP-HMI-2
AIRFRAME FILTER
CAUTION LIGHT
CAUTION LIGHT
TEST
CAUTION LIGHT
TEST
CAUTION LIGHT
RESET SWITCH
FUEL
SHUTOFF
BATTERY
SWITCH
PNL LT
CIRCUIT
BREAKER
PRESS
TO
TEST
START
PUMP
SWITCH
DIMMER
POT
DIMMER
SWITCH
369H90022-503, -505
CIRCUIT
BREAKER
P
U
S
H
PULL
TO
CLOSE
ON
START
PUMP
FUEL
SHUTOFF
START PUMP
SWITCH
BATTERY
O
F
F
BATTERY
SWITCH
369H90022-BSC
G28-2004-1
Figure 601. AntiIce Fuel Filter Controls (Sheet 1 of 2)

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MAINTENANCE MANUAL
AIR FRAME FILTER

(DS21)
AIR FILTER CLOGGED
(DS22)
CSP-HMI-2
CAUTION LIGHT
TEST
FUEL
SHUTOFF
BATTERY
SWITCH
FUEL PUMP SWITCH
(CB118)
FUEL PUMP LIGHT
(XDS7)
600N98110-501
G28-2004-2
Figure 601. AntiIce Fuel Filter Controls (Sheet 2 of 2)
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CSP-HMI-2
MAINTENANCE MANUAL
Page 606
Revision 44
28-25-00
MAINTENANCE MANUAL
CSP-HMI-2

fuel filter.
1. AntiIce Fuel Filter Initial Installation
A. Preparations for Installation
Prevent fuel vapor ignition.
WARNING Turn OFF and disconnect all

electrical power. Attach helicopter to
approved grounding points before
opening fuel system.
(1). Disconnect external power and battery.
(2). Remove aft compartment seats.
(3). Remove aft upper left bulkhead panel.
(4). Remove lower aft bulkhead panel.
(5). Remove pilot compartment left floor
access door.
tal and drill three 0.219 inch (5.56 mm)

diameter holes in pedestal.
(3). Make cutout shown in instrument
pedestal fairing.
(4). Deburr holes and cutout edges. Remove
debris.
(5). Install rivnut and attach anti-ice fuel
filter panel to instrument pedestal with
screws, washers and spacers.
(6). Connect wires (Ref. Figure 903).
(7). Install cover and screws.
(8). Install ANTI-ICE FUEL FILTER
INSTALLATION placard decal on
heater duct three inches (7.62 cm)
above standby compass bracket. Roll
placard edges to follow duct contour.
(9). Seal both ends of electrical conduit with
silicone adhesive/sealant (CM430).
C. AntiIce Fuel Filter Control Panel
Installation: 369H90022503, and 505
(6). Remove instrument panel hood and left

fairing.
(7). Pull FUEL VALVE knob to close fuel
shut off valve.
B. AntiIce Fuel Filter Control Panel
Installation: 369H90022BSC
Item
Nomenclature
CM430
(1). Pull filter wire harness forward

through conduit and along an existing
wire bundle to instrument pedestal.
Secure to engine compartment airframe
with clamps, screws, washers and nuts
and to wire bundle with ty-raps (Ref.
Figure 901).
(2). Use anti-ice fuel filter subpanel as a
template on left side of slimline pedes
Item
(Ref. Section 91-00-00)
Nomenclature
CM430 Sealant, solvent resistant
(1). Pull fuel filter wire harness forward

through conduit and along an existing
wire bundle to instrument pedestal.
(2). Secure wire to engine compartment
airframe with clamps, screws, washers
and nuts and to wire bundle with
ty-raps (Ref. Figure 901).
(3). Install 20 gage bus wire and insulating
sleeve on back side of caution light
DS31 (Ref. Figure 904).
(4). Remove fourth plug from the right on
caution/warning light panel.
(5). Wire and connect electrical system (Ref.
Figure 904).
(6). Install caution light in panel.
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Revision 20
MAINTENANCE MANUAL
CSP-HMI-2

(8). Seal both ends of electrical conduit with
silicone adhesive/sealant (CM430).
D. AntiIce Fuel Filter Control Panel
Installation: 600N98110501
(Ref. Figure 601)
(1). To install caution/warning light:
E. Firewall Modifications and Bracket

Installation
(Ref. Figure 901 for 369H90022-BSC, -503
and -505)
(Ref. Figure 902 for 600N96110-501)
Item
CM318
Nomenclature
Primer
(a). Remove third plug from the right on

caution/warning light panel.
(2). Drain fuel from supply lines into a

suitable container.
(b). Install caution light in panel.
(3). Remove fuel supply hose between

engine driven fuel pump and firewall
fitting elbow. Cap hose ends, firewall
elbow and fuel pump port.
(c). Install 22 gage jumper wire on back

side of caution lights between DS21C
and DS22C.
(d). Run O506D22 wire from DS21-2 to
P12-14 and secure to existing wires.
(2). To install fuel pump switch and light:
(a). Remove edge-lighted switch panel.
(b). Remove tape from start pump switch
and light holes in instrument panel.
(c). Install CB118 in panel.
(d). Run 22 gage jumper wire from
CB115-1 to CB118-1.
(e). Run Q1169A22 wire from CB118-2 to
TB503-2-2.
(f). Install light (XDS7) from back side of
panel.
(g). Run E1181A22 wire from P13-46 to
XDS7.
(h). Run E1181B22N wire from XDS7 to
E31-E.
(i). Reinstall edge-lighted switch panel.
Page 902
Revision 20
28-25-00
(4). Reposition firewall elbow 18 - 22

clockwise (Ref. view A).
Do not score, scratch or gouge
firewall surface when trimming
insulation blanket.
CAUTION
(5). Lay out and remove insulation strips

from firewall to eliminate interference
with filter support bracket installation.
(6). Position doubler on Sta. 124.00 firewall.
Identify, mark and drill-out existing
rivets used in doubler installation. Do
not enlarge rivet holes.
(7). Locate doubler on firewall forward
surface. Drill doubler through existing
rivet holes.
(8). Deburr holes and remove debris.
(9). Cleco doubler to firewall.
(10). Apply primer (CM318) to rivet holes
and rivets.
(11). Install rivets while primer is wet.
(12). Use filter support bracket as a tem
plate. Mark and drill filter bracket rivet
holes.
(13). Deburr holes and remove debris.
(14). Cleco bracket in position.
MAINTENANCE MANUAL
(15). Apply primer to rivet holes and rivets.
(16). Rivet bracket in place while primer is
wet.
(17). Install electrical bonding jumper
between bracket and airframe.
(18). Position double aft of Sta. 124.00
between LBL 4.250 and LBL 8.450.
Drill rivet holes and cleco in place.
(19). Drill hole for drain hose.
(20). Remove doubler , deburr and remove
debris.
(21). Apply primer (CM318) to rivet and
drain holes.
(22). Install doubler while rivets are still
wet.
F. Fuel Filter Installation

valves.
(Ref. Figure 901 for 369H90022-BSC, -503
and -505)
(Ref. Figure 902 for 600N96110-501)
CSP-HMI-2
(4). Apply a thin coat of anti-seize com

pound (CM113) to fitting-bolt threads.
Stack fitting and gaskets on bottom of
filter. Install and torque bolt 185 - 200
inch-pounds (20.90 - 22.60 Nm).
(5). Lubricate drain valve O-ring packing
with clean jet fuel and install on drain
valve. Apply a thin coat of anti-seize
compound to drain valve threads.
(6). Install drain valve with O-ring packing
on fuel filter drain fitting. Torque drain
valve 95 - 105 inch-pounds (10.73 11.86 Nm).
(7). Install and clamp drain tube to drain
valve with lockwire.
NOTE: Provide enough slack in drain tubes to

allow unrestrained drain valve operation.
(8). On 600N96110-501 installation, install
mount to firewall using adhesive
(CM438).
(9). Clamp tube to bulkhead frame or
mount at LBL 8.45 with TY-25M
TYRAP.
(10). Lubricate the two reducer O-rings with
clean jet fuel. Install O-rings on large
ends of reducers. Apply a thin coat of
anti-seize compound to reducer
threads.
(11). Install reducers with O-rings in filter
inlet and outlet ports. Torque reducers
to 550 - 600 inch-pounds (62.14 67.79 Nm).
Do not allow hose to twist when
torquing hose nuts. Use a back
up wrench to stabilize hose.
CAUTION
Item
Nomenclature
CM113
CM438

Adhesive, epoxy
(12). Connect hose between filter outlet port

and engine fuel pump filter inlet port.
Torque hose nuts 230 - 260 inchpounds (25.99 - 29.38 Nm).
(1). Remove engine gearcase cooling duct

clip and attaching hardware.
(13). Install hose between filter inlet port

and firewall fitting elbow. Torque hose
nuts 230 - 260 inch-pounds (25.99 29.38 Nm).
(2). Drill a 0.250 inch (6.35 mm) diameter

hole and relocate clip.
(3). Install filter assembly on bracket with
bolts, washers and spacers. Torque
Nm). Install lockwire.
(14). Secure hoses with clamps, screws,

washers and nuts.
(15). Install wire connector plug on filter
receptacle.
28-25-00
Page 903
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MAINTENANCE MANUAL
CSP-HMI-2
BOLT, WASHER,
LOCKWIRE
RIVET
(7 PLCS)
(NOTE 1)
HOSE
BRACKET
(NOTE 2)
HOSE
(TANK TO FILTER)
LOOKING DOWN
CLAMP, SCREW,
WASHER, NUT
(NOTE 10)
CLAMP
(2 PLCS)
RIVET
(NOTE 8)
CLAMP, SCREW
WASHER, (2 REQD)
RIVET
NUT
RIVET
(NOTE 9)
(NOTE 8)
0.75 INCH
(17.05 MM)
0.260 INCH (6060 MM)
DIA HOLE
DUCT (REF)
ENGINE FUEL
PUMP (REF)
WL 22.85
WIRE HARNESS
RIVET
(NOTE 8)
RIVET
(NOTE 1)
CLIP (NOTE 3)
RIVET
(NOTES 8, 9)
INSULATION
(REF)
RIVET
(NOTE 8)
FILTER
ASSY
ELBOW
(NOTE 4)
WL 13.10
LANDING GEAR DAMPER
(REF)
FITTING, BOLT
TORQUE TO 185-200 IN-LBS
(20.90-22.60 NM)
GASKET (2 REQD) (NOTE 7)
18
20
TUBE
(NOTE 5)
CONDUIT
(REF)
TY-25N TY-RAP
WL 5.14
STA 124.0
CONDUIT (REF)
(NOTE 6)
CLAMP, SCREW,
WASHER, NUT
(NOTE 10)
WIRE HARNESS ASSY
LBL 13.23
LBL 8.45
SCREW, CLAMP,
WASHER, NUT
(NOTE 10)
LOOKING
FORWARD
0.00-0.12 INCH
(0.00-3.05 MM)
(NOTE 15)
STA 137.50
VIEW A-A
G28-2003-1D
Figure 901. AntiIce Fuel Filter Modifications and Installation (369D/E 500N) (Sheet 1 of 2)
Page 904
Revision 19
28-25-00
MAINTENANCE MANUAL
CSP-HMI-2
0.25 INCH
(6.35 MM)
STIFFENER
1.00 INCH
(2.54 CM)
1.00 INCH
(2.54 CM)
PANEL
1.75 INCH
(4.445 CM)
NOTE 13
INSULATION
PANEL
STA 124.0
REDUCER (2 REQD)
PACKING (2 REQD)
(NOTE 12)
DOUBLER
(NOTE 14)
5.00 INCH
(12.70 CM)
BRACKET
HOSE ASSY
PANEL
STIFFENER
SPACER
(3 REQD)
PANEL
STIFFENER
HOSE ASSY
DUCT
PLACARD
(NOTE 11)
WL 13.10
3.00 INCH
(7.62 CM)
VALVE
PACKING
(NOTE 12)
TUBE
COMPASS BRACKET
(REF)
0.12 R
(TYP)
7.25 INCH
(18.415 CM)
5.50 INCH
(13.97 CM)
DOUBLER
G28-2003-2D
Figure 901. AntiIce Fuel Filter Modifications and Installation (369D/E 500N) (Sheet 2 of 2)
28-25-00
Page 905
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
NOTE:
(1) Pick up existing rivet locations, seven places. Install MS296154M rivets or NAS1738 M4 alternates. Install
rivets in wet MILP23377 Type 1, Class 1, epoxy primer or, MILP8585 primer.
(2) Electrically bond bracket to firewall with an approved bonding jumper installed per requirements of FAA
publication EAAC43.131A and 2A.
(3) Reposition clip 0.75 inch (19.05 mm) inboard.
(4) Shim elbow to 1822 degrees clockwise.
(5) Route filter drain tube to clear landing gear damper while allowing unrestrained drain valve operation.
(6) Seal both ends of conduit with RTV 732 sealant/adhesive after wire harness installation.
(7) Apply low temperature antiseize compound, MILT5544B Thread Lube or equivalent to assembly
threads prior to installation. Torque bolt 185 200 inchpounds (20.90 22.60 Nm).
(8) Install MS206153M rivets in wet MILP23377, Type 1, Class 1, epoxy primer or, MILP8585 primer.
(9) Install MS206154M or alternate NAS1738M4 rivets in wet MILP23377, Type 1, Class, 1 epoxy primer
or, MILP8585 primer.
(10) Clamp wire harness in place as shown using existing tool holes.
(11) Roll placard edges to follow heater duct contour.
(12) Apply MILT5544B low temperature antiseize compound to threads prior to assembly.
(13) Cut away insulation blanket per dimensions shown for bracket installation. Remove blanket debris. Do not
scratch firewall surface.
(14) Install doubler on forward firewall surface as shown. Pick up all existing rivet holes in doubler installation.
(15) Trim drain tube protrusion flush to 0.12 inch (3.048 mm) below grommet surface.
Page 906
Revision 19
28-25-00
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE INSTALLATION
CLAMP, SCREW
WASHER (2 REQD)
NUT
(NOTE 8) CONNECTOR
LBL
8.450
RIVET
(NOTE 6)
WL
22.850
REDUCER
O-RING
(NOTE 9)
HOSE
FILTER
MOUNT
(NOTE 4)
BOLT
WASHER
RIVET (7 PL)
(NOTE 1)
NUT
O-RING
LBL
BUSHING
8.450
O-RING
HOSE
(NOTE 3)
BULKHEAD ELBOW
FS
124.000
0.00-0.12 INCH
(0.00-3.05 CM)
(NOTE 12)
LOOKING FORWARD
CLAMPS,
SCREW
WASHERS,
NUT
HOSE
(TANK-TO-FILTER)
FS
137.500
BRACKET
(NOTE 2)
LOOKING DOWN
EFFECTIVITY: 600N
G28-2009-1
Figure 902. AntiIce Fuel Filter Modifications and Installation (600N) (Sheet 1 of 2)
28-25-00
Page 907
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
1.00 INCH
(2.54 CM)
1.75 INCH
(4.45 CM)
STIFFENER
STIFFENER
PANEL
NOTE 10
STIFFENER
0.25 INCH
(6.35 MM)
1.00 INCH
(2.54 CM)
INSULATIO
N
5.00 INCH
(12.70 CM)
PANEL
SPACER
(3 REQD)
PANEL
LOOKING FORWARD
PANEL
WL
13.100
FITTING, BOLT
TORQUE TO 185 - 200 INCH-POUNDS
(20.90 - 22.60 NM)
GASKET (2 REQD) (NOTE 5)
LBL
8.450
DOUBLER
(NOTE
11)
DRAIN VALVE O-RING

(NOTE 9)
RIVET
(NOTE 1)
FS
137.000
RIVET
(NOTE 7)
LOOKING INBOARD
LEFT SIDE
FS
124.000
WL
22.850
RIVET
(NOTE 1)
RIVET
(NOTE 6)
LBL
8.450
RIVET
(NOTE 6, 7)
RIVET
(NOTE 6)
RIVET
(NOTE 1)
LBL
4.250
FS
124.000
LOOKING AFT
DOUBLER
RIVET
GROMMET
LOOKING DOWN
EFFECTIVITY: 600N
G28-2009-2
Figure 902. AntiIce Fuel Filter Modifications and Installation (600N) (Sheet 2 of 2)
Page 908
Revision 19
28-25-00
MAINTENANCE MANUAL
CSP-HMI-2
NOTE:
(1) Pick up existing rivet locations, seven places. Install MS296154M rivets or NAS1738 M4 alternates. Install
rivets in wet MILP23377 Type 1, Class 1, epoxy primer or, MILP8585 primer.
(2) Electrically bond bracket to firewall with an approved bonding jumper installed per requirements of FAA
publication EAAC43.131A and 2A.
(3) Route filter drain tube to clear landing gear damper while allowing unrestrained drain valve operation.
(4) Install with adhesive CM438.
(5) Apply low temperature antiseize compound, MILT5544B Thread Lube or equivalent to assembly
threads prior to installation. Torque bolt 185 200 inchpounds (20.90 22.60 Nm).
(6) Install MS206153M rivets in wet MILP23377, Type 1, Class 1, epoxy primer or, MILP8585 primer.
(7) Install MS206154M or alternate NAS1738M4 rivets in wet MILP23377, Type 1, Class, 1 epoxy primer
or, MILP8585 primer.
(8) Clamp wire harness in place as shown using existing tool holes.
(9) Apply MILT5544B low temperature antiseize compound to threads prior to assembly.
(10) Cut away insulation blanket per dimensions shown for bracket installation. Remove blanket debris. Do not
scratch firewall surface.
(11) Install doubler on forward firewall surface as shown. Pick up all existing rivet holes in doubler installation.
(12) Trim drain tube protrusion flush to 0.12 inch (3.048 mm) below grommet surface.
28-25-00
Page 909
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
PANEL
369H90161-3 HARNESS ALL

NUMBERED WIRE - 20 GA
MS17821-1-9 STRAP A/R
369H4742 SWITCH ASSEMBLY
Q510D20N
2
E23
AMBER 2
C
7
CR25
Q501CC20
CR23
2
CR26
Q503B20
NC
C
S3
NO
NC
E509B20
Q501A20
C
NO
S1
NC
Q506A20
C
NO
S2
CR27
VARISTO
R
NOTE 2
X1+
K254
Q507A20
3
X2-
LOAD - +
KD1
TB22
PRESS-TO-TEST
CB135
P506BA20
7.5
ANTI-ICE
FUEL FILTER
BRIGHT
ANTI-ICE CAUTION LIGHT

DIMMER SWITCH
R254
DIM
R
100 OHM 5 1/4W
TB101
3
G28-2001-1
Figure 903. AntiIce Fuel Filter Wiring Diagram (369D S/N 0001 1204) (Sheet 1 of 2)
Page 910
Revision 19
28-25-00
MAINTENANCE MANUAL
CSP-HMI-2
TB6
Q510D20N
Q501CC20
SP24
A B
START PUMP
ON LT
2
1
E561B22
SP23
B
E560B22
E560A22N
ZDS7
NOTE 1
28 VDC
XDS9
NC
START
1 PUMP 2
NOTE 1
S2
CB118
7.5A
Q503B20
-GRD
NO
NC
S1
S21
(REF) WARNING LGT.
LAMP TEST
+28 VDC
NO
E509B20
TO START
PUMP
Q501A20
P252
Q506A20
369H8021
FILTER
SPLICE PERMISSIBLE
A
NO
C
NC
Q507A20
PRESSURE SWITCH
AIFRAME FUEL
FILTER
NOTES:
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
CB1352
MS25036149
P252B
CRIMP
Q506A20
TB223
MS25036101
P252A
CRIMP
Q501A20 (REF)
TB221
MS25036101
TO START PUMP
E509B20
TB225
MS25036101
S21S1 (NO)
SOLDER
Q503B20
TB226
MS25036101
CB1182
MS25036149
Q501CC20
TB227
MS25036101
SP24A
32445 (AMP)
Q510D20N
E23
MS25036101
TB63
MS25036101
P506BA20
CB1351
MS25036149
TB1013
MS25036101
Figure 903. AntiIce Fuel Filter Wiring Diagram (369D S/N 0001 1204) (Sheet 1 of 2)
28-25-00
Page 911
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
E31
TB503-12
M531C20
P514A20
WARNING LIGHT
TEST SWITCH
ZDS-21-S2 (REF)
NC
E511B2
0
NO
C
CA3108ER12S-3S
CONNECTOR
P252
P9J
K K
E511BB2
0
L
F
NO
C
Q506B20
NC
369H8021 PRESSURE SWITCH
AIRFRAME FUEL FILTER
E13 GRND
M
B
G
N
H
TB505-1/2
Q506C20
R
K
TB503-4
P
1
20 GA BUS WIRE
AND SLEEVING
D531 AIRFRAME FILTER

CAUTION INDICATOR
(REAR VIEW)
Q514B20
P12
DIMMER
B
DC GROUND TEST
+28 VDC PWR
PRESSURE TEMP WARN

SIGNAL
WARNING LT. DIMMER
CB104
1
5A
WARNING
PNL LTS
E508A20
L532A20
TB503-6
E518A20
E559A20
Q514A20
DASHED LINES ARE EXISTING WIRES
G28-2002
Wire Data List

Wire No.
Wire Type
From
Termination
To
Termination
Q506A230
M81381/1120N
J9K
MS3192A20A
P252A
CRIMP
Q510F20N
M81381/1120N
E13
M7928/124
P252B
CRIMP
Q506C20
M81381/1120N
TB5051/2B
M39029/222020
TB5034E
MS39029/222020
Q514B20
M81381/1120N
TB5034D
M39029/222020
DS312
SOLDER
Q514A20
M81381/1120W
TB5036L
M39029/222020
DS31C
SOLDER
Figure 904. AntiIce Fuel Filter Wiring Diagram (369D S/N 1205 & Subs and 369E S/N 001 383)
Page 912
Revision 19
28-25-00
MAINTENANCE MANUAL
CSP-HMI-2
P12J DIMMER
V
A
D
CB10
4
TB5031
F
TB5032
A
NO
K
C
E3
3
B
NC
W1237A2
2
NO
W1040C2
2
TB5032
G
NC
XDS21 WARNING
PRESS-TO-TEST
DS31 AIRFRAME
FILTER
Q506D2
2
Q506D2
2
TB5032
J
LL
LR
TB506-1/2
W1237A22
TB503-8
A
G
H
M
B
Q1232C22
N
C
P
D
R
E
Q506C22
J1301P
P1201J
P252
69
Q506B22
Q506A22
Q510F22N
NO
NC
E13
G28-2005
Figure 905. AntiIce Fuel Filter Wiring Diagram (369E S/N 384 & Subs and 500N S/N 001 & Subs)
28-25-00
Page 913
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
CB115
(ANTI-COLLISION LTS.)
P2002A12
3A
22AWG
JMPR
CB118
(START PUMP)
1
BUS 3
7.5A
Q1169A2
2
P2003A10
P 12 J
J 13 P
CR39
22AWG
JMPR
DS22 (AIR FILTER

CLOGGED)
AMBER LAMP
P1233C22
DS21 (AIR FRAME

FILTER)
AMBER LAMP
CR47
39
39
46
46
W1040F22
9
53
Q506D22
14
14
CR14
22AWG
JMPR
NC
DC GROUND TEST
49
C
NO
+28VDC TEST
NO
C
NC NO NC
S2 C
S1
51
49
NC 14V
50
C
NO
XDS24
WARN LTS.
PTT
52
50
51
52
SWITCHING
REGULATOR
DIMMER CONTROL UNIT

G28-2006-1
Figure 906. AntiIce Fuel Filter Wiring Diagram (600N S/N 003 & Subs) (Sheet 1 of 2)
Page 914
Revision 19
28-25-00
MAINTENANCE MANUAL
CSP-HMI-2
TB503-2
4
A
P 1201 J
Q1170A2
2
Q1169A22
27
E37
H
E31
T
Q1235C22
46
E1181A2
2
Q1170B2
2
Q1170A22
N
J 13 P
39
FUEL PUMP
P/J 250
B250
A
XDS7
(START PUMP ON
LTS.)
E1181B22
N
P252
14
69
Q506B22
R110
6
49
7
5
4
3
PANEL LTS. DIMMER POT.

(PUSH TO DIM CAU/WARN LTS)
Q510F22N
AIR FRAME
FILTER
CB104
(PNL. LIGHTS)
2
B
3A
+28VDC
DC GROUND
DIMMER POT.
ARM
50
51
52
E13
Q506A22
P
K
G28-2006-2
Wire Data List

Wire No.
From
Termination
To
Termination
JUMPER22
CB1151
HDS4123126
CB1181
HDS4123126
O1169A22
CB1182
HDS4123126
TB50322
HDS4123904
O1170A22
TB5032R
HDS4123904
P120127
HDS4123916
O1236C22
TB5032N
HDS4123904
P1339
HDS4123926
(2)
JUMPER
P1239
HDS4123926
P1246
HDS4123926
(3)
E1181A22
P1346
HDS4123926
XDS7
HDS4123999
E1181B22N
XDS7
HDS4123999
E31E
HDS4123904
(2)
JUMPER22
DS22C
HDS4123999
DS21C
HDS4123999
(1)
O506D22
DS212
HDS4123999
P1214
HDS4123926
(1)
O506A22
J120169
HDS4123915
P252A
CRIMP
(3)
O510F22N
P252B
CRIMP
E13
HDS4123135
(1)
(4)
NOTES:
(1) Wire capped and stowed (part of existing wire harness).
(2) Do not exceed three inches (7.62 cm).
(3) Wire connected to ground.
(4) E13 Ground stud mounted on left oleo support.
Figure 906. AntiIce Fuel Filter Wiring Diagram (600N S/N 003 & Subs) (Sheet 2 of 2)
28-25-00
Page 915
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
(16). Measure electrical resistance between

filter bowl and firewall. Resistance
shall not be more than 0.003 ohms.
G. PostInstallation Inspection
(1). Ensure that all installation debris has
been removed.
(2). Check all electrical connections for
correct routing and security.
(3). Ensure that all hardware, tubes, and
hoses are properly secured.
(4). Ensure that no fuel can be trapped by
the drain system.
H. Furnishings, Panels and Equipment
Installation
(1). Install instrument panel hood and
instrument panel left side fairing.
(2). Install pilot's compartment left floor
access panel.

hoses, tubes and fittings as the parts are re
CAUTION
(1). Defuel helicopter (Ref. Sec. 12-00-00).

Drain remaining fuel from tank sump
drain valve into a suitable container.
A. Fuel Cell Cover Removal
(1). To remove left aft fuel cell access cover:
(a). Remove left aft fuel cell access panel
floor.
(b). Unclamp and disconnect control
cable from fuel shutoff valve.
(c). Disconnect engine feed fuel supply
hose assembly between fuel shutoff
valve and Sta. 124.00 bulkhead. Use
backup wrench on fuel shutoff valve
so it will not rotate.
(3). Install upper left aft bulkhead panel

and lower aft bulkhead panel.
(d). Disconnect motive flow fuel hose

assembly between Sta 124.00 bulk
head and fuel cell access cover.
(4). Install aft compartment seats.
(e). Disconnect fuel quantity probe wire

harness connector from fuel cell cover
receptacle.
(5). Close engine access doors.

(6). Connect battery.
2. AntiIce Fuel Pump Initial Installation
(600N98110501 Installation)
(g). Remove cover bolts and washers.

Prop cover open with suitably padded
blocks.
(Ref. Figure 907)
Item
Nomenclature
CM114
CM124
CM702
Petrolatum
Kerosene
Lockwire CRES

quately ventilated.
Page 916
Revision 19
(f). Unfasten and remove Sta. 91.00 and

brackets.
28-25-00
(h). Using a backup wrench on valve,

hose from fuel shutoff valve and fuel
inlet from fuel cell access cover.
(i). Disconnect submerged motive flow
fuel hose assembly between fuel
check valve and ejector pump from
fuel cell access cover.
(j). Disconnect fuel cell scavenge hose
assembly from bottom of fuel cell
access cover bracket assembly to
ejector pump.
(k). Cut safety wire from fuel probe
electrical connector base nut and
remove connector from fuel cell
access cover.
MAINTENANCE MANUAL
CSP-HMI-2
FS
93.15
FUEL PROBE
HOSE
BL
0.00
P250 WIRE HARNESS

COVER
WIRE HARNESS
FUEL CELL
WL 13.10
BOLT
WASHER
LBL 13.00
PUMP
WL 0.00
UNION
O-RING
SPACE
R
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
bracket assembly, bulkhead union
and fuel shutoff valve from fuel cell
cover.
(2). Remove unused bulkhead union from
cover.
B. Pump Installation
(1). Disconnect fuel feed hose from fuel inlet
plate and remove plate.
(2). Clean pump and sump plate mount
contact surfaces to establish an electri
cal bond.
CAUTION
Do not mark torque alignment

stripes on fuel cell internal
hardware.
(3). Install pump on sump plate with bolts,
washers and spacers. Torque bolts to 36
- 46 inch-pounds (4.07 - 5.20 Nm).
(4). Apply a thin coat of petrolatum
(CM114) to a new O-ring and pump
pressure port union threads. Install
O-ring on union. Install union in pump
pressure port and torque to 280 - 305
inch-pounds (31.64 - 34.46 Nm).
(5). Attach fuel supply hose to pump

pressure port union. Torque hose nut to
230 - 260 inch-pounds (25.99 - 29.38
Nm).
C. Fuel Cell Cover Installation
(2). Inspect fuel cell cover seals for debond
Replace covers or left aft cover as
required.
(3). Install left aft fuel cell access cover as
follows:
(a). Apply a coating of petrolatum
(CM114) to a new fuel shutoff valve/
cover sealwasher. Install valve on cell
cover with sealwasher next to valve
body and valve properly aligned to
make connection with valve control
cable. Torque valve jamnut to 240 280 inch-pounds (27.12 - 31.64
Nm).
28-25-00
Page 917
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
(b). Apply a coating of petrolatum to

sealwasher. Install check valve and
sealwasher to inside cover and a
plain washer outside. Torque jamnut
to 85 - 105 inch-pounds (9.6 11.86 Nm).
(c). Install bulkhead elbow to support
bracket. with washer and nut. Torque
(27.12 - 31.64 Nm).
(d). Install support bracket to cover with
bolts, washer, and sealwashers.
Apply a coating of petrolatum to
sealwasher. Torque bolts to 36 - 46
(4). Place left aft fuel cell access cover into
position on fuel cell.
NOTE: Install new seal washer, AS3578-024,

on wire harness connector.
(5). Connect fuel quantity probe and pump
wire harness connectors to cell cover.
Torque connector jamnuts and safety
wire to bulkhead union with lockwire
(CM702).
(6). Install fuel cell inlet hose assembly to
access cover fuel shutoff valve. Torque
(25.99 - 29.38 Nm).
(7). Install submerged motive flow hose
assembly to access cover check valve.
Torque hose assembly 50 - 65 inchpounds (5.65 - 7.34 Nm).
(8). Install scavenge fuel cell hose assembly
to access cover bulkhead elbow. Torque
(25.99 - 29.38 Nm).

(10). Install cover bolts and washers. In a
cross pattern, progressively torque
cover bolts to 70 - 90 inch-pounds
(7.91 - 10.17 Nm).
fuel shutoff valve. Torque hose nut to
230 - 260 inch-pounds (25.99 - 29.38
Nm).
(12). Connect fuel motive flow hose to access
cover/check valve. Torque hose nut (50
- 65 inch-pounds (5.65 - 7.34 Nm).
(13). Connect fuel quantity probe and pump
connectors to wire harness receptacles.
(15). Rig cable control system. (Ref. Sec.
28-00-60, Fuel Shutoff Valve Control
Cable Installation).
(17). Install access panels on passenger
3. AntiIce Fuel Filter Installation Weight
and Balance
(1). After installation of the anti-ice fuel
filter, incorporate changes to helicopter
weight and balance record (Ref. Sec.
Section 08-10-00).

Configuration
Weight
Pounds (kg)
Arm
inches (cm)
Moment
in.lb (kg cm)
369H90022BSC
+6.6
(+2.996)
107.8
(273.81)
+711.48
(+819.710)
369H90022503
+5.3
(+2.406)
122.7
(311.66)
+650.31
(+749.235)
369H90022505
+5.3
(+2.406)
122.7
(311.66)
+650.31
(+749.235)
600N98110501
+7.3
(+3.311)
112.7
(286.26)
+822.7
(+947.807)
Page 918
Revision 19
28-25-00
MAINTENANCE MANUAL
Chapter
32
Landing Gear
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 301. Landing Gear Damper Nitrogen Servicing - On Helicopter . . . . . . .
Table 301. Nitrogen Service Schrader Valve Equipped 369D26301 Extended
Landing Gear Dampers - on Helicopter . . . . . . . . . . . . . . . . . . . . . . . . .
Table 302. Nitrogen Service Schrader Valve Equipped 369D26300 Standard
Landing Gear Dampers - on Helicopter . . . . . . . . . . . . . . . . . . . . . . . . .
301
302
303
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603

4.
Landing Gear Damper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
5.
Cabin Entry Step Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
6.
Landing Gear Fairing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605

Table 601. Minimum Damper Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Table 602. Landing Gear Damper Bench Test Requirements . . . . . . . . . . . . . . . . 605
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1.
Landing Gear System Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2.
Skid Adapter Sleeve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3.
Abrasion Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

Table 801. Maximum Damage Limits - Landing Gear Components . . . . . . . . . . 802
Figure 801. Landing Gear Repairs (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
4.
Ground Handling Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
5.
Safety Walk Tape Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
6.
Landing Gear Fairing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
7.
Landing Gear Fairing Fillet Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8.
Landing Gear Strut Drag Brace Hole Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806

A. Landing Gear Strut with Bushing Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
B. Landing Gear Strut with No Bushing Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 802. Landing Gear Fairing Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807

1.
Extended Landing Gear Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901

A. Standard Landing Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Standard Landing Gear Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Extended Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
Figure 901. Extended Landing Gear Assembly (Early Configuration) . . . . . . . . . 902
Figure 902. Extended Landing Gear Assembly (Current Configuration) . . . . . . 904
D. Early Configuration Extended Landing Gear Assembly Buildup . . . . . . . . . . . . . 906
E. Current Configuration Extended Landing Gear Skid Tube Assembly
Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
F. Extended Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
G. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Figure 903. Extended Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
32-10-60 Landing Gear System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1.
Landing Gear System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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A. Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Entry Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1.
Landing Gear Damper Nitrogen Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Figure 301. Landing Gear Damper Nitrogen Servicing - On Helicopter . . . . . . . 302
Table 301. Nitrogen Recharge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.
Landing Gear Strut Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

A. Landing Gear Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Landing Gear Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2.
Landing Gear Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

A. Landing Gear Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Landing Gear Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401. Landing Gear and Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . 403
3.
Landing Gear Skid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

A. Landing Gear Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Landing Gear Skid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4.
Landing Gear Fairing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

A. Landing Gear Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Landing Gear Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 402. Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. Landing Gear Rubber Washer Locations . . . . . . . . . . . . . . . . . . . . . . . 407
1.
Landing Gear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2.
Landing Gear Skid Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3.
Landing Gear Strut Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4.
Landing Gear Damper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
5.
Forward Cabin Entry Step Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
6.
Landing Gear Fairing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602

Table 601. Minimum Damper Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1.
Landing Gear System Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2.
Abrasion Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
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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

A. Skid Tube and Extension Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Utility Float Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.
Utility Float Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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Table 201. Troubleshooting Utility Floats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Utility Float Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A. Utility Float Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Utility Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Skid Tube Extension Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A. Skid Tube Extension Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Skid Tube Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 201. Utility Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202
202
202
202
203
203
203
204
Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Utility Float Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A. Preparation for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Disassembly of Extended Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 901. Extended Landing Gear - Disassembly . . . . . . . . . . . . . . . . . . . . . . . .
C. Landing Gear Strut Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Landing Gear Skid Extension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 902. Extended Landing Gear Modification . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 903. Skid Tube Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E. Utility Float to Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F. Utility Floats/Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 904. Utility Float Buildup (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
901
901
901
901
902
903
903
904
905
906
907
907
907
909
32-82-00 Emergency Float System

(369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Emergency Float System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . .
A. Emergency Float Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Certification and Shelf/Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Emergency Float Inspection (Stowed Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Emergency Float Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 201. Troubleshooting Emergency Flotation Equipment . . . . . . . . . . . . . . . .
5. Emergency Float Compartment Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Emergency Float Inspection (After Inflation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Emergency Float Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Float Compartments Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Emergency Float Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. Solenoid-to-Squib Rework Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201
201
201
202
202
202
203
203
203
204
204
204
204
1. Emergency Float Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
32 Contents
Page v
Revision 26
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . .
Figure 902. Emergency Float Inflation System Wiring Diagram
(369D290121-501 and -505) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(369D290121-515, -517 and -519) (Sheet 1 of 2) . . . . . . . . . . . . . . . .
(369D290121-521, -523, -525 and -527) (Sheet 1 of 2) . . . . . . . . . . .
Figure 905. Emergency Float Installation with Generic Wire Harness . . . . . . . .
903
904
905
907
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
Revision 26
32 Contents
MAINTENANCE MANUAL
CSP-HMI-2
Section
321000
Landing Gear
System
(369D/E/FF 500N)
MAINTENANCE MANUAL
CSP-HMI-2
LANDING GEAR SYSTEM

1. Landing Gear
The landing gear consists of two strutmounted, shock-dampened skids aligned
longitudinally along the helicopter fuselage.
Both right and left skids pivot as the damper
assemblies extend and retract. Replaceable
abrasion strips are installed on each skid to
retard wear on hard surfaces.
A. Skid
Landing gear skids provide helicopter rest
mounts. Skid tubes are constructed from
seamless, extruded aluminum alloy tubing.
Abrasion strips attached to undersides of skid
tubes retard wear and damage. Ground
handling fittings riveted to skid tubes are the
ground handling attach points. Forward end of
skid contains provisions for night lighting
equipment. An adapter sleeve at the aft end of
skid tube provides a nonrigid mount for the aft
foot bearing and skid extension.
B. Strut
The landing gear struts attach to the fuselage
center beam. Landing gear braces between the
landing gear strut and fuselage center beam
prevent shearing of the strut and keep the
strut in alignment with the landing gear. At
the lower ends of the struts, foot-shaped
components attach the landing gear skids to
the struts. Feet for the aft strut are bearingmounted to provide a nonrigid and pivotal
mount.
C. Damper
Landing gear assemblies are equipped with
front and rear damper assemblies. Dampers
absorb vertical shock to landing gear struts
during helicopter landings. Front damper
assemblies are attached to oleo attachment
fittings on the outboard side of the pilot's
compartment seat structure. Aft damper

assemblies are attached to oleo support fittings
in the engine compartment.
The damper assemblies are approximately
12.21 inches (31.01 cm) long when extended
and 8.96 inches (22.76 cm) long when com
pressed. The dampers are poppet-type and
consist of a barrel, upper and lower mounting
cap, main poppet, rebound poppet and a
piston. Damper exterior surfaces are painted
white for surface protection and as an aid to
identification.
A damper must be replaced if damaged, or if
loss of pneumatic pressure (nitrogen gas) or
hydraulic oil occurs.
D. Entry Step
Entry steps mounted on the landing gear
struts allow for easy access into cabin. The
landing gear step is covered with non-skid
tape and attached to the landing gear strut
with lockbolts.
E. Fairing
Fiberglass/aluminum fairings on each strut
reduce aerodynamic drag during flight. The
fairings extend from the fuselage to the skids
to form streamlined enclosures for the landing
gear struts. Each fairing assembly is con
structed of three main parts: a fillet, an upper,
and lower two-piece fairing. The fillet is
spring-loaded to remain in firm contact with a
fiberglass rubbing plate that is bonded and
riveted to the fuselage. The fairing is secured
to the landing gear and telescopes up inside
the fillet to allow movement of the strut as the
landing gear dampers compress or extend. A
seal on the bottom edge of the fairing forms a
fillet between the fairing and the skid tube.
Fairings also have openings for cabin entry
steps.
32-10-00
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CSP-HMI-2
MAINTENANCE MANUAL
Page 2
Revision 44
32-10-00
MAINTENANCE MANUAL
CSP-HMI-2
LANDING GEAR SYSTEM

SERVICING
1. Landing Gear Damper Nitrogen Servicing
(Ref. Figure 301) Service landing gear damp
ers equipped with schrader valve according to
the following steps.
Do not recharge a damper if
there is evidence of fluid leak
age. Recharging of damper will cause fur
ther leakage of both gas and damper fluid,
posing a danger to the helicopter.
CAUTION
(1). Place helicopter on jacks or hoist.
NOTE: A minimum of two dampers shall be re

charged; either the two forward dampers,
two aft dampers, or both forward and aft
dampers.
(2). For forward damper servicing, remove
footwell panel located in passenger
compartment (Ref. Sec. 25-30-00). For
aft damper servicing, open engine
access doors.
(3). Remove cap from schrader valve and
connect servicing hose, but do not
tighten.
(4). Ensure low side of nitrogen pressure
regulator is backed off to the unpres
surized position. Slowly open the high
pressure nitrogen bottle valve.
(5). Slowly turn regulator control until
nitrogen begins to flow at the loose
servicing hose-schrader valve connec

tion.
(6). Tighten servicing hose while nitrogen is
flowing. Allow nitrogen pressure to
build to the valve according to dash
number and part number of damper
(Ref. Table 301 or Table 302).
To prevent damage to damper or
loss of damper fluid do not open
schrader valve without pressurizing the
servicing line. If fluid loss occurs, damper
will require overhaul.
CAUTION
(7). Once pressure level is reached open

schrader valve by turning outside nut
counter clockwise, allowing system and
damper pressure to equalize for a
minimum of 2 minutes. If slightly over
pressurized, bleed off excess very
slowly.
(8). Close schrader valve by turning the
outside nut clockwise. Torque nut to 60
inch pounds (6.78 Nm) and safety
wire.
(9). Reduce charge pressure to zero, and
remove servicing hose. Install cap on
schrader valve.
(10). Inspect damper for leakage approxi
mately two hours after servicing. Check
damper extension according to
Table 601 of this section.
32-10-00
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Revision 19
CSP-HMI-2
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
Revision 19
32-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Table 301. Nitrogen Service Schrader Valve Equipped 369D26301 Extended Landing Gear
Dampers on Helicopter
Degrees
Winterized Recharge
Pressure (1)
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
24
31
22
MidTemp Recharge
Pressure (2)
psi
kPa
8,791
1,051
7,247
1,277
8,804
1,052
7,255
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
22
1,292
8,905
1,061
7,316
21
1,293
8,918
1,062
7,324
20
1,295
8,931
1,063
7,332
19
1,297
8,943
1,065
7,340
18
1,299
8,956
1,066
7,347
17
1,301
8,969
1,067
7,355
16
1,303
8,981
1,068
7,363
14
1,305
8,994
1,069
7,371
13
1,306
9,007
1,070
7,378
10
12
1,308
9,019
1,071
12
11
1,310
9,032
14
10
1,312
16
18
Ambient Recharge
Pressure (3)
psi
kPa
7,386
1,145
7,891
1,072
7,394
1,146
7,900
9,045
1,074
7,401
1,147
7,908
1,314
9,057
1,075
7,409
1,148
7,917
1,316
9,070
1,076
7,417
1,150
7,925
20
1,317
9,083
1,077
7,425
1,151
7,934
22
1,319
9,096
1,078
7,432
1,152
7,943
24
1,321
9,108
1,079
7,440
1,153
7,951
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Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
Degrees
F
Winterized Recharge
Pressure (1)
psi
kPa
26
1,323
9,121
1,080
7,448
1,154
7,960
28
1,325
9,134
1,081
7,455
1,156
7,968
30
1,327
9,146
1,082
7,463
1,157
7,977
32
1,328
9,159
1,084
7,471
1,158
7,985
34
1,330
9,172
1,085
7,479
1,159
7,994
36
1,332
9,184
1,086
7,486
1,161
8,002
38
1,334
9,197
1,087
7,494
1,162
8,011
40
1,336
9,210
1,088
7,502
1,163
8,019
42
1,338
9,222
1,089
7,510
1,164
8,028
44
1,339
9,235
1,090
7,517
1,166
8,037
46
1,341
9,248
1,092
7,525
1,167
8,045
48
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
Page 304
Revision 19
32-10-00
MidTemp Recharge
Pressure (2)
psi
kPa
Ambient Recharge
Pressure (3)
psi
kPa
MAINTENANCE MANUAL
CSP-HMI-2
Degrees
Winterized Recharge
Pressure (1)
psi
kPa
MidTemp Recharge
Pressure (2)
psi
kPa
Ambient Recharge
Pressure (3)
psi
kPa
92
33
1,195
8,242
94
34
1,197
8,250
96
36
1,198
8,259
98
37
1,199
8,267
100
38
1,200
8,276
102
39
1,202
8,284
104
40
1,203
8,293
106
41
1,204
8,302
108
42
1,205
8,310
110
43
1,207
8,319
112
44
1,208
8,327
114
46
1,209
8,336
116
47
1,210
8,344
118
48
1,212
8,353
120
49
1,213
8,361
122
50
1,214
8,370
124
51
1,215
8,379
126
52
1,216
8,387
NOTES:
(1) For 369D26301221, and 231 extended landing gear dampers.
(2) For 369D26301241, and 251 extended landing gear dampers.
(3) For 369D26301211 extended landing gear dampers.
32-10-00
Page 305
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
Table 302. Nitrogen Service Schrader Valve Equipped 369D26300 Standard Landing Gear
Degrees
Winterized Recharge
Pressure (1)
psi
kPa
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
24
31
22
MidTemp Recharge
Pressure (2)
psi
kPa
4,919
704
4,855
715
4,929
705
4,862
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
22
726
5,003
713
4,916
21
727
5,012
714
4,923
20
728
5,021
715
4,929
19
730
5,031
715
4,936
18
731
5,040
716
4,942
17
732
5,049
717
4,949
16
734
5,058
718
4,955
14
735
5,068
719
4,962
13
736
5,077
720
4,968
10
12
738
5,086
721
12
11
739
5,096
14
10
740
16
18
Ambient Recharge
Pressure (3)
psi
kPa
4,974
637
4,392
722
4,980
638
4,397
5,005
723
4,987
639
4,403
742
5,114
724
4,993
639
4,409
743
5,123
725
4,999
640
4,415
20
744
5,133
725
5,005
641
4,420
22
746
5,142
726
5,011
642
4,426
24
747
5,151
727
5,017
643
4,432
Page 306
Revision 19
32-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Degrees
Winterized Recharge
Pressure (1)
psi
kPa
MidTemp Recharge
Pressure (2)
psi
kPa
Ambient Recharge
Pressure (3)
psi
kPa
26
748
5,160
728
5,023
644
4,438
28
750
5,170
729
5,029
645
4,444
30
751
5,179
730
5,035
645
4,449
32
753
5,188
731
5,041
646
4,455
34
754
5,198
732
5,047
647
4,461
36
755
5,207
732
5,052
648
4,467
38
757
5,216
733
5,058
649
4,473
40
758
5,225
734
5,064
650
4,478
42
759
5,235
735
5,070
650
4,484
44
761
5,244
736
5,075
651
4,490
46
762
5,253
737
5,081
652
4,496
48
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
32-10-00
Page 307
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
Degrees
Winterized Recharge
Pressure (1)
psi
kPa
MidTemp Recharge
Pressure (2)
psi
kPa
Ambient Recharge
Pressure (3)
psi
kPa
92
33
671
4,629
94
34
672
4,635
96
36
673
4,641
98
37
674
4,646
100
38
675
4,652
102
39
676
4,658
104
40
676
4,664
106
41
677
4,670
108
42
678
4,675
110
43
679
4,681
112
44
680
4,687
114
46
681
4,693
116
47
681
4,698
118
48
682
4,704
120
49
683
4,710
122
50
684
4,716
124
51
685
4,722
126
52
686
4,727
NOTES:
(1) For 369D26300221, and 231 standard landing gear dampers.
(2) For 369D26300241, and 251 standard landing gear dampers.
(3) For 369D26300211 standard landing gear dampers.
Page 308
Revision 19
32-10-00
MAINTENANCE MANUAL
CSP-HMI-2
LANDING GEAR SYSTEM

1. Landing Gear Replacement
(Ref. Figure 401)
A. Landing Gear Removal
Item
Nomenclature
CM729
NOTE: Following procedures apply to removal

of entire right or left landing gear assembly.
For component disassembly, refer to appli
cable section. For removal, two persons are
needed.
(1). Jack up helicopter until landing gear
dampers are fully extended (Ref. Sec.
07-00-00). Place support beneath skid
tubes at strut locations.
doors, engine access doors and foot

supporting fairings.
(2). With helicopter supported by jacks,
position landing gear to align struts
with openings in fuselage structure.
NOTE: Check that fairing fillet guide pins en

gage fairing guide holes before positioning
struts for attachment to structure.
(3). Lift and carefully position landing gear;
then place supports beneath landing
gear to hold it in place.
NOTE: Install left forward damper upper bolt

with bolt head aft. Bolt direction on right
side is optional.
(4). Be sure that slotted bushing (view C) is
in place. Align lower bearing of damper
with mating holes in strut and install
attaching hardware.
(2). Pull strut fairing fillet downward

against spring tension and secure with
tape (CM729).
(5). Align struts with mating bearings in

fuselage support fittings. Install bolt,
slotted bushing, two washers, nut and
cotter pin.
(3). Open compartment access doors for

access to forward brace, strut and
damper. Disconnect brace, strut and
damper from attachment points.
(6). Align inboard end of each brace with

mating bearing in fuselage supporting
fitting. Install slotted bushing and
attaching hardware.
(4). For access to aft landing gear attach

ment points, open engine access doors.
Disconnect aft brace, strut and damper
from attachment points.
(7). Secure electrical bonding jumper with

clamp and attaching hardware to aft
strut.
(5). Remove clamp attaching electrical

bonding jumper to aft strut.
(6). Disconnect electrical wiring connections
at upper area forward strut.
(7). Remove supports from below skid and
carefully remove struts, skid and
fairings as an assembled unit.
B. Landing Gear Installation
NOTE: Following procedures apply to installa

tion of right or left landing gear assemblies.
(1). For access to landing gear attachment
points, open or remove fuselage access
Do not over-tighten brace-tostrut hardware. Maximum per

missible nut torque is finger-tight; then
backed off to nearest cancellation for instal
lation of cotter pin.
CAUTION
(8). If brace is detached from strut, align

outboard end of each brace with mating
holes in strut. Attach brace to strut
with attaching hardware. Torque nut to
5 inch-pounds (0.56 Nm) maximum.
(9). Connect wiring at forward strut.
(10). Remove skid supports, lower helicopter,
and remove jacks.
(11). Close or replace all access doors.
32-10-00
Page 401
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
FILLET
FAIRING
SKID
EXTENSION
CABIN ENTRY STEP
KNIFE SPLICE
GROUND HANDLING
FITTINGS
SAFETY
WALK TAPE
ABRASION STRIP
ABC BOLTS
SEALING COMPOUND
LANDING GEAR SKID
POSITION LIGHT
ELECTRICAL HARNESS
TORQUE STRIPE
(NOTE 3)
DAMPER
SERVICE LOOP
0.37-0.62 INCH
(9.398-15.748 MM)
CENTER BEAM
DIMENSION
A
BARREL
CLAMP
SLOTTED
BUSHING
(NOTE 1)
BONDING
JUMPER
0.37-0.62 INCH
(9.398-15.748 MM)
STRUT
TORQUE
STRIPE
(NOTE 3)
5 IN.-LB.
(0.56 NM)
MAXIMUM
BRACE
NOTE 2
STRUT AND BRACE ATTACHMENT
BUSHING
(NOTE 1)
0.030 INCH (0.762 MM)

MAXIMUM DEFECT
DEPTH (TYPICAL)
DAMPER UPPER ATTACHMENT
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
OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.
2. LEFT FORWARD DAMPER ATTACHING BOLT HEAD AFT FOR
REMOVAL CLEARANCE.
3. TORQUE STRIPES PAINTED CONTRASTING BLACK OR WHITE,
AS APPLICABLE.
G32-1000B
Figure 401. Landing Gear and Damper Installation

Page 402
Revision 19
32-10-00
MAINTENANCE MANUAL
CSP-HMI-2
2. Landing Gear Damper Replacement
3. Landing Gear Skid Replacement
(Ref. Figure 401)
(Ref. Figure 401)
A. Landing Gear Damper Removal

(1). Jack up or hoist helicopter on level
surface until landing gear skids just
clear resting surface.
(2). For forward damper removal, remove
foot well fairings located in passenger
compartment. For access for aft damper
removal, open engine access doors.
(3). Remove hardware (except bushings)
attaching forward damper assemblies
to fuselage attachment fittings and
landing gear struts.
(4). Remove hardware from damper
attachment points.
B. Landing Gear Damper Installation
A. Landing Gear Skid Removal

(1). If landing gear assembly is attached to
helicopter, jack up helicopter until
dampers are fully extended (Ref. Sec.
07-00-00). Place supports beneath skid
tubes at strut locations.
(2). Remove lower fairing from two-piece
fairing assembly.
(3). Remove bolts attaching forward
skid-to-foot assembly.
(4). Disconnect electrical connections at
forward strut.
(5). Remove bolts attaching extension to
skid adapter sleeve. Remove extension,
index plug and bearing from skid.
B. Landing Gear Skid Installation
(1). Jack up helicopter on level surface until

landing gear skids (Ref. Sec. 07-00-00)
just clear resting surface.
NOTE:
D Always be sure that replacement damper
is correct for the helicopter. Ensure that
cap torque stripes will be visible for in
spection after installation.
D If installing schrader valve equipped
dampers, ensure fwd damper is installed
with schrader valve facing forward and
aft damper with schrader valve facing aft.
(2). Install replacement damper in upper
and lower mounting position with
attaching hardware. Ensure bushings
are in place.
NOTE: Left forward damper upper bolt must be

installed with bolt head aft. Bolt direction
on right side is optional.
(3). Torque nuts to 48 - 55 inch-pounds
(5.42 - 6.21 Nm) and cotter pin.
(4). Check installation for proper alignment
of torque stripes.
(5). Install foot support fairings and close
engine access doors.
Item
Nomenclature
CM318
CM420
CM425
Primer
Sealant
Sealing compound
NOTE: Left or right replacement skids are in

terchangeable by using or removing nylon
screws from side of skid at forward strut.
(1). Position skid in place with aft foot
bearing installed over skid adapter
sleeve. Connect electrical connections
for skid position light at forward strut.
(2). Apply thin coating of primer (CM318) to
forward strut and skid tube mating
surfaces.
(3). Align mating parts and install bolts
with wet coating of zinc chromate
primer. Torque bolts 40 - 60 inchpounds (4.52 - 6.78 Nm). Apply
sealant (CM420) to head of bolt and to
nuts.
(4). Align skid extension with skid tube
adapter sleeve. Coat attaching bolts
with primer and install while wet.
32-10-00
Page 403
Revision 26
MAINTENANCE MANUAL
CSP-HMI-2
(5). Seal edges of all rigid parts on skid

with an approximate 0.060 inch (1.524
mm) fillet of sealing compound
(CM425).
(e). Carefully spread fillet at trailing

edge and remove in forward direc
tion.
(3). Remove upper part of fairing as follows.
(6). Install lower fairing.
(a). Remove rivets that secure trailing

edge of fairing.
4. Landing Gear Fairing Replacement
(b). Remove rivets that secure fairing to

strut bracket.
(Ref. Figure 402)

A. Landing Gear Fairing Removal
(c). Use putty knife or similar thinbladed tool to carefully pry apart
bonding and separate upper 5 inches
of trailing edge; then separate fairing
from flange of lower guide.
The following instructions are typical for and

apply to all four fairing assemblies.
(1). Remove lower fairing from fairing
assembly as follows.
(a). Remove attaching hardware that
secures lower fairing to two strut
brackets, and that secures trailing
edge of lower fairing.
(b). Carefully spread trailing edge of
lower fairing and remove in forward
direction.
(d). Carefully spread trailing edge of

fairing and remove in forward
direction.
B. Landing Gear Fairing Installation
The following instructions apply to all four
fairing assemblies. Where riveting is required,
use rivets of type shown in Figure 802.
Item
Nomenclature
CM318
CM411
Primer
Adhesive, epoxy
NOTE: Ensure that doublers between lamina

tions at trailing edge are retained for reuse.
(2). Remove fillet from upper part of fairing
(a). Remove rivets from trailing edge of
fillet.
(b). Drill out one of the rivets securing
fillet to upper guide. Replace rivet
with sheet metal hole fastener (Cleco,
or equivalent). Repeat this step on
other rivets.
(c). Open underfloor compartment or
engine compartment doors for access
to strut cutout in fuselage skin. Have
an assistant push down on upper
guide with suitable tool (wood dowel
or equivalent), to relieve spring
tension.
(d). With spring tension off guide, remove
fasteners. Slowly relax dowel pres
sure on guide until springs fully
expand.
Page 404
Revision 26
32-10-00
(1). Install upper part of the fairing as

follows.
(a). Assemble upper guide, pin assembly,
inner guide half, outer guide half,
springs and lower guide on landing
gear strut. Install rivets with wet
primer (CM318) to secure lower
guide to strut.
(b). Push guide pins into matching holes
of lower guide. Wedge temporary
holding device between upper guide
and strut to keep pins engaged.
NOTE: Use two small wood blocks or any simi

lar suitable means to keep springs com
pressed. Device used must be small enough
to be removed through strut cutout in skin
after fillet is assembled.
MAINTENANCE MANUAL
CSP-HMI-2
NUTPLATE
RIVET
FAIRING
ASSY
FAIRING ASSY
SEAL
WASHER
SCREW
NUT
WASHER
WASHER
SCREW
COVER (EXTENDED
LANDING GEAR ONLY)
WASHER
SCREW
SEAL
SEAL
Figure 402. Fairing Installation
32-10-00
Page 405
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
(c). Install blind hole transfer punches

(two or four places, as applicable) or
fabricate suitable tools as shown
(Ref. Figure 802). Install tool(s)
between opposing holes in strut
bracket(s).
(d). Carefully spread trailing edge of
fairing and position fairing on strut
bracket(s) and lower guide. Have an
assistant hold fairing in this position.
(e). Back up fairing with a fiber block at
transfer punch location. Using plastic
hammer, carefully strike opposite
side of fairing to transfer hole
centers.
(f). Remove fairing and check that all
transfer marks appear within outline
of small laminated doublers. Drill out
located holes.
(g). Carefully bond fairing to lower guide
(Ref. Figure 802). Use adhesive
(CM411) according to container
instructions.
(h). Install rivets to secure fairing to
strut bracket(s).
(i). Install rivets to secure trailing edge
of fairing.
(j). Using soft lead pencil, draw a
continuous line along horizontal
center of upper guide flange.
(2). Install fillet as follows.
(a). Drill a #40 hole in center of each 3/8
inch (9.525 mm) square doubler in
fillet. (There are six doublers in the
fiberglass fairings.)
Page 406
Revision 26
32-10-00
(b). Carefully spread trailing edge of fillet

and position about upper guide.
Clamp lower end of fillet trailing
edge to upper end of fairing trailing
edge. Clamping prevents fillet
movement when fillet rivets are
installed. Have an assistant remove
temporary holding device and push
down on upper guide with suitable
tool (wood dowel, etc). Have guide
pushed down where a pencil line
drawn on guide flange is visible
through one #40 hole in fillet. Matchdrill guide and secure fillet and guide
with hole fastener (Cleco, or equiva
lent). Repeat procedure for all rivet
locations. Remove pushing tool from
strut opening.
(c). Remove one fastener at a time, and
install screws and washers (Ref.
Landing Gear Fairing Fillet Modifi
cation).
(d). Install screws, washers and nuts to
secure fillet trailing edge together.
(e). Check for smooth telescoping action
of fairing into fillet by manually
sliding fillet up and down several
times.
(f). Close access doors.
(3). Install lower part of two-piece fairing
as follows.
(a). Carefully spread trailing edge of
fairing and position on upper fairing
and lower strut bracket; at correct
position there should be 0.020 0.080 inch (0.508 - 2.032 mm)
compression of fairing seal against
skid tube. Have an assistant hold
fairing at this position.
(b). Back up fairing with fiber block at
transfer punch location. Using plastic
hammer, carefully strike opposite
side of fairing to transfer hole
centers.
(c). Remove fairing and check that all
transfer marks appear within outline
of small laminated doublers. Drill out
located holes.
MAINTENANCE MANUAL
(d). Reinstall fairing in mounting position
and secure to upper and lower strut
brackets with screws and washers.
(e). Secure fairing trailing edge with
attaching hardware.
NOTE: Be sure doublers are installed between

laminations at trailing edge.
5. Cabin Entry Step Replacement
(Ref. Figure 801)
A. Cabin Entry Step Removal
(1). Remove landing gear fairing.
(2). Remove four lockbolts and step from
forward landing gear strut, or two bolts,
washers and nuts from aft landing gear
strut (extended gear only).
CSP-HMI-2
B. Cabin Entry Step Installation
Item
CM318
Nomenclature
Primer
(1). Install replacement step on forward

landing gear strut, using four lockbolts
with wet primer (CM318). Four holes in
step collar must be drilled out to 0.164
- 0.167 inch (4.166 - 4.242 mm) for
installation of lockbolts. If holes are
elongated, use next size larger lock
bolts.
NOTE: At strut replacement, locate step by us

ing skid centerline-to-step centerline mea
surement of 11.78 inches (29.92 cm).
(2). Install step on aft landing gear strut,
using two bolts, washers and nuts with
wet primer. Torque nuts to 60 - 85
inch-pounds 6.78 - 9.60 Nm).
(3). Install lower fairing on strut.
32-10-00
Page 407
Revision 26
CSP-HMI-2
MAINTENANCE MANUAL
Page 408
Revision 44
32-10-00
MAINTENANCE MANUAL
CSP-HMI-2
LANDING GEAR SYSTEM

INSPECTION/CHECK
1. Landing Gear Inspection
(Ref. Figure 801)
NOTE: Inspection should be performed with

helicopter skids clear of ground.
(1). Inspect skids, skid abrasion strips,
struts, feet, braces and fairings for
dents, cracks, loose components or
rivets, loose nuts and for missing
hardware.
(2). Inspect skid-to-foot and foot-to-strut
attachments for loose bolts. Check aft
foot-to-bearing rivet installation for
security.
NOTE: Loose or defective bolts at forward footto-skid locations requires replacement of

nutplates.
(3). Using 10X glass and bright light,
visually inspect area at, around and
between foot-to-strut attach bolts not
covered by sealant for cracks and
corrosion.
NOTE: If cracks or corrosion other than light

surface corrosion is found, replace affected
part.
(4). Inspect keel beam areas where the
strut assemblies attach for loose
bearings, condition of hardware and
strut adapters.
(5). Check condition of beaded seal around
edges of all rigid-mounted skid tube
components.
2. Landing Gear Skid Inspection
(Ref. Figure 801)
NOTE: If landing gear assembly has not been

removed from helicopter, perform following
steps (1). and (2). before proceeding with in
spection.
(1). Jack helicopter until landing gear

dampers are fully extended.
fairing assembly.
(3). Inspect for dents. If dents exceed a
depth of 0.20 inch (5.08 mm), they will
require repair.
(4). Inspect for punctures and cracks.
(5). Perform fluorescent-penetrant inspec
tion of all crack areas, and of those
areas adjacent to all punctures. These
areas will require repair.
(6). Inspect from aft end of tube to a point
10 inches (25.40 cm) forward of aft strut
for scratches and nicks. If scratches and
nicks exceed a length of 0.25 inch (6.35
mm) and a depth of 0.015 inch (0.381
mm), they will require repair.
(7). Inspect from forward end of tube to 10
inches (25.40 cm) forward of aft strut
for scratches and nicks. If scratches and
(8). Inspect ground handling fittings for
cracks, loose rivets, corrosion and other
damage.
(9). Inspect abrasion strips for damage,
excessive wear, and for loose bolts and
screws.
(10). Check skid adapter sleeve rivet attach
ment for security. On early configura
tions, check sleeve slots for wear and
damage.
(11). Check condition of plug installed in
skid adapter sleeve.
(12). Check aft foot bearing and extension for
wear, damage and corrosion. On early
configurations, check condition of
extension packing.
32-10-00
Page 601
Revision 31
MAINTENANCE MANUAL
CSP-HMI-2
3. Landing Gear Strut Inspection

(Ref. Table 801 and Figure 601)
Item
Nomenclature
CM318
Primer
(1). Check landing gear dampers for correct

servicing by observing stance of
helicopter. Check rear dampers for
correct extension and signs of leakage.
(2). Remove foot support fairings in passen
ger/cargo compartment and open engine
access doors.
(3). Visually inspect strut attachment
points and pivot bearing for signs of
fretting, wear and damage. Fretting
will be evident by gray or black materi
al around bearing, rivets or seams.
(5). Shake landing gear assemblies and
note any play or looseness at pivot
bearings, inboard strut assembly
fittings and drag brace holes.
(6). If any play or looseness is noted,
remove landing gear (Ref. Landing
Gear Removal) and inspect drag brace
and strut.
(7). Inspect strut bolt hole where drag brace
attaches as follows:
(a). If bushing is installed in drag brace
attach hole in strut, proceed as
follows:
a). Diameter of top hole (DIM. A)

should be 0.5313 inch (13.495
mm) maximum in any direction.
b). Diameter of bottom hole (DIM.
B) should be 0.50 inch (12.70
mm) maximum in any direction.
4). If no cracks are found around drag
brace attach hole in strut and hole
is not elongated, install new
bushing in hole with wet primer
(CM318).
5). If either hole is oversized or
cracking is noted, rework strut
(Ref. Landing Gear Strut Drag
Brace Hole Repair).
(b). If no bushing is installed in drag
brace attach hole in strut, proceed as
follows:
1). Using 10X glass and bright light,
inspect strut around drag brace
attach holes (top and bottom
surfaces) for cracks. If any cracks
longer than 0.030 inch (0.762 mm)
in length are noted, strut must be
scrapped and serviceable strut
installed.
2). Check drag brace attach holes in
strut for elongation.
3). If any cracks, 0.030 inch (0.762
mm) in length or less, are noted or
hole is elongated, rework strut
(Ref. Landing Gear Strut Drag
Brace Hole Repair).
(8). Reinstall landing gear (Ref. Landing
Gear Installation).
(9). Inspect strut for cracks or dents.
1). Check bushing for looseness then

remove bushing.
(a). If strut is cracked, scrap strut and

replace with serviceable strut.
2). Using 10X glass and bright light,

inspect strut around drag brace
attach holes (top and bottom
surfaces) for cracks.
(b). If dents in strut exceed 0.060 inch

(1.524 mm) depth; or, if scratches and
repair area depth would exceed 0.010
inch (0.254 mm) when measured to
surrounding unrepaired surface strut
must be scrapped and serviceable
strut installed.
3). Check drag brace attach holes in

strut for elongation.
Page 602
Revision 26
32-10-00
MAINTENANCE MANUAL
CSP-HMI-2
DIM. A
(TOP HOLE)
DAMPER
( REF )
DIM. B
(BOTTOM HOLE)
SECT B-B
BOLT
B
WASHER
STRUT
DRAG
BRACE
WASHER
COTTER PIN
NUT
STRUT AND BRACE ATTACHMENT
88-779a
Figure 601. Landing Gear Strut Inspection
32-10-00
Page 603
Revision 26
CSP-HMI-2
MAINTENANCE MANUAL
(10). For aircraft 369D; 001 & subs, 369E;

0001 thru 0528, 369FF; 0001 thru 0114
and 500N; 001 thru 077: Remove plug
button from underside 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 and
serviceable strut installed.
4. Landing Gear Damper Inspection
(Ref. Table 601, Table 602 and Figure 401)

to remain on damper as a result of wiping
contact with piston seal. Newly-installed
dampers may also have slight oil seepage
from oil trapped in end cap threads during
damper assembly. Neither of these should
be considered damper leakage or cause for
damper replacement.
(1). Inspect for hydraulic oil leakage. If
leakage is visible, wipe oil from damper
after last flight of the day. Re-inspect
the following day for oil leakage. If
leakage persists, perform bench check
(Ref. COM).
(2). With helicopter on jacks, inspect
damper assemblies for evidence of
bearing looseness in upper and lower
caps, worn bearings (excessive radial
play), loose or cracked caps and oil
leakage. Any misalignment of torque
stripes on caps, piston and barrel
indicates loosening of caps. Replace
immediately and repair removed
damper.
(3). Inspect damper attaching hardware for
security.
NOTE: Dampers which have been modified

(winterized) for cold weather operation are
to be checked at not more than 30F above
the coldest temperature at which the heli
copter is operated.
(4). Inspect landing gear dampers for
condition by observing stance of
helicopter (normal stance is slightly
nose up). If stance indicates excessive
Page 604
Revision 26
32-10-00
nose up/nose down attitude, perform

damper extension check.
NOTE:
D The landing gear damper assemblies are
to be checked at a helicopter gross weight
of 1925 - 2075 pounds (874 - 942 kg) at a
longitudinal CG of approximately 103, ex
clusive of skid mounted flotation gear.
The empty weight of the 369D with full
fuel, but no passengers or cargo, is 1775 1925 pounds (806 - 874 kg). Therefore
achieve the test configuration by adding
75 pounds (34 kg) of ballast to both sides
of the cabin floor, just aft of the tail rotor
pedals, 150 pounds (68 kg) total. Place the
helicopter on a smooth concrete or equiva
lent surface (not asphalt).
D Dampers which have been modified (win
terized) for cold weather operation are to
be checked out no more than 30F (-1C)
above the coldest temperature at which
the helicopter is operated.
(a). Raise and lower tailboom above and
below the normal at-rest position
three times. On the last cycle, allow
the tailboom to slowly settle to the
at-rest position.
(b). Measure and record dimension from
upper end cap to upper end of barrel
on all four damper assemblies.
(c). Repeat steps (a). and (b). two more
times.
(d). Lower and raise tailboom below and
above the normal at-rest position
the tailboom to slowly rise to the
at-rest position.
(e). Measure and record dimension from
upper end cap to upper end of barrel
on all four damper assemblies.
(f). Repeat steps (d). and (e). two more
times.
(g). Determine average extension from all
six readings for each damper assem
bly. Remove and overhaul any
damper assembly not meeting
dimensions (Ref. Table 601).
MAINTENANCE MANUAL
NOTE: If two damper assemblies fail to meet

the minimum extension (Ref. Table 601), re
place the damper having the greater
amount of deflection with a known service
able damper and repeat steps (a). thru (g). If
the original damper again fails to meet
minimum extension requirements, replace
it with the known serviceable damper, rein
stall the first damper and repeat steps (a).
thru (g). This will determine whether one or
both dampers require overhaul. For owners
and operators having suitable equipment,
any damper not meeting minimum exten
sion requirements can be bench-checked by
applying a single load and measuring the
deflection when compressed. (Ref. Table 602
for load and compression requirements.)
Dampers meeting specifications in
Table 602 may be returned to service if oth
er defects are not noted.
CSP-HMI-2
(4). Inspect safety walk tape for condition

and security. Replace unserviceable
tape.
(5). Inspect fairing seal for condition.
(6). Install landing gear fairing assembly.
6. Landing Gear Fairing Inspection
(Ref. Figure 802)
(1). Inspect fairing support brackets for
security of attachment to strut, cracks
and deformation.
(2). Inspect fairing-to-skid seal for deterio
ration and bonding.
(3). Inspect fuselage rubbing plate for
security of bond and excessive wear.
(4). On forward fairings (aft fairings with
steps attached to struts), inspect fairing
step seal for deterioration and bonding.
5. Cabin Entry Step Inspection

(Ref. Figure 801)
(1). Remove landing gear fairing assembly.
Table 601. Minimum Damper Extension
(2). Inspect step-to-strut attachment for

loose attaching hardware by checking
for relative motion between mating
parts.
Standard Landing Gear Extended Landing Gear

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
(in/cm)
(in/cm)
Table 602. Landing Gear Damper Bench Test Requirements

Damper P/N (1)
369D26300
(2)
369D2630031
369D26301
369D2630131
(2)
Test Load
Compression Stroke
Pounds
(kg)
Inches
(mm/cm)
1200
(545)
0.80
(20.32 mm)
1320 100
(599 45)
0.80
(20.32 mm)
3780 400
(1716 182)
2.75
(6.99 cm)
1700
(772)
0.80
(20.32 mm)
1900 100
(863 45)
0.80
(20.32 mm)
3950 400
(1793 182)
2.75
(6.99 cm)
NOTES:
(1) Conduct all tests at 70 2 F except as noted.
(2) Coldsoak winterized dampers at 0 3 F for 24 hours minimum before testing.
32-10-00
Page 605
Revision 26
CSP-HMI-2
MAINTENANCE MANUAL
Page 606
Revision 44
32-10-00
MAINTENANCE MANUAL
CSP-HMI-2
LANDING GEAR SYSTEM

REPAIRS
1. Landing Gear System Repairs
(Ref. Figure 801) For more extensive repairs,
refer to CSP-SRM-6.
(1). Repair scratches and nicks by smooth
ing sharp edges.
(2). Repair elongated, enlarged or worn
holes in strut fittings, either inboard or
outboard.
(3). Repair bolt holes at large end of brace
that attaches to strut.
(4). Replace strut; if cracked, if dents in
strut exceed 0.060 inch (1.524 mm)
depth or if scratched and repaired area
depth would exceed 0.010 inch (0.254
mm) when measured to surrounding
unrepaired surface.
(5). Replace defective or badly damaged
fairing.
(6). Repair fairing fiberglass damage, such
as small tears or punctures that do not
impair the telescoping action of the
fairing.
(7). Replace cracked, dented or distorted
braces.
NOTE: Following applies to early configuration

landing gear skids. Installation differences
for current configuration landing gear skids
are noted in Figure 801.
(1). Remove abrasion strip. Drill out rivets
securing adapter sleeve and remove
residue from end of tube.
(2). Coat mating surface of replacement
sleeve with a thin coat of sealing
compound (CM425) and install in skid
tube with 9.06 inch (23.012 cm) over
hang (Ref. Figure 801).
(3). Drill holes for replacement rivets and
abrasion strip attachment bolt.
(4). Coat replacement rivets with primer
(CM318) and install while wet; Main
tain 9.06 inch (23.012 cm) overhang
during installation.
(5). Install replacement plug in sleeve 4
inches (10.16 cm) inside skid from aft
end). Secure in place with bead of
sealant.
(6). Install aft abrasion strip.
3. Abrasion Strip Replacement
(Ref. Figure 801)
(8). Repair or replace damaged skid tube.

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

abrasion strip(s) to skid.
(2). Remove screws securing abrasion strip
to skid extension sleeve. Completely
remove any residual zinc chromate
putty.
(3). Apply putty (CM209) to any bare metal.
(4). Coat new screws or bolts for replace
ment abrasion strip with primer
32-10-00
Page 801
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
(CM318) and install while primer is

still wet.
edges of abrasion strip next to skid tube

with an approximate 0.060 inch (1.524
mm) bead (fillet) of sealing compound
(CM425) to make watertight.
(5). After installation, seal all of parting
Table 801. Maximum Damage Limits Landing Gear Components

Component
Dents
in / mm
Nicks
in / mm
0.010 / 0.254, from aft side of
aft strut to 10 inches (25.4 cm)
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)
Scratches
in / mm
Cracks
in / mm
(Same as for No cracks

nicks) (1)
allowed
Holes
in / mm
0.250 / 6.350
(1) (3)
Skid tube (2)
0.200 / 5.08
(1)
Forward foot
0.060 / 1.524
0.060 / 1.524
Strut
0.060 / 1.524
(1)
Brace
0.050 / 1.270
0.010 / 0.254
0.005 / 0.127 No cracks No holes

allowed
allowed
Damper assembly
0.060 / 1.524
0.010 / 0.254

allowed
allowed
Fittings
0.010 / 0.254
0.010 / 0.254

allowed
allowed
Aft foot
0.060 / 1.524
0.060 / 1.524

allowed
allowed
Foot bearing
0.010 / 0.254
0.010 / 0.254
0.010 / 0.254 No cracks No Holes

allowed
allowed
Indexing plug
0.040 / 1.016
0.040 / 1.016

allowed
allowed
Skid extension
0.010 / 0.254
(4)
0.010 / 0.254 (4)

allowed
(4)
allowed

allowed
allowed
(1)
No cracks No holes
allowed
allowed
NOTES:
(1) For other repair data, refer to CSPSRM6.
(2) Repair of minor skid tube damage aft of rear strut and on forward (curved) section is not required, but
surface finish must be restored.
(3) Hole must be plugged with correct size blind rivet.
(4) No damage is allowed on skid extension where skid and sleeve are attached.
Page 802
Revision 19
32-10-00
MAINTENANCE MANUAL
CSP-HMI-2
CENTER BEAM
BONDING JUMPER
DAMPER
CLAMP
FAIRING BRACKET
(8 PLCS)
STRUT
NUT
BOLT
DAMPER
ABRASION STRIP
RIVET
(TYP)
BOLT
FOOT
GROUND HANDLING
FITTINGS
BRACE
CABIN ENTRY
STEP
STRUT
NONSKID TAPE
SPACER
ABRASION STRIP
SAFETY WALK
TAPE
BOLT
NUT
SKID TUBE
FOOT
BOLT AND WASHER
(4 PLCS) (NOTE 1)
BOLT
NUTPLATE
RIVNUT
SKID POSITION
LIGHT
ABRASION STRIP
WASHER
NUTPLATE
NUT
FOOT
RIVNUT
STEP
BOLT
FORWARD
ABRASION STRIP
RIVNUT
NUTPLATE
FITTING
FOOT
SCREW
RIVNUT
RIVET
(TYP)
LOCKWASHER
BRACKET
EARLY
CONFIGURATION
CURRENT
CONFIGURATION
NUTPLATE/RIVNUT ATTACHMENT
FOR ABRASION STRIP MOUNTING
RIVET
NUTPLATE
EXTENDED
LANDING GEAR
G32-1002-1A
Figure 801. Landing Gear Repairs (Sheet 1 of 2)
32-10-00
Page 803
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
RIVET
SPACER
FOOT
BOLT
WASHER
SPACER
SPACER
FOOT
SCREW
RIVET
EARLY
CONFIGURATION
CURRENT
CONFIGURATION
PIN RIVET
RIVETS (UPPER BRACKET)

HUCKBOLTS (LOWER BRACKET)
(NOTES 3 AND 6)
PACKING
(NOTES 5 AND 6)
FAIRING
BRACKET
SKID EXTENSION
SLEEVE
FOOT
BOLT
INDEXING
PLUG
SKID ADAPTER
SLEEVE
COLLAR
RIVET
PIN
DOUBLER
FORWARD FAIRING
ATTACHMENT
ABRASION
STRIP
SCREW
PLUG
BEARING
EARLY CONFIGURATION
SKID
COLLAR
FOOT
PLUG
NUT
WASHER
RIVET
SKID ADAPTER
SLEEVE
BEARING
PIN
SKID
EXTENSION
SLEEVE
SKID
SKID TUBE ADAPTER AND PIVOT COMPONENTS
NOTES:
SPACER 1. BOLT AND WASHER 4 PLACES. 8 PLACES ON
EARLY CONFIGURATION.
2. HUCKBOLT 4 PLACES. 8 PLACES ON EARLY
CONFIGURATION.
3. INSTALL NEW RIVETS WITH WET PRIMER
BOLT
(CM318).
4. 3/16 INCH (4.7625 MM) WELDING ROD OR
OTHER SUITABLE DEVICE (4 PLACES).
5. FORWARD FAIRING ONLY.
SCREW
6. HUCKBOLT HEAD COUNTERSUNK INSIDE
STRUT; NO PORTION OF HEAD TO PROTRUDE
INSIDE STRUT.
Figure 801. Landing Gear Repairs (Sheet 2 of 2)
Page 804
Revision 19
32-10-00
MAINTENANCE MANUAL
4. Ground Handling Fitting Replacement
(Ref. Figure 801)
Item
Nomenclature
CM209
CM318
CM425
Zinc chromate putty

Primer
Sealing compound
(1). Drill out rivets securing defective

fitting.
(2). Coat mating surfaces with zinc chro
mate putty (CM209) and install
replacement fitting in place.
CSP-HMI-2
fiberglass repair limits, the fillet and fairing

must be removed.
Item
CM418
Nomenclature
Cement, epoxy
(1). Replace an excessively damaged lower

fairing.
(2). Replace damaged fairing bracket or
lower guide. Remove rivets, locate new
part and install blind rivets. Use next
larger size rivets if mating holes in
strut are enlarged.
(3). Coat new rivets with primer (CM318)

and install while primer is wet.
(3). Replace damaged guide/pin assembly or

guide half if guide is cracked, pins are
bent or badly worn or teflon pad is loose
or badly worn.
(4). Seal edges with an approximate 0.060

(1.524 mm) inch bead of sealing
compound (CM425) for waterproofing.
(4). Replace springs that are badly worn or

rusty, or if free length is less than 8.72
inches.
5. Safety Walk Tape Replacement

(Ref. Figure 801)
Item
Nomenclature
CM220
CM724
Naphtha aliphatic
Tape, non-slip
(1). Carefully pull or scrape away damaged

tape.
(2). Remove all residual adhesive from skid
tube by wiping with a clean cloth
wetted by naphtha (CM220).
firmly into place. Expel air bubbles
while pressing down tape.
(5). Replace fillet if teflon strip is loose or

badly worn.
(6). Replace damaged strut bracket.
Remove rivets, locate new part and
install blind rivets. Use next larger size
rivets if mating holes in strut are
enlarged.
(7). Replace unserviceable rubber seals; use
cement (CM418).
7. Landing Gear Fairing Fillet Modification
The following is a procedure for modifying the
landing gear fairing fillet for easy removal and
better access to the landing gear struts.
(1). Remove fillet from upper part of fairing
assembly (Ref. Landing Gear Fairing
Removal).
6. Landing Gear Fairing Repair
(2). Enlarge existing holes in fairing fillets

and fillet guides to 0.220 - 0.230 inch
(5.588 - 5.842 mm).
(Ref. Figure 802) Repair fairings according to

SRM. If upper fairing is damaged beyond
(3). Install A1133-4-3 Nut-Clips on fillet

guides over enlarged holes.
32-10-00
Page 805
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
(4). Reinstall fillets using NAS603-6P

screws and AN960KD10L washers
through fillet into fairing guides.
(5). Secure trailing edge of fillet using
NAS603-6P screws, AN960KD10L
washers and MS21042-3 nuts (washer
under screw head and nut).
(6). Finish reinstalling fillet (Ref. Landing
Gear Fairing Installation).
8. Landing Gear Strut Drag Brace Hole
Repair
(Ref. Figure 601) The following procedure is for
repair of the bolt hole in the landing gear strut
where the drag brace attaches. This rework is
for either elongated or cracks in the bolt hole
area (Ref. Landing Gear Strut Inspection).
Item
CM318
Nomenclature
Primer
A. Landing Gear Strut with Bushing

Installed
(1). Ream out top hole (DIM. A) to
0.5608-0.5613 inch (12.244-14.257
mm) and ream out bottom hole (DIM.
B) to 0.5295-0.530 inch (13.449-13.462
mm).
(2). Perform fluorescent penetrant inspec
tion of reworked areas for cracks.
(a). If any cracks are noted, rework strut
per step (3).
(b). If no cracks are noted, install new
369H6023-1 bushing in hole with
wet primer (CM318).
0.5908-0.5913 inch (15.006-15.019
B) to 0.5595-0.560 inch (14.211-14.224
mm).
(a). If crack is found, strut must be
installed.
Page 806
Revision 26
32-10-00

wet primer.
B. Landing Gear Strut with No Bushing
Installed
0.5308-0.5313 inch (13.482-13.495
B) to 0.4995-0.50 inch (12.687-12.70
mm).
(a). If any cracks are noted, rework strut
per step (3).
wet primer (CM318).
0.5608-0.5613 inch (12.244-14.257
B) to 0.5295-0.530 inch (13.449-13.462
mm).
(a). If any cracks are noted, procede with
step (5).
(b). If no cracks are found around drag
brace attach hole in strut and hole is
not elongated, install new
wet primer (CM318).
0.5908-0.5913 inch (15.006-15.019
B) to 0.5595-0.560 inch (14.211-14.224
mm).
(7). If crack is found, strut must be
installed.
(8). If no cracks are noted, install new
369H6023-3 bushing in hole with wet
primer.
MAINTENANCE MANUAL
CSP-HMI-2
CHAFING PAD
TEFLON STRIP
FILLET
(NOTE 3)
RIVETS
RETAINING BLOCKS
AND CLAMP
NOTE 4
0.35 INCH (8.89 MM)
UPPER
FAIRING
TEFLON PAD
(INSIDE GUIDES)
0.80 INCH (20.32 MM)
0.35 INCH (8.89 MM)
LOWER FAIRING
FAIRING TO LOWER GUIDE

(NOTE 1)
UPPER FAIRING
(NOTE 3)
UPPER GUIDE
PIN ASSEMBLY,
INNER GUIDE HALF
AND SPRINGS
RIVET
(FWD FAIRING, 1 RIVET)
(AFT FAIRING, 2 RIVETS)
OUTER GUIDE HALF

UPPER AND LOWER FAIRING
INSTALLATION
1-7/16 INCH (3.65 CM)

DOUBLER (TYP)
RIVETS
(NOTE 2)
LOWER FAIRING
(NOTE 3)
LOWER GUIDE
(NOTE 1)
RIVETS (UPPER BRACKET)

HUCKBOLTS (LOWER BRACKET)
(NOTES 2 AND 8)
3/4 INCH (19.05 MM)

DOUBLER (TYP)
RIVET
(2 PLCS)
HOLE
AND SEAL
SCREW, WASHER
(4 PLACES)
(NOTES 6, 7)
FORWARD FAIRING
ATTACHMENT
FAIRING
BRACKET
SKID
1/2 X 3/4 INCH

DOUBLER
(TYP)
SKID CL
COVER (EXTENDED
LANDING GEAR ONLY)
NUTPLATE
(9 PLCS)
WASHER
(9 PLCS)
SCREW
(9 PLCS)
RIVET
(18 PLCS)
NOTES:
1. BONDED AREA; USE EPOXY ADHESIVE (CM411).
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
TO PROTRUDE INSIDE STRUT.
9. DIMENSIONS FOR BRACKET AND GUIDE LOCATIONS ON NEW STRUT
INSTALLATION.
G32-1003A
Figure 802. Landing Gear Fairing Repairs
32-10-00
Page 807
Revision 26
CSP-HMI-2
MAINTENANCE MANUAL
Page 808
Revision 44
32-10-00
MAINTENANCE MANUAL
CSP-HMI-2
EXTENDED LANDING GEAR

1. Extended Landing Gear Initial Installation
The following instructions are for both left and
right landing gear assemblies.
attaching hardware, or components
removed for access to work area.
foreign matter until installed.
(2). Ensure all cockpit electrical switches
are OFF.
NOTE: Ensure BATT-OFF-EXT switch is

OFF.
(3). Using jacking or hoisting methods,
raise helicopter clear of ground.
A. Standard Landing Gear Removal
Removal of complete landing gear is not
required.
(2). Remove hardware attaching aft damper
assemblies to fuselage fittings and
landing gear struts; remove aft damper
assemblies. Retain attaching hardware
for reuse.
(3). Remove screws attaching position light
assemblies to skid assembles. Retain
screws for reuse. Disconnect electrical
harness and remove position light
assemblies.
(4). Remove hardware that secures trailing
edge of forward and aft lower fairings.
Remove hardware attaching lower
fairings to strut assemblies. Carefully
spread trailing edge of lower fairings
and remove in forward direction.
for reuse. Remove skid assemblies with

foot assemblies attached.
B. Standard Landing Gear Disassembly
Complete disassembly of landing gear is not
required; however, certain items must be
removed.
(1). On current configuration standard
landing gear, disassemble as follows:
(a). Remove bolt, washer and nut attach
ing aft foot assembly and skid
extension to skid tubes.
(b). Remove bolts and washers attaching
forward foot assembly to skid tubes.
(2). On early configuration standard
landing gear, disassemble as follows:
(a). Remove screws and abrasion strip at
aft section of skid tubes.
(b). Remove bolts attaching skid exten
sion, indexing plug and aft foot
assembly to skid tube.
(c). Remove bolts and washers attaching
forward foot assembly to skid tube.
C. Extended Landing Gear Assembly
Extended landing gear is shipped with as
many parts assembled as practical; however,
certain items require assembly at installation.
Early configuration forward foot assembly and
skid tube have an eight-hole mounting
pattern; current configuration foot assembly
and skid tube have a four-bolt mounting
pattern.
Item
CM318
CM425
Nomenclature
Primer
Sealing compound
NOTE: If preload condition prevents removal of

skid assemblies, disconnect forward foot as
semblies from skid assemblies to eliminate
preload.
(5). Remove ABC bolts from forward and aft
strut assemblies. Retain ABC hardware
(1). If early foot assembly is used with

current skid tube:
(a). Drill out four rivets (48, Figure 902)
and remove two spacers (49) from
skid tube.
32-10-00
Page 901
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
G321009
Figure 901. Extended Landing Gear Assembly (Early Configuration)

Page 902
Revision 19
32-10-00
MAINTENANCE MANUAL
CSP-HMI-2

1. Bolt (MS2125004006)
2. Washer (MS20002C4)
3. Foot assy (369D2921131 LH FWD)
(369D2921132 RH FWD)
4. Screw (NAS14031)
5. Lockwasher (MS3533843)
6. Bracket (369H9211111)
7. Rivet (NAS1921M0403)
8. Nutplate (369H92507)
9. Rivet (CCR2645535)
10. Nutplate (NAS1068A3)
11. Foot (369D291133 LH FWD)
(369D291134 RH FWD)
12. Bolt (NAS1223C1)
13. Washer (HS306222)
14. Abrasion strip (369H6102)
15. Screw (NAS56HK36)
16. Bolt (NAS1223C8P)
17. Extension assy (369D26038)
18. Index plug (369D26037)
19. Foot assy (369D292111101 LH AFT)
(369D292111102 RH AFT)
20. Screw (NAS14031)
22. Bracket (369H9211111)
23. Rivet (ML5100M43)
24. Nutplate (369H92507)
25. Rivet (MS20605AD3C3)
27. Pin rivet (HL3375K8A6)
28. Packing (H53113E142)
29. Rivet (MS20426AD4)
30. Doubler (369D26031)

31. Bearing (369D260301 LH)
(369D260302 RH)
32. Foot (369D291133 LH AFT)
(369D291134 RH AFT)
33. Skid assy (369D292114)
34. Bolt (NAS1223C1)
35. Washer (HS306222)
38. Tape (369D2921143)
39. Tube assy (369D2921145)
40. Screw (NAS1190C3P3)
41. Rivet (NAS1921M0403)
42. Nutplate (369H92507)
43. Rivet (NAS1919M0403)
44. Fitting (369A61073)
45. Rivet (NAS1399D44)
46. Spacer (369A61007)
47. Spacer (369A61005)
48. Rivet (NAS1399C53)
52. Plug (369D26040)
53. Adapter sleeve (369D26032)
54. Tube (369D292115)
55. Nut (MS210455)
56. Washer (AN960KD513)
57. Bolt (NAS130536)
58. Step assy (369D292028)
59. Screw (10304288M)
32-10-00
Page 903
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
G321010
Figure 902. Extended Landing Gear Assembly (Current Configuration)

Page 904
Revision 19
32-10-00
MAINTENANCE MANUAL
CSP-HMI-2

1. Bolt (MS2125004006)
2. Washer (MS20002C4)
3. Foot assy. (369D292113103 LH FWD)
(369D292113104 RH FWD)
(369D292113101 LH FWD)
(369D292113102 RH FWD)
4. Screw (NAS14031)
5. Screw (NAS14035)
7. Bracket (369H9211111)
8. Rivet (NAS1921M0403)
9. Nutplate (369H92507)
10. Rivnut (NAS1329C3KB180)
11. Rivnut (CCR2645535)
13. Foot (369D2921135 LH FWD)
(369D2921136 RH FWD)
14. Bolt (NAS1223C1 (101 assy))
(NAS1223C5 (103 assy))
15. Washer (HS306222)
16. Bolt (NAS110444)
17. Spacer (369D26013)
18. Nut (NAS210424)
20. Extension assy (369D26045)
21. Foot assy (369D292111105 LH AFT)
(369D292111106 RH AFT)
(369D292111103 LH AFT)
(369D292111104 RH AFT)
25. Bracket (369H9211111)
26. Rivet (ML5100M43)
27. Nutplate (369H92507)
28. Rivnut (NAS1329C3KB180)
29. Rivet (MS20605AD3C3)
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
Nutplate (NAS1068A3)
Pin rivet (HL3375K8A6)
Pin rivet (HL3375K8A6)
Bearing (369D260101 LH)
(369D260102 RH)
Foot (369D2921135 LH AFT)
(369D2921136 RH AFT)
Skid assy (369D292114101/103)
Bolt (NAS1223C1 (101 assy))
(NAS1223C4 (103 assy))
Washer (HS306222)
Abrasion strip (369H92583)
Tape (369D2921143)
Tube assy (369D2921147/9)
Screw (NAS1190C3P3 (101 assy))
(NAS1130C3P8 (103 assy))
Rivet (NAS1921M0403)
Nutplate (369H92507)
Rivnut (C2R19471)
Rivnut (C2R19472)
Rivet (NAS1919M0403)
Fitting (369A61073)
Rivet (NAS1399D44)
Spacer (369D26014)
Spacer (369D26015)
Rivet (NAS1399C53)
Rivet (NAS1399C52)
Rivet (NAS1398C53)
Rivet (NAS1398C52)
Plug (369D26040)
Adapter sleeve (369D26012)
Tube (369D292115)
Nut (MS210455)
Washer (AN960KD516)
Bolt (NAS130536)
Step (369D292028)
Screw (10304288M)
32-10-00
Page 905
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
(b). Apply primer (CM318) to replace

ment spacers (47, Figure 901) and
install into skid tube with four
NAS1399D4-4 rivets.
(b). Coat screw (15) and bolts (16) with

primer and install.
(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

0.254 - 0.260 inch (6.452 - 6.604
mm) holes as required.
(b). Install abrasion strip using bolts (12)

and washers (13).
(c). Seal mating edge of abrasion strip
with 0.060 inch (1.524 mm) bead of
sealing compound (CM425).
(2). If current foot assembly is used with

early skid tube:
(a). Fill center four holes with sealing
compound (CM425).
(3). Attach extended wire harness to
position light and install light in
forward end of skid tube (Ref.
Figure 903) using screws retained from
standard landing gear.
D. Early Configuration Extended Landing
Gear Assembly Buildup
(Ref. Figure 901)
Item
Nomenclature
CM318
CM425
Primer
Sealing compound
(1). Coat mating surface of forward foot

assembly (3) and skid tube (54) with
primer (CM318).
(a). Position forward foot assembly on
skid tube.
(b). Apply primer to bolts (1) and washers
(2) and install; torque bolts to 80 100 inch-pounds (9.04 - 11.30
Nm).
(2). Coat mating surfaces of extension (17),
indexing plug (18) and aft foot assembly
(32) with primer.
(a). Position indexing plug, aft foot
assembly and extension on skid tube.
Page 906
Revision 19
32-10-00
E. Current Configuration Extended Landing

Gear Skid Tube Assembly Buildup
(Ref. Figure 903)
Item
Nomenclature
CM318
CM425
Primer
Sealing compound
(1). Coat mating surface of forward foot

assembly (3) and skid tube (57) with
primer (CM318).
(a). Position forward foot assembly on
skid tube.
(b). Apply primer to bolts (1) and washers
(2) and install; torque bolts to 80 100 inch-pounds (9.04 - 11.30
Nm).
(2). Coat mating surfaces of aft foot assem
bly (21) and extension (20) with primer.
Position extension and aft foot assem
bly on adapter sleeve (56).
(3). Coat mating surface of abrasion strip
(19) and hardware with primer and
position on extension (20).
(a). Install aft foot assembly (21), exten
sion (20) and abrasion strip (19)
using bolts (14 and 16), washers (15),
spacer (17) and nut (18).
(b). Seal mating edge of abrasion strip
with 0.060 inch (1.524 mm) bead of
MAINTENANCE MANUAL
F. Extended Landing Gear Installation
(Ref. Figure 901)
Item
CM318
CM420
CM612
CM613
CM703
CM812
N/A
Nomenclature
Primer
Sealant
Tube, silicone
Sleeve, vinyl
Tie strap
Splice, knife
Wire, AWG 20, 47108-B-20
(1). Align foot and skid assembly with strut

assembly.
(2). Slide foot assembly into strut assembly.
(3). Coat ABC bolts with primer (CM318).
(4). While primer is wet, install ABC bolts;
torque bolts to 40 - 60 inch-pounds
(4.52 - 6.78 Nm).
(5). Seal ABC bolts with sealant (CM420).
NOTE: Leave a minimum of one full service

loop in electrical harness to ensure that ten
sion is not applied to position lights, if
installed.
CSP-HMI-2
(6). Route extended wire harness from

position light through forward foot
assembly.
(a). Attach wire with splice (CM812);
cover splice with silicon tube
(CM612) and tie tube with strap
(CM703).
(b). Cover entire length of extended
electrical harness with vinyl sleeve
(CM613).
(7). Install extended landing gear aft
damper assemblies using serviceable
hardware removed from standard
landing gear (Ref. Landing Gear
Damper Replacement).
(8). Apply 0.060 inch (1.524 mm) bead of
sealant (CM420) to mating edge of foot
assemblies and strut assemblies.
(9). Install fairings (Ref. Landing Gear
Fairing Replacement).
G. Weight and Balance
Weight and balance changes that result from
installation of extended landing gear are listed
in Table 901. After installation of extended
landing gear, incorporate changes to helicopter
weight and balance record as instructed in
Section 08-10-00.

Weight
lbs (kg)
Arm
in. (cm)
Moment
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)
32-10-00
Page 907
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
AFT DAMPER
ASSEMBLY (BLACK)
STRUT
(TYPICAL)
LOWER FAIRING
ASSEMBLY
FOOT ASSEMBLY
(TYPICAL)
KNIFE SPLICE
LOWER FAIRING
ASSEMBLY
ABC BOLT
STEP
SEALING COMPOUND
ABC BOLT
SEALING COMPOUND
SKID ASSEMBLY
SERVICE LOOP
POSITION
LIGHT
ELECTRICAL HARNESS
Figure 903. Extended Landing Gear

Page 908
Revision 19
32-10-00
SEALING
COMPOUND
MAINTENANCE MANUAL
CSP-HMI-2
Section
321060
Landing Gear
System (600N)
MAINTENANCE MANUAL
CSP-HMI-2
LANDING GEAR SYSTEM

1. Landing Gear System
The landing gear consists of two strutmounted, shock-dampened skids aligned
longitudinally along the helicopter fuselage.
Both right and left skids pivot as the damper
assemblies extend and retract. Replaceable
abrasion strips are installed on each skid to
retard wear on hard surfaces.
A. Skid
Landing gear skids provide helicopter rest
mounts. Skid tubes are constructed from
seamless, extruded aluminum alloy tubing.
Abrasion strips attached to undersides of skid
tubes retard wear and damage. Ground
handling bolts, bolted through the skid tubes,
are the ground handling attach points. An
adapter sleeve at the aft end of skid tube
provides a nonrigid mount for the aft foot
bearing and skid extension.
B. Strut
The landing gear struts attach to the fuselage
center beam. Landing gear braces between the
landing gear strut and fuselage center beam
prevent shearing of the strut and keep the
strut in alignment with the landing gear. At
the lower ends of the struts, foot-shaped
components attach the landing gear skids to
the struts. Feet for the aft strut are bearingmounted to provide a nonrigid and pivotal
mount.
C. Damper
Landing gear assemblies are equipped with
front and rear damper assemblies. Dampers
absorb vertical shock to landing gear struts
during helicopter landings and help prevent
ground resonance. Front damper assemblies
are attached to oleo attachment fittings on the
outboard side of the pilot's compartment seat
structure. Aft damper assemblies are attached

to oleo support fittings in the engine compart
ment.
The damper assemblies are approximately
12.19 (31 cm) inches long when extended and
8.94 (22.7 cm) inches long when compressed.
The dampers are nozzle-type and consist of a
barrel, upper and lower mounting cap and a
piston.
Damper exterior surfaces are painted white for
the standard gear and black for the extended
gear as an aid to identification and for surface
protection.
A damper must be replaced if damaged, or if
loss of hydraulic oil occurs.
D. Entry Step
Entry steps mounted on the forward landing
gear struts allow for easy access into the cabin.
The landing gear step is covered with non-skid
tape and attached to the landing gear strut
with rivets.
E. Fairing
Aluminum fairings on each strut reduce
aerodynamic drag during flight. The fairings
extend from the fuselage to the skids to form
streamlined enclosures for the landing gear
struts. Each fairing assembly is constructed of
three main parts: a fillet, an mid and lower
fairing. The fillet is spring-loaded to remain in
firm contact with a plastic rubbing plate that
is bonded and riveted to the fuselage. The
fairing is secured to the landing gear and
telescopes up inside the fillet to allow move
ment of the strut as the landing gear dampers
compress or extend. A seal on the bottom edge
of the fairing forms a fillet between the fairing
and the skid tube. Forward fairings also have
openings for cabin entry steps.
32-10-60
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CSP-HMI-2
MAINTENANCE MANUAL
Page 2
Revision 44
32-10-60
MAINTENANCE MANUAL
CSP-HMI-2
LANDING GEAR SYSTEM

SERVICING
1. Landing Gear Damper Nitrogen Servicing
(Ref. Figure 301) Service landing gear damp
ers equipped with schrader valve according to
the following steps.
Do not recharge a damper if
there is evidence of fluid leak
age. Recharging of damper will cause fur
ther leakage of both gas and damper fluid,
posing a danger to the helicopter.
CAUTION
(1). Place helicopter on jacks or hoist and

elevate until dampers are fully ex
tended..
(2). For forward damper servicing, remove
foot support fairings located in passen
ger compartment. For aft damper
servicing, open engine access doors.
(3). Remove cap from schrader valve and
connect servicing hose, but do not
tighten.
(4). Ensure low side of nitrogen pressure
regulator is backed off to the unpres
surized position. Slowly open the high
pressure nitrogen bottle valve.
(5). Slowly turn regulator control until
nitrogen begins to flow at the loose
servicing hose-schrader valve connec

tion.
(6). While the nitrogen is still flowing,
tighten servicing hose. Allow nitrogen
pressure to build to the value according
to part and dash number of damper
(Ref. Table 401).
To prevent damage to damper or
loss of damper fluid do not open
schrader valve without pressurizing the
servicing line. If fluid loss occurs, damper
will require overhaul.
CAUTION
(7). Once pressure level is reached, open

schrader valve by turning outside nut
counter clockwise. Allow system and
damper pressure to equalize for a
minimum of 2 minutes. If slightly over
pressurized, bleed off excess very
slowly.
(8). Close schrader valve by turning the
outside nut clockwise. Torque nut to 50
- 60 inch pounds (5.65 - 6.78 Nm).
Remove servicing hose and install valve
cap finger-tight.
(9). Remove aircraft from jacks or hoist.
(10). Inspect damper for leakage approxi
mately two hours after servicing.
32-10-60
Page 301
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
CAP
DAMPER
OUTSIDE NUT
SERVICING HOSE
SCHRADER VALVE
HIGH PRESSURE VALVE
REGULATOR CONTROL
6G32-045
Figure 301. Landing Gear Damper Nitrogen Servicing On Helicopter
Page 302
Revision 19
32-10-60
MAINTENANCE MANUAL
CSP-HMI-2
Table 301. Nitrogen Recharge Pressure

Ambient Temperature
F ( C)
600N605033
Psig (kPa)
600N605031
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)
32-10-60
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Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
Page 304
Revision 44
32-10-60
MAINTENANCE MANUAL
CSP-HMI-2
LANDING GEAR SYSTEM

1. Landing Gear Strut Replacement
(Ref. Figure 401)
(10). Gently work strut around bearing in

fuselage support fitting and remove.
B. Landing Gear Strut Installation
Item
Nomenclature
(1). For access to forward brace, strut and

damper, open compartment access
doors.
CM318
CM729
Primer

A. Landing Gear Strut Removal
NOTE: For component disassembly, refer to

applicable section. For removal, two persons
are needed.
(1). Jack up or hoist helicopter until skid
assemblies clear surface by 10 - 20
inches (25 - 50 cm) (Ref. Sec.
07-00-00).
(2). Remove skid assemblies (Ref. Landing
Gear Skid Replacement).
(3). Pull strut fairing fillet downward
against spring tension and secure with
tape (CM729).
NOTE: Bushings must be removed from strut

to enable strut to clear bearing in fuselage
support fittings.
(4). For access to forward brace, strut and
damper, open compartment access
doors.
(6). Disconnect brace and damper from
strut.
NOTE: New bushings must be installed when

installing struts. Torquing of the bolt will
press bushing into place.
(3). Gently work struts around bearings in
fuselage support fittings.
(4). Install attaching hardware with new
bushing coated with wet primer
(CM318).
(5). Torque nut to 85 - 110 inch-pounds
(9.60 - 12.43 Nm) plus drag torque
(6). Check for minimum 0.010 inch (0.254
mm) gap between washer and airframe
clevis at slotted bushing.
NOTE: Install forward damper upper bolts

with bolt heads facing aft. Install all other
damper bolts with bolt head facing forward.
(7). Install damper (Ref. Landing Gear
Damper Replacement).
(8). Align inboard end of each brace with
mating bearing in fuselage supporting
fitting and install attaching hardware.
(7). Remove hardware from strut pivot

point.

(8). Use an ezy-out to pull both bushings

from strut clevis at pivot point.
(11). Secure electrical bonding jumpers to

airframe.
(9). Remove electrical bonding jumper

attaching aft strut to airframe.
(12). Align outboard end of each brace with

mating holes in strut.
32-10-60
Page 401
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
CAUTION
Do not over-tighten brace-tostrut hardware.
(13). Attach brace to strut with attaching

hardware.
(15). Reinstall skid assemblies (Ref. Landing
Gear Skid Replacement).
(16). Remove skid supports, lower helicopter,
and remove jacks.
(17). Close or replace all access doors.
2. Landing Gear Damper Replacement
(Ref. Figure 401)
A. Landing Gear Damper Removal
surface until landing gear skids just
clear resting surface.
(2). For forward damper removal, remove
footwell fairings located in passenger
compartment. For access for aft damper
removal, open engine access doors.
(3). Remove hardware (except bushings)
attaching damper assemblies to
fuselage attachment fittings and
landing gear struts.
(4). Remove damper from aircraft.
B. Landing Gear Damper Installation
surface until landing gear skids (Ref.
Sec. 7-00) just clear resting surface.
NOTE:
D Always be sure that replacement damper
is correct for the helicopter.
D Check for proper alignment of cap torque
stripes before installation.
D Install aft dampers with schrader valves
facing aft.
D Install fwd dampers with schrader valves
facing forward.
Page 402
Revision 26
32-10-60
(2). Install replacement damper in upper

and lower mounting position with
attaching hardware. Ensure bushings
are in place.
NOTE: Install forward damper upper bolts

with bolt heads facing aft. Install all other
damper bolts with bolt head facing forward.
(3). Align forward upper damper bearing
with airframe and install attaching
hardware.
(6). Align aft upper damper bearing with
airframe and install attaching hard
ware.
(9). Align lower bearing of damper (forward
and aft) with mating holes in strut and
install attaching hardware.
(12). Install footwell fairings and close
MAINTENANCE MANUAL
CSP-HMI-2
REF. AFT
FOOT ASSEMBLY
LANDING GEAR
SKID
ABRASION
STRIP
REF. FRONT
FOOT ASSEMBLY
ABRASION
STRIP
ABRASION
STRIP
ABRASION
STRIP
AFT BRACE
ASSEMBLY
AFT DAMPER
ASSEMBLY
FUSELAGE
FITTING
FRONT DAMPER
ASSEMBLY
FRONT BRACE
ASSEMBLY
BONDING
JUMPER
FRONT STRUT
ASSEMBLY
REF. AFT
DAMPER ASSEMBLY
REF. FRONT
DAMPER ASSEMBLY
REF. FRONT
STRUT
ASSEMBLY
AFT STRUT
ASSEMBLY
REF. AFT
BRACE ASSEMBLY
REF. AFT
STRUT
ASSEMBLY
MID FAIRING
MID FAIRING
BOLT
WASHER
NUT
STEP
ASSEMBLY
LOWER FAIRING
LOWER FAIRING
BOLT
WASHER
NUT
6G32-046B
Figure 401. Landing Gear and Damper Installation
32-10-60
Page 403
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
3. Landing Gear Skid Replacement

(Ref. Figure 401)
A. Landing Gear Skid Removal
(1). Jack up or hoist helicopter until skid
assemblies clear surface by 10 - 20
inches (Ref. Sec. 07-00).
(2). Remove mid and lower fairings.
(3). Remove bolts attaching forward and aft
feet to forward and aft struts.
(4). Simultaneously, slide front and rear
feet from struts.
B. Landing Gear Skid Installation
(b). Open underfloor compartment or

engine compartment doors for access
to strut cutout in fuselage skin. Have
an assistant push down on upper
guide with suitable tool (wood dowel
or equivalent), to relieve spring
tension.
(c). With spring tension off guide, remove
screws attaching fillet to upper guide.
Slowly relax dowel pressure on guide
until springs fully expand.
(d). Carefully spread fillet at trailing
edge and remove in forward direc
tion.
(3). Remove mid fairing as follows.
(a). Remove hardware that secure
trailing edge of mid fairing.
(1). Simultaneously, slide front and rear

feet onto struts.
(b). Remove hardware that secure fairing

to strut bracket.
(2). Install bolts attaching forward and aft

feet to forward and aft struts; torque
bolts to 95 - 110 inch-pounds (10.73 12.43 Nm) plus drag torque.
(c). Carefully spread trailing edge of

fairing and remove in forward
direction.
(3). Install mid and lower fairings.

4. Landing Gear Fairing Replacement
A. Landing Gear Fairing Removal
(Ref. Figure 402 and Figure 403) The following
instructions are typical for and apply to all
four fairing assemblies.
(1). Remove lower fairing from fairing
(a). Remove attaching hardware that
secures lower fairing to two strut
brackets, and that secures trailing
edge of lower fairing.
(b). Carefully spread trailing edge of
lower fairing and remove in forward
direction.
(2). Remove fillet from upper fairing
(a). Remove hardware that secure
trailing edge of fillet.
Page 404
Revision 20
32-10-60
B. Landing Gear Fairing Installation

(Ref. Figure 402 and Figure 403) Following
instructions apply to all four fairing assem
blies.
(1). Install mid fairing as follows.
(a). Assemble upper guide, pin assembly,
inner guide half, outer guide half,
springs and lower support on landing
gear strut (guide pins must be
installed through matching holes of
lower guide).
(b). Wedge temporary holding device
between upper guide and strut to
keep pins engaged.
NOTE: Use two small wood blocks or any simi

lar suitable means to keep springs com
pressed. Device used must be small enough
to be removed through strut cutout in skin
after fillet is assembled.
(c). Carefully spread trailing edge of
fairing and position fairing on strut
bracket(s) and lower guide.
(d). Install hardware in top hole of
trailing edge of mid fairing.
MAINTENANCE MANUAL
(2). Install fillet as follows.
(a). Carefully spread trailing edge of fillet
and position about upper guide.
CSP-HMI-2
(e). Check for smooth telescoping action

of fairing into fillet by manually
sliding fillet up and down several
times.
(f). Close access doors.
(b). Have an assistant remove temporary

holding device and push down on
upper guide with suitable tool (wood
dowel, etc).
(c). Install hardware securing fillet to
upper guide.
(d). Install hardware to secure fillet
trailing edge together.
(3). Install lower fairing as follows.

(a). Carefully spread trailing edge of
fairing and position under the mid
fairing and over the lower strut
bracket.
(b). Secure to upper and lower strut
brackets with hardware.
(c). Secure fairing trailing edge with
attaching hardware.
32-10-60
Page 405
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
AFT FILLET
ASSEMBLY
FORWARD
FILET ASSEMBLY
MID FAIRING
STRUT
AFT STRUT
MID FAIRING
SEAL
LOWER FAIRING
FLAP
LOWER FAIRING
SCREW
WASHER
NUT (5 PL)
A
A
SCREW
WASHER
(2 PL)
A
A
SCREW
WASHERS (2 EA)
NUT (5 PL)
SCREW
WASHERS (2 EA) (2 PL)
AFT LEFT SIDE SHOWN

AFT RIGHT SIDE IS OPPOSITE
FORWARD LEFT SIDE SHOWN

FORWARD RIGHT SIDE IS OPPOSITE
BRACKET
ASSEMBLY
SCREW
WASHER (2 PL)
FAIRING ASSEMBLY
RIVET
STRUT
SECTION A - A
FLAP
(AFT FAIRING ONLY)
6G32-047A
Figure 402. Fairing Installation

Page 406
Revision 19
32-10-60
MAINTENANCE MANUAL
CSP-HMI-2
NAS603-9P SCREW
AN970-3 WASHER
600N6081-1
WASHER (RUBBER)
NAS603-9P SCREW
AN970-3 WASHER
600N6081-1
WASHER (RUBBER)
600N6081-1
WASHER (RUBBER)
LOWER FORWARD FAIRING

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

NAS603-9P SCREW
AN970-3 WASHER
600N6081-1
WASHER (RUBBER)
600N6081-1
WASHER (RUBBER)
UPPER FORWARD FAIRING
ALL CONFIGURATIONS
AFT FAIRING
600N6081-1
WASHER (RUBBER)
88-757
Figure 403. Landing Gear Rubber Washer Locations
32-10-60
Page 407
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
Page 408
Revision 44
32-10-60
MAINTENANCE MANUAL
CSP-HMI-2
LANDING GEAR SYSTEM

INSPECTION/CHECK
1. Landing Gear Inspection
(Ref. Figure 401)
NOTE: If landing gear is installed, perform in

spection with helicopter skids clear of
ground.
(1). Inspect skids, skid abrasion strips,
struts, feet, braces and fairings for
dents, cracks, loose components or
rivets, loose nuts and for missing
hardware.
(2). Inspect skid-to-foot and foot-to-strut
attachments for loose bolts. Check aft
foot-to-bearing rivet installation for
security.
(3). Using 10X glass and bright light,
visually inspect area at, around and
between foot-to-strut attach bolts not
covered by sealant for cracks and
corrosion.
NOTE: If cracks or corrosion other than light

surface corrosion is found, replace affected
part.
(4). Inspect keel beam areas where the
strut assemblies attach for loose
bearings, condition of hardware and
strut adapters.
(5). Check condition of beaded seal around
edges of all rigid-mounted skid tube
components.
2. Landing Gear Skid Inspection
(Ref. Figure 401)
NOTE: If landing gear assembly has not been

removed from helicopter, perform following
steps (1). and (2). before proceeding with in
spection.

fairing assembly.
(3). Inspect skid for dents. If dents exceed a
depth of 0.20 inch (5.08 mm), they will
require repair.
(4). Inspect for punctures and cracks.
(5). Perform fluorescent-penetrant inspec
tion of all crack areas, and of those
areas adjacent to all punctures. These
areas will require repair.
(6). Inspect from aft end of tube to a point
10 inches (25.4 cm) forward of aft strut
for scratches and nicks.
(7). Inspect from forward end of tube to 10
inches (25.4 cm) forward of aft strut for
scratches and nicks. If scratches and
(8). Inspect abrasion strips for minimum
thickness of 0.040 inch (1 mm), damage
and for loose bolts and screws.
(9). Check skid extension rivet attachment
for security.
(10). Check condition of plug installed in
skid extension.
(11). Check aft foot bearing and extension for
wear, damage and corrosion.
3. Landing Gear Strut Inspection
(Ref. Table 801)
holes in strut, either inboard or out
board (Ref. SRM).
(2). Replace strut if cracked; if dents in
depth; or, if scratches and repair area
unrepaired surface.
32-10-60
Page 601
Revision 31
MAINTENANCE MANUAL
CSP-HMI-2
4. Landing Gear Damper Inspection

(Ref. Table 601 and Figure 401)

to remain on damper as a result of wiping
contact with piston seal. Newly-installed
dampers may also have slight oil seepage
from oil trapped in end cap threads during
damper assembly. Neither of these should
be considered damper leakage or cause for
damper replacement.
(1). Inspect for hydraulic oil leakage. If
leakage is visible, wipe oil from damper
after last flight of the day. Re-inspect
the following day for oil leakage. If
leakage persists, replace damper.
(2). With helicopter on jacks, inspect
damper assemblies for evidence of
bearing looseness in upper and lower
caps, worn bearings (excessive radial
play), loose or cracked caps and oil
leakage. Any misalignment of torque
stripes on caps, piston and barrel
indicates loosening of caps. Replace
immediately and repair removed
damper.
(3). Inspect damper attaching hardware for
security.
NOTE: The landing gear damper assemblies

are to be checked at a helicopter gross
weight of 2130 - 2230 pounds (967 - 1012
kg) at a longitudinal CG of 94 1, exclusive
of skid mounted flotation gear. Place the he
licopter on a smooth concrete or equivalent
surface (not asphalt).
(a). Raise and lower tailboom above and
below the normal at-rest position
the tailboom to slowly settle to the
at-rest position.
(b). Measure and record dimension from
bottom of upper end cap to top of
barrel on all four damper assemblies.
(c). Repeat steps (a). and (b). two more
times.
Page 602
Revision 19
32-10-60
(d). Lower and raise tailboom below and

above the normal at-rest position
the tailboom to slowly rise to the
at-rest position.
(e). Measure and record dimension from
bottom of upper end cap to top of
barrel on all four damper assemblies.
(f). Repeat steps (d). and (e). two more
times.
(g). Determine average extension from all
six readings for each damper assem
bly. Remove and overhaul any
damper assembly not meeting
dimensions (Ref. Table 601).
NOTE: If two damper assemblies fail to meet

the minimum extension (Ref. Table 601), re
place the damper having the greater
amount of deflection with a known service
able damper and repeat steps (a). thru (g). If
the original damper again fails to meet
minimum extension requirements, replace
it with the known serviceable damper, rein
stall the first damper and repeat steps (a).
thru (g). This will determine whether one or
both dampers require overhaul. For owners
and operators having suitable equipment,
any damper not meeting minimum exten
sion requirements can be bench-checked.
Dampers meeting specifications may be re
turned to service if other defects are not
noted.
5. Forward Cabin Entry Step Inspection
(1). Remove landing gear fairing assembly.
(2). Inspect step-to-strut attachment for
loose attaching hardware by checking
for relative motion between mating
parts.
(3). Inspect welded joint of step for cracks.
(4). Inspect safety walk tape for condition
and security. Replace unserviceable
tape.
(5). Install landing gear fairing assembly.
6. Landing Gear Fairing Inspection
(Ref. Figure 402)
(1). Inspect fairing support brackets for
security of attachment to strut, cracks
and deformation.
MAINTENANCE MANUAL
(2). Inspect fairing seals for deterioration
and bonding.
(3). Inspect fuselage rubbing plate for
security of bond and excessive wear.
(4). Inspect rubber washers for cracks or
deterioration.
CSP-HMI-2
Table 601. Minimum Damper Extension

inches (cm)
Fwd
1.60 (4.06)
Aft
1.71 (4.34)
32-10-60
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CSP-HMI-2
MAINTENANCE MANUAL
Page 604
Revision 44
32-10-60
MAINTENANCE MANUAL
CSP-HMI-2
LANDING GEAR SYSTEM

REPAIRS
1. Landing Gear System Repairs
(1). Repair scratches and nicks by smooth
ing sharp edges.
holes in strut, either inboard or out
board.
(3). Repair bolt holes at large end of brace
that attaches to strut.
(4). Replace strut; if cracked, if dents in
depth or if scratched and repaired area
unrepaired surface.
(5). Replace defective or badly damaged
fairing.
(6). Replace cracked, dented or distorted
braces.
(7). Repair or replace damaged skid tube.
(8). Replace center beam-to-landing gear
attachment bearings that exceed 0.040
inch (1.016 mm) axial play.
(9). Repair loose or defective pins and nuts
securing foot to bearing; replace
defective bearing.
(3). Install new abrasion strip. Torque bolts

to 12 - 15 inch-pounds (1.36 - 1.69
Nm) plus drag torque.
(4). After installation, seal around bolts and
all of parting edges of abrasion strip
next to skid tube with an approximate
0.060 inch (1.524 mm) bead (fillet) of
sealing compound (CM426) to make
watertight.
3. Ground Handling Bolt Replacement
(Ref. Figure 401)
(1). Remove nut, washers and spacer from
skid tube.
(2). Slide bolt with washers and spacer from
skid tube.
(3). Install, in order, bolt, washer, new
spacer and washer through skid tube
from outside-to-inside.
(4). Install, in order, washer, spacer, washer
and nut onto bolt. Torque nut to 10 - 20
inch-pounds (1.13 - 2.26 Nm) plus
drag torque.
4. Safety Walk Tape Replacement
(Ref. Figure 401)
Item
Nomenclature
CM220
CM724
Naphtha aliphatic
Tape, non-slip
2. Abrasion Strip Replacement

(Ref. Figure 401)
Item
Nomenclature
CM426
Sealing compound

tape.
(1). Remove bolts securing defective

abrasion strip(s) to skid.
(2). Remove all residual adhesive from step

by wiping with a clean cloth wetted by
naphtha (CM220).
(2). Remove bolts securing abrasion strip to

skid extension. Completely remove any
residual sealant.

firmly into place. Expel air bubbles
while pressing down tape.
32-10-60
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Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
5. Landing Gear Fairing Repair
(3). Replace damaged guide/pin assembly or

guide half if guide is cracked, pins are
bent or badly worn.
(Ref. Figure 402)
Item
Nomenclature
CM412
Adhesive, bonding, vulcanized
(4). Replace springs that are badly worn or

rusty, or if free length is less than 8.72
inches (22.149 cm).
(5). Replace fillet if teflon strip is loose or
badly worn.
(1). Replace an excessively damaged lower

fairing.
(6). Replace damaged strut bracket.

Remove rivets, locate new part and
install blind rivets. Use next larger size
rivets if mating holes in strut are
enlarged.
(2). Replace damaged fairing bracket or

lower guide. Remove rivets, locate new
part and install blind rivets. Use next
larger size rivets if mating holes in
strut are enlarged.
(7). Replace unserviceable rubber seals; use

adhesive (CM412).

Dents
in / mm
Nicks
in / mm
Skid tube (2)
0.200 / 5.08
(1)
0.010 / 0.254, from aft side of

aft strut to 10 inches (25.4 cm).
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
Strut
0.060 / 1.524
(1)
Brace
0.050 / 1.270
0.010 / 0.254

allowed
allowed
Damper assembly
0.060 / 1.524
(5)
0.010 / 0.254

allowed
allowed
Fittings
0.010 / 0.254
0.010 / 0.254

allowed
allowed
Aft foot
0.060 / 1.524
0.060 / 1.524

allowed
allowed
Foot bearing
0.010 / 0.254
0.010 / 0.254
0.010 / 0.254 No cracks No Holes

allowed
allowed
Component
Page 802
Revision 19
32-10-60
Scratches
in / mm
Cracks
in / mm
(Same as for No cracks

nicks) (1)
allowed
Holes
in / mm
0.250 / 6.350
(1) (3)

allowed
allowed
(1)
No cracks No holes
allowed
allowed
MAINTENANCE MANUAL
CSP-HMI-2

Component
Skid extension
Dents
in / mm
Nicks
in / mm
Scratches
in / mm
0.010 / 0.254
(4)
0.010 / 0.254 (4)
Cracks
in / mm
Holes
in / mm

(4)
allowed
allowed
NOTES:
(1) For other repair data, refer to CSPSRM6.
(2) Repair of minor skid tube damage on forward (curved) section is not required, but surface finish must be
restored.
(3) Hole must be plugged with correct size blind rivet.
(4) No damage is allowed on skid extension where skid and sleeve are attached.
(5) No dents allowed in damper barrel.
32-10-60
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CSP-HMI-2
MAINTENANCE MANUAL
Page 804
Revision 44
32-10-60
MAINTENANCE MANUAL
CSP-HMI-2
Section
324000
Ground Handling
Wheels
(369D/E/FF 500N)
MAINTENANCE MANUAL
CSP-HMI-2

1. Ground Handling Wheel Assembly
The standard ground handling wheel assem
blies provide a means of moving the helicopter
by hand or by towing.
The special ground handling wheel assemblies
for use with helicopters equipped with
emergency or utility floats provide a means of
moving the helicopter by hand only.
A. Ground Handling Wheel Description and
Operation
(1). Standard ground handling wheel
assembly consists of one detachable
jack handle and two two-wheeled
jacking assemblies that can be
straddle-mounted to the left and right
landing gear skids by use of existing
ground handling wheel fittings. The
wheels are manually lowered with a
detachable jack handle and are held in
the down position (helicopter raised on
wheels) by a mechanical lock. The
jacking assemblies are equipped with
two tow bar attach fittings for towing.
(2). Special ground handling wheels are
needed in place of standard ground
handling wheel assemblies for moving a
helicopter equipped with emergency or
utility floats. These wheel assemblies
are specially designed for use with
emergency floats and raise the landing
skids higher off the ground than
standard ground handling wheels. A
channel provides support for the
underside of the landing gear skid. A
rubber pad on the channel furnishes
sufficient skid retaining friction
without need for attachment of wheel
assembly to skid. Guards above the
wheel on each side of the channel
prevent wheel chafing of floats.
2. Standard Ground Handling Wheel
Installation and Use
(1). Position ground handling wheel
assembly over the skid tube at the
location of the skid fittings.
(2). With ground handling wheels in the

retracted position, align and engage the
skid fittings.
NOTE: Slide wheel assembly for and aft to en

sure locking mechanism is securely locked
into place.
(3). Install jack handle over the wheel
assembly socket, install lock pin and
rotate handle downward to lower the
wheels and raise the helicopter.
Hold downward pressure on
WARNING jack handle until the extend
lock snaps into locked position. If the

lock is not properly engaged and the
handle is released, the upward swing of
the handle could cause serious person
al injury.
(4). Check that the extend lock is engaged;
then release downward pressure and
remove jack handle.
(5). Install second ground handling wheel
assembly on the other skid in the same
manner.
3. Special Ground Handling Wheel
Installation and Use
(Ref. Figure 201)
Damage may result from push
ing up and/or pulling down on
the tail boom to facilitate installation of spe
cial ground handling wheels.
CAUTION
NOTE: When the helicopter is jacked from one

side only, a cushion saddle-type support
should be placed under the tail boom at the
jacking pad location for extra stability.
(1). Install and use special ground handling
wheel assemblies as follows.
(a). Jack up one side of the helicopter for
clearance to place ground handling
wheel assembly under the landing
gear skid.
32-40-00
Page 201
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
WHEEL ASSEMBLY
HANDLE
G32-4001
Figure 201. Ground Handling Wheel Assembly (Standard)

(b). Position ground handling wheel
assembly below the ground handling
fittings, which is the approximate
center of gravity (CG) point.
Disassembly (Early Configuration)
(1). Remove cotter pin and washer from
axle shaft and slide hub-and-wheel
assembly off axle.
(2). Remove three nuts securing wheel to
hub.
Severe personal injury or
WARNING damage to property can oc

cur if tire is not deflated before at
tempting to separate wheel halves.
(6). To remove axle shaft from housing,

remove roll pin and slide shaft from
housing.
Reassembly (Early Configuration)
(1). If previously removed, install axle shaft
into housing and secure with roll pin.
(2). Using suitable bearing press, install
bearings in hub.
(3). Install washer, hub assembly and
washer on axle. Shim hub assembly,
0.010 inch maximum, using AB2578-24
washers, as required, between bearing
and outer washer and install cotter pin.
(4). Using talcum powder, insert tube into
tire and install on wheel halves.
(3). Deflate tire and remove six nuts,

washers and screws securing wheel
halves.
(5). Secure wheel halves together using six

screws, washers and nuts.
(4). Remove tire and tube from wheel.
(6). Inflate tire in accordance with man

ufacturers specifications.
(5). Using suitable bearing press, remove

bearings from hub.
(7). Install wheel on hub assembly using

three nuts and washers.
Page 202
Revision 19
32-40-00
MAINTENANCE MANUAL
BUSHING
ROLL
PIN
LOCK
PIVOT PIN
SPRING
RETAINER
CSP-HMI-2
LOCK PIN
ROLL PIN
HANDLE
INNER
WHEEL
TIRE
BUSHING
TUBE
BASE
OUTER WHEEL
ROLL
PIN
HUB
RACE
BEARING
WASHER
NUT
DUST CAP
COTTER PIN
ROLL PIN
AXLE
SEAL
BEARING
RACE
G32-4003
Figure 202. Ground Handling Wheel Assembly/Disassembly
32-40-00
Page 203
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL

Disassembly (Current Configuration)
(7). Secure wheel halves together using six

(Ref. Figure 202)
(8). Inflate tire in accordance with man

ufacturers specifications.
(1). Remove three nuts and washers

securing wheel and tire assembly to
hub and axle assembly.
(2). Remove dust cap, cotter pin, nut and
washers from hub and axle assembly.
Severe personal injury or
WARNING damage to property can oc
cur if tire is not deflated before at
tempting to separate wheel halves.
(3). Deflate tire and remove six nuts,
washers and screws securing wheel
halves.
(4). Remove tire and tube from wheel.
Do not remove spacer from hub
body. Spacer is a close tolerance
press fit and should not be removed.
CAUTION
(5). Remove seal, bearings and races from

hub body.
(6). To remove axle shaft from housing,
remove roll pin and slide shaft from
housing.
(9). Install wheel on hub assembly using

three nuts and washers.
Servicing
At regular intervals, Ground Handling Wheel
Assemblies should be maintained to provide
safe use and longer life of components.
(1). Ensure tire pressure is within manufac
turer's specifications.
(2). Grease bearing using MIL-G-81322,
Mobil Grease 28 or alternate grease
MIL-G-25537, Aero Shell using
available grease zerk (primary method)
or hand pack (alternate method).
(3). Remove excess play of hub-to-axle by
inserting AB2578-24 washers, as
required, between bearing and outer
washer to maintain 0.010-inch axial
play.
Disassembly
(Ref. Figure 204)

Reassembly (Current Configuration)
(1). Remove cotter pin, nut and washer and

remove wheel assembly.
(Ref. Figure 202)
(2). To remove axle shaft, remove slotted

pin and slide shaft from housing.
(1). If previously removed, install axle into

housing and secure with roll pin.
(2). Install races, bearings and seal in hub.
(3). Install hub assembly on axle shaft and
secure with washer and nut.
(3). Using suitable bearing press, remove

bearings from hub.
Reassembly
(Ref. Figure 204)
(4). Tighten nut until there is a maximum

of 0.010 inch axial play. Remove excess
axial play by inserting AB2578-24
washers, as required, between bearing
and outer washer.
(1). Insert axle shaft into housing and

insert slotted pin.
(5). Install cotter pin and dust cap.
(3). Install wheel on axle using washer, nut

and cotter pin. Adjust axial play, 0.010
inch maximum, using AN960C1016
washers as required.
(6). Using talcum powder, insert tube into

tire and install on wheel halves.
Page 204
Revision 19
32-40-00
(2). Using suitable bearing press, install

bearings into hub.
MAINTENANCE MANUAL
11. Special Ground Handling Wheel Servicing
(Ref. Figure 204) The special ground handling
wheel assemblies have sealed bearings and
CSP-HMI-2
solid rubber tires and therefore require no

servicing.
SKID TUBE
RUBBER PAD
(NOTE 1)
SKID FITTING
(REF) (NOTE 2)
GUARD
FAIRING
WELD SUPPORT
STRUT
EMERGENCY FLOAT
CONTAINMENT COVER
SHAFT
CAUTION: BE SURE THAT FLOAT CONTAINMENT

COVER CLEARS AND IS NOT PINCHED BY
HANDLING WHEEL ASSEMBLY.
RUBBER TREAD WHEEL
NOTES:
1. LANDING GEAR SKID TUBE UNDERSIDE RESTS ON
RUBBER PAD AND IS SUPPORTED BY WELD SUPPORT
WITHOUT RESTAINING ATTACHMENT.
2. NOT USED WITH GROUND HANDLING WHEELS SHOWN.
3. MAXIMUM LOAD RATE 800 LBS. (363 KG) AT 8 RPM.
G32-4000A
Figure 203. Special Ground Handling Wheel Assembly (Float Type)
32-40-00
Page 205
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
PAD
WELD ASSEMBLY
WHEEL
WASHER
COTTER PIN
SLOTTED PIN
WHEEL
SHAFT
NUT
G324002
Figure 204. Special Ground Handling Wheel Assembly/Disassembly
Page 206
Revision 19
32-40-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
324060
Ground Handling
Wheels (600N)
MAINTENANCE MANUAL
CSP-HMI-2

The standard ground handling wheel assem
blies provide a means of moving the helicopter
by hand or by towing.
A. Ground Handling Wheel Assembly
Description and Operation
The ground handling wheel set consists of two
dual wheel assemblies, which are designed to
support a fully equipped helicopter. The wheel
assembly consists of two pneumatic tires, rims,
spindles, hydraulic jack and attach cradle.
(1). Tires:
The tires are 10 ply with a maximum
rating of 1120 lb at 65 psi (508 kg at
448 kPa).
(2). Rims:
The rim rotates on a spindle by means
of inner and outer tapered roller
bearings with an external grease fitting
on the hub for periodic servicing.
(3). Hydraulic Jacks:
A six ton jack is held in place on the
main frame by a support plate.
The jack retains a vertical position

during raising and lowering of the
wheels.
The ram of the jack is in constant
contact with the upper cross frame of
the main body, providing vertical
pumping leverage forcing the wheels
down.
(4). Attach Cradle and Main Frame Body:
The attach cradle is attached to the
main frame body by means of two pins
with cotter pins. The contoured cradle
is slotted to lock onto the skids.
Maintenance
(1). Ensure tire pressure is within manufac
turer's specifications.
(2). Inspect tires for wear and cuts, none
allowed.
(3). Inspect wheels for cracks and defects,
none allowed.
(4). At regular intervals, repack wheel
bearings and grease spindle assembly
guides.
(5). At regular intervals, inspect hydraulic
jacks for proper fluid levels.
32-40-60
Page 201
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
NOTE
FRAME ASSEMBLY
JACK
GUIDE
NUT
SPINDLE ASSEMBLY
SEAL
WHEEL BEARING
HANDLE ASSEMBLY
TIRE
GUIDE
WHEEL BEARING
CLEVIS
HUB CAP
COTTER PIN
CARRIER
NOTE:
PERIODICALLY GREASE SPINDLE-TO-GUIDE
INTERFACE FOR PROPER OPERATION.
SPINDLE
WASHER
Figure 201. Ground Handling Wheel Assembly
Page 202
Revision 19
32-40-60
6G32-042
MAINTENANCE MANUAL
CSP-HMI-2
Section
328100
Utility Float System
(369D/E)
MAINTENANCE MANUAL
CSP-HMI-2
UTILITY FLOAT SYSTEM

1. Utility Float Description and Operation
Utility floats consists of neoprene airtight
chambers separated by internal walls that
provide six individual watertight compart
ments. Skid attachment strips (girts), bonded
to underside of floats, are bolted to landing
gear skids and extensions. Floats are inflated
to a normal operating pressure of 2.0 psig (14
kPa). Relief valves release air pressure if
compartment pressure becomes excessive. A
stabilizer assembly is attached at the aft end
of the skid tube extension.
NOTE: If a helicopter with utility floats is tilted

back on the tail skid to install ground handl
ing wheels, approximately 1 pint (0.437 li
ter) of oil is trapped in the tail rotor trans
mission. This condition gives a false sight
plug oil level indication immediately after
return to a level attitude. After ground ru
nup, oil level indication is normal.
A. Utility Float Operational Check
With helicopter on the ground and utility
floats inflated to normal operating pressure,
perform the following operational checks:
(1). Check all float compartments for 2.0
psig (14 kPa).
NOTE: Changes in atmospheric pressure, and

temperature of float compartments affects
pressure gage readings. A temperature
change of 1 degree equals 0.032 psig (0.2206
kPa).
(2). Check for pressure drop with pressure
gage that indicates 0 - 15 psi (0 - 103
kPa), graduated in 0.5 psi (3.447 kPa)
increments. Maximum allowable
pressure drop in 24 hours is limited to
0.5 psig (3.447 kPa) for each compart

ment.
(3). Place BATTERY-OFF-EXT PWR
switch at BATTERY. Actuate POS LT
switch to the ON position. Observe that
left and right position lights illuminate.
Place all switches at OFF position.
2. Utility Float Inspection
(1). Inspect float chambers for correct air
pressure.
(2). Inspect float bags for abrasion and
chafing.
(3). Inspect pressure relief and fill valves
for condition and closure.
A. Skid Tube and Extension Assembly
Inspection
Inspection of skid tube and extension assembly
is identical to that described in Sec. 32-10-00.
B. Utility Float Repair
Repair materials and information are avail
able from the float manufacturer. Make
repairs to utility floats using materials
according to manufacturer's instructions.
3. Utility Float Troubleshooting
Refer to Table 201 for troubleshooting informa
tion. Troubles presented are listed in order of
possible occurrence during performance of
operational check. This information is pro
vided to aid in isolating faults found during
operational check or normal operation of the
system. The fault is then removed by repair or
replacement to return the system to troublefree operation. Troubleshooting and repair of
internal components of the float is beyond the
scope of this section.
32-81-00
Page 201
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Troubleshooting Utility Floats

Symptom
Low air pressure
Position lights do not

illuminate
Probable Trouble
Corrective Action
Damaged float
Repair float.
Defective fill valve
Replace fill valve.
Defective pressure relief valve
Replace pressure relief valve.
POS LT switch not at ON position
Actuate switch to ON position.
Position light lamp defective
Replace lamp.
Defective electrical wire splice
Repair electrical splice.
4. Utility Float Replacement
B. Utility Float Installation
(Ref. Figure 201)

A. Utility Float Removal
Prior to removal of utility floats, jack or hoist
helicopter until landing gear dampers are fully
extended and landing gear skid tubes are at
least six inches (15cm) from ground. Skid and
fairing assemblies must be removed to remove
float assemblies Ref. Sec. 32-10-00).
Maintain helicopter in level at
CAUTION titude during jacking or hoist
ing. Do not raise one side of helicopter at a
time.
(1). Remove position light cover screws,
then remove cover. Remove position
light mounting screws and position
light. Retain electrical wire for installa
tion.
(2). Remove bolts and washers attaching
stabilizer assembly to aft section of
floats.
(3). Open fill valve at each of six float
chambers. A suction device such as a
vacuum cleaner speeds air evacuation.
(4). Remove bolts, washers, gravel guards
and abrasion strip attaching float to
skid assembly and skid extension.
(5). Depress float around strut assemblies
and pull float free from skid tube
assembly and skid extension.
Page 202
Revision 19
32-81-00
Item
CM209
CM318
CM425
CM717
Nomenclature
Zinc chromate putty
Primer
Sealing compound
NOTE: Prior to assembly, apply primer

(CM318) to all mating surfaces.
(1). On early configuration extended
landing gear, coat abrasion strip with
zinc chromate putty (CM209) and
install using screws.
(2). Install bolt covers using existing screws
and wrap with two overlapping layers
of tape (CM717).
(3). Install tyrap bracket on forward struts.
(4). Align extension and bearing sleeve
holes; install rivets using wet primer
(CM318).
landing gear, install skid tube extension
as follows:
(a). Install indexing plug in float kit
extension tube.
(b). Align indexing plug tabs with slots in
foot bearing sleeve on helicopter;
install indexing plug and forward end
of extension tube over bearing sleeve.
Use care not to damage packing
MAINTENANCE MANUAL
(c). Align bolt holes in bearing sleeve,
indexing plug and extension tube;
install rivets with wet primer.
(d). Coat mating surfaces of abrasion
strip with zinc chromate putty.
(e). Install abrasion strip on extension
tube with rivets and wet primer.
(f). Seal all edges of abrasion strip with
approximately 0.060 (1.524 mm) bead
of sealing compound (CM425).
(6). Position floats on skid and extension
assembly. Align bolt holes in float girt
and skid assembly. Secure floats in
place using gravel guards, abrasion
strips, bolts and washers. Coat bolts
and washers with primer and torque to
25 - 35 inch-pounds (2.82 - 3.95
Nm).
(7). Position stabilizer cap on skid tube
extension. Coat mating surfaces with
sealing compound and secure with bolts
and washers.
(8). Position stabilizer assembly on aft
section of skid extension and secure in
place using bolts and washers. Torque
CSP-HMI-2

(9). Connect wiring to position light then
install position light with screws.
Install cover and secure with screws.
5. Skid Tube Extension Replacement
(Ref. Figure 901)
A. Skid Tube Extension Removal
(1). Remove bolts and washers; then
remove stabilizer support from aft end
of skid extension.
(2). Remove bolts and nuts attaching
extension to skid tube assembly.
(3). Separate skid extension from skid tube.
B. Skid Tube Extension Installation
(1). Insert skid extension into aft section of
skid tube.
(2). Align bolt holes and secure in place
using bolts and nuts as applicable.
(3). Position stabilizer support on aft end of
skid extension and secure in place
using bolts and washers.
32-81-00
Page 203
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
G328012
Figure 201. Utility Float Installation
Page 204
Revision 19
32-81-00
MAINTENANCE MANUAL
CSP-HMI-2
UTILITY FLOAT SYSTEM

1. Utility Float Initial Installation
The utility float kit may not be installed in
combination with the following:
Passenger steps
Hoist kit
Litter kit
Four-bladed tail rotor
Item
Nomenclature
CM425
Sealing compound
(6). Remove cargo compartment and aft

landing gear steps.
NOTE: Passenger steps, 369D26505 and

369D292028, may not be installed in combi
nation with utility floats. Upon removal of
369D292028 step assembly, install
PLT210-10-3 bolts (2 per assembly) coated
with sealing compound (CM425) into holes
where step attaching hardware was located.
(7). Remove hardware that secures trailing
edge of lower fairings to strut assem
blies. Carefully spread trailing edge of
lower fairings and remove fairings.
NOTE: If preload condition prevents removal of

applicable to both left and right landing gear
assemblies. Preparation for installation of
utility floats includes the following:
NOTE: Make sure that the BATT-OFF-EXT

switch is set to OFF.
(1). Check all cockpit electrical switches in
the OFF position.
attaching hardware, or components
removed for access to work areas.
foreign matter until installed.
(3). Using jacking or hoisting methods,
raise helicopter 6 inches (15 cm) clear of
ground.
(4). Remove landing gear (Ref. Sec.
32-10-00). Removal of landing gear is
identical to that described in Sec.
32-10-00, except that removal of
complete landing gear is not required.
Remove extended landing gear accord
ing to Sec. 32-10-00, except as follows:
(5). Remove screws attaching position light
assemblies to skid assemblies. Retain
screws for reuse. Disconnect electrical
harness and remove position light
assemblies.
skid assemblies, disconnect one brace as

sembly from skid assemblies to eliminate
preload (Ref. Sec. 32-10-00).
(8). Remove ABC bolts from forward and aft
strut assemblies (Ref. Sec. 32-10-00).
Retain ABC hardware for reuse.
Remove skid assemblies with foot
assemblies attached.
B. Disassembly of Extended Landing Gear
(Ref. Figure 901) Complete disassembly of
landing gear is not required; however, certain
items must be removed.
Item
Nomenclature
CM318
Primer
(1). Remove screws from float attach

fittings.
(2). Remove bolts and abrasion strip from
skid extension.
(3). Remove bolts attaching skid tube
extension.
(4). Remove skid tube extension.
32-81-00
Page 901
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
G328008
Figure 901. Extended Landing Gear Disassembly

Page 902
Revision 19
32-81-00
MAINTENANCE MANUAL
NOTE: When installing the 369D292808-17

and -18 extension tubes, it will be necessary
to remove and replace the 369D26012 or the
369D26012-5 sleeve adapter with a new -5
(undrilled at aft end) sleeve adapter (Ref.
Sec. 32-10-00).
(5). Remove bolts attaching abrasion strip
to skid tube. Do not remove abrasion
strips. Retain four bolts for reuse.
(6). Remove fairing attach brackets from
foot assemblies. Coat screws and
washers with primer (CM318) and
reinstall screws and washers.
C. Landing Gear Strut Modification
(Ref. Figure 902) For modification of landing
gear strut assemblies to accommodate installa
tion of utility floats and return to extended
landing gear configuration when utility floats
are removed, perform the following:
Item
Nomenclature
CM318
Primer
CM425
Sealing compound
(1). Using drill motor and number 15 drill

bit, drill two holes through lower
fairing attach brackets and aft wall of
landing gear strut assemblies (view A).
Enlarge holes to 0.250 inch (6.350 mm)
diameter using 1/4 inch (6.35 mm) drill
bit.
(2). Using number 30 drill bit, drill out
huckbolts attaching bracket to strut.
Remove bracket. Seal huckbolt attach
holes in strut with sealing compound
(CM425). Coat bare metal with primer
(CM318).
(3). Remove rivets attaching nutplates
(view B).
NOTE: When floats are removed from landing

gear assembly, modified foot assembly
brackets may be reinstalled by using screws
and washers.
CSP-HMI-2
D. Landing Gear Skid Extension Assembly

(Ref. Figure 903)
Item
CM209
CM318
CM425
Nomenclature
Zinc chromate putty
Primer
Sealing compound
(1). On all types of landing gear skid tube

extensions:
(a). Coat mating surfaces of the correct
plug with zinc chromate putty
(CM209); assemble plug to tube with
rivets coated with primer (CM318).
Seal edges with sealing compound
(CM425).
(b). Coat mating surface of support
assembly and tube with zinc chro
mate putty; install using bolts and
washers.
(2). Assembly of landing gear skid exten
sion (369D292808-17 and -18) on
current configuration landing gear:
NOTE: The 369D292808-17 and -18 skid tube

extension assemblies may only be installed
on extended skid gear having new (un
drilled) 369D26012-5 adapter, sleeve-skid
installed. For replacing the 369D26012 ba
sic sleeve with the -5 sleeve (Ref. Sec.
32-10-00).
(a). Insert skid tube extension on to -5
adapter sleeve. Align skid tube
rivnut centerline with extension tube
rivnut centerline. Secure both
assemblies with a suitable fixture.
(b). Mark and match drill eight 0.1945 0.1965 inch (4.9403 - 4.9911 mm)
diameter holes through tube and
sleeve (use locations and dimensions
as stated in Figure 903); separate
skid tube extension from adapter
sleeve.
(c). Countersink holes, 100 x 0.378 0.385 inch (100 x 9.6012 - 9.779
mm) diameter in skid tube extension,
deburr and apply primer to bare
metal surfaces.
32-81-00
Page 903
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
STRUT
CL
BRACKET C
L
SILASTIC
2 50
STRUT ASSEMBLY (TYPI
CAL)
REMOVE NUT PLATE
LOWER FAIRING AT
TACH BRACKET
0.59
KNIFE SPLICE
SEALANT
2.41
1.28
1.13
TYRAP BRACKET
0.250 DIAMETER 2
HOLES
BRACKET C
L
STRUT MODIFICATION
FORWARD FOOT MODIFICATION

G328009
Figure 902. Extended Landing Gear Modification

Page 904
Revision 19
32-81-00
MAINTENANCE MANUAL
5.98 INCH
(15.189 CM)
0.40 INCH
(10.16 MM)
3.92 INCH
(9.957 CM)
CSP-HMI-2
369D26012-5 SLEEVE
(REF)
NOTE 1
SUPPORT ASSEMBLY
(NOTES 3 & 4)
2.90 INCH
(7.37 CM)
BOLT
(NOTE 2)
RIVNUT
(NOTE 2)
COMPONENT OF 369D292808-17 AND -18
(FOR UTILITY FLOATS ONLY)
VISU-LOK
(8 PLS) (NOTE 2)
RIVET
(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 PLS) (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
32-81-00
Page 905
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
(d). Reinstall skid tube extensions on to

-5 adapter sleeve using a thin coat of
sealing compound on mating sur
faces. Seal with sealing compound.
Secure with eight visu-lok fasteners
coated with primer.
(e). Install abrasion strip to each exten
sion tube with bolts and washers.
Coat attaching hardware with
primer. Coat mating surfaces with
zinc chromate putty and seal mating
edges with approximately 0.060 inch
(1.524 mm) bead of sealing compound
to insure watertight fit.
sion - On current configuration ex
tended landing gear:
E. Utility Float to Landing Gear Assembly

(Ref. Figure 904) The Utility Float Kit is shipped
with as many parts assembled as practical;
however, certain items require assembly at
installation.
Item
CM209
CM318
CM425
CM717
Nomenclature
Zinc chromate putty
Primer
Sealing compound
NOTE: Prior to installation, apply primer

(CM318) to all attaching hardware.
(a). Insert float kit extension tube over

adapter sleeve.

landing gear, coat abrasion strip with
zinc chromate putty (CM209) and
install with screws (view D).
(b). Align extension tube and sleeve

holes, attach tube to skid with bolt
spacer and nut.
(2). Install bolt cover pads using existing

screws and wrap with two overlapping
layers of tape (CM717) (view B).

sion - On early configuration extended
landing gear:
(3). Coat mating surfaces of cap with

sealing compound (CM425) and install
using position light attaching screws.
(a). Seal all edges of skid plug with

sealing compound; install in tube by
using using rivets.
(b). Coat all surfaces of indexing plug and
sleeve with sealing compound.
(c). Insert sleeve adapter in tube and
install using rivets.
(d). Install packing and indexing plug in
tube; align holes in sleeve, plug
assembly and tube with skid assem
bly. Install rivets and bolts with
primer (4).
(e). Coat mating surfaces of abrasion
strip with zinc chromate putty (71).
Install abrasion strips with screws
and primer (4). Seal all edges with
approximately 0.06 in. bead of
sealant (3).
Page 906
Revision 19
32-81-00
(4). Temporarily install tyrap bracket with

screw (view E).
(5). Position utility floats over landing gear
skids.
(6). Align bolt holes in floats with bolt holes
in skid assembly. Position gravel
guards, coat bolts and washers with
primer (CM318); attach floats, gravel
guards and abrasion strip using bolts
(7). Position cap assembly (view C) on skid
tube extension. Coat mating surfaces
with sealing compound and secure with
bolts and washers.
(8). Assemble structure assembly and
support assembly (view C). Coat mating
surfaces with sealing compound and
secure with bolts, washers, nuts and
plate. Secure assembled stabilizer
assembly using bolts and washers.
MAINTENANCE MANUAL
F. Utility Floats/Landing Gear Installation
Item
Nomenclature
CM318
CM425
CM430
CM717
Primer
Sealing compound
CSP-HMI-2
If a preload condition prevents alignment,

disconnect one brace from strut assembly to
eliminate preload (Ref. Sec. 32-10-00).
(4). Secure new wire to forward foot using
tyrap bracket and screw (view E). Route
wire to position light location through
tunnel provided in float. Use tie strap
as required. Attach wire to position
light.
(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

3 feet (92 cm) of wire to position light
electrical harness using splice and
silicone tube. Apply sealant (CM430) to
ends of splice. Route wire through
nutplate hole in forward foot (Ref.
Figure 902, view A) and seal gaps and
holes with sealing compound (CM425).
(6). Install bolt cover pads using tape

(CM717) (view B).
(7). Locate strobe light (Ref. Figure 901
view A). Remove attaching hardware
and disconnect wire harness. Remove
strobe light and doubler. Retain
attaching hardware and strobe light.
(2). Connect wire harness to position light

using bracket, screw, washer and nut
(Ref. Figure 904, view A). Secure wire
harness to bracket with strap. Seal
connection with sealant (CM430).
(8). Position shield and strobe light (Ref.

Figure 904). Connect wire harness to
strobe light and install shield and
strobe light using hardware retained
from removal.
(3). Apply sealing compound (CM425) to

mating surfaces of foot and strut
assemblies. Insert forward and aft foot
assemblies into strut assemblies. Align
bolt holes, apply thin coat of primer
(CM318) to ABC bolts and install bolts
while primer is still wet. Torque bolts to
40 - 60 inch-pounds (4.52 - 6.78
Nm).
(9). Install landing gear fairings (Ref. Sec.

32-10-00).
Weight and balance changes that result from in
stallation of utility floats are listed in Table 901.
After installation of utility floats, incorporate
changes to helicopter weight and balance record
as instructed in Section 08-10-00.

Configuration
Weight
lbs (kg)
Arm
in. (cm)
Moment
in.lb/100 (kg mm/100)
369D290086Basic
Added
+131.8
(59.783)
122.2
(310.39)
+161.06
(1855.60)
Removed
9.5
(4.309)
103.9
(263.91)
9.87
(113.71)
Change
+122.3
(55.474)
123.6
(313.94)
+151.19
(1741.89)
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)
369D290086501
32-81-00
Page 907
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2

Configuration
lbs (kg)
in. (cm)
in.lb/100 (kg mm/100)
+135.0
(61.235)
127.0
(322.58)
+171.51
(1976.00)
143.1
(64.909)
125.5
(318.77)
179.59
(2069.09)
369D2920353
71.5
(32.432)
125.5
(318.77)
8.97
(103.35)
369D2920354
71.5
(32.432)
125.5
(318.77)
8.97
(103.35)
369D2920355
+25.7
(11.657)
162.0
(411.48)
+4.16
(47.93)
369D2920356
+25.7
(11.657)
162.0
(411.48)
+4.16
(47.93)
Change
+51.5
(23.360)
161.9
(411.23)
+8.33
(95.97)
Change
369D290086503
Same as 501 except delete:
and install:
Page 908
Revision 19
32-81-00
MAINTENANCE MANUAL
CSP-HMI-2
G3280111
Figure 904. Utility Float Buildup (Sheet 1 of 2)
32-81-00
Page 909
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
G3280112
Figure 905. Utility Float Buildup (Sheet 2 of 2)

Page 910
Revision 19
32-81-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
328200
Emergency Float
System
(369D/E/FF 500N)
MAINTENANCE MANUAL
CSP-HMI-2
EMERGENCY FLOAT SYSTEM

1. Emergency Float System Description and
Operation
A collapsed emergency float with an emergen
cy inflation system (stowed condition) is
attached to each landing gear skid. The floats
may be fully inflated during flight in approxi
mately five seconds. The electrically controlled
inflation system includes a self-test capability
to provide the pilot with a visual indication of
the electrical circuit reliability. Landing on
water or land is permitted when emergency
floats are inflated.
Emergency flotation equipment in the stowed
condition does not restrict normal land
operation of the helicopter. When inflated, the
floats will support the helicopter on water at
maximum gross weight. After emergency
inflation, the inflation system may be serviced
with fully charged dry air or nitrogen pressure
vessels, and the floats repackaged to a
streamlined stowed condition.
A. Emergency Float Description
(1). Electrical System The emergency float
electrical installation assumes prior
incorporation of the 369H90129-31,
369H90129-505 or 369H90129-511
pilot's cyclic stick grip kit. The emer
gency float electrical system includes a
circuit breaker, visual indicator switch
for testing circuit operation reliability,
and a relay. The pilot's cyclic stick grip
is equipped with an EMERG/FLOAT
push-button switch. When the pilot's
grip switch is actuated, the electrical
system energizes and provides electrical
power for simultaneous operation of the
left and right emergency float inflation
system. The float inflation system
consists of an electrically operated
solenoid valve, or squib valve, attached
to a compressed dry air or dry nitrogen
pressure vessel. When the solenoid is
energized or the squib is actuated, the
pressure vessel valve opens and
releases compressed dry air or dry
nitrogen into compartments of each
float.
(2). Flotation Equipment Emergency

flotation equipment consist of two
inflatable emergency floats, electroni
cally controlled inflation equipment,
four landing gear fairings and landing
gear skid tube extensions. Nutplates on
each skid tube and extension provide
for float attachment. A cabin entry step
may be used with the landing gear
without interference with the floats.
(3). Inflatable Emergency Floats Each of
the two inflatable neoprene emergency
floats consists of sealed airtight
chambers separated by internal walls
that provide five individual watertight
compartments. Skid attachment strips
(girts), bonded to the underside of the
floats, are bolted to the landing gear
skids. In addition, fore and aft web
support straps secure the floats to the
skids. The floats are inflated to a
nominal operating pressure of 4.0 psig
(28 kPa) by the emergency inflation
system upon pilot activation of the
inflation system electrical control
equipment. Relief valves provide for air
pressure release at a compartment
pressure of 4.5 psi (31 kPa) or above.
A snap-on containment cover with
lacing restrains the float in the stowed
configuration until the emergency
inflation system inflates the float. The
containment cover inboard side auto
matically unsnaps and is pushed
outboard as the float inflates. After
emergency float use, deflation, pressure
vessel recharging and folding, the cover
is again snapped in place over the float
and replaced for subsequent reuse.
A mooring ring atop each end of the
float is furnished for towing and
mooring. An extended landing gear skid
tube extension supports the float aft
section on the landing gear. Forward
and aft restraining straps are provided
at landing gear strut and fairing
locations. Gap covers close off the
inboard cutouts for the strut fairings.
32-82-00
Page 201
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
(4). Emergency Inflation System The

emergency inflation system consists of
a charged compressed pressure vessel,
air hoses, valves and associated
components for inflation of the emer
gence floats. A complete emergency
inflation system is installed on and is
part of each float.
When actuated by inflation system
electrical control equipment, a solenoid
valve or squib valve attached to the
pressure vessel releases compressed dry
air or dry nitrogen for distribution
through the air hoses and inlet check
valves for the five float compartments.
A relief valve on each float compart
ment opens if compartment pressure
exceeds 5 0.5 psi (34.5 3.5 kPa).
The pressure vessel operating pressure
is 3000 - 3575 psig (20684 - 24649 kPa)
at 65 - 85F (18 - 30C); 3500 75 psig
(24132 517 kPa) at 65 - 85F (18 30C) is preferred. The manifold is
attached to the pressure vessel along
with an indicating pressure gage, filler
valve and a pressure relief valve. The
pressure vessel relief valve operates at
and above 4250 250 psig (29303 1724
kPa). Detachable rubber boots cover the
filler and pressure relief valves for
protection against chafing. The pres
sure vessel may be detached from the
float for servicing.
2. Certification and Shelf/Service Life
The Federal Aviation Administration (FAA)
has granted Squib PN 5003527-1 of the
squib-actuated emergency float valve a
provisional five-year life limit. This life limit
is established by date of manufacture, which is
ink-stamped on the body of the squib (Ref.
Sec. 04-00-00).
3. Emergency Float Inspection (Stowed
Configuration)
NOTE: The following inspections must be per

formed daily and before each flight.
(1). Observe vessel pressure through
inspection window.
Page 202
Revision 19
32-82-00
(2). Check girt to skid attaching hardware

for condition and corrosion.
(3). Check float cover fasteners and lacing
for security.
(4). Examine float stowage cover for
abrasive damage that may have
disturbed package float.
(5). Perform an operational check of float
inflation system electrical control
equipment.
4. Emergency Float Inspection
NOTE: To be performed every six months or as

necessary.
(1). Check for proper air pressure indication
on pressure gage.
(2). If float is stowed, unsnap containment
cover and loosen restraining lacing for
access to emergency inflation system
components.
(3). Remove pressure vessel, inspect for
damage and scratched, nicked or
otherwise damaged paint coating.
NOTE: Superficial paint coating damage

should be repaired by paint touchup.
(4). Inspect valves, air hoses and other air
distribution components for damage,
deformity, strain, chafing or corrosion.
NOTE: Corrosion of the electrically operated

solenoid/squib valve may occur as a result of
improper charging of the pressure vessel.
Ensure that only dry air or dry nitrogen is
used to charge the pressure vessel.
(5). Perform an inflation system electrical
control equipment operational check to
ensure electrical continuity and
connection of solenoid/squib valve.
Ensure that pressure vessel
gage is visible through inspec
tion window.
CAUTION
(6). Tighten and re-tie the lacing and snap

the containment cover in place if not
continuing to Float Compartment
Pressure Test.
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Troubleshooting Emergency Flotation Equipment

Symptom
CAUTION
Probable Trouble
Corrective Action
A charged float pressure vessel must be discharged before the associated float valve is removed
from the pressure vessel. Use care to prevent accidental float inflation.
No reliability light indication,

either left or right.
Burnedout lamp.
Replace lamp.
Defective connection or wiring.
Repair connection or wiring.
Open circuit to solenoid float valve.
Replace float valve.
No reliability light indication,

both left and right.
Defective connection or wiring.
Repair connection or wiring.
Reliability light indication for

both floats; neither float
inflates.
Defective actuating switch.
Replace actuating switch.
Defective actuating switch wiring.
Repair wiring.
Float leaks air.
Damaged float.
Repair float.
5. Emergency Float Compartment Pressure

Test
6. Emergency Float Inspection (After

Inflation)
To be performed every 6 months or after 5

inflations (Ref. Sec. 04-00-00).
(1). Inflate all float compartments at the fill
valves to 4.5 psi (31 kPa) for one hour.
Check for leaks and condition.
(2). Continue inflation to 5.5 psi (38 kPa)
and check that chamber pressure relief
valves operate.
Item
CM220
Nomenclature
Naphtha aliphatic
(1). Clean float as follows:

(a). Clean away any oil or grease with
naptha (CM220).
(3). Lower pressure in all five float com

partments to 2.0 psi (14 kPa) and let
stand for 24 hours.
(b). Wash down with soapy water; flush

with clear fresh water and allow to
air dry.
NOTE: Changes in atmospheric pressure and
(c). Clean air pressure gage inspection

window with a clean cloth and fresh
water.
temperature during pressure test of float

compartments will affect pressure gage
readings. A temperature change of 1 degree
equals 0.032 psig (0.2206 kPa).
(4). Check the pressure drop with a pres
sure gage that indicates 0 - 15 psi (0 103 kPa), graduated in 0.5 psi (5 kPa)
increments. The maximum allowable
0.5 psi (5 kPa) per compartment.
(5). If a pressure drop occurs, check floats
for soundness.
(6). Tighten and re-tie the lacing and snap
the containment cover in place.
(d). After inspection is complete, dust

with talc.
(2). Recharge pressure vessel to 3500 psig
(24132 kPa) at 75F (24C).
(3). Inspect float bags for abrasion and
chafing.
(4). Inspect pressure relief valves for
condition and closure.
(5). Inspect check valves for condition.
(6). Inspect all hoses and connectors for
32-82-00
Page 203
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
(7). Check float girts, web support and

restraining straps for condition and
secure attachment to skid tube.
(8). Check all release snaps and fasteners
for condition and serviceability.
(9). Check that pressure vessel relief valve
and filler valve boots are installed.
(10). Repack floats.
7. Emergency Float Test
The squib is an electrically
WARNING fired explosive device. Keep
squibs away from all sources of heat,
open flame, sparks and electrical con
tacts. Squib plugs are to be in place un
til squibs are installed in aircraft.
(1). Perform inflation operational reliability
test of float inflation electrical system
as follows:
(a). Press LH/FLT and RH/FLT combi
nation press-to-test switch located
below the lower switch and circuit
breaker panel on the sllmline instru
ment panel and at the top-center of
the T panel, to test float inflation
electrical circuit reliability.
NOTE: Pressing the press-to-test switch ap

plies low voltage (insufficient to energize/
actuate the pressure vessel valve solenoid/
squib) to the emergency float circuit.
Internal light bulbs in the switch will illu
minate if the circuit is operational.
(b). Observe that each switch faceplate is
illuminated when pressed and goes
out when switch is released.
NOTE: Failure to illuminate indicates a bur

ned-out light bulb in the switch or a defec
tive circuit. Extreme brightness indicates a
defective circuit.
(2). Check each pressure vessel for proper
(normal) air pressure, 3500 psig (24132
kPa) at 70F (24C).
8. Float Compartments Pressure Test
(1). Inflate all five float compartments to
2.0 psi (14 kPa) and let stand for 24
hours.
Page 204
Revision 19
32-82-00
NOTE: Changes in atmospheric pressure and

temperature during pressure test of float
compartments will affect pressure gage
readings. A temperature change of 1 degree
equals 0.032 psig (0.2206 kPa).
(2). Check the pressure drop with a pres
sure gage that indicates 0 - 15 psi (0 103 kPa), graduated in 0.5 psi (5 kPa)
increments. The maximum allowable
0.5 psi (5 kPa) per compartment.
(3). If a pressure drop occurs, check floats
for soundness.
9. Emergency Float Repair
Contact MDHS Field Service Department for
repair information.
10. SolenoidtoSquib Rework Procedure
The following is a procedure to replace the
solenoid, which is no longer manufactured, to
the squib valve.
(1). Turn off electrical power.
(2). Unpack emergency floats.
(3). Remove valve protector and unlace
cylinder sling lacing cords (Ref.
Figure 402).
(4). Disconnect solenoid valve electrical
wiring knife splice at (SP4, SP5, SP9
and SP10) solenoid.
(5). Loosen nut at outlet port of solenoid
valve. Disconnect valve assembly from
union by unscrewing cylinder and valve
assembly in counterclockwise direction.
Remove cylinder and valve assembly.
(6). If cylinder is not empty, discharge as
follows:
Exercise care when dis
WARNING charging cylinder. Person

nel can be injured by high pressure air
or flying debris.
(a). Secure cylinder in chain vise or
equivalent. Point filler valve outlet in
safe direction.
(b). Use two open end wrenches, one on
filler valve body and one on nut. Turn
nut slowly counterclockwise 2-1/4
turns and allow all pressure to
escape. Check gage to verify that no
pressure remains in cylinder.
MAINTENANCE MANUAL
(7). Remove solenoid valve from cylinder.
Discard solenoid valve and packing.
(8). Install new squib valve (PN 23111380-3
LH float, PN 23111380-4 RH float) with
PN MS28778-12 packing on cylinder.
Torque to 360 - 504 inch pounds
(40.67 - 56.95 Nm) (Ref. Figure 403).
(9). Install fitting with PN MS28778-6
packing on existing union.
CSP-HMI-2
3). Install one lead of 0.5 ohm 5%,

10W resistor in pin A of lefthand
connector (P101). Connect one test
lead of ammeter (VOM) to other
lead of resistor. Connect other test
lead of ammeter (VOM) to pin D of
connector (P101).
4). Close emergency float circuit
breaker (CB121).
(11). Install charge cylinder and squib valve

assembly with PN MS28778-6 packing
on fitting.
5). Press PRESS-TO-TEST switch

and observe current reading on
ammeter and brilliance of lamps.
Current should be 75 MA mini
mum and brilliancy of lamps
should be fairly bright.
(12). Revise emergency float electrical

system as follows:
6). Open emergency float circuit

breaker (CB121).
(10). Recharge cylinder and test for air leaks.
(a). Remove access panels and/or covers

as necessary to expose emergency
float wiring.
(b). Remove all emergency float wiring
except as noted in Figure 903.
(c). Remove and discard relay installa
tion, doubler and attaching hardware
located on pilot's floor support, left
bulkhead.
(d). Remove emergency float switch light
assembly and install new switch light
assembly.
(e). Install wiring as shown in
Figure 902. Do not plug in electrical
connectors (P101 and P102) until
after electrical system check.
(f). Reinstall access panels and/or covers.
(13). Turn on electrical power.
(14). Perform inflation system electrical
control equipment operational check as
follows:
(a). Test light check;
1). Check ship voltage with VOM.
Voltage should be 27.5 Vdc.
2). Open emergency float circuit
breaker (CB121).
7). Remove meter and resistor from

connector (P101).
8). Repeat steps 3). through 7). for
righthand connector (P102).
(b). System check;
1). Ensure that circuit breaker
(CB121) is open and connectors
(P101 and P102) are disconnected.
2). Install one lead of 40 ohm 1%,
20W resistor in pin A of lefthand
connector (P101) and install other
lead of resistor in pin D of connec
tor (P101).
3). Connect test leads of voltmeter
(VOM) across resistor.
4). Close emergency float circuit
breaker (CB121).
5). Press firing switch on pilot's grip
and observe voltage on meter.
Voltage should be 25.5 Vdc mini
mum.
6). Open circuit breaker (CB121).
7). Remove meter and resistor from
connector (P101).
8). Repeat steps 2). through 7). for
righthand connector (P102).
(c). Connect connectors (P101 and P102)
to squib valves.
32-82-00
Page 205
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
(d). Close emergency float circuit breaker

(CB121).
(e). Press PRESS-TO-TEST switch and
observe that lamps light.
(16). Repack emergency floats (Ref.

Figure 404).
(f). Open circuit breaker (CB121).
(17). Remove existing VNE cards (solenoid

valve, floats stowed (3) and solenoid
valve, floats inflated (1)).
(15). Ensure that cylinder is positioned so

that pressure gage is visible through
inspection window when floats are
stowed, pressure gage axis inclined
outboard approximately 40.
(18). Install PN 369D292574-49, -51 and

-53 VNE cards (squib valve, floats
stowed) and PN 369D292573-19 VNE
card (squib valve, floats inflated).
Page 206
Revision 19
32-82-00
MAINTENANCE MANUAL
CSP-HMI-2

1. Emergency Float Replacement
A. Emergency Float Removal
(Ref. Figure 401)
(1). If float is in stowed configuration,
release fasteners to gain access to float
package.
(2). Detach lower restraining strap and gap
cover at forward and aft struts.
wiring at knife splice at solenoid valve
or disconnect squib valve electrical
connector at squib and install shunt.
(4). Remove strut fairing, insulate strut
wire end knife splices, attach wiring to
strut in a stowed position and reinstall
fairing.
(5). Remove bolts and washers attaching for
and aft web support strap fittings to
skid tube.
float girts to skid tube extension;
remove float assembly.
B. Emergency Float Installation
(Ref. Figure 401)
Item
Nomenclature
CM209
Zinc chromate putty
NOTE: The float assembly must be removed

from the stowage envelope for installation.
(1). Open float package and release re
straining straps.
NOTE: If extension tubes are not installed on

helicopter, refer to Skid Tube Extension Re
placement.
(2). Position float girts over skid tube
attach points.
(3). Temporarily attach float web support
strap fittings at forward location;
Secure strap fitting at aft attach
location with bolts and washers.
(4). Place gravel guards over float girts and
secure with bolts and washers. Torque
all bolts securing float girts to skid
tubes to 25 - 35 inch-pounds (2.82 3.95 Nm).
(5). Apply zinc chromate putty (CM209) to
contact surfaces of previously removed
abrasion strips, and skid extension
abrasion strips to ensure watertight fit
on landing gear skids.
(6). Loosen float forward web strap fitting
and position abrasion strip on skid
below strut; position web strap fitting
over forward attach hole on abrasion
strip and secure strip to skid with bolts
and washers. Install remaining abra
sion strips; remove excess zinc chro
mate putty.
(7). Install remainder of bolts and washers
securing float girts to skid tube exten
sion.
(8). Adjust and secure float landing gear
strut cutout restraining straps.
(9). Unsnap float containment cover and
loosen restraining lacing to gain access
to emergency inflation system compo
nents.
(10). Connect squib valve electrical connector
at squib.
32-82-00
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Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
FLOAT GIRTS
FLOAT ATTACHMENT
CONTROL
SWITCHES
STOWED FLOAT
GRAVEL GUARDS
CIRCUIT
BREAKERS
WEB
ATTACHMENT
AFT LANDING GEAR STRUT

NARROW FAIRING
SKID TUBE
EXTENSION
WEB SUPPORT
STRAP
PRESSURE GAGE
COVER
INSPECTION WINDOW
GIRT
ABRASION STRIP
SKID
COVER
ABRASION STRIP
FITTING
(NOTE)
INFLATED FLOAT
GRAVEL GUARD
FORWARD LANDING GEAR
STRUT NARROW FAIRING
CONTAINMENT
COVER
ABRASION STRIP
SUPPORT TUBE
AIR HOSE (TYP)
GRAVEL GUARD
RETAINING STRAP
(TYP)
STRUT-TO-SKID
COVER
ABRASION STRIP
SOLENOID
PRESSURE RELIEF VALVE
AND FILLER VALVE
PRESSURE VESSEL
FOOT
FILL VALVE
GAP COVER
(TYP)
MOORING
RING
MANIFOLD
PRESSURE
GAGE
SKID TUBE
ABRASION
STRIP
FORWARD FOOT - OUTBOARD SIDE

INLET CHECK VALVE
(TYP)
PRESSURE RELIEF
VALVE (TYP)
NOTE:
FORWARD FITTINGS ATTACHED AT FIRST NUTPLATE
FORWARD OF STRUT FOOT. REAR FITTINGS ATTACHED
AT FIRST NUTPLATE AFT OF STRUT FOOT.
Figure 401. Emergency Float Installation

Page 402
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32-82-00
G32-8002
MAINTENANCE MANUAL
2. Emergency Float Pressure Vessel
Servicing and Replacement
(Ref. Figure 401) Maximum allowable temper
ature during charging is 165F (75C).
Detaching the pressure vessel from the float
during charging is the preferred procedure.
Maximum pressure vessel pressure is 3500
psig (24132 kPa) at room temperature, 70F
(21C). As outside air temperature will affect
the day-to-day gage reading, temperature
versus pressure readings are important during
servicing or inspection of the pressure vessel
air pressure. The indicated pressure on the
gage will increase or decrease 6.6 psig (45.5
kPa) per 1F (0.4C) increase or decrease,
respectively, in vessel air temperature. Slow
variations in ambient air temperature will be
reflected in the vessel air temperature;
however, it must be considered that direct or
reflected solar radiation will result in higher
pressure than would be anticipated for the
existing ambient air temperature.
Item
CM810
Nomenclature
(1). If float is stowed, unsnap containment

cover to extent required for access to
pressure vessel.
(2). Open manifold change valve to verify
that there is no pressure remaining in
pressure vessel.
(3). Remove the three air hoses at air
manifold. Do not allow the manifold to
turn when disconnecting the hoses.
wiring knife splice at solenoid or
disconnect squib valve electrical
connector at squib and install plug.
Use a wide-strap wrench, 2 inch
(5 cm) minimum width, to apply
torque on the pressure vessel, taking care
not to damage it. Use crowfoot adapter on
the torque wrench at the valve body.
CAUTION
NOTE:
D Solenoid valve: Do not remove solenoid
and relief valve assembly from pressure
vessel.
CSP-HMI-2
D Squib valve: If actuated, replace with a

serviceable valve. Install valve on pres
sure vessel and torque to 380-420
inch-pounds (42.93 - 47.45 Nm).
(5). Detach restraining lacing and remove
pressure vessel from float.
(6). Recharge pressure vessel with dry
nitrogen or compressed dry air to 3000
- 3500 psi (20684 - 24132 kPa) at 75F
(24C); 3500 psig (24132 kPa) at 75F
(24C) is preferred. Cool cylinder with
water and charge slowly to maintain
vessel surface temperature below 250F
(122C).
NOTE: The pressure vessel may also be serv

iced by weight. When servicing by weight,
use a scale and weigh the empty vessel with
attaching hardware installed. Charge the
empty vessel until a weight increase of 3.7 4.4 pounds (1.68 - 2.0 kg) is obtained; 4.4
0.1 pounds (2.0 0.05 kg) is preferred.
When charging by weight, air temperature
variation will have no affect. Observe vessel
cooling precaution.
(7). Test for air leaks by applying liquid
leak detector (CM810) to the valvepressure vessel interface. No air
bubbles are permitted.
(8). Dry with clean lint-free cloth and then
allow to air-dry completely.
(9). Inspect the emergency inflation system.
(10). Cover vessel with bag and tie closure
lacing.
(11). Reinstall vessel and bag on float;
re-connect air hose fittings and
solenoid/squib valve electrical wiring
knife splice/squib valve electrical
connectors. The pressure vessel must be
positioned so that air hose connections
place no strain on the solenoid/squib
and the pressure gage is visible through
the pressure gage inspection window
when the floats are stowed.
32-82-00
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Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
VALVE PROTECTOR
SOLENOID VALVE PROTECTOR
NUT
UNION
CROSS
PRESSURE VESSEL
G32-8003
Figure 402. Solenoid Valve Assembly

(12). Reinstall manifold cover.
(13). Perform an inflation system electrical
control equipment reliability test.
3. Squib and Squib Actuated Valve
Replacement
(Ref. Figure 402 and Figure 403) Each time
the emergency floats are inflated using the
emergency float inflation system, the squib
and squib actuating valve must be replaced.
NOTE: Solenoid valves used in the emergency

float system are no longer available from the
manufacturer. Emergency float systems
equipped with the solenoid valve must be
converted to the squib valve system when
the service life of the solenoid valve is ex
ceeded.
(1). Open manifold change valve to verify
that there is no pressure remaining in
pressure vessel.
(2). Remove pressure vessel with squib
valve assembly attached.
(3). Note orientation of squib with respect
to pressure gage.
Page 404
Revision 19
32-82-00
(4). Spread plastic cover at it's parting line

until small round end of white plastic
buttons pull through the black plastic
and over the squib connector, allowing
access to four screws that retain the
actuating valve body.
(5). Using Allen wrench, remove four
screws near the outlet port retaining
the actuated valve body. Retain screws
for installation of new valve.
(6). Pull spent valve and squib off vessel.
Discard activated valve and squib.
(7). Lightly lubricate O-ring on new valve
with MIL-G-4343 or equivalent
pneumatic grease.
The squib is an electrically
WARNING fired explosive. Ensure con

nector plug is installed in connector
prior to installation.
(8). Maintain squib orientation noted in
step (3).. Install squib actuated valve,
with squib installed, into manifold.
Squib actuated valve must bottom
metal-to-metal on face of manifold.
MAINTENANCE MANUAL
CSP-HMI-2
SQUIB
OUTLET
SCREW
VALVE BODY-TOMANIFOLD 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
Figure 403. Squib Valve Assembly
32-82-00
Page 405
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
(9). Install four screws removed in step e.

hand tight until locking thread of
helicoil insert in manifold is engaged.
(10). Using Allen wrench, tighten the four
screws evenly until bottomed. Torque
(11). Remove plug from squib connector.
Note that plug only fits one way.
Realign black plastic cover and pull it
back over the squib connector. Replace
squib connector plug.
(12). Snap white plastic buttons back
through holes in black plastic cover.
Check plug in squib connector to ensure
it is bottomed.
(13). Charge pressure vessel and reinstall on
emergency float assembly.
4. Emergency Float Folding
(Ref. Figure 404) Folding instructions con
tained in this procedure are provided as a
general guide for float packing. Float folding
will require the aid of an assistant and
considerable care in preparing the smallest
float package possible during the initial folding
steps. A minimum amount of wrinkles and
complete air evacuation is essential to final
closure of cover snap fasteners.
(1). Position deflated float (five fill valves
OPEN).
NOTE: The float assembly must be removed

from the stowage envelope for installation.
Do not attempt to position the float for pack
aging with the float chambers fully col
lapsed.
(2). Fold the float as outlined in the figure.
On completion, the folded float must be
contained within the float stowage
Page 406
Revision 19
32-82-00
cover, all snaps must be closed and the

pressure vessel pressure gage must be
visible in the inspection window.
Special attention should be paid to the
following information which is pres
ented as an aid in establishing a final
float folding technique.
(a). Accomplish float folding in two
stages, first performing float arrange
ment (pre-folding) to the extent
necessary to position the float and
float components in approximate
required positions and then proceed
ing with the final folding.
NOTE: Partial inflation of float compartments

is required to enable float arrangement dur
ing initial pre-folding.
(b). During pre-folding and before air
evacuation of the forward compart
ments (cells) as outlined in step 4, do
the following. Gather and compress
the float fabric tightly against the
vessel and pull the cover over the
inboard-facing pressure gage to
estimate final cover window-to-gage
relationship. This fabric bunching/
cover pulling action may be required
several times before an approxima
tion (best guess) of final window
position is established. When cover
position appears good, evacuate all
air from the forward cells and
recheck the window-to-gage rela
tionship.
(c). As soon as a float chamber is ar
ranged in the desired position, hold
the components in place, flatten as
many wrinkles as possible and
evacuate air from the float chamber.
While the vacuum is still being
applied, close the fill valves.
MAINTENANCE MANUAL
CSP-HMI-2
STEP 7
FOLD HERE
STEP 2
LANDING GEAR AFT
STRUT (REF)
LANDING GEAR
FORWARD STRUT
(REF)
STEP 5
STEP 3
SKID TUBE
EXTENSION
(REF)
STEP 8
STEP 10 AND 11
STEP 6
STEP 4
STEP 1
STEP 9
STEP 1
OPEN ALL FILL VALVES OF INFLATED FLOAT AND COMPRESS CELLS LIGHTLY BY HAND SO THAT FLOAT IS FLAT
AND AS SMOOTH AS POSSIBLE.
STEP 2
PLACE FOLD AT AFT END OF SKID EXTENSION THEN EVACUATE AFT OUTBOARD AIR COMPARTMENT (CELL)
UNTIL FOLD IS FIRM AND SHARP. CLOSE FILL VALVE.
STEP 3
WHILE COMPRESSING SUPPORT TUBE AND HOLDING FLOAT CENTER FORWARD AND DOWN, PLACE A FOLD IN
INBOARD CENTER CELL BETWEEN INLET CHECK VALVE AND FILL VALVE. REARRANGE AIR HOSE AS REQUIRED.
CONTINUE HOLDING PRESSURE ON SUPPORT TUBE. EVACUATE CENTER CELL THEN AFT INBOARD CELL UNTIL
FOLDS ARE SHARP AND SUPPORT TUBE IS FIRMLY HELD FROM MOVING AFT. CLOSE FILL VALVE.
STEP 4
POSITION PRESSURE VESSEL SNUG AGAINST OUTBOARD SIDE OF FORWARD STRUT. WHILE HOLDING VESSEL IN
POSITION, EVACUATE FORWARD OUTBOARD CELL THEN FORWARD INBOARD CELL UNTIL CREASES ARE FIRM
AND SHARP. CLOSE FILL VALVE.
STEP 5
RECHECK FLOAT. CHECK THAT FLOAT IS AS FLAT AS POSSIBLE AND FREE OF ALL AIR POCKETS. DOUBLE CHECK
FIRMNESS OF ALL CREASES AND REEVACUATE CELLS AS NECESSARY.
NOTE: ANY REMAINING AIR MIGHT CAUSE FLOAT OPENING AT ALTITUDE AND DIFFICULTY IN PACKING.
STEP 6
FOLD FLOAT AFT AT FORWARD END. REPOSITION HOSES AS REQUIRED. STOWAGE COVER MUST BE OUTSIDE
OF FOLD LINE.
STEP 7
FOLD FLOAT FORWARD AT AFT END. REPOSITION AIR HOSES AS REQUIRED. STOWAGE COVER MUST BE
OUTSIDE OF FOLD LINE.
STEP 8
ROLL AND FOLD LENGTH OF FLOAT TOWARDS CENTER. DO NOT COVER PRESSURE GAGE.
STEP 9
ROLL AND FOLD LENGTH OF FLOAT TOWARDS CENTER. FASTEN SNAPS STARTING AT FORWARD END. ENSURE
THAT PRESSURE GAGE IS VISIBLE IN INSPECTION WINDOW. DO NOT FASTEN END COVER SNAPS.
STEP 10
TIGHTEN LACING. ENSURE THAT SNAP FASTENERS REMAIN CLOSED.
STEP 11
SECURE END COVER SNAPS. ALL SNAP FASTENERS MUST BE USED.
Figure 404. Emergency Float Folding
32-82-00
Page 407
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
Page 408
Revision 44
32-82-00
MAINTENANCE MANUAL
CSP-HMI-2

1. Emergency Float System Initial
Installation
A. General
the operator's discretion. Instructions are
provided for installation of emergency float kit
on either the current or early configurations of
the extended landing gear. Subsequent
installation instructions for the emergency
floats and the float electrical control system
are identical for the current and early ex
tended landing gear configurations. Equip
ment removal and modification differences
between the current and early configurations
are noted in the subsequent instructions.
The emergency float kits are provided with as
many assembled parts as practicable to
facilitate initial installation on the helicopter.
Installation of electrical equipment assumes
prior incorporation of pilot's cyclic stick grip
kit (369D90129-507 or 369D90129-511).
B. Initial Preparation
applicable to both left and right landing gear
assemblies. Prepare the aircraft for installa
tion of emergency floats as follows:
NOTE: When installing emergency floats, the

VNE cards must be replaced with the cards
that come with the floats (Ref. appropriate
PFM).
attaching hardware, and components
removed for access to work areas.
contamination until installed.
(2). Raise aircraft clear of ground; Use
authorized hoisting or jacking methods
(Ref. Sec. 07-00-00). Place support
beneath skid tubes at strut locations.
C. Existing Equipment Removal
(1). Remove Battery (Ref. Sec. 96-05-00).
(a). Ensure that all flight compartment

switches are in OFF position.
CAUTION
Make certain BATT-OFF-EXT

switch is in OFF position.
(2). Remove landing gear strut fillets and

fairings (Ref. Sec. 32-10-00). Retain all
doublers, guides, pins and springs for
reinstallation.
(3). On current configuration landing gear,
remove forward nut, bolt and spacer
attaching existing extension to aft end
of skid tube; retain nut for reinstalla
tion.
(4). On early configuration landing gear,
remove abrasion strip attached to
existing skid tube extension (Ref. Sec.
32-10-00).
(5). Remove screws and bolts securing skid
tube extension; retain early configura
tion indexing plugs for reinstallation.
(6). Remove skid abrasion strips below for
and aft fairings; retain abrasion strips
for reinstallation.
D. Landing Gear Skid Extension Assembly
(Ref. Sec. 32-81-00)
E. Emergency Float System Electrical
Equipment Installation
(Ref. Figure 901)
(1). Remove attaching hardware and
separate lower switch and circuit
breaker panel from instrument panel
structure.
(2). Remove covers from emergency float
press-to-test switch and circuit
breaker cutouts from lower switch and
circuit breaker panel.
(3). Install emergency float circuit breaker
in panel.
NOTE: Press-to-test switch is installed during

subsequent wiring installation procedure.
32-82-00
Page 901
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
PILOT'S CYCLIC
STICK GRIP
GROMMET
FLOAT
SWITCH
CLIP
FLOAT
SWITCH
FORWARD STRUT
STANDARD GRIP
OPTIONAL ``T'' GRIP
MOUNTING
SLEEVE
DOUBLER
PILOT'S FLOOR SUPPORT
FORWARD LEFT BULKHEAD
SWITCH
HOUSING
EXISTING
HOLE
RELAY
BRACKET
LAMP (4)
INDICATOR
MODULE
LOCKING
CAM
LOCKING CAM
SCREW (2)
LEGEND
FACE
RELAY
SWITCH INSTALLATION
(SLIMLINE PANEL)
PILOT'S FLOOR SUPPORT

FORWARD LEFT BULKHEAD
1 NAV 2
FLOAT
PRESS-TO-TEST
ADF
XPDR
HOOK
FLOATS
CIRCUIT
BREAKER
INSTRUMENT PANEL (COMM. ``T'' PNL.)

G32-8007A
Figure 901. Emergency Float Kit Electrical Installation

Page 902
Revision 19
32-82-00
MAINTENANCE MANUAL
F. Emergency Float System Electrical
Wiring Installation
(Ref. Figure 902 thru Figure 905)
Item
Nomenclature
CM318
CM601
Primer
Insulation sleeving, electrical
(1). Identify wires as required and form

wire bundle of applicable wires to
emergency float circuit breaker and
press-to-test switch on lower switch
and circuit breaker panel.
(2). From battery compartment area, route
wire bundle forward and up through
instrument panel support structure;
route wire bundle with existing bundles
where possible.
(3). Install insulation sleeving (CM601) and
connect applicable wires to contacts on
press-to-test switch and circuit
breaker; assemble and secure press-totest switch to panel.
(4). Adjust wire bundle and allow sufficient
slack for maintenance; strap and string
tie bundle to form smooth flow of wires
to battery compartment area.
(5). Ensure all switch and circuit breaker
contacts are secure and that sleeving is
properly installed; remove paint from
panel and console in upper screw area
to ensure good ground contact. Install
panel on console.
CSP-HMI-2
(6). Install wiring through landing gear

struts as follows:
(a). Drill 0.442 inch (11.2268 mm) hole
centered on outboard side of forward
struts located five inches (12.7 cm)
above centerline of skid tube; deburr
holes internally and externally.
(b). Coat bare metal in holes with primer
(CM318); allow primer to dry.
(c). Remove left and right foot support
fairing in passenger compartment for
access to landing gear forward struts.
(d). Install insulation sleeving on float
valve squib wires.
(e). Locate position light wire bundle exit
holes on top inboard portion of left
and right landing gear struts; Insert
respective float squib wire bundles
through position light wire bundle
exit holes. Locate wires through
previously drilled wire exit hole at
bottom of each strut. Carefully pull
wires through holes allowing suffi
cient length for connections at either
end.
(f). Slide grommet over wire bundle on
both struts; Install grommet in
previously drilled wire exit holes.
(g). Attach clip (Ref. Figure 901, view G).
(h). Coil and stow wires to avoid damage
during float equipment installation.
(7). Complete balance of all wiring. Install
insulation sleeving as required to
prevent shorting and chafing through
out circuit wiring.
32-82-00
Page 903
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
NOTES:
1. THIS WIRING DIAGRAM SHOULD BE USED WITH THE
ELECTRICAL SYSTEM WIRING DIAGRAM IN CSP-HMI-3
FOR COMPLETE CIRCUIT IDENTIFICATION.
2. DASHED LINE (- - -) ITEMS ARE PART OF HELICOPTER
BASIC ELECTRICAL SYSTEM, UNLESS OTHERWISE NOTED.
3. PART OF SOLENOID FLOAT VALVE.
4. ENDS OF WIRE A507B20 (PART OF BASIC ELECTRICAL
SYSTEM) MUST BE DISCONNECTED AND INSULATED.
BUS
28 VDC
P506M20
OR
P506AD20
CB121
5A
1
2
M503A20
TB1-9
A
B
J130P
A508B20
16-20
M531E20
12-20
A506B20
15-20
A510A20
18-20
M521C20
11-2
0
A507A20
17-20
TB1-18
C
TB1-10
C
D
SP20
A B
TB1-7
D
C
M506B20
M506H20
TB1-18
M510F20
B
TB1-10
(NOTE 4)
A
B
SWITCH TOP
5
NC
NO
C
NC
NO
C
TB1-17
NC
M530B20
M509F20
NO
A507B20
(NOTE 4)
C
S5 EMERGENCY
FLOAT SWITCH
(PART OF 369H90129
GRIP KIT)
JMPR AWG 22
(4 PLCS)
M510K20
S9-1
S9-2
RELIABILITY (PRESS-TO-TEST)
SWITCH-INDICATOR (DS8, S9)
M509C20
JMPR AWG 20
(6 PLCS)
M510C20
A
TB1-15
B D C
RELA
Y
M509K20
M511A20
N
E20
M506C20
B
A SP6
A
B SP3
A
B SP8
GND
BLK-A20
B
A SP5
YEL-A20
A
B SP4
BLK (NOTE 3) YEL

LEFT SOLENOID
FLOAT VALVE L1
YEL-AA20
A
B SP9
A1
B1
C1
D1
A3
B3
C3
D3
M519A20N
M506E20
M512A20N
B
A SP1
1
E25
E24
GND
GND M506N20
A2
B2
Revision 19
CR3
C2
D2
BLK-AA20
B
A SP10
YEL (NOTE 3) BLK

LEFT SOLENOID
FLOAT VALVE L2

(369D290121501 and 505)
Page 904
X1
X2
32-82-00
G32-8013A
MAINTENANCE MANUAL
CSP-HMI-2
RED OR YELLOW
BLACK OR BLUE
TB1-15
A
B
SP3
A
B
NOTE 2
SP3
SQUIB FLOAT
VALVE R.H.
PILOT'S INFLATE FLOAT SWITCH

1
S5
4
3
17.20
11.20
12.20 16.20 18.20
15.20
FOR 369H92557-511
SEE SHEET 2 FOR
369H92557-513
(NOTE 1)
M512A20N
369H90129-505
GRIP (REF)
NOTE 2
M509B20
NOTE 3
NOTE 3
M925181-1 SPLICE
4 REQD
JMPR GA.20
8 REQD
NOTE 3
J130
NOTE 3
TB101 (REF)
33
E5
M521E20
M508B20
MPCM20M-H2 PIN
1 REQD
P506M20 EMERGENCY
FLOAT SYSTEM BUS WIRE TB1-18 C
28 V. BUS
MS25036-103
TERMINAL
M506A20
1
2
2TC13-7.5 CIR. BRK

MS25036-149 TERMINAL
FOR -511
M510B20
NOTE 2
NOTE 2
E20
M506M20 CABLE
A
TB1-9
M506N20
CABLE
(REF)
E2
S3
SQUIB FLOAT
VALVE L.H.
BENDIX PLUG
P101
A
C
D
B
BENDIX PLUG
P/N PT06P-8-4-S
RNF 100X1/4 SLEEVE

(A/R LH AND RH SIDES)
R1
S2
M506H20
NO
NC
RED OR
YELLOW
S1
NO
NC
R2
NOTE 1
CB11
1
NO
2.0 MAX
P102
B
D
C
A
NC
2 REQD
7.5A
1
2
M511AN20
MS 25036-103 TERMINAL
2 REQD
D121 SOLDER SLEEVE
8 REQD
BLACK
OR BLUE
NOTE 2
CB121
7.5A
28V BUS
(REF)
E25
MS25244-7.5
CIRCUIT BRK.
P506M20
EMERGENCY FLOAT
SYSTEM BUS WIRE
CB118
(REF)
FOR -513
4 1
L.H.
R.H.
369H92557-61
SWT/LT ASSY
NOTE 1
SYSTEM TEST PRESS
NOTES:
1. EXISTING EMERGENCY FLOAT SYSTEM WIRING. DO NOT REMOVE.
2. SHIELDS TO BE TERMINATED 0.50 INCH (12.70 MM) MAX. FROM END
OF INSULATION ON WIRE (EXCEPT AS NOTED). JUMPERS TO BE
MIN. LENGTH.
3. REMOVE WIRE A510A20 FROM PIN J130-H, M521C20 FROM PIN
J130-D, A507A20 FROM PIN J130M, A506B20 FROM J130-N AND
STOW WITH 3/16 PD CAPS.
PARTS REQUIRED:
JUMPER #22 GA. 4 REQ'D
3/16 PD CAPS
4 REQ'D
32445 SPLICE
4 REQ'D
SLEEVING
A/R
MS 25036-103 TERMINAL
MPCM20M-H2 PIN
D121 SOLDER SLEEVE
2 REQ'D
2 REQ'D
2 REQ'D
G32-8014-1B

(369D290121515, 517 and 519) (Sheet 1 of 2)
32-82-00
Page 905
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
S5
1
20 GA
369D297846 GRIP
(REF)
12-20
16-20
SP101
J109
(REF)
B
A
18-20
SP103
B
A
15-20
SP106
B
A
11-2
0 SP104
SP105
B
A
B
A
17-20
SP102
B
A
32445 SPLICE
10 REQD
E5
M506C20
MPCM20MH2 PIN
M506G20
TB1-8
C
RED OR
YELLOW
TB1-9
BLACK OR
BLUE
BLACK OR
BLUE
RED OR
YELLOW
A
M506M20 CABLE
(REF)
M506N20
(REF)
SP3
A
SP9
A
TB1-15
(REF)
FOR 369H92557-513
(NOTE 1)
BLACK
M506N20
CABLE
NOTE 2
NC
NC
NC
NO
NO
NO
(S9-3)
R.H. FLOAT
(REF)
(S9-2)
(S9-1)
L.H. FLOAT
(REF)
NOTE 2
RED
MPCM20MH2 PIN 1 REQ'D
MS 25036-103 TERMINAL 1 REQ'D
D121 SOLDER SLEEVE 2 REQ'D
JUMPER #22 GA
M506H20
369H92557-61 SWITCH LIGHT ASSY

(369D290121515, 517 and 519) (Sheet 2 of 2)
Page 906
Revision 19
32-82-00
G32-8014-2A
MAINTENANCE MANUAL
TB503-1
1
A
D
CB121
C
1
M506A20
2
M511G2
0
NO
S2NC
TB505-3/4
A
NC
S3
NO
S1NC
M506B20
E511F2
0
RH
LH
R2
22
5 1/4 W
CSP-HMI-2
R1
22
5 1/4 W
C
+28V
BLU OR BLK
C
C
RED OR WHT
M506H20
F
M531B20
TB503-5
M L K
M506N20
NO
TB503-10
A B C
BLU OR BLK
V
Y
M506NN20
X
RED OR WHT
FOR DIAGRAM
BEYOND P110,
SEE SCHEMATIC
BELOW
(515 VERSION)
Z
W
E33-K
-81 SWITCH LIGHT ASSY
GREEN LIGHTS
3
4
LH
RH
R2
22
5 1/4 W
NC
S2
NO
NC
S1
NO
NC
S3
NO
BUS
TB101
CB121
3 1
2
M506A20
7.5A
R1
22
5 1/4 W
P11
0
V
TB503-8
A
M506HH20
W
B
RED OR WHT
C
M506H20
RED OR WHT
CABLE
M506N20
BLU OR BLK
XDS9
-61 SW/LT ASSY
E2
B
C
CABLE
M506NN20
C
D
D
E
F
TB503-9
E
F
X
Z
Y
BLU OR BLK
G32-8015-1

(369D290121521, 523, 525 and 527) (Sheet 1 of 2)
32-82-00
Page 907
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
NO
NC
S3
NO
NO
NC
S2
XDS8
NC
S1
(TB503-11M)
M511G20
(E33K)
(TB503-5C)
(TB503-5J)
RED OR WHT
M506N20
BLU OR BLK
M506H20
(TB503-5M)
(TB503-5F)
S5
PILOT'S INFLATE
FLOAT SWITCH
P102
SP103
J130
SP104
E J H
TB1-19
A
RED OR
WHT
E30
D
C
B
A
M506AA20
M506J20
A506J20
M520F20
BLU OR
BLK
CABLE CABLE A507C20
A510A20
TB1-22
A
B
C
CABLE
A510B20
D
RED OR
WHT
A
B
BLU OR
BLK
BLU OR BLK
CABLE M509B20
RED OR WHT
90 BOOT (REF)
BLU OR
BLK
SQUIB FLOAT
VALVE RH
TB1-20
RED OR
WHT
TB1-20
A
B
C
D
RED OR WHT
CABLE M512A20N
BLU OR BLK
CABLE
A507C20
E30
BLU OR BLK
CABLE M510B20
RED OR WHT
SQUIB FLOAT
VALVE LH
RED OR WHT
CABLE M511A20N
BLU OR BLK
BLU OR BLK
RED OR WHT
CABLE
A510C20
J109
J E
REF
TB1-22
A
B
P101
M
SP101
SP102
G32-8015-2

(369D290121521, 523, 525 and 527) (Sheet 2 of 2)
Page 908
Revision 19
32-82-00
MAINTENANCE MANUAL
CSP-HMI-2
DS25 BATT 180 o
TB505-3/4
L
W1041A22
2
1
C
3
4
(TB503-2C)
A
M
XDS8 FLOAT
PRESS TO
TEST
NOTES:
1. DASHED LINES (- - -) ARE PART OF
BASIC SHIP WIRING.
2. EFFECTIVE ON HELICOPTERS
369E S/N 384 AND SUBS.
369FF S/N 076 AND SUBS.
500N S/N 001 AND SUBS.
ND
NC
C
S3
ND
NC
P/J1201
W1007B22
W100E22
W1007A22
W1007F22
WHT
BLU W100J22
17
18
19
20
WHT
BLU W100K22
W1236B22
W1236B22
NC
WHT W1007H22
BLU W1007H22
(FLOATS)
CB121
W1007AA22
5A
2
P/J130
WHT
BLU
WHT
1W1007M22
1W1007L22
S5
FLOATS
M
N
15
15
11
BLU
H
b
H
b
11
RED
C
S1
W1007G22
21
BLU
C
S2
ND
TB503-9
1W100D22
16
1W100C22
12
f
g
f
g
RED
BLU
TB200-2
P/J109
BLU
1FLOAT1A22 BLU
1W1007M22 WHT
2FLOAT1A22 BLU
1FLOAT1A22 WHT
WHT
2W1007M22
BLU
2FLOAT1A22 WHT
WHT
15
RED
BLU
BLU
15
11
BLU
BLU
H
b
H
b
11
RED
16
12
f
g
f
g
WHT
JUMPER 22AWG
TB200-3
A
1W1007L22
WHT
BLU
BLU
2W1007LC22
2W1007D22
S5
FLOATS
BLU
2W1007L22
WHT
E38
P/J102 (RH FLOAT)

N
T
P
W
R
Y
S
Z
1FLOAT2A22N
2FLOAT2A22N
WHITE
BLUE
WHITE
BLUE
B
D
C
A
SQUIB
FLOAT
VALVE
P/J101 (LH FLOAT)
B
D
C
A
SQUIB
FLOAT
VALVE
G32-8017
Figure 905. Emergency Float Installation with Generic Wire Harness
32-82-00
Page 909
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
G. Emergency Float Electrical System

Inspection
CAUTION
Ensure that the BATT-OFFEXT switch is in the OFF posi
tion.
Before connecting battery plug, the following
wiring installation inspection must be per
formed.
(1). Inspect all wiring connections for
security and insulation.
(2). Inspect all wiring for interference with
moving parts and for areas where
chafing could occur.
(3). Inspect all wiring for conformance with
wiring diagrams.
(4). Install all access panels, doors and
access covers previously removed.
(5). Remove insulation and temporarily
connect each set of float squib wires.
(6). Install battery, connect battery plug
and place BATT-OFF-EXT switch in
BATT position.
(7). Momentarily press emergency float
press-to-test switch to verify proper
wiring continuity; all four switch lamps
should illuminate.
(8). Separate float squib wires at base of
struts.
(9). Actuate EMERG/FLOAT switch on
pilot's cyclic stick grip; use voltmeter to
check for proper voltage and continuity
through float squib valve circuits.
(10). Pull out emergency float circuit breaker
to remove power and release relay;
push circuit breaker in again to prepare
circuit for emergency use.
Page 910
Revision 19
32-82-00
H. Emergency Float System Strut Fairing

Installation
(Ref. Figure 906)
Item
CM209
Nomenclature
Zinc chromate putty
The following installation instructions are

typical for all four strut fairing assemblies.
Where riveting is required, Refer to referenced
instructions for proper rivet types.
(1). Install center fairing, fillet and lower
fairing in respective order, and general
ly in accordance with instructions (Ref.
Sec. 32-10-00).
(2). During installation of fairings, ensure
that doublers, removed during disas
sembly, are installed between fairings
and fillers at screw attach points.
(3). Ensure blocks are installed at lower
trailing edge of fillets to ensure free
action of fillet with strut movement.
(4). Ensure that float solenoid/squib wire
bundles are free at bottom of lower
fairings on forward struts.
(5). Install bolt covers over inboard bolt
heads on strut foot/skid attach point.
Apply sufficient zinc chromate putty
(CM209) to fill all voids between cover
and bolt head area; secure forward
strut bolt covers with existing nylon
hardware. Torque screws to 25 - 35
MAINTENANCE MANUAL
CSP-HMI-2
DOUBLER
FAIRING
NUTPLATE
WASHER
DOUBLER
CHAFING PAD
(FORWARD FAIRING)
SCREW
FAIRING
TEFLON STRIP
(FORWARD FAIRING)
0.50 IN.
FILLET
0.50 IN.
RIVET
1.25 IN.
FILLER
BLOCK
FILLER-TO-FAIRING
ATTACHMENT (TYP)
FAIRING
CENTER FILLER
CENTER
FAIRING
NUTPLATE
DOUBLER
FAIRING
FAIRING
MOUNTING
BRACKET
LANDING
GEAR
STRUT
SCREW
DOUBLER
WASHER
FILLER
LOWER FAIRING
SCREW
CENTER-TO-LOWER FAIRING
FILLER ATTACHMENT
LOWER FAIRING
STRUT-TO-SKID
BOLT COVER
STRUT FOOT
STRUT FOOT
SKID TUBE
FOOT
CONTAINMENT
COVER
STRUT-TO-SKID
BOLT COVER
SKID
SEAL
NYLON SCREW
BOLT COVER INSTALLATION
G32-8016
Figure 906. Emergency Float System Strut Fairing Installation
32-82-00
Page 911
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
I. Emergency Float Installation
Item
CM209
(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
strip and secure strip to skid with bolts
and washers. Install remaining abra
sion strips; remove excess zinc chro
mate putty.
Nomenclature
Zinc chromate putty
Installation of the left and right emergency

floats is identical except for opposite positions.
(1). Open float package and release re
straining straps.
(2). Position float girts over skid tube
attach points.
(3). Temporarily attach float web support
strap fittings at forward location;
secure strap fitting at aft attach
location with bolts and washers.
(4). Place gravel guards over float girts and
secure with bolts and washers.
(5). Apply zinc chromate putty (CM209) to
contact surfaces of previously removed
abrasion strips, and skid extension
abrasion strips, to ensure watertight fit
on landing gear skids.
(7). Install balance of bolts and washers

securing float girts to skid tube exten
sions. Torque all bolts to 25 - 35
(8). Adjust and secure float landing gear
strut cutout restraining straps.
(9). Unsnap float containment cover and
loosen restraining lacing to gain access
to emergency inflation system compo
nents.
(10). Connect squib valve electrical connector
at squib.
(11). Perform inspection of emergency float
inflation system (Ref. Emergency Float
Inspection - Stowed Configuration).

Configuration
Weight
lbs (kg)
Arm
in. (cm)
Moment
in.lb/100 (kgmm/100)
501
+151.7
(+68.872)
95.9 (243.59)
+145
(+1670.57)
505
+150.8
(+68.463)
96.0 (243.84)
+145
(+1670.57)
515
+129.1
(+58.611)
99.1 (251.71)
+128
(+1474.71)
517
+127.7
(+57.976)
98.9 (251.21)
+126
(+1451.67)
519
+152.7
(+69.326)
96.4 (244.86)
+147
(+1693.62)
521
+152.6
(+69.280)
96.5 (245.11)
+147
(+1693.62)
523
+152.5
(+69.235)
96.5 (245.11)
+147
(+1693.62)
525
+127.5
(+57.885)
99.0 (251.46)
+126
(+1451.67)
527
+152.5
(+69.235)
96.5 (245.11)
+147
(+1693.62)
529
+152.5
(+69.235)
96.5 (245.11)
+147
(+1693.62)
531
+152.5
(+69.235)
96.5 (245.11)
+147
(+1693.62)
Page 912
Revision 19
32-82-00
MAINTENANCE MANUAL
Chapter
52
Doors
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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
52 Contents
Page i
Revision 36
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 204. Door Hinge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 205. Window and Hinge Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 206. Current Style Window Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
216
216
217
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
Page ii
Revision 36
52 Contents
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 201. Access and Inspection Provisions Information . . . . . . . . . . . . . . . . . . . .
Figure 201. Access and Inspection Provisions and Locations (369D/E/FF)
(Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 202. Access and Inspection Provisions and Locations (500N)
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 203. Access and Inspection Provisions and Locations (600N) . . . . . . . . . .
Figure 204. Floor Access Covers and Engine Bypass Door (600N) . . . . . . . . . . . .
52 Contents
201
202
204
207
209
210
Page iii
Revision 36
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page iv
Revision 36
52 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
521000
Crew, Passenger,
Cargo Doors and
Windows
MAINTENANCE MANUAL
CSP-HMI-2
CREW, PASSENGER, CARGO DOORS AND WINDOWS

1. Crew and Passenger/Cargo Door
The pilot and passenger/cargo doors are
bonded aluminum alloy frames containing
large smoke-grey-tinted cast acrylic windows.
Plastic snapvents are installed in each door
window. An acrylic stop, bonded to the doubler,
prevents normal airflow from pulling the
snapvent from the window during flight. These
units may be rotated for intake or exhaust of
ventilating air and may be pulled inward for
complete closure. Damaged snapvents should
be replaced, (Ref. Snapvent Replacement);
repair is not practical.
Pilot and passenger/cargo doors are equipped
with an automatic latching mechanism. Two
door hinges on each door are provided with
quick-removal type ball-lock hinge pins.
Pilot and passenger/cargo doors are equipped
with automatic latching mechanisms. The
latching mechanisms permit the door to be
closed and safelocked from inside or outside.
Each installation contains a key-operated cam
lock, actuated from outside. Opening door from
inside overrides key-operated cam lock. Pilot
and cargo door latching mechanisms are
essentially the same except for length of
interconnecting rods.
A. Early DoorLatching System
Early mechanisms, installed within the door
panel, consist of four latch blocks that house
spring-loaded latch bolts and safelock triggers
together with latch sliders.
The latch sliders are interconnected to rods

and clevis devices and are moved by turning
inside or outside door handle.
Movement of either handle into safelock
position is prevented until door is closed and
safelock position is prevented until door is
closed and safelock triggers are actuated by
the strikes. This actuation causes the safelock
triggers to clear notches on latch sliders,
allowing the latch sliders and linkage to move
into safelock position.
B. Current Door Latching System
(HookLatch)
Current door latching mechanisms used on
pilot and passenger/cargo compartment doors
consist of four hook type latches mounted on
the door frame. The four latches are actuated
by latch sliders which are synchronized and
connected by steel connector rods to the door
handle.
With the door handle at the rest position, the
door may be firmly shut and the hooks will
ride up over and engage their striker pins.
Safelocking is accomplished by moving the
door handle to the lock position, which causes
the latch slider that operates each hook latch
to engage a pin within the latch block,
preventing further movement until the handle
is moved to the open position. When the
handle is moved to the open position, the latch
sliders fully extend the latch hooks from their
latch blocks, disengaging them from their
striker pins and allowing the door to open.
52-10-00
Page 201
Revision 25
MAINTENANCE MANUAL
CSP-HMI-2
2. HookLatch Automatic Door Latching

System Troubleshooting
Table 201. HookLatch Automatic Door Latching System Troubleshooting
Problem
Probable Cause
Hooks fail to engage striker

pin, or more than 0.050 inch
(1.27 mm) gap between latch
hook and striker pin (Latch
hooks extend normally).
Latches fail to extend from

latch block when handle
moved to open position.
Door does not safelock when

door handle is moved to lock
position.
Repair
Door seal swollen or bonding

to door frame failed.
Repair seal (Ref. Door Seal Repair).
Striker assembly mounted too

far inboard or outboard on
door frame.
Loosen striker assembly mounting screws and

adjust striker assembly position.
Latch block assembly too far

from striker pin.
Add or remove 0.063 inch (1.60 mm) and

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

rubbing on door waffle.
Route out waffle enough to clear.
Striker assembly hitting latch

cover (2).
Check latch covers for dents or chipped paint

that indicates contact between latch cover and
striker assembly. Remove material from latch
cover to allow striker assembly clearance.
Latch hooks or latch sliders

sticking in latch block.
Lubricate latch block moving parts.
Connector rod(s) improperly

adjusted.
Adjust connector rod(s) by removing clevis

from sliding cam and raising or lowering
threaded connector as required on threaded
portion of rod. Threads of rod and connector
must be engaged through solid portion of
connector. Rod end may be flush with or
extend beyond bottom, of solid part of
connector.
Connector rod bent or

damaged.
Check connector rods and clevis. Replace

damaged part.
Connector rod(s) improperly

adjusted.
Check witness hole in latch blocks.

Semicircle cutout in each latch slider must be
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.
Page 202
Revision 25
52-10-00
MAINTENANCE MANUAL
3. Crew Compartment Door Replacement
(369D/E/FF 500/600N)
(Ref. Figure 201)
A. Crew Compartment Door Removal
(369D/E/FF 500/600N)
(1). Remove cover plates from interior trim
forward of crew doors.
(2). While supporting door, turn hinge pins
to unlock the tabs.
(3). Remove lower pin, then remove top pin.
(4). Remove door from helicopter.
B. Crew Compartment Door Installation
(369D/E/FF 500/600N)
(1). Slide door hinges into slots on side of
airframe.
(2). Insert pins, from inside the aircraft,
into airframe holes and though hinges.
(3). Turn hinge pins to lock tabs into slots
in airframe.
(4). Install interior trim covers.
4. Passenger/Cargo Compartment Door
Replacement (369D/E/FF 500N)
A. Passenger/Cargo Compartment Door
Removal (369D/E/FF 500N)
(1). Remove cover plates from interior trim
aft of crew doors.
(2). Remove safety from top hinge pin.
(3). While supporting door, turn hinge pins
to unlock the tabs.
(4). Remove lower pin, then remove top pin.
B. Passenger/Cargo Compartment Door
Installation (369D/E/FF 500N)
(1). Slide door hinges into slots on side of
airframe.
(2). Insert pins, from inside the aircraft,
into airframe holes and though hinges.
(3). Turn hinge pins to lock tabs into slots
in airframe.
CSP-HMI-2
(4). Re-safety from top hinge pin.

(5). Install interior trim covers.
5. Mid and Aft Door Replacement (600N)
A. Mid and Aft Door Removal (600N)
(1). Remove nuts and washers from door
hinge bolts.
(2). While supporting door, slide bottom
bolt, and then top bolt from hinges.
B. Mid and Aft Door Installation (600N)
(1). Position door so door-mounted hinge
aligns with airframe-mounted hinge.
(2). Insert bolt, with washer, into each
hinge.
(3). Install washer and nut on bolt and
torque to 50 - 70 inch-pounds (5.65 7.91 Nm).
6. Door Seal Compression Check
(Ref. Figure 208) Inspect rubber weatherstrip
compression seal for tight compression
between the door and frame as follows:
(1). Open door.
(2). Hold a strip of heavy paper against
door seal so that strip extends approxi
mately 1/4 inch (6.35 mm) beyond seal
toward outside of doorway.
(3). While holding paper strip in place, close
door.
(4). Attempt to pull paper strip from
between door frame and seal. Strip
should not pull out unless a moderately
heavy pull is exerted.
NOTE: Correct fit is indicated by an approxi

mate 0.060 inch (1.524 mm) interference fit
between door seal and bumper. Where strip
can be withdrawn with a light pull, fit of
door against frame is not sufficiently tight
to provide an adequate seal. This condition
may be due to deterioration of weatherstrip
compression seal, deformation of door
frame, worn hinges or improper latching.
(5). Repeat this procedure at approximately
1 foot (30 cm) increments along length
of door seal.
52-10-00
Page 203
Revision 25
MAINTENANCE MANUAL
CSP-HMI-2
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)

Page 204
Revision 25
52-10-00
MAINTENANCE MANUAL
CSP-HMI-2
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)
52-10-00
Page 205
Revision 25
MAINTENANCE MANUAL
CSP-HMI-2
7. Mid and Aft Door Strut Replacement

(600N)
(Ref. Figure 201)
A. Mid and Aft Door Strut Removal (600N)
(1). Remove nut and washer that secures
gas strut pivot post ball to door fitting.
(2). Remove nut and washer that secures
gas strut pivot post ball to airframe
fitting.
(3). With door in open position, pull gas
strut up away from fittings to remove.
B. Mid and Aft Door Strut Installation (600N)
(1). Insert pivot post ball fitting, at shaft
end of strut, into outboard hole in
airframe fitting and install washer and
nut.
(2). Insert pivot post ball fitting, at tube
end of strut, into hole in door fitting
and install washer and nut.
(3). While holding pivot post ball fitting to
prevent rotation, torque nuts to 60 - 85
(4). Adjust strut pressure after installation
by carefully loosening screw at end of
strut and releasing pressure until door
opens fully and operates smoothly
through full range of travel.
8. Snapvent Replacement
A. Snapvent Removal
(1). Push snapvent outward in window
(open position).
(2). Grasp open side of snapvent and gently
(3). Slip snapvent out of window hole at
about a 30 degree angle to surface of
window.
B. Snapvent Installation
(1). Grasp open end of snapvent and gently
Revision 25
(3). Be sure that ends of wire stiffener are

inside window hole.
9. Outside Handle or Spindle Replacement
(Ref. Figure 202)
A. Outside Handle or Spindle Removal
(1). Remove three screws and washers
securing escutcheon to door exterior.
(2). Drive spring pin from handle and slide
handle from spindle.
B. Outside Handle or Spindle Installation
(1). Attach replacement handle to escutch
eon with handle washers. Use maxi
mum number of handle washers
possible without impeding free move
ment between handle and escutcheon.
(2). Slide handle on spindle and secure
escutcheon to door with washers and
screws.
10. Automatic Latch Block Assembly
Replacement
(Ref. Figure 202)
A. Automatic Latch Block Removal
(1). Perform this procedure with door in
open position and handles at latched
rest position.
(2). Remove screws securing latch cover.
(Ref. Figure 201)
Page 206
(2). Slip snapvent flange into window hole

at an angle of about 30 degrees to
window surface.
52-10-00
(3). Mark lockplate/nutplate so that

replacement latch block can be installed
at approximately same position as latch
that is to be removed.
(4). Remove four screws and washers
securing latch block to lockplate/nut
plate. Note any washers found between
latch block and lockplate/nutplate.
These are adjustment shims and should
be reinstalled at same location and
position at reinstallation of latch block.
(5). Remove cotter pin, washer and pin
securing rod end clevis to latch block.
(6). Remove latch block from door.
MAINTENANCE MANUAL
(7). Lubricate moving parts of latch block
(Ref. Automatic Latch Block Assembly
Repair).
B. Automatic Latch Block Installation
(1). Reconnect link and connector rod end to
handle arm with cotter pin and washer.
NOTE: Cotter pin and washer are to be in

stalled on outboard side of connector rod end
to eliminate possibility of interference. To
eliminate excess play, use extra washers for
shimming.
(2). Secure latch block to lock plate with
four screws and washers.
(3). Check door latching and safelocking
operation and make any necessary
adjustment.
11. Cam Lock Replacement
(Ref. Figure 202)
A. Cam Lock Removal
B. Cam Lock Installation
NOTE: Currently available cam lock is longer

than early cam lock and requires a spacer
between lock flange and outside surface of
door skin.
(1). Position lock boss, torsion spring,
washer and replacement handle into
position and insert spindle.
(2). Install spindle washers and screw to
secure spindle in lock plate.
(3). Attach one spring hook in hole of lock
boss and attach other spring hook at
notch in lock plate. Use wire to pull
spring hook into place.
(4). Install outside handle.
(5). Check door latching and safelocking
operation and make any necessary
adjustment.
12. Latch Assembly or Striker Adjustment
(Ref. Figure 203)
(1). Remove outside handle.

(2). Remove latch block.
Item
Nomenclature
(3). Note position of lock boss and handle

torsion spring to aid at reinstallation.
CM425
Sealing compound
(4). Hold handle, lock boss and torsion

spring in position and withdraw
spindle. Then slide handle lock boss
and torsion spring out of lock plate.
(5). Remove handle grip from handle arm
by loosening setscrew and sliding grip
from arm.
NOTE: When lock is set to locked position, be

sure that cam actuates hinged lock bar.
When lock is in correct position, secure it in
place by center-punching surface of lock
plate assembly close to flat on hexagonal
locking nut.
(6). Replace key-operated cam lock by
unscrewing hexagonal nut.
CSP-HMI-2
(1). Adjust latch assemblies and strike as

necessary to ensure proper door
latching, safelocking and keylocking
functions.
(2). After adjustments are made, perform a
final inspection of all latching and
locking functions, then install latch
covers.
(3). Fill in gaps and fair-in area between
strikes and bumper stripes at each
position with sealant (CM425).
A. Door Seal Compression Adjustment
To adjust door seal compression, remove latch
covers. Move strikes as necessary in their
slotted mounting holes.
52-10-00
Page 207
Revision 25
MAINTENANCE MANUAL
CSP-HMI-2
SNAPVENT
DOUBLER
SNAPVENT
LATCH COVER
(TYP)
DOUBLER
STOP
AUTOMATIC
DOOR LATCH
MECHANISM
WINDOW
STOP
DOOR SEAL
AUTOMATIC
DOOR LATCH
MECHANISM
LATCH COVER
(TYP) (4 PLCS)
PASSENGER/CARGO DOOR
(369D/E/FF - 500N)
DOOR SEAL
CONNECTOR
ROD
CLEVIS
DOOR PANEL
PILOT'S DOOR
(369D/E/FF - 500/600N)
LATCH SLIDER
LATCH BLOCK
ROD MOUNTING
BRACKET
STRIKER
ASSEMBLY
LATCH BLOCK
MOUNTING
BRACKET
SPACER
NOTE 2
SPRING
SHIM WASHER
(NOTE 3)
CLEVIS
(NOTE 1)
DOOR PANEL
(NOTE 2)
LOCKPLATE ASSEMBLY
(NOTE 4)
LATCH BLOCK ASSEMBLY

SPRING
SPRING HOOK NOTCH
CONNECTOR ROD
CLEVIS
LINK PIN
SPINDLE
SHIM
LINK
ARM
GRIP
ESCUTCHEON
SET SCREW
SPRING PIN
CAM LOCK
(KEY OPERATED)
DOOR
FRAME
LATCH SLIDER
LOCK BOSS
SPACER
(NOTE 5)
CONNECTOR
ROD END
LATCH ASSEMBLY - EXPLODED VIEW

EARLY SYSTEM
LATCH BLOCK
ASSEMBLY
NOTES:
1. FOR ADJUSTMENT INFORMATION, REFER TO
ADJUSTING LATCH COMPRESSION.
2. INSTALL OUTBOARD TO ELIMINATE POSSIBILITY
OF INTERFERENCE.
3. AS REQUIRED, FOR LATCH ADJUSTMENT, NOT
ON ALL WINDOWS.
4. IDENTIFIED AS NUTPLATE AT OTHER LOCATIONS.
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
Revision 25
52-10-00
MAINTENANCE MANUAL
CSP-HMI-2
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)
52-10-00
Page 209
Revision 25
MAINTENANCE MANUAL
CSP-HMI-2
B. Engagement Depth of Latch Bolts with

Striker Adjustment
Adjust engagement depth of latch bolts with
strikes by removing latch covers and moving
latch assemblies as necessary in their slotted
mounting holes or by adding shims under
strikes.
NOTE: Complete safelocking exists when latch

bolt extension is at maximum and roller on
safelock trigger is engaged in safelock slot in
latch slider. At this condition, safelock trig
ger retracts when latch slider is moved
slightly in unlatch direction.
C. Connector Rod Adjustment
(1). Open door or remove from helicopter.
(2). Remove latch cover.
(3). Press all safelock triggers and rotate
handle to safelock position. Remove
clevis pin from connector rod or latch
being adjusted.
(4). Move latch slider manually to complete
safelock position. Adjust connector rod
length so that clevis pin can be in
stalled easily.
NOTE: Position of fourth and first latches can

be individually adjusted without disturbing
adjustment of other latches. If position of
second or third latches is adjusted, then all
should be checked. When adjusting all four,
start with third latch, and proceed to sec
ond, first and then fourth.
D. Latch Compression Adjustment (Early
System)
Latch compression spring adjustment may be
necessary and should be checked if part
replacement, particularly in stack-up between
upper clevis on third latch and first mounting
bracket or change in position of clevis has been
made.
Item
CM425
Nomenclature
Sealing compound
(1). Readjust spring load using shorter or

longer spring compressor spacer and by
Page 210
Revision 25
52-10-00
modifying as required to compress

spring 0.060 - 0.080 inch (1.524 - 2.032
mm) when mechanism is at safelocked
position.
(2). Fill gaps and fair-in area between latch
strikes and bumper strips at each
position, using sealant (CM425).
13. Latching Mechanism Operational Check
(Early System)
(1). Check inside and outside door handle at
all positions for function.
(2). Close door from inside. Entire beveled
face of each bolt must make contact
with strike and must hold door firmly
against door seals. Bolts must be
positioned on strike such that there is
sufficient space for bolt to extend an
additional minimum 0.125 inch (3.175
mm) into strike for safelocking latches
(Ref. Figure 203).
(3). Check that each latch bolt makes
contact with mating strike. Unequal
striking and latching indicates latch
assembly or strike require adjustment
or shimming.
(4). Safelock door and observe that door is
forced inward for seal compression at
each latch position. Unequal safelock
ing may indicate that connector rods
are not properly adjusted for complete
extension of latch bolts.
14. HookLatch Door Latching System
Operational Check
(Ref. Figure 203)
Perform following operational check of
hook-latch door-latching system. If malfunc
tion is noted, refer to Table 201 for trouble
shooting and repair information.
(1). Check inside and outside door handle at
all positions for function. From open
and lock positions door handle should
spring back to rest position when
released.
(2). Move handle to open position. Ensure
all four latch hooks are fully extended
from their latch blocks.
MAINTENANCE MANUAL
CSP-HMI-2
INSIDE HANDLE UNLATCH

ACTION POSITION
OUTSIDE HANDLE SAFELOCK
ACTION POSITION
INSIDE HANDLE
TUBING
OUTSIDE HANDLE SAFE

LOCKED POSITION
OUTSIDE HANDLE
INSIDE HANDLE LATCHED

REST POSITION (NOTE 2)
DOOR FRAME STRUCTURE

CHANNEL STRIP
LATCH COVER
OUTSIDE HANDLE LATCHED
REST POSITION (NOTE 2)
INSIDE HANDLE
SAFELOCKED POSITION
DOOR PANEL
OUTSIDE HANDLE UNLATCH

ACTION POSITION
HANDLE POSITIONS
(RIGHT DOOR INSIDE VIEW)
SAFELOCK ACTION
LATCH SLIDER
CLEVIS
DOOR FRAME
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
LATCH ENGAGEMENT
(THIRD LATCH INTERIOR
SHOWN FOR CLARITY)
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
STRIKER PLATE.
2. LATCHED REST POSITION APPLIES WITH DOOR
OPEN OR CLOSED.
G52-1003-1
Figure 203. Door Handle Positions and Latch Engagement (Sheet 1 of 3)
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MAINTENANCE MANUAL
CSP-HMI-2
MID DOOR ASSY
AFT DOOR ASSY
WINDOW SEAL
VIEW LOOKING DOWN
DOOR
DOOR FRAME
LATCH BLOCK ENGAGEMENT

(TYP)
G52-1003-2

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MAINTENANCE MANUAL
CSP-HMI-2
WITNESS HOLE
PIN
LATCH BLOCK
ASSEMBLY
LATCH
SLIDER
LATCH
HOUSING
0.050 INCH (1.27 MM) MAX
GAP BETWEEN DOOR
STRIKER PIN AND HOOK
LATCH WHEN DOOR
CLOSED AND LATCH IN
REST POSITION.
LATCH
SLIDER
G52-1003-3A

(3). Check latch blocks, latch sliders, door
waffle and striker pin assemblies for
any nicks, dents, scratches, chipped
paint or other evidence of contact
caused by misalignment of door latches
or striker pin assemblies.
NOTE: Extreme temperatures may cause door

seal to swell or door seal-to-door frame
bonding failure. Door seal protrusions
caused by swelling or bonding failure may
interfere with latching function.
(4). Check door seal and repair as required.
(5). Close door firmly from inside helicopter.
Check that all four latch hooks engage
their striker pins and that there is not
more than 0.050 inch (1.27 mm)
between each hook and striker pin.
(6). Move handle to lock (full down). With
door locked, use flashlight to check
witness hole on each latch block. Note
that semi-circle cutout on latch slider is

fully seated around pin on latch block.
(7). Move handle to open. Note that all four
latch hooks extend fully from their
latch blocks and fully disengage their
striker pins, allowing the door to open.
Handle should spring back to rest
position when released.
15. Autolatching Pilot and Cargo Doors
Operational Check
NOTE: When opening door, apply light inward

force on door. This reduces wear of latching
mechanism by overcoming door seal pres
sure.
(1). Open and close door to check for smooth
operation of handles and latch mecha
nism. Check operation of door stop.
(2). Close door from inside. Check all inside
latches for correct engagement at latch
and safelock positions of interior and
exterior handle. (Ref. Figure 203).
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MAINTENANCE MANUAL
CSP-HMI-2
(3). Check that setting interior and exterior

handles to safelock position pulls door
inward for proper closure and sealing.
(4). Check that key locks and unlocks door
handle.
16. DoorLatching Mechanism Inspection (All
Systems)
Make following checks with magnification
glass and strong light:
Item
CM219
CM717
18. Window Replacement

A. Early Style Window Replacement
(Ref. Figure 205) For repair of plastics refer to
FAA AC 43.13-1B. Replace window as follows:
(1). All parts for excessive wear, nicks,

cracks and corrosion.
(2). Threaded parts for worn, crossed or
otherwise damaged threads.
(3). Early latch block assemblies for broken
springs and wear on strike contact
surfaces of latching bolts; and for undue
wear of latch sliders, bolts and bolt
rollers. Current latch block assemblies
for wear, damage or distortion of latch
sliders and latch hook.
(4). Cam lock for jamming when key is
operated.
(5). Link for wear or distortion.
(6). Handles for distortion, worn pivot holes
and worn finish.
(7). Escutcheon and handle for looseness,
distortion, thread damage and break
age.
(8). Lockplate assembly for wear, distortion,
thread damage and breakage.
(9). Latch block nutplates for thread
damage and loose rivets.
(10). Rods and clevis for wear in clevis pin
holes, thread damage, and distortion.
17. AntiChafing Tape on Door Frame Repair
(Ref. Figure 208) Inspect condition of antichafing tape installed on pilot's and cargo
compartment door frames. For minor repair,
remove defective tape where necessary. Clean
frame surface with MEK (CM219). Replace
with polyurethane pressure-sensitive tape
(CM717).
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Nomenclature
Methyl-ethyl-ketone
Item
CM415
CM418
CM425
CM432
CM433
CM717
Nomenclature
Cement
Cement, epoxy
Sealing compound
Dichloromethane
Ethylene chloride
(1). Remove snapvent from window (Ref.

Snapvent Replacement).
(2). Drill out rivets attaching window
retainers to door structure and remove
window. Remove two screws, washers
and nuts from door hinge doubler.
(3). If door frame or window is to be reused,
carefully scrape off sealant around edge
of door or window frame using a
wooden, plastic or other suitable
nonmetallic scraper.
(4). Repair retainer-to-window bond, if
applicable, with dichloromethane
(CM432) or ethylene chloride (CM433);
or use PS-18 or S147 cement (CM415).
(5). Trim retainer as required to provide
clearance for door handle and end butt
joint.
(6). Place window in position and check for
0.380 inch (9.652 mm) minimum
engagement and flush fit with window
frame. Trim excess if required.
(7). Use 1/2 inch (12.70 mm) pressure-sen
sitive tape (CM717) on edge of window.
Bond seals to retainer and to door
MAINTENANCE MANUAL
frame using cement, epoxy (CM418);
bond inside of seals to window using
sealant (CM425). Do not stretch seals
when bonding.
(8). With retainer and window in position
on door frame, press down firmly and
evenly on retainer so that seals are
compressed tightly against window
around full circumference of door
frame.
(9). Locate existing holes in door-reinforc
ing frame. Mark and drill holes in
retainer. It is permissible to install new
rivets between existing holes in rivet
pattern.
(10). Rivet window to door using rivets of
correct length. Blind rivets are used for
retainers riveted to door reinforcing
frame.
(11). Install doubler over retainer at hinge
area with two screws, washers and
nuts. Drill (No. 21 drill) and ream to
0.166 inch (4.216 mm) diameter window
panel for screws, using slow speed drill
(700-800 rpm).
(12). Install snapvent (Ref. Snapvent
Replacement).
(13). Remove protective covering and clean
window (Ref. Sec. 20-20-00).
B. Current Style Window Replacement
(Ref. Figure 206)
(1). Using a blunt plastic spatula or probe,
pull back edge of window seal and
gradually work window out from groove
in seal.
(2). Remove seal and clean for re-installa
tion of window, discard if not pliable.
(3). Mask around new glass for marking.
(4). Place new glass against door and center
over the window opening.
(5). Trace line on glass from window
opening in door.
NOTE: The following step is to ensure the glass

is larger than the door opening so glass will
not blow out in flight.
CSP-HMI-2
(6). Apply 0.250 inch (6.35 mm) tape

around outside of drawn line.
(7). Trim glass to the outside of applied
0.250 inch (6.35 mm) tape.
(8). Remove tape and gently smooth the
edges.
NOTE:
D It is best to have ends of seal on aft side of
window to help keep moisture out while
in flight.
D Ensure seal is firmly worked onto door to
prevent seal from being cut too short.
(9). Install window seal around periphery of
window opening with groove for glass to
the inside. Cut seal to size if new.
(10). Gently trim seal, where needed, around
top door hinges.
Do not use any tools with sharp
edges to aid in installing glass
into seal, glass is easily damaged.
CAUTION
NOTE: To aid in installation of glass into seal,

use a mild mixture of soapy water liberally
applied to the edge of the glass and into
groove in seal. Do not use any lubricants.
(11). Install glass from inside by sliding up
into the seal.
(12). With hands on either side of glass, work
glass firmly into seal.
gradually work edge of window into
groove of window seal.
(14). If there is a gap at the seal ends, use
commercially available clear silicone
seal to fill gap.
19. Hinge Replacement
(Ref. Figure 204)
(1). Remove door and drill out hinge-at
taching rivets.
(2). Install replacement hinges at body
attach points with door hinge pins.
(3). With damaged hinges removed, install
doors in closed position. Have an
assistant retain door in place by
actuating door handle locking levers.
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MAINTENANCE MANUAL
CSP-HMI-2
(4). If required for door fit, use one-piece

solid aluminum alloy shim, up to 0.040
inch (1.016 mm) maximum thickness
trimmed flush with hinge outer edges,
under upper or lower hinge (between
hinge and door exterior).
(5). Mark hinge rivet attach locations
through existing holes in door. Locate
and mark blind rivet attach points
(cargo door only).
(6). Remove door hinges and check for
proper edge distance.
(7). Drill holes with a No. 28 drill at pilot's
door upper and lower hinge aft attach
points. Use a No. 21 drill at all other
pilot and cargo door attach points.
(8). On pilot's door upper hinge, install
rivets with washers under bucked
heads.
(9). Install rivets at remaining pilot's door
attach points.
(10). Install two mechanically-expanding
rivets at aft cargo door hinge attach
points.
(3). Replace preload spring; with longest

flat area outboard and aft in hinge body
recess.
(4). Replace door spring; with longest flat
area also outboard and aft in body
hinge recess.
NOTE: Forward curved area of door hinge pres

ses against preload spring inboard curved
area, at installed position.
(5). Install hinge pins and cotter pins. Pins
may be installed upward if interference
does not permit installation with cotter
pin hole down.
(6). Cover exposed sharp edges of cotter
pins and pins with sealer (CM424).
(7). Install doors and perform operational
check (Ref. Automatic Latching Mecha
nism (Early System) Operational
Check.
SHIM AS REQUIRED
(NOTE)
(11). Install four rivets at remaining attach

points.
(12). Paint as required.
(13). Install doors and perform an operation
al check (Ref. Automatic Latching
Mechanism (Early System) Operational
Check).
A. Preload Spring Replacement
DOOR STRUCTURE
DOOR HINGE HALF

SHIM AS REQUIRED
(NOTE)
(Ref. Figure 205)
Item
Nomenclature
CM424
Sealing compound
NOTE: The following procedures apply to both

upper and lower hinges.
(1). Remove two cotter pins and clevis pins.
(2). Remove door spring first; then remove
preload spring.
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NOTE: SHIM AS REQUIRED UNDER HINGE WITH ONE PIECE

OF 2024-T3 ALUMINUM, 0.050 IN. (1.270 MM) MAXIMUM. TRIM
TO OUTER PERIPHERY OF HINGE.
G52-1004
Figure 204. Door Hinge Replacement
MAINTENANCE MANUAL
WINDOW
CSP-HMI-2
LATCH COVER
(TYPICAL)
FUSELAGE
DOOR FRAME
DOOR SEAL
DOOR SEAL
DOOR PANEL
PILOT'S DOOR
(369D/E/FF - 500/600N)
CARGO DOOR
(369D/E/FF - 500N)
CLEVIS PIN
FUSELAGE STRUCTURE
SHIM
(AS REQUIRED)
(NOTE)
HINGE PIN
PRELOAD
SPRING
DOOR
SPRING
DOOR HINGE
DOUBLER
RETAINER
RIVET
PRESSURE
SENSITIVE TAPE
WINDOW
HINGE
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
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MAINTENANCE MANUAL
CSP-HMI-2
SEAL
SEAL
0.25 IN.
(6.35 MM)
I
N
B
R
D
WINDOW
O
U
T
B
R
D
DOOR FRAME
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
damaged or partially separated. Remove door
stops by carefully prying bonded rubber out of
hinge recess. Bond new stop to forward end of
hinge recess with adhesive (CM411).
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52-10-00
Item
Nomenclature
CM411
Adhesive, epoxy
MAINTENANCE MANUAL
CSP-HMI-2
20. Automatic Latch Block Assembly Repair
(2). Replace antichafing tape if damaged.
(Ref. Figure 201 and Figure 207, Sheet 1 of 2)

Replace worn or damaged parts as necessary.
Disassemble only to extent required for
replacement of parts. Perform following steps
as required:
(3). Install washer (if applicable), shims,

dam (if applicable), strike pin and
secure with screws.
Item
Nomenclature
CM108
CM118
CM234
CM307
Graphite, powdered
Grease
Lacquer, acrylic semi-gloss
22. Litter Door Inspection (50 Hour)

The following is a procedure for inspecting the
litter door installation for proper condition and
security of the quick-release fastener assem
blies and the rubber seal (gasket) installed
between the window glass and door frame. The
visual inspection is applicable to the PN
369H92733-1 / -2 bubble window assemblies
(or PN 369H92731-1 / -2 flat window assem
blies, if installed) in the PN 369H90085 litter
door installation.
(1). Lubricate all moving parts except lock,

with grease (CM118) to prevent
binding.
(1). Remove quick-release fasteners

securing bubble (or flat) windows to
litter doors.
(2). Lubricate lock with powdered graphite

(CM108).
(2). Visually inspect each fastener for

condition, and each anchor receptacle in
door structure for condition and
(3). At time of disassembly clean reusable

parts except locks, using soft bristle
brush dipped in solvent (CM234).
(4). Dry parts using clean, lint-free cloth or
dry compressed air at 20 psi maximum.
(5). Clean key-operated cam locks, using
dry compressed air at 20 psi maximum.
(6). Touchup handles with semigloss black
acrylic lacquer (CM307).
(7). Eliminate binding by lubricating
moving parts.
21. Strike Pin Repair
(Ref. Figure 207)
NOTE: The 369 model has three different con

figurations. Select the configuration that
pertains to your specific application.
(1). Remove screws, strike pin, dam (if
applicable), shim and washers (if
applicable) from door frame.
(a). Replace each fastener if stud is loose

or worn.
(b). Replace anchor receptacle and/or
rivets as required.
(3). Visually inspect rubber seal (gasket) on
window assemblies for condition. Seal
must be fully intact; rebond seal to door
structure as required.
(a). Replace seal if worn, cracked or hard.
(4). Reinstall window assemblies to litter
doors using quick-release fasteners.
(5). Check for gaps between window glass,
rubber seal and door structure.
(6). Replace seal and/or use shorter length
studs if any gap is noted.
(7). If seal is extruded, use longer length
studs; replace seal if extrusion still
exists.
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MAINTENANCE MANUAL
CSP-HMI-2
LATCH HOOK
CONNECTOR ROD
LATCH
BLOCK
CONNECTOR ROD
CONNECTOR ROD
CLEVIS
LATCH SLIDE
NOTE
LATCH
BLOCK
MOUNTING
BRACKET
LATCH BLOCK
STRIKER ASSEMBLY
LATCH
BLOCK
LATCH
HOOK
HANDLE
ASSEMBLY
DOOR FRAME
LATCH
BLOCK
CONNECTOR ROD
LATCH
HOOK
CLEVIS
LATCH BLOCK ASSEMBLY
NOTE:
1. SPRING USED WITH EARLY SYSTEMS ONLY.
SOLID ROD USED ON CURRENT SYSTEM.
CONNECTOR
ROD
HANDLE
ASSEMBLY
LATCH
BLOCK
LATCH
HOOK
CURRENT SYSTEM
CONFIGURATION
G52-1005-1A
Figure 207. Automatic Latch Block and Striker Repairs (Sheet 1 of 2)

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MAINTENANCE MANUAL
CSP-HMI-2
DOOR FRAME
(CARGO DOOR
FRAME SHOWN)
RIVNUT
ANTI-CHAFING TAPE
SHIM
WASHER
SCREW
SCREW
SHIM
STRIKER
DOOR FRAME
SCREW
STRIKER PIN
SCREW
SHIM
SCREW
RIVNUT
DOOR FRAME
WASHER
STRIKER PIN
NUTPLATE
RIVET
WASHER
RIVET
NUTPLATE
G52-1005-2A
Figure 207. Automatic Latch Block and Striker Repairs (Sheet 2 of 2)
52-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
UPPER LATCHES
3.50 INCH
(8.89 CM)
3.50 INCH (8.89 CM)

8.00 INCH (20.32 CM) BLENDED FROM 0.12 INCH (3.05 MM)
DIMENSION TO EDGE OF DOOR (2 PLACES)
0.12 INCH (3.05 MM)
8.00 INCH
(20.32 CM)
SEAL
A
0.12 INCH (3.05 MM)
0.25 INCH (6.35 MM)
8.00 INCH (20.32 CM)

SEAL
(FLUSH WITH
EDGE OF DOOR
AT BOTTOM)
0.12 INCH (3.05 MM)
A
B
0.12 INCH
(3.05 MM)
0.35 INCH
(8.89 MM)
PILOT'S DOOR
(LEFT DOOR SHOWN)
(NOTE 1)
FINGER TYPE SEAL
(NOTE 2, 3)
SEAL
SECTION
A-A
DOOR REINFORCING
FRAME
(NOTE 1)
0.12 INCH
(3.05 MM)
A
SEAL (FLUSH WITH
EDGE OF DOOR AT
BOTTOM)
CARGO DOOR
(LEFT DOOR SHOWN)
0.025 INCH
(6.35 MM)
(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.
Figure 208. Door Seal Repair

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52-10-00
G52-1000A
MAINTENANCE MANUAL
23. Pilot and Cargo Door Repair
A. Seal Repair
(Ref. Figure 208)
Item
Nomenclature
CM418
Cement, epoxy

seal.
(2). Restore chemical film protection to any
base metal exposed during cleaning
process (Ref. Sec. 20-20-00).
(3). Clean seal contact area on metal and
rubber seal.
(4). Carefully align and bond seal to
mounting surface with cement, epoxy
(CM418) according to container instruc
tions.
NOTE: Correct seal mounting position results

in an approximately 0.060 inch (1.52 mm)
interference fit between door seal and bum
per.
B. PartiallySeparated Seal Repair
(Ref. Figure 208)
Item
Nomenclature
CM220
Naphtha aliphatic
CM418
Cement, epoxy
(1). Clean separated area with naphtha

(CM220) and allow to dry for minimum
of 20 minutes.
(2). Apply one uniform brush coat of
cement, epoxy (CM418) to rubber seal
and mating surface contact area. Allow
to dry for 5 minutes and press mating
surfaces together.
CSP-HMI-2
24. Improved Door Seal Installation

installation of QGR2178 door seals on the
cargo/passenger doors.
Item
CM220
CM235
CM322
CM414
CM439
Nomenclature
Naphtha aliphatic
Cleaner
Primer, Silicone, Red
Adhesive, cyanoacrylic / Accelerator
Adhesive
(1). Remove existing door seals using

Desoclean 45 (CM235) or naphtha
aliphatic (CM220). Ensure that all
surfaces are clean to allow proper
adhesion of new seal material. Allow
surface to air-dry a minimum of 15
minutes.
NOTE:
D On the 369D/E/FF - 500N helicopters,
seals are to be installed around the entire
circumference of the aft doors.
D On the 600N helicopters, seals are to be
installed around the entire circumference
of the mid doors. Seals are to the applied
to the top, bottom and aft edges of the
aft-cabin doors.
(2). Prime seal faying surface with red
silicone primer (CM321) and allow to
air-dry a minimum of 15 minutes.
(3). Apply a thin uniform coat of adhesive
(CM439) to faying surface of door and
seal. Allow to air-dry a minimum of
five minutes.
(4). Apply a second thin uniform coat of
adhesive to faying surface of door and
seal. Allow to air-dry a minimum of
five minutes.
(5). Test glue with clean knuckle. If adhe
sive does not transfer to knuckle, press
the seal into place.
(6). Butt joints at forward and aft lower
locations.
(7). Maximum gap of 0.030 inch (0.762 mm)
at butt joints.
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CSP-HMI-2
MAINTENANCE MANUAL
NOTE: Use glue very sparingly to achieve best
(8). Miter joints at upper locations.
bond.
(9). Bond mitered joints with adhesive

(CM414).
(10). Trim seal flush with edge of door.
QGR2178 SEAL
TRIM SEAL FLUSH WITH

EDGE OF DOOR.
SEAL MAY BE LOCATED FROM

EDGE TO INCLINE AS SHOWN
AND AS REQUIRED TO ENSURE
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.
Figure 209. Improved Door Seal Installation
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88-759
MAINTENANCE MANUAL
CSP-HMI-2
Section
524000
Engine Access
Doors
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE ACCESS DOORS

1. Engine Access Door General
3. Engine Access Door Inspection
(Ref. Figure 201) Engine access doors have

upper and lower door hinges that allow door fit
adjustment. Fore and aft adjustment and fit of
doors is made possible by slotted holes in
hinges and serrated mating surfaces between
hinges and doors. Lateral adjustment is
obtained with laminated shims under door
hinges. Closed-door alignment is provided by
spring-type retainers on door frames at the
lower latch, and two locating pins that engage
holes in lower fuselage structure.
(1). Check door hinges, door-attaching

hardware and latches for looseness,
cracks and damage.
2. Engine Access Door Replacement
(4). For repairs (Ref. Engine Access Doors

Repairs).
A. Engine Access Door Removal

(1). Release three latches to open access
doors. Index mark hinge, shim and
serrated plate to door structure.
Remove three engine access door hinge
attachment screws with washers.
Forward screws are attached with nuts
and aft screws attach to rivnuts.
(2). For inspection (Ref. Engine Access Door
Inspection).
(2). Check outside edge of door for security

of bonding between outer and inner
skin. Any separation requires repair.
(3). Inspect doors for corrosion, distortion,
breaks or cracks and condition of
abrasion strip tape along upper inside
door edge and under retainers.
4. Engine Access Door Repair

A. Sheet Metal Repair
(Ref. CSP-SRM-6, Structural Repair Manual)
Abrasion strip tape along upper inside door edge
and on area that mates with retainers must be
replaced when worn.
B. Abrasion Strip Replacement
B. Engine Access Door Installation

Item
Item
Nomenclature
CM425 Sealing compound
(1). Position door and temporarily install

shim, serrated plate and attachment
hardware.
(2). Align indexing marks on shim, serrated
plate and hinge with those on door and
then tighten screws.
(3). Close and latch doors and check for
firm fit with no deflections.
(4). Apply sealing compound (CM425) to all
cotter pins.
(5). For adjustment (Ref. Engine Access
Door Adjustment).
Nomenclature
CM220 Naphtha aliphatic

CM710 Tape, high temperature
CM717 Tape, pressure sensitive
(1). Replace worn abrasion strip tape along

upper inside door edge by cleaning
contact area with naphtha (CM220);
allow to air-dry a minimum of 30
minutes. Install 0.50 x 40.0 inch (1.27 x
101.60 cm) strip of polyurethane tape
(CM717) to clean, dry surface. Apply
hand pressure to ensure firm contact
and trim as required.
(2). Replace worn abrasion strip on area
that mates with retainers by cleaning
retainers with naphtha (CM220).
Install high temperature tape (CM710)
to clean, dry surface. Apply hand
pressure to ensure firm contact. Trim as
required.
52-40-00
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MAINTENANCE MANUAL
CSP-HMI-2
C. Hinge Replacement
Replace door hinges as follows:
Item
Nomenclature
CM318 Primer
(1). Remove door from fuselage structure

(Ref. Engine Access Door Removal).
(2). Remove nut, washers and hinge pivot
screw.
(3). Carefully press out hinge pivot point
spacer and separate hinge halves.
Retain two nylon washers.
(4). Carefully drill out rivets that secure
defective hinge half to fuselage struc
ture.
(5). Transfer existing hole pattern in
fuselage structure to replacement
fuselage hinge half and drill out holes.
Install hinge and shim on fuselage
structure and secure with replacement
rivets.
(6). Assemble hinge halves with nylon
washers as shown. Press steel pivot
spacer coated with primer (CM318)
through mating holes. Install pivot
screw with washer and nut.
NOTE: Install shims under door hinge to obtain

firm fit without binding at door-to-fuselage
contact surfaces when door is closed. Use
slotted holes in hinge and serrated surfaces
to obtain forward and aft adjustment. When
adjustments are complete, tighten screws
that secure hinge to access door.
(7). Refinish repaired area (Ref. Sec.
20-30-00).
D. Catch/Latch Hook Replacement
Replace defective catches or latch hooks as
follows:
Page 202
Revision 18
52-40-00
(1). Carefully drill out rivets and remove

defective latch hook or catch from
engine access door or fuselage structure
Replace defective stops or serrated
adjustment plates, if required, by
drilling out attaching rivets.
(2). Locate existing rivet holes and install
replacement latch, catch, door stop or
adjustment plate. Secure with replace
ment rivets.
(3). Adjust latches as required for proper
tension of latch lever to catch without
deflecting door (Ref. Engine Access
Door Adjustment).
(4). Refinish area (except latch lever
assembly) as required (Ref. Sec.
20-30-00).
5. Engine Access Door Adjustment
Door alignment is provided by means of
spring-type retainers riveted in door frames
adjacent to lower latch.
Item
Nomenclature
CM702 Lockwire CRES
(1). Remove lockwire from threaded

(adjustment) end of hooks.
(2). Loosen all hooks until spring type
retainers engage in light contact with
no door deflection when hooks are
latched.
(3). Unlatch doors and tighten all hooks
four to five turns. Check door latching
and make additional minor adjust
ments as required.
(4). Install lockwire (CM702) in hook
threaded end in a manner to allow
latching and unlatching without
interference.
MAINTENANCE MANUAL
CSP-HMI-2
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
Figure 201. Engine Access Doors (Sheet 1 of 3)
52-40-00
Page 203
Revision 18
MAINTENANCE MANUAL
CSP-HMI-2
CATCH
HOOK
LEVER
C30/C47 FAIRING
RETAINER
ABRASION
STRIP
RETAINER
CATCH
LEVER
C20/C20R2 FAIRING
AFT LOWER LOCKING ASSEMBLY
G5240002A

Page 204
Revision 18
52-40-00
MAINTENANCE MANUAL
CSP-HMI-2
FUSELAGE STRUCTURE
FORWARD HALF
RIVNUT
STEEL SPACER
PLATE
NYLON WASHERS
SHIM
AFT HALF
LOWER HINGE
FUSELAGE STRUCTURE
SHIM
STEEL SPACER
FORWARD HALF
SHIM
PLATE
AFT HALF
NYLON WASHERS
UPPER HINGE
52-40-00
Page 205
Revision 18
CSP-HMI-2
MAINTENANCE MANUAL
Page 206
Revision 44
52-40-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
525000
Miscellaneous
Access Doors
MAINTENANCE MANUAL
CSP-HMI-2
MISCELLANEOUS ACCESS DOORS

1. Access and Inspection Provisions
Any time maintenance work is
to be performed near engine air
and engine cooling air inlets, use care to pre
vent entry of foreign objects that might later
be sucked into compressor or cooling air
blower. Tape covers of cardboard or other
suitable material in place over engine cool
ing air screens. Covers should not be re
moved until work is completed and debris is
thoroughly cleaned out of the area.
CAUTION
Removable access doors and covers are

provided in the helicopter for servicing,
inspection, removal, installation and adjust
ment of components.
Locations of access and inspections provisions
are shown in Figure 201 for 369D/E/FF,
Figure 202 for 500N and Figure 203 for 600N
helicopters.
Areas, components and items accessible
through locations shown in the figures are in
Table 201. Screws are used to secure access
doors in stress areas.
Liquid level sight gages allow inspection of
lubricant levels for main transmission, engine
oil tank and tail rotor transmission (369
D/E/FF) or fan transmission (500/600N).
obvious for most doors and covers.
For information on access doors and covers
that are also used for interior trim, Refer to
Sections 25-30-00 and 25-40-00.
2. General Access Doors Inspection
(1). Check door hinges, door-attaching
hardware and latches for looseness,
cracks and damage.
(2). Check outside edge of door for security
of bonding between outer and inner
skin. Any separation requires repair,
refer to Structural Repair Manual.
(3). Inspect doors for corrosion, distortion,

breaks and cracks.
3. Pilot Compartment Floor Access Doors
Each of the two pilot's compartment floor
access doors are formed by two hinged panels,
hinged at the forward edge to the pilot's
compartment floor.
A latch at the rear, secures each door in place.
Two stainless steel heel strips are hinged and
held in place over each door by a spring.
NOTE: Remove heel strips for better access.

Detach springs from clips on underside of
strips. Remove hinge pins attaching forward
ends of strips to natatorium pedal mounting
bracket.
4. Pilot Compartment Floor Access Door
Replacement
A. Pilot Compartment Floor Access Door
Removal
(1). Remove floor access doors by releasing
latch at rear of door.
(2). Raise and hold up rear of heel strips for
access to hinge pins at forward end of
door.
(3). Remove hinge pin securing forward
edge of door to pilot's compartment floor
and remove door.
B. Pilot Compartment Floor Access Door
Installation
(1). Position door and secure forward edge
to floor using hinge pin.
(2). If removed, heel strips are reinstalled
by inserting hinge pins through
brackets on forward end of strip and
anti-torque pedal mounting bracket
and connecting springs to clips on
underside of heel strips.
52-50-00
Page 201
Revision 18
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Access and Inspection Provisions Information

Door, Cover or Access Provision
Provides Access To
Air inlet forward fairings
Main rotor mixer controls, main rotor mast base and supporting
structure.
Collective stick cover
Aft end of collective stick and associated electrical wiring.
Wiring cover
Electrical wiring at seat structure and auxiliary power receptacle.
Pilots seat cover or inboard collective

pitch stick cover
Underseat controls for engine and flight control systems.
Plenum chamber access door (air inlet Interior of engine air inlet aft fairing.
bypass door)
Tail rotor drive shaft access door
Tail rotor drive shaft and interior of air inlet forward fairing.
Pilots compartment floor access door
Left door battery.

Right door optional avionics equipment and controls linkage.
Aft bulkhead access covers
Right side oil tank, oil cooler and oil system drain valve.
Left side components of optional cabin heating installation and main
transmission oil cooler.
Footwell fairing
Forward landing gear struts and dampers, controls of engine and flight
control systems and electrical wiring. Outboard windows allow
inspections of forward landing gear dampers.
Control access door (1)
Lower end of tunnelrouted flight control rods and other control

components in underseat area.
Fuel vent cover
Fuel cells vent system crossover fitting.
Tail rotor control bellcrank access

fitting
Bellcrank connecting tail rotor control rod to tailboom control rod.
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

engine cooling air inlet screen)
Forward end of tail rotor drive shaft and limited access to aft end of
main transmission.
Instrument panel lower section front

panel
Electrical and avionics wiring at lower forward area of instrument panel.
Page 202
Revision 18
52-50-00
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Access and Inspection Provisions Information

Door, Cover or Access Provision
Instrument panel lower section side
panels
Provides Access To
Wiring, tubing, fuel shutoff control cable, and antitorque control torque
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

transmission trim panel (Ref. Sec.
2500)
Sight gage to check main transmission oil level. Chip detectors and
main transmission drain valve.
Blower access door
Main transmission, air cooler blower, and engineto transmission drive

shaft.
Instrument panel fairings
Avionics, gages and electrical wiring.
Engine oil filter access panel
Gain access for replacement of engine oil filter. (369FF 600N)
Access Provisions Unique to 500/600N

Air inlet forward fairings
Main rotor mixer controls, main rotor mast base and supporting
structure.
Antitorque splitter assembly, forward, intermediate and aft control
tube.
Engine plenum access fairing
Inner area of air inlet aft fairing.
Fan inlet screen
Fan blades and fan/gearbox access cover.
Fan gearbox access cover
Fan gearbox and forward driveshaft.
Driveshaft door
Forward driveshaft rear coupling.
Pressure relief screens
Fan gearbox oil level sight gauge (L/H side).
Tailboom fairing (1)
Tailboom attach bolts.

Antitorque control cable quick disconnect and electrical connectors.
Horizontal stabilizer end plates (1)
Vertical stabilator controls and YSAS actuator (R/H side).
Horizontal stabilizer access panel (1)
Vertical stabilator controls.
Thruster fairing
Rotating thruster attachment.
Access Provisions Unique to 600N

Forward floor access covers
Fuel cell components.
Engine air bypass door
Interior of engine.
NOTE:
(1) Items are stressed and must be installed prior to helicopter flight.
52-50-00
Page 203
Revision 18
MAINTENANCE MANUAL
CSP-HMI-2
# $ TAILBOOM MOUNTING
BOLTS ACCESS DOORS
PLENUM ACCESS
COVER
# AIR INLET FORWARD

FAIRING
# TAIL ROTOR CONTROL

BELLCRANK ACCESS COVER
# * ENGINE OIL FILTER
ACCESS DOOR
CONTROLS TUNNEL
COVER
# $ TAIL ROTOR DRIVE ACCESS

HOLE (UNDER ENGINE COOLING
AIR INLET SCREEN)
# $ BLOWER ACCESS DOOR
# COLLECTIVE STICK COVER

INSTRUMENT PANEL
FAIRING-LEFT SIDE
# WIRING COVER
# 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
Revision 18
52-50-00
MAINTENANCE MANUAL
CSP-HMI-2
# $ * CONTROLS
ACCESS DOOR
# FOOTWELL
FAIRING
INSTRUMENT PANEL
FAIRING-RIGHT SIDE
TAIL ROTOR DRIVE

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
ENGINE ACCESS
DOORS
# AFT BULKHEAD
ACCESS COVER
# * FUEL CELL
ACCESS DOOR
# * FUEL CELL
ACCESS DOOR
# FOOTWELL FAIRING
# AFT BULKHEAD
ACCESS COVER
# FUEL VENT COVER
CARGO HOOK COVER

(FUSELAGE UNDERSIDE)
INSTRUMENT
PANEL FAIRING

SECTION SIDE PANEL

SECTION FRONT PANEL
G52-5000-2A
52-50-00
Page 205
Revision 18
MAINTENANCE MANUAL
CSP-HMI-2
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

STICK COVER (500MD)
SUPPORT TUBE
CLAMP
SUPPORT TUBE
ASSEMBLY
LOWER CURTAIN
UPPER
CURTAIN
CURTAIN STOP
SLIDER
FASTENER
BUTTON
COTTER PIN
FASTENER STUD
EXPLODED VIEW (ROTATED)
G52-5000-3A
Page 206
Revision 18
52-50-00
MAINTENANCE MANUAL
CSP-HMI-2
# $ HORIZONTAL STABILIZER
ACCESS PANEL
# $ FAN INLET
SCREEN
# ENGINE PLENUM
ACCESS FAIRING
END PLATE (2 PLCS)
# AIR INLET
FORWARD FAIRINGS
# $ TAILBOOM FAIRING
PRESSURE RELIEF SCREEN
(2 PLCS)
# CONTROL
ACCESS
COVER
# $ BLOWER ACCESS COVER
# COLLECTIVE STICK COVER

# WIRING COVER
INSTRUMENT PANEL
FAIRING - LEFT SIDE
# TRIM MOTOR
ACCESS PANEL
SECTION SIDE PANEL
CAUTION:
NOTES:
G52-5001-1B
Figure 202. Access and Inspection Provisions and Locations (500N) (Sheet 1 of 2)
52-50-00
Page 207
Revision 31
MAINTENANCE MANUAL
CSP-HMI-2
# FOOTWELL
FAIRING
# $ CONTROLS
ACCESS DOOR
INSTRUMENT PANEL
FAIRING - RIGHT SIDE
INLET ACCESS PANEL
ENGINE PLENUM
BYPASS DOOR
# FAN GEARBOX
ACCESS COVER
SECTION SIDE PANEL
PRESSURE
RELIEF SCREEN

SECTION FRONT PANEL
# $ TAILBOOM
FAIRING
PILOT'S COMPARTMENT
FLOOR ACCESS DOOR
ENGINE ACCESS
DOORS
# * FUEL CELL
ACCESS COVER
# AFT BULKHEAD
ACCESS COVER
# AFT BULKHEAD
ACCESS COVER
# FOOTWELL FAIRING
# * FUEL CELL # FUEL VENT COVER

ACCESS COVER
CARGO HOOK COVER
(FUSELAGE UNDERSIDE)
G52-5001-2A
Figure 202. Access and Inspection Provisions and Locations (500N) (Sheet 2 of 2)
Page 208
Revision 18
52-50-00
MAINTENANCE MANUAL
CSP-HMI-2
# CONTROL AC
CESS COVER
# COLLECTIVE
STICK COVER
# WIRING COVER
ACCESS PANEL
INSTRUMENT PANEL
FAIRING-LEFT SIDE
# INSTRUMENT PAN
EL LOWER SECTION
SIDE PANEL
# $ TRIM MOTOR
ACCESS PANEL
# $ FAN INLET SCREEN

# ENGINE PLENUM
ACCESS FAIRING
END PLATE (2 PL)
# $ TAILBOOM FAIRING
BYPASS DOOR ASSY
PRESSURE RELIEF
SCREEN (2 PL)
# $ CONTROLS FAIRING
# * ENGINE OIL FILTER

ACCESS DOOR
# $ BLOWER ACCESS COVER
* FUEL CELL AC
CESS COVER
INSTRUMENT PANEL
FAIRING-RIGHT SIDE
# FOOTWELL
FAIRING
PILOT'S COMPARTMENT
FLOOR ACCESS DOOR
# $ CONTROLS
ACCESS DOOR
# FAN GEAR
BOX ACCESS
COVER
# FOOTWELL
FAIRING
CAUTION:
NOTES:
# FUEL VENT
COVER
# AFT BULKHEAD
ACCESS COVER
6G52-096
Figure 203. Access and Inspection Provisions and Locations (600N)
52-50-00
Page 209
Revision 18
MAINTENANCE MANUAL
CSP-HMI-2
FLOOR ACCESS COVERS

(4 PL)
BYPASS DOOR ASSY
6G52-089A
Figure 204. Floor Access Covers and Engine Bypass Door (600N)
Page 210
Revision 18
52-50-00
MAINTENANCE MANUAL
Chapter
53
Fuselage
CSP-HMI-2
MAINTENANCE MANUAL
CSPHMI2
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 201. Negligible Damage Inspection - Fuselage . . . . . . . . . . . . . . . . . . . . . . .
Figure 201. Fuselage - Major Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 202. Fuselage - Model 600N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201
202
203
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7.
Water Leak Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8.
Geon Strips Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 201. Negligible Damage of Canopy/Windshield . . . . . . . . . . . . . . . . . . . . . . .
Figure 201. (Round Nose) Windshields and Aft Section Windows . . . . . . . . . . . . .
Figure 202. (Extended Nose) Windshield and Aft Section Windows . . . . . . . . . . .
Figure 203. Windshield Installation (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 204. (Extended Nose) Windshields and Aft Section Windows
(New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202
202
203
204
205
206
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
53 Contents
Page i
Revision 44
CSPHMI2
MAINTENANCE MANUAL

Para/Figure/Table
4.
Title
Page
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
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 . . . . . .
Figure 204. Forward Fuselage Section Structure Rework . . . . . . . . . . . . . . . . . . .
Figure 205. Installation of Air Baffle, Seal and Cover Assemblies
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
209
210
211
212
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
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Title
Page
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
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. Forward Upper Longeron Inspection (L137, R137) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 204. Inspection Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
12. Control Tunnel (FS 78.50) Beam Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
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
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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
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
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Para/Figure/Table
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53-50-10 Stabilizer (T-Tail) (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1.
Stabilizer - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

A. Stabilizer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.
Horizontal Stabilizer and Tip Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

A. Horizontal Stabilizer and Tip Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Horizontal Stabilizer and Tip Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.
Vertical Stabilizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

A. Vertical Stabilizer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Vertical Stabilizer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.
Horizontal Stabilizer and Tip Plate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.
Vertical Stabilizer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Figure 201. Stabilizer T-Tail Removal and Installation . . . . . . . . . . . . . . . . . . . . . 203
6.
Horizontal Stabilizer and Tip Plate Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
7.
Vertical Stabilizer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8.
Angle of Incidence Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Table 201. Horizontal Stabilizer Angle of Incidence . . . . . . . . . . . . . . . . . . . . . . . . . 204
9.
Angle of Incidence Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10. Horizontal Stabilizer Tab Weight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 202. Troubleshooting Tailboom and Tail Surfaces . . . . . . . . . . . . . . . . . . . . .
Figure 202. Horizontal Stabilizer Incidence Angle Measuring Tool . . . . . . . . . . .
Figure 203. Establishing Horizontal Stabilizer Angle of Incidence . . . . . . . . . . . .
Figure 204. Sealing - Vertical Stabilizer (0003D - 0286D) . . . . . . . . . . . . . . . . . .
205
205
206
206
207
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
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4.
Title
Page
Horizontal Stabilizer Eye Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

A. Horizontal Stabilizer Eye Bolt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Horizontal Stabilizer Eye Bolt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5.
Horizontal/Vertical Stabilizer Control Tube and Bellcrank Replacement . . . . . . . . 205

A. Horizontal/Vertical Stabilizer Control Tube and Bellcrank Removal . . . . . . . . . . 205
B. Horizontal/Vertical Stabilizer Control Tube and Bellcrank Installation . . . . . . . 205
6.
Vertical Stabilizer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7.
Vertical Stabilizer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8.
Horizontal Stabilizer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9.
Vertical Stabilizer Torque Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

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
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CSP-HMI-2
Section
530000
Fuselage
MAINTENANCE MANUAL
CSP-HMI-2
FUSELAGE
1. Fuselage General
(Ref. Figure 201) The helicopter fuselage
consists of three major structural sections; the
forward, lower and aft fuselage sections. For
classification and definition of types of
negligible damage, and for guidelines defining
extent of damage requiring repair or replace
ment, (Ref. Stressed Sheet Metal Panels,
Non-Stressed Sheet Metal Panels and
Table 201).
(Ref. Figure 202) The fuselage of the 600N
helicopter is a stretched version of the 500N
Series helicopter with numerous upgrades and
improvements. (shaded areas indicate new
sections to fuselage) The longer cabin area of
the 600N greatly increases passenger and/or
cargo carrying capacity. Upper deck area
fairings and covers were added or modified to
accommodate control surfaces or air inlet
passages.
The tailboom on the 600N helicopter is
essentially the same as the 500N Series, only
longer. The vertical stabilizers or endplates are
longer than on the 500N model, providing an
increased control surface area.
An extended passenger step alongside the
passenger/cargo compartment allows for easy
entrance and exit through either mid or aft
cabin doors.
2. Stressed Sheet Metal Panels
Stressed sheet metal panels consist primarily
of helicopter fuselage skins and bulkhead
webs. The most-highly-stressed skin sections

are those that form the cylindrically-tapered
tailboom assembly (Ref. Sec. 53-40).
NOTE: No damage can be considered negligi

ble. All damage shall be repaired upon de
tection.
3. Stressed Sheet Metal Panel Inspection
Cracks, tears or punctures in stressed sheet
metal panels that do not exceed 0.20 inch (5.08
mm) diameter and can be removed by drilling
out with 1/4 inch (6.35 mm) or smaller
diameter drill do not require structural
doublers. If cracks, tears or punctures exceed
0.20 inch (5.08 mm) diameter, they are to be
repaired or the panel must be replaced per
instructions in FAA AC 43.13-1B and FAA AC
43.13-2B Inspection and Repair for Standard
Sheet Metal Repair and Alterations and
Structural Repair Manual.
4. NonStressed Sheet Metal Panels
Non-stressed sheet metal members consist
primarily of hinged covers and doors, except
fuel cell access and controls access doors,
which are stressed (Ref. Stressed Sheet Metal
Panels).
5. Negligible Damage Inspection
(Ref. Table 201) Panels damaged in excess of
negligible damage limits (Ref. Table 201)
should be repaired, or damaged panel should
be replaced per instructions in FAA AC
43.13-1A & 2A and CSP-SRM-6 (Structural
Repair Manual).
53-00-00
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Table 201. Negligible Damage Inspection Fuselage

Area
*Damage
Maximum
Depth
Maximum Length
or Surface
Remarks
Stressed sheet
metal panels.
No unrepaired damage
allowed.
(For tailboom, Ref. Sec.
5340).
Nonstressed sheet Dents.

metal panels.
Small dents allowed.**
Scratches/nicks.
Minor scratches/nicks
allowed.**
Cracks.
Smaller of 0.250
inch (6.35 mm) or
onefourth panel
width.
Must be one inch or more

from any attachment fitting
and/or panel edge.
Main rotor mast.
allowed (Ref. Figure 201)
Firewalls.
allowed.
Fuselage fittings.
Longitudinal
scratches, dents, and
nicks.
0.010 inch
(0.254 mm)
15% of fitting
length.
After polishing or repair.
Transverse scratches,
dents, and nicks.
0.010 inch
(0.254 mm)
10% of fitting
thickness.
After polishing or repair.
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.
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53-00-00
MAINTENANCE MANUAL
CSP-HMI-2
LOWER FUSELAGE
FORWARD
FUSELAGE
AFT FUSELAGE
Figure 201. Fuselage Major Sections
53-00-00
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Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
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
Revision 20
53-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
531000
Windshields and Aft
Section Windows
MAINTENANCE MANUAL
CSP-HMI-2
WINDSHIELDS AND AFT SECTION WINDOWS

1. Windshields
Center and lower windshield panels are
clearest acrylic (Ref. Figure 201 and
Figure 202). Upper windshield panels are
smoke-grey-tinted cast acrylic. The center
windshield panels are approximately 0.100
inch (2.540 mm) thick.
2. Aft Section Windows
For repair of plastics, Ref. FAA AC 43.13-1B.
Replace aft section window if it is damaged
beyond practical repair, according to applicable
instructions in Structural Repair Manual.
(Ref. Figure 204) On the 600N helicopter the
Aft Section Windows refer to the upper mid
section windows located above the mid
passenger/cargo doors. On the 500 Series
helicopters this area was referred to as the
Aft Section.
3. Aft Section Windows Replacement
(Ref. Figure 204)
A. Aft Section Windows Removal

gradually work edge of window under
flap surface of window seal.
(3). Maintain pressure on window until
entire perimeter of window is under
seal.
(4). Apply an even amount of sealing
compound (CM425) to form a water
tight seal around window seal to
fuselage and from window seal to
window.
4. Windshield Frame Replacement
Item
CM305
CM425
Nomenclature
Lacquer, acrylic
Sealing compound
For older model helicopters with riveted-in

windshields, remove or replace windshield
according to applicable instructions in the
A. NewStyle Windshield Installation
(1). Remove old sealing compound from

around edge of window and window
seal.
(1). Install windshields in place and install

hardware (Ref. Figure 203 and
Figure 204).

pull back flap of window seal and
gradually work window out from under
flap of seal.
(2). After normal installation of windshield,

grind two screws flush with nuts (Ref.
Figure 203).
(3). Remove seal and clean for re-installa

tion of window.
(4). Seal all windshield seams with sealing

compound (CM425).
Item
Nomenclature
CM425
Sealing compound
B. Aft Section Windows Installation

(1). Install window seal around periphery of
window opening in fuselage.
(3). Touch-up with lacquer (CM305).
5. Windshield Inspection
Minor defects or imperfections that do not
impair pilot's critical visibility, or that obvious
ly are not signs of impending structural failure
may be considered as negligible. (For allowable
damage limits, Refer to Table 201.)
6. Windshield Repair
For repair of plastics, Ref. FAA AC 43.13-1B.
Replace windshields if damage beyond
53-10-00
Page 201
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
practical repair, according to applicable

instructions in Structural Repair Manual.
having less than 0.125 inch (3.175 mm)

insertion. Replace parts with debonding
areas over 8 inches (20.32 cm) in
length.
7. Water Leak Prevention
Item
Nomenclature
CM425
Sealing compound
If water leakage through geon strips of the

forward canopy occurs, remove any existing
sealant using a plastic or other non-metallic
scraper which will not scratch the canopy
glass. Apply 0.060 inch (1.524 mm) bead of
sealant (CM425) along gaps between geon
strips. Apply sealant as directed by sealant
manufacturer.
8. Geon Strips Repair
(2). Mask the geon weatherstrip and

windshield on both sides with tape
(CM722).
(3). Wipe all faying surfaces with aliphatic
naphtha (CM220) and dry for a mini
mum of 15 minutes.
(4). For small voids:
(a). Apply adhesive (CM414) to all faying
surfaces using syringe if necessary.
(b). Use light pressure to hold the joint
closed for a minimum of 2 minutes.
(5). For large voids:
Item
Nomenclature
CM220
CM414
CM722
Naphtha aliphatic
Adhesive, cyanoacrylic / Accelerator
Tape, polyethylene
(a). Apply accelerator to the acrylic

transparency and air dry for a
minimum of 2 minutes.
(b). Apply adhesive to the geon weather
strip only.
(c). Apply local pressure to insure
complete contact between adherents
and maintain pressure for a mini
mum of 30 seconds.
Fill voids between geon strips and transparen

cies as follows:
(1). Measure the insertion depth of acrylic
windshield into geon slot, reject parts
(d). Remove tape and remove excess

residue with aliphatic naphtha.
Table 201. Negligible Damage of Canopy/Windshield

Maximum
Depth
Maximum
Length or
Surface Area
Nicks
0.010 inch
(0.254 mm)
0.250 inch
(6.35 mm)
Scratches
0.010 inch
(0.254 mm)
5.000 inch
(12.7 cm)
Area
Canopy and Windshield.
Damage
Spots or stains
Panels (not windshields or
windows).
Punctures
Windshield.
Polarization faults
(distortion)
Page 202
Revision 19
53-10-00
Remarks
One per square foot
only.
If removable by light
polishing.
0.200 inch
(5.08 mm) dia
Small area near edges.
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Negligible Damage of Canopy/Windshield (Cont.)

Damage
Area
Doublers or stiffeners.
Maximum
Depth
Maximum
Length or
Surface Area
Delamination
Grazing around
delamination
Remarks
No more than one area
within each square foot
of windshield.
0.010 inch
(0.254 mm)
UPPER CANOPY WINDSHIELD

(TWO SECTIONS)

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
ROUND-NOSE HELICOPTERS ONLY.
G53-1000
Figure 201. (Round Nose) Windshields and Aft Section Windows
53-10-00
Page 203
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
UPPER CANOPY WINDSHIELD

(TWO SECTIONS)
CENTER CANOPY WINDSHIELD

(TWO SECTIONS)

INDICATOR
LOWER CANOPY WINDSHIELD

(TWO SECTIONS)
CABIN VENTILATION PANEL

(FIBERGLASS)
G53-1001A
Figure 202. (Extended Nose) Windshield and Aft Section Windows
Page 204
Revision 19
53-10-00
MAINTENANCE MANUAL
CSP-HMI-2
SCREW
SCREW
WINDSHIELD
WINDSHIELD
NUT
AFTER
BEFORE
CL FUSELAGE
BL 0.0
NUT
2X ONLY
(SEE NOTE)
STA 75.24
NOTE:
SCREW LENGTH INTERFERES WITH INSTALLATION
OF AIR DUCT INSIDE COCKPIT.
600n6501--010101
6G53-087
Figure 203. Windshield Installation (New Style)
53-10-00
Page 205
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
AFT SECTION WINDOW

(RH SIDE IS TYPICAL)
WINDOW
WINDSHIELDS
(EXTENDED NOSE)
SEALANT
WINDOW SEAL
SEALANT
MID DOOR
FUSELAGE
LOOKING AFT
SCREW
SCREW
RETAINER
WASHER
RETAINER
WASHER
RETAINER
WINDSHIELD
FUSELAGE
WASHER
NUT
WINDSHIELD
WINDSHIELD
WINDOWTOSTRUCTURE INSTALLATION
LOOKING INBD
WASHER
NUT
WINDOWTOWINDOW INSTALLATION
LOOKING AFT
600n6501--010101
6G53-053
Figure 204. (Extended Nose) Windshields and Aft Section Windows (New Style)
Page 206
Revision 19
53-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
532000
Lower Center
Fuselage
MAINTENANCE MANUAL
CSP-HMI-2
LOWER CENTER FUSELAGE

1. Lower Center Fuselage General
(Ref. Figure 201) Lower center fuselage is
those areas below fuselage floor level (WL
13.10) on both sides of the center beam and
between Sta. 78.50 and Sta. 124.00.
(Ref. Figure 202) The Lower Center Fuselage
for the Model 600N helicopter is similar to that
of the 500 Series helicopters except for the
additional stretched or extended fuselage
IplugI station. The extended lower center
fuselage section is located at Sta. 78.50
(designated P. Sta. 0.00 thru 30.00) (Ref.
Section 06-00-00). Additional floor access
covers for the fuel cell are also contained
within this section of fuselage.
(4). Perform repair (Ref. Fuel Tank Support

Skins Repair (Fuel Cells Removed)).
3. Fuel Tank Support Skin Inspection (Fuel
Cells Removed)
(1). Check security of fiberglass skin
attachment to support angles and
brackets.
(2). Inspect anti-abrasion tape for security
of adhesion over rivet heads, all sharp
edges and lap joints.
(3). Negligible damage (Ref. Table 201,
53-00-00).
4. Fuel Tank Support Skins Repair (Fuel
Cells Removed)
2. Lower Center Fuselage Inspection

(1). Ref. FAA AC 43.13-1B Aircraft Inspec
Metal Repair and Structural Repair
Manual for standard sheet metal
repair.
Item
CM711
Nomenclature
(2). Inspect electrical harnesses and wiring

for frayed insulation and grounding
terminals for corrosion.
(1). Repair fuel tank support skins accord

ing to applicable instructions in FAA
AC 43.13-1A & 2A or Structural Repair
Manual.
(3). If cargo floor is bent or punctured,

remove appropriate fuel cell access
cover and inspect fuel cell.
(2). Cover exposed rivet heads with 10 mil

by 1 inch (2.54 cm) tape (CM711) to
prevent chafing fuel cell fabric.
53-20-00
Page 201
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
FLOOR WEB
(0.016 IN. (0.4064 MM)
2024-T3 AL ALY)
CENTER BEAM
STIFFENERS
(0.032 IN. (0.8128 MM)
7075-T6 AL ALY)
(TYPICAL 7 PLCS)
STIFFENER
(0.020 IN. (0.508 MM)
7075-T6 AL ALY)
(TYPICAL 8 PLCS)
WEB
(0.016 IN. (0.4064 MM)
7075-T6 AL ALY)
DOUBLER
(0.032 IN. (0.8128 MM)
7075-T6 AL ALY)
STIFFENER
(0.032 IN. (0.8128 MM)
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
(0.025 IN. (0.635 MM)
7075-T6 AL ALY)
STA 108.04 RIB
(0.025 IN. (0.635 MM)
7075-T6 AL ALY)
STIFFENERS
(0.020 IN. (0.508 MM)
2024-T3 AL ALY)
DOUBLER
(0.025 IN. (0.635 MM)
2024-T3 AL ALY)
WEB
(0.016 IN. (0.4064 MM)
2024-T3 AL ALY)
STA 90.61 RIB

(0.040 IN. (1.016 MM)
7075-T6 AL ALY)
DOUBLER
(0.050 IN. (1.270 MM)
7075-T6 AL ALY)
STIFFENER
(0.032 IN. (0.8128 MM)
7075-T6 AL ALY)
STA 102.23 RIB

(0.025 IN. (0.635 MM)
7075-T6 AL ALY)
DOUBLER
(0.050 IN. (1.270 MM)
7075-T6 AL ALY)
STA 96.42 RIB ASSY

(0.050 IN. (1.270 MM)
7075-T6 AL ALY)
CARGO HOOK FITTING

(IF APPLICABLE)
CANT STA 78.50

LOWER FRAME
(0.040 IN. (1.016 MM)
2024-T3 AL ALY)
JACK FITTING
(PART OF STA 96.42 RIB)
STA 84.70 RIB

(0.032 IN. (0.8128 MM)
7075-T6 AL ALY)
Figure 201. Lower Center Fuselage (369D/E/FF 500N)
Page 202
Revision 19
53-20-00
G53-2002A
MAINTENANCE MANUAL
CSP-HMI-2
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)
53-20-00
Page 203
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
Page 204
Revision 44
53-20-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
533000
Upper Aft Section
Fuselage
(369D/E/FF)
MAINTENANCE MANUAL
CSP-HMI-2
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;
then apply tape (CM721).
Item
Nomenclature
CM234
(10). Install compressor cooling air duct

support bracket.
CM721
Tape, aluminum foil
(11). Install tailpipes.
Use care when working on or

CAUTION around firewall shell because of
its light-weight construction.
(1). Remove tailpipes (Ref. Chap. 78,
Exhaust System Replacement).
(2). Remove tape covering fasteners and
firewall edges.
(3). Detach compressor cooling air duct
support bracket (Ref. Chap. 71, Engine
Cooling System Repair and Replace
ment). Remove firewall shell by pulling
out button head fasteners (Ref.
Figure 202).
(4). If burn marks are detected on firewall
shell or button head fasteners, inspect
airframe above burn marks for damage.
(5). Replace damaged or corroded fasteners.
(6). Replace aft firewall shell if damaged
beyond practical repair. Trim replace
ment shell to fit installation. Allow
sufficient trim excess for folding back to
provide double thickness at attach
points.
(7). Pierce fastener holes in new firewall
shell to align holes in surrounding
fuselage rings and waterline 34.96 rib.
(8). Place firewall shell in position and
secure in place by pressing fasteners
into holes. Attach compressor cooling
air duct support bracket to hoist fitting
(Ref. Chap. 75, Engine Cooling System
Repair and Replacement).
2. Firewall and Plenum Chamber Panels

Replacement
Item
Nomenclature
CM234
CM419
Sealer
Replace all defective, torn or fraying sound

proofing panels. Loose panels may be pressed
back in place. (For part number identification
of individual panels, refer to the IPC.)
(1). Open engine compartment access doors.
(2). Remove individual panels (Ref.
Figure 201, Sheet 1 of 2) by pulling
away from structure.
(3). (If applicable) Remove individual
panels (Ref. Figure 201, Sheet 2 of 2) by
removing fasteners.
NOTE: Panels have pressure-sensitive tape

backing.
(4). Prior to installing replacement panel,
clean surfaces with solvent (1, Table
201, 91-00).
(5). Install replacement panel in place and
trim edges as necessary. Press panel in
place to secure.
(6). Seal edges of replacement panel with
sealer (130).
(7). Reinstall trim (Ref. Sec. 25-30, Interior
Trim Replacement) and close engine
access doors.
53-30-00
Page 201
Revision 35
MAINTENANCE MANUAL
CSP-HMI-2
-3 PANEL
-5 PANEL
-7 PANEL
-39 PANEL
SOUNDPROOFING PANELS
(FIREWALL AND PLENUM
CHAMBER)
AFT SECTION AND CANTED

FORWARD FIREWALL
-37
-29
-1
1
-45
-35
-33
-31
-9
-43
-15
-17
-21
(ON AFT SIDE OF ACCESS
DOORS) (NOTE 1)
-13
-23
-18
-16
-22
-19
-14
-20
-27
NOTES:
1. RIGHT PANEL SHOWN. OPPOSITE
SIDE LEFT PANEL (-41) IS SAME;
EXCEPT MIRROR IMAGE AND A
SOLID PANEL.
2. ALL DASH NUMBERS SHOWN
APPLY TO BASIC PART NO.
369H2008. (EXAMPLE: -25
INDICATES PART NO. 369H2008-25.)
-25
-28
(ENGINE COMPARTMENT
SIDE OF FIREWALL)
G53-3003-1
Figure 201. Soundproofing Insulation Firewall and Plenum Chamber (Sheet 1 of 2)

Page 202
Revision 19
53-30-00
MAINTENANCE MANUAL
CSP-HMI-2
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)
53-30-00
Page 203
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
A. Mast Support Structure

The mast support structure is part of the
fuselage structure and is composed of two
longitudinal forged fittings, a lower pan and
an aft pan. The mast support structure
supports and mounts the main rotor mast.
NOTE: The main rotor static mast has been re

moved, in it's entirety, from this section be
cause of duplicate information in Section
63-30-00. Refer to Section 63-30-00 for all
information concerning the main rotor stat
ic mast.
3. Mast Support Structure Inspection
Accomplish the following inspection at
specified intervals (Ref. Chap. 05).
When working near or around
engine air and cooling inlets,
use care to prevent entry of foreign objects
(Ref. Sec. 71).
CAUTION
(1). Remove left and right sections of air

inlet forward fairing (Ref. Engine Inlet
(2). Remove interior trim (Ref. Sec. 25-30,
Interior Trim Replacement) and main
gearbox access cover (same section).
(3). Detach control tunnel cover from
structure and slide out of way.
NOTE: Use bright light and 5-power magnify

ing glass to carefully inspect areas described
in steps below for evidence of cracks.
(4). Inspect visible areas of mast support
fitting, mast base and mast tube, with
particular attention to base attachment
areas and shaded areas.
(5). Inspect both side of channels on aft
canted bulkhead from mast support
fitting down to waterline 34.00 with
particular attention to points of
attachment.
(6). Inspect side channels and fore and aft
webs of controls tunnel, from mast
support fitting down to top of pilot's
seatback (canted bulkhead waterline
45.36).
Page 204
Revision 38
53-30-00
(7). Clean and inspect any suspected area;

use dye-penetrant to determine if a
crack does exist. If a crack is found,
part must be replaced.
(8). Inspect mast support structure for
corrosion, loose bolts and rivets and
general condition of finish.
(9). Check that mast support structure pan
drain hole is open.
(10). Reinstall controls tunnel cover.
(11). Reinstall left and right forward sections
of air inlet fairing (Ref. Engine Inlet
(12). Reinstall main gearbox access cover
and trim.
A. Firewalls
(Ref. Figure 202) A shell-like aft section upper
firewall surrounds the upper portion of engine
combustion chamber and exhaust pipe
assembly. The design contains engine heat as
well as any fire that might develop within the
engine compartment. Upper firewall is thin,
0.0015 inch (0.0381 mm) thick sheet, rigidized
CRES sheet covered with double thickness of
nonflammable ceramic fiber blanket.
4. Firewalls Inspection
No unrepaired damage is permissible. (For
repairs to forward firewall, Ref. FAA AC
43-13-1A & 2A or Structural Repair Manual.)
For repairs of the upper firewall (Ref. Silver
Brazing Upper Firewall Shelf Patch).
(1). Inspect forward firewall for punctures
and corrosion.
(2). Inspect upper firewall for punctures,
corrosion and evidence of contact with
discoloration. If contact with discolor
ation is observed on the firewall
attachment button heads, remove the
upper firewall and inspect the attach
frames for discoloration or damage;
contact MDHI for further directions.
(3). Inspect for complete seal around
openings for overrunning clutch, engine
compressor air inlet and oil cooler.
MAINTENANCE MANUAL
CSP-HMI-2
TAIL ROTOR DRIVE SHAFT FAIRING

REMOVABLE
PANEL
CANTED STA. 124.00
CHANNEL
ENGINE AIR INLET
INSTALLATION
(PLENUM CHAMBER)
WATERLINE 34.96 RIB

AFT SECTION UPPER FIREWALL
(NOTE)
FORWARD ENGINE
AIR INLET PANEL
ENGINE AIR INLET SIDE PAN
DRAIN FITTING
ENGINE AIR
INLET PAN
AFT SECTION FORWARD FIREWALL

(NOTE)
369D/E/FF SHOWN
NOTE:
AFT SECTION FIREWALL IS A REMOVABLE ASSEMBLY. BOTTONHEAD FASTENERS
ARE WITHDRAWN FROM INSIDE SURFACE OF FIREWALL SHELL TO REMOVE.
G53-3008A
Figure 202. Firewall and Aft Section

A. Firewall, Station 124.00 Insulation and
Soundproofing
(Ref. Figure 201, Sheet 1 of 2) Engine compart
ment forward firewall is insulated and
soundproofed for heat and noise reduction in
passenger/cargo compartment.
5. Firewall and Plenum Chamber
Soundproofing Panel Inspection
(Ref. Figure 201, Sheet 1 of 2 and Figure 202)
(1). Remove trim (Ref. Sec. 25-30-00,
Interior Trim Replacement) for access
to passenger/cargo compartment
firewall areas. Open engine access
doors to inspect engine compartment
panels.
(2). Check for defective, torn, loose or
missing panels.
(3). Inspect aft firewall for security, punc
tures and corrosion.
(4). Check that all individual panels are

securely attached to firewall and
plenum areas with no loose edges.
(5). Check panels in passenger compart
ment of defects, tears, looseness, or
missing panels.
(6). For applicable repairs refer to Plenum
Chamber Hole Sealing reference.
A. Engine Air Inlet Fairing
The engine air inlet fairing on top of the
fuselage structure directs ambient outside air
to the engine air inlet and oil cooler blower.
The fairing installation consists of a forward
fairing section and an aft fairing section. Right
and left halves of forward fairing are remov
able. The aft fairing is riveted to fuselage
structure. A UHF/VHF antenna is bonded to
the aft vertical face and is part of aft fairing.
53-30-00
Page 205
Revision 38
CSP-HMI-2
MAINTENANCE MANUAL
6. Engine Air Inlet (Plenum Chamber)

Inspection
(1). For access, open bypass door on right
side of engine air inlet and engine
compartment access doors for view of
rear side of plenum (Ref. Figure 202).
(2). Inspect all panels for evidence of
corrosion, security of rivets and punc
tures.
(3). Inspect engine air shield mounting clips
for secure attachment.
(4). Inspect aft section strut for rivet
corrosion and edge clearance where it
passes through cutout in forward panel.
For applicable repairs (Ref. Aft Section
Strut Repair).
(5). Ensure that removable forward panels
are secure. Inspect rubber seals for
security and partial compression.
(6). Inspect drive shaft tube fairing for
dents, buckled or wrinkled areas and
signs of corrosion.
(7). Close engine compartment access doors
and two air inlet access doors.
A. Upper Aft Section General Repair
Ref. FAA AC 43.13-1B and FAA AC 43.13-2B
Inspection and Repair for Standard Sheet
Metal Repair and Alterations and Structural
Repair Manual for additional repair proce
dures.
Mast support structure fitting and fuselage
boom fairing frame fitting are critical fatigueloaded parts. Any damage in excess of negligi
ble limits specified in (Ref. Aft Section Strut
Repair) requires replacement of part.
C. Aft Fuselage Fittings General Repair
Repair of cast and forged fittings should only
be temporary and be performed only when
replacement components are not immediately
available. Replacement of bushings or inserts
that become part of fitting assembly are
considered insertion repairs. (Insertion repairs
are described in FAA AC 43.13-1B and FAA
AC 43.13-2B Inspection and Repair for
Standard Sheet Metal Repair and Alterations
and Structural Repair Manual.)
Revision 44
(2). Replacement. Replace fittings according

to Structural Repair Manual.
7. Aft Section Strut Repair
Repair of strut is limited to smoothing out
minor dents, scratches or nicks. Replace strut
if it is badly damaged according to Structural
Repair Manual.
8. Silver Brazing Procedure Upper Firewall
Shell Patch
(Ref. Figure 203)
Item
Nomenclature
CM234
CM721
CM817
CM818
Tape, aluminum foil
Brazing flux
Brazing alloy
(1). Remove aft section upper firewall (Ref.

Upper Firewall Replacement).
(2). Remove tape and ceramic fiber blankets
from firewall shell.
(3). Clean firewall shell with stiff bristle
brush moistened with solvent (CM234)
and wipe dry with clean, dry cloth.
(4). Smooth out rigidized pattern in area on
which patch will be brazed.
B. Aft Fuselage Fittings
Page 206
(1). Negligible Damage (Ref. Table 201,

53-00-00).
53-30-00
(5). Cut suitable repair patch for Type 321

stainless steel sheet in thickness range
of 0.0015-0.0018 inch (0.0381-0.04572
mm).
(6). Contour patch to match contour of
firewall shell repair area.
Use only stainless steel wire
brush in next step. Particles
from bristles of other metals can contami
nate the patch area and cause brazing to
fail.
CAUTION
(7). Use stainless steel wire brush to clean

and abrade inner and outer surfaces of
stainless steel patch and firewall.
MAINTENANCE MANUAL
CSP-HMI-2
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
oughly with clean water and allow to
air dry.
(9). Coat surfaces to be joined with a thin
even coating of silver alloy brazing flux
(CM817).
(10). Use clamp or other suitable device to
hold patch in place during brazing
operation.
CAUTION
Use extreme care not to over

heat and burn through firewall
shell.
(11). Braze patch in place with Class 8 silver
brazing alloy (CM818), using suitable
torch to heat patch area to temperature
moderately above 1295F (707C) flow
point of brazing alloy.
(12). Allow joint to cool for at least 60
seconds before removing clamping
device.
53-30-00
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Revision 38
MAINTENANCE MANUAL
CSP-HMI-2
(13). Remove flux by immersing repaired

area in water at 160-212F
(72-101C) for 40 minutes.
(14). Thoroughly rinse in clear, running
water; air dry, or wipe dry with clean,
dry cloth.
(15). Install ceramic blanket on outer surface
of firewall shell.
(16). Install aft section upper firewall shell
(Ref. Upper Firewall Replacement).
(17). Install tape (CM721) on flanges of
firewall shell.
9. Plenum Chamber Hole Sealing
(Ref. Figure 203)
Item
Nomenclature
CM418
CM424
CM713
Cement, epoxy
Sealing compound
All tape must be applied to out

side of inlet surfaces, so that
any subsequently loosened tape cannot en
ter plenum chamber to cause engine dam
age.
CAUTION
(1). Using 10 mil by 1 inch (2.54 cm)

pressure-sensitive tape (CM713), tape
all 0.130 inch (3.302 mm) diameter or
larger holes.
(2). Using sealant (CM424), seal all holes
less than 0.130 inch (3.302 mm)
diameter.
(3). Rebond loose rubber seals with adhe
sive (CM418) according to container
instructions.
10. Forward Fuselage Section Structure
Rework
(Ref. Figure 204) The following information is
a procedure for installing support assemblies
to the fuselage frame structure to provide
reinforcement at the forward attach points for
the engine inlet fairing assemblies.
Page 208
Revision 44
53-30-00
Item
Nomenclature
CM318
Primer
(1). Remove engine inlet forward fairing

assemblies from helicopter (Ref. Engine
Inlet Fairing Replacement).
(2). Remove interior trim panels and wire
harnesses, as applicable, to gain access
to work area at forward area at forward
attach nutplate assembly for L/H and
R/H engine inlet forward fairings.
(3). Remove existing forward nutplate (for
both L/H and R/H fairing assemblies)
from fuselage frame structure.
(4). Inspect upper fuselage skin for cracks
or damage at area of forward nutplate
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, perform the fol
lowing:
(a). Stop drill all cracks or remove
damaged skin area or damaged
repair doublers prior to rework.
Perform all work in accordance with
FAA AC 43.13-1B and FAA AC
43.13-2B Inspection and Repair for
Standard Sheet Metal Repair and
Alterations and Structural Repair
Manual.
(b). Field fabricate and install doublers
on outer fuselage skin. Drill
0.196-0.204 inch (4.978-5.182 mm)
diameter hole in each doubler to
match existing hole in fuselage skin
for fairing attach screw. Use existing
rivet pattern as shown; install
MS20470AD3 rivets with primer
(CM318).
(c). Prime and paint double to match
finish color of helicopter.
(5). Inspect fuselage frame structure
(channel) for cracks or damage at
forward nutplate attach areas.
MAINTENANCE MANUAL
NOTE: If no cracking or damage to fuselage

frame is noted, install 80-369D22400-3 and
-4 support assemblies at FWD side of frame
structure using rivets. Drill holes in support
assemblies for nutplates and for conduit
clearances as required. Install nutplate
rivets (MS20470AD3) through support,
frame, upper skin and doubler, if installed.
(6). If cracking or damage to fuselage frame
is noted, perform the following:
(a). Stop drill all cracks or remove
damaged area prior to installation of
repair angles and support assem
blies. Perform all work in accordance
with FAA AC 43.13-1B and FAA AC
43.13-2B Inspection and Repair for
Standard Sheet Metal Repair and
Alterations and Structural Repair
Manual.
(b). Field fabricate and install repair
angles at AFT side of fuselage frame
structure (channel) and install
80-369D22400-3 and -4 support
assemblies at FORWARD side of
frame structure using MS20470AD3
rivets. Drill 0.096 inch (2.4384 mm)
diameter holes in angles to match
support assemblies.
(c). Drill holes in support assemblies and
repair angles for nutplates and for
conduit clearance as required. Install
nutplate rivets through support,
frame, angle, upper skin and doubler,
if installed.
(7). Check installation of 80-369D22400-3
and -4 assemblies and repair angles
and doublers, if installed, for discrepan
cies.
(8). Reinstall removed components.
CSP-HMI-2
11. Transmission Compartment Air Baffle,

Seal and Cover Initial Installation
(Ref. Figure 205) (Serial No. 0003D thru
0333D only)
Item
N/A
CM425
CM712
Nomenclature
Calking compound
Sealing compound
(1). Remove engine air inlet forward

fairings.
(2). Remove cooling fan inlet screen.
(3). Remove aft compartment interior trim
panels and blower access door.
(4). Install PN 369D26541-19 upper baffle
assembly as follows;
(a). Position baffle between main trans
mission and mast support structure.
Align four attach holes in baffle with
existing holes in structure.
(b). Install baffle with screws, washers
and nuts. Seal screw heads with
sealant (CM425).
(5). Install PN 369D26542 lower baffle to
upper baffle with two screws and
washers at matching nutplates in upper
baffle.
(6). Disconnect 5/8 inch (15.875 mm)
diameter drain tube at mast support
base and insert tube though hole in
baffle. Safetywire drain tube to struc
ture.
(7). Reinstall blower access door.
(8). Position and install PN 369D26543-11
and -12 seal assemblies at lower baffle
and blower access door as shown.
Install seal assemblies with screws and
washers at matching clipnuts on lower
baffle and on blower.
NOTE: If excessive gap, 0.060 inch (1.524 mm)

or more, exists between structure and rub
ber extrusion on seals, fill gap by bonding
strip of adhesive-backed gasket to struc
ture.
53-30-00
Page 209
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
NOTE: Not applicable if modified rotor brake
(9). Position PN 369D26545-11 and -21

cover assemblies as shown; align cover
attach holes with existing fairing attach
nutplates. Temporarily secure cover
assemblies with screws and washers, 5
places each.
handle trim cover panel has already been in

stalled.
(a). Carefully trim modified trim cover
panel assembly (for LH or RH rotor
brake handle assembly). Locate and
drill screw attach holes in modified
panel.
(10). Using caulking compound, seal all gaps

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
make minor trim adjustments as
required.
(11). Remove screws securing cover assem

blies. Reinstall engine air inlet forward
fairings.
(12). Reinstall aft compartment trim.
(c). Install panel if removed and secure

panel with attaching hardware.
(13). For helicopters equipped with Rotor

Brake Kit, perform the following;
(d). Push panel boot aft on brake handle

approximately two inches and secure
with fastener tape.

Weight
Arm
Moment
lbs
(kg)
inches
(cm)
inlbs
(kgmm)
+1.5
(+0.681)
110.2
(279.908)
+169
(+1947.0828)
Page 210
Revision 38
53-30-00
MAINTENANCE MANUAL
CSP-HMI-2
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
TO MATCH EXISTING
SCREW HOLE
OUTER SKIN
369A2400-5 ANGLE
STA.
89.39
VIEW
DOUBLER
369H2508 FRAME
3 RIVETS EACH SIDE

OF DAMAGE (AD3)
SKIN
80-369D22400-3, -4
SUPPORT FORWARD
SIDE OF FRAME
(NOTE 3)
NUTPLATE
(NOTE 5)
FRAME
SUPPORT
(LH SHOWN)
UP
ANGLE 0.020 INCH

(0.508 MM) AFT
SIDE OF FRAME
(NOTES 2, 3)
DOUBLER
ANGLE
(NOTES 2, 3)
VIEW
INBOARD
SKIN
NOTES:
1. DOUBLER ON OUTER SKIN TO PICK UP EXISTING RIVETS.
2. REPAIR ANGLE INSTALLED ONLY IF FRAME DAMAGE IS NOTED.
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
(IF INSTALLED), SKIN AND DOUBLER.
6. INSTALL RIVETS WITH PRIMER.
80-369D22400-3, -4
SUPPORT FORWARD
SIDE OF FRAME
(NOTE 3)
FRAME
VIEW
G53-3007A
Figure 204. Forward Fuselage Section Structure Rework
53-30-00
Page 211
Revision 38
NOTE 1
-15 GASKET
CANTED STATION
124.0
NOTE 2
-13 SEAL
-19 GASKET
NOTE 3
369D26542 BAFFLE
-15 GASKET
369D23009 FRAME
INSTL.
NOTE 6
ACCESS DOOR
369D26541-19 BAFFLE
NOTE 4
NOTE 8
NOTE 9
-3 COVER
369D26542 BAFFLE
369D26543-9 GASET
ACCESS DOOR
MAST SUPPORT STRUCTURE
NOTE 5
369D26542 BAFFLE
-15 GASKET
NOTE 4
CL SHIP
-11 SEAL ASSEMBLY
-9 GASKET
-19 BAFFLE
NOTE 2
G53-3009-1
ACCESS
DOOR
NOTE 8
-7 SEAL
HEATER
DUCT
NOTE 3
-9 GASKET
CANTED
STATION
124.0
INSIDE CONTOUR TO MATCH 369D26542 BAFFLE.

FORWARD FLANGE TO MATCH 369D26542 BAFFLE.
JOGGLE TO CLEAR 369D26542 BAFFLE.
OPTIONAL 0.50 INCH WIDTH CUTOUT FOR ROTOR BRAKE (RH CONTROL)
HOLE(S) MATCH CLIP NUTS IN 369D22070 ACCESS DOOR.
HOLE(S) MATCH CLIP NUTS IN 369D26542 BAFFLE.
Figure 205. Installation of Air Baffle, Seal and Cover Assemblies (Sheet 1 of 2)
369D26543-15 GASKET
-19 BAFFLE
-5 COVER
NOTE 7
NOTE 9
NOTE 8
-21 SEAL ASSEMBLY
4.
5.
6.
7.
8.
9.
NOTES:
1. MOLD ALONG STRUCTURE AND JOGGLE ON 369D22070 ACCESS DOOR.
2. TRIM REAR END ALONG CANTED STA. 124.0 TO CLEAR STRUCTURAL
COMPONENTS. CLEARANCE TO STRUCTURE BEFORE BONDING SEAL
IS 0.16 INCH.
3. MOLD BOTTOM END ALONG UPPER OUTSIDE CONTOUR OF 369D22070
ACCESS DOOR. TRIM BOTTOM END TO SECURE MINIMUM OVERLAP
OF 0.50 INCH.
Revision 38
53-30-00
Page 212
MAINTENANCE MANUAL
CSP-HMI-2
MAINTENANCE MANUAL
CSP-HMI-2
369D26541-19 BAFFLE
SHIP STRUCTURE
RUBBER
EXTRUSION
369D26543 SEAL
369D26541-19
BAFFLE
NOTE 1
B
GASKET
369D26543-11 SEAL
(LH SHOWN)
GAP (NOTE 3)
369D26543-21 SEAL
NAS603-8 SCREW (4)
AN960PD10L WASHER (4)
(LH SHOWN)
NOTE 2
B
369D26542
BAFFLE
369D22070
ACCESS DOOR
369D26545-21 COVER
(-11 OPPOSITE)
NAS608-3 SCREW
AN960PD10L WASHER
369D22070
ACCESS DOOR
369D26542 BAFFLE
NAS602-8 SCREW (2)
369D26543-11 SEAL
369D22025-3 FAIRING PLATE
(NOTE 5)
VIEW B-B
NOTE 4
D
VIEW D-D
369D22025
FAIRING
369D26541-19 BAFFLE
(TYP BOTH SIDES)
D
VIEW C-C
NAS603-8 SCREW (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
HOLE TO INSTALL COVER OR FAIRING.
5. TRIM PLATE, AS REQUIRED, TO CLEAR SCREW HEAD.
G53-3009-2
Figure 205. Installation of Air Baffle, Seal and Cover Assemblies (Sheet 2 of 2)
53-30-00
Page 213
Revision 38
CSP-HMI-2
MAINTENANCE MANUAL
Page 214
Revision 38
53-30-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
533030
Upper Aft Section
Fuselage (500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
UPPER AFT SECTION FUSELAGE (500/600N)

NOTE: For all the following items, refer to Sec.
53-30-00.
Upper Firewall
Firewall and Plenum Chamber Panels
General Inspection
Mast Support Structure
Main Rotor Mast
Firewalls
Firewall Insulation and Soundproofing
1. Engine/AntiTorque Air Inlet Fan Fairings
When working near or around
engine air and cooling inlets,
use care to prevent entry of foreign objects.
CAUTION
(Ref. Figure 201) On the 500N, the engine air

inlet fairing on top of the fuselage structure
directs ambient outside air to the engine air
inlet and the oil cooler blower. The fairing
installation consists of a forward fairing
section and an aft fairing section. Right and
left halves of forward fairing are removable.
(Ref. Figure 202) On the 600N, the engine air
inlet fairing on top of the fuselage structure
directs ambient outside air to the engine air
inlet bypass door and the oil cooler blower. The
fairing installation consists of a forward inlet
fairing sections and an aft fairing section. The
controls cover and right and left halves of
forward fairing are removable.
On the 600N, the engine inlet or particle
separator is mounted aft of the inlet fairings
and wraps around the engine plenum for
increased air flow due to the larger engine
installation.
The aft section consists of an air inlet screen
on top of the fuselage structure which directs
ambient air to the anti-torque fan assembly.
The engine plenum access cover bolted to the
fuselage and is removable to provide access to
the engine plenum, particle separator and mist
eliminator (optional equipment) if installed.
The engine plenum access cover on the 600N
helicopter mounts to the aft end of the particle
separator/bypass door frame. The plenum
cover directs air downward for the engine air
intake and when removed provides access to
the engine plenum chamber area. With the

installation of a particle separator, ejector
outlets are positioned on each side of the
plenum cover.
On the 500N, the R/H side of the aft fairing is
the inlet bypass door which remains on the
fuselage when the aft fairing is removed.
On the 600N, the inlet bypass door is just aft
of the mast assembly and just forward of the
engine plenum access cover.
A removable fan hub and transmission gear
box fairing is also located in the fan plenum
chamber.
For general maintenance practices for the
upper aft section (Ref. Sec. 53-30-00).
2. Engine Air and Fan Inlet (Plenum
Chamber Area) Inspection
Avoid FOD, Cover compressor
inlet prior to working in plenum
chamber area. Vacuum all FOD debris out of
the plenum chamber before removing the
protective cover from the inlet bell. Severe
damage to the engine may result from entry
of foreign objects.
CAUTION
(1). Open the plenum chamber bypass door

by pulling the handle located in the
cockpit. Open the engine access doors to
inspect the rear side of the plenum
panels.
(2). For access, remove the fan air inlet
screen and engine plenum fairing
assemblies.
(3). Inspect all panels for evidence of
corrosion, punctures and security of
rivets and fasteners.
(4). Inspect the engine air inlet bypass door
attaching hardware and installation
(Ref. Sec. 71-10-10, Engine Air Intake
System).
(5). Inspect engine air shield mounting for
secure attachment.
53-30-30
Page 201
Revision 26
CSP-HMI-2
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
Revision 34
53-30-30
MAINTENANCE MANUAL
CSP-HMI-2
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)
53-30-30
Page 203
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
(6). Inspect aft section strut for rivets

corrosion and edge clearance where it
passes though cutout in forward panel.
(7). Inspect engine air cooling inlet screen
for damage, seal deterioration and
security.
(8). Inspect fan transmission driveshaft
tube fairing and access panel for dents,
buckled or wrinkled areas and signs of
corrosion.
(9). Inspect the fan inlet screen mesh for
(10). If fan inlet screen needs repair, re
welded using 0.063 inch (1.600 mm)
annealed cres 302 or 304 wire per
AMS5336 or AMS5639.
(11). Visually inspect through the fan inlet
screen for security of the transmission
fairing and FOD.
(12). Ensure that forward removable inlet
fairings and engine access doors are
secure.
A. Upper Aft Section General Repair
(Ref. FAA AC 43.13-1B and FAA AC 43.13-2B
Inspection and Repair for Standard Sheet
Metal Repair and Alterations and Structural
Repair Manual for additional repair proce
dures.
3. Upper Fuselage Controls Fairing (600N)
The Upper Fuselage Controls Fairing covers
the flight control rods that travel longitudinal
ly aft along the roof of the fuselage for the
rotor collective and cyclic controls.
4. Upper Fuselage Controls Fairing
Replacement (600N)
The Upper Fuselage Controls Fairing is made
of a lightweight Kevlar fabric and is used on
the 600N installation only.
A. Upper Fuselage Controls Fairing
Removal
(1). Remove hardware that attaches upper
fuselage controls fairing to mounting
surfaces.
(2). Remove controls fairing.
Page 204
Revision 44
53-30-30
B. Upper Fuselage Controls Fairing

Installation
(1). Inspect upper fuselage controls fairing
for cracks, delaminations and overall
general condition.
(2). Position controls fairing to align with
holes in mounting surfaces.
(3). Install attaching hardware.
5. Engine Inlet Fairings Replacement
The R/H and L/H engine inlet fairings are
made of a lightweight Kevlar fabric and are
used on the 500/600N installation only.
A. Engine Inlet Fairing Removal
(1). Remove hardware from left-hand inlet
fairing and remove fairing.
(2). Remove hardware from right-hand
inlet fairing and remove fairing.
B. Engine Inlet Fairing Installation
(1). Inspect fairings for cracks, delamina
tions and condition of pressure sensi
tive tape.
(2). Install right-hand inlet fairing and
attaching hardware.
(3). Install left-hand inlet fairing and
attaching hardware.
(4). Ensure that 1-1/2 threads protrude
through nutplates.
6. AntiTorque Fan Air Inlet Screen
Replacement
A. Fan Air Inlet Screen Removal
(1). Remove attaching hardware and
remove air inlet screen.
B. Fan Air Inlet Screen Installation
(1). Install air screen and attaching
hardware.
7. Fan Hub and Transmission Cover Fairing
Replacement
A. Fan Hub and Transmission Cover
Removal
(1). Remove attaching hardware on the fan
hub transmission fairing.
MAINTENANCE MANUAL
B. Fan Hub and Transmission Cover
Installation
CSP-HMI-2
(2). Install hardware attaching plenum

cover to structure.
(1). Inspect fairing for cracks and general

condition.
9. Tailboom Attach Fitting Inspection
(Ref. Figure 203) Inspect the upper left-hand

and right-hand tailboom attach fittings,
angles and nutplates as follows:
(3). Check for minimum run-on torque of

attaching screws, 2 inch-pounds
(0.226 Nm) minimum.
8. Engine Plenum Access Cover
Replacement
Avoid FOD, Cover compressor
CAUTION inlet prior to working in plenum
chamber area. Vacuum all FOD debris out of
the plenum chamber before removing the
protective cover from the inlet bell. Severe
damage to the engine may result from entry
of foreign objects.
A. Engine Plenum Access Cover Removal
NOTE: If particle separator is installed, ejector

ducting is not removed with plenum access
cover.
(1). Remove hardware that attaches engine
plenum access cover to supporting
structure.
(2). Remove plenum cover.
B. Engine Plenum Access Cover Installation
(1). Position engine plenum access cover to
align with mounting holes in fuselage.
(1). Remove button plug from attach fitting

access cover.
(2). Using a bright light, inspect fitting and
angle:
(a). Inspect attach fittings for cracks.
NOTE: Pay particular attention to area around

aft rivet holes. No cracks are allowed.
(b). Inspect angle for cracks.
(c). If any cracks are found in attach
fitting or angle, contact MDHI Field
Service Dept. for replacement
instructions.
(3). Inspect nutplate for thread damage and
cracks.
NOTE: Cracks would appear from top of selflocking nut split to base of nut.
(a). Replace nutplate if threads are
damaged or cracked.
53-30-30
Page 205
Revision 34
CSP-HMI-2
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
Revision 34
53-30-30
MAINTENANCE MANUAL
10. Lower Longeron Inspection (L158, R158)
(Ref. Figure 204) Inspect the lower left-hand
and right-hand longerons as follows:
Item
CM425
Nomenclature
Sealing compound
(1). Remove button plugs (L158, R158) from

side of helicopter.
(2). Using bright light and mirror, or
borescope, inspect the longeron, Sta.
155.75 frame and Cant. Sta. 159.97
frame for cracks.
CSP-HMI-2
11. Forward Upper Longeron Inspection

(L137, R137)
(Ref. Figure 204) Inspect the foreword upper
left-hand and right-hand longerons as follows:
Item
Nomenclature
CM425
Sealing compound
(1). Remove button plugs (L137, R137) from

side of helicopter.
(2). Using a borescope, inspect the longeron
and Sta. 137.50 frame for cracks.
(3). If any cracks are found, contact MDHI

Field Service Dept. for repair instruc
tions.
(3). If any cracks are found, contact MDHI

Field Service Dept. for repair instruc
tions.
(4). Install button plugs in inspection hole

and seal with sealing compound
(CM425).
(4). Install button plugs in inspection hole

and seal with sealing compound
(CM425).
53-30-30
Page 207
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
UPPER LONGERON, FWD

(L137, R137)
LOWER LONGERON
(L158, R158)
0.75 IN. (19.05 MM)

HOLE IN SKIN
HOLE IN
STA. 146.62
NOTE
NOTE
LOWER LONGERON (VIEW

LOOKING DOWN)
UPPER LONGERON
(VIEW LOOKING UP)
NOTE:
AREAS WHERE CRACKS ARE MOST LIKELY TO APPEAR.
G53-3013A
Figure 204. Inspection Hole Locations

12. Control Tunnel (FS 78.50) Beam
Inspection
(1). Remove Ty-Raps securing boots to

control tubes and shelf assembly.
(Ref. Figure 205)
(2). Slide boots up to top of tubes.
Page 208
Revision 34
53-30-30
MAINTENANCE MANUAL
(3). Using a mirror and bright light, inspect
tunnel beams, both sides, for cracks in
the rivet area; no cracks allowed.
If cracks are found, contact MDHI field
CSP-HMI-2
service department for repair instruc

tions.
(4). Slide boots down over shelf assembly
and secure top and bottom of boots with
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
53-30-30
Page 209
Revision 34
CSP-HMI-2
MAINTENANCE MANUAL
Page 210
Revision 34
53-30-30
MAINTENANCE MANUAL
CSP-HMI-2
Section
534000
Tailboom
(369D/E/FF)
MAINTENANCE MANUAL
CSP-HMI-2
TAILBOOM
1. Tailboom General
(Ref. Figure 201) The tailboom assembly, a
monocoque structure of aluminum skin over
forged aluminum frames, houses the tail rotor
drive shaft and tail rotor control rod, and
supports the horizontal and vertical stabiliz
ers.
2. Tailboom Replacement
A. Tailboom Removal
Item
Special Tools
Nomenclature
ST1005
ST1006
Insertion/extraction tool
Insertion/extraction tool
(1). Remove vertical stabilizer (Ref. Sec.

53-50-10).
(2). Remove tail rotor transmission and tail
rotor drive shaft as a unit (Ref. Sec.
63-15-00).
(3). Remove tail rotor control rod (Ref. Sec.
67-20-10).
(4). (369FF Model Only) Remove tailboom
extension (Ref. Tailboom Extension
Replacement).
(5). Position suitable cradles under tail
boom at Cant. Sta. 209.78 frame fitting
and the forward stabilizer boom
mounting frame (Cant. Sta. 273.00)
(Ref. Figure 202).
To avoid damage, ensure that
boom is properly supported be
fore removing boom attach bolts.
CAUTION
(6). Open boom bolts access doors and

remove bond jumper from boom.
(7). Disconnect connector of chip detector
wiring and night lighting system
wiring. Disconnect knife splice by hand
or use appropriate connector insertion/
extraction tool (ST1005 or ST1006) for
wire mate type connector.
(8). Remove nuts and washers from bolts

that attach boom to fuselage. Remove
lower bolts first and top bolt last; then
remove boom.
B. Tailboom Installation
Item
CM103
Nomenclature
Solid film lubricant
Item
ST2010
Special Tools
Nomenclature
Adapter, torque wrench
(1). Support tailboom so that mating

bulkheads are flush.
NOTE: Prior to tailboom installation, coat

threads of external wrenching bolts and at
taching nuts with lubricant (CM103).
(2). Slide countersunk washers on external
wrenching bolts with countersunk side
facing bolt heads.
If washers are installed back
wards, structural failure may
result due to insufficient surface in bearing
that can cause spreading or cracking of
washers and result in loss of clamp-up
torque.
CAUTION
(3). Install bolts through aft section

fuselage frame into boom frame and
place flat washer(s) on each bolt as
required for correct bolt grip. Use no
more than three flat washers under
each nut. Install nuts and torque only
the nuts to 380 - 410 inch-pounds
(42.93 - 46.32 Nm).
NOTE: Bolts may be reversed for access to

torque nuts. Torque wrench adapter
(ST2010) or a thin-walled deep socket is
used for torquing.
(4). Install vertical stabilizer.
(5). (369FF Model Only) Install tailboom
extension.
53-40-00
Page 201
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
STABILIZER MOUNTING
FITTINGS
GROMMET
GEARBOX AND
STABILIZER MOUNT
FRAME
WIRING CONDUIT
GROMMET
FORWARD STABILIZER BOOM

MOUNTING FRAME
RIGHT SKIN PANEL

STA. 264.32
CANT.
FRAME
GROMMET
STA. 209.78
CANT. FRAME
STA. 242.14
CANT. FRAME
NUT
WASHER
LEFT SKIN PANEL

STA. 219.96
CANT. FRAME
FORWARD STABILIZER
BOOM MOUNTING FRAME
TAILBOOM
EXTENSION
STA. 197.78 CANT.

FRAME FITTING
GEARBOX AND STABILIZER

MOUNT FRAME
369FF ONLY
G53-4000
Figure 201. Tailboom Assembly and Tailboom Extension

(6). Install tail rotor transmission and tail
rotor drive shaft as a unit.
(3). Remove tailboom extension from

tailboom assembly.
(7). Install control rod.
(4). Apply primer (CM318) in holes, on

faying surfaces and on the grip area of
the mounting studs and install tail
boom extension while primer is still
wet.
(8). Perform tail rotor control rigging (Ref.

Sec. 67-20-10).
(9). Install bond jumper to boom and
connect chip detector wiring. Connect
night lighting wiring.
3. Tailboom Extension Replacement (369FF)
Item
Nomenclature
CM318
Primer
(5). Install tailboom extension on tailboom

assembly and secure with four washers
and four nuts.
(8.47 - 10.73 Nm) plus drag torque.
(1). Remove tail rotor transmission and tail

rotor drive shaft as a unit (Ref. Sec.
63-15-00).
(2). Remove four nuts and four washers
from tailboom assembly.
Revision 19
D Note the drag torque for each nut and it's

location on the extension, in the helicop
ter for later use.
D Torque nuts while primer is still wet.
(Ref. Figure 201)
Page 202
NOTE:
53-40-00
(7). Apply torque stripe paint.

(8). Between 2 and 10 hours of helicopter
operation (to allow parts to seat), check
the torque of each mounting nut as
follows:
MAINTENANCE MANUAL
(a). Using the drag torque previously
measured and noted, apply a torque
load of 95 3 inch-pounds (10.73
0.34 Nm) plus the noted drag
torque (noted at each individual
nut) to each mounting nut of the
extension.
(b). Re-apply torque stripe paint.
(9). Install tail rotor driveshaft and tail
rotor transmission as a unit.
4. Tailboom Inspection
CSP-HMI-2
(4). Inspect bond jumper for security and

corrosion.
(5). Inspect boom exterior for loose or
missing rivets.
(6). Inspect boom and gearbox stabilizer
mounting frames for cracks, security of
attachment, elongated holes or condi
tion of mounting studs.
(7). Replace damaged or deformed studs
(Ref. CSP-SRM-6, Structural Repair
Manual).
(Ref. Figure 201)

(1). Inspect boom interior skin and frames
for corrosion and cracks.
(2). Check attaching nuts and bolts in boom
Cant. Sta. 197.78 frame fitting for
security.
(3). Inspect tail rotor control rod grommets
in boom frames for evidence of deterio
ration.
5. Tailboom Repair
There is no damage that can be
considered negligible. All dam
age must be repaired upon detection (Ref.
CSP-SRM-6, Structural Repair Manual).
CAUTION
NOTE: The skins forming the monocoque boom

assembly are highly stressed (Ref.
Figure 201).
53-40-00
Page 203
Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
FORWARD STABILIZER
BOOM MOUNTING FRAME
(CANTED STA 273.00)
CANT. STA 209.78
SELF-LOCKING NUT
FLAT WASHER (CRES)
NUT
(NOTE 4)
PLAIN HEX NUT

FLAT WASHER (AL-ALY
UNTREATED)
SPRING LOCKWASHER
FLAT WASHER(S)
(NOTE 2)
(NOTE 1)
BOND JUMPER
SPRING LOCKWASHER
FLAT WASHER
(AL-ALY UNTREATED)
FLAT WASHER
(NOTE 2)
ACCESS HOLE
COUNTERSUNK WASHER
CHIP DETECTOR WIRING
TAIL LIGHT WIRING

EXTERNAL WRENCHING BOLT
(NOTE 4)
BOOM FITTING
JUMPER CONNECTION
ACCESS HOLE
TAILBOOM ATTACHMENT
BRACKET
FLAT
WASHER
(NOTE 1)
SPRING LOCKWASHER
FLAT WASHER (CRES)
BOND JUMPER
FLAT WASHER
(AL-ALY UNTREATED)
BOOM FITTING BRACKET AND

JUMPER-INSTALLATION
NOTES:
1. ENSURE THAT GROUND CONTACT SURFACE IS CLEAN
BEFORE BOND JUMPER INSTALLATION. AFTER
INSTALLATION, COAT EXPOSED BARE METAL GROUNDED
AREA WITH LACQUER (CM306).
2. THREE FLAT WASHERS MAXIMUM UNDER NUT. WASHERS
ADDED UNDER BOLT HEAD. COUNTERSUNK WASHER IS
REQUIRED.
3. CRES-CORROSION RESISTANT STAINLESS STEEL.
4. PRIOR TO INSTALLATION, COAT THREADS
WITH LUBRICANT (CM103).
Figure 202. Tailboom Installation and Removal

Page 204
Revision 19
53-40-00
G53-4001A
MAINTENANCE MANUAL
CSP-HMI-2
Section
534030
Tailboom (500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
TAILBOOM (500/600N)
1. Tailboom Description
(Ref. Figure 201) The tailboom assembly is a
fully monocoque construction of graphite
composites, it provides directional control for
the helicopter.
The tailboom for the Model 600N helicopter is
a similar version to that on the Model 500N
helicopter. One of the obvious differences is the
length, approximately 28 inches (71.12 cm)
longer on the 600N. Also, two of the four
mounting bolts that hold the boom to the
fuselage are a larger diameter. These two
points have been reinforced both on the boom
and on the fuselage for added strength.
(1). The tailboom converts energy from the
main rotor downwash to an anti-torque
force. In order to accomplish this, a
variable pitch fan pushes low pressure
air through two longitudinal slots on
the right side of the tailboom and two
thrusters ports at the end of the
tailboom. These slots located at 130
and 76 degrees, direct low pressure air
downward over the tailboom surface.
(2). Slot air flow mixes with main rotor
downwash air, delaying its separation
at the bottom of the tailboom and
effectively creating a lifting force.
(3). Air from the main rotor passing over
the boom provides directional control to
neutralize the main rotor torque.
(4). Approximately 60% of the anti-torque
force required in a hover, is provided by
the tailboom lift, the remaining 40% is
by metered air flowing out the end of
the tailboom rotating thruster cone.
(5). A stationary thruster cone port directs
air flow to the left or to the right.
(6). The rotating thruster cone (a canshaped structure) meters exit air for
left or right directional control.
(7). Pedal movement opens and closes the
thruster cone ports and changes fan
blade pitch angle for engine power
changes.
(8). A Strake, a composite strip bonded to

the left side of the tailboom, breaks up
airflow on the left side of the boom for
hovering stability.
(9). A Stator located directly behind the fan
and mounted inside the tailboom
straightens low pressure air flowing
through the boom. The stator has
eleven composite removable blades, and
is accessible by removing the tailboom.
(10). A tail skid mounted bottom aft on the
tailboom is constructed of aluminum
tubing.
(11). A jack pad is located on the tailboom
underside. The jackpad can be accessed
by removing the tail skid.
(12). The tailboom provides for the mounting
of the horizontal stabilizer and a control
cable conduit for the flight controls.
2. Tailboom Replacement
(Ref. Figure 201)
NOTE: When removing tailboom as an assem

bly with the horizontal and vertical stabiliz
ers installed, precaution should be taken to
adequately support and balance the tail
boom assembly equally due to the mass of
the stabilizers.
A. Tailboom Removal
(1). Remove tailboom fairing.
(2). Disconnect the forward end of the
anti-torque control cable by turning
outside collar sleeve counter-clockwise
and back to expose the inner cable.
Apply sufficient right pedal to expose
engagement pin and pull collar sleeve
outward.
(3). Disconnect electrical connector.
(4). Have assistants support tailboom.
(5). Remove four mounting bolts and
washers and remove tailboom. Inspect
bolts for corrosion.
53-40-30
Page 201
Revision 36
CSP-HMI-2
MAINTENANCE MANUAL
500N TAILBOOM SHOWN
Figure 201. Tailboom Assembly (Sheet 1 of 3)

Page 202
Revision 19
53-40-30
G53-4002-1A
MAINTENANCE MANUAL
CSP-HMI-2
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)
53-40-30
Page 203
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
500N THRUSTER SHOWN
G53 4002 3
Figure 201 Tailboom Assembly (Sheet 3 of 3)

Page 204
Revision 19
53-40-30
MAINTENANCE MANUAL
B. Tailboom Installation
Before tailboom installation, in
spect radius blocks for brinnel
ing, corrosion, cracks and indication of in
dent on face; none allowed.
CAUTION
NOTE: If installing a new tailboom, the

500N3500-5 cover will have to be installed
after internal tailboom components are
installed (Ref. 500N3500-5 Cover Installa
tion).
(1). Support tailboom so that the mating
bulkhead surfaces are flush.
(5).
(6).
(2). Slide countersunk/chamfered washers

on external wrenching bolts with
countersunk side facing bolt head.
result due to insufficient surface in load
bearing area that can cause spreading or
cracking of washers and result in loss of
clamp-up torque.
CAUTION
(3). 600N:
Install washer on bolt after the counter
sunk washer.
(a). Install either an AN960C516 or
NAS1149C0563R washer on -5 bolts.
(b). Install either an AN960C616 or
NAS1149C0663R washer on -6 bolts.
Do not lubricate tailboom attach
bolts or nutplates, this will
cause a false torque reading and lead to bolt
loosening.
CAUTION
(4). With the tailboom supported in place,

install four bolts with washers.
(a). 500N:
Torque bolts to 130 - 150 inchpounds (14.69 - 16.95 Nm) plus
drag torque. Verify minimum run
on torque of 6.5 inch-pounds (0.73
Nm).
(b). 600N:
RN003 - RN059 without
TB600N-007 complied with; torque
the two smaller diameter bolts to 130
(7).
(8).
(9).
CSP-HMI-2
- 150 inch-pounds (14.68 - 16.94

Nm) plus drag torque and the two
larger diameter bolts to 180 - 220
inch-pounds (20.33 - 24.85 Nm)
plus drag torque. Safety bolts.
RN003 - RN059 with TB600N-007
complied with and RN060 & subs;
torque bolts to 180 - 220 inchpounds (20.33 - 24.85 Nm) plus
drag torque. Safety bolts.
Check for a minimum of two threads
protruding from nutplates.
Using a 0.002 inch (0.051 mm) feeler
gauge, check for gap between tailboom
and fuselage flange within 0.60 inch
(15.3 mm) of centerline of each of the
four attach bolts; no gap allowed.
Re-connect electrical connectors.
Re-connect control cable assembly.
Install tailboom fairing.
3. Tailboom Inspection
(Ref. Figure 201)
(1). Inspect tailboom exterior as follows:
(a). Inspect tailboom fairing for cracks
and delaminations.
(b). Inspect tailboom flange and mount
ing bolt holes attachment area for
cracks at Sta. 168.20.
(c). Inspect radius blocks for brinneling,
corrosion and indication of indent on
face; none allowed. If found, scrap
radius block and install new radius
block.
(d). Inspect strake for cracks, delamina
tions, debonding, dents, nicks and
separation.
NOTE: Damage to slots can cause significant
degradation of aircraft performance in a
hover.
(e). Inspect tailboom surface area and
tailboom circulation control slots
surface area for cracks, voids, dents,
holes, scratches, separation, delami
nations at tailboom and security.
1). Using a bright light, inspect fore
and aft radii of the lower portion of
the three upper slot bridges for
cracks, illuminate area under the
flap.
53-40-30
Page 205
Revision 39
CSP-HMI-2
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 may be raised slightly, using

finger pressure only, to aid in checking this
area.
(f). Inspect flaps for cracking and
debonding (Ref. Figure 202):
1). A crack of any length, in line with
aft edge of flap, is permissible at
interface between flap and tail
boom.
2). A crack of 1.25 inch (3.175 cm)
maximum length, in line with the
forward edge of flap, is permissible
at interface between flap and
tailboom.
NOTE: If crack in forward edge of flap is longer

than 1.25 inch (3.175 cm), contact your local
MDHI Field Service Representative for dis
position.
(g). Inspect horizontal stabilizer mount
ing brackets (pay particular attention
Page 206
Revision 39
53-40-30
to the forward inboard legs) and

attachment fittings for cracks, voids,
separation and delamination.
(h). Inspect stabilizers (Ref. Sec.
53-50-30).
(i). Inspect (tail-skid) for cracks, dents,
holes and delamination.
(j). Inspect rotating thruster cone for
freedom of operation, cracks, holes,
(k). Inspect tailboom grommets (2) places
for cracks and proper fit.
(2). Inspect tailboom interior as follows:
(a). Check stator vanes and stator
diffuser cone for cracks, delamina
tions and separation.
1). Maximum allowable cracks found
emanating from stator vane inserts
should not exceed 0.10 inch (2.54
mm) span-wise.
MAINTENANCE MANUAL
2). No cracks allowed running cordwise towards leading or trailing
edge
(b). Inspect slot air foils for cracks,
delamination and separation from
boom.
(c). Inspect control cable assembly
attachment points for looseness,
cracks and condition.
(d). Inspect cable conduit for cracks,
(e). Inspect air circulation area for FOD
and cleanliness. If necessary, clean
with mild soap and water.
(3). Inspect rotating thruster cone collar
strap ring rivets for looseness, strap for
cracks and condition.
4. Tailboom Repair
Minor repair procedures for the tailboom are
in the Repair section (Ref. Sec. 53-40-30).
5. Stator Replacement
(Ref. Figure 201, View D)
A. Stator Removal
(1). Remove tailboom.
(2). Note or index top of stator for reas
semble. Support stator and remove
seven exterior screws and washers
mounted around the forward part of the
tailboom.
B. Stator Installation
(1). Support stator and align stator vanes in
tailboom, install seven screws and
washers, torque screws to 3 - 6 inchpounds (0.34 - 0.68 Nm) plus drag
torque. Total torque should not exceed
15 inch-pounds (1069 Nm) total
torque.
(2). Install tailboom.
(3). Verify that stator does not rub against
the fan and for clearance of 0.020-0.080
inch (0.508-2.032 mm) between stator
and fan.
CSP-HMI-2
6. Stator Blade Replacement

(Ref. Figure 201, View E)
(1). Stator Blade Removal: Remove two
self-locking screws and two surface
washers.
(2). Stator Blade Installation: Install two
surface washers and two self-locking
screws. Torque screws to 3 - 6 inchpounds (0.34 - 0.68 Nm) plus drag
torque. Total torque should not exceed
15 inch-pounds (1069 Nm) total
torque.
7. Rotating Thruster Cone Replacement
(Ref. Figure 201, View H)
A. Rotating Thruster Cone Removal
(1). Remove cone tip cap by removing eight
screws and washers.
(2). Support rotating thruster cone and
remove three bolts and washers that
attach the rotating thruster cone,
carefully slide rotating cone aft to clear
stationary cone, bearings and followers
and the cable and drum assembly.
B. Rotating Thruster Cone Installation
(1). Carefully slide rotating thruster cone
over stationary cone, bearings, rollers
and followers.
(2). With the thruster supported in place,
install three bolts with washers
attaching the rotating thruster to
thruster gear box. Torque bolts 70 - 90
Safety wire bolts.
(3). Install cone tip cap with eight screws
and washers, torque screws per general
aircraft practices.
8. Rotating Thruster Cone Inspection
(1). Inspect for cracks and separation of
composite laminates.
(2). Check for freedom of rotational move
ment within the control range of
thruster.
(3). When the thruster is removed from
helicopter, check roller surface area
(strap) for cracks and condition.
53-40-30
Page 207
Revision 44
CSP-HMI-2
MAINTENANCE MANUAL
NOTE: Refer to MD Helicopters Inc. Represen
washer and bolt, torque bolt per

standard aircraft torque values and
safety wire.
tative for structural repairs, cracks, etc.

9. Stationary Thruster Cone Replacement
(Ref. Figure 201)
A. Stationary Thruster Cone Removal
(1). Remove rotating thruster cone (Ref.
Rotating Thruster Cone Removal).
(2). Remove eight off wing screws from pan
cover, remove cotter pin, nut and
washer from sector input shaft and
remove pan cover. Remove washer and
bushing from sector bellcrank input
shaft.
(3). Remove bolt, washer and bushing from
thruster input sector bellcrank clevis
(Ref. View J).
(4). Remove thruster cone fairings.
(5). Support stationary thruster cone and
remove eight bolts and washers, with
cable assembly attached to cone,
carefully lift cone off tailboom so that
the control rod passes through the
thruster cone cutout.
B. Stationary Thruster Cone Installation
(1). Support stationary thruster cone to
tailboom so that the control rod passes
through the cutout of the stationary
cone, and that the mating surfaces are
flush to the tailboom. Slide counter
sunk/chamber washers on external
wrenching bolts with countersunk side
facing bolt head.
result due to insufficient surface clamp-up
in load bearing areas that can cause spread
ing or cracking, resulting in loss of clampup torque.
(4). Install thruster cone fairings.

(5). Install rotating thruster (Ref. Rotating
Thruster Cone Installation).
10. Stationary Thruster Cone Inspection
(1). Inspect for cracks and delamination of
composites structure for the following:
Internal ducts, air foil supports, pan
cover and pan (hat section).
(2). Inspect rollers and bearings for condi
tion and freedom of rotation. Inspect for
cleanliness.
(3). Inspect sector bellcrank, cable assem
blies, pulleys and support brackets for
condition, inspect of cleanliness.
(4). Inspect upper input shaft for damage
and wear. Check for play in mounting
pins. If mounting pins are found to
have play, replace with new pins and
collars.
(5). Inspect thruster aft support shaft for
damage and wear. Check for play in
mounting hardware. If top bolt is found
to be loose, retorque to 10 - 15 inchpounds (1.13 - 1.69 Nm). If bottom
mounting pins are found to be loose,
replace with new pins and collars.
11. Conduit and Support Strap Rebonding
rebonding of the conduit supports.
CAUTION
(2). With the stationary thruster cone

support in place, install eight bolts and
washers. Torque bolts 30 - 40 inchpounds (3.39 - 4.52 Nm) plus drag
torque.
(3). Connect control rod to input sector
bellcrank clevis and install bushing,
Page 208
Revision 39
53-40-30
Item
Nomenclature
CM217
CM402
Isopropyl alcohol
Adhesive
(1). Lightly abrade faying surfaces with

Scotchbrite until surface gloss of the
laminate is gone.
(2). Solvent-wipe parts using a clean
lint-free cloth dampened with isopropyl
alcohol (CM217).
MAINTENANCE MANUAL
(3). Wipe dry using a clean, lint-free, dry
cloth and allow to air dry for 15 min
utes at ambient temperature.
Do not heat conduit to more
than 170F (77C). Conduit and
tailboom can be damaged from too much
heat.
CAUTION
(4). If conduit is bent away from tailboom,

heat conduit to make more flexible for
re-bonding.
CSP-HMI-2
NOTE: Adhesive must be applied within 2

hours of preparation. If more than 2 hours
elapse before adhesive application, re-pre
pare surfaces.
(5). Mix adhesive (CM402) according to
manufacturer's instructions and apply
to faying surfaces.
(6). Secure parts together with light
pressure and allow to cure for 24 hours
at ambient temperature.
CANT
FS 168.200
CANT
BL
0.000
BL
0.000
APPLY ADHESIVE HERE
38 28
28 20
TAILBOOM
SUPPORT
APPLY
ADHESIVE
HERE
APPLY
ADHESIVE
HERE
CONDUIT
APPLY
ADHESIVE
HERE
SECTION A-A
LOOKING AFT
SECTION B-B
SECTION C-C
LOOKING FORWARD
500N TAILBOOM SHOWN
G53-4004A
Figure 203. Conduit and Support Strap Rebonding
53-40-30
Page 209
Revision 39
MAINTENANCE MANUAL
CSP-HMI-2
12. Horizontal Stabilizer Mount Fitting

Replacement
(Ref. Figure 201)
Empennage Fitting
L/H, Aluminum
R/H, Aluminum
L/H, CRES
R/H, CRES
Part No.
500N35303, 7
500N35304, 8
500N35309
500N353010
Item
Nomenclature
CM101
CM206
CM222
CM304
CM315
CM318
CM418
CM425
CM801

Chemical coating
Enamel, epoxy
Adhesive primer
Primer
Cement, epoxy
Sealing compound
(1). Remove horizontal stabilizer (Ref. Sec.

53-50-30, Horizontal Stabilizer
Replacement).
Rotating Thruster Cone Replacement).
(3). Remove stationary thruster cone (Ref.
Stationary Thruster Cone
Replacement).
(4). Remove collars from pins in mount
fittings.
(5). Drive pins out of fittings.
Do not allow fittings to reach
CAUTION 200F (94C), damage to tail
boom composite material will occur.
NOTE: Heating the fitting to 150F (66C) may

assist in removing them from tailboom.
(8). Locate new fitting on tailboom.

(9). Back-drill fittings to 0.186-0.188 inch
(4.724-4.775 mm).
(10). Remove fitting and deburr rivet holes.
(11). Touch up rivet holes with solid film
lubricant (CM101) for steel fittings or
chemical coating (CM206) for alumi
num fittings.
(12). Steel fittings only:
(a). Using abrasive paper (CM801),
lightly abrade tailboom where fitting
is to be mounted.
(b). Clean fitting and tailboom abraded
area with 1,1,1-Trichloroethane
(CM222).
(c). Prime fitting with adhesive primer
(CM315).
(d). Apply a thin layer of cement (CM418)
between fitting and tailboom.
NOTE:
D Use HTS12-6-4/-5 pin rivets with
HTS1176DU-6AWU collars or alternate
HTS48-6-4/-5
pin
rivets
with
HST2000-6AW collars.
D Gage rivet holes to ensure proper length
pin rivets.
(13). Relocate fitting on tailboom and install
with pin rivets wet with primer
(CM318).
(14). Seal edges around fittings with sealing
compound (CM425).
(15). If installing steel fittings, prime with
adhesive primer (CM315).
(16). Touch up with paint (CM304).
(17). Reinstall stationary thruster cone (Ref.
Stationary Thruster Cone
Replacement).
(18). Reinstall rotating thruster cone (Ref.
Rotating Thruster Cone Replacement).
(6). Carefully pop fittings loose from

tailboom while not damaging fiberglass
sheets under fitting.
(19). Reinstall horizontal stabilizer (Ref. Sec.

53-50-30, Horizontal Stabilizer
Replacement).
(7). Clean area with 1,1,1-Trichloroethane

(CM222).
(20). Check rigging of thruster (Ref. Sec.

67-20-30).
Page 210
Revision 39
53-40-30
MAINTENANCE MANUAL
(21). Check rigging of vertical stabilizers
(Ref. Sec. 67-20-30).
13. 500N35005 Cover Installation
(Ref. Figure 204) New tailbooms come with the
500N3500-5 cover separate. This cover must
be bonded in place after the wiring and cables
are installed.
Item
CM222
CM410
CM802
CM819
Nomenclature
Adhesive, epoxy (parts A & B)
Abrasive cloth, aluminum oxide
Kimwipe
(1). With cutout facing down and forward,

gently role cover to shape of tailboom
and position inside aft end of tailboom.
Slide cover in until aft end is flush with
tailboom.
NOTE: Right edge of cover should be just to the

right of the torque tube housing (8 to the
right of centerline). Left edge should be un
der the left horizontal stabilizer empennage
fitting.
(2). Check holes in cover to ensure they line
up with electrical connectors on
tailboom.
(3). If holes do not line up with electrical
connectors, remove cover, role 180 and
reposition in tailboom.
NOTE: Tailboom is manufactured with 1.0 x 1.0

inch (25.4 x 25.4 mm) spots marked for
abrasion.
CSP-HMI-2
(a). If tailboom is not previously marked,

place a mark every 2.0 inches (50.8
mm) around cover and tailboom.
(b). Do not bond the bottom 8.0 inches
(203.2 mm) on aft end of cover.
(4). Abrade around the cover mating
surface with 240 grit abrasive cloth
(CM802) to remove gloss.
NOTE:
D Use care to avoid damage to the fiber re
inforcement.
D Metallic faying surfaces do not require
abrading.
(5). Using 240 grit abrasive cloth (CM802),
lightly abrade spots, where marked,
around the tailboom until the surface
gloss is removed.
(6). Wipe abraded surfaces with kimwipes
(CM819) dampened with
1,1,1-Trichloroethane (CM222). Allow
to air dry for 15 minutes.
(7). Mix adhesive according to manufactur
er's instructions.
NOTE: Adhesive must be applied within two

hours of cleaning. Repeat solvent prep if
more than two hours elapses before bond
ing.
(8). Apply adhesive to abraded areas and
position cover in tailboom. Clean up
excessive adhesive.
(9). Allow to cure per manufacturer's
instructions.
53-40-30
Page 211
Revision 39
MAINTENANCE MANUAL
CSP-HMI-2
CL
R/H HORIZONTAL
EMPENNAGE FITTING
LEFT EDGE OF
-5 COVER
RIGHT EDGE OF
-5 COVER
TORQUE TUBE
HOUSING
RIGHT EDGE OF
-5 COVER
U
P
-5 COVER
TAILBOOM
LEFT EDGE OF
-5 COVER
VIEW LOOKING DOWN
L/H HORIZONTAL
EMPENNAGE FITTING
8.0 IN. (203.2 MM)

DO NOT BOND
THIS AREA

G53-4005
Figure 204. 500N35005 Cover Installation

14. Tail Skid Replacement
(Ref. Figure 205)
(a). Insert removed shims and install two

bolts and washers.
(b). Torque bolts to 36 - 40 Inch-pounds
A. Tail Skid Removal

(1). Remove two bolts with washers from aft
tail skid brace.
(4). If installing a new tail skid:
(2). Retain shims between base and brace if

same tail skid is to be reinstalled.
(a). Install bolts finger tight, ensure gap

is even on both sides.
(3). Slide tail skid from forward bracket

assembly.
(b). Measure gap between brace and

base.
B. Tail Skid Installation

(1). Slide tail skid into forward bracket
assembly.
(2). Install aft brace onto aft base.
(3). If reinstalling the same tail skid:
Page 212
Revision 39
53-40-30
(c). Subtract 0.010 in. (0.254 mm) and

peel shims to that thickness.
(d). Insert shims between brace and base
and torque bolts to 36 - 40 Inchpounds (3.95 - 4.52 Nm) plus drag
torque.
MAINTENANCE MANUAL
FORWARD BRACKET
ASSEMBLY
CSP-HMI-2
AFT BASE
SHIM
AFT BRACE
BOLT
WASHER
TAIL SKID
G53-4006
Figure 205. Tail Skid Installation
53-40-30
Page 213
Revision 39
CSP-HMI-2
MAINTENANCE MANUAL
Page 214
Revision 39
53-40-30
MAINTENANCE MANUAL
CSPHMI2
TAILBOOM (500/600N)
REPAIRS
1. Rotating Thruster Cone Strap Repair
A. Rotating Thruster Cone Strap Removal
For minor repairs not described in this section,

refer to MDHI Field Service Representative.
(1). Remove the rotating thruster cone

assembly. (Ref. Sec. 53-40-30).
(Ref. Figure 801)
(2). Remove rivets (2) from rotating

thruster cone (1).
Item
CM235
CM214
CM409
CM441
Nomenclature
Cleaner
Releasing agent
Adhesive, epoxy
Sealing compound, corrosion inhibiting
(3). Remove strap (3) from rotating thruster

cone.
(4). Remove any adhesive residue from
rotating thruster cone strap bonding
area.
(5). Clean the bonding area with cleaner
(CM235).
3
2 (24 PL)
G53-4007
Figure 801. Rotating Thruster Cone

1. ROTATING THRUSTER CONE
2. RIVET
3. STRAP
53-40-30
Page 801
Revision 44
CSPHMI2
MAINTENANCE MANUAL
B. Rotating Thruster Cone Strap Installation
NOTE: The rotating thruster cone strap bond

ing area must be smooth. Small surface de
fects in the bonding area can be filled with
adhesive (CM409) before bonding. Do not let
excess adhesive change the contour of the
bonding area.
(9). Install the strap in the rotating

thruster cone.
(10). Apply releasing agent (CM214) to cleco
fasteners.
(11). Use cleco fasteners to align the rotating
thruster cone and strap rivet holes.
(1). Put the rotating thruster cone strap (3)

in position on the rotating thruster cone
(1) bonding area.
(12). Remove excess adhesive from rotating

thruster cone strap and bonding area.
(2). Transfer the 24 rivet hole locations in

the rotating thruster cone to the strap.
CAUTION
(3). Match drill the strap for the rivets (2).

(4). Remove the strap from the rotating
thruster cone.
(5). Clean and deburr the rivet holes in the
strap.
Make sure the strap is not de

formed or out-of-round when
installed in the rotating thruster cone. An
out-of-round contour can cause the rotat
ing thruster cone to bind during operation.
(13). Cure adhesive for 24 hours at ambient

temperature or heat to 170 to 190 F
(76.7 to 87.7 C) for 90 minutes.
(6). Inspect the rotating thruster cone strap

bonding area for any surface defects.
(14). Remove cleco fasteners from rivet holes.
(7). If necessary, fill bonding area surface

defects with adhesive (CM409).
(15). Wet install rivets with sealing com

pound (CM441).
(8). Apply adhesive (CM409) to the rotating

thruster cone strap bonding area.
(16). Paint exterior of rotating thruster cone

as required (Ref. Sec. 20-30-00).
Page 802
Revision 44
53-40-30
MAINTENANCE MANUAL
CSP-HMI-2
Section
535010
Stabilizer (TTail)
(369D/E/FF)
MAINTENANCE MANUAL
CSP-HMI-2
STABILIZER (TTAIL) (369D/E/FF)

1. Stabilizer General
(Ref. Figure 201) The tail surfaces (empen
nage) stabilize the helicopter and maintain it
in a relatively level attitude during high speed
forward flight. The tail surfaces consist of a
vertical and horizontal stabilizer attached to
the aft end of the tailboom.
The horizontal stabilizer mounts atop of the
vertical stabilizer in a T-shaped arrangement.
Tip plates are attached to ends of the horizon
tal stabilizer with a steel tip weight between
each tip plate and the stabilizer. The horizon
tal stabilizer is constructed of aluminum alloy
skins riveted to formed ribs and spars.
The vertical stabilizer is constructed of
aluminum alloy skins bonded to formed spars.
The vertical stabilizer includes fittings,
honeycomb core, and non-structural leading
and trailing edges. The tip plates are con
structed of aluminum alloy skins bonded over
a honeycomb core. The vertical stabilizer is
mounted aft right of the tail boom and is
bolted to the gearbox and stabilizer mount
frame and a upper and lower mount fitting.
The vertical stabilizer fitting supports the
horizontal stabilizer. The lower end of the
vertical stabilizer incorporates a tail skid
assembly.
Lighting provisions are provided on both
vertical and horizontal stabilizers. (Ref. Sec.
96-40 contains information on exterior lights.)
A. Stabilizer Troubleshooting
(Ref. Table 201)
2. Horizontal Stabilizer and Tip Plate
Replacement
A. Horizontal Stabilizer and Tip Plate
Removal
(Ref. Figure 201)
NOTE: Tip weights are installed at manufac

turing and are only required to reduce TTail vibration.
(1). Remove four screws securing tip plate

and tip weight (if applicable, right and
left tip plates and/or tip weights are
interchangeable) to horizontal stabiliz
er.
(2). Remove nuts and washers securing
horizontal stabilizer to vertical stabiliz
er fitting.
(3). Disconnect position light electrical
connection and bond jumper.
NOTE: MDHI Notice DN-63 contains informa

tion relative to adding drain holes and seal
ing doubler edges on some 369D helicopters.
MDHI Notice DN-44.1 contains informa
tion relative to replacement of trailing edge
tabs, relocation of static pressure tube and
adding doublers to some 369D helicopters.
(4). Inspect horizontal tip plates and
stabilizer (Ref. Horizontal Stabilizer
and Tip Plate Inspection).
B. Horizontal Stabilizer and Tip Plate
Installation
Item
Nomenclature
CM425
Sealing compound
(1). Support helicopter at rear jackpoint

(Ref. Sec. 07-00-00) when installing
horizontal stabilizer to ensure that
helicopter angle of incidence does not
change during measurements.
(2). Measure inclination angle of horizontal
stabilizer at B.L. 10.66 inches (27.076
cm) to right (S RIGHT) and left (S
LEFT) of horizontal stabilizer center
line (Ref. Figure 202). If angles S
RIGHT and S LEFT differ by more than
one degree, replace horizontal stabiliz
er.
(3). For aircraft 0003D - 0286D (Ref.
Figure 204);
53-50-10
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Revision 19
MAINTENANCE MANUAL
CSP-HMI-2
(a). Apply a 0.030 - 0.040 inch (0.762 1.016 mm) bead of sealant (CM425)
around perimeter of top rib assem
blies and at attach fitting.
NOTE: Do not seal drain holes.

(b). Apply sealant around electrical
conduit and seal over tooling holes.
(4). Position horizontal stabilizer on vertical
stabilizer fitting (Ref. Figure 201).
(5). Connect position light electrical
connection and bond jumper.
(6). Install nuts and washers. Torque nuts
to 90 - 110 inch-pounds (10.17 12.43 Nm).
(7). Check angle of incidence (Ref. Angle of
Incidence Measurement).
(8). Install tip plates with tip weight
between tip plate and horizontal
stabilizer, using four screws.
(9). Remove support from rear jackpoint.
3. Vertical Stabilizer Replacement
A. Vertical Stabilizer Removal
(Ref. Figure 201)
(1). Remove horizontal stabilizer (Ref.
Horizontal Stabilizer and Tip Plates
Removal).
(2). Disconnect anti-collision light electrical
connection.
(3). Remove bolts and washers securing
stabilizer to tailboom.
(4). Inspect vertical stabilizer (Ref. Vertical
Stabilizer Inspection).
B. Vertical Stabilizer Installation
(Ref. Figure 201)
Item
CM109
Nomenclature
Molybdenum disulfide powder lubricant
(1). Align stabilizer with mounting holes on

the tailboom fitting. Spray bolt threads
with lubricant (CM109) and install.
Page 202
Revision 19
53-50-10
(2). Torque bolts 190 - 220 inch-pounds

(21.47 - 24.86 Nm); then lockwire bolts
in pairs.
(3). Connect anti-collision light electrical
connection.
(4). Install horizontal stabilizer, refer to
(Ref. Horizontal Stabilizer and Tip
Plate Installation).
4. Horizontal Stabilizer and Tip Plate
Inspection
(1). Inspect metal skin for holes, cracks,
loose rivets or corrosion. Any crack is to
be stop drilled or patched.
(2). Inspect attach fittings and light
mounting bracket for cracks, loose
rivets or corrosion.
(3). Inspect attach studs and mating holes
for evidence of wear caused by loose
ness in service. Inspect questionable
studs by dye-penetrant or magnetic
particle method, as applicable.
(4). Inspect drain holes on lower surface.
Ensure they are not blocked or clogged
with debris.
(5). Inspect seal around upper and lower
doublers. Ensure all gaps/edges
between doublers and stabilizer skin
are sealed.
(6). Repair horizontal stabilizer and tip
plates (Ref. Horizontal Stabilizer and
Tip Plates Repair).
5. Vertical Stabilizer Inspection
(1). Inspect skin for holes, cracks, bonding
separation or corrosion.
(2). Inspect attach fitting for cracks, loose
rivets or corrosion.
(3). Inspect tail skid for cracks, deformation
and loose or missing rivets.
(4). Inspect anti-collision light bracket for
cracks, loose rivets or screws and
corrosion.
(5). Check condition of grommets.
MAINTENANCE MANUAL
CSP-HMI-2
POSITION LIGHT
BRACKET
GROMMET
HORIZONTAL
STABILIZER
TIP WEIGHT
(NOTE 1)
VERTICAL
STABILIZER
HORIZONTAL
STABILIZER
ELECTRICAL
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)
MS20470AD4 RIVET
(2 REQD)
HS306-318 WASHER
(2 REQD) (NOTE 3)
1 OZ (28.35 G)
LEAD WEIGHT
(NOTES 2, 3, 4)
GROMMET
FORWARD
SEAL
SEAL
HORIZONTAL STABILIZER TAB

WEIGHT INSTALLATION
(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
VERTICAL
STABILIZER
FITTING
G53-5000B
Figure 201. Stabilizer TTail Removal and Installation
53-50-10
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Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
(6). Check mount holes for elongation.

(7). For repair (Ref. Vertical Stabilizer
Repair).
6. Horizontal Stabilizer and Tip Plate Repair
Item
Nomenclature
CM220
CM425
Naphtha aliphatic
Sealing compound
(1). Seal gaps/edges between doublers and

stabilizer skin with sealant (CM425).
Remove excess sealant with naphtha
(CM220).
(2). Repaint sealed areas.
(3). Make other horizontal stabilizer repairs
according to applicable instructions in
NOTE: Support helicopter at rear jackpoint

when installing horizontal stabilizer.
(4). Install horizontal stabilizer (Ref.
Horizontal Stabilizer and Tip Plate
Installation).
7. Vertical Stabilizer Repair
Item
Nomenclature
CM418
Cement, epoxy
(1). For allowable repairs and additional

inspection criteria, Ref. Structural
Repair Manual.
(2). Replace damaged or worn seals; bond
replacement seal with cement (CM418).
(3). Replace damaged, worn or missing
grommets.
(4). Install vertical stabilizer (Ref. Vertical
Stabilizer Installation).
8. Angle of Incidence Measurement
Page 204
Revision 37
53-50-10
Item
Special Tools
Nomenclature
ST2014
Angle measuring tool
Table 201. Horizontal Stabilizer Angle of

Incidence
Angle
8 55 9 25
8 55 9 25
7 30 8 00
Model
369D
369E
369FF
NOTE: It is not necessary to level helicopter

when establishing horizontal stabilizer
angle of incidence.
D If the mast is tilted forward of 0, add H
to S.
D If the mast is tilted aft of 0, subtract H
from S.
(1). Remove hub fairing from main rotor
hub assembly.
(2). Measure incidence angle of horizontal
stabilizer (Ref. Figure 202) using angle
measurement tool (ST2014) at B.L.
10.66 inches (27.076 cm) to right (S
RIGHT) and left (S LEFT) of horizontal
stabilizer centerline. If angles S RIGHT
and S LEFT differ by more than one
degree, replace horizontal stabilizer.
(3). Measure inclination of top of main rotor
hub (Ref. Figure 203). Record as angle
H.
(4). Compute average of angles S RIGHT
and S LEFT. Record results as angle S.
(5). (D/E Only) Determine incidence of
stabilizer by adding angles H and S. If
H plus S is between 8 degrees 55
minutes and 9 degrees 25 minutes,
angle of incidence is correct.
(6). (FF Only) Determine incidence of
stabilizer by adding angles H and S. If
H plus S is between 7 degrees 30
minutes and 8 degrees 00 minutes,
angle of incidence is correct.
(7). If angle of incidence is not acceptable
(Ref. Angle of Incidence Adjustment).
MAINTENANCE MANUAL
(8). Install hub fairing onto main rotor hub
assembly.
9. Angle of Incidence Adjustment
horizontal stabilizer to vertical stabiliz
er fitting.
CAUTION
Do not add more than two wash

ers under each boss.
CSP-HMI-2
(1). Temporarily apply one ounce tab weight

to upper right trailing edge of the right
tab using tape.
(2). Locate weight spanwise to the point of
observed maximum amplitude vibra
tion.
NOTE: Tab weight can be made from commer

cial automobile alloy wheel balance weight
(0.100 x 0.75 x 2.00 inch).
(2). Lift horizontal stabilizer and add equal

number of AN960PD416L washers
under each of two front, or each of two
rear bosses.
(3). Run engine at 102% - 105% N2 and

observe horizontal stabilizer tab,
weight may be moved inboard or
outboard on tab depending on response.
(3). Install horizontal stabilizer with

washers and bolts.
(4). If needed, a one ounce weight may also

be installed on left tab.
(4). Torque bolts to 90 - 110 inch-pounds

(10.17 - 12.43 Nm).
(5). A maximum of two ounces may be

installed on each tab.
(5). Repeat angle of incidence measurement

(Ref. Angle of Incidence Measurement).
10. Horizontal Stabilizer Tab Weight
Installation
Item
Nomenclature
CM318
CM425
Primer
Sealing compound
(6). Once correct position and amount of

weight has been established, install
weight(s) as follows:
(a). Cleco weight in place on stabilizer.
(b). Drill two #31 holes through each
weight and stabilizer.
(c). Remove weight and deburr holes;
touch up stabilizer holes with primer
(CM318).
(Ref. Figure 201) Installation of tab weight is

optional on the 421-087 -505 horizontal
stabilizer if difficulty in tail rotor balance and
horizontal stabilizer tab resonance vibration is
encountered (Ref. Sec. 18-20-00, Horizontal
Stabilizer Tuning).
(d). Install weight, rivets and washers

with wet primer.
(e). Seal mating edges of weight with
(7). Touch up with paint to match.
Table 202. Troubleshooting Tailboom and Tail Surfaces

Symptom
Probable Trouble
Corrective Action
High frequency vibration.
Loose vertical stabilizer.
Retorque bolts to 190 220

inchpounds (21.47 24.86 Nm).
NOTE: High frequency vibrations in

helicopter can be caused by
components in other systems (Ref.
Chap. 63, 64 and 71).
Loose horizontal stabilizer.
Retorque nuts to 90 110

inchpounds (10.17 - 12.43 Nm).
Check angle of incidence, (Ref. Angle
of Incidence Measurement).
53-50-10
Page 205
Revision 37
MAINTENANCE MANUAL
CSP-HMI-2
S LEFT
S RIGHT
B.L. 10.66 INCH

(27.076 CM)
NOTE
HORIZONTAL
STABILIZER
B.L. 10.66 INCH

(27.076 CM)
13.850 INCH
(35.179 CM)
0.50 INCH (12.7 MM)

RADIUS (3 PLACES)
2.030 INCH
(5.1562 CM)
0.50 INCH
(12.7 MM)
1.090 INCH (2.769 CM)

1.575 INCH (4.0005 CM)
CHORD PLANE
14.015 INCH
(35.598 CM)
OML SKIN AT
STABILIZER STA. 10.66
NOTE:
TOOL FUNCTION - TO CHECK STABILIZER INCIDENCE.
G53-5001B
Figure 202. Horizontal Stabilizer Incidence Angle Measuring Tool
TOP OF M/R
HUB PLANE
STAB. INCIDENCE
ANGLE `Ì''
HORIZONTAL STAB.
CHORD PLANE
HUB INCLINATION ANGLE ``H''
AVERAGE STAB. INCLINATION

ANGLE ``S'' AVERAGE
CL
MAST
GROUND LEVEL PLANE
G53-5002
Figure 203. Establishing Horizontal Stabilizer Angle of Incidence

Page 206
Revision 40
53-50-10
MAINTENANCE MANUAL
CSP-HMI-2
TOP OF RIB
369D23608
0.250 INCH
(6.35 MM)
-0.000
+0.010
(-0.000)
(0.762 MM)
(+0.254)
0.030 INCH
VIEW
TOP OF RIB
369D23609
B-B
CL
-0.000
+0.010
(-0.000)
(0.762 MM)
(+0.254)
0.030 INCH
VIEW
SEALANT (NON-HARDENING), EDGES AND

TOOLING HOLES, EXCEPT DRAIN HOLES RTV
C-C
SEALANT TO BE APPLIED
AROUND ELECTRICAL
CONDUIT
C
B
DRAIN HOLE 0.60 INCH

(1.524 MM) DIAMETER
THRU SEALANT SHOULD
NOT COVER DRAIN HOLE
C
TOOLING HOLES
DRAIN HOLE 0.60 INCH (1.524 MM)
DIAMETER THRU SEALANT SHOULD
NOT COVER DRAIN HOLE
369D23600 VERTICAL
STABILIZER ASSEMBLY
VIEW
A-A
Figure 204. Sealing Vertical Stabilizer (0003D 0286D)
53-50-10
Page 207
Revision 19
CSP-HMI-2
MAINTENANCE MANUAL
Page 208
Revision 44
53-50-10
MAINTENANCE MANUAL
CSP-HMI-2
Section
535030
Stabilizer (500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
STABILIZER
1. Stabilizers Description
The tail surfaces consist of two verticals and a
horizontal stabilizer. The tail surfaces (empen
nage) stabilize the helicopter and maintain it
in a relatively contain level attitude and
heading during autorotation and forward
flight.
A. Horizontal Stabilizer Description
The horizontal stabilizer is constructed of
laminated fiber glass composite ribs and skin,
bonded to a formed graphite composite spar.
The horizontal stabilizer includes a non-struc
tural leading and trailing edges. hollow core
spar, sparbox fittings, access panels, torque
tubes, bellcranks and control rods.
On the 500N and optional on the 600N, a
stability augmentation system (S.A.S.) is
attached to the right-hand vertical stabilizer,
the early 600N does not have a S.A.S system.
The horizontal stabilizer mounts atop the
tailboom. Four eye bolts from the horizontal
attach to clevis attachment points on the
tailboom. Access plates are attached to the
ends caps of the horizontal stabilizer and at
center line for access to the control rods, S.A.S.
and bellcranks. Two control rods, S.A.S. and
bellcranks are routed in the center aft of the
sparbox. The angle of incidence of the horizon
tal stabilizer is preset at -2. An anti-collision
light is mounted in the top center of the
stabilizer. Position lighting provisions are
provided on both ends of the stabilizers.
On the 600N without S.A.S., gurney flaps were
added to the trailing edge of the horizontal for
the purpose of increasing lift without increas
ing the stabilizer area or weight.
Refer to Section 96-40-00 for information on
exterior lights and Section 67-20-30 for
rigging requirements.
B. Vertical Stabilizers Description
The vertical stabilizers (upper and lower) are
constructed of laminated fiber glass composite
ribs and skin, bonded to a formed fiberglass
composite spar. The vertical stabilizers include
a hollow core spar, retainer fittings and

nonstructural leading and trailing edges.
The differences on the 600N are that the
vertical stabilizers are slightly longer, the skin
is thicker and on standard 600N helicopters,
are both controlled by the directional control
pedals. The lower vertical stabilizer angle of
attack is eight degrees clockwise relative to the
upper vertical stabilizer. Refer to Section
67-20-30 for flight controls linkage details.
The left vertical stabilizer is mounted to the
horizontal on a torque tube fitting assembly
and has approximately 6.5 inches (16.51 cm) of
travel.
On the 500N and S.A.S. equipped 600N, the
right vertical stabilizer, also mounted on a
torque tube, is controlled by the stability
augmentation system. From the fully extended
to the fully retracted position on the S.A.S.
actuator, the tip of the right vertical stabilizer
trailing edge will travel a minimum of 2.70
inches (6.86 cm). The amount of travel is
determine by the S.A.S. computer and gyro.
NOTE: The anti-torque control system must be

re-rigged immediately after removal or re
placement of control rods, linkages, and
components or if helicopter operation re
veals a rigging deficiency.
2. Vertical Stabilizer Replacement
(Ref. Figure 201, Figure 202)
A. Vertical Upper and Lower Stabilizer
Removal
(1). Remove nuts, washers, and bolts.
Remove by lifting vertical stabilizer off
torque tube.
B. Vertical Upper and Lower Stabilizer
Installation
(1). Installation with Standard Hardware:
Do not over-torque nut. Overtorquing nut can crack vertical
stabilizer fitting.
CAUTION
(a). Install stabilizer onto torque tube

fittings.
53-50-30
Page 201
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2
(b). Install bolts, washers and nuts.

Torque to 30 - 40 inch-pounds
(2). Installation with Expandable Bolts:
Do not over-torque nut. Overtorquing nut can crack vertical
stabilizer fitting.
CAUTION
(a). Install bolt with washer under bolt

head and thick washer under nut.
NOTE:
D Do not remove any expanding elements
from bolt.
D If 600N2012-5 spacers are not present,
up to two spacers may be added to achieve
proper installation.
(b). Remove one (1) or two (2)
600N2012-5 spacers, as required) to
obtain 0.005-0.035 inch (0.127-0.889
mm) gap between the washers and
the vertical stabilizer, equal on each
side.
(c). Install nut and note drag torque.
(d). Perform a break in cycle by torquing
the nut to 20 - 25 inch-pounds
(e). Back off nut until bolt moves freely
in hole.
(f). Torque nut to 20 inch-pounds (2.26
(g). Check for equal gap of 0.005-0.035
inch (0.127-0.889 mm) between the
washers and the vertical stabilizer.
NOTE: NAS1149C0332R or NAS1149C0363R

washers may be added under the nut for ad
equate cotter pin engagement.
(h). If necessary, tighten nut until cotter
pin hole aligns with castillation in
nut.
(i). Install cotter pin.
3. Horizontal Stabilizer Replacement
Page 202
Revision 42
53-50-30
NOTE: Horizontal stabilizer can be removed

with vertical stabilizers installed. Support
stabilizer during removal.
A. Horizontal Stabilizer Removal
(1). Remove seven screws securing center
access plate to horizontal stabilizer.
(2). Disconnect position light electrical
interconnect.
(3). On 500N, disconnect S.A.S. electrical
interconnect.
(4). Remove cotter pin, nut, washer and bolt
from center bellcrank shaft. Index mark
bellcrank with grease pencil in relation
ship to shaft. Disconnect bellcrank.
(5). Remove nuts, washers and expandable
bolts securing horizontal stabilizer to
tailboom attachment clevis fittings.
Remove horizontal stabilizer.
B. Horizontal Stabilizer Installation
NOTE: When installing horizontal stabilizer it

may be necessary to loosen eye bolts and
nuts to align with clevises, if so, install
mounting expandable bolts first and torque
per step (2). below, then torque clevis nuts to
80 - 120 inch-pounds (9.04 - 13.56 Nm).
(1). Position horizontal stabilizer on
tailboom attach fittings.
(2). Install expandable bolts, washers and
nut. Torque to 30 - 40 inch-pounds
(3.39 - 4.52 Nm). Install cotter pin.
(3). Connect position light/strobe light
electrical connector.
(4). On 500N, connect S.A.S. electrical
interconnect.
When installing bellcrank on
center bellcrank shaft it is possi
ble to be one spline tooth off in either direc
tion, install bellcrank centered on shaft
(Ref. Sec. 67-20 -30).
CAUTION
(5). Connect bellcrank to center bellcrank

shaft and install bolt, washers and nut.
Torque nut to 30 - 40 inch-pounds
(3.39 - 4.52 Nm) and install cotter pin.
(6). Install center access plate with seven
screws and washers.
MAINTENANCE MANUAL
CSP-HMI-2
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
Figure 201. Stabilizer Installation with YSAS (Sheet 1 of 2)
53-50-30
Page 203
Revision 33
MAINTENANCE MANUAL
CSP-HMI-2
YSAS ACTUATOR
(500N, AND 600N WITH YSAS)
CENTER ACCESS
PLATE
HORIZONTAL
STABILIZER
END TIP
ACCESS
COVER
EYEBOLT
TORQUE
TUBE
WASHE
R
SPACER
(NOTE 3)
BEARING RACE
TAILBOOM
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).
Figure 201. Stabilizer Installation with YSAS (Sheet 2 of 2)

Page 204
Revision 33
53-50-30
G53-5003-2F
MAINTENANCE MANUAL
4. Horizontal Stabilizer Eye Bolt
Replacement
A. Horizontal Stabilizer Eye Bolt Removal
(1). Remove horizontal stabilizer.
(2). Remove eye bolts by holding the flat
surface of eye bolt with a wrench and
removing nut.
CSP-HMI-2
(2). Install control tubes and bellcranks as

required, safety wire or cotter pin.
(3). Install center access plate with seven
screws and washers.
6. Vertical Stabilizer Inspection
B. Horizontal Stabilizer Eye Bolt Installation
(1). Inspect skin for cracks, bonding

separation, delamanation and obvious
damage.
(1). Install eye bolts in horizontal stabilizer,

the short eye bolts in the forward holes
and the longer eye bolts with spacer to
the aft holes of horizontal stabilizer.
(2). Inspect stabilizer for freedom of

movement through pedal travel range,
check for clearance between vertical to
horizontal.
(2). Torque eye bolts to 80 - 120 inchpounds (9.04 - 13.56 Nm) plus drag
torque.
(3). Check mounting fitting holes for

elongation.
(3). Install horizontal stabilizer.

5. Horizontal/Vertical Stabilizer Control Tube
and Bellcrank Replacement
A. Horizontal/Vertical Stabilizer Control Tube
and Bellcrank Removal
(1). Remove horizontal stabilizer end tip
covers and center access cover for
access to bellcranks and control tubes.
from center bellcrank shaft. Index mark
bellcrank with grease pencil in relation
ship to shaft. Disconnect bellcrank.
(3). Disconnect control tube from vertical
stabilizer torque tube bellcrank.
Remove controls from horizontal
stabilizer as required for maintenance.
B. Horizontal/Vertical Stabilizer Control Tube
and Bellcrank Installation
Refer to adjustment and test control rigging
(1). Connect bellcrank to center bellcrank
shaft and install bolt, washers and nut.
Torque bolt to standard aircraft torque
values and install cotter pin.
NOTE: Internal stabilizer fitting may display

cracking after installation of expandable
bolts. This cracking, internal fitting only, is
acceptable for continued service. Cracking
of the external skin from the mounting bolt
holes is unacceptable and stabilizer must be
removed from service and scrapped.
7. Vertical Stabilizer Repair
Refer to MDHI Field Service Representative.
8. Horizontal Stabilizer Inspection
(1). Inspect skin for cracks, bonding
separation, delamination and obvious
damage.
(2). Inspect mounting fitting and attach
ment hardware for condition.
(3). Inspect center access panel and nut
plate fasteners for condition, end tip
plate access covers and position lights
for condition.
(4). Inspect vertical stabilizer torques tubes
for excessive axial and radial move
ment, 0.010 inch (0.254 mm) axial end
play maximum allowable.
(5). Inspect torque tube bushings for wear
and security.
(6). If the bushings are not bonded to the
horizontal stabilizer, rework Vertical
Stabilizer Torque Tube Bushings.
53-50-30
Page 205
Revision 40
MAINTENANCE MANUAL
CSP-HMI-2
9. Vertical Stabilizer Torque Tube

Replacement
A. Vertical Stabilizer Torque Tube Removal
(1). Remove vertical stabilizers (Ref.
Vertical Stabilizer Replacement).
(2). Remove horizontal tip plate access
cover and disconnect YSAS torque tube
(if installed) from vertical stabilizer
bellcrank.
(3). Remove bellcrank from torque tube by
removing expandable bolt.
(4). Remove cotter pin, locknut and bushing
from torque tube. Remove torque tube
by lifting upward.
B. Vertical Stabilizer Torque Tube
Installation
(1). Slide torque tube from the top thru the
horizontal stabilizer.
Page 206
Revision 40
53-50-30
(2). Apply one layer of teflon tape (CM726)

to threads of torque tube prior to
installing locknut.
(3). Install locknut, hand tighten and adjust
to a 0.005-0.010 inch (0.127-0.254 mm)
gap; Install cotter pin.
NOTE: When installing the bellcrank, opening

in bellcrank must face outboard.
(4). Install bellcrank, with opening facing
outboard, on torque tube and install
expandable bolt; Torque to 30 - 40
drag torque; Install cotter pin.
(5). Connect YSAS actuator to vertical
stabilizer torque tube bellcrank. Torque
nut to 30 - 40 inch-pounds (3.39 4.52 Nm) and install cotter pin.
(6). Install end plate access covers.
Stabilizer Replacement).
MAINTENANCE MANUAL
CSP-HMI-2
GURNEY FLAPS
RIGHT
CONTROL ROD
AFT
CONTROL ROD
NOTE 1
LEFT
CONTROL ROD
NOTE 2
NOTE:
1. EXTRA WASHER BETWEEN RADIUS BLOCK
AND SPACER.
2. OPENING IN BELLCRANK ALWAYS FACES
OUTBOARD (LH AND RH SIDES).
EARLY 600N SHOWN
G53-5003-3B
Figure 202. Stabilizer Installation without YSAS
53-50-30
Page 207
Revision 40
MAINTENANCE MANUAL
CSP-HMI-2
TORQUE TUBE
VERTICAL STABILIZER
EXPANDABLE
ELEMENTS
NON EXPANDABLE
ELEMENT
THIN WASHER
THIN WASHER
THICK
WASHER
SPACERS
(2)
EXPANDABLE
ELEMENTS
EXPANDABLE DIAMETER
BOLT INSTALLATION
WASHER
(OPTIONAL)
NUT
COTTER PIN
THICK WASHER
WASHE
R
BOLT
SPACERS
WASHER
(OPTIONAL)
NUT
COTTER
PIN
THICK WASHER
WASHE
R
BOLT
SPACERS
NOTE:
THE BOLT, WASHER, THICK WASHER, SPACERS AND NUT ARE
COMPONENTS OF THE EXPANDABLE DIAMETER BOLT ASSEMBLY.
MAX. DIA. O.254 IN. (6.4516 MM)

(8 PLCS) EACH TORQUE TUBE
TORQUE TUBE
Figure 203. Vertical Stabilizer Installation with Expandable Bolts

Page 208
Revision 40
53-50-30
53-5007
MAINTENANCE MANUAL
10. Horizontal Stabilizer Repair
Refer to MDHI Field Service Representative.
11. Vertical Stabilizer Torque Tube and/or
Bushing Replacement (NonBonded
Bushings)
replacing the early style (non-bonded) torque
tube bushings.
Item
Nomenclature
CM726
Tape, teflon
4.52 Nm) plus drag torque; Install

cotter pin.
12. Vertical Stabilizer Torque Tube and/or
Bushing Replacement (Bonded Bushings)
replacing the current style (bonded) torque
tube bushings.

bellcrank.
by lifting upward.
(5). Remove bushing from bearing race of
torque tube.
(6). Install one bushing on bearing race of
torque tube and insert torque tube
through fitting of horizontal stabilizer
from the top downward.
installing locknut.
(8). Install bushing and locknut, hand
tighten locknut and adjust to a
0.005-0.010 inch (0.127-0.254 mm)
NOTE: Ensure shouldered bushings are

installed in bellcrank.
(9). Install bellcrank on torque tube and
install expandable bolt and washers;
Torque to 30 - 40 inch-pounds (3.39 -
CSP-HMI-2
Item
CM222
CM402
CM726
CM802
Nomenclature
Adhesive
Tape, teflon

bellcrank.
by lifting upward.
In the following steps, care must
be taken to not damage the fi
bers of the horizontal stabilizer.
CAUTION
(5). Remove bushing(s) from horizontal

stabilizer by gently working a sharp
scraper between bushing and stabilizer.
(6). Sand excess sealant from horizontal
stabilizer taking care not to disturb the
composite fibers of the stabilizer.
(7). Clean faying surfaces of horizontal
stabilizer, where bushings are to be
53-50-30
Page 209
Revision 40
CSP-HMI-2
MAINTENANCE MANUAL
bonded, with 1,1,1-trichloroethane

(CM222).
(8). Wipe dry using a clean dry rag and
then allow to air dry for 15 minutes.
(9). Lightly abrade the faying surface of the
new bushings with abrasive cloth
(CM802) until all gloss is removed.
Wipe clean with 1,1,1-trichloroethane.
manufacturers instructions. Apply
adhesive within 2 hours of cleaning.
(12). Apply a thin uniform layer of adhesive
to faying surfaces.
CAUTION
Do not apply too much pressure,

damage to horizontal stabilizer
may occur.
(13). Press the faying surfaces firmly
together and maintain contact pressure
or apply 50 psi (3.45 kPa) maximum for
24 hours at ambient temperature.
13. Vertical Stabilizer Torque Tube Bushing

Rework (NonBonded Bushings to
Bonded Bushings)
converting the vertical stabilizer torque tube to
the current 500N3980-3 bushings,
500N3970-3 locknuts and MS24665-361
cotter pins.
Item
CM222
CM402
CM726
CM802
Nomenclature
Adhesive
Tape, teflon

(2). Remove cotter pins, locknuts and
bushings, and scrap. Remove torque
tube by lifting upward. Remove bushing
and scrap.
(14). Using 1,1,1-trichloroethane, clean

excess adhesive from parts before
adhesive has had time to cure.
(3). Clean faying surfaces of horizontal

stabilizer, where bushings are to be
bonded, with 1,1,1-trichloroethane
(CM222).



installing locknut.
(5). Lightly abrade the faying surface of the

new bushings with abrasive cloth
(CM802) until all gloss is removed.
Wipe clean with 1,1,1-trichloroethane.

to a 0.005-0.010 inch (0.127-0.254 mm)


install expandable bolt; Torque to 30 40 inch-pounds (3.39 - 4.52 Nm)
plus drag torque; Install cotter pin.
Page 210
Revision 40
53-50-30

manufacturers instructions. Apply
adhesive within 2 hours of cleaning.
(8). Apply a thin uniform layer of adhesive
to faying surfaces.
CAUTION
Do not apply too much pressure,

damage to horizontal stabilizer
may occur.
(9). Press the faying surfaces firmly
together and maintain contact pressure
or apply 50 psi (3.45 kPa) maximum for
24 hours at ambient temperature.
MAINTENANCE MANUAL
(10). Using 1,1,1-trichloroethane, clean
excess adhesive from parts before
adhesive has had time to cure.
to new 500N3970-3 locknut.
to a 0.005-0.010 inch (0.127-0.254 mm)
gap; Install MS24665-361 cotter pin.
install expandable bolt; Torque to 30 40 inch-pounds (3.39 - 4.52 Nm)
plus drag torque; Install cotter pin.
14. Vertical Stabilizer Torque Tube Bearing
Race Replacement
removal of the bearing race from the vertical
stabilizer torque tube. Some special tools will
need to be manufactured for this procedure.
CSP-HMI-2
(a). Locate a steel plate of approximately

0.250 inch (6.35 mm) thickness.
(b). Drill a 1.510 inch (38.3540 mm) hole
in the plate.
(c). Deburr edges of hole to prevent
damage to torque tube.
(d). Apply tape (CM730) to tool to prevent
damage to bearing race.
(4). Insert torque tube through the removal
tool and install on arbor press.
be taken to not damage the hori
zontal stabilizer torque tube.
CAUTION
(5). Place suitable device over torque tube

end to protect tube from damage from
arbor press.
(6). Remove bearing from the torque tube
by gently pressing torque tube through
the removal tool.
(7). Using solvent (CM234), clean primer
residue from torque tube.
(8). Inspect torque tube for damage to
bearing race contact surface.
(9). Fabricate the following tool for bearing
race installation.
Item
Nomenclature
CM234
CM318
CM730
Primer
Tape, duct
(b). Drill a 1.390 inch (35.306 mm) hole

in the plate.
Item
Special Tools
Nomenclature
(d). Apply tape (CM730) to tool to prevent

damage to bearing race.
N/A
Arbor press

(2). Remove vertical stabilizer torque tubes
(Ref. Vertical Stabilizer Torque Tube
Replacement).
(3). Fabricate the following tool for bearing
race removal.
(a). Locate a steel plate of approximately

0.250 inch (6.35 mm) thickness.
(c). Deburr edges of hole to prevent

damage to torque tube.
(10). Insert bearing race into tool and mount

on arbor press.
(11). Coat torque tube bearing race mating
surface with primer (CM318).
be taken to not damage the the
horizontal stabilizer torque tube.
CAUTION
(12). Place suitable device over torque tube

end to protect tube from damage from
arbor press.
53-50-30
Page 211
Revision 40
MAINTENANCE MANUAL
CSP-HMI-2
In the following step, ensure

bearing race is not cocked on
torque tube, this will cause non-repairable
damage to bearing race and torque tube.
ensure no warpage occurred during

installation.
CAUTION
(13). While primer is wet, press torque tube

down through the bearing race until
bearing race is tight against flange on
torque tube.
(14). Inspect bearing race flanged surface to
(15). Reinstall vertical stabilizer torque

tubes (Ref. Vertical Stabilizer Torque
Tube Replacement).
(16). Reinstall vertical stabilizers (Ref.
15. Stabilizer Troubleshooting
(Ref. Table 201)
Table 201. Troubleshooting Tailboom and Tail Surfaces

Symptom
High frequency vibration
Probable Trouble
Corrective Action
Fan assembly out of balance
Rebalance fan assembly.
Loose fan blades
Replace and rebalance fan assy.
Loose bolts/nuts on Horizontal or

Vertical stabilizer
Inspect mounting hardware; adjust or

replace as necessary.
NOTE: High frequency vibrations in helicopter can be caused by components in other systems (Ref. Sec.
640000, 632510, 632530 and 710000).
Page 212
Revision 40
53-50-30
MAINTENANCE MANUAL
Chapter
62
Main Rotor
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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
3.
Main Rotor Blade and Damper Attach Pin Disassembly and Special
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
4.
Main Rotor Blade Forward Tip Cap Inspection and Corrosion Protection . . . . . . . . 605
5.
Main Rotor Blade Upper and Lower Root Fitting Attach Lug and 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
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1.
Main Rotor Blade Repair (Nicks, Scratches and Wear Spots) . . . . . . . . . . . . . . . . . . . 801
2.
Main Rotor Blade Repair (Dents, Depressions and Erosion) . . . . . . . . . . . . . . . . . . . . 801
62 Contents
Page i
Revision 37
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
3.
Trim Tab Damage Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
4.
Forward Tip Cap Threaded Insert Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802

Figure 801. Main Rotor Blade Trailing Edge Weight Rework. . . . . . . . . . . . . . . . . 803
5.
Loose Balance Weight Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
6.
Loose Trailing Edge Weight Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
7.
Loose or Missing Rivets or Aft Tip Cap Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804

Figure 802. Repair and Removal of Trim Tab, Main Rotor Blade . . . . . . . . . . . . . 805
Figure 803. Bearing Replacement - Main Rotor Blade Damper Attach
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8.
Damper Attach Blade Fitting Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 806
9.
Leading Edge Protective Tape Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806

Figure 804. Installation/Replacement of Stainless Steel Abrasion Tape
(Main Rotor Blade Leading Edge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
Figure 805. Installation/Replacement of Double Layer Abrasion Tape
(369D21100-505 and -509 Rotor Blades) . . . . . . . . . . . . . . . . . . . . . . . . 808
10. Leading Edge Abrasion Strip Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809

11. Tip Cap Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
Figure 806. Main Rotor Blade Abrasion Strip and Tip Cap Sealing . . . . . . . . . . . 810
12. Main Rotor Blade Protective Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
A. Stainless Steel Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
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

Figure 402. Main Rotor Hub - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
1.
Main Rotor Hub Balancing - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2.
Main Rotor Blade Phasing Check and/or Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 601
3.
Main Rotor Hub Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
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Figure 601. Strap Pack Lamination - Exploded View . . . . . . . . . . . . . . . . . . . . . . . 602

4.
Lead-Lag Bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
5.
Main Rotor Strap Pack Lamination Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603

Figure 602. Strap Pack Lamination Inspection (Sheet 1 of 2) . . . . . . . . . . . . . . . . 605
Table 601. Strap Pack Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
6.
Main Rotor Hub Droop Angle Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
7.
Main Rotor Damper and Attachments Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
8.
Main Rotor Damper Weight Loading and Extension Check . . . . . . . . . . . . . . . . . . . . 609

Figure 603. Periodic Check of Main Rotor Damper Assembly . . . . . . . . . . . . . . . . 610
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1.
Main Rotor Retention Strap Pack Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2.
Pitch Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3.
Unbushed Outboard Clevis Lug Hole Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

Figure 801. Field Repair of Main Rotor Hub Pitch Control Lugs
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
4.
Pitch Control Bearing Housing Assembly, Spacer or Striker Strip

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
5.
Pitch Control Bearing Housing Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
6.
Pitch Control Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805

Figure 802. Main Rotor Hub Components - Repair and Installation
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
7.
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
17. Main Rotor Hub Tapered Bearing Grease Repack, Inspection and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
18. Main Rotor Hub Scissors Attach Lug Bearing Replacement . . . . . . . . . . . . . . . . . . . . 815
Figure 805. Main Rotor Hub - Cross Section (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . 817
Figure 806. Tapered Bearing Tools - Main Rotor Hub (Sheet 1 of 2) . . . . . . . . . . 819
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
6.
Main Rotor Damper and Attachments Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
7.
Main Rotor Damper Weight Loading and Extension Check . . . . . . . . . . . . . . . . . . . . 609

Figure 603. Periodic Check of Main Rotor Damper Assembly . . . . . . . . . . . . . . . . 610
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1.
Main Rotor Retention Strap Pack Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2.
Pitch Control Bearing Housing Assembly, Spacer or Striker Strip

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Striker Strip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
3.
Lead-Lag Link Blade Stop Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802

Figure 802. Main Rotor Hub Components Repair and Installation . . . . . . . . . . . 803
4.
Lead-Lag Bolt Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
5.
Pitch Control Bearing Pivot Pin Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . 804
6.
Droop Stop Roller Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
7.
Droop Stop Ring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8.
Droop Stop Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
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Title
Page
Droop Stop Follower (T-Head) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805

Figure 803. Droop Stop Ring Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . 806
10. Droop Stop Plunger Removal, Inspection and Installation . . . . . . . . . . . . . . . . . . . . . 807

11. Main Rotor Hub Droop Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
12. Main Rotor Hub Tapered Bearing Grease Repack, Inspection and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Figure 804. Tapered Bearing Tools - Main Rotor Hub (Sheet 1 of 2) . . . . . . . . . . 809
13. Main Rotor Hub Upper Bearing Grease Repack, Inspection and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
14. Main Rotor Hub Scissors Attach Lug Bearing Replacement . . . . . . . . . . . . . . . . . . . . 813
Figure 805. Main Rotor Hub - Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
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
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
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
8.
Pitch Control Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9.
Pitch Control Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

A. Pitch Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Pitch Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. Main Rotor Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
1.
Swashplate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2.
Mixer Controls Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Page vi
Revision 37
62 Contents
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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
62 Contents
Page vii
Revision 37
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page viii
Revision 37
62 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
620000
Main Rotor
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR
FAULT ISOLATION
1. Main Rotor System General Information
NOTE: Auto-Rotation RPM charts are found in

Chapter 18.
The main rotor located over the helicopter
center-of-gravity provides lift, lateral and
longitudinal control. The fundamental
components of the rotor are five or six remov
able blades, pitch housings and a hub. Each
articulated blade is controlled through a pitch
housing and link arrangement which transfers
flight control inputs into the rotor blades.
Rotor blades, pitch housings and links are
secured to the hub by five sets of laminated
steel straps. The collective, stick working
through linkages, increases or decreases rotor
blade angle affecting helicopter ascent and
descent (collective pitch). Helicopter pitch and
roll angles are controlled by the cyclic stick.
Mixed collective and cyclic control inputs are
simultaneously transferred into the main rotor
for coordinated flight control. The four main
equipment groups of the main rotor and
control system are the rotor blades, hub, upper
exterior controls, and cyclic and collective
controls in the pilot's compartment.
NOTE: Unless specifically indicated in the text

and illustrations, information applies to all
model helicopters. Where information is
limited to a specific model helicopter or con
figuration, the text or effectivity block will
indicate.
2. Main Rotor System Troubleshooting
Sudden onset of excessive
WARNING and/or unusual main rotor

vibration should be investigated imme
diately as to the cause, prior to contin
ued flight. Under no circumstance
should main rotor tracking be at
tempted to correct the problem until a
thorough inspection of the main rotor
blades, hub assembly and strap pack
assembly has been performed.
(1). First determine which major installa
tion is defective.
(2). Isolate each linkage installation from
others until area of malfunction is
located.
(1). Main rotor blades

(Ref. Sec. 62-10-00).
(3). Investigate and determine exact

location of malfunction.
(2). Main rotor hub

(Ref. Sec. 62-20-00 and 62-20-60).
(4). Repair or replace defective components.
(3). Main rotor swashplate and mixer

(Ref. Sec. 62-30-00 and 62-30-60).
(4). Main rotor flight controls
(Ref. Chap. 67).
NOTE: First indications of trouble are usually

felt through cyclic or collective controls. Iso
lation procedures (Ref. Table 101, Sec.
67-10) indicate symptoms detected through
these controls.
62-00-00
Page 101
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
Table 101. Troubleshooting Main Rotor Vibrations

Symptom
Probable Trouble
Corrective Action
Unusual or excessive vibration.
Main rotor blades damaged.
Inspect blades
(Ref. Sec. 621000).
Vertical or Lateral vibration.
Main rotor hub or hub components

damaged.
Inspect main rotor hub assembly

(Ref. Sec. 622000/622060).
Inspect strap pack assemblies.
Oneper revolution lateral beat in

hover and cruise. May also occur
on ground during warmup or
shutdown.
Defective damper or blade phasing.
Check damper nominal adjustment

(Ref. Sec. 622000/622060)
Replace defective damper.
Fiveperrevolution or
mediumfrequency beat.
Worn pitch control bearings.
Replace pitch control bearings

(Ref. Chap. 67).
Oneper revolution vertical beat.

Beat may appear throughout
entire flight regime, becoming
more pronounced at higher
airspeeds.
Main rotor blades out of track.
Track main rotor blades

(Ref. Sec. 181000/181060).
Lateral feedback (beat) in cyclic

control stick with no longitudinal
feedback detected.
Rotor blades out of track.
Track main rotor blades

(Ref. Sec. 181000/181060).
Oneperrevolution lateral beat,

continuous.
Main rotor blade tip balance weights

not secure.
Check balance weights for security;

repair as necessary:
(Ref. Sec. 621000).
Incorrect blade phasing.
Check main rotor track and balance

(Ref. Sec. 181000/181060).
High frequency vibrations.
Loose or defective component in

another system.
(Ref. Chaps. 18, 62, 64 and 67)
Main rotor track and/or balance

inconsistant.
Play between longitudinal pitch mixer Rebond collective pitch mixer

bellcrank and collective pitch mixer
bellcrank.
bearings (Ref. Sec. 623000 or
623060).
Page 102
Revision 31
62-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
621000
Main Rotor Blade
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR BLADE

1. Main Rotor Blade General
Each of the main rotor blades are a balanced
airfoil consisting primarily of a wraparound,
aluminum alloy skin bonded to an extruded
aluminum alloy spar, an upper root fitting and
a lower root fitting (Ref. Figure 401). Two
pre-set balance weights are installed in the tip
end of each blade. A removable forward tip
cap, at the outboard end of each blade, is
replaced with a tracking cap when tracking.
Blade trailing edge tab may be bent up or
down to compensate for differences in diving or
climbing characteristics between individual
blades during forward flight.
A. Main Rotor Blade Leading Edge Erosion
Protection General
Rotor blades produced since 1980 have an 18
inch or 36 inch leading edge abrasion strip to
reduce wear. Earlier model blades without the
abrasion strip that are used in a highly
abrasive environment should have outer 24
inches of each blade (PN 369D21100-503 or
-507, Ref. Figure 804) or outer 18 inches of
each blade (PN 369D21100-505 or -509, Ref.
Figure 805) leading edge covered equally by
protective tape so blade life is not reduced by
excessive erosion.
2. Main Rotor Blade Replacement
A. Main Rotor Blade Removal
(Ref. Figure 401)
(1). Relieve load on blade attachment points
by supporting main rotor blade from
below.
(2). Identify blade attaching hardware and
pins for location (grease pencil, tape,
etc). Detach damper clevis from blade.
Remove two blade fitting attaching
pins.
(3). If rotor system is not already color
coded, use masking tape and/or grease
pencil, to mark each blade and its
respective pitch housing links so that
blades can be reinstalled in same

relative positions.
(4). Slide blade from lead-lag links.
B. Main Rotor Blade Installation
(Ref. Figure 401)
(1). Position main rotor blade in its
(marked) pitch housing links. Install
blade attaching pins.
If new blade is to be installed, or
if blades are not reinstalled in
same positions from which removed or are
installed on new rotor hub, blade attach
pins must be adjusted. It is also necessary to
track blades.
CAUTION
(2). Align damper clevis on fitting of main

rotor blade; install damper attach bolt
to attach clevis to blade.
(3). Remove blade-to-pitch housing link
match-markings.
3. Main Rotor Blade and Damper Attach Pin
Installation and Adjustment
Whenever new attach pin is in
stalled, main rotor blade is re
placed, or rotor hub assembly is replaced,
adjustment is required to ensure that pins
properly fit in mating holes.
CAUTION
(1). Check main rotor blade and damper

arm attach pins for cracks, wear and
corrosion.
(2). Support blade tip to establish align
ment of holes in blade root fittings and
pitch housing lead-lag links; install
pin.
NOTE: After final adjustment of main rotor

blade and damper attach pins, thread pro
trusion from adjuster nut of 1/2 to 1 thread
is acceptable if adjuster nut run-on torque
is a minimum of 4 inch-pounds (0.45
Nm) and attach pin safety latch is securely
latched over adjuster nut.
(3). Adjust pin for correct fit by rotating
small hex nut at end of pin until 25 -
62-10-00
Page 401
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
35 pounds force (111.2 - 155.68 N) is

required to snap safety latch into place
over nut.
NOTE: After adjustment, measure installed
length of pins from face of thrust washer to
outer edge of last bushing, dimension
should be 0.99-1.04 inch (2.515-2.642 cm)
for damper pins and 2.84-2.89 inches
(7.214-7.341 cm) for main rotor blade pins.
Page 402
Revision 20
62-10-00
(4). At final installation, locking levers of

both blade root fitting pins should be
located inboard of (behind) stop springs
of pitch housing lead-lag links.
MAINTENANCE MANUAL
TURNBUCKLE
CSP-HMI-2
JAMNUT
MINIMUM 2-THREAD
PROTRUSION AFTER
FINAL ADJUSTMENT
BOLT
WASHER
WASHER
NUT
JAMNUT
COTTER PIN
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
FORWARD
TIP CAP
THREADED
INSERT
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
62-10-00
Page 403
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
Page 404
Revision 44
62-10-00
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR BLADE

INSPECTION/CHECK
1. Main Rotor Blade Inspection
Item
N/A
Special Tools
Nomenclature
Plastic inspection tool (Fabricate from
0.001-0.002 inch (0.025-0.051 mm) thick
plastic material)
(1). Inspect skin for evidence of cracks and

holes. Cracks or holes in blade skin
surface, regardless of location, are
cause for rejection of blade. Scratches,
dents, nicks and other surface defects
in blade skin are limited according to
(3). below. Use suitable dial indicator to
check depth of blade dents and
scratches.
Repairable limit dimensions in
following procedures apply to
surfaces that have not been repaired before.
Be sure that material has not been removed
from damaged areas before determining
that damage depth limit has not been ex
ceeded. Refer all questionable surface dam
age not covered by following information to
MDHI.
CAUTION
(2). (Ref. Figure 601) Limitations for

surface scratches, nicks, gouges and
erosion in seven areas of blade skin are
described below. Scratches that do not
penetrate clad surface are acceptable
without reword in all areas except
AREAS 5 and 8.
AREA 1: Minor scratches, nicks and
gouges without skin penetrations are
acceptable without repair. Skin defor
mation with holes is cause for replace
ment. Blade leading edge erosion may
be repaired if skin is not eroded
through. If leading edge skin is eroded
through, no matter how slightly, blade
must be replaced immediately.
AREA 2: Scratches to 0.005 inch (0.127
mm) depth if oriented 0-30 degrees
from spanline and to 0.003 inch (0.076
mm) depth if oriented between 30 and
90 degrees from spanline are acceptable

without repair. Nicks and gouges not
exceeding 0.003 inch (0.076 mm) depth
are acceptable without repair and to
0.005 inch (0.127 mm) with repair.
mm) depth if oriented 0-30 degrees
from spanline and to 0.003 inch (0.076
mm) deep if oriented between 30-40
degrees from spanline must be re
moved. No sharp nicks or gouges
requiring more than 0.005 inch (0.127
mm) removal of skin surface are
permissible.
mm) depth if oriented 0-30 degrees and
to 0.003 inch (0.076 mm) depth if
oriented between 30-90 degrees from
spanline must be removed. No sharp
nicks or gouges requiring more than
0.003 inch (0.076 mm) removal of skin
surface are permissible.
AREA 5: Scratches exceeding a depth
of 0.001 inch (0.025 mm) are cause for
rejection. Remove scratches to a depth
of 0.001 inch (0.025 mm). Area inside
outboard two root fitting bolt holes
(both upper and lower surfaces) and
including skin surface adjacent to these
bolt holes within radius of 1.00 inch
(2.54 cm) from each hole must be free of
scratches, nicks, or gouges as would be
detected under 5X magnification
(minimum).
mm) depth and oriented 0-15 degrees
from spanline are acceptable without
repair. Scratches to 0.005 inch (0.127
mm) depth and oriented from 15-30
degrees from spanline must be re
moved. Scratches 0.003 inch (0.076
mm) deep and oriented from 15-30
degrees from spanline are acceptable
without repair. Scratches to 0.003 inch
(0.076 mm) depth and oriented from
30-90 degrees from spanline must be
repaired. Nicks and gouges not exceed
ing 0.005 inch (0.127 mm) depth must
be repaired. All gouges, nicks, scratches
62-10-00
Page 601
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
and cracks on trailing edge not exceed

ing 0.030 inch (0.076 mm) depth must
be smoothed and radiused out over
0.120 inch (3.048 mm) area on each side
of damage. Defects beyond 0.030 inch
(0.762 mm) depth are cause for rejec
tion.
AREA 7: Scratches, nicks, or gouges up
to 0.005 inch (0.127 mm) deep and
detectable with 5X magnification are
not acceptable without repair. Defects
beyond 0.005 inch (0.127 mm) depth are
cause for rejection. Gouges, nicks,
scratches and cracks not exceeding
0.250 inch (6.35 mm) depth on trailing
edge, except for AREA 8, must be
smoothed and radiused out to 0.250
inch (6.35 mm) area on each side of
damage center. Defects beyond 0.250
inch (6.35 mm) depth require blade
replacement.
AREA 8: Check for gouges, nicks,
scratches and cracks detected by using
a bright light and 5X magnification at
trailing edge corners where blade and
tabs join. View area from different
angles during inspection. Damage at
this point not exceeding 0.030 inch
(0.762 mm) depth must be smoothed
and radiused out over a 0.120 inch
(3.048 mm) area on each side of
damage. Defects beyond 0.030 inch
(0.762 mm) depth (Ref. Trim Tab
Damage Repair).
(3). (Ref. Figure 602) Depth limitations for
surface dents or depressions in eight
areas of blade skin are described below.
A dent or depression is defined as a
smooth depression or discontinuity with
no sharp changes in section.
AREA A: Dents and depressions
exceeding 0.015 inch (0.381 mm)
without sharp changes in section to a
maximum of 0.062 inch (1.575 mm)
must be repaired.
AREA B: Dents and depressions to a
maximum of 0.010 inch (0.254 mm) are
Page 602
Revision 20
62-10-00
acceptable without repair. No repairs

are permitted in this area.
AREA C: No repairs permitted.
AREA D: Dents and depressions
without sharp change in section to a
must be repaired.
AREA E: Dents and depressions
without sharp change in section to a
must be repaired.
AREA F: Dents and depressions
without sharp change in section to
must be repaired.
AREA G: No repairs permitted.
AREA H: Dents and depressions
must be repaired.
AREA J: Dents and depressions
must be repaired. Dents and depres
sions exceeding these limitations, refer
to trim tab damage repair.
(4). Inspect surface areas of upper and
lower root fittings (other than AREA 5)
for evidence of nicks, scratches, and
wear spots. Nicks, scratches, and wear
spots deeper than 0.010 inch (0.254
mm) in attachment lug area, and bolt
hole area are not repairable. Damage
0.010 inch (0.254 mm) deep or less
must be repaired.
(5). Inspect four attachment lug bushings
in root fittings (Ref. Figure 401) for
security, and evidence of cracks or
severe scoring.
MAINTENANCE MANUAL
CSP-HMI-2
DAMAGE 0.010 INCH (0.254 MM)

IN DEPTH OR LESS IS REPAIR
ABLE IN THESE AREAS (NOTE
1)
1.00 INCH (2.54 CM) RADIUS AROUND LAST
2 BOLT HOLES 0.001 INCH (0.025 MM) MAXI
5
MUM DEPTH
CHORD LINE
SPAN LINE
0.380 INCH
(9.652 MM)
90
120
3.00 INCH
(7.62 CM)
4
1.25
2
30
30
120
120
30
305
DAMAGE LESS THAN

0.030 INCH (0.762 MM)
DEPTH REPAIRABLE IN
THIS AREA (NOTE 1)
3
120
30
30
15
1.00 INCH
(2.54 CM)
6
30
15
7
8
23.00 INCH
(58.42 CM)
SCRATCHES
GOUGES AND NICKS
ORIENTATION
FROM SPANLINE
MAXIMUM DEPTH WITH

OUT REPAIR
MAXIMUM DEPTH
WITH REPAIR
MAXIMUM DEPTH WITH

OUT REPAIR
MAXIMUM DEPTH
WITH REPAIR
0-90
MINOR WITHOUT
SKIN PENETRATION
MINOR WITHOUT
SKIN PENETRATION
MINOR WITHOUT
SKIN PENETRATION
MINOR WITHOUT
SKIN PENETRATION
0-30
30-90
0.005 INCH (0.127 MM)

0.003 INCH (0.076 MM)
0.005 INCH (0.127 MM)

0.003 INCH (0.076 MM)
0.003 INCH (0.076 MM)

0.003 INCH (0.076 MM)
0.005 INCH (0.127 MM)

0.005 INCH (0.127 MM)
0-30
30-90
NONE
NONE
0.005 INCH (0.127 MM)

0.003 INCH (0.076 MM)
NONE
NONE
0.005 INCH (0.127 MM)

0.005 INCH (0.127 MM)
0-30
30-90
NONE
NONE
0.003 INCH (0.076 MM)

0.002 INCH (0.051 MM)
NONE
NONE
0.003 INCH (0.076 MM)

0.003 INCH (0.076 MM)
0-90
NONE
0.001 INCH (0.025 MM)

(NOTE 2)
NONE
0.001 INCH (0.025 MM)

(NOTE 2)
0-15
15-30
30-90
0.005 INCH (0.127 MM)

0.003 INCH (0.076 MM)
NONE
0.005 INCH (0.127 MM)

0.005 INCH (0.127 MM)
0.003 INCH (0.076 MM)
NONE
NONE
NONE
0-90
NONE
0.005 INCH (0.127 MM)

(NOTE 2)
NONE
AREA
5
(NOTE 2)
GOUGES, NICKS AND CRACKS

TRAILING EDGE ONLY
MAXIMUM DEPTH WITH MAXIMUM DEPTH WITH
REPAIR
OUT REPAIR
N/A
N/A
0.005 INCH (0.127 MM)

0.005 INCH (0.127 MM)
0.005 INCH (0.127 MM)
NONE
0.030 INCH (0.762 MM)

(NOTES 2, 4)
0.005 INCH (0.127 MM)

(NOTES 2, 5)
NONE
0.250 INCH (6.35 MM)

(NOTES 2, 3, 5)
NONE
0.030 INCH (0.762 MM)

(NOTES 2, 4, 5)
NOT APPLICABLE
TAB END
NOTES:
1. DAMAGE LIMITS APPLY TO BOTH UPPER AND LOWER ROOT FITTING
SURFACES.
2. INSPECTION UNDER 5X MAGNIFICATION (MINIMUM) REQUIRED.
3. AREAS NOTED: 0.250 INCH (6.35 MM) SMOTHERED AND RADIUSED
CLEANOUT ALLOWED.
4.
5.
SMOOTHED AND RADIUSED CLEANOUT OVER 0.120 INCH (3.048 MM)

AREA ON EACH SIDE OF DAMAGE.
REFER TO TRIM TAB DAMAGE REPAIR.
G62-1001A
Figure 601. Main Rotor Blade Damage and Repair Limits

Nicks, Scratches, Gouges and Cracks
62-10-00
Page 603
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
(6). Inspect damper-attachment bearing for

binding, evidence of galling or scoring
in bore and wear. No radial play is
permissible. Maximum axial play is
0.015 inch (0.381 mm).
and aft balance weights (Ref.

Figure 401) for security. Weights are
normally recessed 0.050 inch (1.270
mm) inside end surface of tip. Security
of weights may be checked by using
torque wrench with screwdriver socket
in slot of weight to detect if weight can
be rotated by less than 20 inchpounds (2.26 Nm). If torque wrench is
not available, check weight security by
fitting small coin in weight slots and
applying maximum force that can be
exerted by only index finger and thumb.
If weights are found to be loose,
retighten (Ref. Loose Balance Weight
Repair).
(7). Inspect all bonded areas for evidence of

separation. If there appears to be
separation of trailing edge bond, lightly
probe joint with a 0.001-0.002 inch
(0.025-0.051 mm) plastic inspection
tool. If plastic inspection tool can be
inserted to a depth of 1/2 inch (12.70
mm) or more, either above or below V
insert, separation is excessive.
NOTE: Trailing edge structural bond line to V

insert starts 1/4 inch (6.35 mm) in (chord
wise) from trailing edge joint: therefore
above tolerance allows 1/4 inch (6.35 mm)
separation. Be sure measurement is taken
from trailing edge joint, not tab trailing
edge. Maximum trailing edge joint gap al
lowed during fabrication is 0.080 inch (2.032
mm).
(8). Inspect doubler shown in AREA G
(Ref. Figure 602) for bonding voids
between doubler and blade skin top and
bottom. Use a heavy coin and lightly
tap doubler surface. A void is detected
by a distinct change in sound. Note that
tapping sounds differ slightly due to
blade structure in leading and trailing
edge, internal channel and doubler
areas. Allowable voids or debonds on
main rotor blade ribs are as follows:
(a). 50% void or debond.
(b). Maximum four (4) ribs, no more than
two (2) adjacent for the 369D21100
and 369D21102 blades.
(9). Ensure that vent holes are open (Ref.
Figure 401).
(10). Inspect fasteners that secure upper and
lower root fittings, and six rivets that
secure skin to spar near tip, for securi
ty. Inspect forward tip cap screw insert
for security and thread damage. Inspect
trailing edge upper and lower weights
for debonding and loose rivets.
(11). When continuous one-per-revolution
lateral vibration occurs, inspect forward
Page 604
Revision 20
62-10-00

Inspection and Corrosion Protection
(Ref. Figure 603)
Item
CM120
Nomenclature
(1). Inspect pin cam handle lobe for cracks

and excessive wear. Remove pin from
service if cracking or excessive wear is
noted.
NOTE: If hard anodizing surface of cam lobes is

worn, cam lobes can be re-anodized or
treated with corrosion preventive oil
(CM120).
(2). Inspect attach pin for evidence of
corrosion, or wear, and for straightness.
Pay particular attention to area along
edges of barrel nut and bore in cam
handle. Remove pin from service if
corrosion or wear is noted or if pin is
bent.
NOTE: If subject to salt laden atmosphere, fol

lowing corrosion prevention treatment is to
be applied at each periodic inspection to en
sure continued serviceability of attach pin;
and at each pin removal.
(3). With attach pin removed, lubricate
mating surfaces of barrel nut and cam
handle, using corrosion preventive oil
(CM120). Rotate cam handle back and
forth on barrel nut several times to
MAINTENANCE MANUAL
ensure that oil penetrates all sections of
pin operating mechanism. Wipe excess
oil from pin surfaces.
Disassembly and Special Inspection
(Ref. Figure 603) This inspection is to be
preformed in event of a main rotor blade
strike.
Item
Nomenclature
CM217
Isopropyl alcohol
Do not intermix bushings,

spacers and thrust washers be
tween bolts. Component parts make up a
single bolt assembly.
CAUTION
(1). Remove adjusting nut and remove

adjusting bushings, spacers and thrust
washers from pin.
(2). Using brush and clean cloth, clean
parts with isopropyl alcohol (CM217).
Dry with clean cloth.
(3). Inspect pin as follows:
(a). Fluorescent inspect pin per MILSTD-6866.
(b). Magnetic particle inspect thrust
washers, bushings and spacer per
MIL-STD-1949.
(4). Reassemble pin in sequence as follows;
install thrust washer, three (3) adjust
able bushings, spacer, three (3) adjust
able bushings and secure with adjust
ing nut.
4. Main Rotor Blade Forward Tip Cap
Inspection and Corrosion Protection
(Ref. Figure 603)
Item
Nomenclature
CM217
CM232
Isopropyl alcohol
Rust inhibitor spray
CSP-HMI-2
(1). Inspect tip caps for evidence of corro

sion, with particular attention at
mating area of blade skin to tip weight
interface. Verify integrity of sealant
coating.
(2). If damage is evident, remove tip caps
and apply penetrating oil to blade tip
weight area. Oil arrests any corrosion
between blade skin and weight assem
bly.
(3). Using brush and clean cloth, clean area
with isopropyl alcohol (CM217). Dry
with clean cloth.
(4). Spray area with light film of rust
inhibitor (CM232); then apply thin film
of primer and paint lightly as required
(Ref. Sec. 20-40-00).
5. Main Rotor Blade Upper and Lower Root
Fitting Attach Lug and LeadLag Link
Attach Lug Inspection (25 Hour)
procedure pertains to helicopters equipped
with 369D21100-BSC thru -515 and
369D21102-BSC and -501 main rotor blades
and/or 369H1203-BSC, -11, -21 and -31
lead-lag link assemblies.
Item
Nomenclature
CM805
Dye penetrant kit
NOTE: Main rotor blades and hub assemblies

installed on helicopters operating in a salt
water or corrosive environment should be
cleaned and washed on a daily basis as a
preventative measure to arrest corrosion
(Ref. Main Rotor Hub Corrosion Prevention
(Tri-Flow Wash Procedures)).
(1). Visually inspect exposed portion of all
installed main rotor blade upper and
lower root 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.
62-10-00
Page 605
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
0.38 INCH
(9.652 MM)
2.12 INCH
(5.385 CM)
1.58 INCH
(3.81CM)
2.00 INCH
(5.08 CM)
0.58 INCH
(14.732 MM)
0.96 INCH
(24.384 MM)
2.17 INCH
(5.512 CM)
23.00 INCH
(58.42 CM)
DENTS AND DEPRESSIONS
AREA
MAXIMUM DEPTH
WITHOUT REPAIR
MAXIMUM DEPTH
WITH REPAIR
MAXIMUM
ALLOWED
AREA
MAXIMUM NUMBER
OF DEFECTS
MINIMUM DISTANCE
BETWEEN DEFECT
CENTERS
0.015 INCH
(0.381 MM)
0.062 INCH
(1.575 MM)
1.5 INCH (3.81 MM)

X
1.5 INCH (3.81 MM)
N/A
0.010 INCH
(0.254 MM)
0.000
0.250 INCH (6.35 MM)

X
0.25 INCH (6.35 MM)
18
0.000
0.000
NONE
ALLOWED
N/A
0.005 INCH
(0.127 MM)
0.030 INCH
(0.762 MM)
1.5 INCH (3.81 MM)

X
1.5 INCH (3.81 MM)
18
0.010 INCH
(0.254 MM)
0.040 INCH
(1.016 MM)
1.5 INCH (3.81 MM)

X
1.5 INCH (3.81 MM)
18
0.010 INCH
(0.254 MM)
0.040 INCH
(1.016 MM)
1.5 INCH (3.81 MM)

X
1.5 INCH (3.81 MM)
18
0.000
NONE
ALLOWED
N/A
0.000
0.000
0.000
0.010 INCH
(0.254 MM)
0.040 INCH
(1.016 MM)
1.5 INCH (3.81 MM)

X
1.5 INCH (3.81 MM)
N/A
0.010 INCH
(0.254 MM)
0.350 INCH
(8.89 MM)
(NOTE 2)
1.5 INCH (3.81 MM)

X
1.5 INCH (3.81 MM)
N/A
N/A
NOTES:
1. N/A - NOT APPLICABLE.
2. REFER TO TRIM TAB DAMAGE REPAIR.
Figure 602. Main Rotor Blade Damage Limits for Dents and Depressions
Page 606
Revision 40
62-10-00
G62-1002B
MAINTENANCE MANUAL
CSP-HMI-2
OIL
BARREL NUT
OIL
CAM HANDLE
THRUST WASHER
BUSHING SEGMENTS
SPACER
SAFETY LATCH
G62-1008
Figure 603. Main Rotor Blade Attach Pin
62-10-00
Page 607
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
NOTE: If movement is suspected but cannot be

verified with the blades installed, remove
those blades and inspect bushings for move
ment.
(2). Using a bright light, inspect slippage
marks on the root fitting bushings to
ensure there has been no movement of
the bushings. If bushings have moved,
replace main rotor blade before next
flight. Return those main rotor blades
where bushing movement has occurred
to MDHI for possible rework.
Item
CM217
CM318
CM420
CM805
Nomenclature
Isopropyl alcohol
Primer
Sealant
Dye penetrant kit
(1). Remove affected main rotor blades (Ref.

Main Rotor Blade Removal).
CAUTION
CAUTION
D If broken or cracked lugs are noted in
main rotor blade upper and lower root fit
tings, replace main rotor blade before fur
ther flight (Ref. Main Rotor Blade Remov
al).
D If broken or cracked lugs are noted in
main rotor lead-lag links, replace main
rotor hub (Ref. Sec. 62-20) (Ref. NOTE:
below).
D If cracking is suspected in either the rotor
blade or hub lead-lag link attach lugs,
perform dye penetrant (CM805) inspec
tion of lugs per MIL-I-25135. If cracking
is noted, replace main rotor blade (Ref.
Main Rotor Blade Removal) or replace or
repair main rotor hub assembly (Ref. Sec.
62-20), before further flight (Ref. NOTE:
below).
NOTE: Lead-Lag link assemblies may only be

replaced by MDHI authorized personnel or
under MDHI supervision. Contact your local
MDHI Field Service Representative for fur
ther information.
6. Main Rotor Blade Upper and Lower Root
Fitting, Attach Lug and LeadLag Link
Attach Lug Inspection (100 Hour)
procedure pertains to helicopters equipped
with 369D21100-BSC thru -523,
369D21120-501, 369D21102-BSC thru -523
and 369D21121-501 main rotor blades and/or
369H1203-BSC, -11, -21 and -31 lead-lag
link assemblies.
Page 608
Revision 33
62-10-00
D If cracked or broken lug is noted in main

rotor blade upper and lower root fittings,
replace main rotor blade (Ref. Main Rotor
Blade Removal) before further flight.
D If cracked or broken lug is noted in main
rotor lead-lag links, replace or repair
main rotor hub before further flight (Ref.
Sec. 62-20) (Ref. NOTE: below).
D If a crack is suspected in either the rotor
blade or lead-lag link attach lug, perform
dye penetrant (CM805) inspection per
MIL-I-25135 of lug. If a crack in noted,
replace main rotor blade (Ref. Main Rotor
Blade Removal) or replace or repair main
rotor hub assembly (Ref. Sec. 62-20) (Ref.
NOTE: below).
NOTE: Do not remove bushings or corrosion in

hibiting sealer.
(2). Using bright light and 5X magnifying
glass, visually inspect the attach lugs of
all main rotor blade upper and lower
root fitting and main rotor lead-lag
links for broken or cracked lugs,
corrosion or other damage to the lug
areas.
NOTE:
D Pay particular attention to area around
attach pin hole bushings in the lugs.
D Pay particular attention to the crosshatched areas.
(3). If slippage marks have already been
applied, inspect the root fitting for any
indication of movement of the bushings;
no movement is allowed. Return main
rotor blades that have root fitting
bushing movement to MDHI for
MAINTENANCE MANUAL
possible rework. If slippage mark is
degraded, reapply.
(4). Perform main rotor blade upper and
lower root fitting inspection as follows:
(a). Inspect main rotor blade root fitting
for missing (no squeeze-out) or
cracked adhesive/paint around the
periphery of the root fitting. If this
condition exists, proceed as follows:
1). Loosen, but do not remove the
extreme outboard bolt.
2). Insert a 0.004 inch (0.102 mm)
thick piece of mylar/viewfoil
between the fitting and the dou
bler.
3). If the mylar can be inserted,
contact Field Service Representa
tive for disposition of blade.
4). If the insertion is 0.10 inch (2.54
mm) or greater, remove blade from
service.
NOTE: Measurement of the insertion is from

the edge of the root fitting.
5). Retorque root fitting outboard bolt
to 60 - 65 inch-pounds (6.78 7.34 Nm) plus drag torque.
In the following step, a crack
CAUTION might be difficult to detect if
bright light is not used.
NOTE: The lower side of the blade is more sus

ceptible to cracking.
(b). Using a bright light, inspect doubler
and root fitting, paying particular
attention to the lower side, for
cracks. If crack is found, blade is to
be scrapped.
NOTE: Lead-Lag link assemblies may only be

replaced by MDHI authorized personnel or
under MDHI supervision. Contact your local
Field Service Representative for further in
formation.
CSP-HMI-2
(5). Inspect lead-lag link blade attach pin

hole bushings for any indication of
movement of the bushings in the links.
If any of the bushings have movement,
replace the links.
If required, apply a light but
thorough coat of sealer (CM420)
or primer (CM318) around bushings. Note
that excessive amounts of sealant or primer
around the bushings are not desirable and
can unbalance the main rotor system.
CAUTION
(6). If sealing compound is not already

installed or becomes loose, clean and
then seal all junctions between all the
steel bushings and the main rotor blade
root fitting attach lugs with a film of
sealing compound or zinc-chromate
primer without removing the bushings.
(7). For the main rotor blade root fitting
attach lugs, carefully remove sufficient
amount of sealant and paint from only
the bushing in the area where the
slippage mark is to be applied (if not
already done). Using isopropyl alcohol
(CM217), clean the area where the
slippage mark is going to be applied to
allow adequate adherence of epoxy
paint.
NOTE:
D Locate slippage mark in a position that
can be viewed at subsequent inspections
with main rotor blade installed in the
hub. Slippage marks should not be ap
plied to cross-hatched areas to preclude
masking possible cracks.
D Insure that slippage mark is applied to
bushing at upper and lower root fitting in
side surfaces.
D Do not use torque seal.
(8). Apply epoxy paint slippage marks to
four locations as shown.
(9). Install main rotor blades (Ref. Main
Rotor Blade Installation).
62-10-00
Page 609
Revision 29
CSP-HMI-2
MAINTENANCE MANUAL
7. Main Rotor Blade Leading Edge Abrasion

Strip Check
8. Main Rotor Blade Torque Event Inspection
The leading edge abrasion strip should be

checked prior to each flight or on every daily
check. The following is a comprehensive
checklist:
NOTE: This inspection requires the use of a
NOTE: If void is noted towards end of blade, re

move tip cap and check for presence of bal
ance weights. If weights are not installed, a
false indication of a void is possible.
(1). Check for any blistering, bubbling or
lifting of the abrasion strip; this
indicates a void.
(a). Voids cannot be closer than 0.50 inch
(12.70 mm) to any outside edge of
abrasion strip.
(Ref. Figure 604)

bright light.
(1). Lifting from the outboard end of the
blade, lift blade off the droop stop.
(2). Inspect the bottom-side of the blade as
follows:
(a). Using a bright light and 10x magni
fying glass, inspect for chordwise
cracks protruding from under root
fitting and doubler (View C and Note
7).
(b). Inspect the area around the root
fitting, doubler and skin for cracks.
(b). Voids exceeding 1.5 square inch

(9.677 square cm) are unacceptable.
(c). Inspect the attach lugs at the bush

ings for cracks.
(c). Voids cannot be closer than one inch

(2.54 cm) to any other void.
(d). Inspect the entire length of the blade

for cracks.
(2). Number of acceptable voids depends

upon length of abrasion strip.
(a). There cannot be more than three
voids on either the top or bottom of
the 36 inch (91.44 cm) long abrasion
strip surface.
(b). There cannot be more than two voids
on either the top or bottom of the 18
inch (45.72 cm) long abrasion strip
surface.
(3). Record all voids in regards to size and
location in the helicopter log book and
check each void prior to each flight for
growth and acceptable criteria.
Page 610
Revision 35
62-10-00
(e). Lower blade back onto droop stop.

(3). With blade resting on the droop stop,
inspect the top-side of the blade as
follows:
(a). Inspect the area around the root
fitting, doubler and skin for cracks.
(b). Inspect the attach lugs at the bush
ings for cracks.
(c). Inspect the entire length of the blade
for cracks.
(4). If any of the above defects are found,
the main rotor blade is to be rejected
and scrapped.
MAINTENANCE MANUAL
CSP-HMI-2
NOTES 2, 3 AND 4
DOUBLER
NOTE 6
ROOT FITTING
NOTE 5
(NOTES 1, 2 AND 3)
NOTE 7
NOTE 5
VIEW LOOKING UP
ROTATED
LOOSEN BUT DO NOT REMOVE BOLT.
RETORQUE BOLT TO 60 - 65 INCH-POUNDS
(6.78 - 7.34 NM) PLUS DRAG TORQUE.
UPPER ROOT FITTING ATTACH LUG
(TYP 2 PLACES) (NOTE 1)
NOTE 5
LEAD-LAG LINK ATTACH LUG
(TYP 8 PLCS) (NOTE 1)
MAIN ROTOR BLADE
LOWER ROOT FITTING AT

TACH LUG (TYP 2 PLCS)
(NOTE 1)
NOTES:
1. VISUALLY INSPECT AREAS OF ALL ROOT FITTINGS AND LEAD-LAG ATTACH LUGS FOR CRACKS OR
BREAKS. INSPECT BLADE ATTACH BUSHINGS FOR LOOSENESS. IF LOOSE, REPLACE LEAD-LAG LINKS.
2. PAY PARTICULAR ATTENTION TO AREA AROUND ATTACH PIN HOLES IN LUGS.
3. SEAL ALL JUNCTIONS BETWEEN BUSHINGS AND ATTACH LUGS WITH SEALER OR PRIMER (CM318).
4. LEAD-LAG LINK ASSEMBLIES ARE SUB-ASSEMBLIES OF THE MAIN ROTOR HUB ASSEMBLY.
5. INSPECT MAIN ROTOR BLADE UPPER AND LOWER ROOT FITTING FOR MISSING OR CRACKED ADHESIVE.
6. USING BRIGHT LIGHT, INSPECT MAIN ROTOR BLADE DOUBLER FOR CRACKS. PAY PARTICULAR ATTENTION
TO BOTTOM SIDE OF BLADE, JUST BEYOND ROOT FITTING AND IN LINE WITH ROOT FITTING ATTACH BOLTS.
7. USING A BRIGHT LIGHT AND 10X MAGNIFYING GLASS, INSPECT FOR CHORDWISE CRACKS PROTRUDING
FROM UNDER ROOT FITTING AND DOUBLER.
G62-1009D
Figure 604. Main Rotor Blade Root Fitting, Attach Lugs and LeadLag Link
Assembly Inspection
62-10-00
Page 611
Revision 35
MAINTENANCE MANUAL
CSP-HMI-2
* ONLY REMOVE 1/2 DEPTH OF

CORROSION INHIBITING SEALER
AT LOCATION WHERE SLIPPAGE
MARK IS TO BE APPLIED.
UPPER ROOT FITTING
SLIPPAGE MARK LOCA

TIONS
SLIPPAGE MARK LOCA

TIONS (INSIDE SURFACES)
DO NOT APPLY SLIPPAGE

MARK TO CROSS-HATCH
AREAS
LOWER ROOT FITTING
VIEW LOOKING UP
SLIPPAGE MARK LOCATIONS

(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
Revision 20
62-10-00
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR BLADE

REPAIRS
1. Main Rotor Blade Repair (Nicks,
Scratches and Wear Spots)
Item
CM206
CM801
Nomenclature
Chemical coating
(Ref. Figure 601)

Do not use chemical paint re
mover to remove paint from
abrasion strip. Chemicals can attack the
abrasion strip to blade bonding agent.
CAUTION
(1). Using abrasive paper (CM801), not

coarser than grade 320, remove nicks,
scratches and wear spots from upper
and lower root fittings, and from blade
skin.
(2). Use finer grade of paper, as necessary
to restore surface roughness to original
finish.
(3). Remove material in such a manner that
no abrupt changes occur in surface
contours.
(4). Apply chemical film surface treatment
(CM206) to repaired surface(s) (Ref.
Sec. 20-30).
2. Main Rotor Blade Repair (Dents,
Depressions and Erosion)
(Ref. Figure 602)
Item
CM220
CM229
CM234
CM304
CM507
CM508
CM708
CM801
Nomenclature
Naphtha aliphatic
Paint remover
Enamel, epoxy
Resin, filler
Resin, filler
Tape
CAUTION
D Repair only those damaged areas that are
within repairable limits specified.
D Do not use chemical paint remover to re
move paint from abrasion strip. Chemi
cals can attack the abrasion strip to blade
bonding agent.
(1). Using abrasive paper (CM801), not
coarser than grade 320, remove paint
from surface area to be repaired.
(2). Clean abraded area with clean cloth
dampened by solvent (CM234). Allow to
dry for minimum of 15 minutes.
(3). Mask edges of repair areas with one
layer of tape (CM708).
CAUTION
Do not cut tape after it is

applied to blade.
(4). Mix filler (CM507), three parts A and

two parts B by weight. Mix thorough
ly until mixture is dark red in color. An
alternate filler (CM508) may be used if
equal parts A and B by weight are
mixed.
(5). Allow filler to cure for minimum of 24
hours at room temperature.
(6). Smooth filler area with grade 400
abrasive paper (CM801). Limit smooth
ing to masked area.
(7). Remove the tape and inspect alclad
coating of area around repair. Penetra
tion of coating is cause for blade
replacement.
(8). Clean repaired area with a cloth
dampened by solvent (CM220).
(9). Apply chemical film treatment to
repaired surface (Ref. Sec. 20-30-00).
(10). Touch-up reworked area with paint
(CM304) as required.
62-10-00
Page 801
Revision 33
MAINTENANCE MANUAL
CSP-HMI-2
3. Trim Tab Damage Repair

(Ref. Figure 802)
Item
Nomenclature
CM206
Chemical coating
CM220
Naphtha aliphatic
CM234
CM304
Enamel, epoxy
CM318
Primer
(6). If excessive damage requires full or

partial removal of trim tab from blade,
perform the following (no minimum
length of trim tab is required):
(a). Position blade on workbench so that
a straight edge is provided for cutting
or filing off trim tab.
Cutting, grinding or filing to re
move trim tab, and deburring of
reworked blade trailing edge, are to be per
formed in a SPANWISE direction only. Do
NOT use shears or clippers to remove trim
tab.
CAUTION
Provide protective surface and/

or covering to prevent scratch
ing, nicking or other damage to blade during
rework. Position blade on work bench or
equivalent.
(b). Use metal cutting saw or equivalent

to remove the 0.38 inch (9.65 mm)
wide trim tab per dimensions shown
Ref. Figure 802, View A-A). Deburr
edges in a SPANWISE direction only.
CAUTION
NOTE: No minimum length of trim tab is re

quired. In addition, the entire trim tab, or
portion of the trim tab, may be removed if
required. Removal of entire trim tab elimi
nates adjustment of blade tracking capabili
ty for that blade. Main rotor blades with and
without trim tabs are 100% interchange
able, individually and in ship sets.
(1). Remove main rotor blade with damaged
trim tab.
(7). Peel and remove tape from blade and

inspect area around repair; clean
repaired area with cloth dampened in
naptha (CM220).
(8). Apply chemical film treatment (CM206)
to reworked area of blade trailing edge
or trim tab; apply a thin film of primer
(CM318) and paint (CM304) lightly.
(9). Reinstall main rotor blade and perform
track and balance (Ref. Sec. 18-10).
(2). Wipe away dirt on and around trim tab

area with clean cloth dampened with
dry cleaning solvent (CM234).
NOTE: Removal of entire trim tab eliminates
(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
at the bottom of the V. Maximum V-cut
depth is 0.35 inch (8.89 mm); do not cut
past trim tab area into main portion of
blade.
(5). If damage occurs within 1 inch (2.54
cm) of either or both ends of trim tab,
remove tab end(s) and restore contour
as shown.
Page 802
Revision 20
62-10-00
adjustment of blade tracking capability for

that blade.
Item
Nomenclature
CM318
Primer
Replace a loose or stripped insert. Use

self-locking insert of correct size and install
with wet primer (CM318). Comply with
replacement requirements of applicable NAS
standard.
MAINTENANCE MANUAL
CSP-HMI-2
MS2070AD3
RIVETS (2 PLS)
EXISTING
BLADE RIVET
6.312 INCH
(16.033 CM)
(REF)
EXISTING
BLADE RIVET
EXISTING
BLADE RIVET
1.58 INCH
(4.013 CM)
(REF)
9.25 INCH
(23.495 CM)
0.75 INCH
(19.05 MM)
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
G62 1003A
Figure 801. Main Rotor Blade Trailing Edge Weight Rework.
62-10-00
Page 803
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
5. Loose Balance Weight Repair

(Ref. Figure 401) Reinstall loose forward and aft
balance weights as follows:
Item
Nomenclature
CM431
(1). Unscrew loose weight until it projects

approximately one-half inch (12.7 mm)
and remove old accumulation of
powdered compound.
(2). Apply grade A locking compound
(CM431) and screw weight back into
blade until slotted end of weight is
recessed 0.050 inch (1.27 mm) below tip
surface. Wipe off excess compound.
Allow to cure for a minimum of
12 hours. If faster cure is de
sired, complete cure can be obtained by al
lowing part to set for 30 minutes at room
temperature and then heating for 30 min
utes at approximately 212F (101C).
CAUTION
(3). If locking compound is not available,

screw weight into normal position and
centerpunch end of weight into mating
threads at three evenly spaced points to
prevent rotation.
6. Loose Trailing Edge Weight Repair
(Ref. Figure 801)
Item
Nomenclature
CM220
CM318
CM409
CM804
Naphtha aliphatic
Primer
Adhesive, epoxy
Emery cloth, fine
(1). Carefully remove loose or partially

debonded weights.
(2). Abrade debonded surface using
#200-300 grit emery cloth (CM804).
(3). Clean bonding surfaces with naptha
aliphatic (CM220).
Page 804
Revision 20
62-10-00
(4). Mix epoxy adhesive (CM409) per

manufacturer`s instructions and apply
to bonding surfaces.
(5). Position weights on blade by aligning
holes in weights to existing rivet holes
on blade and apply light pressure to
weights until epoxy sets.
(6). Install (3 ea.) rivets in existing holes.
(7). If not already installed, install two
more rivets as follows.
(a). Mark location of rivets to be in
stalled.
(b). Drill holes at marked locations.
(c). Deburr and clean debris from holes.
(d). Coat all exposed surfaces with primer
(CM318).
(e). Install rivets.
(f). Allow epoxy adhesive to cure per
manufacturer's instructions before
flying aircraft.
7. Loose or Missing Rivets or Aft Tip Cap
Repair
(Ref. Figure 401) Replace all loose or missing
rivets. Reinstall or replace loose or missing aft tip
cap as follows:
Item
CM234
CM318
CM411
CM801
Nomenclature
Primer
Adhesive, epoxy
NOTE: Spare tip caps are supplied with bond

ing surface coated with nylon primer to fa
cilitate installation. Main rotor balance is
not affected by following repair.
(1). Lightly abrade primed surfaces of tip
cap with grade 180 abrasive paper
(CM801). Wipe away residue with cloth
dampened in solvent (CM234) and
allow tip cap to dry at room tempera
ture for 30 minutes.
(2). Mix two-part bonding adhesive
(CM411) in equal proportions by
weight.
MAINTENANCE MANUAL
CSP-HMI-2
NOTE 2
NOTE 2
TOP
SURFACE
0.38 INCH
(9.652 MM)
6.80 INCH (17.272 CM)
NOTES 2, 3
NOTE 1
NOTE 3
0.00 - 0.10 INCH

(0.00 - 2.54 MM)
0.38 INCH
(9.652 MM)
VIEW A-A
1.00 INCH
(2.54 CM)
NOTE 4
1.00 INCH
(2.54 CM)
NOTES:
1. REMOVE DAMAGED END(S) IF THEY OCCUR WITHIN 1 INCH (2.54 CM) OF TAB ENDS.
2. 0.25 INCH (6.35 MM) RADIUS CLEANUP. FINISH PER BASIC HMI.
3. MAXIMUM DEPTH OF REPAIR 0.35 INCH (8.89 MM).
4. NO MINIMUM LENGTH OF TAB REQUIRED. IF DAMAGE OCCURS AT BOTH ENDS, IT IS
PERMISSIBLE TO REMOVE AT BOTH ENDS.
5. ENTIRE TAB MAY BE REMOVED IF REQUIRED.
Figure 802. Repair and Removal of Trim Tab, Main Rotor Blade
0.002 INCH
(0.0508 MM)
MAXIMUM
ARM
EDGE OF
STAKING TOOL
FLUSH TO
+0.010 INCH
(+0.254 MM)
BEARING WITH STAKING
GROOVE IN OUTER RACE
PRESSING
BEARING IN ARM
STAKING
BEARING IN ARM
G62 1005A
Figure 803. Bearing Replacement Main Rotor Blade Damper Attach Fitting
62-10-00
Page 805
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
(3). Apply bonding adhesive to abraded tip

cap and mating surfaces at rotor blade
tip. To extent possible, be sure that
there are no adhesive voids.
(4). Install tip cap in blade tip, apply
uniform clamping pressure to joint, and
wipe away excessive adhesive. Allow to
cure for eight hours at room tempera
ture or two hours at 150F (66C).
(5). Install two MS20604AD3C2 blind
rivets, one though each side of blade tip
and tip cap.
8. Damper Attach Blade Fitting Bearing
Replacement
(Ref. Figure 803)
Item
Nomenclature
CM216
CM219
CM318
Loctite remover
Methyl-ethyl-ketone
Primer
Item
Special Tools
Nomenclature
ST709
ST710
Arbor press fixture

Staking tool
(1). Use fly or circle cutter with 5/16 inch

(7.9375 mm) pilot to remove staked lip
from one side of bearing without
removing any material from fitting. If
fitting is damaged by cutter, blade must
be replaced.
(2). Use an arbor press to press bearing
from fitting.
(5). Measure fitting bore diameter. Accept

able limits are 0.7488-0.7493 inch
(19.01952-19.03222 mm).
(6). Apply thin coat of primer (CM318) to
fitting bore.
(7). Press bearing into fitting with arbor
press and fixture (ST709). Wipe away
excess primer.
(8). Stake bearing at both sides of fitting
with staking tool (ST710) in hydraulic
press with 6000-8000 pounds
(2722-3629 Kg) of force. When staked,
outer race of bearing shall be flush to
not more than 0.010 inch (0.254 mm)
above fitting surface (both sides). Gap
between staked lip of bearing race and
chamfered surface of fitting bore shall
not exceed 0.002 inch (0.0508 mm) as
checked with feeler gage. Staking
operation shall produce no cracks in
fitting or bearing.
(9). Fill staking gap, if any, with primer
(CM318).
9. Leading Edge Protective Tape
Replacement
(Ref. Figure 804 and Figure 805) Replace
protective tape when it is abraded. Operation in
rain reduces tape life and more frequent replace
ment is necessary.
Item
Nomenclature
CM220
CM801
Naphtha aliphatic
(1). Lightly abrade faying surface of main

rotor blade with 400 grit abrasive paper
(CM801).
(3). Clean primer residue from fitting bore

with MEK (CM219). Remove locking
compound residue, if any, with locking
compound remover (CM216).
(2). Wipe faying surface of blade with

naptha aliphatic (CM220) to eliminate
grease or dirt film.
(4). Using 10-power magnifying glass,

inspect fitting bore for cracks. No
cracks are permitted.
(3). Use heat gun or equivalent to warm

blade faying surface. Temperature must
not exceed 120F (49C).
Page 806
Revision 20
62-10-00
MAINTENANCE MANUAL
CSP-HMI-2
24.00 INCH
(60.96 CM)
NOTE 1
MAIN ROTOR
BLADE
BLADE PROFILE
ABRASION STRIP
NOTE 2
CHORDWISE
BALL. WEIGHT
ABRASION STRIP TIP

EROSION 0.40 INCH
(10.16 MM) MAXIMUM
SKIN TIP EROSION

0.30 INCH (7.62 MM)
MAXIMUM
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.
G62-1006A
Figure 804. Installation/Replacement of Stainless Steel Abrasion Tape

(Main Rotor Blade Leading Edge)
62-10-00
Page 807
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
30.00 INCH
(76.2 CM)
(REF)
12.00 INCH
(30.48 CM)
M50459-1
ABRASION TAPE
(BOTTOM LAYER)
0.50 INCH
(12.7 MM)
M50459-7
ABRASION TAPE
1.00 INCH
(2.54 CM)
A
369D21100-505 OR
369D21100-509 MAIN
ROTOR BLADE ASSY
M50459-1 ABRASION
TAPE (BOTTOM LAYER)
1.00 INCH
(2.54 CM)
369D21105
OR
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.
Figure 805. Installation/Replacement of Double Layer Abrasion Tape

(369D21100505 and 509 Rotor Blades)
Page 808
Revision 20
62-10-00
G62-1007A
MAINTENANCE MANUAL
(4). Remove backing and apply stainless
steel abrasion tape to outboard leading
edge of main rotor blade as follows:
(a). Apply 6.50 inch (16.5 cm) wide and
24 inch (61 cm) long abrasion tape
along blade leading edge (Ref.
Figure 804) so tape overlaps bottom
and top of blade edge equally or (Ref.
Figure 805) for 369D21100-505 and
-509 blades.
(b). Smooth and press abrasion tape into
place by hand. Use heat gun or
equivalent to maintain temperature.
(c). Re-apply pressure by hand following
initial installation to ensure proper
bonding. Abrasion tape must be free
of surface wrinkles or air bubbles.
MEK is flammable. Use in
WARNING well ventilated area and

away from open flame.
(3). Clean areas to be sealed with clean
cloth moistened with solvent (CM228).
For hard to clean problem areas, MEK
(CM219) may be used.
(4). Prepare adhesive (CM404) per
(5). Apply bead of adhesive to interface of
abrasion strip and blade skin. Ensure
there are no gaps or bridges in bead.
(6). Cure adhesive per manufacturer's
instructions.
11. Tip Cap Sealing
(Ref. Figure 805)
NOTE: A second abrasion tape may be applied

on top of the first tape to facilitate replace
ment when top tape becomes eroded. To ap
ply second tape, wipe surface of installed
strip clean with naptha aliphatic (CM220)
and repeat steps (3). and (4). above. Second
abrasion tape must be evenly aligned with
first at top surface of blade (Ref. Figure 804)
for 369D21100 blades or (Ref. Figure 805)
for 369D21100-505 and -509 blades.
CSP-HMI-2
Item
Nomenclature
CM212
CM213
CM318
CM420
CM427
CM428
Releasing agent
Releasing agent
Primer
Sealant
Sealing compound
Sealing compound
10. Leading Edge Abrasion Strip Sealing

(Ref. Figure 805)
Item
Nomenclature
CM219
Methyl-ethyl-ketone
CM228
Surface cleaner
CM404
Adhesive, epoxy
(1). Remove screw and tip cap from main

rotor blade.
(1). Apply release agent (CM212 or CM213)

to inside of tip cap per manufacturer's
instructions.
(2). Prepare and apply a 0.010-0.020 inch
(0.254-0.508 mm) coating of sealant
(CM420, CM427 or CM428) to faying
surfaces per manufacturer's instruc
tions.
(3). Attach tip cap to blade and install
screw with primer (CM318).
(4). Wipe off squeezed out sealant flush
with surface.
NOTE: To inhibit moisture entering bond joint

(2). Remove any loose or cracked sealant or
adhesive from areas of main rotor
blade.
of abrasion strip after initial application,

reapply sealant, when sealant is worn away
or becomes cracked.
62-10-00
Page 809
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
C
SEAL WITH EC2216 B/A FROM L.E. TO
0.75 INCH (19.05 MM) DIM. ON T.E.
RADIUS (UPPER AND LOWER SURFACE)
0.75 INCH
(19.05 MM)
369A1116 TIP CAP

SEAL WITH
PR1436G, CLASS B-2
OR
PR1422G, CLASS B
C
0.75 INCH
(19.05 MM)
369D21100 MAIN ROTOR BLADE

ASSEMBLY
369D21105 ABRASION STRIP REF.
0.003-0.005 INCH
TYP
(0.0762-0.127 MM)
.
369A1103 SKIN REF.
SEAL WITH
EC2216 B/A
0.010 INCH
(0.254 MM)
TYP
369A1109-501, 269A1186
BAL. WT. REF.
SEAL WITH
EC2216 B/A
A-A
SEAL SKIN / BAL. WT.

ASSY INTERFACE
WITH EC2216 B/A
TIP CAP OMITTED FOR CLARITY
0.12 INCH
(3.048 MM)
TYP
369D21105 ABRASION STRIP
C-C
TYP 2 PLCS
SEAL SCREW BY INSTALLING

WITH WET PRIMER
369A1103 SKIN
NAS517-3-0
G62-1013A
Figure 806. Main Rotor Blade Abrasion Strip and Tip Cap Sealing
Page 810
Revision 20
62-10-00
MAINTENANCE MANUAL
12. Main Rotor Blade Protective Tape
Installation
In an effort to reduce the amount of erosion in
the area inboard of the abrasion strip, MDHS
has approved the installation of stainless steel
or Mylar tape to the blade leading edge.
Installation of the tape is optional.
The approved 3M Mylar tape, P/N 8671-1, is
one inch (2.54 cm) wide and the 304 stainless
steel tape, P/N 87-369D21104, is 0.027 inch
(0.6858 mm) thick and two inch (5.08 cm)
wide.
The length of the tape can vary, up to 8.0
inches (20.32 cm) in length, but must be equal
on all blades.
It is recommended to start with 2.5 inch (6.35
cm) length and increase the length as erosion
occurs by replacing the tape.
NOTE:
D This installation is only approved on
main rotor blades equipped with the 36
inch (91.44 cm) abrasion strips.
D For installation of the Mylar tape, refer to
manufacturer's instructions. Use of aero
sol primer Promoter 86 may be used to
speed cure time of the tapes adhesive.
Mylar tape comes in rolls one inch (2.54
cm) wide by 36 yards (329184 m) in length
and the promoter comes in 36 ounce
(1.065 L) cans. Mylar tape can be pur
chased from RS Hughes Company
(1-800-453-8116).
A. Stainless Steel Tape Installation
Item
Nomenclature
CM220 Naphtha aliphatic
CM801 Abrasive paper, silicon carbide
Do not cut or trim tape after

installation on blade, damage to
blade will occur.
CAUTION
(1). Measure length of eroded area on blade

with the most erosion.
CSP-HMI-2
NOTE: Tape must be of equal length on all

blades to ensure proper balance.
(2). Cut tape long enough to cover erosion
plus approximately one-half inch (12.7
mm) overlap on leading edge abrasion
strip.
(3). Round off square corners of tape to
reduce peeling.
(4). Lightly abrade faying surface of main
rotor blade in area where tape is to be
installed with 400-grit abrasive paper
(CM801).
(5). Wipe abraded area with naphtha
aliphatic (CM220) to eliminate grease
and dirt film.
(6). Treat any bare metal with epoxy-type
paint.
NOTE: Do not allow temperature to exceed

120F (49C).
(7). Using a heat gun, or equivalent, heat
abraded area.
(8). Apply aerosol primer to bonding area
and allow to dry.
(9). Remove backing and apply tape to
leading edge of blade.
(a). Apply tape so it overlaps each side of
blade equally.
(b). Tape should overlap the inboard end
of abrasion strip 0.5 0.03 inch (12.7
0.762 mm) at the leading edge of
blade.
NOTE: Tape must be free of surface wrinkles or

air bubbles.
(10). Smooth and press tape into place by
hand.
(11). Re-apply pressure by hand following
bonding.
(12). Perform main rotor balance (Ref. Sec.
18-10-00 or 18-10-60).
62-10-00
Page 811
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
Page 812
Revision 44
62-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
622000
Main Rotor Hub
(369D/E/FF 500N)
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR HUB

1. Main Rotor Hub General
The main rotor hub consists of a central hub,
five identical pitch housings spaced 72 degrees
apart horizontally around the hub with
associated mechanisms and linkages.
Lead-lag links, a lead-lag damper, a droop
stop striker strip and spacer, and a pitch
control bearing with each pitch housing
produce the pivoting axis, blade flapping stop
contact surfaces and lead-lag hinge function
for the rotor blades.
(3). Remove lockwire and disconnect

flexible boot from lower end of hub
liner.
(4). Disconnect each pitch control rod from
pitch housing.
(5). Disconnect scissors crank from main
rotor hub or scissors link.
NOTE: To facilitate assembly, color code each

pitch control rod to match pitch housing to
which it is attached.
Five laminated retention strap assemblies that

are flexible both vertically and torsionally
extend through the pitch housings and connect
to the lead-lag links.
(6). Remove two screws securing retainer to

main rotor hub nut.
A lower shoe, attached to the central hub,

contains a droop stop ring and droop restrain
ers that support the blades at rest and
distribute droop loads at low blade rpm.
(8). Using main rotor mast nut wrench

(ST701), remove nut from mast.
The following instructions provide field

maintenance and repair procedures for the
main rotor hub.
2. Main Rotor Hub Replacement
A. Main Rotor Hub Removal
(7). Remove nut retainer.
(9). Using hub puller (ST702), break loose

main rotor hub (Ref. Figure 401).
Remove hub puller.
(10). Attach hoisting adapter, to eyebolts and
hoist hub from mast.
B. Main Rotor Hub Installation
(Ref. Figure 402)
(Ref. Figure 401)
Item
Special Tools
Nomenclature
ST201
ST701
ST702
Hoisting adapter
Main rotor wrench assembly
Hub puller
Item
Nomenclature
CM111
CM115
CM204
CM702
Grease, aircraft
Grease, oscillating bearing
Compound, corrosion preventative
Lockwire CRES
Item
Special Tools
Nomenclature
ST201
ST701
ST703
Hoisting adapter
Main rotor hub driver
(1). Remove all main rotor blades.

(2). Remove main rotor drive shaft; then
reinstall hoisting eyebolts, washers and
nuts in rotor hub. Locate them to
correspond with lugs of hoisting
adapter (ST201).
62-20-00
Page 401
Revision 36
CSP-HMI-2
MAINTENANCE MANUAL
Main rotor hub is a highly

stressed component. Use ex
treme care to prevent it from striking any
object. Any impact damage may require re
placement of hub.
CAUTION
NOTE:
D Removal of recessed spacer, upper bear
ing cone, upper seal and seal retainer is
not mandatory for installation of the
main rotor hub. If these items are in
stalled, perform steps (1). thru (4). and
(11). thru (22). Caution should be used
when installing hub to prevent damage to
these parts.
D If recessed spacer, upper bearing cone,
upper seal and seal retainer have been re
moved, these parts should not be as
sembled in hub before installation of hub
on helicopter. These items are reas
sembled in hub after seating hub on mast.
Prior to installing main rotor hub, insure
that all bearings are adequately serviced
D Replacement main rotor hubs do not come
balanced from MDHS. If installing a re
placement hub, perform a main rotor hub
balance (Ref. Sec. 18-10-00, Main Rotor
Hub Balance Procedure).
(1). Attach hoisting adapter (ST201) to
eyebolts in main rotor hub and connect
suitable hoist.
If hub assembly (with sleeve
bushing, spacer, upper bearing
and seal retainer installed) does not seat
properly onto mast, do not attempt to force it
into position. Remove hub assembly from
mast and determine cause of hub not seat
ing, correct the problem and follow the pro
cedures for reinstallation.
CAUTION
(2). Check that rotor mast is clean. Hoist

main rotor hub and position over mast;
then lower hub onto mast.
NOTE: To inhibit mast corrosion when operat

ing in salt water environment, lightly coat
bearing journals of mast with grease
(CM115).
(3). Remove adapter, hoist and eyebolts.
(4). Check that hub is fully seated on mast.
Page 402
Revision 20
62-20-00
(5). Hand-pack hub cavity, between sleeve

bushing and hub, with grease (CM111).
(6). Place recessed spacer, recess down, on
top of sleeve bushing.
(7). Hand-pack upper bearing cup and cone
with grease; then install cone on mast
and use hub drive tool (ST703), to fully
seat cone.
(8). Fill remaining cavity to upper seal with
grease.
(9). Position upper seal in seal retainer
with lip up; then press seal and retain
er in hub counterbore.
(10). Using a soft drift, carefully tap seal
outer ring to seat in counterbore. Wipe
away any excess grease.
(11). Apply grease (CM111) to exposed
threads on mast.
Be sure that seal is properly po
sitioned against seal retainer
and that seal retainer does not pinch seal.
Check by inserting a loop of approximately
0.050 inch (1.27 mm) diameter lockwire,
round feeler gage or other suitable tool with
out sharp edges between seal lip and retain
er.
CAUTION
NOTE: To insure that hub is seated onto mast

properly before torquing, 2 - 4 threads
should be showing above the mast nut with
nut installed finger tight.
(12). Install mast nut, using wrench (ST701);
torque nut to 200 foot-pounds (271
Nm). Apply coat of corrosion preventive
compound (CM204) to screw holes in
mast nut.
(13). Place retainer on nut and check
retainer-to-nut screw hole alignment.
(14). Increase nut torque to not more than
250 foot-pounds (339 Nm) to align
holes in retainer and nut.
NOTE: If holes cannot be aligned in 200 - 250

foot-pound (271 - 339 Nm) torque range,
remove and invert nut and repeat proce
dures in (12). thru (14). to align holes.
(15). Secure retainer to nut with two screws;
lockwire screws.
MAINTENANCE MANUAL
CSP-HMI-2
SLEEVE BUSHING
ROTOR HUB
OUTER LINER
SEAL
JAW CONTACT
POINT
MAIN ROTOR PULLER

(ST702)
LIFT POINT
(TYPICAL 3 PLACES)
THRUST PAD
ROTOR MAST
ROTOR MAST
G62-2004A
Figure 401. Pulling Hub Assembly
62-20-00
Page 403
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
Ensure that no washers are

used under screwheads and that
screwheads are free of burrs.
CAUTION
(16). Verify that screwheads do not project

more than 0.020 inch (0.508 mm) above
hub upper surface, for adequate
clearance between screwheads and
driveshaft flange.

avoid lead-lag loads in excess of 35 pounds
(155.68 N) at the tip of the main rotor
blades.
CAUTION
NOTE:
(17). Connect scissors crank to main rotor
hub lower shoe and/or to scissors link.
NOTE: Ensure pitch control rods are installed

at same locations from which removed.
(18). Install five pitch control rods to pitch
housings (Ref. Sec. 62-30-00, Pitch
Control Rod Replacement).
(19). Connect flexible boot to lower end of
rotor hub liner and secure with lock
wire (CM702).
(20). Install main rotor drive shaft (Ref. Sec.
63-10-00).
(21). Install five main rotor blades.
(22). Perform main rotor blade droop angle
check if hub is new or replacement.
(23). Perform main rotor hub balance (Ref.
Sec. 18-10-00, Main Rotor Hub
Balance Procedure) if a new or rebuilt
hub is installed.
3. Main Rotor Damper
(Ref. Figure 603) A main rotor damper is
attached to each pitch housing of the rotor
hub. The damper is connected to the inboard
trailing edge of the associated main rotor blade
by an adjustable clevis to prevent lateral
vibrations from occurring in main rotor blades.
Neither damper travel nor stiffness is adjust
able on the helicopter. Phasing of rotor blades
is affected by turnbuckle adjustment. Any
phasing problem caused by a defective damper
should be corrected by replacing damper.
Page 404
Revision 36
62-20-00
D Refer to MDHS Notice DN-45.2 for infor

mation concerning required modification
of dampers produced prior to October
1979. If lead-lag dampers, P/N
369D21400-501 are installed, they must
be modified to M50452 or be replaced
with P/N 369D21400-503 dampers.
D If one or more main rotor blades strike an
object while rotating or the drive system
has been subjected to sudden stop, inspect
damper.
4. Main Rotor Damper Replacement
A. Main Rotor Damper Removal
(1). Note and record location from which
damper is to be removed from main
rotor hub.
NOTE: At reinstallation, if damper is not rein

stalled at same location, a check of and/or
blade phasing is required.
(2). Support blade parallel to ground.
(3). Remove damper.
NOTE: If damper is to be reinstalled at same lo

cation, do not disturb damper clevis, jam
nuts or turnbuckle setting. Otherwise, blade
phasing is required at reinstallation of
damper.
(4). If damper is not to be reinstalled,
remove bushing from damper ear and
retain with hub.
B. Main Rotor Damper Installation
(1). Check, and if necessary, preset main
rotor damper length (Ref. Nominal
Damper Adjustment Procedure). Leave
jamnuts fingertight.
NOTE: Ensure that bushing is installed in

large hole of damper ears.
MAINTENANCE MANUAL
(2). With damper rotational direction decal
facing outboard so it can be read, attach
damper ears to pitch housing lug with
bolt (head up), washers, and nut.
(3). Adjust main rotor blade phasing for
associated main rotor blade.
(4). After final phasing adjustments, torque
jamnuts to 95 - 110 inch-pounds
(10.73 - 12.43 Nm). Safety jamnuts to
turnbuckle with new lockwire. Lock
wire must be located out-board, away
from pitch housing.
NOTE: Threaded end of damper turnbuckle

shaft must protrude through clevis base a
minimum of two full threads and must clear
blade damper attach fitting.
(5). Connect damper to blade.
(6). Remove blade support.
5. Main Rotor Damper Nominal Adjustment
(1). Remove all five main rotor blade
dampers from helicopter if installed.
NOTE: If dampers are being replaced, do not

mix part numbers.
CSP-HMI-2
(2). Store all five dampers together in

horizontal position for minimum of six
hours. Preferred ambient temperature
during storage is 55 to 85F (13 to
30C).
(3). Set damper length, centerline-to-cent
erline of bolt attach holes, for initial
installation.
369D/E
8.229 0.005 inch (209.017 0.127 mm)
369F/FF
8.132 0.005 inch (206.553 0.127 mm)
500N
8.132 0.005 inch (206.553 0.127 mm).
(4). Install dampers on helicopter.
NOTE: If ground rock or stick shake is noted,

complete following step.
(5). Length of damper may be adjusted
after initial setting by checking main
rotor system balance (Ref. Sec. 18-10,
Main Rotor Balancing Procedure).
Check of main rotor system balance
should be accomplished only after main
rotor blades have been tracked.
If more than four flats turn of
turnbuckle adjustment is neces
sary to correct balance, return to step (1).
and repeat procedure.
CAUTION
62-20-00
Page 405
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
SCREW (2 PLACES)
(NOTE 2)
MAST
LOCKNUT
RETAINER
0.020 INCH (0.508 MM)
MAXIMUM SCREW HEAD
HEIGHT ABOVE HUB
LOCKWIRE
RETAINER
SCREW
LOCKNUT
DRIVE SHAFT
MAST
SEAL
SEAL RETAINER
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
FLEXIBLE BOOT
NOTE 1
ROTATING SWASHPLATE
NOTE 3
PITCH
CONTROL
ROD
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
OUTSIDE SURFACE OF PART AFTER NUT IS
TIGHTENED.
2. IF LOCKNUT AND RETAINER SCREWHOLES
DO NOT MATCH WITHIN CORRECT TORQUE
RANGE, LOCKNUT IS TO BE INVERTED.
3. WASHER(S) AS REQUIRED FOR BOLT END
TO SWASHPLATE BOOT CLEARANCE.
4. SHIMS / SHIM WASHERS USED TO FILL GAP
ON SHOULDERED BUSHING SIDE.
SCISSORS CRANK
G62-2005A
Figure 402. Main Rotor Hub Installation

Page 406
Revision 20
62-20-00
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR HUB

INSPECTION/CHECK
1. Main Rotor Hub Balancing General
(Ref. Sec. 18-20) Main rotor hub balancing is
accomplished by adding or removing weight
(flat washers) as required at the lead-lag
bolts. Analysis of main rotor hub balance is
accomplished using instrumentation that
measures and localizes vibrations due to main
rotor hub imbalance. Data provided by the
instrumentation is plotted on a chart designed
to indicate how much weight must be added or
removed from the lead-lag bolt. No other
means of balancing is to be used.
2. Main Rotor Blade Phasing Check and/or
Adjustment
Main rotor blade phasing (alignment) is
necessary at damper installation or replace
ment, and may be necessary if there is ground
rocking, or if one-to-one lateral (main rotor)
vibration occurs during flight (Ref. Main Rotor
Damper Nominal Adjustment).
3. Main Rotor Hub Inspection
Item
Nomenclature
CM232
(1). Inspect pitch housing for scratches,

nicks and cracks. No cracks are permis
sible. Scratches and nicks must be
cleaned up before measuring depth of
damage to determine housing service
ability.
(2). Inspect sleeve bushing for snug fit in
pitch housing arm clevis lug (Ref.
Figure 805); lug must not show evi
dence of wear caused by bushing
movement. Maximum allowable
diameter for hole in bushed lug is
0.5004 inch (12.71016 mm); for un
bushed lug, not more than 0.3135 inch
(7.9629 mm). Inspect inner surfaces of
all pitch housing arm clevis lugs for
chafing caused by misaligned pitch
control rod end bearings. Chafing is in
form of crescent-shaped grooves. If

chafing wear exists, repair or replace.
Chafed area must be cleaned up before
measuring depth of damage to deter
mine housing serviceability.
(3). Inspect droop stop ring for corrosion,
dents and scratches. If defects are
found, repair or replace.
NOTE: To inhibit corrosion, spray droop stop

ring, rollers and pitch bearings with rust in
hibitor (CM232).
(4). Inspect droop stop roller for flat spots,
pit marks and looseness on roller shaft.
(5). Inspect striker plate for dents and pit
marks that exceed 0.030 inch (0.762
mm) depth. Damage exceeding this
limit requires replacement of striker
plate.
(6). Press each pitch housing downward
several times and check for evidence of
binding pitch bearing or droop restrain
er follower. Inspect visible portion of
droop restrainer for cracks and follower
spring for breaks.
NOTE: Do not remove tetrafluoroethylene

(TFE) debris which works out of pitch bear
ing edge. Debris is normal and helps lubri
cate bearing. Removal of debris increases
bearing wear rate.
(7). Use bright light and 5-power magnify
ing glass to inspect all main rotor hub
lead-lag links (Ref. Figure 802) for
discoloration, pitting, intergranular
cracks or stress corrosion cracks. Any
discoloration or pitting is evidence of
more than superficial corrosion and
main rotor hub must be removed for
replacement of lead-lag links.
NOTE: Normal or premature overhaul requires

visual inspection plus dye-penetrant in
spection of links for same conditions.
(8). Inspection lead-lag link stop for broken
spring, cracks, breaks or visible bond
line cracks.
62-20-00
Page 601
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
DAMAGE AREA
369D21271-5
LAMINATE
369D21271-3
LAMINATE
369D21271-7
LAMINATE
G62-2006
Figure 601. Strap Pack Lamination Exploded View

Page 602
Revision 20
62-20-00
MAINTENANCE MANUAL
(9). Inspect interiors of lead-lag bolts using
bright light and 5X glass for cracks or
corrosion per Lead-Lag Bolt Inspection.
(10). Inspect each striker strip for cracks,
deformation and badly worn contact
surfaces.
(11). Inspect all parts of main rotor hub for
cracks, breaks, scratches and nicks.
(Refer all questionable damage to
MDHI for disposition.)
(12). Inspect lower shoe scissors attach
bearings for binding, looseness in bore
and wear. Maximum wear limits are
0.010 inch (0.254 mm) radial and 0.020
inch (0.508 mm) axial.
(13). Inspect each of five main rotor reten
tion strap packs (Ref. Main Rotor Strap
Pack Lamination Inspection) at
specified intervals (Ref. Sec. 5-10).
(Ref. MDHI Notices DN-154 / EN-44 /
FN-33 for specific inspection require
ments.)
4. LeadLag Bolt Inspection
Item
Nomenclature
CM318
CM420
Primer
Sealant

corrosion.
(a). Remove cotter pin securing nut to
lower end of lead-lag bolt. Do not
disturb torque on nut or remove nut.
(b). Remove screw, nut, washers and
balance hardware, if installed, from
lead-lag bolt.
(c). Inspect bolt interior. Treat minor
surface corrosion if noted. If corrosion
pitting or cracks are noted remove
and replace hub.
(d). Swab entire ID of bolt with primer
(CM318).
CSP-HMI-2
(e). Reinstall screw, nut, washers and

balance hardware removed in step 2.
Ensure hardware is installed exactly
as removed. Torque MS21042L08
locknut on screw to 20 - 35 inchpounds (2.26 - 3.95 Nm). Torque
MS21042L3 locknut on screw to 30 60 inch-pounds (3.39 - 6.78 Nm).
Coat exposed screw threads, washers
and nut with sealant (CM420).
NOTE: Excessive amount of sealant can unbal

ance rotor system. Apply light but thorough
coat of sealant.
(f). Install new cotter pin to secure nut to
lead-lag bolt.
NOTE: There are prebalanced rotor hubs in

service. Lead-lag bolts of prebalanced hubs
may contain balancing hardware. If so, re
move balancing hardware to perform in
spection. Each set of removed hardware
should be tagged or color-coded to ensure
correct reinstallation.
5. Main Rotor Strap Pack Lamination
Inspection
CAUTION
D Figure 601 and Figure 602 depict the
main rotor hub and strap pack assembly
disassembled for clarity of location and
area to be inspected for cracks. Under no
circumstances should the strap pack or
main rotor hub assembly ever be disas
sembled in the field. MDHI and MDHI
Approved Licensees are the only ap
proved repair stations for main rotor hub
assembly overhaul.
D If a hub assembly or strap pack assembly
(other than new parts in storage) are sub
jected to extended periods of non-use,
whether installed on the helicopter or not,
the strap assembly should be inspected
critically for corrosion and pitting before
return to service. If corrosion is found on
the strap pack assemblies, contact MDHI
for disposition.
D It is acceptable to operate a helicopter
with a hub assembly having a strap pack
with up to two failed laminates in any one
leg of the strap assembly. When a lami
nate in the strap assembly fails, the re
maining laminates pick up and carry the
62-20-00
Page 603
Revision 29
MAINTENANCE MANUAL
CSP-HMI-2
load. This increased load causes slightly

more elongation in the remaining lami
nates of that leg thus shifting the mass of
the rotor system. Any time a vibration de
velops or there is an increase in vibration
level over a short period of time, the main
rotor strap pack assembly should be in
spected for cracked or failed laminates.
NOTE: Conduct inspection indoors, if possible,

or in a shaded area to eliminate glare of sun
or bright outdoor light. To facilitate inspec
tion, field fabricate and use plastic inspec
tion tool and wooden probe (Ref Figure 602).
(2). If required, trim teflon from edges of
laminates using a aluminum chisel.
Fabricate from stock 0.250 x 6.00 x
0.100 inch (6.35 x 152.4 x 2.54 mm).
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.
NOTE:
areas of the outboard shoes and pitch

housing assemblies.
(5). Using a 10X magnifying glass, visually
inspect the edge of strap pack lami
nates on both sides at outboard end of
blade pitch housing (area between
outboard shoes).
(6). Use the following as acceptance/rejec
tion criteria for laminate inspection:
(a). A laminate has failed if cracked in
tongue area or in lead and lag legs of
the same laminate.
(b). Reject strap pack and return hub
for overhaul when:
1). Three or more laminates in a
single strap pack have failed.
2). Three or more laminates in a
single strap pack are cracked in
the same lead or lag leg.
3). One laminate is cracked at the
outboard end in the area between
outboard shoes (Ref. Figure 602).
D Do not pry at strap pack assemblies with

sharp or hard edged tools. If edges become
nicked or laminates get scratched, addi
tional cracking can occur thus causing
hub replacement.
4). There are two or more gaps in the

same strap pack. A single gap in
any one strap pack assembly is
allowed.
D Where accessible, ends of acceptable

cracked or broken laminates should be
taped to prevent scratching and damag
ing of adjacent laminates.
(7). Visually inspect strap pack assemblies

for evidence of corrosion. If corrosion is
found on strap pack laminates contact
MDHI service department for disposi
tion.
(3). (Ref. Figure 602) Field fabricate plastic

tool. Run plastic inspection tool in both
directions along each laminate, feeling
for a catch from a crack on a single
laminate. Use the wooden or phenolic
probe and probe at upper and lower end
of pack. Failed laminate in lead or lag
will move away from the other lami
nates.
(8). Using a blunt-nosed wooden or pheno

lic pin, pencil size with 1/16 inch
(1.5875 mm) radius point, probe at the
upper and lower strap laminations at
the outboard ends of the blade pitch
housings for evidence of laminate
failure. A failed laminate, either at the
lead or lag end of the strap pack, will
move away from the other laminates. If
the adjacent upper and lower laminates
remain in tension under the probing
operation, no laminate failures have
occurred. Refer to Step (5). Caution for
gap limitations.
(4). Using a light and mirror, visually

inspect each of the main rotor strap
pack assemblies for evidence of cracks
or breaks in strap pack laminates in the
Page 604
Revision 25
62-20-00
MAINTENANCE MANUAL
CSP-HMI-2
ALL LAMINATES STRAIGHT,

NO GAPS.
DETAIL 1
ACCEPTABLE
ALL LAMINATES STRAIGHT. SINGLE GAP

EXISTING ADJACENT TO EITHER SHOE.
DETAIL 2
ACCEPTABLE
NOTE:
WHILE TEFLON MAY APPEAR WRINKLED AND EXTEND PAST END OF LAMINATES,
PREVENTING CLEAR VIEW OF LAMINATES. WHEN THIS OCCURS, LOOK ALONG
EITHER SIDE IN AREA A-A OR B-B (DETAIL 3).

EXISTING ANYPLACE WITHIN LAMINATES.
B
DETAIL 3
ACCEPTABLE
REMOVE EXCESS TEFLON IN THIS AREA
G6220071
Figure 602. Strap Pack Lamination Inspection (Sheet 1 of 2)
62-20-00
Page 605
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
PLASTIC IN
SPECTION
TOOL
1
LEAD LEG
LAMINATE HAS FAILED IF CRACK OCCURS
ON BOTH LEAD AND LAG LEGS OF SAME
LAMINATE.
WOODEN OR
PHENOLIC
0.125 INCH PROBE
(3.175 MM)
0.250 INCH
(6.35 MM)
LAG LEG
2

IN TONGUE OF LAMINATE (SHADED AREA
SHOWN BEYOND JOINT OF STRAP PACK
LEGS).
TONGUE
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
AND/OR 2 ARE ALLOWED IN EACH STRAP
PACK ASSEMBLY. (TOTAL OF TEN LAMINATE
FAILURES PER HUB ASSEMBLY.)
1.00 INCH
(2.54 CM)
0.50 INCH
(12.7 MM)
FIELD FABRICATION INSPECTION TOOLS

ALUMINUM CHISEL NOT SHOWN
(REF. TABLE 601, NOTE 2)
STRAP PACK IS REJECTED IF THREE OR MORE

LAMINATES IN SAME PACK HAVE FAILED AS
DEFINED IN 1 AND/OR 2 ABOVE.
0.050-0.125 INCH
(1.27-3.175 MM)

LAMINATES IN SAME PACK ARE CRACKED IN
THE LEG (LEAD OR LAG).
FAILED LAMINATE IF CRACK IS
FOUND ON EITHER EDGE OF
LAMINATE. IF ONE LAMINATE
HAS FAILED IN THIS AREA, RE
PLACE HUB.
CAUTION:
DO NOT DISASSEMBLE STRAP PACK ASSEMBLY,
LAMINATIONS ARE SHOWN SEPARATED ONLY TO
DEPICT POSSIBLE CRACK LOCATIONS.
NOTE:
ANY CRACK IN LAMINATE IS CONSIDERED A BREAK.
THE LAMINATE HAS NOT FAILED HOWEVER, UNLESS
BOTH LEAD AND LAG LEGS ARE CRACKED, CRACK
IS LOCATED IN TONGUE AREA OF LAMINATE OR IS
UNDER SHOES (SEE DETAIL 6).
1.50 INCH
(3.81 CM)
G62-2007-2B

Page 606
Revision 20
62-20-00
MAINTENANCE MANUAL
CSP-HMI-2
Table 601. Strap Pack Inspection

Inspect
Outboard end.
In area of and
within pitch
housing assemblies.
Procedure (1)
For
Acceptable
Replace or Return
Hub for Overhaul
Visually. Use blunt nosed

wooden or phenolic probe
(Figure 602). Probe at
upper and lower end of
pack. Failed laminate in
lead or lag leg will move
away from other
laminates.
Failed laminates
(3).
Two or less per

pack.
Three or more laminate

failures in one pack.
Visually.
Gaps between
laminates.
Single straight
gap not exceeding 0.030 inch
(0.762 mm) within
pack or next to
either upper or
lower outer shoe.
More than one gap

found; gap exceeds
acceptable limit.
Visually using light and

mirror (2).
Cracks or breaks.
None.
Cracks or breaks are

noted.
Visually with light and

mirror (2).
Cracks or breaks.
Two or less
Three or more laminate
laminate failures
failures (2) in a pack;
per strap pack (2). three or more laminates
in pack with crack in
same leg (lead or lag).
Crack or break.
Inspect top
laminate around
shim (4).
Shims at each of Visually with light and

two attach
mirror.
points.
Top laminate is cracked

in area of cracked or
broken shim.
NOTES:
(1) Conduct visual inspections indoors or in shaded area to eliminate glare of sun or bright outdoor light.
(2) Removal of teflon covering is required for visual inspection of laminate edges. Use aluminum chisel,
fabricated from stock 0.025 x 6.00 x 0.100 inch (0.635 x 152.4 x 25.4 mm) to carefully scrape excess
interlaminate teflon sheets from both sides of strap pack between top and bottom shoes at outboard
attachment bolt of all five strap packs. Remove excess teflon from a point 1/2 inch (12.70 mm) outboard of
bolt centerline to 11/2 inches (38.1 mm) inboard of bolt centerline. Field fabricate and use plastic tool
(Ref. Figure 602). Run plastic tool in both directions along each laminate feeling for cracked laminate. Use
of plastic tool will ensure that shreds of teflon still hanging free does not obscure small cracks.
(3) Laminate has failed if crack is found in tongue area or if crack is found in both legs (lead and lag).
(4) Pay particular attention to shim installed at upper side of lead leg of each strap pack assembly. Maximum
of two shims may have been installed on top side of lead leg of strap pack to accommodate tolerance
buildup during strap pack assembly. If more than one shim is installed, pay particular attention to lower
shim when checking for cracks or breaks.
62-20-00
Page 607
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
NOTE: Laminate failures are defined in step

(6).
(9). Inspect upper, lower and center lami
nates for cracks and breaks (Ref.
Figure 601).
NOTE: Cracks, breaks or other noticeable dam

age to the laminate/shims require main ro
tor hub overhaul/replacement.
(10). Install main rotor blades.
(11). Perform tracking of main rotor blades
(Ref. Sec. 18-20-00).
ance weight per pitch case hous
ing on the main rotor hub assembly is 150
grams.
CAUTION
(12). Record location of all cracked/broken

laminates in helicopter Log Book
including strap serial number, blade
color, leg, lead or lag, and laminate
position, if possible numbering from the
top down.
6. Main Rotor Hub Droop Angle Check
(Ref. Figure 805) Whenever new or replacement
main rotor hub is installed or whenever excessive
droop angle is suspected, measure static droop
angle of all five rotor blades. Droop angle must be
5.5 0.5 degrees.
Item
Special Tools
Nomenclature
LeftHand Command:
ST501
Collective rigging fixture
(LH command)
ST504
Longitudinal rigging fixture
(LH command)
ST506
Lateral rigging fixture
(LH command)
RightHand Command
ST502
(RH command)
ST505
(RH command)
ST507
(RH command)
Page 608
Revision 37
62-20-00
(1). Install cyclic lateral rigging fixture

(ST506 or ST507), cyclic longitudinal
rigging fixture (ST504 or ST505), and
collective rigging fixture (ST501 or
ST502).
(2). Rotate main rotor to position one blade
over tailboom.
(3). Raise and support other four blades
until four corresponding droop stop
rollers no longer contact their striker
plates.
(4). Place accurate propeller protractor on
top of main rotor drive shaft. Adjust
protractor to zero setting.
(5). Place protractor on machined surface of
outboard end of blade pitch housing,
alongside lead-lag bolthead. Measure
and record static droop angle.
(6). Repeat (2). thru (5). above for remain
ing blades.
(7). Maximum allowable static droop angle
is six degrees. If measured droop angle
exceeds six degrees, inspect striker
plate and roller for excessive wear and
adjust droop angle (Ref. Main Rotor
Hub Droop Angle Adjustment).
7. Main Rotor Damper and Attachments
Inspection
blades.
CAUTION
(1). Inspect bearing in rotor blade and

bearing in the pitch housing for
looseness around outer race. No degree
of radial or axial play is permitted.
(2). Inspect pitch housing and blade
bearings for binding, galling, or scoring
in bore and for wear. No radial play is
permitted. Maximum allowable axial
play is 0.015 inch (0.381 mm).
(3). Inspect clevis bushings for wear and
looseness.
MAINTENANCE MANUAL
(4). Inspect damper flange bushing for wear
and play.
(5). Inspect lower bolt hole in damper
flange for wear.
(6). Inspect damper housing (including
flanges) for damage.
(7). Inspect damper turnbuckle, jamnuts
and safetywire for security. No end play
is permitted when manually tested.
NOTE: When performing lead-lag of main ro

tor blades, apply rotor brake (if installed) or
have assistant hold main rotor hub from
moving. A second assistant is recommended
to measure approximate damper extension
and compression.
(8). Lead-lag each main rotor blade in turn
to provide approximately 0.10 inch
(2.54 mm) extension and compression of
the damper elastomer.
(9). Visually check each damper in turn for
cracks in elastomer or in elastomer-tometal bond at end face of damper: If
bonding or elastomer cracks are noted,
measure depths of cracks, using depth
gage fabricated of shim stock or
equivalent having a 0.20 inch (5.08
mm) indication. If depth of crack
exceeds 0.20 inch (5.08 mm), remove
and check damper.
8. Main Rotor Damper Weight Loading and
Extension Check
(Ref. Figure 603)
(1). Remove damper assembly (Ref. Main
Rotor Damper Removal).
CSP-HMI-2
(2). Attach dial indicator or equivalent to

outer case of damper; position indicator
arm on center aluminum disc as shown.
NOTE: Fabricate holding bar or fixture capable

of sustaining 100 pound (45.359 kg) static
load (Ref. Figure 603).
(3). Attach damper end cap to holding bar
or fixture.
NOTE: Perform weight loading and extension
check at ambient temperature of 70 l0F

(21 5C). Apply total 100 pound (45.359
kg) weight load to damper at one time, not in
weight increments.
(4). Using hydraulic jack or equivalent,

raise and attach 100 pound (45.359 kg)
weight load at damper clevis end.
Slowly lower jack to avoid shock
loading. After period of two minutes
under load, measure damper extension
on dial indicator.
(5). If extension exceeds 0.056 inch (1.4224
mm) for M50452 damper, or 0.063 inch
(1.6002 mm) for 369D21400-503
damper, replace the damper assembly.
(6). Reinstall existing damper; or as
required; install replacement damper of
same type and part number (Ref. Main
Rotor Damper Installation). Do not
intermix PN 369D21400-503 damper
with any other part number damper
assemblies.
NOTE: If replacement damper is installed, re

cord part number, serial number, and other
pertinent information in Components Re
cord of helicopters Log Book.
62-20-00
Page 609
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
ELASTOMER
(NOTE)
MAIN ROTOR
DAMPER
ALUMINUM
DISC
ELASTOMER-TO-METAL
BOND (NOTE)
END FACE - MAIN ROTOR DAMPER
HOLDING BAR
OR FIXTURE
END CAP
DAMPER
CLAMP
INDICATOR
INDICATOR ARM
THREADED
SHAFT
CLEVIS
100 POUND (45.359 KG)
WEIGHT
NOTE:
CHECK ELASTOMER AND
ELASTOMER-TO-METAL
BOND FOR CRACKS.
G62-2008A
Figure 603. Periodic Check of Main Rotor Damper Assembly

Page 610
Revision 20
62-20-00
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR HUB

REPAIRS
1. Main Rotor Retention Strap Pack Repair
Item
Nomenclature
CM234
CM725
(Ref. Table 601) Where accessible, ends of

permissible cracks or broken laminates should
be taped to prevent scratching and damaging
adjacent laminates.
CAUTION
Do not bend broken ends exces

sively and scratch adjacent
straps.
(1). Carefully wipe ends of broken strap
with a clean soft cloth moistened with
solvent (CM234).
(2). After smoothing (removal of all sharp or

raised edges) repair depth must not
exceed 0.010 inch (0.254 mm) in any
area of housing except inner surfaces of
arm clevis lugs.
(3). Maximum repair depth of 0.050 inch
(1.27 mm) is acceptable in clevis lug
with sleeve bushing.
(4). On opposite clevis lug repair depth of
0.030 inch (0.762 mm) is permissible in
area of spot faces and maximum of
0.050 inch (1.27 mm) in area outside
spot faces.
(5). Touch up repaired areas with chemical
film (CM206) followed by primer
(CM318) and remove main rotor hub for
pitch housing replacement.
(2). Use mild blast of filtered air to dislodge

any foreign particles between broken
strap ends and adjacent strap.
3. Unbushed Outboard Clevis Lug Hole

Repair
(3). Carefully tape broken ends of strap

with plastic electrical tape (CM725).
(Ref. Figure 801) Repair elongated outboard hole

in unbushed side of clevis lug if inside diameter of
hole exceeds 0.3135 inch (7.9629 mm).
2. Pitch Housing Repair
Item
Nomenclature
CM118
Grease
CM318
Primer
CM431
(Ref. Figure 801)
Item
Nomenclature
CM206
CM318
CM802
Chemical coating
Primer
(1). Remove existing bushing from inboard

lug.
During repair of pitch housing,
comply with precautions for cov
ering engine air inlet fairing opening to pre
vent entry of foreign objects into air intake.
CAUTION
(1). Use grade 320 abrasive cloth (CM802)

to smooth scratches, nicks and chafing
wear in pitch housing.
(2). Drill elongated hole in outboard lug to

0.3680 inch (9.3472 mm). Use drill
bushing as guide.
(3). Line ream hole to 0.3760-0.3770 inch
(9.5504-9.5758 mm) diameter.
62-20-00
Page 801
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
0.360 IN. (9.144 MM) MINI

MUM WALL WIDTH
AROUND LUG (NOTE 1)
OUTBOARD LUG
PITCH HOUSING
0.250 IN. (6.35 MM)
MINIMUM LUG WIDTH
(NOTE 1)
INBOARD LUG
INBOARD LUG
OUTBOARD LUG
0.220 IN.
(5.588 MM)
MINIMUM LUG
THICKNESS
(NOTE 1)
0.20 IN. (5.08 MM)

LUG THICKNESS
(NOTE 1)
0.146 IN. (3.7084 MM) MINI

MUM LUG THICKNESS AT
SPOTFACE
(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.
G62-2012-1B
Figure 801. Field Repair of Main Rotor Hub Pitch Control Lugs (Sheet 1 of 2)
Page 802
Revision 34
62-20-00
MAINTENANCE MANUAL
CSP-HMI-2
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
REMOVAL OF HS610 SP 5010 R 313 X 290 SOLID BUSHING

DRILL BUSHING
1.13 INCH LONG
0.4990-0.4995 INCH
0.3775-0.3780 INCH
O.D. X
(12.6746-12.6873 MM)
(9.5885-9.6012 MM) I.D. X (2.8702 CM)
0.3760-0.3770 INCH
REAMER (9.5504-9.5758 MM) DIA
DRILL NO. U 0.3689 INCH DIA
(9.37006 MM)
DRILL BUSHING
DRILL BUSHING
0.375 X 0.250 X 0.31 IN.
(9.525 X6.35 X 7.874 MM) LONG
0.875 INCH
(22.225 MM)
DRILL THEN REAM
2 DRILL AND REAM OUTBOARD LUG
NOTE 2
BACK SPOTFACE
0.875 IN. (22.225 MM) DIA X
0.250 IN. (6.35 MM) DIA SHAFT
0.020-0.030 INCH
(0.508-0.762 MM)
TREAT SPOTFACE SURFACE AND REAMED

HOLE WITH SEALING COMPOUND (CM431)
0.010-0.030 INCH
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)
(0.381-0.635 MM)
369D21306 SPLIT BUSHING, COAT WITH

LUBRIPLATE (CM118) AT INSTALLATION.
0.814-0.818 INCH
(20.6756-20.7772 MM)
4
0.360 IN.
(9.144 MM) MIN.
0.000-0.015 INCH
(0.000-0.381 MM)
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)
62-20-00
Page 803
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
NOTE: Check outboard lug two places for mini

mum wall thickness of 0.146 inch (3.7084
mm) and 0.20 inch (5.08 mm).
(4). Back spotface inside surface of outboard
lug to 0.875 inch (22.225 mm) diameter
and 0.020-0.030 inch (0.508-0.762 mm)
depth. Use drill bushing as guide for
spotface pilot. Add chamfer to clear
bushing two places.
NOTE: Measure height of bushing and thick

ness of lug prior to installation. Grind off
end surface of bushing as required to secure
0.000-0.015 inch (0.000-0.381 mm) clear
ance. Brush cadmium plate ground end of
bushing before installation. If equipment is
not available coat ground end thoroughly
with primer (CM318) and install while wet.
If primer is used check for corrosion around
lug hole and bushing.
(5). Install flanged bushing using loctite
(CM431). Use attach bolt or assembly
pin as guide to ensure proper align
ment. Seal edges with loctite.
(6). Install slotted bushing with grease
(CM118) in inboard lug.
NOTE: Check outboard and inboard lugs of

pitch control horn for interference with up
per jamnut on pitch control rod. Use file or
portable grinder to carefully trim off interf
ering corner of pitch housing lugs to provide
sufficient pitch control rod clearance. It is
not necessary to trim to minimum wall
thickness. Do not exceed rework limitations.
Touch up reworked area with chemical film
and primer. Paint with matching color.
(7). Reconnect pitch control rod assembly.
Check for proper clearance between
outboard lug and upper jamnut on pitch
control rod.
Use care during removal of
parts from around strap pack.
Any nicks or scratches on straps require
scrapping of strap pack.
CAUTION
Page 804
Revision 20
62-20-00
4. Pitch Control Bearing Housing Assembly,

Spacer or Striker Strip Replacement
(Ref. Figure 802)
Item
Nomenclature
CM222
CM425
Sealing compound
(1). Support blade and pitch housing from

beneath. Remove nuts. washers, and
bolts that secure bearing housing.
If droop shim washers are in
stalled between spacer and
striker strip, they must be retained for rein
stallation to establish correct static droop
angle between pitch housing and hub.
CAUTION
(2). Carefully remove spacer by sliding it

downward past striker strip. Retain
exact number of droop shim washers, if
installed.
(3). Slide bearing housing assembly off
pivot pin. Inspect pivot pin for grooving
or excessive wear.

bearing wear rate.
(4). Remove and discard pitch bearing if
defective, total radial looseness of
assembled ball and pivot pin must not
exceed 0.010 inch (0.254 mm).
(5). Replace striker strip if it is cracked or
lead-lag contact areas are worn
through hard anodized surface.
(6). Remove sealant between pitch housing
and striker strip. use care not to scratch
pitch housing. Remove striker strip
from pitch housing.
(7). Cut old striker strip to facilitate
removal from retention strap assembly.
Do not scratch strap assembly.
(8). Clean old sealant from pitch housing
using 1,1,1, trichloroethane (CM222).
MAINTENANCE MANUAL
(9). Cut out area of new striker strip (Ref.
Figure 803). Deburr, smooth and radius
cut edges.
(10). Apply sealant (CM425) to faying
surfaces of the striker strip and pitch
housing.
(11). Position pitch control bearing housing
on pivot pin (Ref. Figure 802).
If droop shim washers were re
moved from between spacer and
striker strip, same exact thickness removed
must be reinstalled. There must be an equal
number of washers on each of all three bolts.
These washers establish correct static droop
between pitch housing and hub.
CAUTION
(12). Slide spacer into position between

bearing housing assembly and striker
strip on pitch housing. Install exact
thickness of droop shim washers
removed at time of disassembly. Align
holes for all three bolts.
(13). Install bolts, washers and nuts; torque
to 50 - 70 inch-pounds (5.65 - 7.91
Nm) and install safety wire.
(14). Seal all parting lines (joints) of the
assembly with bead of sealing com
pound (CM425).
(1). Remove housing, striker plate and pitch

control bearing.
(2). Place housing on drill press, striker
surface down.
(3). Drill rivet hole out to 0.192-0.198 inch
(4.8768-5.0292 mm) dia.
(4). Using a 0.453 inch (11.5062 mm) dia.
counterbore, counterbore rivet hole
0.396 inch (10.0584 mm) deep.
NOTE: The screw-held striker plate is dimen

sionally thicker.
(5). Counterbore should have a 0.030 inch
(0.762 mm) radius. Deburr counterbore.
(6). Clean drilled and counterbored surfaces
with solvent (CM234) and treat with
chemical film (CM206).
(7). Prime and paint counterbored surface
with primer (CM318) and black paint
(CM305).
(8). Reinstall pitch control bearing and
striker plate and reinstall housing.
6. Pitch Control Bearing Replacement
(Ref. Figure 802)
(15). Perform droop angle check (Ref. Main

Rotor Hub Droop Angle Adjustment).
5. Pitch Control Bearing Housing
Modification
(Ref. Figure 802) To replace riveted striker plate
with screw held striker plate, refer to following
instructions.
Item
Nomenclature
CM206
Chemical coating
CM234
CM305
Lacquer, acrylic
CM318
Primer
CSP-HMI-2
Item
Nomenclature
CM206
CM219
CM318
CM425
CM803
Chemical coating
Methyl-ethyl-ketone
Primer
Sealing compound
Crocus cloth
(1). To remove striker plate, remove screw,

nut and washer or drill out rivets as
required. Discard striker plate if
brinnelling or pits exceed 0.030 inch
(0.762 mm) depth.
(2). Press bearing from housing bore. Clean
any residual primer from housing bore
with MEK solvent (CM219).
62-20-00
Page 805
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
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
BOLT
DROOP SHIM WASHERS
(SEE CAUTION)
LEAD-LAG
LINKS
SLEEVE
BUSHING
SPACER
PIVOT PIN
STRIKER STRIP
PITCH CONTROL BEAR

ING HOUSING AS
SEMBLY
MAIN ROTOR
STRAP PACK
PITCH BEARING HOUSING AND
SPACER - INSTALLATION
(CURRENT CONFIGURATION)
NOTE 1
ELONGATED HOLE LINE REAMED (USING

SLEEVE BUSHING AS GUIDE) TO PROVIDE 0.001
-0.0015 IN. (0.0254-0.0381 MM) INTERFERENCE
FIT FOR 0.3675-0.3685 IN. (9.3345-9.3599 MM)
OUTSIDE DIAMETER REPAIR BUSHING
NOTE 2
LEAD-LAG
STOP
LEAD-LAG LINK AND STOP
PITCH HOUSING ARM
(CLEVIS LUG)
REPAIR BUSHING (2024-T3 OR 7075-T6

ALUMINUM PRESS FIT
SLEEVE
BUSHING
PRESS-FITTED REPAIR BUSHING LINE

DRILLED AND LINE REAMED USING SLEEVE
BUSHING AS GUIDE:
FINAL ID; 0.3125-0.3135 IN. (7.9375-7.9629 MM)
PITCH HOUSING BUSHINGS - REPAIR
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 (CM405 OR CM410).
3. INSTALL WITH WET PRIMER (CM318).
4. WET PRIMER (CM318) ON WASHER AND MATING SURFACES
BEFORE INSTALLATION.
5. NUT RETAINING BRACKET IS BONDED TO HUB.
6. EARLY CONFIGURATION MODIFIED BY HUGHES SERVICE
NOTICE DN-3.
NOTES: (CONT)
7. COUNTERSUNK RIVET HEAD OR SCREW HEAD MUST BE
FLUSH WITH HOUSING. UPSET END MUST BE FLUSH
WITH PLATE.
8. UPSET END MUST BE FLUSH WITH PLATE.
9. MANUFACTURED RIVET HEAD MUST BE FLUSH WITH
PLATE IN ALTERNATE RIVET INSTALLATION.
10. REPLACEMENT HOUSING FOR BOTH VERSIONS
ATTACHED TO STRIKER PLATE WITH SCREW, WASHER
AND NUT FOR EASE OF REMOVAL.
G62-2013-1A
Figure 802. Main Rotor Hub Components Repair and Installation (Sheet 1 of 2)
Page 806
Revision 20
62-20-00
MAINTENANCE MANUAL
CSP-HMI-2
NOTE 7
HOUSING
NOTE 10
NUT
PITCH BEARING
SCREW
WASHER
NUT
STRIKER
PLATE
WASHER
THREADED
(2 PLACES)
COUNTERSUNK
HEAD SCREW
SUPPORT NUT
PITCH BEARING INSTALLATION
MODIFIED CONFIGURATION (RO

TATED) (NOTE 6)
MAXIMUM ALLOWABLE WEAR IS 90%

CIRCUMFERENCE OF 0.4328 INCH
(10.99312 MM) MINIMUM DIAMETER
HOUSING
0.4328 INCH
(10.99312 MM)
MINIMUM DIA.
SPECIAL WASHER
(NOTE 4)
NOTE 7
NUT RETAINING
BRACKET (NOTE 5)
0.125 INCH (3.175 MM)

MAXIMUM WEAR
PITCH PIVOT PIN
(CURRENT CONFIGURATION)
(NOTE 3)
HUB
STRIKER
PLATE
ROUND HEAD RIV
ET (NOTE 8)
RETAINING NUT
BRACKET (NOTE 5)
EARLY CONFIGURATION
CAPTIVE NUT
MAXIMUM ALLOWABLE WEAR IS 90%

CIRCUMFERENCE OF 0.4328 INCH
(10.99312 MM) MINIMUM DIAMETER
COUNTERSUNK HEAD RIVET

(ALTERNATE) (NOTE 9)
EARLY CONFIGURATION
PITCH
BEARING
PITCH PIVOT PIN
(EARLY CONFIGURATION)
(NOTE 3)
0.4328 INCH
(10.99312 MM)
MINIMUM DIA.
0.125 INCH (3.175 MM)
MAXIMUM WEAR
PIVOT PITCH PIN - INSTALLATION
62-2013-2A
Figure 802. Main Rotor Hub Components Repair and Installation (Sheet 2 of 2)
62-20-00
Page 807
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
NOTE: Diameter of bearing bore, after cleanup,

should not exceed 1.1880 inch (3.01752 cm).
Localized areas of clean up should not ex
ceed 0.003 inch (0.0762 mm) within an area
of 25% of the circumference.
(3). Rework minor surface abrasion in
housing bore by polishing with crocus
cloth (CM803). Restore chemical film
(CM206), where removed.
(4). Press bearing into bore using wet
primer (CM318). Wipe away any excess
primer using care to keep it out of
bearing. Check teflon linings of bearing
after installation to determine that no
damage occurred from pressing opera
tion.
NOTE: Ensure bearing is seated completely in

bore of housing and striker plate fits flush
on housing.
surfaces and install striker plate with
screw, washer and nut or rivets. Head
of countersunk screw or rivet must be
completely flush.
7. LeadLag Link Blade Stop Replacement
(Ref. Figure 802) Replace blade stop if it is
broken, cracked, has broken spring, or if there
are visible bond line cracks.
Item
Nomenclature
CM206
Chemical coating
CM217
Isopropyl alcohol
CM228
Surface cleaner
CM411
Adhesive, epoxy
CM802
CM803
Crocus cloth
Lead-lag link assembly must

not be removed from pitch con
trol housing for this repair, since retention
bolt cannot be retorqued without special
adapter.
CAUTION
Page 808
Revision 20
62-20-00
(1). Provide a backup support for link

assembly. Use 0.5 inch (12.7 mm) wood
dowel and hammer to drive stop from
link. Strike dowel sharply to break
adhesive bond.
(2). Using sharp-edge metal scraper,
carefully scrape any adhesive residue
from link. If scraper penetrates through
paint and chemical surface film, surface
must be refinished. Depth of gouges or
nicks is limited to 0.010 inch (0.254
mm) maximum after rework. Rework
by smooth blending into surrounding
area with grade 320 abrasive cloth
(CM802). Final polish with crocus cloth
(CM803). Restore chemical film protec
tion (CM206).
(3). Clean bond area of all contact surfaces
by wiping with cleaner (CM228).
Flush-wipe cleaned surface four times
with mixture of equal parts of distilled
water and isopropyl alcohol (CM217) to
remove all traces of phosphoric acid.
Rinse cleaned surface with tap water,
followed by a rinse of distilled water
until surface is water break free. Dry
for 30 minutes minimum at 150F
(66C).
(4). Check fit of stop in link. Flange and
radius contact surfaces of stop must
mate with link within 0.010 inch (0.254
mm). Maximum clearance between stop
and inside surfaces of link ears is
limited to 0.020 inch (0.508 mm). This
tolerance applies to both sides of stop.
(5). Prepare mixture of epoxy adhesive
(CM411). Apply uniform coating of
mixed adhesive to all contact surfaces.
Hand press stop into place between link
ears until all mating surfaces are in
firm contact. Apply a clamping device
so that contact is maintained. Cure for
minimum of eight hours at room
temperature, or two hours at 150F
(66C).
MAINTENANCE MANUAL
CSP-HMI-2
2.50 INCH
(6.35 CM)
CAUTION:
DO NOT SCRATCH STRAP PACK WHEN INSTALLING
THROUGH STRAP ASSY.
NOTE:
CUT OUT 0.25-0.50 IN. (6.35-12.70 MM) PIECE OF THE
STRIKER STRIP BETWEEN LOWER BOLT HOLES.
DEBURR AND RADIUSCUT EDGES.
0.25-0.50 IN.
(6.35-12.70 MM)
(NOTE)
G62-2009A
Figure 803. Striker Strip Replacement

8. Damper Attach Lug Bearing Replacement
Item
Nomenclature
CM216
CM219
CM318
Loctite remover
Methyl-ethyl-ketone
Primer
Item
Special Tools
Nomenclature
ST706
ST707
Arbor press fixture

Staking tool
(1). Use fly or circle cutter with 0.25 inch

(6.35 mm) pilot to remove staked lip
from one side of bearing without
removing any material from fitting. If
fitting is damaged by cutter, blade must
be replaced.
(2). Use an arbor press to press bearing
from fitting.
(3). Clean primer residue from fitting bore
with MEK (CM219). Remove locking
compound residue (if any) with locking
compound remover (CM216).
(4). Using 10-power magnifying glass,

inspect fitting bore for cracks. No
cracks are permitted.
(5). Measure fitting bore diameter. Accept
able limits are 0.6548-0.6552 inch
(16.63192-16.64208 mm).
(6). Apply thin coat of primer (CM318) to
fitting bore.
(7). Press bearing into fitting with arbor
press and fixture (ST706). Wipe away
excess primer.
(8). Stake bearing at both sides of fitting
with staking tool (ST707) in hydraulic
press with 6000-8000 pounds
(26688-35584 N) of force. When staked,
outer race of bearing shall be flush to
not more than 0.010 inch (0.254 mm)
above fitting surface (both sides). Gap
between staked lip of bearing race and
chamfered surface of fitting bore shall
not exceed 0.002 inch (0.0508 mm) as
checked with feeler gage. Staking
operation shall produce no cracks in
fitting or bearing.
(9). Fill staking gap (if any) with primer
(CM318).
62-20-00
Page 809
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
9. LeadLag Bolt Corrosion Control
Item
Nomenclature
CM219
CM318
CM425
CM802
Methyl-ethyl-ketone
Primer
Sealing compound
Do not disturb torque on leadlag bolts. Special adapter is

needed to retorque lead-lag bolts.
CAUTION
(1). Remove and tag or color-code each set

of balance hardware that is installed.
(2). Remove corrosion with grade 180
abrasive cloth (CM802) and finish with
grade 400 abrasive cloth.
(3). Swab cleaned surface with MEK
(CM219) and apply unthinned zinc
chromate primer (CM318).
(4). Reinstall original balance hardware
that was removed. Using sealant
(CM425), reseal balance hardware.
10. Pitch Control Bearing Pivot Pin Repair or
Replacement
(Ref. Figure 802) Minimum allowable pin
diameter is 0.4328 inch (10.99312 mm). Pivot
pin grooving or excessive side wear may be
polished to original finish as long as minimum
allowable pin diameter, 0.4328 inch (10.99312
mm), remains after rework. Replace any pin
requiring more rework as follows.
Item
Nomenclature
CM318
CM420
Primer
Sealant
(1). Remove pivot pin.

(2). Install replacement pivot pin wet with
primer (CM318).
Page 810
Revision 20
62-20-00
NOTE: Torque pivot pin to 70 - 80 inchpounds (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
mounting lug surface. No gap is allowed.
(3). Install pivot pin in mounting lug with
washer (Ref. Figure 802). Torque pivot
pin to 250 - 280 inch-pounds (28.25 31.64 Nm). Apply sealant (CM420) at
junctures of pivot pin flange, washer
and hub.
11. Droop Stop Roller Repair or Replacement
(Ref. Figure 804) Replace defective droop stop
roller if clearance between roller bearing liner
and shaft is more than 0.015 inch (0.381 mm).
Roller shaft outside diameter must not be less
than 0.4370 inch (11.0998 mm).
Item
CM217
Nomenclature
Isopropyl alcohol
(1). Remove pitch control bearing housing

that contacts lower shoe roller to be
removed.
NOTE: Only one roller can be removed at one

time. Two opposing droop stop followers
must be pressed against droop stop ring to
force opposite follower out and expose roller
shaft for removal. Same condition exists at
installation.
(2). Press down on pitch housing that is
opposite roller that is to be removed.
Remove cotter pin and shaft.
(3). Remove droop stop roller.
(4). Wet down and clean plunger and
mating shoe bushing with isopropyl
alcohol (CM217).
(5). To install replacement roller, press
down on pitch housings at opposite
sides of hub from roller to be installed.
Install roller, shaft and new cotter pin.
(6). Install pitch control bearing housing.
MAINTENANCE MANUAL
12. Droop Stop Ring Repair
(Ref. Figure 804)
Item
Nomenclature
CM103
(1). Repair depth limit for corrosion, nicks

or scratches in droop stop ring is 0.007
inch (0.1778 mm) for all surfaces except
outer edges of ring outer flanges. Depth
limit is 0.030 inch (0.762 mm). All
reworked areas must be blended
smoothly with 15 to 1 ratio into sur
rounding area.
(2). Spray repaired areas of rings with solid
film lubricant (CM103).
(3). Replace droop stop ring if repair limits
are exceeded.
13. Droop Stop Ring Replacement
(Ref. Figure 804)
(1). With hub upside down, support hub so
that pitch housings unload cam follow
ers and provide maximum clearance
between striker plates and droop stop
rollers.
(2). Release retaining (snap) ring of each
droop stop restrainer from its groove.
Move retaining ring flush against droop
stop follower (T-head) to provide
additional clearance and reduce spring
tension.
(3). Remove five droop stop rollers.
(4). Starting from either scissors crank
attach lug, number all five droop stop
follower assemblies in clockwise
direction for location identification at
replacement. This number code should
be placed on outer, upper end of plunger
and on adjacent area of lower shoe.
Make sure codes are not accidentally
removed during remaining steps.
(5). Push droop stop ring toward number 3
and 4 followers. Pull number 1 follower
T-head from droop stop ring channel.
CSP-HMI-2
When T-head is free of ring channel,

turn it perpendicular (vertical) to
channel.
NOTE: Followers can be easily rotated by use of

nonmetallic drift in hole for droop stop roller
shaft.
When T-head is free of channel, turn it
perpendicular to channel.
When T-head is free of channel, turn in
perpendicular to channel.
(8). Tilt ring up on number 1, 2, and 3
T-heads as far as possible.
(9). While pulling upward on ring, rotate (in
succession) number 1, 2, and 3 T-heads
so that they are out of, and below, droop
stop ring.
(10). Withdraw number 4 and 5 T-heads
from droop stop ring channel and
remove ring.
When installing droop stop ring,
droop stop followers T-Heads
must be offset away from lower shoe to pre
vent damage to lower shoe.
CAUTION
(11). Install replacement droop stop ring by

reversing removal procedure, steps (1).
through (10)., making certain to
reinstall followers according to mark
ings placed thereon prior to removal.
(12). Compress follower spring and install
retaining (snap) ring in its groove on
each follower.
(13). Reinstall droop stop rollers.
14. Droop Stop Follower (THead)
Replacement
(Ref. Figure 804) Replace the droop stop
follower (T-head) if it is worn, scored or is
causing damage to the droop stop ring. After
the droop stop ring has been removed, the
droop stop follower assemblies may be
removed from hub.
(1). Remove droop stop follower assembly
from hub.
62-20-00
Page 811
Revision 37
MAINTENANCE MANUAL
CSP-HMI-2
(2). Remove pins that secure follower to

plunger.
Droop stop followers T-Heads
must be offset away from lower
shoe to prevent droop stop ring from damag
ing lower shoe.
CAUTION
(3). Insert new follower. T-head must be at

right angle to roller shaft in plunger.
(4). Drill two 0.156-0.158 inch
(3.9624-4.0132 mm) diameter holes
through follower in line with holes in
plunger.
(5). Insert pins and stake ends. No burrs or
roughness permissible after staking.
(6). Install follower assembly in hub.
(7). Reinstall droop stop ring.
15. Droop Stop Plunger Removal, Inspection
and Installation
(Ref. Figure 804)
Item
Nomenclature
CM217
Isopropyl alcohol
(1). Remove droop stop ring.

(2). Remove pitch control bearing housing
assembly that contacts the lower shoe
roller.
(3). Remove cotter pin and shaft from droop
stop follower assembly.
(c). The maximum wear condition may

exist in one spot or in several spots
totaling 2.1 square inches (13.55
cm2).
alcohol (CM217).
(7). Install droop stop plunger into lower
shoe.
(8). Install roller, shaft and new cotter pin.
(9). Complete droop stop ring installation.
16. Main Rotor Hub Droop Angle Adjustment
(Ref. Figure 802) If static droop angle exceeds
six degrees, adjust as follows.
(1). Remove main rotor blade.
(2). Use flat washers of thickness required
to adjust spacing between spacer and
striker strip. Any one type, or combina
tion, of correct part number washers
(IPC) may be used; however, an identi
cal washer selection must be installed
on each of three bolts that secure pitch
control bearing assembly to pitch
housing.
(3). Remove nuts and washers and separate
spacer from striker strip. The use of one
0.016 inch washer raises static droop
angle approximately one-half degree.
Add sufficient washers to adjust droop
angle within range of 5.5 0.5 degrees.
Reinstall nuts and washers.
(4). If more than 0.063 inch (1.6002 mm)
spacing is required (above factory
spacing), inspect striker plate and
droop stop roller or follower and droop
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
(a). The minimum acceptable diameter

after wearing in service should be
0.996 inch (25.2984 mm).
(5). Reinstall blade. Repeat measurement of

static droop angle.
(b). The acceptable amount of wear

though the anodized coating shall not
exceed 40% or 2.1 square inches
(13.55 cm2) of the total sliding
surface area of the cylinder.
Page 812
Revision 37
62-20-00
rebuilt hubs is 0.063 inch (1.6002 mm).
(6). As required, repeat above procedures

for remaining blades.
(7). Following reinstallation or replacement
of parts, check track of main rotor
blades.
MAINTENANCE MANUAL
CSP-HMI-2
LOWER
SHOE
PINS
DROOP STOP
PLUNGER
0.007 INCH (0.1778 MM)

MAX. DEPTH (15 TO 1
RADIUS) AFTER REWORK
DROOP STOP
ROLLER
15 TO 1
RADIUS
DROOP STOP
FOLLOWER
(T-HEAD) (NOTE)
COTTER
PIN
SHAFT
SNAP RING
SPRING
DROOP STOP FOLLOWER - INSTALLATION
0.007 INCH (0.1778 MM)

MAX. DEPTH (15 TO 1
RADIUS) AFTER
REWORK
0.030 IN. MAX.

AFTER REWORK
DROOP STOP
RING
DROOP STOP RING - REPAIR LIMITS
DROOP STOP FOLLOWER

ASSEMBLY (5 PLCS)
SCISSORS CRANK
ATTACH LUG
LOWER SHOE - INVERTED
NOTE: DROOP STOP FOLLOWER T-HEADS TO
BE OFFSET AWAY FROM LOWER SHOE.
BEARING ROTATIONAL DRAG

1.0 - 2.0 IN-LBS
(0.113 - 0.226 NM)
G62-2011C
Figure 804. Main Rotor Hub Assembly Repair
62-20-00
Page 813
Revision 37
MAINTENANCE MANUAL
CSP-HMI-2
17. Main Rotor Hub Tapered Bearing Grease

Repack, Inspection and Replacement
(Ref. Figure 805) Replace tapered roller
bearing cup or cone if it has any flat spots,
scoring, pitting, grooving, discoloration (blue)
or if it feels rough when rotated.
Item
Nomenclature
CM111
CM121
CM234
CM802
CM803
Grease, aircraft
Preservation oil
Crocus cloth
Item
Special Tools
Nomenclature
ST701
Do not intermix Timken or NTN

bearing cups and cones at upper
and lower tapered roller bearing locations of
main rotor hub.
CAUTION
NOTE:
D Roller bearing cones and cups should al
ways be replaced as a set.
D Replace tapered roller bearing cup and
cone if it has any flat spots, scoring, pit
ting, grooving, discoloration (blue) or if it
feels rough when rotated.
(1). Use pressing tools equivalent to items
A and B (Ref. Figure 806) to press
upper and lower bearing cups from hub.
A press ram of one to two tons is
sufficient for removal.
(2). Press lower bearing cone from sleeve
bushing.
In next step, do not spin reus
able bearings while cleaning.
Coat bearings lightly with oil (CM121) after
cleaning.
CAUTION
(3). Clean hub bore, sleeve bushing, seal

retainer and reusable bearings using
filtered solvent (CM234) spray.
Page 814
Revision 21
62-20-00
(4). Check bearing cup hub bore for scoring.

Smooth out any roughness with grade
400-600 abrasive cloth (CM802).
Restore chemical film protection where
removed. Maximum diameter of hub
bore for upper bearing cup (Ref.
Figure 805) is 4.4335 inch (11.26109
cm), measured in any direction.
Maximum diameter of hub bore for
lower bearing cup is 4.3095 inch
(10.94613 cm), measured in any
direction.
(5). Check upper seal retainer. No cracks,
sharp nicks or burrs are allowed. Minor
corrosion or other surface defects may
be polished out using crocus cloth
(CM803). Grooving on seal contact
surfaces must not exceed 0.004 inch
(0.1016 mm) depth after polishing.
Bearing cups are installed in
WARNING hub by differential tempera

ture (shrink-fit) method. Take appro
priate precautions to prevent burns
when handling parts that are cooled to
sub-zero temperatures.
(6). Place bearing cups in closed container
of dry ice and cool for not less than 20
minutes to -40F (-40C).
(7). Coat bore of hub with grease (CM111).
Use care to maintain cup-to-hub bore
alignment and press cup into bore,
using tools D and E (Ref. Figure 806),
until cup is seated.
(8). Apply film of grease to sleeve bushing.
Use pressing tool equivalent to tool C,
and press bearing cone onto sleeve
bushing.
(9). With lip on center seal up, hand press it
into hub (Ref. Figure 805).
(10). Apply film of grease on mast. Install
preassembled sleeve bearing and
bearing cone on mast. Do not apply any
additional lubricant to roller bearing
set. Wipe any excess preservative oil
from bearing cone and cup.
(11). Place assembled hub over mast and
seat on lower roller bearing cone.
(12). Install lead spacer 369A1224-5 (thick
ness gage substitute for recessed
MAINTENANCE MANUAL
spacer) over mast. Rest spacer on top of
sleeve bushing.
NOTE: If lead spacer is not available, fabricate

its equivalent from lead sheet. Spacer di
mensions are; 2.96 inch (7.5184 cm) outside
diameter; 2.68 inch (608072 cm) ID;
0.075-0.085 inch (1.905-2.159 mm) thick.
(13). Install upper bearing cone into hub and
on top of lead spacer.
(14). Install steel ring washer, equivalent to
tool F (Ref. Figure 806), as substitute
for seal retainer (Ref. Figure 805).
NOTE: Step (14). is not required. However, use

of substitute washer for retainer prevents
unnecessary scoring of retainer. Several
tightening and loosening actions may be re
quired to get correct rotational drag on hub
bearings.
(15). Install mast nut on mast using mast
nut wrench (ST701), tighten until
bearings are preloaded to 10 - 12
inch-pounds (1.13 - 1.36 Nm) of
rotational drag. Measure rotational
drag using 0 - 10 pound (0 - 4.536 kg)
spring scale hooked over one of hub
support web bosses, 6.5 inch (16.51 cm)
from hub centerline). A 1.50 - 1.75
pound (0.681 - 0.7945 kg) pull with hub
in motion indicates correct rotational
drag.
(16). Remove mast nut, tool F (Ref.
Figure 806), (or seal retainer), and
upper bearing cone. Remove lead spacer
and measure compressed thickness.
Obtain serviceable recessed spacer of
same thickness, or grind new recessed
spacer to required dimension. Discard
lead spacer after recessed spacer is
correctly ground.

properly before torquing, 2 - 4 threads
(17). Install recessed spacer, recess down, on
top of sleeve bushing. Reinstall upper
bearing cone, seal retainer and mast
nut. Torque nut to 200 - 250 footpounds (271 - 339 Nm) and check for
rotational drag of 10 - 15 inch-
CSP-HMI-2
pounds (1.13 - 1.69 Nm). This will be

1.5 - 3 pounds (0.681 - 1.362 kg) on
spring scale used as in step (15). above.
(18). Remove hub and sleeve bushing with
lower bearing cone from mast.
(19). Position hub upside-down. Hand-pack
lower hub cavity (Ref. Figure 805) and
bearing cone on sleeve bushing with
grease.
(20). Install sleeve bushing with bearing
cone in hub. Hand-pack cavity between
bearing and hub liner with grease; then
press in lower seal with seal lip toward
top of hub. Wipe off excess grease.
(21). Turn hub assembly right side up.
(22). Complete reassembly of hub by install
ing recessed spacer, upper bearing cone,
upper seal and seal retainer in hub at
installation of hub on mast.
18. Main Rotor Hub Scissors Attach Lug
Bearing Replacement
Item
CM206
CM216
CM304
CM321
CM431
Nomenclature
Chemical coating
Loctite remover
Enamel, epoxy
Surface primer locking compound
(1). Remove main rotor hub (Ref. Main

Rotor Hub Replacement).
(2). Invert hub and place on work bench.
(3). Remove droop stop ring (Ref. Droop
Stop Ring Replacement).
(4). Press bearing from hub lug.
(5). Clean bearing bore with Loctite
remover (CM216).
(6). Inspect bearing bore for nicks,
scratches and grooves.
(7). Inspect bore for diameter of
0.6551-0.6556 inch (16.63954-16.65224
mm).
(8). Touch up bearing bore with chemical
coating (CM206).
62-20-00
Page 815
Revision 35
CSP-HMI-2
MAINTENANCE MANUAL
(9). Apply surface primer (CM321) to

mating surfaces of bearing and bores
per manufacturer's instructions.
room temperature or heat to 140 160F (60 - 72C) for one hour.
NOTE: Do not allow primer to enter bearing.
(13). As required, touch up bearing lug with

paint (CM304).
(10). Apply locking compound (CM431) to

faying surfaces of bearing and bore,
press bearing into bore while locking
compound is wet.
(14). Check bearing for a no-load rotational

drag of 1.0 - 2.0 inch-pounds (0.113 0.226 Nm).
(11). Remove excess sealant, do not allow

sealant to enter bearing.
(15). Reinstall droop stop ring (Ref. Droop

(12). Apply a small fillet of sealant around

bearing and allow to dry for 24 hours at
(16). Reinstall main rotor hub (Ref. Main

Page 816
Revision 34
62-20-00
MAINTENANCE MANUAL
CSP-HMI-2
STRIKER
STRIP
SEALANT
(NOTE 2)
PITCH BEARING
(NOTE 1)
PITCH
HOUSING
(NOTE 1)
DROOP SHIM
WASHER (NOTE 9)
LAMINATED
STRAP PACK
SPACER
SEALANT
(NOTE 2)
STRIKER
PLATE
PITCH CONTROL
BEARING HOUSING
DROOP RESTRAINER
AND ROLLER
SEAL
(NOTE 4)
HUB
UPPER BEARING CONE

(NOTE 10)
SEAL
RETAINER
UPPER BEARING CUP

(NOTE 10)
RECESSED SPACER
(NOTE 3)
SEAL
(NOTE 4)
PIVOT PIN
SEALANT
(NOTE 2)
LOWER
SHOE
NOTE
NOTE 1
NOTES:
11
1. HEAVY LINES INDICATE REINFORCED
NOTE 5
TEFLON BEARINGS (TYPICAL)
2. SEALANT (CM425) APPLIED TO LOCATIONS SHOWN.
HUB OUTER
3. RECESSED SPACER SPECIALLY GROUND TO ESTABLISH CORRECT
LINER
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.
SEAL
(NOTE 4)
DROOP STOP
RING
LOWER BEARING CUP
(NOTE 10)
G62-2014-1B
Figure 805. Main Rotor Hub Cross Section (Sheet 1 of 2)
62-20-00
Page 817
Revision 40
MAINTENANCE MANUAL
CSP-HMI-2
LEAD-LAG
PIVOT BOLT
LEAD-LAG
LINKS
SEALANT
(NOTE 2)
NOTE 2
NOTE 2
NOTE 1
COTTER PIN
NOTE 7
RIVET
(NOTE 7)
EARLY CONFIGURATION
NOTE 8
MS21042L08
LOCKNUT
MS21042L3
LOCKNUT
NOTE 8
SUPPORT
NUT
WASHERS
FOR BALANCE
AS REQUIRED
WASHER
STEP
WASHER
WASHER
WASHER
LEAD LAG
PIVOT BOLT
SCREW
SCREW
SERIAL NO. 0260D AND SUBS
EARLY CONFIGURATION
SERIAL NO. 003D THRU 0259D
G62-2014-2A
Figure 805. Main Rotor Hub Cross Section (Sheet 2 of 2)

Page 818
Revision 40
62-20-00
MAINTENANCE MANUAL
2.875 IN. (7.3025 CM)

OUTSIDE DIAMETER
0.50 IN.
(12.7 MM)
CUT OUT AFTER

BEVELING
CSP-HMI-2
3.50 IN. (8.89 CM)

OUTSIDE DIAMETER
3.875 IN.
(9.8425 CM)
11.0 IN.
(27.94 CM)
53
5.75 IN.
(14.605 CM)
3.375 IN.
(8.5725 CM)
0.375 IN.
(9.525 MM)
0.1875 IN. (4.7625 MM)

WALL STEEL PIPE
B
4130 STEEL PLATE

A
4.40 IN.
(11.176 CM)
0.203125 IN. (5.159375 MM)

WALL STEEL PIPE
C
4.30 IN.
(10.922 CM)
2.58 IN.
(6.5532 CM)
0.30 IN.
(7.62 MM)
3.50 IN.
(8.89 CM)
2.0 IN.
(5.08 CM)
2.0 IN.
(5.08 CM)
ALUMINUM ALLOY
D
ALUMINUM ALLOY
STEEL RING WASHER
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)
62-20-00
Page 819
Revision 37
MAINTENANCE MANUAL
CSP-HMI-2
7.0 INCH (17.78 CM)

SQUARED
4.75 INCH
(12.065 CM)
MATERIAL: WOOD
0.75 INCH
(19.05 MM)
10.0 INCH (25.40 CM)

SQUARED
Page 820
Revision 37
62-20-00
H62-2010-2A
MAINTENANCE MANUAL
CSP-HMI-2
Section
622060
Main Rotor Hub
(600N)
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR HUB

1. Main Rotor Hub General
(Ref. Figure 402) The main rotor hub consists
of a central hub, six identical pitch housings
spaced 60 degrees apart horizontally around
the hub with associated mechanisms and
linkages. Lead-lag links, a lead-lag damper, a
droop stop striker strip and spacer, and a pitch
control bearing with each pitch housing
produce the pivoting axis, blade flapping stop
contact surfaces and lead-lag hinge function
for the rotor blades. Six laminated retention
strap assemblies that are flexible both
vertically and torsionally extend through the
pitch housings and connect to the lead-lag
links. A lower shoe, attached to the central
hub, contains a droop stop ring and droop
restrainers that support the blades at rest and
distribute droop loads at low blade rpm. The
following instructions provide field mainte
nance and repair procedures for the main rotor
hub.
2. Main Rotor Hub Replacement
A. Main Rotor Hub Removal
(Ref. Figure 401)
Item
Special Tools
Nomenclature
ST201
ST701
ST702
Hoisting adapter
Hub puller
(3). Remove lockwire and disconnect

flexible boot from lower end of hub
liner.
(4). Disconnect each pitch control rod from
pitch housing.
(5). Disconnect scissors crank from main
rotor hub or scissors link.
NOTE: To facilitate assembly, color code each

pitch control rod to match pitch housing to
which it is attached.
(6). Remove two screws securing retainer to
main rotor hub nut.
(7). Remove nut retainer.
(8). Using main rotor mast nut wrench
(ST701), remove nut from mast.
(9). Using hub puller (ST702), break loose
main rotor hub. Remove hub puller.
(10). Attach hoisting adapter (ST201), to
eyebolts and hoist hub from mast.
B. Main Rotor Hub Installation
(Ref. Figure 402)
Item
CM111
CM115
CM204
CM702
Nomenclature
Grease, aircraft
Lockwire CRES
Item
ST201
ST701
ST703
Special Tools
Nomenclature
Hoisting adapter

(2). Remove main rotor drive shaft; then
reinstall hoisting eyebolts, washers and
nuts in rotor hub. Locate them to
correspond with lugs of hoisting
adapter (ST201).
62-20-60
Page 401
Revision 36
CSP-HMI-2
MAINTENANCE MANUAL
Main rotor hub is a highly

stressed component. Use ex
treme care to prevent it from striking any
placement of hub.
CAUTION
NOTE:
D Removal of recessed spacer, upper bear
ing cone, upper seal and seal retainer is
not mandatory for installation of the
main rotor hub. If these items are in
stalled, perform steps (1). thru (4). and
(11). thru (22). Caution should be used
when installing hub to prevent damage to
these parts.
D If recessed spacer, upper bearing cone,
upper seal and seal retainer have been re
moved, these parts should not be as
sembled in hub before installation of hub
on helicopter. These items are reas
sembled in hub after seating hub on mast.
Prior to installing main rotor hub, insure
that all bearings are adequately serviced
D Replacement main rotor hubs do not come
balanced from MDHS. If installing a re
placement hub, perform a main rotor sys
tem balance (Ref. Sec. 18-10-60, Main
Rotor System Balance Procedure).
(1). Attach hoisting adapter (ST201) to
eyebolts in main rotor hub and connect
suitable hoist.
If hub assembly (with sleeve
bushing, spacer, upper bearing
and seal retainer installed) does not seat
properly onto mast, do not attempt to force it
into position. Remove hub assembly from
mast and determine cause of hub not seat
ing, correct the problem and follow the pro
cedures for reinstallation.
CAUTION


(CM115).
Page 402
Revision 20
62-20-60

(6). Place recessed spacer, recess down, on
top of sleeve bushing.
(7). Hand-pack upper bearing cup and cone
with grease; then install cone on mast
and use hub driver (ST703), to fully
seat cone.
(8). Fill remaining cavity to upper seal with
grease.
(9). Position upper seal in seal retainer
with lip up; then press seal and retain
er in hub counterbore.
(10). Using a soft drift, carefully tap seal
outer ring to seat in counterbore. Wipe
away any excess grease.
(11). Apply grease (CM111) to exposed
threads on mast.
Ensure that seal is properly po
sitioned against seal retainer
and that seal retainer does not pinch seal.
Check by inserting a loop of approximately
0.050 inch (1.27 mm) diameter lockwire,
round feeler gage or other suitable tool with
out sharp edges between seal lip and retain
er.
CAUTION

properly before torquing, two to four threads
(12). Install mast nut, using wrench (ST701);
torque nut to 200 foot-pounds (271
Nm). Apply coat of corrosion preventive
compound (CM204) to screw holes in
mast nut.
(13). Place retainer on nut and check
retainer-to-nut screw hole alignment.
(14). Increase nut torque to not more than
250 foot-pounds (339 Nm) to align
holes in retainer and nut.
NOTE: If holes cannot be aligned in 200 - 250

foot-pound (271 - 339 Nm) torque range,
remove and invert nut and repeat proce
dures in (12). thru (14). to align holes.
(15). Secure retainer to nut with two screws;
safety screws with lockwire (CM702).
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR
PULLER
ROTOR HUB
6G62-009A
Figure 401. Pulling Hub Assembly

Ensure that no washers are
used under screw heads and
that screw heads are free of burrs.
CAUTION
(16). Verify that screwheads do not project

more than 0.020 inch (0.508 mm) above
hub upper surface, for adequate
clearance between screw heads and
driveshaft flange.
(17). Connect scissors crank to main rotor
hub lower shoe and/or to scissors link.
NOTE: Ensure pitch control rods are installed

(22). Perform main rotor blade droop angle
check if hub is new or replacement.
(23). Perform main rotor system balance
(Ref. Sec. 18-10-60, Main Rotor System
Balance Procedure) if a new or rebuilt
hub is installed.
3. Main Rotor Damper
at same locations from which removed.

(18). Install pitch control rods to pitch
housings (Ref. Sec. 62-30-60, Pitch
Control Rod Replacement).
(19). Connect flexible boot to lower end of
rotor hub liner and secure with lock
wire (CM702).
(20). Install main rotor drive shaft (Ref. Sec.
63-10-00).
(Ref. Figure 603) A main rotor damper is

attached to each pitch housing of the rotor
hub. The damper is connected to the inboard
trailing edge of the associated main rotor blade
by an adjustable clevis to prevent lateral
vibrations from occurring in main rotor blades.
Neither damper travel nor stiffness is adjust
able on the helicopter. Phasing of rotor blades
is affected by turnbuckle adjustment. Any
phasing problem caused by a defective damper
should be corrected by replacing damper.
62-20-60
Page 403
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2

blades.
CAUTION
NOTE: If one or more main rotor blades strike

an object while rotating or the drive system
has been subjected to sudden stop, inspect
damper.
4. Main Rotor Damper Replacement
A. Main Rotor Damper Removal
(1). Note and record location from which
damper is to be removed from main
rotor hub.
NOTE: At reinstallation, if damper is not rein

stalled at same location, a check of and/or
blade phasing is required.
(2). Support blade parallel to ground.
(3). Remove damper.
NOTE: If damper is to be reinstalled at same lo

cation, do not disturb damper clevis, jam
nuts or turnbuckle setting. Otherwise, blade
phasing is required at reinstallation of
damper.
(4). If damper is not to be reinstalled,
remove bushing from damper ear and
retain with hub.
B. Main Rotor Damper Installation
(1). Check, and if necessary, preset main
rotor damper length (Ref. Nominal
Damper Adjustment Procedure). Leave
jamnuts fingertight.
Page 404
Revision 36
62-20-60
NOTE: Ensure that bushing is installed in

large hole of damper ears.
(2). With damper rotational direction decal
facing outboard so it can be read, attach
damper ears to pitch housing lug with
bolt (head up), washers, and nut.
(3). Adjust main rotor blade phasing for
associated main rotor blade.
(4). After final phasing adjustments, torque
jamnuts to 95 - 110 inch-pounds
(10.73 - 12.43 Nm). Safety jamnuts to
turnbuckle with new lockwire. Lock
wire must be located out-board, away
from pitch housing.
NOTE: Threaded end of damper turnbuckle

shaft must protrude through clevis base a
minimum of two full threads and must clear
blade damper attach fitting.
(5). Connect damper to blade.
(6). Remove blade support.
5. Main Rotor Damper Nominal Adjustment
(1). Remove main rotor blade dampers from
helicopter if installed.
(2). Store all dampers together in horizontal
position for minimum of six hours.
Preferred ambient temperature during
storage is 55 to 85F (13 to 30C).
(3). Set damper length, centerline-to-cent
erline of bolt attach holes, for initial
installation.
600N
8.132 0.005 inch (206.553 0.127 mm.
(4). Install dampers on helicopter.
MAINTENANCE MANUAL
CSP-HMI-2
DRIVE SHAFT
SCREW AND
LOCKWIRE
RETAINER
RETAINER
LOCKNUT
LOCKNUT
MAIN ROTOR
HUB
LOCKNUT AND SEAL
INSTALLATION
LOCKWIRE
SHIMS/
SHIM WASHERS
(NOTE 2)
SCREW
RETAINER
LOCKNUT
SHOULDERED
BUSHING
DRIVE
SHAFT
LOWER SHOE
MAST
MAIN ROTOR
MAST
FLEXIBLE
BOOT
SAFETYING
NOTE 1
PITCH CONTROL
ROD
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 OUTSIDE SURFACE
OF PART AFTER NUT IS TIGHTENED.
2. SHIMS/SHIM WASHERS USED TO FILL GAP ON
SCISSORS
CRANK
ROTATING
SWASHPLATE
6G62-026
Figure 402. Main Rotor Hub Installation
62-20-60
Page 405
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
Page 406
Revision 44
62-20-60
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR HUB

INSPECTION/CHECK
1. Main Rotor System Balancing General
Main rotor system balancing is accomplished
by adding or removing weight (flat washers) as
required at the lead-lag bolts. Analysis of
main rotor system balance is accomplished
using instrumentation that measures and
localizes vibrations due to main rotor system
imbalance. Data provided by the instrumenta
tion is plotted on a chart designed to indicate
how much weight must be added or removed
from the lead-lag bolt. No other means of
balancing is to be used. If there is ground
rocking, or if one-per-rev lateral (main rotor)
vibration occurs during flight refer to Sec.
18-10-60, Main Rotor System Balance
Procedure.
2. Main Rotor Hub Inspection
Item
Nomenclature
CM104
Lubricant, spray
(1). Inspect pitch housing for scratches,

nicks and cracks. No cracks are permis
sible. Scratches and nicks must be
cleaned up before measuring depth of
damage to determine housing service
ability.
(2). Inspect sleeve bushing (Ref. Figure 805)
for snug fit in pitch housing arm clevis
lug; if bushings are loose, remove and
inspect. Inspect lug for evidence of wear
caused by bushing movement. Maxi
mum allowable diameter for hole in
each lug is 0.4380 inch (11.13 mm).
Inspect inner surfaces of all pitch
housing arm clevis lugs for chafing
caused by misaligned pitch control rod
end bearings. Chafing is in form of
crescent-shaped grooves. If chafing
wear exists, repair or replace. Chafed
area must be cleaned up before measur
ing depth of damage to determine
housing serviceability.
(3). Inspect droop stop ring for corrosion,

dents and scratches. If defects are
found, repair or replace.
NOTE: To inhibit corrosion, spray droop stop

ring, rollers and pitch bearings with spray
lubricant (CM104).
(4). Inspect droop stop roller for flat spots,
pit marks and looseness on roller shaft.
(5). Inspect striker plate for dents and pit
marks that exceed 0.030 inch (0.762
mm) depth. Damage exceeding this
limit requires replacement of striker
plate.
(6). Press each pitch housing downward
several times and check for evidence of
binding pitch bearing or droop restrain
er follower. Inspect visible portion of
droop restrainer for cracks and follower
spring for breaks.

bearing wear rate.
(7). Use bright light and 5-power magnify
ing glass to inspect all main rotor hub
lead-lag links (Ref. Figure 805) for
discoloration, pitting, intergranular
cracks or stress corrosion cracks. Any
discoloration or pitting is evidence of
more than superficial corrosion and
main rotor hub must be removed for
replacement of lead-lag links.
NOTE: Normal or premature overhaul requires

visual inspection plus dye-penetrant in
spection of links for same conditions.
(8). Inspect lead-lag link stop for broken
spring, cracks, breaks or visible bond
line cracks.
corrosion per Lead-Lag Bolt Inspection.
(10). Inspect each striker strip for cracks,
deformation and badly worn contact
surfaces.
62-20-60
Page 601
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
DAMAGED AREA
CUSHIONING
LAMINATE
CUSHIONING
LAMINATE
CUSHIONING
LAMINATE
6G62-027
Figure 601. Strap Pack Lamination Exploded View
Page 602
Revision 20
62-20-60
MAINTENANCE MANUAL
(11). Inspect all parts of main rotor hub for
cracks, breaks, scratches and nicks.
(Refer all questionable damage to
MDHI for disposition.)
(12). Inspect lower shoe scissors attach
bearings for binding, looseness in bore
and wear. Maximum wear limits are
0.010 inch (0.254 mm) radial and 0.020
inch (0.508 mm) axial.
(13). Inspect each of six main rotor retention
strap packs (Ref. Main Rotor Strap
Pack Lamination Inspection) at
specified intervals (Ref. Section 05-10).
3. LeadLag Bolt Inspection
Item
Nomenclature
CM318
CM425
Primer
Sealing compound

corrosion.
(a). Remove cotter pin securing nut to
lower end of lead-lag bolt. Do not
disturb torque on nut or remove nut.
(b). Remove screw, nut, washers and
balance hardware, if installed, from
lead-lag bolt.
(c). Inspect bolt interior. Treat minor
surface corrosion if noted (Ref.
Lead-Lag Bolt Corrosion Control). If
corrosion pitting or cracks are noted
remove and replace hub.
(d). Swab entire ID of bolt with primer
(CM318).
(e). Reinstall screw, nut, washers and
balance hardware removed in step 2.
Ensure hardware is installed exactly
as removed. Torque MS21042L08
locknut on screw to 20 - 35 inchpounds (2.26 - 2.82 Nm). Torque
MS21042L3 locknut on screw to 30 60 inch-pounds (3.39 - 6.78 Nm).
Coat exposed screw threads, washers
and nut with sealant (CM425).
CSP-HMI-2
NOTE: Excessive amount of sealant can unbal

ance rotor system. Apply light but thorough
coat of sealant.
(f). Install new cotter pin to secure nut to
lead-lag bolt.
4. Main Rotor Strap Pack Lamination
Inspection
CAUTION
D Figure 601 and Figure 602 depict the
main rotor hub and strap pack assembly
disassembled for clarity of location and
area to be inspected for cracks. Under no
circumstances should the strap pack or
main rotor hub assembly ever be disas
sembled in the field. MDHI and MDHI
Approved Licensees are the only ap
proved repair stations for main rotor hub
assembly overhaul.
D If a hub assembly or strap pack assembly
(other than new parts in storage) are sub
jected to extended periods of non-use,
whether installed on the helicopter or not,
the strap assembly should be inspected
critically for corrosion and pitting before
return to service. If corrosion is found on
the strap pack assemblies, contact MDHI
for disposition.
D It is acceptable to operate a helicopter
with a hub assembly having a strap pack
with one failed laminate in any one leg of
the strap assembly. When a laminate in
the strap assembly fails, the remaining
laminates pick up and carry the load. This
increased load causes slightly more elon
gation in the remaining laminates of that
leg thus shifting the mass of the rotor sys
tem. Any time a vibration develops or
there is an increase in vibration level over
a short period of time, the main rotor
strap pack assembly should be inspected
for cracked or failed laminates.
NOTE: Conduct inspection indoors, if possible,

or in a shaded area to eliminate glare of sun
or bright outdoor light. To facilitate inspec
tion, field fabricate and use plastic inspec
tion tool and wooden probe (Ref Figure 602).
62-20-60
Page 603
Revision 33
MAINTENANCE MANUAL
CSP-HMI-2
ALL LAMINATES STRAIGHT,

NO GAPS.
DETAIL 1 ACCEPTABLE

EXISTING ADJACENT TO EITHER SHOE.
DETAIL 2 ACCEPTABLE
NOTE:
WHILE TEFLON MAY APPEAR WRINKLED AND EXTEND PAST END OF LAMINATES,
PREVENTING CLEAR VIEW OF LAMINATES. WHEN THIS OCCURS, LOOK ALONG
EITHER SIDE IN AREA A-A OR B-B (DETAIL 3).

EXISTING ANYPLACE WITHIN LAMINATES.
DETAIL 3 ACCEPTABLE
REMOVE EXCESS TEFLON IN THIS AREA
6G62-078-1

Page 604
Revision 20
62-20-60
MAINTENANCE MANUAL
CSP-HMI-2
PLASTIC
INSPECTION TOOL
1
LEAD LEG

ON BOTH LEAD AND LAG LEGS OF SAME
LAMINATE.
0.125 INCH
(3.175 MM)
WOODEN OR
PHENOLIC PROBE
0.250 INCH
(6.35 MM)
LAG LEG
2

IN TONGUE OF LAMINATE (SHADED AREA
SHOWN BEYOND JOINT OF STRAP PACK
LEGS).
TONGUE
6.00 INCH
(15.24 CM)
4.00 INCH
10.16 CM)
1.5 INCH
(3.81 CM)
(REF)
3
ONE LAMINATE FAILURE AS DEFINED IN 1
AND/OR 2 ARE ALLOWED IN EACH STRAP
PACK ASSEMBLY. (TOTAL OF SIX LAMINATE
FAILURES PER HUB ASSEMBLY.)
1.00 INCH
(2.54 CM)
0.50 INCH
(12.7 MM)
FIELD FABRICATION INSPECTION TOOLS

ALUMINUM CHISEL NOT SHOWN
(REF. TABLE 601, NOTE 2)
STRAP PACK IS REJECTED IF TWO OR MORE

LAMINATES IN SAME PACK HAVE FAILED AS
DEFINED IN 1 AND/OR 2 ABOVE.
0.050-0.125 INCH
(1.27-3.175 MM)

LAMINATES IN SAME PACK ARE CRACKED IN
THE LEG (LEAD OR LAG).
FAILED LAMINATE IF CRACK IS
FOUND ON EITHER EDGE OF
LAMINATE. IF ONE LAMINATE
HAS FAILED IN THIS AREA,
REPLACE HUB.
6
CAUTION:
DO NOT DISASSEMBLE STRAP PACK ASSEMBLY,
LAMINATIONS ARE SHOWN SEPARATED ONLY TO
DEPICT POSSIBLE CRACK LOCATIONS.
NOTE:
ANY CRACK IN LAMINATE IS CONSIDERED A BREAK.
THE LAMINATE HAS NOT FAILED HOWEVER, UNLESS
BOTH LEAD AND LAG LEGS ARE CRACKED, CRACK
IS LOCATED IN TONGUE AREA OF LAMINATE OR IS
UNDER SHOES (SEE DETAIL 6).
1.50 INCH
(3.81 CM)
6G620782B
62-20-60
Page 605
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
Table 601. Strap Pack Inspection

Inspect
Outboard end.
Procedure (1)
For
Acceptable
Replace or Return
Hub for Overhaul
Visually. Use blunt nosed

wooden or phenolic probe
(Figure 602). Probe at
upper and lower end of
pack. Failed laminate in
lead or lag leg will move
away from other
laminates.
Failed laminates
(3).
One or less per

pack.
Two or more laminate

failures in one pack.
Visually.
Gaps between
laminates.
Single straight
gap not exceeding 0.03 inch
(0.762 mm) within
pack or next to
either upper or
lower outer shoe.
More than one gap

found; gap exceeds
acceptable limit.
Visually using light and

mirror (2).
Cracks or breaks.
None.

noted.
In area of and
within pitch
housing assemblies.

mirror (2).
Cracks or breaks.
One or less
Two or more laminate
laminate failures
failures (2) in a pack;
per strap pack (2). two or more laminates
in pack with crack in
same leg (lead or lag).
Cushioning
laminates at
each of two
attach points.

mirror.
Crack or break.
None

noted.
NOTES:
(1) Conduct visual inspections indoors or in shaded area to eliminate glare of sun or bright outdoor light.
(2) Removal of teflon covering is required for visual inspection of laminate edges. Use aluminum chisel,
fabricated from stock 0.025 x 6.00 x 0.100 (6.35 x 152.4 x 25.4 mm) to carefully scrape excess
interlaminate teflon sheets from both sides of strap pack between top and bottom shoes at outboard
attachment bolt of all six strap packs. Remove excess teflon from a point 0.50 inch (12.7 mm) outboard of
bolt centerline to 1.50 inches (38.1 mm) inboard of bolt centerline. Field fabricate and use plastic tool (Ref.
Figure 602). Run plastic tool in both directions along each laminate feeling for cracked laminate. Use of
plastic tool will ensure that shreds of teflon still hanging free does not obscure small cracks.
(3) Laminate has failed if crack is found in tongue area or if crack is found in both legs (lead and lag).
Page 606
Revision 33
62-20-60
MAINTENANCE MANUAL
(2). If required, trim teflon from edges of
laminates using a aluminum chisel.
Fabricate chisel from stock, 0.250 x 6.00
x 0.100 inch (6.35 x 152.4 x 25.4 mm).
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.
NOTE:
D Do not pry at strap pack assemblies with
sharp or hard edged tools. If edges become
nicked or laminates get scratched, addi
tional cracking can occur thus causing
hub replacement.
D Where accessible, ends of acceptable
cracked or broken laminates should be
taped to prevent scratching and damag
ing of adjacent laminates.
(3). (Ref. Figure 602 for field fabricate
plastic tool) Run plastic inspection tool
in both directions along each laminate,
feeling for a ``catch'' from a crack on a
single laminate. Use the wooden or
phenolic probe and probe at upper and
lower end of pack. Failed laminate in
lead or lag will move away from the
other laminates. If the adjacent upper
and lower laminates remain in tension
under the probing operation, no
laminate failures have occurred.
(4). Using a light and mirror, visually
inspect each of the main rotor strap
pack assemblies for evidence of cracks
or breaks in strap pack laminates in the
areas of the outboard shoes and pitch
housing assemblies.
(5). Using a 10X magnifying glass, visually
inspect the edge of strap pack lami
nates on both sides at outboard end of
blade pitch housing (area between
outboard shoes).
CSP-HMI-2
(6). Use the following as acceptance/rejec

tion criteria for laminate inspection:
(a). A laminate has failed if cracked in
tongue area or in lead and lag legs of
the same laminate.
(b). Reject strap pack and return hub
for overhaul when:
1). Two or more laminates in a single
strap pack have failed.
2). Two or more laminates in a single
strap pack are cracked in the same
lead or lag leg.
3). One laminate is cracked at the
outboard end in the area between
outboard shoes (Ref. Figure 602).
4). There are two or more gaps in the
same strap pack. A single gap in
any one strap pack assembly is
allowed.
(7). Visually inspect strap pack assemblies
for evidence of corrosion. If corrosion is
found on strap pack laminates contact
MDHI service department for disposi
tion.
(8). Inspect upper, lower and center cush
ioning laminates for cracks and breaks
(Ref. Figure 601).
NOTE: Cracks, breaks or other noticeable dam

age to the cushioning laminates require
main rotor hub overhaul/replacement.
(9). Record location of all cracked/broken
laminates in Helicopter Log Book
including strap serial number, blade
color, leg (lead or lag) and laminate
position, if possible, numbering from
the top down.
62-20-60
Page 607
Revision 33
MAINTENANCE MANUAL
CSP-HMI-2
5. Main Rotor Hub Droop Angle Check

(Ref. Figure 805) Whenever new or replacement
main rotor hub is installed or whenever excessive
droop angle is suspected, measure static droop
angle of all six rotor blades. Droop angle must be
5.5 0.5 degrees.
Item
Special Tools
Nomenclature
ST206
Prop protractor
LeftHand Command:
ST501
(LH command)
ST504
(LH command)
ST506
(LH command)
RightHand Command
ST502
(RH command)
ST505
(RH command)
ST507
(RH command)
(1). Install cyclic lateral rigging fixture

(ST506 or ST507), cyclic longitudinal
rigging fixture (ST504 or ST505), and
collective rigging fixture (ST501 or
ST502).
(2). Rotate main rotor to position one blade
over tailboom.
(3). Raise and support other five blades
until five corresponding droop stop
rollers no longer contact their striker
plates.
(4). Place accurate prop protractor (ST206)
on top of main rotor drive shaft. Adjust
protractor to zero setting.
(5). Place protractor on machined surface of
outboard end of blade pitch housing,
alongside lead-lag bolthead. Measure
and record static droop angle.
(6). Repeat (2). thru (5). above for remain
ing blades.
Page 608
Revision 20
62-20-60
(7). Maximum allowable static droop angle

is six degrees. If measured droop angle
exceeds six degrees, inspect striker
plate and roller for excessive wear and
adjust droop angle (Ref. Main Rotor
Hub Droop Angle Adjustment).
6. Main Rotor Damper and Attachments
Inspection
blades.
CAUTION
(1). Inspect bearing in rotor blade and

bearing in the pitch housing for
looseness around outer race. No degree
of radial or axial play is permitted.
(2). Inspect pitch housing and blade
bearings for binding, galling, or scoring
in bore and for wear. No radial play is
permitted. Maximum allowable axial
play is 0.015 inch (0.381 mm).
(3). Inspect clevis bushings for wear and
looseness.
(4). Inspect damper flange bushing for wear
and play.
(5). Inspect lower bolt hole in damper
flange for wear.
(6). Inspect damper housing (including
flanges) for damage.
(7). Inspect damper turnbuckle, jamnuts
and safetywire for security. No end play
is permitted when manually tested.
NOTE: When performing lead-lag of main ro

tor blades, apply rotor brake (if installed) or
have assistant hold main rotor hub from
moving. A second assistant is recommended
to measure approximate damper extension
and compression.
(8). Lead-lag each main rotor blade in turn
to provide approximately 0.10 inch
(2.54 mm) extension and compression of
the damper elastomer.
MAINTENANCE MANUAL
(9). Visually check each damper in turn for
cracks in elastomer or in elastomer-tometal bond at end face of damper: If
bonding or elastomer cracks are noted,
measure depths of cracks, using depth
gage fabricated of shim stock or
equivalent having a 0.20 inch (5.08
mm) indication. If depth of crack
exceeds 0.20 inch (5.08 mm), remove
and check damper.
7. Main Rotor Damper Weight Loading and
Extension Check
(Ref. Figure 603)
CSP-HMI-2
(3). Attach damper end cap to holding bar

or fixture.
NOTE: Perform weight loading and extension
check at ambient temperature of 70 l0F

(21 5C). Apply total 100 pound (45.359
kg) weight load to damper at one time, not in
weight increments.
(4). Using hydraulic jack or equivalent,

raise and attach 100 pound (45.359 kg)
weight load at damper clevis end.
Slowly lower jack to avoid shock
loading. After period of two minutes
under load, measure damper extension
on dial indicator.
(1). Remove damper assembly (Ref. Main

Rotor Damper Removal).
(5). If extension exceeds 0.063 inch (1.6002

mm), replace the damper assembly.
(2). Attach dial indicator or equivalent to

outer case of damper; position indicator
arm on center aluminum disc as shown.
(6). Reinstall existing damper; or as

required; install replacement damper.
NOTE: Fabricate holding bar or fixture capable

of sustaining 100 pound (45.359 kg) static
load (Ref. Figure 603).
NOTE: If replacement damper is installed, re

cord part number, serial number, and other
pertinent information in Components Re
cord of helicopters Log Book.
62-20-60
Page 609
Revision 25
MAINTENANCE MANUAL
CSP-HMI-2
ELASTOMER
(NOTE)
MAIN ROTOR
DAMPER
ALUMINUM
DISC
ELASTOMER-TO-METAL
BOND (NOTE)
END FACE - MAIN ROTOR DAMPER
HOLDING BAR
OR FIXTURE
END CAP
DAMPER
CLAMP
INDICATOR
INDICATOR ARM
THREADED
SHAFT
CLEVIS
100 POUND (45.359 KG)
WEIGHT
NOTE:
CHECK ELASTOMER AND
ELASTOMER-TO-METAL
BOND FOR CRACKS.
G62-2008A
Figure 603. Periodic Check of Main Rotor Damper Assembly

Page 610
Revision 20
62-20-60
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR HUB

REPAIRS
1. Main Rotor Retention Strap Pack Repair
Where accessible, ends of permissible cracks or
broken laminates (Ref. Table 601) should be
taped to prevent scratching and damaging
adjacent laminates.
Item
Nomenclature
CM234
CM725
CAUTION
Do not bend broken ends exces

sively and scratch adjacent
straps.
(1). Carefully wipe ends of broken strap
with a clean soft cloth moistened with
solvent (CM234).
(2). Use mild blast of filtered air to dislodge
any foreign particles between broken
strap ends and adjacent strap.
(3). Carefully tape broken ends of strap
with plastic electrical tape (CM725).
2. Pitch Control Bearing Housing Assembly,
Spacer or Striker Strip Replacement
(Ref. Figure 801)
Item
Nomenclature
CM222
CM425
Sealing compound
(1). Support blade and pitch housing from

beneath. Remove nuts. washers, and
bolts that secure bearing housing.
If droop shim washers are in

stalled between spacer and
striker strip, they must be retained for rein
stallation to establish correct static droop
angle between pitch housing and hub.
CAUTION
(2). Carefully remove spacer by sliding it

downward past striker strip. Retain
exact number of droop shim washers, if
installed.
(3). Slide bearing housing assembly off
pivot pin. Inspect pivot pin for grooving
or excessive wear.

bearing wear rate.
(4). Remove and discard pitch bearing if
defective, total radial looseness of
assembled ball and pivot pin must not
exceed 0.010 inch (0.254 mm).
(5). Replace striker strip if it is cracked or
lead-lag contact areas are worn
through hard anodized surface.
(6). Remove sealant between pitch housing
and striker strip. use care not to scratch
pitch housing. Remove striker strip
from pitch housing.
(7). Cut old striker strip to facilitate
removal from retention strap assembly.
Do not scratch strap assembly.
(8). Clean old sealant from pitch housing
using 1,1,1, trichloroethane (CM222).
(9). Cut out area of new striker strip.
Deburr, smooth and radius cut edges.
surfaces of the striker strip and pitch
housing.
62-20-60
Page 801
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
2.50 INCH
(6.35 CM)
CAUTION:
DO NOT SCRATCH STRAP PACK WHEN INSTALLING
THROUGH STRAP ASSY.
NOTE:
CUT OUT 0.25-0.50 IN. (6.35-12.70 MM) PIECE OF THE
STRIKER STRIP BETWEEN LOWER BOLT HOLES.
DEBURR AND RADIUSCUT EDGES.
0.25-0.50 IN.
(6.35-12.70 MM)
(NOTE)
G62-2009A
Figure 801. Striker Strip Replacement

(11). Position pitch control bearing housing
on pivot pin (Ref. Figure 802).
If droop shim washers were re
moved from between spacer and
striker strip, same exact thickness removed
must be reinstalled. There must be an equal
number of washers on each of all three bolts.
These washers establish correct static droop
between pitch housing and hub.
CAUTION
(12). Slide spacer into position between

bearing housing assembly and striker
strip on pitch housing. Install exact
thickness of droop shim washers
removed at time of disassembly. Align
holes for all three bolts.
(13). Install bolts, washers and nuts; torque
to 50 - 70 inch-pounds (5.65 - 7.91
Nm) and install safety wire.
(14). Seal all parting lines (joints) of the
assembly with bead of sealing com
pound (CM425).
(15). Perform droop angle check (Ref. Main
Rotor Hub Droop Angle Adjustment).
Page 802
Revision 20
62-20-60
3. LeadLag Link Blade Stop Replacement

Replace blade stop if it is broken, cracked, has bro
ken spring, or if there are visible bond line cracks
(Ref. Figure 802).
Item
Nomenclature
CM206
Chemical coating
CM217
Isopropyl alcohol
CM228
Surface cleaner
CM411
Adhesive, epoxy
CM802
CM803
Crocus cloth
Lead-lag link assembly must

not be removed from pitch con
trol housing for this repair, since retention
bolt cannot be retorqued without special
adapter.
CAUTION
(1). Provide a backup support for link

assembly. Use 1/2 inch (12.7 mm) wood
dowel and hammer to drive stop from
link. Strike dowel sharply to break
adhesive bond.
MAINTENANCE MANUAL
LEAD-LAG
BOLT
CSP-HMI-2
LEAD-LAG LINKS
MAIN ROTOR
STRAP PACK
STRIKER STRIP
PITCH CONTROL BEARING
HOUSING ASSEMBLY
PITCH PIVOT PIN
(NOTE 3)
SLEEVE
BUSHING
SPECIAL WASHER
(NOTE 4)
DROOP SHIM WASHERS

(CAUTION)
HUB
SPACE
R
NOTE 2
NOTE 1
NUT RETAINING
BRACKET
(NOTE 5)
PITCH
BEARING
STRIKER
PLATE
COUNTERSUNK
HEAD SCREW
NUT
PITCH BEARING HOUSING AND

SPACER - INSTALLATION
0.4328 IN.
(1.03872 MM)
DIA. MIN.
LEAD-LAG
STOP
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.
6G62-029A
Figure 802. Main Rotor Hub Components Repair and Installation
62-20-60
Page 803
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
(2). Using sharp-edge metal scraper,

carefully scrape any adhesive residue
from link. If scraper penetrates through
paint and chemical surface film, surface
must be refinished. Depth of gouges or
nicks is limited to 0.010 inch (0.254
mm) maximum after rework. Rework
by smooth blending into surrounding
area with grade 320 abrasive cloth
(CM802). Final polish with crocus cloth
(CM803). Restore chemical film protec
tion (CM206).
(3). Clean bond area of all contact surfaces
by wiping with cleaner (CM228).
Flush-wipe cleaned surface four times
with mixture of equal parts of distilled
water and isopropyl alcohol (CM217) to
remove all traces of phosphoric acid.
Rinse cleaned surface with tap water,
followed by a rinse of distilled water
until surface is ``water break'' free. Dry
for 30 minutes minimum at 150F
(66C).
(4). Check fit of stop in link. Flange and
radius contact surfaces of stop must
mate with link within 0.010 inch (0.254
mm). Maximum clearance between stop
and inside surfaces of link ears is
limited to 0.020 inch (0.508 mm). This
tolerance applies to both sides of stop.
(5). Prepare mixture of epoxy adhesive
(CM411). Apply uniform coating of
mixed adhesive to all contact surfaces.
Hand press stop into place between link
ears until all mating surfaces are in
firm contact. Apply a clamping device
so that contact is maintained. Cure for
minimum of eight hours at room
temperature, or two hours at 150F
(66C).
4. LeadLag Bolt Corrosion Control
Item
Nomenclature
CM219
CM318
CM425
CM802
Methyl-ethyl-ketone
Primer
Sealing compound
Page 804
Revision 20
62-20-60
Do not disturb torque on leadlag bolts. Special adapter is

needed to retorque lead-lag bolts.
CAUTION
(1). Remove and tag or color-code each set

of balance hardware that is installed.
(2). Remove corrosion with grade 180
abrasive cloth (CM802) and finish with
grade 400 abrasive cloth.
(3). Swab cleaned surface with MEK
(CM219) and apply unthinned primer
(CM318).
(4). Reinstall original balance hardware
that was removed. Using sealant
(CM425), reseal balance hardware.
5. Pitch Control Bearing Pivot Pin Repair or
Replacement
(Ref. Figure 802) Minimum allowable pin diame
ter is 0.4328 inch (10.993 mm). Pivot pin grooving
or excessive side wear may be polished to original
finish as long as minimum allowable pin diameter
remains after rework. Replace any pin requiring
more rework as follows.
Item
CM115
CM420
Nomenclature
Sealant
(1). Remove pivot pin.

(2). Lightly lubricate shank of replacement
pivot pin with grease (CM115).
NOTE: Torque pivot pin to 70 - 80 inchpounds (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
mounting lug surface. No gap is allowed.
(3). Install pivot pin in mounting lug with
washer. Torque pivot pin to 250 - 280
inch-pounds (28.25 - 31.64 Nm).
Apply sealant (CM420) at junctures of
pivot pin flange, washer and hub.
6. Droop Stop Roller Repair or Replacement
(Ref. Figure 803) Replace defective droop stop roll
er if clearance between roller bearing liner and
shaft is more than 0.015 inch (0.381 mm). Roller
shaft outside diameter must not be less than
0.4370 inch (11.0998).
MAINTENANCE MANUAL
Item
CM217
Nomenclature
Isopropyl alcohol
(1). Move pitch control bearing housing out

of the way that contacts lower shoe
roller to be removed.
NOTE: It may be easier if only one roller is re

moved at one time. The opposing pitch hous
ing may be pressed against it's follower to
force opposite follower out and expose roller
shaft for removal. Same condition exists at
installation.
alcohol (CM217).
(5). Install pitch control bearing housing.
7. Droop Stop Ring Repair
(Ref. Figure 803)
Item
CM103
Nomenclature
(1). Repair depth limit for corrosion, nicks

or scratches in droop stop ring is 0.007
inch (0.1778 mm) for all surfaces except
outer edges of ring outer flanges where
the depth limit is 0.030 inch (0.762
mm). All reworked areas must be
blended smoothly with 15 to 1 ratio into
surrounding area.
(2). Spray repaired areas of rings with solid
film lubricant (CM103).
(3). Replace droop stop ring if repair limits
are exceeded.
8. Droop Stop Ring Replacement
(Ref. Figure 803)
(1). With hub upside down, support hub so

that pitch housings unload droop stop
followers and provide maximum
CSP-HMI-2
clearance between striker plates and

droop stop rollers.
(2). If necessary, release retaining (snap)
ring of each droop stop restrainer from
its groove. Move retaining ring flush
against droop stop follower (T-head) to
provide additional clearance and reduce
spring tension.
(3). Remove six droop stop rollers.
(4). Starting from either scissors crank
attach lug, number, or color code, all six
droop stop follower assemblies in
clockwise direction for location identifi
cation at replacement. This number
code should be placed on outer, upper
end of plunger and on adjacent area of
lower shoe. Ensure codes are not
accidentally removed during remaining
steps.
(5). Compress each droop stop follower and
insert a small wedge from the back side
to hold follower away from droop ring.
(6). After all followers are compressed,
remove droop stop ring.
When installing droop stop ring,
droop stop followers T-Heads
must be offset away from lower shoe to pre
vent damage to lower shoe.
CAUTION
(7). Install replacement droop stop ring by

reversing removal procedure, steps (1).
thru (6)., making certain to reinstall
followers according to markings placed
thereon prior to removal.
(8). Compress follower spring and install
retaining (snap) ring, if removed, in its
groove on each follower.
(9). Reinstall droop stop rollers, shafts and
cotter pins.
9. Droop Stop Follower (THead)
Replacement
(Ref. Figure 803) Replace the droop stop follower
(T-head) if it is worn, scored or is causing damage
to the droop stop ring. After the droop stop ring
has been removed, the droop stop follower assem
blies may be removed from hub.
(1). Remove droop stop follower assembly

from hub.
62-20-60
Page 805
Revision 37
MAINTENANCE MANUAL
CSP-HMI-2
LOWER SHOE
DROOP STOP
FOLLOWER
(T-HEAD) (NOTE)
PINS
SNAP RING
SPRING
COTTER PIN
DROOP STOP
ROLLER
SCISSORS CRANK
ATTACH LUG
BEARING ROTATIONAL DRAG
1.0 - 2.0 IN-LBS
(0.113 - 0.226 NM)
DROOP STOP
RING
DROOP STOP PLUNGER

SHAFT
DROOP STOP FOLLOWER INSTALLATION
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.
Figure 803. Droop Stop Ring Replacement and Repair

Page 806
Revision 37
62-20-60
6G62-028C
MAINTENANCE MANUAL
(2). Remove pins that secure follower to
plunger.
Droop stop followers T-Heads
must be offset away from lower
shoe to prevent droop stop ring from damag
ing lower shoe.
CAUTION
(3). Insert new follower. T-head must be at

right angle to roller shaft in plunger.
(4). Drill two 0.156-0.158 inch (3.962-4.013
mm) diameter holes through follower in
line with holes in plunger.
(5). Insert pins and stake ends. No burrs or
roughness permissible after staking.
(6). Install follower assembly in hub.
(7). Reinstall droop stop ring.
10. Droop Stop Plunger Removal, Inspection
and Installation
(Ref. Figure 803)
Item
Nomenclature
CM217
Isopropyl alcohol

(2). Check droop stop plunger for wear by
using the following criteria:
NOTE: The minimum acceptable diameter af

ter wearing in service should be 0.996 inch
(25.298 mm). The acceptable amount of
wear though the anodized coating shall not
exceed 40% or 2.1 square inches (28.45
square cm) of the total sliding surface area
of the cylinder. The maximum wear condi
tion may exist in one spot or in several spots
totaling 2.1 inches (28.45 square cm).
CSP-HMI-2

alcohol (CM217).
(4). Install droop stop plunger into lower
shoe.
(5). Complete droop stop ring installation.
11. Main Rotor Hub Droop Angle Adjustment
(Ref. Figure 802) If static droop angle exceeds six
degrees, adjust as follows.
(1). Remove main rotor blade.

(2). Use flat washers of thickness required
to adjust spacing between spacer and
striker strip. Any one type, or combina
tion, of correct part number washers
(IPC) may be used; however, an identi
cal washer selection must be installed
on each of three bolts that secure pitch
control bearing assembly to pitch
housing.
(3). Remove nuts, washers and bolts, and
separate spacer from striker strip. The
use of one 0.016 inch (0.406 mm)
washer raises static droop angle
approximately one-half degree. Add
sufficient washers to adjust droop angle
within range of 5.5 0.5 degrees.
Reinstall nuts, washers and bolts.
(4). If more than 0.063 inch (1.6 mm)
spacing is required (above factory
spacing), inspect striker plate and
droop stop roller or follower and droop
stop ring for excessive wear. Replace as
required.
(5). Reinstall blade. Repeat measurement of
static droop angle.
(6). As required, repeat above procedures
for remaining blades.
(7). Following reinstallation or replacement
of parts, check track of main rotor
blades.
62-20-60
Page 807
Revision 37
MAINTENANCE MANUAL
CSP-HMI-2
12. Main Rotor Hub Tapered Bearing Grease

(Ref. Figure 805)
Item
CM111
CM121
CM234
CM802
CM803
Nomenclature
Grease, aircraft
Preservation oil
Crocus cloth
Item
ST701
Special Tools
Nomenclature

main rotor hub.
CAUTION

upper and lower bearing cups from hub.
A press ram of one to two tons is
sufficient for removal.
(2). Press lower bearing cone from sleeve
bushing.
CAUTION able bearings while cleaning.
cleaning.
retainer and reusable bearings using
(4). Check bearing cup hub bore for scoring:
(a). Smooth out any roughness with
grade 400-600 abrasive cloth
(CM802).
Revision 37
(c). Maximum diameter of hub bore for

upper bearing cup (Ref. Figure 805)
is 4.4335 inches (11.25 cm), measured
in any direction.
(d). Maximum diameter of hub bore for
lower bearing cup is 4.3095 inches
(10.95 cm), measured in any direc
tion.
(5). Check upper seal retainer:
(a). No cracks, sharp nicks or burrs are
allowed.
(b). Minor corrosion or other surface
defects may be polished out using
crocus cloth (CM803).
(c). Grooving on seal contact surfaces
must not exceed 0.004 inch (0.10 mm)
depth after polishing.
NOTE:
Page 808
(b). Restore chemical film protection

where removed.
62-20-60

(6). Place bearing cups in closed container
of dry ice and cool for not less than 20
(7). Coat bores of hub with grease (CM111).
(8). Use care to maintain cup-to-hub bore
(9). Apply film of grease (CM111) to sleeve
bushing. Use pressing tool equivalent to
tool C, and press bearing cone onto
sleeve bushing.
(10). With lip on center seal up, hand press it
into hub (Ref. Figure 805).
(11). Apply film of grease (CM111) on mast.
Install preassembled sleeve bearing
and bearing cone on mast. Do not apply
any additional lubricant to roller
bearing set. Wipe any excess preserva
tive oil from bearing cone and cup.
MAINTENANCE MANUAL
2.875 IN. (7.3025 CM)

OUTSIDE DIAMETER
0.50 IN.
(12.7 MM)
CUT OUT AFTER

BEVELING
CSP-HMI-2
3.50 IN. (8.89 CM)

OUTSIDE DIAMETER
3.875 IN.
(9.8425 CM)
11.0 IN.
(27.94 CM)
53
5.75 IN.
(14.605 CM)
3.375 IN.
(8.5725 CM)
0.375 IN.
(9.525 MM)
0.1875 IN. (4.7625 MM)

WALL STEEL PIPE
B
4130 STEEL PLATE

A
4.40 IN.
(11.176 CM)
0.203125 IN. (5.159375 MM)

WALL STEEL PIPE
C
4.30 IN.
(10.922 CM)
2.58 IN.
(6.5532 CM)
0.30 IN.
(7.62 MM)
3.50 IN.
(8.89 CM)
2.0 IN.
(5.08 CM)
2.0 IN.
(5.08 CM)
ALUMINUM ALLOY
D
ALUMINUM ALLOY
STEEL RING WASHER
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
62-20-60
Page 809
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
7.0 INCH (17.78 CM)

SQUARED
4.75 INCH
(12.065 CM)
MATERIAL: WOOD
0.75 INCH
(19.05 MM)
10.0 INCH (25.40 CM)

SQUARED
H62-2010-2A

If hub assembly does not seat
properly onto mast, do not at
tempt to force it into position. Remove hub
assembly from mast and determine cause of
hub not seating, correct the problem and fol
low the procedures for reinstallation.
CAUTION
(12). Place assembled hub over mast and

seat on lower roller bearing cone.
(13). Install upper bearing cone into hub.
NOTE: Use of substitute steel ring washer for

retainer prevents unnecessary scoring of re
tainer. Several tightening and loosening ac
tions may be required to get rotational drag
on hub bearings.
for seal retainer (Ref. Figure 805)
pound (0.681 - 0.795 kg) pull with
hub in motion indicates correct rota
tional drag.
(16). Remove locknut, washer and cone.
(17). To determine thickness required for
spacer:
Page 810
Revision 37
62-20-60
NOTE: When determining spacer thickness,

start with thick spacer and work down to
thinner spacer.
(a). Install subsequently thinner spacers,
from kit K-600N-1200A, starting
with a thick spacer, along with cone,
substitute washer for retainer and
locknut.
(b). Torque nut to to 200 - 250 footpounds (271 - 339 Nm) until 10 15 inch-pounds (1.13 - 1.69 Nm)
of rotational drag (not breakaway torque) is obtained on hub.
(18). When proper torque has been reached,
disassemble and remove steel ring
washer.
(19). Alternative method for determining
thickness required for spacer:
(a). Install 369A1224-5 lead spacer in
place of the 369A1224-3 spacer.
(b). Place steel ring washer for retainer
and locknut on the mast and gradual
ly tighten the retaining nut until
rolling torque of 10 - 15 inchpounds (1.13 - 1.69 Nm) of rota
tional drag (not break-away
torque) is obtained on hub. If the 10
- 15 inch-pounds (1.13 - 1.69 Nm)
of rotational drag is exceeded,
discard the lead washer, install new
washer and continue.
MAINTENANCE MANUAL
(c). When proper torque has been
reached, disassemble and measure
thickness of the lead washer in the
bearing seat area. Grind the
369A1224-3 spacer to the same
thickness as measured on the lead
washer. Check thickness of ground
washer at six locations to ensure
thickness does not vary by more than
0.0005 inch (0.0127 mm).
(d). Re-assemble with the ground steel
washer, steel ring washer and
locknut and torque to 200 - 250
foot-pounds (271 - 339 Nm) until
10 - 15 inch-pounds (1.13 - 1.69
Nm) of rotational drag (not
break-away torque) is obtained on
hub.
(20). Remove hub and sleeve bushing with
lower bearing cone from mast.
CSP-HMI-2
Item
CM111
CM204
CM121
CM234
CM702
CM802
Nomenclature
Grease, aircraft
Preservation oil
Lockwire CRES
Item
ST701
ST703
Special Tools
Nomenclature
(1). Remove main rotor hub assembly (Ref.

Main Rotor Hub Removal) and place on
bench.
(2). Remove upper bearing cone.
main rotor hub.
CAUTION
(21). Position hub upside-down. Hand-pack
lower hub cavity (Ref. Figure 805) and
bearing cone on sleeve bushing with
grease (CM111).
(22). Install sleeve bushing with bearing
cone in hub. Hand-pack cavity between
bearing and hub liner with grease
(CM111); then press in lower seal with
seal lip toward top of hub. Wipe off
excess grease.
(23). Turn hub assembly right side up.
(24). Complete reassembly of hub by install
ing recessed spacer, upper bearing cone,
upper seal and seal retainer in hub at
installation of hub on mast.
13. Main Rotor Hub Upper Bearing Grease

The following procedure is for greasing, inspection
and replacement of the main rotor hub upper
bearing only.
NOTE:
upper bearing cup from hub. A press
ram of one to two tons is sufficient for
removal.
able bearing while cleaning.
cleaning.
CAUTION

retainer and reusable bearing using
(5). Check bearing cup hub bore for scoring:
(a). Smooth out any roughness with
grade 400-600 abrasive cloth
(CM802).
62-20-60
Page 811
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
(b). Restore chemical film protection

where removed.

(c). Maximum diameter of hub bore for

upper bearing cup (Ref. Figure 805)
is 4.4335 inches (11.25 cm), measured
in any direction.
(14). Apply film of grease (CM111) on upper

bearing cone and place into hub.
(6). Check upper seal retainer.

(a). No cracks, sharp nicks or burrs are
allowed.
NOTE: Use of substitute steel ring washer for

retainer prevents unnecessary scoring of re
tainer. Several tightening and loosening ac
tions may be required to get rotational drag
on hub bearings.
(b). Minor corrosion or other surface

defects may be polished out using
crocus cloth (CM803).

for seal retainer (Ref. Figure 805)
(c). Grooving on seal contact surfaces

depth after polishing.

pound (0.681 - 0.795 kg) pull with
hub in motion indicates correct rota
tional drag.

(7). Place bearing cup in closed container of
dry ice and cool for not less than 20
(8). Coat bore of hub with grease (CM111).
(9). Use care to maintain cup-to-hub bore
If hub assembly does not seat
properly onto mast, do not at
tempt to force it into position. Remove hub
assembly from mast and determine cause of
hub not seating, correct the problem and fol
low the procedures for reinstallation.
CAUTION


(CM111).
Page 812
Revision 34
62-20-60
(17). Remove locknut, washer and cone.

(18). To determine thickness required for
spacer:
NOTE: When determining spacer thickness,

start with thick spacer and work down to
thinner spacer.
(a). Install subsequently thinner spacers,
from kit K-600N-1200A, starting
with a thick spacer, along with cone,
steel ring washer for retainer and
locknut.
(b). Torque nut to to 200 - 250 footpounds (271 - 339 Nm) until 10 15 inch-pounds (1.13 - 1.69 Nm)
of rotational drag (not breakaway torque) is obtained on hub.
(19). When proper torque has been reached,
disassemble and remove steel ring
washer.
(20). Alternative method for determining
thickness required for spacer:
MAINTENANCE MANUAL
CSP-HMI-2
(a). Install 369A1224-5 lead spacer in

place of the 369A1224-3 spacer.
(1). Remove main rotor hub (Ref. Main

(b). Place steel ring washer for retainer

and locknut on the mast and gradual
ly tighten the retaining nut until
rolling torque of 10 - 15 inchpounds (1.13 - 1.69 Nm) of rota
tional drag (not break-away
torque) is obtained on hub. If the 10
- 15 inch-pounds (1.13 - 1.69 Nm)
of rotational drag is exceeded,
discard the lead washer, install new
washer and continue.
(2). Invert hub and place on work bench.
(c). When proper torque has been

reached, disassemble and measure
thickness of the lead washer in the
bearing seat area. Grind the
369A1224-3 spacer to the same
thickness as measured on the lead
washer. Check thickness of ground
washer at six locations to ensure
thickness does not vary by more than
0.0005 inch (0.0127 mm).
(d). Re-assemble with the ground steel
washer, steel ring washer and
locknut and torque to 200 - 250
foot-pounds (271 - 339 Nm) until
10 - 15 inch-pounds (1.13 - 1.69
Nm) of rotational drag (not
break-away torque) is obtained on
hub.
(21). Complete reinstallation of main rotor
hub assembly (Ref. Main Rotor Hub
Installation).
14. Main Rotor Hub Scissors Attach Lug
Bearing Replacement
Item
Nomenclature
CM206
Chemical coating
CM216
Loctite remover
CM304
Enamel, epoxy
CM321
CM431

(4). Press bearing from hub lug.
(5). Clean bearing bore with locktite
remover (CM216).
(6). Inspect bearing bore for nicks,
scratches and grooves.
(7). Inspect bore for diameter of
0.6551-0.6556 inch (16.63954-16.65224
mm).
(8). Touch up bearing bore with chemical
coating (CM206).
(9). Apply surface primer (CM321) to
mating surfaces of bearing and boreas
per manufacturer's instructions.
NOTE: Do not allow primer to enter bearing.

(10). Apply locking compound (CM431) to
faying surfaces of bearing and bore,
press bearing into bore while locking
compound is wet.
(11). Remove excess sealant, do not allow
sealant to enter bearing.
(12). Apply a small fillet of sealant around
bearing and allow to dry for 24 hours at
room temperature or heat to 140 160F (60 - 72C) for one hour.
(13). As required, touch up bearing lug with
paint (CM304).
(14). Check bearing for a no-load rotational
drag of 1.0 - 2.0 inch-pounds (0.113 0.226 Nm).
(15). Reinstall droop stop ring (Ref. Droop
(16). Reinstall main rotor hub (Ref. Main
62-20-60
Page 813
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
SEAL
(NOTE 4)
DROOP SHIM WASHER

(NOTE 6)
SEAL RETAINER
HUB
PIVOT PIN
UPPER BEARING CONE

(NOTE 7)
SEALANT
(NOTE 2)
STRIKER
STRIP PITCH
HOUSING
NOTE 1
UPPER BEARING CUP

(NOTE 7)
(NOTE 5)
PITCH
BEARING
SEAL
(NOTE 4)
SLEEVE
BUSHING
RECESSED
SPACER
(NOTE 3)
SEALANT
(NOTE 2)
STRAP
PACKS
LOWER SHOE
NOTE 5
DROOP STOP RING
STRAP
ASSEMBLY
NOTE 8
NOTE 1
SPRING
HUB OUTER LINER

SEAL
(NOTE 4)
PITCH HOUSING
ROLLER
SPACER
ASSEMBLY
RETAINING
PITCH CONTROL
CLIP FOLLOWER
ASSEMBLY
BEARING HOUSING
LOWER BEARING CUP
(NOTE 7)
LEAD-LAG PIVOT BOLT
BUSHING
LOWER BEARING CONE

(NOTE 7)
SEALANT
(NOTE 2)
BEARING
(NOTE 1)
LEAD-LAG
LINKS
SHIM
STRAP ASSEMBLY
BUSHING
NUT
COTTER PIN
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.
Figure 805. Main Rotor Hub Cross Section

Page 814
Revision 37
62-20-60
6G62-030A
MAINTENANCE MANUAL
CSP-HMI-2
Section
623000
Swashplate and
Mixer (369D/E/FF
500N)
MAINTENANCE MANUAL
CSP-HMI-2
SWASHPLATE AND MIXER

1. Main Rotor Swashplate
(Ref. Figure 403) The main rotor swashplate
includes a rotating swashplate, stationary
swashplate, bearing and retainer and two
counterweights.
2. Swashplate Replacement
A. Swashplate Removal
(1). Tag or color-identify five pitch control
rods (Ref. Figure 401) to simplify
replacement at same locations.
Failure to reinstall pitch control
rods at correct locations prob
ably will result in main rotor blades exces
sively out of track.
CAUTION
(2). Disconnect pitch control rods from

(3). Remove scissors.
(4). Remove main rotor hub.
B. Swashplate Installation
(1). If swashplate lower boot was removed,
install boot on mast (Ref. Figure 403).
(2). Position swashplate over main rotor
mast and carefully lower into place.
(3). Engage upper end of boot in groove at
lower side of stationary swashplate.
Secure boot with self-clinching nylon
strap (Ref. Figure 403).
(4). Align longitudinal link with stationary
swashplate (Ref. Figure 402).
(5). Install flanged bushing, if removed,
bolt, two washers, nut and cotter pin to
secure upper end of longitudinal link.
(6). Align upper ends of mixer links with
stationary swashplate. Install slotted
bushing (if removed), bolt, two washers,
nut and cotter pin to secure each link to
swashplate.
(7). Install scissors.
(5). Disconnect longitudinal link (Ref.

Figure 402) from stationary swash
plate.
(8). Using color code, reinstall pitch control

rods at same locations from which
removed.
(6). Disconnect right and left side mixer

links (Ref. Figure 402) from stationary
swashplate.
(9). Check track of main rotor blades (Ref.

Chap. 18) following any maintenance
activity that could result in a dimen
sional variation affecting rigging or
tracking.
(7). Remove protective boot from groove in

lower side of stationary swashplate
(Ref. Figure 403).
Do not strike rotating swash
plate or bearing assembly (Ref.
Figure 403) with tools or in any way deface
these components. Rotating swashplate is a
stressed part; all surfaces are shot peened.
Use particular care to protect teflon liner in
bearing bore. A damaged swashplate bear
ing must not be retained in service.
CAUTION
(8). Lift swashplate carefully up and off of

mast.
(9). To remove boot from mast, remove
self-clinching nylon strap.
3. Mixer Controls
Mixer controls consist of various links,
bellcranks, idlers, support bracket and
associated fasteners that secure these compo
nents in place and to the control rods and main
rotor swashplate.
4. Mixer Controls Replacement
A. Mixer Controls Removal
(Ref. Figure 402)
(1). Remove air intake forward fairing for
access.
62-30-00
Page 401
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
ROTOR HUB
LOWER SHOE
6.25 IN.
(15.875 CM)
CLOSE TOLERANCE
BOLT
WASHERS
(NOTE 4)
SCISSORS CRANK
PITCH CONTROL ROD - LENGTH
(NOTE 3)
MAXIMUM ALLOWABLE LOOSENESS
0.040 IN. (1.016 MM)
AT INSTALLATION, ROD ENDS
TO BE PARALLEL WITH
MATING CLEVIS
SLOTTED BUSHING
(NOTE 1)
BEARING
1.30 IN. (3.302 CM) TYPICAL

(UPPER BEARING ONLY)
WASHERS
(NOTE 4)
BUSHING
SCISSORS LINK
BEARING
PITCH CONTROL ROD

(NOTE 2)
ELASTOMER RING
(NOTE 6)
SLOTTED BUSHING
(NOTE 1)
ELASTOMER RING
(NOTE 5)
ROTATING
SWASHPLATE
INTERRUPTER
SLOTTED BUSHING
(NOTE 1)
COLLECTIVE PITCH
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
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
7. DELETED
Figure 401. Pitch Control Rods and Swashplate Scissors Installation

Page 402
Revision 36
62-30-00
MAINTENANCE MANUAL
(2). Disconnect upper ends of collective
mixer, lateral mixer and longitudinal
mixer control rods (Ref. Figure 401).
NOTE: Control rods are attached by slightly

different length bolts. Reinstall each bolt in
its bellcrank following control rod removal
to simplify reinstallation at correct loca
tions.
(3). Remove mixer links. (Mixer link
bearings are not replaceable.)
(4). Disconnect longitudinal link from
stationary swashplate.
(5). Remove longitudinal control mixer link.
(6). Disconnect lateral bellcrank from
collective pitch mixer bellcrank.
(7). Remove connecting hardware (includ
ing flanged bushing) from each side of
longitudinal pitch mixer bellcrank.
Carefully remove bellcrank. Retain any
shims that may be installed.
CSP-HMI-2
support bracket and bore in mast base

lug is 0.015 inch (0.381 mm) or less.
NOTE: If necessary, loosen aft two bracket-tofitting nuts, position support bracket to
minimize misalignment and retighten nuts.
(4). Install mixer support attaching bushing
in bracket and mast base lug.
(5). Check that sleeve bushing is in place;
then install bolt, two washers and nut.
(9.04 - 11.30 Nm).
(6). Position longitudinal pitch idler and
collective pitch mixer bellcrank on
support bracket. Position washer
between right side of longitudinal pitch
idler bearing and center bearing of
mixer support bracket. Install lefthand bearing, with attaching hardware.
(7). Position lateral bellcrank between
collective pitch mixer bellcrank bear
ings and install attaching hardware.
(8). Remove bolt from hingeline of support

bracket, longitudinal pitch idler and
Separate the three parts.
(8). Position longitudinal pitch mixer

bellcrank with collective pitch mixer
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
and bearings in collective pitch bell
crank.
To prevent washing dirt into

bearings, or washing grease out
of bearings, do not permit solvent to enter
bearings when cleaning mixer control com
ponents.
CAUTION
B. Mixer Controls Installation

(Ref. Figure 402)
(1). Position support bracket over forward
lug on mast base.
(10). Using HS5079-2646 laminated wash

er(s), shim evenly to take up gap.
(11). Insert flanged bushings, bolts, six
washers (two under each nut) shims
and nuts. Torque nut to 30 - 40 inchpounds (3.39 - 4.52 Nm) and install
cotter pin.
(2). Install two aft bolts and washers in

support bracket and mast base. Install
two thin washers and nuts; torque nuts
to 80 - 100 inch-pounds (9.04 - 11.30
Nm) above drag torque.
(12). Position longitudinal control mixer link

between longitudinal pitch idler and
longitudinal pitch mixer bellcrank;
check that two slotted bushings are in
place. Install bolt, three washers (two
under each nut), nut and cotter pin at
each end of link.
(3). Using ball hole gage and standard

micrometer, check that misalignment
between forward bolt hole bore in
(13). Position longitudinal link between

longitudinal pitch mixer bellcrank
bearings. Install attaching hardware.
62-30-00
Page 403
Revision 31
MAINTENANCE MANUAL
CSP-HMI-2
BUSHING
(NOTE 2)
LONGITUDINAL
PITCH IDLER
LONGITUDINAL
CONTROL MIXER LINK
*LATERAL MIXER
BELLCRANK
BEARING
MIXER LINK
STATIONARY
SWASHPLATE
STATIONARY
SWASHPLATE
BUSHING
(NOTE 2)
WASHER
MIXER
SUPPORT
ATTACHING
BUSHING
(NOTE 6)
BUSHING
(NOTE 2)
FLANGED
BUSHING
BEARING
MIXER
LINK
LONGITUDINAL
LINK (NOTE 3)
BEARING
MIXER
SUPPORT
BRACKET
BEARING
BUSHING
(NOTE 2)
FLANGED
BUSHING
(NOTE 4)
BEARING
*COLLECTIVE
PITCH MIXER
BELLCRANK
NOTE 1
NOTE 1
BEARING
NOTE 7
SLEEVE
BUSHING
BEARING
FLANGED
BUSHING
(NOTE 4)
NOTE 1
*LONGITUDINAL
PITCH MIXER
BELLCRANK
2 PLS
MAST
BASE
NOTES:
1. DIRECTION OF BOLT OPTIONAL.
2. EDGE OF BUSHING MUST PROTRUDE MINIMUM OF 0.010 IN. (0.254 MM) TO MAXIMUM OF
0.060 IN. (1.524 MM) ABOVE OUTSIDE OF PART AFTER NUT IS TIGHTENED.
3. LONGITUDINAL LINK DETAILS ROTATED FOR CLARITY.
4. MUST BE PULLED OUT FIRST TO REMOVE BELLCRANK.
5. ASTERISK ( * ) INDICATES PART THAT MAY BE EITHER MAGNESIUM OR ALUMINUM ALLOY.
(FOR ALLOY IDENTIFICATION AND CORROSION CONTROL, REF. SEC. 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.
Figure 402. Mixer Controls Assembly

Page 404
Revision 31
62-30-00
G62-3003C
MAINTENANCE MANUAL
(14). Position mixer links in stationary
swashplate and lateral bellcrank; check
that slotted bushings are in place.
Install attaching hardware.
(15). Place collective mixer, lateral mixer
longitudinal mixer control rods (Ref.
Figure 401) in mounting position; check
that slotted bushing in place. Install
attaching hardware.
(16). Install air intake forward fairing.
(17). Check rigging of collective and cyclic
controls.
5. Scissors
The scissors provide a movable connection
between the rotating swashplate and main
rotor hub.
6. Scissors Replacement
A. Scissors Removal
CSP-HMI-2
Scissors crank must be posi

tioned (Ref. Figure 401) with de
cal up and proper direction towards lower
side lugs.
CAUTION
NOTE: Ensure crank-to-hub lower shoe lugs

are not preloaded.
(3). Position scissors crank on hub lower
shoe lugs; install connecting hardware
(Ref. Figure 401). Torque nuts to 30 60 inch-pounds (3.39 - 6.78 Nm);
install cotter pin.
NOTE: Shim washers may be required on

shouldered bushing side of clevis.
(4). Position elastomer rings and lower end
of pitch control rod in swashplate lug
and install attaching hardware. (Nut is
to be adjacent to bushing in swash
plate.) Torque nut to 30 - 60 inchpounds (3.39 - 6.78 Nm).
7. Scissors Link Replacement
(Ref. Figure 401)

Removal of all pitch control rods
CAUTION is recommended prior to scissors
removal. Failure to observe this precaution
could result in damage to pitch control rods,
swashplate and/or hub.
(1). Disconnect lower end of pitch control
rod that is in line with scissors link in
(2). Remove cotter pin, nut, washer, and
bolt from each leg of scissors crank.
Disconnect crank from hub lower shoe.
bolt connecting scissors link to swash
plate; remove scissors.
B. Scissors Installation
Item
Nomenclature
CM103

that join link and crank.
(2). Remove two bushings from link only if
replacement is necessary.
(3). Do not remove bearing from link,
replace complete link if bearing is
defective.
NOTE: Install new bushings using solid film lu

bricant (CM103); do not use zinc chro
mate.
(1). Place scissors link in mounting posi

tion, chamfered edge of link must face
outboard.
(4). If bushings were removed at disassem

bly, install new bushings. After installa
tion, dimension between outer faces of
bushings should be 1.579-1.586 inches
(4.0107-4.0284 cm).
(2). Check that slotted bushing is in

swashplate web and install attaching
hardware. Torque nut to 15 - 20
(5). Align bore of link with bore of crank;

install bolt, washer and nut. Torque nut
to 30 - 40 inch-pounds (3.39 - 4.52
Nm), install cotter pin.
(Ref. Figure 401)
62-30-00
Page 405
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2
8. Pitch Control Rods

Five pitch control rods transfer pitch control
from the rotating swashplate to the main rotor
blades.
9. Pitch Control Rod Replacement
A. Pitch Control Rod Removal
(Ref. Figure 401)
NOTE:
D If rod is not to be reinstalled, but is to be
replaced, measure and record length of
removed rod. Optimum length may have
been changed at previous rigging; pre-ad
just replacement rod to length of rod re
moved.
D Rods are color coded for reinstallation at
correct locations. If more than one rod is
being removed and color coding is not vis
ible, identify each by color or similar
means to points of connection to simplify
reinstallation.
from each end of pitch control rod.
(2). Remove pitch control rod and O-ring.
B. Pitch Control Rod Installation
(Ref. Figure 401)
At installation, install rod at
correct color code location. Cen
ter bearing rodends between attach clevis. If
rod length is changed, blades must be
tracked.
CAUTION
(1). If actual rod length is incorrect or

either actual or required rod length is
unknown, preset rod length to optimum
length of 6.25 inches (15.875 cm).
NOTE: Install both pitch change rod bolts in

direction of rotation.
(2). Install rod with elastomeric rings on
both sides of lower bearing.
NOTE: Add washers as required to align nut

with cotter pin hole.
(3). Torque upper nut to 100 - 130 inchpounds (11.30 - 14.69 Nm).
Page 406
Revision 27
62-30-00
NOTE: Bushing must project 0.010-0.060 inch

(0.254-1.524 mm) after nut is torqued.
(4). Torque lower nut to 30 - 60 inchpounds (3.39 - 6.78 Nm).
(5). Secure nuts with cotter pins.
(6). Rotate pitch change rod assembly fore
and aft to ensure clearance exists
between rod end bearing and pitch
housing clevis at both ends.
(7). If installation is final and tracking is
not required, safetywire rod ends to rod;
ensure rod ends are centered.
(8). As necessary, repeat above procedures
for remaining pitch control rods.
10. Counterweight and Interrupter Installation
Item
CM111
CM409
Nomenclature
Grease, aircraft
Adhesive, epoxy
NOTE: If counterweights are to be added, one

thick and one thin (any position) is recom
mended for ease of balancing; Hub must be
re-balanced.
(1). Apply coat of adhesive (CM409) to
counterweight OD. Reinstall weight
with smaller hole outboard, using
dummy bolt to align weight to rotating
swashplate. Remove bolt and allow
adhesive to cure according to container
instructions.
NOTE: Ensure interrupters are installed with

same type and number of washers removed
at disassembly, and that correct part num
ber interrupter is installed in each swash
plate arm. (Ref. CSP-IPC-4 for correct part
numbers and corresponding locations).
(2). Install interrupters, beveled edges
inboard, with bolts, washers, nuts and
new cotter pins. Coat bolts with grease
(CM111) prior to installation. Torque
(3). Install interrupters using bolts,
washers and nuts; torque nuts to 15 20 inch-pounds (1.69 - 2.26 Nm).
MAINTENANCE MANUAL
CSP-HMI-2
COUNTERWEIGHT
NOTE 2
BEARING
ASSEMBLY
INTERRUPTER
(NOTE 3)
DOUBLE
INTERRUPTER
(NOTE 4)
COUNTERWEIGHT
ROTATING
SWASHPLATE
NOTE 2
SPACER
INTERRUPTER
(NOTE 3)
INTERRUPTER
(NOTE 4)
INTERRUPTER
(NOTE 4)
STATIONARY
SWASHPLATE
DRAIN HOLES
(HIDDEN)
INDEX
PROTRUSIONS
STATIONARY
SWASHPLATE
GROOVE
DRAIN HOLES
(2 PLCS)
BOOT
NYLON STRAP
MAST
BOOT INSTALLATION
NOTES:
1. COLOR CODED TO MATCH BLADES.
2. IF COUNTERWEIGHTS ARE USED, COAT BOLT WITH
GREASE (CM116) BEFORE INSTALLATION.
G62-3001B
Figure 403. Main Rotor Swashplate
62-30-00
Page 407
Revision 44
CSP-HMI-2
MAINTENANCE MANUAL
Page 408
Revision 35
62-30-00
MAINTENANCE MANUAL
CSP-HMI-2

INSPECTION/CHECK
1. Swashplate Inspection
Item
Nomenclature
CM217
Isopropyl alcohol
When cleaning swashplate for

inspection, prevent solvent from
entering either spherical ball bearing or
double row ball bearing. Use cloth moist
ened in alcohol (CM217) to wipe clean
spherical ball, ball bore liner and exterior of
double row ball bearing.
CAUTION
NOTE:
D Stationary swashplate may be con
structed of either magnesium or alumi
num alloy. For corrosion control and iden
tification of magnesium and aluminum
alloys (Ref. Sec. 20-40-00).
D In the following inspection, the rotating
and stationary swashplates must be dis
connected (Ref. Swashplate and Mixer
Removal/Installation).
(1). Inspect swashplate bearing assembly
(Ref. Figure 403 for evidence of binding
in either radial or axial movement.
(2). Inspect teflon liners for condition.
(3). Ensure that all flexible rubber seals
enclosing ball bearing races are in
place; inspect for deterioration and
indication of grease leakage. (For
bearing maintenance information
(including lubrication), Ref. COM).
NOTE: New swashplate bearing assembly nor

mally shows some signs of grease leakage
for first 10-15 hours of operation after in
stallation.
(4). Inspect swashplate spherical ball and
double row ball bearing for radial or
axial play.
(a). Maximum radial play between

sliding surface liner and stationary
mast is 0.020 inch (0.508 mm).
(b). Maximum axial play between spheri
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
until arms line up with those of
stationary swashplate and check
motion between arms at control bolt
(d). Maximum total vertical movement of
0.015 inch (0.381 mm) is allowable.
(e). If movement limit is exceeded replace
double row ball bearing (Ref. COM).
(5). Inspect swashplate spherical and
double row ball bearings for condition.
(a). Nicks and dents that do not deform
ID chamfered edge of hard anodized
ball, and not more than 0.10 inch
(0.254 mm) deep along spherical ball
surface from edge are allowed.
(b). Scratches, any length, on OD of
spherical ball are allowed if they are
no deeper than 0.010 inch (0.254
mm) or wider than 0.060 inch (1.524
mm).
(c). Not more than two scratches are
permitted in a one inch wide area.
(6). Check existing preload on spherical
bearing.
(a). Hook spring scale over one of the
bolts securing stationary swashplate
to the bearing flange.
(b). With stationary swashplate in
motion, drag should be no more than
30 pounds (13.61 kg). (Use average
of four readings taken 90 degrees
apart).
(c). If readings are more than 30 pounds
(13.61 kg), clean spherical bearing
with isopropyl alcohol and recheck
drag.
62-30-00
Page 601
Revision 32
MAINTENANCE MANUAL
CSP-HMI-2
(d). Repair damage or replace bearings

(Ref. COM).
(7). Check double row ball bearing for
serviceability, with seals in place and
unbroken.
(a). Check for correct operation and
lubrication.
(b). Bearing must rotate smoothly,
without roughness. Binding or
catching should not exist when
bearings are rotated 360.
(c). Replace defective double row ball
bearings (Ref. COM).
(8). Perform careful visual inspection of
stationary and rotating swashplate for
cracks, wear in bolt and bushing bores,
and fork inner surfaces; and for
corrosion, nicks and dents.
(9). Perform dye penetrant check on
questionable areas.
(10). Check that counterweights are securely
bonded in rotating swashplate.
2. Mixer Controls Inspection
(Ref. Figure 402)
(1). Inspect all bushings for security of fit.
(2). Inspect longitudinal link, support
bracket, longitudinal control mixer link,
mixer links, longitudinal pitch idler,
longitudinal pitch mixer bellcrank,
lateral bellcrank and collective pitch
mixer bellcrank for scratches, cracks,
corrosion and similar surface defects.
For components that are questionable,
perform fluorescent dye penetrant
inspection.
(3). Inspect spherical, teflon (or equivalent)
lined, bearings in longitudinal link,
mixer link, and longitudinal control
Page 602
Revision 32
62-30-00
mixer link for binding, play in link bore

and wear. Wear limit is 0.008 inch
(0.203 mm) radially and 0.040 inch
(1.016 mm) axially. Replace complete
mixer link if bearings are faulty.
Inspect bearings in other linkage for
binding and looseness in mating bores.
3. Scissors Inspection
(Ref. Figure 401)
Any evidence of failure,
WARNING damage, or deformation of

crank or link is justification for re
placement of either crank, link, or com
plete scissors assembly. Failure of any
of these components in flight can result
in failure of movable flight controls,
loss of helicopter, and possible injury
or loss of life.
(1). Inspect crank and link for evidence of
impact damage and deformation. If
condition is questionable, perform
fluorescent dye penetrant inspection.
(2). Inspect bearings for binding, looseness
in bore and wear. Maximum wear limits
are 0.010 inch (0.254 mm) radial and
0.020 inch (0.508 mm) axial.
4. Pitch Control Rod Inspection
(Ref. Figure 401)
Ensure that rod end bearings
are centered and do not contact
attach clevis.
CAUTION
(1). Visually inspect upper and lower rod

end bearings for evidence of excessive
axial play, 0.040 inch (1.016 mm)
maximum; and for any extrusion,
displacement or damage to the bearing
teflon liner.
(2). Replace rod end bearing if discrepan
cies are noted.
MAINTENANCE MANUAL
CSP-HMI-2

REPAIRS
1. Swashplate Repairs
(Ref. Figure 403) Disassembly other than as
illustrated is considered a part of swashplate
overhaul (Ref. COM). If tracking interrupters
are to be removed, mark them for reinstalla
tion at original locations.
2. Mixer Controls Repair
(Ref. Figure 402)
Item
Nomenclature
CM321
CM431
CM802

NOTE: Following depth limits are total limits,

including effects of all previous repairs to
any given area.
(1). Repair minor surface defects such as
scratches, nicks and corrosion using
abrasive cloth, grade 400 - 600
(CM802) to smooth out and blend in
such defects.
(2). Cast and forged surfaces may be
reworked to depth of 0.020 inch (0.508
mm).
be restored on magnesium and alumi

num parts.
(7). Replace defective bearings and bush
ings, except swaged spherical bearings
in mixer links which require link
replacement. Remove bearings or
bushings by pressing them out. Install
new bearing with surface primer and
grade A locking compound (CM321 and
CM431).
NOTE: Left-hand bearing in support bracket is

not supplied as part of bracket. This bearing
is installed at time support bracket and lon
gitudinal pitch idler are assembled. Install
new bearing by seating flush with inner face
of support bracket flange.
3. Scissors Bushing and Bearing
Replacement
(Ref. Figure 401)
Item
CM103
CM222
CM318
CM321
CM431
Nomenclature
Primer
(3). Flat machined surfaces, except clevis

inner ears, may be reworked to depth of
0.015 inch (0.381 mm). Clevis inner ear
surfaces may be reworked to depth of
0.020 inch (0.508 mm).

bolt that join link and crank.
(4). Machined holes may have 0.003 inch

(0.076 mm) removed from bore wall in
an area no greater than 15 percent of
circumference and 50 percent of depth.
(3). Do not remove bearing from link.

Replace complete link if bearing is
defective.
(5). All edges may have 0.030 inch (0.762

mm) removed except around machined
holes which are limited to 0.010 inch
(0.254 mm) chamfer.
(6). All rework must be smoothly blended
into adjacent surfaces and finish must

(4). Remove slotted bushings and bearings

from crank, only if replacement is
necessary.
CAUTION
During cleaning, do not allow

solvent to enter bearings.
(5). Install new bushings using solid film

lubricant (CM103); do not use zinc
62-30-00
Page 801
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
chromate. Press in bushing until end

is flush with inside surface of crank
inboard ears.
(6). If bearings were removed from crank at
disassembly, reinstall using the
following procedure:
NOTE: Do not allow sealant to enter bearing

race.
(a). Clean bearing outer face, counterbore
and faying surfaces with trichloroe
thane (CM222). Do not allow trichlo
roethane to enter bearing.
(b). Coat the faying surfaces with surface
primer (CM321) as per manufactur
er's instructions.
(c). Apply locking compound (CM431) to
faying surfaces.
(d). Press bearing until outer face is
seated firmly against shoulder of
counterbore.
(e). Remove excess sealant. Do not allow
sealant to enter bearing race.
(f). Apply a small fillet of sealant to the
faying edges of bearing housing. Use
cellophane or masking tape to
exclude air and allow sealant to cure
for 24 hours at ambient temperature
or force cure by heating to
140-160F (60-72C for one hour
prior to use of assembly.
(7). If bushings were removed from link at
disassembly, install new bushings.
After installation, dimension between
outside faces of bushings should be
1.579-1.586 inches (4.0107-4.0284 cm).
to 30 - 40 inch-pounds (3.39 - 4.52
Nm).
4. Scissors Modification
modification of 369D21002 main rotor hub
Page 802
Revision 20
62-30-00
scissors to 369D21002-21 configuration to

preclude shimming problems experienced with
the early crank configuration. Field rework
consists primarily of relocating existing
bushings in the crank outboard attach lugs to
the inboard lugs, and installing new flange
type bushings in the outboard lugs. The wall
thickness of the crank outboard attach lugs
must be reduced to accommodate installation
of the flange bushings.
Instructions are also provided for replacement
of existing hardware for the crank assembly.
Existing attach bolts may have insufficient
thread length which, in some cases, can cause
loosening of the bolt in service.
It is to be noted that the field modification and
installation of the PN 369D21002-21 crank
assembly with new attach hardware also
upgrades the PN 369D21001 scissors assembly
to PN 369D2101-501 configuration.
Item
Nomenclature
CM206
Chemical coating
CM318
Primer
(1). Disconnect scissors crank from hub

lower shoe and scissors link.
(2). Remove existing HS626-S-4-500
bushings from outboard lugs of scissors
crank.
(3). Using grinder or file, remove minimum
0.063 inch (1.6002 mm) material from
inner side of both outboard attach lugs,
to obtain distance of 9.735 inches
(24.7295 cm) between lugs. After
removal of material, wall thickness of
lugs should not be less than 0.230 inch
(5.842 mm). Coat reworked area of lug
with iridite (CM206) or equivalent
corrosion protective chemical film.
MAINTENANCE MANUAL
CSP-HMI-2
9.736 IN.
(24.7295 CM)
NOTE 5
NAS77-4-23 BUSHING
(TYP. 2 PLCS)
369D21002-21 CRANK
ASSEMBLY
0.020 IN. (0.508 MM) X 45

CHAMFER (4 PLCS)
NAS6204-38D BOLT
AN960C416 WASHER
2 REQ'D (NOTE 2)
MS17826-4 NUT (NOTE 1)
0.3750 IN. (9.5250 MM)

0.3755 IN. (9.5377 MM)
(NOTE 3)
6.421 IN.
16.3093 CM)
DIA.
PLAT
E
NOTE 4
NOTES:
1. TORQUE NUT 30 - 40 INCH-POUNDS (3.39 - 4.52 NM).
2. ONE WASHER EACH UNDER BOLT HEAD AND NUT.
3. TWO HOLES IN LINE (TYP. 2 PLACES)
4. FILL GAP WITH HS5079-2646 WASHERS. SHIM WASHERS
SHOULD BE EQUALLY SPACED.
5. REMOVE MATERIAL EVENLY FROM INNER SIDE OF OUTBOARD
MINIMUM WALL 0.230 IN. (5.8420 MM) TYP.

MAXIMUM WALL 0.249 IN. (6.3246 MM) TYP.
NOTE 5
HS626-S-4-500
BUSHING (2 REQ'D)
INSTALL THIS SIDE

TOWARD BLADES
SCISSORS LINK
ASSEMBLY
G62-3004B
Figure 801. Field Modification 369D2100211 Crank Assembly to 369D2100221 Configuration
NOTE: Remove material only from inner side of

existing crank outboard attach lugs.
(4). Using existing hole in outboard lug as
guide, drill and ream 0.252 inch (6.4008
mm) dia. hole in outboard lugs to
0.3750-0.3755 inch (9.5250-9.5377
mm) dia. for press fit of
HS626-S-4-500 bushings.
(5). Install HS626-S-4-500 bushings in
inboard lugs of scissors crank with
primer (CM318).
(6). Install new NAS77-4-23 flanged
bushings with primer (CM318) in
outboard lugs.
(7). Re-identify crank assembly as PN
369D21002-21 on ID plate.
(8). zinc chromate
(9). Reinstall scissors crank assembly using
new attach hardware as follows:
(a). Install scissors crank to hub lower

shoe with NAS6204-18D bolts,
AN960PD416L washers, MS17826-4
nuts and cotter pins (Ref.
Figure 802).
(b). Install scissors link to scissors crank
assembly with NAS6204-38D bolt,
AN960C416 washers, MS17826-4
nut and cotter pins (Ref. Figure 801).
(3.39 - 4.52 Nm).
(10). Record upgrade of PN 369D21002 main
rotor hub scissors crank assembly to
PN 369D21002-21 configuration per
DN-46.1 in Component Record of
Helicopter Log Book.
(11). Record upgrade of PN 369D21001 main
rotor hub scissors assembly to PN
369D21001-501 configuration per
DN-46.1 in Component Record of
Helicopter Log Book.
62-30-00
Page 803
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
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 369D2100221 Crank to Hub Lower Shoes

5. Mixer Controls Rework
(Ref. Figure 803) The following lists
instructions and criteria for rework of the
mixer controls to preclude interference
between mixer components. Rework is
applicable to 369D helicopter, Serial No.
0001D thru 0129D only, unless already
accomplished, and is to be performed prior to
rigging the main rotor controls.
Item
Nomenclature
CM206
Chemical coating
CM305
Lacquer, acrylic
CM312
Ink stamp, permanent
CM314
Varnish, moisture resistant
CM318
Primer
(1). Remove and rework the 369D21002-3

scissors crank assembly and scissors
link assembly as follows:
Page 804
Revision 20
62-30-00
(a). Chamfer 369D21002-3 scissors crank

and 369A1003 link assembly per
dimensions shown (Ref. Figure 803).
(b). Touch up reworked area with chemi
cal film (CM206) and refinish with
primer (CM318) and black paint
(CM305).
(c). Using permanent ink stamp
(CM312), reidentify scissors link part
number as 369A1003-501.
(d). Apply a coat of varnish (CM314) over
ink stamp.
(2). Rework installed 369D27611 rotating
swashplate as follows:
(a). Chamfer 369D27611 swashplate per
dimensions shown (Ref. Figure 803).
cal film and refinish with primer and
black paint.
(c). Using permanent ink stamp, reiden
tify rotating swashplate assembly
part number as 369A27611-501.
(d). Apply a coat of varnish over ink
stamp.
MAINTENANCE MANUAL
(3). Remove and rework 369N2664 collec
tive mixer bellcrank and 369N2670
lateral mixer bellcrank as follows:
(a). Chamfer collective and lateral
bellcrank assemblies per dimensions
cal film and refinish with primer and
black paint.
(c). Using permanent ink stamp, re-iden
tify collective bellcrank part number
as 369N2664-501; reidentify lateral
bellcrank part number as
369N2670-501.
CSP-HMI-2
(d). Apply a coat of varnish over ink

stamp.
NOTE: The 369N2666-503 longitudinal mixer

idler is compatible installed with the
369N2668 basic longitudinal mixer bell
crank only. If the 369N2666-505 idler is in
stalled, the 369N2668-503 bellcrank must
be used.
(4). Reinstall removed components.
(5). Perform rigging of main rotor controls
(Ref. Sec. 67-10-00).
62-30-00
Page 805
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
0.080 IN. (2.032 MM) X 45

CHAMFER AND BLEND
BOTH ENDS SMOOTHLY
ROTOR HUB
LOWER SHOE
0.38 IN.
(9.652 MM)
CHAMFERED ZONE
(TYP 4 PLACES)
0.38 IN. (9.652 MM)
369D21002
SCISSORS
CRANK
SECTION
A-A
0.20 IN. (5.08 MM)

0.25 IN. (6.35 MM)
(TYP 4 PLACES)
(TYP BOTH SIDES)

0.040 IN. (1.016 MM)
CHAMFER
0.060 IN. (1.524 MM)
BLEND BOTH ENDS
AT 0.25 IN. (6.35 MM)
WIDTH SMOOTHLY
0.25 IN.
(6.35 MM)
369A1003
SCISSORS
LINK
0.25 IN.
(6.35 MM)
SECTION
B-B
(TYP BOTH SIDES)

0.040 IN. (1.016 MM) X 45 CHAMFER
0.060 IN. (1.524 MM)
BLEND BOTH ENDS
SMOOTHLY
B
CL OF 0.625 IN.
(15.875 MM)
SLOT
LONGITUDINAL
CONTROL
MIXER LINK
LONGITUDINAL
PITCH IDLER
COLLECTIVE PITCH
MIXER BELLCRANK
369D27611 ROTATING
SWASHPLATE
COLLECTIVE PITCH
CONTROL ROD
LONGITUDINAL PITCH
CONTROL ROD
2.25 IN. (5.715 CM)

(TYP)
LATERAL MIXER
BELLCRANK
C
C
1.50 IN. (3.81 CM)
(TYP FAR SIDE)
0.10 IN. (2.54 MM) X 30

CHAMFER, BLEND
BOTH ENDS WITH
SMOOTH RADIUS TO
2.25 IN. (5.715 CM) DIM.
0.10 IN. (2.54 MM)
(TYP BOTH SIDES
SECTION
C-C
G62-3006-1A
Figure 803. Rework of Main Rotor and Mixer Controls (Sheet 1 of 2)

Page 806
Revision 20
62-30-00
MAINTENANCE MANUAL
CSP-HMI-2
369N2666 LONGITUDINAL
PITCH IDLER
369A7607 LONGITUDINAL
CONTROL MIXER
MIXER BELLCRANK
STATIONARY
SWASHPLATE
369N2670
LATERAL MIXER
BELLCRANK
CHAMFER
0.15 IN. (3.81 MM)
0.040 IN. (1.016 MM) X
BLEND BOTH ENDS 0.20 IN. (5.08 MM)
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)
1.50 IN. (3.81 CM)
1.75 IN. (4.445 CM)
MAST BASE
1.62 IN. (4.1148 CM)

1.75 IN. (4.445 CM)
0.180 IN.
(4.57 MM)
32
0.425 IN. (10.795 MM)

0.440 IN. (11.176 MM)
6
0.45 IN. (11.43 MM) (TYP 4
PLACES)
4.375 IN.
(11.1125 CM)
0.48 IN. (12.19 MM) R (TYP 4

PLACES)
0.48 IN. (12.19 MM) R

(TYP)
30
(TYP 4 PLACES)
0.50 IN. (12.70 MM) R
G62-3006-2A
Figure 803. Rework of Main Rotor and Mixer Controls (Sheet 2 of 2)
62-30-00
Page 807
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
Page 808
Revision 44
62-30-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
623060
Swashplate and
Mixer (600N)
MAINTENANCE MANUAL
CSP-HMI-2

1. Main Rotor Swashplate
(Ref. Figure 403) The main rotor swashplate
includes a rotating swashplate, stationary
swashplate, bearing and retainer and one
counterweight. The rotating swashplate
converts movement from the stationary
swashplate into rotating motion and transfers
it to the main rotor hub assembly for lift, and
longitudinal and lateral control of the helicop
ter.
2. Swashplate Replacement
A. Swashplate Removal
(1). Tag or color-identify six pitch control
rods (Ref. Figure 401) to simplify
replacement at same locations.
Failure to reinstall pitch control
rods at correct locations may re
sult in main rotor blades excessively out of
track.
CAUTION
(2). Disconnect pitch control rods from

Do not strike rotating swash

plate or bearing assembly (Ref.
Figure 403) with tools or in any way deface
these components, the rotating swashplate
is a stressed part. Use particular care to pro
tect teflon liner in bearing bore. A damaged
swashplate bearing must not be retained in
service.
CAUTION
(8). Lift swashplate carefully up and off of

mast.
(9). To remove boot from mast, remove
self-clinching nylon strap.
B. Swashplate Installation
(1). If swashplate lower boot was removed,
install boot on mast (Ref. Figure 403).
(2). Position swashplate over main rotor
mast and carefully lower into place.
(3). Engage upper end of boot in groove at
lower side of stationary swashplate.
Secure boot with self-clinching nylon
strap (Ref. Figure 403).
(4). Align longitudinal link with stationary
swashplate (Ref. Figure 402).
(5). Install flanged bushing, if removed,
bolt, two washers, nut and cotter pin to
secure upper end of longitudinal link.
(3). Remove scissors.

(4). Remove main rotor hub.
(5). Disconnect longitudinal link (Ref.
Figure 402) from stationary swash
plate.
(6). Disconnect right and left side mixer
links (Ref. Figure 402) from stationary
swashplate.
(7). Remove protective boot from groove in
lower side of stationary swashplate
(Ref. Figure 403).
(6). Align upper ends of mixer links with

stationary swashplate. Install slotted
bushing (if removed), bolt, two washers,
nut and cotter pin to secure each link to
swashplate.
(7). Install scissors.
(8). Using color code, reinstall pitch control
rods at same locations from which
removed.
(9). Check track of main rotor blades (Ref.
Sec. 18-10-60) following any mainte
nance activity that could result in a
dimensional variation affecting rigging
or tracking.
62-30-60
Page 401
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
ROTOR HUB
LOWER SHOE
WASHERS
(NOTE 4)
SLOTTED BUSHING
(NOTE 1)
BEARING
SCISSORS CRANK
WASHERS
(NOTE 4)
BUSHING
SCISSORS LINK
CLOSE TOLERANCE
BOLT (NOTE 5)
BEARING
PITCH CONTROL
ROD (NOTE 2)
SLOTTED BUSHING
(NOTE 1)
ROTATING
SWASHPLATE
ELASTOMER RING
ELASTOMER RING
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
ENDS TO BE PARALLEL
WITH MATING CLEVIS
SLOTTED BUSHING
(NOTE 1)
LATERAL CONTROL
LINK ASSEMBLY
1.30 IN. (3.302 CM)

(TYP UPPER BEARING ONLY)
NOTES:
1. END OF SLOTTED BUSHING MUST PROTRUDE MINIMUM OF
0.010 IN. (0.254 MM) TO MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE
2. COLOR CODED TO MATCH BLADE.
3. OPTIMUM INITIAL SETTING (SIX PLACES).
4. AS REQUIRED TO FILL GAP.
5. BOLT HEADS TO FACE INWARD.
Figure 401. Pitch Control Rods and Swashplate Scissors Installation

Page 402
Revision 27
62-30-60
6G62-031B
MAINTENANCE MANUAL
3. Controls Mixer
Controls mixer includes links, bellcranks,
idlers, support bracket and fasteners to secure
these components in place and to the control
rods and main rotor swashplate.
4. Controls Mixer Replacement
A. Controls Mixer Removal
(Ref. Figure 402)
(1). Remove air intake forward fairing for
access.
(2). Disconnect upper ends of collective,
lateral and longitudinal control links
(Ref. Figure 401).
NOTE: Control links are attached by slightly

different length bolts. Reinstall each bolt in
its bellcrank following control rod removal
to simplify reinstallation at correct loca
tions.
(3). Remove mixer links. (Mixer link
bearings are not replaceable.)
(4). Disconnect longitudinal link from
stationary swashplate.
(5). Remove longitudinal control mixer link.
(6). Disconnect lateral mixer bellcrank from
(7). Remove connecting hardware (includ
ing flanged bushing) from each side of
Carefully remove bellcrank. Retain any
shims that may be installed.
(8). Remove bolt from hingeline of support
bracket, longitudinal pitch idler and
Separate the three parts.
(9). Remove mixer support bracket from
mast base.
To prevent washing dirt into
bearings, or washing grease out
of bearings, do not permit solvent to enter
bearings when cleaning mixer control com
ponents.
CAUTION
B. Mixer Controls Installation

(Ref. Figure 402)
CSP-HMI-2
(1). Position support bracket over forward

lug on mast base.
(2). Install two aft bolts and washers in
support bracket and mast base. Install
two thin washers and nuts; torque nuts
to 80 - 100 inch-pounds (9.04 - 11.30
(3). Using ball hole gage and standard
micrometer, check that misalignment
between forward bolt hole bore in
support bracket and bore in mast base
lug is 0.015 inch (0.381 mm) or less.
NOTE: If necessary, loosen aft two bracket-tofitting nuts, position support bracket to
minimize misalignment and retighten nuts.
(4). Install mixer support attaching bushing
in bracket and mast base lug.
(5). Check that sleeve bushing is in place;
then install bolt, two washers and nut.
(9.04 - 11.30 Nm).
(6). Position longitudinal pitch idler and
collective pitch mixer bellcrank on
support bracket. Position washer
between right side of longitudinal pitch
idler bearing and center bearing of
mixer support bracket. Install lefthand bearing, with attaching hardware.
(7). Position lateral bellcrank between
collective pitch mixer bellcrank bear
ings and install attaching hardware.
(8). Position longitudinal pitch mixer
bellcrank with collective pitch mixer
bellcrank; insert two flanged bushings.
Install two bolts.
(9). Push longitudinal bellcrank to one side
and measure gap between bellcrank
and bearings in collective pitch bell
crank.
(10). Using HS5079-2646 laminated wash
er(s), shim evenly to take up gap.
(11). Insert flanged bushings, bolts, six
washers (two under each nut) shims
and nuts. Torque nut to 30 - 40 inchpounds (3.39 - 4.52 Nm) and install
cotter pin.
62-30-60
Page 403
Revision 31
MAINTENANCE MANUAL
CSP-HMI-2
BUSHING LONGITUDINAL CONTROL

(NOTE 2)
MIXER LINK
LONGITUDINAL
MIXER LINK
PITCH IDLER
STATIONARY
SWASHPLATE
BUSHING
(NOTE 2)
STATIONARY
SWASHPLATE
LONGITUDINAL
FLANGED
LINK
BUSHING
(NOTE 3)
LATERAL MIXER
BELLCRANK
(NOTE 5)
BEARING
NOTE 1
MIXER
LINK
BEARING
WASHER
NOTE 1
NOTE 1
BUSHING
(NOTE 2)
BEARING
MIXER
SUPPORT
ATTACHING
BUSHING
(NOTE 6)
FLANGED
BUSHING
(NOTE 4)
BEARING
BEARING
MIXER
SUPPORT
BRACKET
SLEEVE
BUSHING
BUSHING
(NOTE 2)
NOTE 7
BEARING
BEARING
LONGITUDINAL
PITCH MIXER
BELLCRANK
COLLECTIVE PITCH
MIXER BELLCRANK
FLANGED BUSHING
(NOTE 4)
MAST BASE
TWO IDENTIFYING LOCATORS
(FACING UP AND OUT)
R/H SIDE ONLY
ONE IDENTIFYING LOCATOR

(FACING OUT) L/H SIDE ONLY
NOTES:
1. DIRECTION OF BOLT OPTIONAL.
2. EDGE OF BUSHING MUST PROTRUDE MINIMUM OF 0.010 IN.
(0.254 MM) TO MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE
OUTSIDE OF PART AFTER NUT IS TIGHTENED.
3. LONGITUDINAL LINK DETAILS ROTATED FOR CLARITY.
4. MUST BE PULLED OUT FIRST TO REMOVE BELLCRANK.
5. PART MAY BE EITHER MAGNESIUM OR ALUMINUM ALLOY.
(FOR ALLOY IDENTIFICATION AND CORROSION CONTROL,
REFER TO SECTION 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.
LEFT-HAND
MIXER LINK
(600N7636-1/-9)
RIGHT-HAND
MIXER LINK
(600N7636-3/-11)
LONGITUDINAL LINK
MAST CL
MIXER LINK IDENTIFICATION
FOR PROPER INSTALLATION
Figure 402. Controls Mixer Assembly

Page 404
Revision 35
62-30-60
6G62-032C
MAINTENANCE MANUAL
(12). Position longitudinal control mixer link
between longitudinal pitch idler and
longitudinal pitch mixer bellcrank;
check that two slotted bushings are in
place. Install bolt, three washers (two
under each nut), nut and cotter pin at
each end of link.
(13). Position longitudinal link between
longitudinal pitch mixer bellcrank
bearings. Install attaching hardware.
NOTE: In the following step, ensure mixer

links are not installed inverted and are
installed in the correct position (Ref.
Figure 402, View A).
(14). Position mixer links in stationary
swashplate and lateral mixer bellcrank;
check that slotted bushings are in
place. Install attaching hardware.
(15). Place collective, lateral longitudinal
control links (Ref. Figure 401) in
mounting position; check that slotted
bushing is in place. Install attaching
hardware.
(16). Install air intake forward fairing.
(17). Check rigging of collective and cyclic
controls.
5. Scissors
The scissors provide a movable connection
between the rotating swashplate and main
rotor hub.
6. Scissors Replacement
A. Scissors Removal
(Ref. Figure 401)
Removal of all pitch control rods
is recommended prior to scissors
removal. Failure to observe this precaution
could result in damage to pitch control rods,
swashplate and/or hub. Ensure all rods are
color-coded or marked so they will be rein
stalled in the correct location.

bolt from each leg of scissors crank.
Disconnect crank from hub lower shoe.
bolt connecting scissors link to swash
plate; remove scissors.
B. Scissors Installation
(Ref. Figure 401)
(1). Place scissors link in mounting posi
tion, chamfered edge of link must face
outboard.
(2). Check that slotted bushing is in
swashplate web and install attaching
hardware. Torque nut to 15 - 20
Scissors crank must be posi
tioned (Ref. Figure 401) with de
cal up and proper direction towards lower
side lugs.
CAUTION
NOTE: Ensure crank-to-hub lower shoe lugs

are not preloaded.
(3). Position scissors crank on hub lower
shoe lugs; install connecting hardware.
Install bolts with bolt heads facing
inward and a washer under head of bolt
(Ref. Figure 401). Torque nuts to 30 60 inch-pounds (3.39 - 6.78 Nm).
NOTE: Shim washers may be required on

shouldered bushing side of clevis.
(4). Position elastomer rings and lower end
of pitch control rod in swashplate lug
and install attaching hardware. (Nut is
to be adjacent to bushing in swash
plate.) Torque nut to 30 - 60 inchpounds (3.39 - 6.78 Nm).
7. Scissors Link Replacement
CAUTION
(1). Disconnect lower end of pitch control

rod that is in line with scissors link in
CSP-HMI-2
Item
CM103
Nomenclature

that join link and crank.
62-30-60
Page 405
Revision 35
MAINTENANCE MANUAL
CSP-HMI-2
(3). Do not remove bearing from link,

replace complete link if bearing is
defective.
NOTE: Install new bushings using solid film lu

bricant (CM103); do not use zinc chro
mate.
(4). If bushings were removed at disassem
bly, install new bushings. After installa
tion, dimension between outer faces of
bushings should be 1.579-1.586 inches
(4.011-4.028 cm).
to 30 - 40 inch-pounds (3.39 - 4.52
Nm); install cotter pin.
8. Pitch Control Rods
Six pitch control rods transfer pitch control
from the rotating swashplate to the main rotor
blades.
9. Pitch Control Rod Replacement
A. Pitch Control Rod Removal
(Ref. Figure 401)

At installation, install rod at
correct color code location. Cen
ter bearing rodends between attach clevis. If
rod length is changed, blades must be
tracked.
CAUTION
(1). If actual rod length is incorrect or

either actual or required rod length is
unknown, preset link length to opti
mum length of 6.25 inches (15.88 cm).
NOTE: Install both pitch change rod bolts in

direction of rotation.
(2). Install rod with elastomeric rings on
both sides of lower bearing.
NOTE: Add washers as required to align nut

with cotter pin hole.
(3). Torque upper nut to 100 - 130 inchpounds (11.30 - 14.69 Nm).
(0.254-1.524 mm) after nut is torqued.
NOTE:
D If rod is not to be reinstalled, but is to be
replaced, measure and record length of
removed link. Optimum length may have
been changed at previous rigging; pre-ad
just replacement link to length of link re
moved.
D Rods are color coded for reinstallation at
correct locations. If more than one rod is
being removed and color coding is not vis
ible, identify each by color or similar
means to points of connection to simplify
reinstallation.
from each end of pitch control rod.
Revision 35
B. Pitch Control Rod Installation
NOTE: Bushing must project 0.010-0.060 inch
(Ref. Figure 401)
Page 406
(2). Remove pitch control rod and O-ring.
62-30-60
(4). Torque lower nut to 30 - 60 inchpounds (3.39 - 6.78 Nm).

(5). Secure nuts with cotter pins.
(6). Rotate pitch control rod assembly fore
and aft to ensure clearance exists
between rod end bearing and pitch
housing clevis at both ends.
(7). If installation is final and tracking is
not required, safetywire rod ends to rod;
ensure rod ends are centered.
(8). As necessary, repeat above procedures
for remaining pitch control rods.
MAINTENANCE MANUAL
CSP-HMI-2
BEARING
ASSEMBLY
ROTATING
SWASHPLATE
BALANCE
WEIGHT
INTERRUPTER
(NOTE 2)
INTERRUPTER
(NOTE 1)
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
62-30-60
Page 407
Revision 44
CSP-HMI-2
MAINTENANCE MANUAL
Page 408
Revision 44
62-30-60
MAINTENANCE MANUAL
CSP-HMI-2

INSPECTION/CHECK
1. Swashplate Inspection
Item
Nomenclature
CM217
Isopropyl alcohol
When cleaning swashplate for

inspection, prevent solvent from
entering either spherical ball bearing or
double row ball bearing. Use cloth moist
ened in alcohol (CM217) to wipe clean
spherical ball, ball bore liner and exterior of
double row ball bearing.
CAUTION
NOTE:
D Stationary swashplate may be con
structed of either magnesium or alumi
num alloy. For corrosion control and iden
tification of magnesium and aluminum
alloys (Ref. Sec. 20-40-00).
D In the following inspection, the rotating
and stationary swashplates must be dis
connected (Ref. Swashplate and Mixer
Removal/Installation).
(1). Inspect swashplate bearing assembly
(Ref. Figure 403 for evidence of binding
in either radial or axial movement.
(2). Inspect teflon liners for condition.
(3). Ensure that all flexible rubber seals
enclosing ball bearing races are in
place; inspect for deterioration and
indication of grease leakage. (For
bearing maintenance information
(including lubrication), Ref. COM).
NOTE: New swashplate bearing assembly nor

mally shows some signs of grease leakage
for first 10-15 hours of operation after in
stallation.
(4). Inspect swashplate spherical ball and
double row ball bearing for radial or
axial play.
(a). Maximum radial play between

sliding surface liner and stationary
mast is 0.020 inch (0.508 mm).
(b). Maximum axial play between spheri
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
until arms line up with those of
stationary swashplate and check
motion between arms at control bolt
(d). Maximum total vertical movement of
0.015 inch (0.381 mm) is allowable.
(e). If movement limit is exceeded replace
double row ball bearing (Ref. COM).
(5). Inspect swashplate spherical and
double row ball bearings for condition.
(a). Nicks and dents that do not deform
ID chamfered edge of hard anodized
ball, and not more than 0.10 inch
(0.254 mm) deep along spherical ball
surface from edge are allowed.
(b). Scratches, any length, on OD of
spherical ball are allowed if they are
no deeper than 0.010 inch (0.254
mm) or wider than 0.060 inch (1.524
mm).
(c). Not more than two scratches are
permitted in a one inch wide area.
(6). Check existing preload on spherical
bearing.
(a). Hook spring scale over one of the
bolts securing stationary swashplate
to the bearing flange.
(b). With stationary swashplate in
motion, drag should be no more than
30 pounds (13.61 kg). (Use average
of four readings taken 90 degrees
apart).
(c). If readings are more than 30 pounds
(13.61 kg), clean spherical bearing
with isopropyl alcohol and recheck
drag.
62-30-60
Page 601
Revision 32
MAINTENANCE MANUAL
CSP-HMI-2
(d). Repair damage or replace bearings

(Ref. COM).
(7). Check double row ball bearing for
serviceability, with seals in place and
unbroken.
(a). Check for correct operation and
lubrication.
(b). Bearing must rotate smoothly,
without roughness. Binding or
catching should not exist when
bearings are rotated 360.
(c). Replace defective double row ball
(8). Perform careful visual inspection of
stationary and rotating swashplate for
cracks, wear in bolt and bushing bores,
and fork inner surfaces; and for
corrosion, nicks and dents.
(9). Perform dye penetrant check on
questionable areas.
(10). Check that counterweights are securely
bonded in rotating swashplate.
2. Mixer Controls Inspection
(Ref. Figure 402)
(1). Inspect all bushings for security of fit.
(2). Inspect longitudinal link, support
bracket, longitudinal control mixer link,
mixer links, longitudinal pitch idler,
longitudinal pitch mixer bellcrank,
lateral bellcrank and collective pitch
mixer bellcrank for scratches, cracks,
For components that are questionable,
perform fluorescent dye penetrant
inspection.
(3). Inspect spherical, teflon (or equivalent)
lined, bearings in longitudinal link,
mixer link, and longitudinal control
Page 602
Revision 32
62-30-60
mixer link for binding, play in link bore

and wear. Wear limit is 0.008 inch
(0.203 mm) radially and 0.040 inch
(1.016 mm) axially. Replace complete
mixer link if bearings are faulty.
Inspect bearings in other linkage for
binding and looseness in mating bores.
3. Scissors Inspection
(Ref. Figure 401)
Any evidence of failure,
WARNING damage, or deformation of

crank or link is justification for re
placement of either crank, link, or com
plete scissors assembly. Failure of any
of these components in flight can result
in failure of movable flight controls,
loss of helicopter, and possible injury
or loss of life.
(1). Inspect crank and link for evidence of
impact damage and deformation. If
condition is questionable, perform
fluorescent dye penetrant inspection.
(2). Inspect bearings for binding, looseness
in bore and wear. Maximum wear limits
are 0.010 inch (0.254 mm) radial and
0.020 inch (0.508 mm) axial.
4. Pitch Control Rod Inspection
(Ref. Figure 401)
Ensure that rod end bearings
are centered and do not contact
attach clevis.
CAUTION
(1). Visually inspect upper and lower rod

end bearings for evidence of excessive
axial play, 0.040 inch (1.016 mm)
maximum; and for any extrusion,
displacement or damage to the bearing
teflon liner.
(2). Replace rod end bearing if discrepan
cies are noted.
MAINTENANCE MANUAL
CSP-HMI-2

REPAIRS
1. Swashplate Repairs
(Ref. Figure 403) Disassembly other than as
illustrated is considered a part of swashplate
overhaul (Ref. COM). If tracking interrupters
are to be removed, mark them for reinstalla
tion at original locations.
2. Mixer Controls Repair
(Ref. Figure 402)
Item
Nomenclature
CM321
CM431
CM802

NOTE: Following depth limits are total limits,

including effects of all previous repairs to
any given area.
scratches, nicks and corrosion using
abrasive cloth (CM802), grade 400 600 to smooth out and blend in such
defects.
(2). Cast and forged surfaces may be
mm).
be restored on magnesium and alumi

num parts.
(7). Replace defective bearings and bush
ings, except swaged spherical bearings
in mixer links which require link
replacement. Remove bearings or
bushings by pressing them out. Install
new bearing with surface primer and
grade A locking compound (CM321 and
CM431).
NOTE: Left-hand bearing in support bracket is

not supplied as part of bracket. This bearing
is installed at time support bracket and lon
gitudinal pitch idler are assembled. Install
new bearing by seating flush with inner face
of support bracket flange.
3. Scissors Bushing and Bearing
Replacement
(Ref. Figure 401)
Item
CM103
CM222
CM318
CM321
CM431
Nomenclature
Primer

0.015 inch (0.381 mm). Clevis inner ear
surfaces may be reworked to depth of
0.020 inch (0.508 mm).

bolt that join link and crank.

(3). Do not remove bearing from link.

Replace complete link if bearing is
defective.

holes which are limited to 0.010 inch
(0.254 mm) chamfer.

(4). Remove slotted bushings and bearings

from crank, only if replacement is
necessary.
CAUTION
During cleaning, do not allow

solvent to enter bearings.
(5). Install new bushings using solid film

lubricant (CM103); do not use zinc
62-30-60
Page 801
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
chromate. Press in bushing until end

is flush with inside surface of crank
inboard ears.
(6). If bearings were removed from crank at
disassembly, reinstall using the
following procedure:
NOTE: Do not allow sealant to enter bearing

race.
(a). Clean bearing outer face, counterbore
and faying surfaces with trichloroe
thane (CM222). Do not allow trichlo
roethane to enter bearing.
(b). Coat the faying surfaces with surface
primer (CM321) as per manufactur
er's instructions.
(c). Apply locking compound (CM431) to
faying surfaces.
(d). Press bearing until outer face is
seated firmly against shoulder of
counterbore.
Page 802
Revision 20
62-30-60
(e). Remove excess sealant. Do not allow

sealant to enter bearing race.
(f). Apply a small fillet of sealant to the
faying edges of bearing housing. Use
cellophane or masking tape to
exclude air and allow sealant to cure
for 24 hours at ambient temperature
or force cure by heating to
140-160F (60-72C) for one hour
prior to use of assembly.
(7). If bushings were removed from link at
disassembly, install new bushings.
After installation, dimension between
outside faces of bushings should be
1.579-1.586 inches (4.0107-4.0284 cm).
to 30 - 40 inch-pounds (3.39 - 4.52
Nm).
MAINTENANCE MANUAL
CSP-HMI-2
Chapter
63
Transmission and
Drive System
MAINTENANCE MANUAL
CSPHMI2
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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 Kamatic) . . . . . . . . . . . . . 404
B. Main Transmission Drive Shaft Installation (Bendix and Kamatic) . . . . . . . . . . 404
Figure 402. Main Transmission Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . 405
5.
Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
6.
Overrunning Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

A. Overrunning Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Overrunning Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403. 369A5350 Overrunning Clutch Installation . . . . . . . . . . . . . . . . . . . . . 407
Figure 404. 369F5450 Overrunning Clutch Installation . . . . . . . . . . . . . . . . . . . . . 408
7.
Overrunning Clutch Subassembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

A. Overrunning Clutch Subassembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Overrunning Clutch Subassembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
8.
Overrunning Clutch-to-Firewall Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
9.
Overrunning Clutch-to-Firewall Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 410
10. Main Transmission Drive Shaft Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411

11. Main Transmission Drive Shaft Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . 411
A. Main Transmission Drive Shaft Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Main Transmission Drive Shaft Coupling Installation . . . . . . . . . . . . . . . . . . . . . . 411
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Title
Page
12. Tail Rotor Drive Shaft Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

A. Tail Rotor Drive Shaft Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Tail Rotor Drive Shaft Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Figure 405. 369F5468/5469 Bolt Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
1.
369D25510 Main Rotor Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2.
600N5510 and 369F5510 Main Rotor Drive Shaft Inspection . . . . . . . . . . . . . . . . . . 601

Figure 601. Main Rotor Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 602. Main Rotor Drive Shaft Overtorque Verification Stripe . . . . . . . . . . 603
3.
Main Transmission Drive Shaft Inspection (Bendix) . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4.
Main Transmission Drive Shaft Inspection (Kamatic) . . . . . . . . . . . . . . . . . . . . . . . . . 604
5.
Overrunning Clutch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
6.
Overrunning Clutch-to-Firewall Seal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
7.
Bendix Tail Rotor Drive Shaft Coupling Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
8.
Kamatic Coupling Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
9.
Main Rotor Drive Shaft Inspection (300 Hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1.
Main Rotor Drive Shaft Exterior Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2.
Main Rotor Drive Shaft Corrosion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
3.
Main Transmission Drive Shaft Repair (Bendix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
4.
Main Transmission Drive Shaft Repair (Kamatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
5.
Overrunning Clutch Repair/Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
6.
Overrunning Clutch-to-Firewall Seal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
7.
Main Transmission Drive Shaft Coupling Corrosion Removal . . . . . . . . . . . . . . . . . . 803
8.
Bendix Coupling Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
9.
Kamatic Coupling Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
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Page
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
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
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9.
Title
Page
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
Figure 201. 369D25100 Main Transmission Installation . . . . . . . . . . . . . . . . . . . . 202
B. Main Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3.
Main Transmission Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.
Main Transmission Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5.
Input Drive Assembly - Oil Leakage Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . 204

Figure 202. Input Drive Assembly O-Ring Replacement . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Assembly Aid Tool for Input Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
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
Figure 201. 369F5100 Main Transmission Installation . . . . . . . . . . . . . . . . . . . . . . 202
3.
Main Transmission Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Figure 202. 369F5100 Main Transmission Build-Up . . . . . . . . . . . . . . . . . . . . . . . . 204
4.
Main Transmission Build-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5.
Main Transmission Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6.
Main Transmission Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7.
Input Drive Assembly - Oil Leakage Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . 206

A. Input Pinion O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Drive Assembly O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Input Pinion Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8.
Main Transmission Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
9.
Main Transmission Run-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
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Page
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
3.
Main Transmission Lubrication Pump Replacement

(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Transmission Lubrication Pump Removal
(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Transmission Lubrication Pump Installation
(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Main Transmission Lubrication Pump
(369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 402. Main Transmission Lubrication Pump
(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4.
Main Transmission Filter Replacement (369D25100 Transmission) . . . . . . . . . . . . 404
5.
Main Transmission Filter Replacement (369F5100 Transmission) . . . . . . . . . . . . . . 404
6.
Main Transmission Scavenge Pump Replacement (369F5100 Transmission) . . . . 404

A. Main Transmission Scavenge Pump Removal (369F5100 Transmission) . . . . . . 404
B. Main Transmission Scavenge Pump Installation (369F5100 Transmission) . . . 404
7.
Main Transmission Oil Cooler Bypass Valve Replacement . . . . . . . . . . . . . . . . . . . . . 405
8.
Main Transmission Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

A. Main Transmission Oil Cooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Main Transmission Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 403. Main Transmission Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . 406
9.
Main Transmission Oil Temperature Sender Replacement . . . . . . . . . . . . . . . . . . . . . 407
10. Main Transmission Oil Pressure Sender Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 407

11. Liquid Level Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 404. Main Transmission - Cross-Section View . . . . . . . . . . . . . . . . . . . . . . 408
12. Chip Detector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
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Page
13. Cooling Blower Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

A. Cooling Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Cooling Blower Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
C. Cooling Blower Installation (369D25100 Transmission) . . . . . . . . . . . . . . . . . . . . . 409
Figure 405. Cooling Blower Installation (369D25100 Transmission) . . . . . . . . . . 410
D. Cooling Blower Installation (369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . 411
Figure 406. Oil Cooler Blower Installation (369F5100 Transmission) . . . . . . . . . 412
E. 369D, E, F, and 500N - Cooling Blower Belt Tracking . . . . . . . . . . . . . . . . . . . . . . 413
Figure 407. Cooling Blower Belt Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
1.
Lubrication System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2.
Cooling Blower Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
3.
Cooling Blower Inspection (Disassembled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

Figure 601. Main Transmission Cooling Blower and Duct . . . . . . . . . . . . . . . . . . . 602
4.
Cooling Blower Belt Tension Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1.
369D25630 Cooling Blower Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

Figure 801. 369D25630 Cooling Blower - 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
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63 Contents
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CSPHMI2

Para/Figure/Table
Title
Page
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
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
63 Contents
Page vii
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CSPHMI2
MAINTENANCE MANUAL

Para/Figure/Table
6.
Title
Page
Caliper Assembly, Brake Disc, and Drive Coupling Replacement

(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Caliper Assembly, Brake Disc, and Drive Coupling Removal
(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Caliper Assembly, Brake Disc and Drive Coupling Installation
(369F5100 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Figure 406. Rotor Brake Caliper Installation (369F5100 Transmission) . . . . . . 411
7.
Hydraulic Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

A. Hydraulic Relief Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Hydraulic Relief Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
8.
Hydraulic Tube Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413

A. Hydraulic Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
B. Hydraulic Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
9.
Rotor Brake Forward Cover Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
1.
Rotor Brake Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2.
Rotor Brake Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602

1.
Rotor Brake Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901

A. Aircraft Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
B. Installation Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
C. Removing Components to be Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
D. Angle Assembly Installation (500D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
E. Master Cylinder Linkage Assembly and Mount Bracket Installation . . . . . . . . . 902
Figure 901. Locating Permanently Installed Components (Sheet 1 of 2) . . . . . . 903
F. Handle Retainer Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
G. Rivnut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Figure 902. Rotor Brake Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 906
H. Window Support Channel Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
I. Caliper Mounting Bracket Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
J. Caliper Assembly, Brake Disc and Drive Coupling Installation . . . . . . . . . . . . . . . 908
Figure 903. Modifying Window Support Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . 909
Figure 904. Hydraulic Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910
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63 Contents
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CSPHMI2

Para/Figure/Table
Title
Page
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
63-25-10 Tail Rotor Transmission (Two and Four Blade) (369D/E/FF) . . . . . . . . . . A
1.
Tail Rotor Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.
Tail Rotor Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

A. Tail Rotor Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Tail Rotor Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Tail Rotor Transmission - Stripping/Buildup . . . . . . . . . . . . . . . . . . . . 202
3.
Tail Rotor Transmission Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Figure 202. Replacement of Liquid Level Plug and Breather-Filler . . . . . . . . . . 204
4.
Tail Rotor Transmission Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5.
Tail Rotor Transmission Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6.
Tail Rotor Transmission Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7.
Input and Output Gearshaft Cover Oil Leak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8.
Tail Rotor Transmission Housing Assembly Rework (PN 369D25401) . . . . . . . . . . 206

Figure 203. Tail Rotor Transmission Mount Stud Limits . . . . . . . . . . . . . . . . . . . . 206
Figure 204. Rework of Tail Rotor Transmission Housing Assembly . . . . . . . . . . . 207
63 Contents
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Revision 42
CSPHMI2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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
B. Main Rotor Static Mast Installation (369F5100 Transmission Installation) . . . 203
4.
Main Rotor Static Mast Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Figure 202. Main Rotor Mast and Support Structure
(369F5100 Transmission Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 203. Main Rotor Mast - Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . 206
Page x
Revision 42
63 Contents
MAINTENANCE MANUAL
CSP-HMI-2
Section
630000
Transmission and
Drive System
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
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,
consists primarily of the overrunning clutch,
drive shafts, and transmissions.
(Ref. Table 101) Diagnose and repair power

train system malfunctions using procedures as
follows.
Table 101. Troubleshooting Power Train System

Symptom
Probable Trouble
Corrective Action
Main drive shaft vibrates

excessively. (For serviceability
limits, refer to Section 631000).
Coupling flange bolts on main drive Retorque bolts to 50 70

shaft are loose.
inchpounds (5.65 7.91 Nm).
Excessive noise or vibration in

cooling blower.
Defective impeller or damaged

scroll.
Replace impeller or scroll (Ref. Sec.

632100).
Main drive shaft turns erratically or

not at all.
Defective overrunning clutch.
Replace overrunning clutch (Ref.

Sec. 631000).
Main transmission requires

frequent addition of oil.
Leakage at main transmission input If leakage is found at input shaft or

or output seals.
tail rotor shaft, replace seal
according to instructions (Ref. COM).
If leakage is at main rotor drive shaft,
replace transmission (Ref. Sec.
632000).
Oil leak around accessory drive
cover.
Tighten cover or replace

transmission (Ref. Sec. 632000).
Oil temperature warning light

comes on when oil temperature is
normal.
Defective oil temperature sender.
Replace oil temperature sender (Ref.

Sec. 632100).
Oil temperature warning light

comes on when oil temperature is
abnormally high.
Defective cooling blower.
Repair or replace cooling blower

(Ref. Sec. 632100).
Low or high oil level in

transmission.
Establish correct oil level (Ref. Sec.

120000).
Defective lubrication pump.
Replace pump (Ref. COM).
Defective oil cooler bypass valve.
Replace valve. (Ref. Sec.

632100).
Defective bearings or gears.
Replace transmission (Ref. Sec.

632000).
63-00-00
Page 101
Revision 28
MAINTENANCE MANUAL
CSP-HMI-2
Table 101. Troubleshooting Power Train System (Cont.)

Symptom
Probable Trouble
Corrective Action
NOTE: Noise that indicates a defective transmission should not be confused with normal gear backlash noise at
rundown or low rpm and power conditions.
Inadequate oil supply.
Service main transmission (Ref. Sec.

120000).
Defective bearings or gears.

632000).
Low oil in main transmission.
Service main transmission (Ref. Sec.

120000).
Defective oil pressure switch.
Replace oil pressure switch (Ref.

Sec. 632100).
Defective lube pump.
Replace lube pump (Sec.

632000).
Filter clogged.
Replace filter (Ref. Sec. 632100).
Filter clogged.
Reset indicator. On second popup,

replace filter (Ref. Sec. 632100).
Defective differential pressure

indicator.
Replace differential pressure

indicator (Ref. COM).
369F5100 Transmission impending

bypass indicator popped in less
than 100 hours since filter change.
Defective differential pressure

indicator.
Replace differential pressure

indicator (Ref. COM).
Tail rotor drive shaft damper

vibrates.
Damper out of adjustment.
Adjust damper (Ref. Sec. 631500).
Damper defective.
Replace damper (Ref. Sec.

631500).
Excessive noise in main

transmission.
Oil pressure warning light (low oil

pressure) remains lighted at above
55% N2.
369F5100 Transmission impending

bypass indicator popped.
Tail rotor drive shaft bent or dented. Replace defective drive shaft (Ref.
Sec. 631500).
Tail rotor transmission output shaft

vibrates.
Tail rotor out of balance.
Adjust tail rotor balance (Ref. Sec.

181000).
Worn or damaged bearing or gear

in tail rotor transmission.
Replace tail rotor transmission (Ref.

Sec. 632510).
Excessive shaft wobble or end play Replace tail rotor transmission (Ref.
(Ref. Sec. 631510).
Sec. 632510).
Excessive noise in tail rotor
transmission.
Page 102
Revision 29
Inadequate oil supply.
Service tail rotor transmission (Ref.

Sec. 120000).
Defective bearings or gears in tail

rotor transmission.
Replace tail rotor transmission (Ref.

Sec. 632510).
63-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Table 101. Troubleshooting Power Train System (Cont.)

Symptom
Probable Trouble
Corrective Action
Chip detector caution light on.
Metallic chips in either main

transmission, fan transmission or
tail rotor transmission.
Inspect and clean chip detector

magnetic plugs. If there are heavy
chip deposits (chips larger than 1/8
inch in any direction), replace
transmission. If chips are smaller,
drain and refill transmission with new
oil. Reinstall chip detector and check
after four hours of flight. If more
chips are found, replace
transmission (main Sec. 632000
or 632025; tail rotor Sec.
632510; fan 632530).
Chip detector caution light is on,

but no chips are on detector.
Defective chip detector circuit

components.
Troubleshoot chip detector circuit

(Ref. CSPHMI3).
NOTE: High frequency vibrations in helicopter can also be caused by components in other systems.
High frequency vibrations.
Loose tail rotor drive shaft

coupling(s).
Tighten coupling bolts (Ref. Sec.

631500).
Tail rotor drive shaft coupling

shimmed improperly.
Shim correctly (Ref. Sec. 631500).
Loose, mismatched or bottomed

hardware retaining tail rotor drive
shaft coupling to main
transmission.
Tighten or install correct hardware

and be sure hardware is installed
correctly (Ref. Sec. 631500).
Cooling blower impeller has cracks, Replace impeller (Ref. Sec.

loose rivets, defective blades or
632100).
other damage.
Abnormal drag in drive system.
Tail rotor drive shaft damper out of

adjustment.
Adjust damper friction (Ref. Sec.

631500).
Defective overrunning clutch.
Replace overrunning clutch (Ref.

Sec. 631000).
Tail rotor drive shaft damaged.
Replace shaft (Ref. Sec. 631500).
Excessive drag in main

transmission.

632000).
NOTE: Drag is excessive when force required to rotate transmission input shaft exceeds 25 inchpounds (2.82
Nm) with all shafting disconnected and transmission temperature between 50F (10C) and 100F (38C).
63-00-00
Page 103
Revision 30
MAINTENANCE MANUAL
CSP-HMI-2
TAIL ROTOR TRANSMISSION
TAIL ROTOR DRIVE

SHAFT DAMPER
MAIN ROTOR DRIVE

SHAFT
MAIN TRANSMISSION
TAIL ROTOR DRIVE SHAFT
COOLING BLOWER
MAIN TRANSMISSION
DRIVE SHAFT
FAN TRANSMISSION
DRAIN LINE
FAN GEARBOX
DRIVE SHAFT
ANTI-TORQUE FAN
FAN INTER-CONNECT
DRIVE SHAFT
G63-0000A
Figure 101. Power Train System

Page 104
Revision 28
63-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
631000
Drive Shafts /
Clutches / Couplings
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
DRIVE SHAFTS / CLUTCHES / COUPLINGS

1. Main Rotor Drive Shaft
The main rotor drive shaft is a shot-peened,
steel alloy forging having a nitrided spline at
one end that mates with the transmission
output shaft, and a flanged opposite end that
attaches to the rotor hub with seven bolts and
three eyebolts.
2. Main Rotor drive Shaft Replacement
(Ref. Figure 401)
When removing or installing the
main rotor drive shaft externalwrenching bolts or eyebolts, always hold
bolts stationary while installing or remov
ing nuts. Never turn external-wrenching
bolts or eyebolts while inserting or removing
from drive shaft holes.
CAUTION
A. Main Rotor Drive Shaft Removal

Main rotor drive shaft is a high
ly stressed part. Do not allow
tools to strike shaft, or shaft to strike any
placement of drive shaft.
CAUTION
(1). Remove main rotor fairing.

(2). Remove seven external-wrenching
bolts; and associated hardware. Lift off
main rotor fairing support and remove
seven spacers.
Any time drive shaft is removed,
cover opening in top of main ro
tor hub to prevent possible entry of foreign
matter into hub, mast and transmission.
CAUTION
NOTE: If special washers between fairing sup

port and drive shaft dome are not bonded to
the underside of fairing support, remove
washers before proceeding.
(3). Remove three eyebolts and associated
hardware and lift drive shaft clear of
main rotor hub.
B. Main Rotor Drive Shaft Installation
Item
Special Tools
Nomenclature
ST704
Damage to main rotor drive

shaft or transmission splines
can occur during installation. Care should
be taken while meshing driveshaft splines
into transmission output splines to prevent
damage.
CAUTION
(1). Slowly and carefully lower drive shaft

through main rotor hub and mast until
rotor shaft splines and transmission
shaft splines engage.
(2). Rotate hub to align holes in flange with
holes in drive shaft.
(3). Install three eyebolts, washers, and
nuts. Using torque wrench adapter
(ST704), torque nuts to 120 - 140
inch-pounds (13.56 - 15.82 Nm).
(4). With fairing support spacers and
special washers in place, position main
rotor fairing support so that eyebolt
shoulders are inserted in large holes in
fairing support. Make certain that
support extensions are between pitch
housings.
(5). Install seven external-wrench bolts,
seven washers and nuts as in step (3).
above.
NOTE: Phillips screws, used to attach main ro

tor hub fairing, may be replaced with hex
head Phillips screws (PN NAS1096-3-10)
and washers (PN HS306-223). The hex
head will make torquing the screws easier.
(6). Install main rotor fairing with five
screws. Torque screws to 20 - 25
63-10-00
Page 401
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
HUB
FAIRING
EYEBOLT (3 PLCS AS SHOWN)

(NOTE 4)
NOTE 1
SCREW
(5 PLCS)
WASHER
(5 PLCS)
EXTERNAL
WRENCHING BOLT
(7 PLCS)
NOTE 1
FAIRING
SUPPORT (NOTE
5)
NOTE 3
SPACER
(7 PLCS)
CORK
(NOTE 2)
DRIVE SHAFT
HUB
THIN WASHERS
(TYP, 10 PLACES)
TORQUE WRENCH
ADAPTER
369D/E/FF - 500N INSTALLATION
NOTES:
1. INSTALLED WITH COUNTERSINK NEXT TO BOLT HEAD, WASHERS UNDER NUT ARE FLAT.
2. INSTALLED WITH SEALING COMPOUND.
3. MAY BE BONDED TO FAIRING SUPPORT.
4. WHEN INSTALLING EYEBOLTS, ENSURE FAIRING SUPPORT ARMS ARE NOT POSITIONED OVER
PITCH HOUSINGS.
5. THREE HOLES IN FAIRING SUPPORT ARE LARGER TO GO OVER EYEBOLTS AND TO AID IN FAIRING
SUPPORT ALIGNMENT.
Figure 401. Main Rotor Drive Shaft Installation (Sheet 1 of 2)

Page 402
Revision 20
63-10-00
G63-1001B
MAINTENANCE MANUAL
CSP-HMI-2
BOLT
(9 PLACES)
MAIN ROTOR
DRIVE SHAFT
EYEBOLT
(3 PLACES)
(NOTE 1)
COUNTERSUNK WASHER
(NOTE 2)
COUNTERSUNK WASHER
(NOTE 2)
FLAT WASHER
FLAT
WASHER
MAIN ROTOR HUB
WASHE
R
WASHE
R
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)
63-10-00
Page 403
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
3. Main Transmission Drive Shaft

The main transmission drive shaft is equipped
with a flexible diaphragm-type joint and
mounting flange (coupling) at each end. The
shaft connects the overrunning clutch and the
transmission input shaft.
4. Main Transmission Drive Shaft
Replacement
(Ref. Figure 402)
A. Main Transmission Drive Shaft Removal
(Bendix and Kamatic)
(1). Remove sound insulation and main
transmission access cover over main
transmission drive shaft in cargo
compartment.
(2). Remove eight bolts and washers that
secure shaft to couplings.
(3). Remove drive shaft; use care to keep it
from striking any object.
NOTE: Clutch oil level should be checked any

time engine or main drive shaft is removed
(Ref. Sec. 12-00-00).
B. Main Transmission Drive Shaft
Installation (Bendix and Kamatic)
Item
Nomenclature
CM111
CM112
Grease, aircraft
(1). Check overrunning clutch for correct oil

level, indications of oil seepage, drive
shaft couplings for corrosion and that
coupling bolt securing clutch coupling is
torqued to:
(a). For 369A5350 clutch, actual drag
torque plus 250 - 300 inchpounds (28.25 - 33.90 Nm). If bolt
is not seated and/or existing torque is
found to be less than 250 - 300
inch-pounds (28.25 - 33.90 Nm),
ensure self-locking drag torque is not
Page 404
Revision 36
63-10-00
less than 25 inch-pounds (2.82

Nm) before torquing bolt.
(b). For 36F5450 clutch, actual drag
torque plus 315 - 365 inchpounds (35.59 - 41.24 Nm). If bolt
inch-pounds (35.59 - 41.24 Nm),
Compression of drive shaft dia
phragms (static state) is limited
to 0.020 inch (0.508 mm). Do not stress dia
phragms by forcing drive shaft into position
for installation in step (2). below.
CAUTION
NOTE: If original shaft and couplings are being

reinstalled, a check of shimming as de
scribed below is not necessary. Install drive
shaft to clutch and transmission couplings
as described in steps (1). above and (4). be
low.
(2). Position drive shaft alongside transmis
sion input and clutch couplings. If
compression is required to fit shaft
between couplings, continue with step
(3). below. If there is a gap between
drive shaft flanges and coupling
flanges, continue with step (6). below.
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
vent O-ring damage and oil leakage.
(3). Remove coupling bolt that secures
transmission input coupling; remove
coupling and shims.
CAUTION
D The 0.010 inch (0.254 mm) minimum
measurement between the bolt seating
surface and the input shaft must be ob
tained to ensure proper clamp up. Warped
shims or foreign material could provide a
false 0.010 inch (0.254 mm) minimum
measurement and improper clamp up
could result during normal operation
which may damage the main transmis
sion input shaft.
MAINTENANCE MANUAL
D Do not use clutch coupling shims under
transmission input coupling. Inside diam
eter of clutch coupling shims, 1.260-1.270
inches (3.2004-3.2258 cm), is approxi
mately 0.070 inch (1.778 mm) larger than
inside diameter of shims used at trans
mission coupling. Incorrect diameters can
cause an improperly seated shim, mis
alignment and cocked coupling.
NOTE: Transmission input coupling shims are

laminated stock. Each lamination is 0.002
inch (0.051 mm) thick. Peel to thickness re
quired.
(4). Add sufficient shims to get a measure
ment of 0.010 inch (0.254 mm) mini
mum between bolt seating surface on
coupling and transmission input shaft.
(5). Lubricate input shaft splines with
grease (CM111). Coat bolt threads with
anti-seize compound (CM112). Rein
stall coupling and bolt. Check coupling
bolt for minimum drag of 25 inchpounds (2.82 Nm). Torque bolt to 250
- 300 inch-pounds (28.25 - 33.90
(6). Attach drive shaft to clutch coupling
with four bolts and washers. Torque
CSP-HMI-2

(7). Manually align drive shaft and trans
mission input coupling flanges:
(8). Using feeler gage, measure gap be
tween flanges. Gap should be 0.010
inch (0.254 mm) gap to 0.020 inch
(0.508 mm) compression.
(a). If gap is 0.010 inch (0.254 mm) or
less, attach upper end of drive shaft
to transmission input coupling with
four bolts and washers. Torque bolts
to 50 - 70 inch-pounds (5.65 - 7.91
Nm).
(b). If gap exceeds 0.010 inch (0.254 mm),
repeat step (3). thru (5). above,
except install thickness of shims
equal to measured gap, plus thick
ness that results in not more than
0.010 inch (0.254 mm) gap between
coupling and drive shaft nor more
than 0.020 inch (0.508 mm) compres
sion of flexible couplings. Install four
bolts and washers and torque bolts to
50 - 70 inch-pounds (5.65 - 7.91
Nm).
(9). Install access door and sound insulation
over main transmission drive shaft.
TRANSMISSION INPUT COUPLING
INTERNAL-WRENCHING BOLT
MAIN TRANSMISSION DRIVE SHAFT
(EARLY CONFIGURATION) (BENDIX)
DIAGRAM
0.010 IN. (0.254 MM)

MAXIMUM GAP
0.020 IN. (0.508 MM)
MAXIMUM COMPRESSION
MAIN TRANSMISSION DRIVE SHAFT
(CURRENT CONFIGURATION) (KAMATIC)
DRIVE
PULLEY
TRANSMISSION INPUT
COUPLING-TO-DRIVE SHAFT ATTACHMENT
G63-1002B
Figure 402. Main Transmission Drive Shaft Installation
63-10-00
Page 405
Revision 27
MAINTENANCE MANUAL
CSP-HMI-2
5. Overrunning Clutch
The overrunning clutch transmits power from
the engine to the main transmission drive
shaft. The clutch disengages the engine from
the remainder of the drive system in case of
engine failure and during autorotations.
The clutch contains a sprag unit that disen
gages automatically when N2 rpm is less than
corresponding main rotor rpm.
Repair and overhaul information for the
overrunning clutch can be found in COM.
6. Overrunning Clutch Replacement
A. Overrunning Clutch Removal
(b). Insert a long 3/8 inch (9.525 mm) hex

wrench, approximately 10 inches
(25.4 cm) long, through tool and into
back of clutch assembly.
(c). While holding internal hex wrench
[3/8 inch (9.525 mm)], turn external
hex wrench [1.00 inch (2.54 cm)]
counter-clockwise to remove bolt
from back of clutch.
(5). Remove nuts and washers that secure
overrunning clutch; remove clutch.
(6). If clutch is being replaced, install spare
coupling bolt and O-ring or suitable
plug in output shaft (clutch inner race
bore) to prevent contamination during
clutch handling, shipping or storage.
NOTE: Operating lubricant is an approved pre

servative for shipping or storage.
Item
Nomenclature
CM208
Barrier material
(7). Wrap clutch in barrier material

(CM208) to protect splined areas of
shafts.
B. Overrunning Clutch Installation
NOTE: For removal of only the internal clutch

subassembly as an alternative to complete
clutch removal, refer to Overrunning Clutch
Subassembly Removal.
(1). Remove engine.
(2). Remove bolts, washers, nuts and engine
shaft firewall seal from clutch.
NOTE: Removal of clutch coupling from clutch

is unnecessary unless clutch is being re
placed.
(3). Remove coupling bolt, packing, clutch
coupling and coupling shim(s). Keep
shim(s) with coupling for reuse.
Reinstall bolt and packing to prevent
spillage of lubricating oil from clutch
housing during final steps of removal.
(4). On 369F5450 clutch, remove output
shaft cover plate from back of engine
accessory drive to gain access to clutch
bolt.
(a). Insert tool (Ref. Figure 405) to
engage bolt in back of clutch.
Page 406
Revision 42
63-10-00
Item
CM111
CM112
CM125
CM126
Nomenclature
Grease, aircraft
Oil
Oil, turbine
(1). If clutch is new, (369A5350 clutch only)

drain preservative oil. Trapped oil can
be removed by inverting clutch a
minimum of three times. Add lubricat
ing oil (CM125 or CM126) (Ref. Sec.
12-00-00). Temporarily install coupling
bolt and packing.
NOTE: Relubricate splines on clutch input

shaft and splines inside engine power and
accessory gearbox with grease (CM111)
prior to reinstalling overrunning clutch.
(2). Coat clutch splines and internal splines
of engine power accessory gearbox with
lubricant (CM111). Insert overrunning
clutch outer-race spline into engine and
install six washers and nuts.
Deleted.
MAINTENANCE MANUAL
CSP-HMI-2
CLUTCH
LAMINATED
SHIM
GAP
0.035 IN. (0.889 MM)
0.055 IN. (1.397 MM)
MAIN DRIVE SHAFT

COUPLING
COUPLING
BOLT
OVERRUNNING
CLUTCH SHAFT
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
OF CLUTCH SUBASSEMBLY
CLUTCH HOUSING
G63-1003A
Figure 403. 369A5350 Overrunning Clutch Installation
63-10-00
Page 407
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
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
Figure 404. 369F5450 Overrunning Clutch Installation

Page 408
Revision 32
63-10-00
CSP102-013C
MAINTENANCE MANUAL
(3). For 369F5450 clutch installation:
(a). Remove power output shaft cover
plate from back of engine (Ref. Sec.
01-00-00, Allison Engine Operation
and Maintenance Manual).
(b). Install O-rings on 369F5469
(C30/C47 engine) or 369F5468 (C20
series engines) bolt (Ref. Figure 404).
NOTE: Fill all voids and gaps between the out

side of bolt and inside of engine shaft with
grease.
(c). Lubricate internal spline area of
engine output shaft with grease
(CM111).
(d). Lubricate bolt threads with antiseize compound (CM112) and insert
through engine into overrunning
clutch assembly.
(e). Using bolt removal tool (Ref.
Figure 405) either hold output
coupling to prevent overrunning
clutch from turning or insert hex
wrench through bolt to engage and
hold clutch.
(f). Torque bolt to 250 - 300 inchpounds (28.25 - 33.90 Nm) plus
drag torque.
(g). Using existing hardware, reinstall
power output shaft cover plate on
back of engine (Ref. Sec. 01-00-00,
Maintenance Manual).
(4). Shim coupling on 369F5450 clutch
assembly as follows:
(a). Remove output coupling bolt and
coupling.
(b). Shim coupling to achieve 0.010-0.030
inch (0.254-0.762 mm) step above
clutch output shaft.
(5). Shim coupling on 369A5350 clutch
(a). Remove output coupling bolt and
coupling.
CSP-HMI-2
(b). Shim coupling to achieve 0.035-0.055

inch (0.889-1.397 mm) step above
clutch output shaft.
When installing clutch coupling
bolt, installation torque on the
bolt must be 250 - 300 inch-pounds (28.25
- 33.90 Nm) for the 369A5350 clutch or 315
- 365 inch-pounds (35.59 - 41.24 Nm) for
the 369F5450 clutch. Torquing to lower val
ue reduces clutch bearing clamp-up and can
result in bearing race spinning.
CAUTION
(6). Coat clutch-to-coupling splines with

grease (CM111); install shim(s) and
clutch coupling. Coat coupling bolt
threads with anti-seize compound
(CM112); install bolt with new O-ring.
Check for bolt self-locking drag torque
of 25 inch-pounds (2.82 Nm) mini
mum to 200 inch-pounds (22.60
Nm) maximum. Replace bolt if torque
values are exceeded.
(a). For 369A5350 clutch, torque coupling
bolt to actual drag torque plus 250
- 300 inch-pounds (28.25 - 33.90
Nm).
(b). For 36F5450 clutch, torque coupling
bolt to actual drag torque plus 315
- 365 inch-pounds (35.59 - 41.24
Nm).
(7). Install engine shaft firewall seal, bolts,
washers, and nuts.
(8). Reinstall engine.
7. Overrunning Clutch Subassembly
Replacement
A. Overrunning Clutch Subassembly
Removal
(1). Remove main transmission drive shaft.
(b). Insert tool (Ref. Figure 405) to
engage bolt in back of clutch.
63-10-00
Page 409
Revision 39
MAINTENANCE MANUAL
CSP-HMI-2
(c). Insert a long 3/8 inch (9.525 mm) hex

wrench, approximately 10 inches
(25.4 cm) long, through tool and into
back of clutch assembly.
(d). While holding internal hex wrench
[3/8 inch (9.525 mm)], turn external
hex wrench [1.00 inch (2.54 cm)]
counter-clockwise to remove bolt
from back of clutch.
(3). Remove coupling bolt, clutch coupling
and shims.
(4). Remove retaining ring from clutch
housing. Then pull complete clutch
subassembly out of housing.
B. Overrunning Clutch Subassembly
Installation
Item
Nomenclature
CM111
CM125
CM126
Grease, aircraft
Oil
Oil, turbine
(1). Remove shipping plug and O-ring from

end of shaft in replacement clutch
subassembly.
(2). Drain preservative oil from clutch
subassembly by inverting it several
times. Add lubricating oil (CM125 or
CM126) (Ref. Sec. 12-00-00).
(3). Coat clutch splines with grease
(CM111).
(4). Using care to avoid oil spillage, insert
clutch subassembly into clutch housing
and install retaining ring with beveled
side outward.
(5). Check fluid level of clutch assembly
before installing clutch coupling (Ref.
Sec. 12-00-00).
Page 410
Revision 32
63-10-00
(b). Install O-rings on 369F5469

(C30/C47 engine) or 369F5468 (C20
series engines) bolt (Ref. Figure 404).
NOTE: Fill all voids and gaps between the out

side of bolt and inside of engine shaft with
grease.
(c). Lubricate internal spline area of
engine output shaft with grease
(CM111).
(d). Lubricate bolt threads with antiseize compound (CM112) and insert
through engine into overrunning
clutch assembly.
(e). Using bolt removal tool (Ref.
Figure 405) either hold output
coupling to prevent overrunning
clutch from turning or insert hex
wrench through bolt to engage and
hold clutch.
(f). Torque bolt to 250 - 300 inchpounds (28.25 - 33.90 Nm) plus
drag torque.
(g). Using existing hardware, reinstall
power output shaft cover plate on
back of engine (Ref. Sec. 01-00-00,
(h). Lubricate coupling bolt threads with
anti-seize compound (CM112).
(7). Install clutch coupling, shims and
coupling bolt.
(8). Install main transmission drive shaft.
8. Overrunning ClutchtoFirewall Seal
The overrunning clutch-to-firewall seal
consists of a stamped steel backing and a seal
bonded to the cupped diameter of the backing.
Replacement
(Ref. Figure 403)
(1). Remove engine.
(2). Remove three bolts, six washers and
three nuts that attach firewall seal to
overrunning clutch.
(3). Position replacement clutch-to-firewall
seal assembly on flange of clutch with
MAINTENANCE MANUAL
seam orientated at the 6 o'clock position
and secure with attaching hardware.
10. Main Transmission Drive Shaft Couplings
The main transmission drive shaft couplings
connect the overrunning clutch to the drive
shaft and the drive shaft to the main transmis
sion.
11. Main Transmission Drive Shaft Coupling
Replacement
(Ref. Figure 402)
A. Main Transmission Drive Shaft Coupling
Removal
(1). Remove drive shaft; use care to keep it
from striking any object.
(2). Remove coupling bolt from main
transmission and overrunning clutch.
Retain shim(s) with couplings for
reinstallation.
B. Main Transmission Drive Shaft Coupling
Installation
Item
Nomenclature
CM111
CM112
Grease, aircraft
CAUTION
D The 0.010 inch (0.254 mm) minimum
measurement between the bolt seating
surface and the input shaft must be ob
tained to ensure proper clamp up. Warped
shims or foreign material could provide a
false 0.010 inch (0.254 mm) minimum
measurement and improper clamp up
could result during normal operation
which may damage the main transmis
sion input shaft.
CSP-HMI-2

eter of clutch coupling shims, 1.260-1.270
inches (3.2004-3.2258 cm), is approxi
mately 0.070 inch (1.778 mm) larger than
inside diameter of shims used at trans
mission coupling. Incorrect diameters can
cause an improperly seated shim, mis
alignment and cocked coupling.
NOTE: Transmission input coupling shims are

laminated stock. Each lamination is 0.002
inch (0.051 mm) thick. Peel to thickness re
quired.
(1). Install previously removed shims or
refer to Main Transmission Drive Shaft
Installation for shim thickness calcula
tion.
(2). Lubricate drive shaft splines with
grease (CM111) and install in place.
Coat bolt threads with anti-seize
compound (CM112) and install.
(a). For 369D25100 transmission instal
lation, torque coupling bolt to actual
drag torque plus 250 - 300 inchpounds (28.25 - 33.90 Nm). If bolt
inch-pounds (28.25 - 33.90 Nm),
(b). For 369F5100 transmission installa
tion, torque coupling bolt to actual
drag torque plus 315 - 365 inchpounds (35.59 - 41.24 Nm). If bolt
inch-pounds (35.59 - 41.24 Nm),
(3). Reinstall main transmission drive
shaft, main transmission access cover
and sound insulation.
63-10-00
Page 411
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
12. Tail Rotor Drive Shaft Coupling

Replacement
A. Tail Rotor Drive Shaft Coupling Removal
(1). Remove tail rotor drive shaft (Ref. Sec.
63-15-10).
NOTE: With Bendix coupling installed, remove

socket from main transmission coupling
only if visual inspection reveals signs of con
tact between coupling bolt and socket.
(2). Remove couplings from main and tail
rotor transmissions. Retain shims with
couplings for reinstallation.
Page 412
Revision 32
63-10-00
Do not immerse Bendix flexible

couplings in fluid or cleansers
such as magnetic particle, fluorescent pene
trant, visible dye etc. Do not apply corrosion
protection fluids unless coupling has been
cleaned with solvent or detergent. Apply
any corrosion protection very sparingly to
outside only.
CAUTION
B. Tail Rotor Drive Shaft Coupling

Installation
According to type of coupling installed, instal
lation of tail rotor shaft requires shimming of
couplings, and in some instances, tail rotor
gearbox-to-tailboom shimming (Ref. Sec.
63-15-10, Tail Rotor Drive Shaft Installa
tion).
MAINTENANCE MANUAL
CSP-HMI-2
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)
0.72 IN.
(18.29 MM)
1.23 IN.
(3.124 CM)
(NOTE 3)
TOOL REQUIRED
FOR BOLT REMOVAL
0.68 IN.
(17.27 MM)
ENGINE PTO SHAFT
9.00 IN.
(22.86 CM)
(NOTE 3)
2.50 IN.
(6.35 CM)
(NOTE 3)
369F5450 CLUTCH ASSEMBLY
0.375 IN. (9.53 MM) HEX
0.375 IN. (9.53 MM) SQUARE

DRIVE EXTENSION
STANDARD 3/8 SOCKET
1.00 IN. (2.54 CM) HEX

(NOTES 2, 3)
369F5468/5469 BOLT REMOVAL TOOL
NOTES:
1. HOLD HEX BAR STEADY WHEN TORQUING BOLT.
2. TOOL TO BE A MINIMUM OF 2.5 INCHES IN LENGTH
TO CLEAR STUDS ON ENGINE.
3. THIS IS MINIMUM LENGTH, TOOL MAY BE MADE
LONGER FOR EASE OF MAINTENANCE.
G63-1024A
Figure 405. 369F5468/5469 Bolt Removal Tool
63-10-00
Page 413
Revision 32
CSP-HMI-2
MAINTENANCE MANUAL
Page 414
Revision 32
63-10-00
MAINTENANCE MANUAL
CSP-HMI-2

INSPECTION/CHECK
1. 369D25510 Main Rotor Drive Shaft
Inspection
(a). Thoroughly clean shaft spline with

dry cleaning solvent (CM234) to
remove oil, dirt and grease.
(Ref. Figure 601)
Item
Nomenclature
CM234
CM425
Sealing compound
(1). Inspect all surfaces of drive shaft for

dents, nicks, scratches and evidence of
deformation. No damage of any kind is
permissible in the area within two
inches of the spline. Dents less than
0.050 inch (1.270 mm) deep and 0.050
inch (1.270 mm) diameter are permissi
ble in other areas. A dent is defined as
a smooth depression of surface with no
sharp edges or abrupt changes in
contour. No nicks or scratches are
permitted.
(2). If shaft condition is questionable,
perform magnetic particle inspection
according to Specification MIL-I-6868.
No surface or subsurface defects are
permissible.
(3). Inspect all external surfaces of shaft for
corrosion.
(4). 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).
(5). 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.
(6). Inspect shaft spline for cracks-using
bright light and 5X to 10X magnifying
glass.
(b). Using magnifying glass and light,

inspect spline for cracks. Pay particu
lar attention to side of each tooth
with large wear pattern (hairline
cracks appear crescent-shaped
usually at center bottom of tooth in
root area).
(c). Inspect neck of spline (area where
spline and shaft meet) for cracks.
(7). Check shaft straightness. When rotated
between centers, run-out must not
exceed 0.040 inch (1.016 mm) TIR
(allowable dents excluded).
2. 600N5510 and 369F5510 Main Rotor Drive
Shaft Inspection
Item
Nomenclature
CM234
Anytime main rotor drive shaft

is removed, cover opening at top
of main rotor hub to prevent entry of any
foreign material into hub, mast and trans
mission.
CAUTION
(1). Inspect overtorque verification stripe

for straightness.
(2). Inspect all surfaces of drive shaft for
dents, nicks, scratches and evidence of
deformation. No damage of any kind is
permissible in the area within two
inches of the spline. Dents less than
0.050 inch (1.270 mm) deep and 0.050
inch (1.270 mm) diameter are permissi
ble in other areas. A dent is defined as
a smooth depression of surface with no
sharp edges or abrupt changes in
contour. No nicks or scratches are
permitted.
63-10-00
Page 601
Revision 26
MAINTENANCE MANUAL
CSP-HMI-2
1.70 IN.
(4.318 CM)
8.0 IN.
(20.32 CM)
AREA 1:
MAX. PIT DEPTH 0.0012 IN. (0.03048 MM)
AREA 2:
AREA 3:
AREA 4:
CHECK TEETH BY MEASURING ACROSS

TWO 0.108 IN. (2.7432 MM)-DIAMETER PINS
PLACED IN OPPOSITE INTER-TOOTH
GROOVES. MEASURED DIMENSION
SHOULD BE 2.2625 IN. (5.74675 CM) MIN.
0.010 IN.
(0.254 MM)
MAX. DEPTH
0.050 IN. (1.270 MM)

MAX
TOOTH
CONTACT
AREA
5.40 IN.
13.716 CM)
0.050 IN.
(1.270 MM)
MAX
AREA 4
AREA 4
ROOT AREA
(TYP)
NOTE:
PAY PARTICULAR ATTENTION TO ROOT AREA AT EACH
SPLINE TOOTH. SIMULATED CRACKS SHOWN. ALSO
CHECK SPLINE NECK (SHADED AREA) FOR CRACKS.
LARGER WEAR
PATTERN (TYP)
Figure 601. Main Rotor Drive Shaft Inspection

Page 602
Revision 20
63-10-00
SPLINE
NECK
SIMULATED CRACKS
SHOWN
G631011A
MAINTENANCE MANUAL
CSP-HMI-2
(3). If shaft condition is questionable,

perform 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
dry cleaning solvent (CM234) to
remove oil, dirt and grease.
(b). Using magnifying glass and light,
inspect spline for cracks. Pay particu
lar attention to side of each tooth
with large wear pattern (hairline
cracks appear crescent-shaped
usually at center bottom of tooth in
root area).
6G63-003
Figure 602. Main Rotor Drive Shaft

Overtorque Verification Stripe
3. Main Transmission Drive Shaft Inspection
(Bendix)
(Ref. Figure 402)
Item
Nomenclature
CM318
Primer
(c). Inspect neck of spline (area where

spline and shaft meet) for cracks.
(8). Check shaft straightness. When rotated
between centers, run-out must not
exceed 0.040 inch (1.016 mm) TIR
(9). Apply thin coat of sealing compound
(CM425), mixed according to container
instructions, to all cork plug surfaces;
press cork into drive shaft until top of
cork is flush with top of drive shaft.
Allow sealing compound to cure
according to container instructions.
Apply second coat of sealing compound
to exposed surfaces of cork; allow to dry.
(1). Inspect drive shaft diaphragms for

dents, cracks, scratches, nicks, rust
spots and evidence of joint separation
from shaft or outside edges. Evidence of
any such defects on either diaphragm
requires removal of shaft from service.
(2). Inspect drive shaft tube between
diaphragms for dents, scratches, cracks
or corrosion pits.
63-10-00
Page 603
Revision 26
CSP-HMI-2
MAINTENANCE MANUAL
(a). Measure depth and diameter of

dents. Dents that blend smoothly into
surrounding surface area with no
sharp change in contour and do not
exceed 0.015 inch (0.381 mm) depth
are acceptable. Dents not within
these limits require removal of shaft
from service.
(b). Measure depth of cracks, nicks,
corrosion pits, or scratches; length
and direction are not limited. Maxi
mum depth allowed before rework is
0.003 inch (0.076 mm).
(c). Check suspected cracks using dye
penetrant. If crack indication ap
pears, remove black (phenolic com
pound) coating from area.
NOTE: Drive shaft is coated with special phe

nolic thermosetting compound. It is a brittle
coating that may indicate a crack that does
not penetrate tube.
(d). Re-inspect suspected area using
magnetic-particle or dye-penetrant
methods. If crack does not reappear,
touch up cleaned area with primer
coating (CM318) and return part to
service.
NOTE: Perform inspection steps (3). and (4).

only if shaft damage is suspected.
(3). Inspect shaft tube for out-of-round
condition, which shall not exceed 0.060
inch (1.524 mm).
(4). Inspect shaft for straightness. Shaft
shall be straight within 0.030 inch
(0.762 mm) at all locations relative to
centerlines of two flange mounting bolt
patterns.
4. Main Transmission Drive Shaft Inspection

(Kamatic)
(Ref. Figure 402)
Item
CM318
Nomenclature
Primer
(1). Inspect drive shaft for dents, cracks,

scratches, nicks, rust spots and evi
dence of joint separation from shaft or
outside edges.
couplings for dents, scratches, cracks or
corrosion pits.
exceed 0.010 inch (0.254 mm) in
depth are acceptable. Dents not
within these limits require removal
of shaft from service.
corrosion pits or scratches; length
0.005 inch (0.127 mm).
pears, remove coating from surface.
magnetic particle or dye penetrant
service. If shaft is found to be
cracked, remove shaft from service.
CAUTION
Kamatic parts cannot be inter

changed between drive shafts.
(3). Inspect all attaching hardware for

serviceable condition. Discard and
replace defective hardware.
NOTE: Perform the following inspections if

serviceable condition. Check nut plates
for drag torque. Discard and replace
defective hardware.
Page 604
Revision 20
63-10-00
shaft damage is suspected.

condition not to exceed 0.060 inch
(1.524 mm).
MAINTENANCE MANUAL
patterns.
5. Overrunning Clutch Inspection
(Ref. Figure 403 and Figure 404) Perform the
following inspections any time the helicopter
engine or overrunning clutch assembly is
removed from the helicopter. For further
inspection requirements, refer to Chapter 05
and Component Overhaul Manual.
NOTE: Overrunning clutch subassembly can

be replaced with engine installed.
(1). Check clutch oil level (Ref. Sec.
12-00-00).
(2). Remove grease and visually check
clutch input shaft splines for wear (Ref.
COM).
NOTE: Component Overhaul Manual contains

information relative to inspection of over
running clutch on helicopters equipped with
any cargo hook.
Inspection
Inspect firewall seal and backing for cracks,
breaks, corrosion or other damage that may
prevent complete sealing of firewall opening.
7. Bendix Tail Rotor Drive Shaft Coupling
Inspection
(1). Inspect coupling diaphragms for dents,
cracks, nicks, rust spots and joint
separation at weld junction.
(2). Inspect coupling splined section and
flange for scratches, nicks, dents,
cracks and corrosion pits. No cracks are
allowed. Maximum depth of other
defects allowed before rework is 0.005
inch (0.127 mm).
(3). Measure overall length of couplings at
three different points. If average of
readings exceed 2.541 inches (6.45414
cm), coupling must be replaced.
CSP-HMI-2
(4). Inspect socket and main transmission

coupling bolt for signs of contact. If
signs of contact are noted, remove and
reinstall coupling bolt and socket (Ref.
Sec. 63-15-00). Reposition socket and
or bolt so maximum clearance between
bolt key and socket is obtained.
8. Kamatic Coupling Inspection
(1). Inspect coupling springs for dents,
cracks, nicks and rust spots.
flange for scratches, nicks, dents,
cracks and corrosion pits. No cracks are
inch (0.127 mm).
(3). Measure overall length of coupling at
three different points. If average of
readings exceed 2.630 inch (6.6802 cm),
coupling must be replaced.
(4). Inspect drive shaft flange for signs of
contact. If signs of contact are noted,
remove coupling bolt, re-shim coupling
and reinstall coupling bolt (Ref. Sec.
63-15-00).
9. Main Rotor Drive Shaft Inspection (300
Hour)
(Ref. Figure 601)
Item
Nomenclature
CM234
Anytime main rotor drive shaft

is removed, cover opening at top
of main rotor hub to prevent entry of any
foreign material into hub, mast and trans
mission.
CAUTION
(1). Remove main rotor drive shaft (Ref.

Main Rotor Drive Shaft Removal).
(2). Perform a visual inspection of the shaft
spline as follows:
(a). Thoroughly clean with cleaning
solvent (CM234) to remove oil, dirt,
etc.
63-10-00
Page 605
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
(b). Use 5X to 10X magnifying glass and

bright side light (45 or less; down
ward lighting may not define cracks).
(c). Pay particular attention to side of
(each) tooth with larger wear pattern.
Hairline cracks appear crescentshaped and at the center and bottom
of tooth in the root area. Also, inspect
neck (shaded area) of spline for
cracks.
NOTE:
D If cracking is suspected, perform magnet
ic particle inspection of shaft spline and
teeth.
D If cracking or damage is found, the shaft
is no longer airworthy. Discard drive shaft
and return it to MDHS Customer Service
Department.
D Inspect replacement drive shaft per steps
(a). thru (c). prior to installation of shaft
on helicopter.
Page 606
Revision 20
63-10-00
(3). Inspect all other surfaces of the drive

shaft (Ref. Main Rotor Drive Shaft
Inspection).
NOTE: If surface corrosion or pitting of the

shaft surface is noted, perform field repair of
drive shaft (Ref. Main Rotor Drive Shaft Exterior Repair and Main rotor Drive Shaft
- Corrosion Removal).
(4). Remove protective cover and install
main rotor drive shaft (Ref. Main Rotor
Drive Shaft Installation).
MAINTENANCE MANUAL
CSP-HMI-2

REPAIRS
1. Main Rotor Drive Shaft Exterior Repair
(Ref. Figure 601) No repair of drive shaft is
permitted except for removal of light surface
corrosion and polishing of minor nicks and
chips in noncritical spline areas indicated
below.
Item
Nomenclature
CM121
Preservation oil
CM222
CM228
Surface cleaner
CM302
Epoxy primer / Catalyst reducer
CM803
Crocus cloth
(1). Remove corrosion as follows:

(a). Degrease corroded area of drive shaft
with clean cloth saturated with
trichloroethane (CM222).
Surface cleaner, used in step
WARNING below, irritates hands on re

peated exposure. Rubber gloves should
be worn.
(b). Swab shaft exterior with diluted
solution of surface cleaner (CM228).
(Mix one part surface cleaner with
four parts water.) Keep wet with
solution for 10 minutes or until
corrosion appears to be removed.
Wipe clean and inspect. Repeat as
necessary until there is no further
evidence of corrosion.
(c). Rinse with water and dry with
compressed air.
Exercise care when removing

pits to ensure that shot peening
is not completely penetrated. Remove only
minimum material necessary to remove
pits. Minimum wall thickness of 0.1775 inch
(4.5085 mm) must be maintained.
CAUTION
(d). Lightly abrade corroded surface with

crocus cloth (CM803) to remove pits.
If pit removal exceeds depth of
0.0012 inch (0.03048 mm) in Area 1
or 0.0008 inch (0.02032 mm) in Area
2, shaft is unserviceable and must be
replaced.
(e). Repeat steps (a). thru (c). above.
(f). Spray two coats of epoxy primer and
catalyst reducer (CM302), mixed per
manufacturers instructions, on shaft
exterior. Do not prime spline teeth or
mounting surface.
(2). Polish out minor nicks and chips on
shaft spline teeth as follows:
(a). Using 320 - 400 grit abrasive stone,
carefully grind, blend and polish out
nicks and chips which are outside the
critical (active) spline tooth contact
areas (Area 4 profile and end views
for permissible repair areas).
(b). If the repair (grind and polish)
operation extends beyond limits
shown, or if any tooth damage exists
within the critical tooth contact area,
shaft is unserviceable and must be
replaced.
(c). Perform magnetic particle inspection
according to Specification MILI-6868. No surface or subsurface
defects are permissible.
(3). Apply preservation oil (CM121) to
spline teeth.
63-10-00
Page 801
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
(4). Immediately reinstall main rotor drive

shaft.
2. Main Rotor Drive Shaft Corrosion
Removal
(Ref. Figure 601)
Item
Nomenclature
CM222
CM228
CM302
CM303
CM304
CM425
Surface cleaner
Wash primer
Enamel, epoxy
Sealing compound
(1). Degrease entire shaft inner diameter

(ID), using 1, 1, 1, trichloroethane
(CM222).
(2). Using a fine wire rotary brush or wire
brush, remove corrosion and contami
nants from drive shaft ID.
Turco WO-1 will irritate the
WARNING skin; always use rubber
gloves when handling this material.
Wash skin exposed to Turco WO-1,
thoroughly with water.
(3). Using swab and extension rod, swab ID
of driveshaft with Turco WO-1
(CM228), diluted one part to four parts
water.
(4). Thoroughly rinse drive shaft ID with
clear water; dry with compressed air.
(5). Using suitable light or borescope,
inspect shaft ID for corrosion pitting.
Remove pitting by honing locally. Shaft
ID may not exceed 1.655 inches (4.2037
cm) after honing. Blend honed area
with existing surrounding area. If
pitting removal causes or would cause
shaft ID to exceed 1.655 inches (4.2037
cm), replace shaft.
(6). Apply one coat of wash primer (CM303)
to shaft ID according to primer man
ufacturer's instructions.
Page 802
Revision 20
63-10-00
Do not allow epoxy primer or

epoxy enamel to contact drive
shaft splines or mounting surfaces.
CAUTION
(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
room temperature.
(8). Apply one coat of black epoxy enamel
(CM304) to driveshaft by filling and
draining shaft. Allow enamel to dry 48
hours at room temperature or let dry 30
minutes at room temperature, then
cure for three hours in oven at 250 275F (122 - 136C).
(9). Apply thin coat of sealing compound
(CM425), mixed according to container
instructions, to all cork plug surfaces;
press cork into drive shafts until top of
cork is flush with top of drive shaft.
Allow sealing compound to cure
according to container instructions.
Apply second coat of sealing compound
to exposed surfaces of cork; allow to dry.
3. Main Transmission Drive Shaft Repair
(Bendix)
(Ref. Figure 402)
Item
CM318
CM801
CM803
Nomenclature
Primer
Crocus cloth
(1). Repair of drive shaft diaphragms

(Bendix) is not permissible.
(2). Repair all damage that is no deeper
than 0.003 inch (0.076 mm).
(a). Completely remove defect. Maintain
smooth transition into surrounding
surface.
(b). Use grade 400 wet or dry abrasive
paper (CM801) for preliminary
finishing, and then polish with crocus
cloth (CM803). Restore surface until
it equals original finish of shaft.
MAINTENANCE MANUAL
(c). After rework, check shaft tube wall
thickness in repair area. Wall thick
ness shall not be less than 0.025 inch
(0.635 mm).
Care should be taken when re

moving or installing nutplates
in Kamatic drive shafts. Damage to flex
frames could cause drive shaft replacement.
CAUTION
(a). Carefully drill out rivets securing

nutplate.
(d). Apply primer coating (CM318) for

corrosion protection.
(b). Using two MS20605-MP3W3 rivets,

install a new MS21075-L4 nutplate
in place.
4. Main Transmission Drive Shaft Repair

(Kamatic)
Nomenclature
Item
CM318
Primer
CM801
CM803
Crocus cloth
(1). Repairs of Kamatic drive shaft flexible

couplings are limited. Repairs to spring
area are not allowed. No cracks are
allowed.
(2). Repair drive shaft tube area damage
that is no deeper than 0.005 inch (0.127
mm). Maximum depth after repair is
0.010 inch (0.254 mm). The maximum
thickness of material removed shall not
be more than 10 percent of the original
material thickness.
surface.
finishing, then polish with crocus
cloth (CM803). Restore surface until
it equals original finish of shaft.
thickness in repair area.
CSP-HMI-2
5. Overrunning Clutch Repair/Overhaul

Accomplish repair/overhaul of overrunning
clutch according to instructions in COM.
Repair
Item
Nomenclature
CM411
Adhesive, epoxy
Replace engine firewall seal by bonding new

seal to backing with adhesive (CM411).
7. Main Transmission Drive Shaft Coupling
Corrosion Removal
Item
Nomenclature
CM801
CM804

Emery cloth, fine
(1). Prior to installing original drive shaft

coupling (369A5512 or 369H5560 only),
inspect flange face of coupling for
corrosion. Evidence of corrosion may be
removed by hand lapping the affected
parts by using a sheet of #440 (or finer)
emery cloth (CM804) or wet or dry
abrasive paper (CM801) placed on a
surface table with a figure eight motion,
using care not to let the part rock.
NOTE: Couplings may be reused if flange is not

(3). Replace nutplates on Kamatics drive
shafts as follows:
less than 0.100 inch (2.540 mm) after clean

up. Recheck shimming.
63-10-00
Page 803
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
8. Bendix Coupling Repair
Item
CM202
CM318
CM801
CM803
Nomenclature
Metal protector, aerosol
Primer
Crocus cloth
NOTE: If coupling is cleaned with solvent or de

tergent, spray a light coating of metal pro
tector (CM202) on interior and exterior of
coupling diaphragm. Dip flange of coupling
in liquid or spray with aerosol metal protec
tor. Wipe away excess liquid. Metal protec
tor cures in eight hours at room tempera
ture or 15 minutes at 150F (66C).
Metal protector (CM202)
WARNING must only be used in a well

ventilated area. Persons using the met
al protector must follow all safety pre
cautions normally used with a chlori
nated solvent and all safety
precautions on the product label.
(1). Repairs to flexible web areas of dia
phragms are not allowed.
(2). Repair damage to splined section and
flange of coupling that is no deeper
than 0.005 inch (0.127 mm). Use
abrasive paper (CM801) grade 400 600 and crocus cloth (CM803) to
completely remove and polish out
defect. Maximum depth after rework is
0.010 inch (0.254 mm). Apply primer
(CM318) to repaired area.
(3). Repair damage to outer welded portion
of diaphragm halves as in step (2).
above, except that maximum thickness
of material removed shall be not more
than 10 percent of original material
thickness.
Page 804
Revision 20
63-10-00
9. Kamatic Coupling Repair
Item
Nomenclature
CM318
CM801
CM803
CM804
Primer
Crocus cloth
Emery cloth, fine
(1). Repairs to coupling spring areas are not

allowed.
(2). Repair damage to splined section and
abrasive paper grade 320 grit or finer
(CM801) and crocus cloth (CM803) to
NOTE: Flange may be hand-lapped using a

sheet of #440 emery cloth (CM804), placed
on a surface table. A figure ``8'' motion
should be used while lapping the coupling,
using care not to let part ``rock''.
(3). Minimum flange thickness after
cleanup is 0.100 inch (2.540 mm).
(4). Replace nutplates on Kamatics cou
plings as follows:
Care should be taken when re
moving or installing nutplates
in Kamatic couplings. Damage to flex
frames could cause coupling replacement.
CAUTION
(a). Carefully drill out rivets securing

nutplate.
(b). Using two MS20605-MP3W3 rivets,
install a new MS21075-L4 nutplate
in place.
MAINTENANCE MANUAL
CSP-HMI-2
Section
631510
Tail Rotor Drive
Shaft (369D/E/FF)
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSP-HMI-2

1. Tail Rotor Drive Shaft
The tail rotor drive shaft connects the main
transmission and the tail rotor transmission.
The total drive shaft length is approximately
13 feet long for 369D/E and approximately 14
feet long for 369FF. Flanges at each end of the
shaft attach to flexible joint couplings on the
transmission shafts.
2. Tail Rotor Drive Shaft Replacement
A. Tail Rotor Drive Shaft Removal
(Ref. Figure 401, and Figure 402)
(1). Remove (or open) tail rotor drive shaft
access doors.
(2). Remove three bolts and washers that
secure tail rotor drive shaft to output
shaft coupling on main transmission.
(3). Disconnect chip detector wire from tail
rotor transmission.
(4). Detach Sta. 284.00 bellcrank from tail
rotor transmission.
(5). Remove nuts and washers that attach
tail rotor transmission to tailboom.
To prevent damage to transmis
sion input shaft coupling during
and after shaft removal, provide level sup
port for both transmission and tail rotor, as
weight of these items might buckle coupling
diaphragm.
CAUTION
(6). With assistance in guiding shaft

through damper, remove tail rotor, tail
rotor transmission and tail rotor drive
shaft as an assembly. Slowly and
carefully slide assembly aft until drive
shaft clears tailboom.
Do not carry or otherwise sup
port transmission by use of cou
pling. Use care with removal tools to pre
vent scratching of coupling diaphragms.
CAUTION
(7). Support assembly along its entire

length, remove three coupling bolts and
washers, and remove drive shaft from

tail rotor transmission.
B. Tail Rotor Drive Shaft Installation with
Bendix Couplings
(Ref. Figure 401) Whenever main transmis
sion, tail rotor transmission, forward coupling
bolt and/or socket, transmission couplings or
coupling shims, tail rotor drive shaft or
tailboom assembly have been replaced, start
installation with step (1). below. If none of
these components has been replaced, and only
installation is involved, start with step (7).
below.
Item
Nomenclature
CM111
Grease, aircraft
CM112
CM115
CM311
Coating, logo white / Thinner
CM318
Primer
NOTE: If tail rotor drive shaft is replaced for

torsional buckling, replace and discard
transmission output gear shaft coupling bolt
and socket, and tail rotor gearbox coupling
and coupling bolt.
(1). Remove existing shims. Coat coupling
splines with grease (CM111) and
coupling failsafe bolt threads with
anti-seize compound (CM112) before
assembly. Install coupling and tighten
failsafe coupling bolt to 250 - 300
drag torque. (Check coupling bolt for
drag torque serviceability of 25 inchpounds (2.82 Nm) minimum, 200
inch-pounds (22.60 Nm) maximum.)
(2). Determine shim thickness required at
forward flexible coupling:
63-15-10
Page 401
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
COUPLING
SHIMS
TAIL ROTOR DRIVE

SHAFT DAMPER
MAIN TRANSMISSION
OUTPUT GEARSHAFT
COUPLING
SHAFT DAMPER
SLEEVE
TAIL ROTOR
DRIVE SHAFT
FAILSAFE
SOCKET
FAILSAFE
COUPLING
BOLT
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.
Figure 401. Tail Rotor Drive Shaft Installation (369D/E/FF) (Sheet 1 of 3)

Page 402
Revision 42
63-15-10
G63-1005-1B
MAINTENANCE MANUAL
CSP-HMI-2
LOCK RING
AND STUD
(4 PLCS)
TRANSMISSION
COUPLING (NOTE 1)
COUPLING SHIM
(NOTE 2)
TAIL
BOOM
COUPLING
BOLT
FAILSAFE
COUPLING BOLT
INPUT
SHAFT
TAIL ROTOR
TRANSMISSION
1.370 IN.
(34.798 MM) OD
(NOTE 4)
MEASURED GAP
0.010-0.020 IN.
(0.254-0.508 MM)
COUPLING SHIM
(NOTE 2)
ALIGNMENT
BOLT OR PIN
FAILSAFE
SOCKET
TRANSMISSION
COUPLING (NOTE 1)
THIN WASHER
(3 PLCS)
AFT
COUPLING
TAIL ROTOR
GEARSHAFT
INPUT SHAFT
NOTE 3
SHIMS
MAIN TRANSMISSION
OUTPUT PINION
FORWARD KAMATIC COUPLING
COUPLING BOLT
(NOTE 5)
TAIL ROTOR
DRIVE SHAFT
COUPLING BOLT
(NOTE 5)
AFT KAMATIC COUPLING

0.010 IN. (0.254 MM)
MINIMUM STEP
(NOTE 6)
KAMATIC COUPLINGS
G63-1005-2A
63-15-10
Page 403
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2
MEASURED GAP
0.010-0.020 IN.
(0.254-0.508 MM)
ALIGNMENT
BOLT OR PIN
MAIN TRANSMISSION
OUTPUT PINION
WASHER
(3 PLCS)
THIN
WASHER
(3 PLCS)
FAILSAFE
BOLT
TAIL ROTOR
DRIVE SHAFT
AFT
COUPLING
NOTE 3
SHIMS
1.370 IN
(34.798 MM) OD
(NOTE 5)
FAILSAFE BOLT
(NOTE 5)
FORWARD BENDIX COUPLING
TAIL ROTOR GEARBOX

OUTPUT SHAFT
SHIMS
FAILSAFE SOCKET
AFT BENDIX COUPLING
COUPLING
0.010 IN. (0.254 MM)

MINIMUM STEP
(NOTE 6)
FAILSAFE BOLT
(NOTE 7)
FAILSAFE SOCKET
D-D
FAILSAFE INSTALLATION
G63-1005-3D

Page 404
Revision 42
63-15-10
MAINTENANCE MANUAL
(a). Install minimum shim thickness on
main transmission output shaft.
Bottom the flexible coupling by
holding at the 1.370 inch
(3.4798 cm) OD of coupling. Do not bottom
coupling by pushing on drive shaft attach
flange; doing so may damage coupling.
CAUTION
(b). Bottom forward coupling on main

transmission output shaft.
(c). Measure step between aft end of
output shaft and shoulder of flexible
coupling, by bottoming coupling
against shims (refer to CAUTION
above).
NOTE: Maintain minimum 0.010 inch (0.254

mm) step between aft end of output shaft
and coupling shoulder to prevent coupling
bolt from bottoming on output shaft.
(d). Install additional shims to maintain
0.010 inch (0.254 mm) minimum step
as required.
(3). Position failsafe socket on aft face of
forward coupling so that three of the
nine holes are indexed to the three
nutplates of the coupling in such a way
that maximum clearance is obtained
between the bolt key and socket.
Visually verify proper clearance before
installing tail rotor drive shaft.
(4). Repeat previous step to install failsafe
socket on input coupling of tail rotor
transmission.
(5). Support entire length of tail rotor drive
shaft and position end stamped AFT to
align with tail rotor transmission
coupling.
(6). Install three bolts and washers to
connect tail rotor transmission coupling
to shaft; torque bolts to 80 - 100
drag torque.
CSP-HMI-2
CAUTION
D Ensure security of tail rotor gearbox
mount studs. Maximum allowable side
play at end of stud is 0.004 inch (0.102
mm), maximum allowable axial play is
0.005 inch (0.127 mm) (Ref. Sec.
63-25-10).
D When installing tail rotor transmission
and drive shaft, do not compress the for
ward or aft couplings as damage to the
coupling could result.
(7). With assistance, support transmission
and shaft in line, for minimum deflec
tion of coupling, and guide drive shaft
carefully through tailboom and damper
into position.
(8). Secure transmission to four tailboom
mounting studs (Ref. Sec. 63-25-10).
Install four washers and nuts, torque
nuts to 75 - 95 inch-pounds (8.47 10.73 Nm) plus drag torque.
(9). Align forward end of drive shaft with
coupling on main transmission output
gearshaft. Partially install two bolts as
an alignment aid but do not tighten.
Align drive shaft inspection markings.
If any of four white stripes is indistinct
or does not exist, paint (CM311)
replacement stripe:
(10). Obtain 0.010-0.020 inch (0.254-0.508
mm) gap between forward flange of tail
rotor drive shaft and aft end of socket,
using the following procedure:
(a). Back off three attach bolts on for
ward flange of tail rotor drive shaft
assembly 0.050-0.100 inch
(1.270-2.540 mm).
(b). Pull and hold tail rotor output shaft
of main rotor transmission aft (out of
transmission) to remove end play. If
rotor brake is installed, make certain
that brake pucks do not restrict axial
travel of tail rotor output shaft.
63-15-10
Page 405
Revision 43
CSP-HMI-2
MAINTENANCE MANUAL
(c). Remove end play in tail rotor trans

mission by applying force to tail rotor
blades in opposite direction of
operational rotation (while holding
forward coupling of tail rotor drive
shaft on main transmission output
shaft to prevent rotation). Do not
push tail rotor drive shaft fore or aft.
(d). Using feeler gage, measure gap
between socket and flange of tail
rotor drive shaft. Socket flange must
be in full contact with flange of
flexible coupling.
(e). With assistance, remove tail rotor
transmission and driveshaft in line
for minimum deflection of coupling.
(f). Using measured gap from step (d).
above, add or remove required
number of shims at tail rotor trans
mission input pinion shaft and
coupling to obtain specified gap of
0.010-0.020 inch (0.254-0.508 mm).
NOTE:
D Maintain minimum 0.010 inch (0.254
mm) step between coupling shoulder and
output shaft (Ref. step (2).).
D If less than specified gap, 0.010-0.020
inch (0.254-0.508 mm) exists under mini
mum shim requirements, install a maxi
mum of one HS306-326 or HS306-326H
washer on each of the four tail rotor
transmission mounting studs, between
gearbox housing and boom fitting. Apply
primer (CM318) to both sides of washer at
installation. After washer installation, re
peat step (10).
(11). Coat forward coupling splines with
grease (CM111) and coupling bolt
threads with antiseize compound (36)
before assembly. Install coupling and
torque failsafe bolt to 250 - 300
drag torque serviceability of 25 inchpounds minimum (2.82 Nm), 200
Page 406
Revision 42
63-15-10

and shaft in line for minimum deflec
tion of coupling and guide drive shaft
carefully through tailboom and damper
into position.
(13). Apply primer (CM318) to the four
gearbox mounting studs. Install nuts
and washers while the primer is still
wet; torque evenly to 75 - 95 inchpounds (8.47 - 10.73 Nm) plus drag
torque.
Verify that a minimum of (1) one
thread protrudes through each
nut from the four tail rotor transmission
mounting studs. If less than one thread is
showing, refer to CSP-DEF-6, Structural
Repair Manual, to replace with a longer
MS1992A803-14 stud and insert.
CAUTION
(14). Install three bolts and washers at

forward end of tail rotor drive shaft to
connect to forward coupling; torque
bolts to 80 - 100 inch-pounds (9.04 11.30 Nm) plus drag torque.
(15). Connect electrical wire to tail rotor
transmission chip detector. Torque nut
to 12 - 15 inch-pounds (1.36 - 1.69
Nm).
(16). Coat pin of Sta. 284.00 bellcrank with
grease (CM111) and insert it into
bearing in tail rotor pitch control. Pivot
bellcrank to align with mating hole in
tail rotor transmission and install bolt,
washers, nut and cotter pin.
(17). Check transmission oil level and service
as required.
(18). Slowly rotate drive shaft and visually
check to ensure shaft is not bent and for
not less than 0.250 inch (6.35 mm)
clearance between shaft and fairing
tube at Sta. 137.5. In addition, check
for minimum clearance of 0.190 inch
(4.83 mm) between shaft and cooling
blower scroll.
(19). Install all access doors and covers.
MAINTENANCE MANUAL
CSP-HMI-2
COUPLING SHIMS
MAIN TRANSMISSION OUTPUT

GEARSHAFT COUPLING
TAIL ROTOR
DRIVE SHAFT
TAIL ROTOR DRIVE

SHAFT DAMPER
TAIL ROTOR DRIVE

SHAFT DAMPER
SHAFT DAMPER SLEEVE

(2 PLCS)
LOCK RING AND STUD

(4 PLCS)
DRIVE SHAFT
INSTALLATION
TAILBOOM
COUPLING SHIM
(NOTE)
EXTENSION
COUPLING
BOLT
TRANSMISSION COUPLING
INPUT SHAFT
NOTE:
SHIM AS REQUIRED.
G63-1006
Figure 402. Tail Rotor Drive Shaft Installation (369FF)
63-15-10
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MAINTENANCE MANUAL
CSP-HMI-2
C. Tail Rotor Drive Shaft Installation with

Kamatic Couplings
(Ref. Figure 401 and Figure 402) Whenever
main transmission, tail rotor transmission,
transmission couplings, coupling shims, tail
rotor drive shaft or tailboom assembly have
been replaced, start installation with step (1).
below. If none of these components have been
replaced, and only installation is involved,
start with step (5). below.
Item
Nomenclature
CM111
CM112
CM115
CM311
CM318
Grease, aircraft
Primer
NOTE:
D Kamatic couplings do not require failsafe
bolts or sockets.
D When installing 369D25501-3 Kamatic
coupling, install SKCP2554-13 coupling
bolt supplied with the Kamatic coupling.
D If tail rotor drive shaft is replaced for tor
sional buckling, replace and discard main
transmission output gear shaft coupling,
tail rotor gearbox coupling and both cou
pling bolts.
(1). Coat coupling splines with grease
(CM111) and coupling bolt threads with
assembly. Install coupling onto tail
rotor gearbox and torque coupling bolt
to 250 - 300 inch-pounds (28.25 33.90 Nm) plus drag torque (Check
coupling bolt for drag torque service
ability of 25 inch-pounds (2.82 Nm)
minimum, 200 inch-pounds (22.60 Nm)
maximum.)
(CM112) before assembly. Install
Page 408
Revision 20
63-15-10
coupling onto main transmission;

torque coupling bolt to 250 - 300
drag torque serviceability of 25 inchpounds (2.82 Nm) minimum, 200
(3). Support entire length of tail rotor drive
shaft and position end marked AFT to
align with tail rotor transmission
coupling.
connect tail rotor gearbox coupling to
shaft; torque bolts to 80 - 100 inchpounds (9.04 - 11.30 Nm) plus drag
torque.
Ensure security of tail rotor
gearbox mount studs. Maxi
mum allowable side play at end of stud is
0.004 inch (0.102 mm), maximum allowable
axial play is 0.005 inch (0.127 mm) (Ref. Sec.
63-25-10).
CAUTION
(5). With assistance, support tail rotor

transmission and shaft in line, for
minimum deflection of coupling, and
guide drive shaft carefully through
tailboom and damper into position.
mounting studs with washers and nuts;
torque to 75 - 95 inch-pounds (8.47 10.73 Nm) plus drag torque.
(7). Align forward end of driveshaft with
gearshaft. Partially install two bolts as
an alignment aid but do not tighten.
Align drive shaft inspection markings.
If any of four white stripes is indistinct
or does not exist, paint replacement
stripes.
(8). Obtain 0.010-0.020 inch (0.254-0.508
mm) gap between forward flange of tail
rotor drive shaft and flange of forward
coupling using the following procedure:
(a). Ensure alignment bolts in previous
step are backed off between
0.050-0.100 inch (1.270-2.540 mm).
MAINTENANCE MANUAL
(b). Pull and hold tail rotor output shaft
rotor brake is installed, ensure that
brake pucks do not restrict axial
travel of tail rotor output shaft.
(c). Remove end play in tail rotor trans
mission by applying force to tail rotor
blades in opposite direction of
operation (while holding forward
coupling of tail rotor drive shaft on
main transmission to prevent rota
tion). Do not push tail rotor drive
shaft fore or aft.
between forward coupling flange and
flange of tail rotor drive shaft. Record
the gap.
(e). With assistance, remove tail rotor
transmission and driveshaft in line
for minimum deflection of coupling.
(f). Using measured gap from step (d).
above, add or remove required
number of shims at tail rotor trans
mission input pinion shaft and
coupling to obtain specified gap of
0.010-0.020 inch (0.254-0.508 mm).
NOTE:
D Maintain minimum 0.010 inch (0.254
mm) step between coupling shoulder and
output shaft (Ref. Figure 401).
D If less than specified gap, 0.010-0.020
inch (0.254-0.508 mm) exists under mini
mum shim requirements, install a maxi
mum of one HS306-326 or HS306-326H
washer on each of the four tail rotor
transmission mounting studs, between
gearbox housing and boom fitting. Apply
primer (CM318) to both sides of washer at
installation. After washer installation, re
peat step (10).
(9). Re-install coupling and torque coupling
bolt to 250 - 300 inch-pounds (28.25
- 33.90 Nm) plus drag torque.
(10). With assistance, support tail rotor
transmission and shaft in line for
minimum deflection of coupling and
CSP-HMI-2
guide drive shaft carefully through

tailboom and damper into position.
mounting studs with washers and nuts;
torque to 75 - 95 inch-pounds (8.47 10.73 Nm) plus drag torque.
forward coupling; torque bolts to 80 100 inch-pounds (9.04 - 11.30 Nm)
plus drag torque.
(13). Connect electrical wire to tail rotor
transmission chip detector. Torque nut
to 12 - 15 inch-pounds (1.36 - 1.69
Nm).
(14). Coat pin of Sta. 284.00 bellcrank with
grease (CM111) and insert into bearing
in tail rotor pitch control. Pivot bell
crank to align with mating hole in tail
rotor transmission and install bolt,
(15). Check transmission oil level and service
as required (Ref. Sec. 12-10-00).
(16). Slowly rotate driveshaft and check for
blower scroll.
3. Tail Rotor Drive Shaft Damper
(Ref. Figure 603) The tail rotor drive shaft
damper is a graphite-filled teflon plate that
controls and limits deflection of the tail rotor
drive shaft about its approximate mid-point.
The damper is spring-loaded against a
structural support bracket mounted on the aft
section tailboom fairing. On 369FF Model
helicopters, a second damper is located at Sta.
137.50 (Ref. Figure 602).
4. Tail Rotor Drive Shaft Damper
Replacement
(Ref. Figure 602)
(1). Remove boom-bolts access covers.
(2). Remove tail rotor drive shaft.
63-15-10
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Revision 43
MAINTENANCE MANUAL
CSP-HMI-2
(3). Remove two bolts, washers, springs,

thin washers, plate and spacers and
damper.
NOTE: The damper at Sta. 137.50 (369FF only)

has 369DSK152-13 bushings installed in
side the Teflon Graphite Damper in conjunc
tion with the spacers.
(4). Position new damper over mounting
holes in support bracket. Install plate
and spacers with bolts, washers,
springs and spacer washers.
Ensure washers under bol
theads are seated against
spacer when tightened. Bolts wear rapidly if
clamp-up is not solid.
CAUTION
(5). Adjust damper friction.
Page 410
Revision 28
63-15-10
(6). Install tail rotor drive shaft.

(7). Displace damper so that it touches tail
rotor drive shaft.
(8). Use wire gage to measure damper to
shaft clearance 180 from contact point.
Minimum acceptable clearance is 0.020
inch (0.508 mm).
(9). Repeat steps (7). and (8). above at 90
intervals from initial check point.
(10). Install boom-bolts access covers.
MAINTENANCE MANUAL
CSP-HMI-2

INSPECTION/CHECK
1. Tail Rotor Drive Shaft Inspection
Inspect shaft as described below. Replace bent
shaft. Other damage (scratches, nicks, etc)
that exceeds repairable limits also requires
shaft replacement.
(1). Inspect for scratches in shaft section
that passes through plenum chamber
fairing tube. Such scratches indicate
possible contact with tube edges at
bulkhead openings.
(2). Inspect for evidence of torsional
buckling or shaft bending as result of
blade strike or hard ground contact by
lower stabilizer.
(3). Inspect for corrosion.
(4). Inspect for evidence of shaft damper
sleeve bond failure (sleeve shifting)
from excessive heat or loads.
(5). If there is abnormal shaft vibrations,
check damper friction and shaft
straightness. When rotated between

centers, or with ends plugged and rolled
over roller, runout of large diameter
2. Tail Rotor Drive Shaft Twist Inspection
(Ref. Figure 601 and Figure 602) Following
inspection determines if drive shaft has been
torsionally strained to extent that permanent
twist exists.
(1). Hand-turn main rotor until two white
stripes (A, Figure 601) are aligned.
(2). Look inboard from tail rotor side of
helicopter and locate two white stripes
(B, Figure 601). Stripe on input shaft
bearing retainer flange of tail rotor
transmission is located at approximate
ly 2 o'clock, looking aft. Stripe on
coupling should be at approximately 10
o'clock, looking forward. Both stripes
should be aligned.
63-15-10
Page 601
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
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
TAIL ROTOR
TRANSMISSION
INPUT SHAFT
BEARING RETAINER
WHITE STRIPES
1/8 INCH (3.175 MM)
WIDE
COUPLING
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
Revision 20
63-15-10
MAINTENANCE MANUAL
CSP-HMI-2
TAIL ROTOR
TRANSMISSION
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)
WIDE
STA. 137.50 RING
TAIL ROTOR
DRIVE SHAFT
COUPLING
STA. 137.50
(LOOKING FORWARD)
(CURRENT
CONFIGURATION)
AFT COUPLING
G63-1008B
Figure 602. Tail Rotor Drive Shaft Inspection Markings (Extended Tailboom)
63-15-10
Page 603
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
3. Tail Rotor Drive Shaft Damper Inspection
to perform following inspection.
(Ref. Figure 603)
NOTE: If there is excessive drive shaft vibra

tion as shaft passes through first critical
rpm range, probable cause is defective or
loose damper.
(1). Inspect damper for shaft clearance as
follows:
(a). Remove boom-bolts access cover.
(b). Inspect tail rotor drive shaft damper
and support structure for broken,
cracked or bent parts.
(c). Displace damper so that it touches
tail rotor drive shaft.
(d). Use wire gage to measure damper to
shaft clearance 180 from contact
point. Minimum acceptable clearance
is 0.020 inch (0.508 mm).
(e). Repeat steps (c). and (d). above at 90
intervals from initial check point.
(f). Dampers not meeting minimum
clearance of 0.020 inch (0.508 mm) at
four equidistant points are to be
replaced.
Page 604
Revision 37
NOTE: Tail rotor drive shaft must be removed
63-15-10
(2). Inspect damper for correct drag friction

adjustment.
(3). Inspect inside diameter of damper for
excessive wear. If diameter is more
than 3.035 inches (7.7089 cm), damper
must be replaced.
(4). Adjust friction damper as necessary to
achieve the required drag as follows:
(a). Fabricate friction-checking tool.
(b). Using 0-10 pound spring scale,
measure force required to move
damper radially on bulkhead. Fric
tion must be adjusted so that pull of
2 0.25 pounds (0.91 0.11 kg) is
required to slide damper between
plate and support bracket.
NOTE: Minimum of one washer must always

remain between each spring and plate.
(c). To increase friction, add thin washers
between springs and plate. To
decrease friction, remove washers.
(Add or remove same number of
washers at each spring.)
MAINTENANCE MANUAL
CSP-HMI-2
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)
2.88 IN.
(7.3152 CM)
2.00 IN.
(5.08 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
63-15-10
Page 605
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
Page 606
Revision 44
63-15-10
MAINTENANCE MANUAL
CSP-HMI-2

REPAIRS
1. Tail Rotor Drive Shaft Repair Procedure
Item
Nomenclature
CM206
CM318
CM801
CM803
Chemical coating
Primer
Crocus cloth
Nicks and scratches no deeper than 0.0015

inch (0.0381 mm) are allowable without
rework but require finish protection with
chemical film (CM206). Other surface damage
shall be evaluated and repaired according to
limits specified below. Use grade 400 abrasive
paper (CM801) to smooth out and blend repair
area into surrounding material until damage
is completely removed; then polish with crocus
cloth (CM803) to equal original finish. Apply
finish protection with chemical film and two
coats of primer (CM318).
Any section of shaft that ap
pears to be scratched, nicked or
corroded in a previously reworked area
must not be repaired a second time. Remove
such shaft from further service. Replace any
shaft that has damage in excess of following
limits.
CAUTION
(1). Scratches 0.007 inch (0.178 mm) deep

to maximum length of 1.00 inch (2.54
cm) at any random angle may be
repaired.
(2). Scratches 0.010 inch (0.254 mm) deep
to maximum length of 0.250 inch (6.35
mm) at any random angle may be
repaired.
(3). Circumferential scratches 0.004 inch
(0.102 mm) deep may be repaired.
(4). Smoothly contoured dents are allowable
when ratio of dent diameter to dent
depth is at least 15:1; for example,
when depth is 0.040 inch (1.016 mm)
minimum acceptable diameter is 0.60
inch (15.24 mm). Maximum acceptable
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
CM311
If any of the four white index stripes used for

twist inspection of tail rotor drive shaft are
indistinct or do not exist, paint (CM311)
replacement aligning index stripes as follows:
To prevent damage to gearbox
coupling during and after shaft
removal, provide good level support for both
tail rotor transmission and shaft, as the
weight of these items might buckle the cou
pling.
CAUTION
NOTE: Any time the associated tail rotor drive

shaft units are removed or replaced, an in
dexing check and re-application of index
marks is required.
(1). Remove tail rotor transmission and
drive shaft as an assembly.
(2). Inspect tail rotor drive shaft for
evidence of torsional twist or buckling.
(3). Remove any old index stripes.
(4). Apply white index stripe 0.120 inch
(3.048 mm) wide and 0.250 inch (6.35
mm) long onto tail rotor transmission
input shaft bearing flange, at approxi
mate 10 o'clock position (viewed looking
forward), so it can be seen when viewed
on left side of tailboom.
(3.048 mm) wide and any length, on the
aft coupling in line with index stripe on
tail rotor gearbox retainer.
63-15-10
Page 801
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
(6). Install tail rotor drive shaft.

(7). Align index stripes on tail rotor gearbox
bearing retainer and aft coupling.
mm) long on boom bulkhead doubler

(Sta. 137.50), at approximately 6 - 8
o'clock position looking forward.
(8). Remove tail rotor bellcrank access door

at the forward left side of fuselage boom
fairing and observe the area where tail
rotor drive shaft passes through the
fairing forward bulkhead.
(10). Apply a corresponding joining index

stripe on the tail rotor drive shaft at
Sta. 137.50, approximately 0.120 inch
(3.048 mm) wide and 0.50 inch (12.70
mm) long.

(3.048 mm) wide and 0.50 inch (12.70
Page 802
Revision 20
63-15-10
MAINTENANCE MANUAL
CSP-HMI-2
Section
631530
NOTAR
AntiTorque System
Drive Shafts
(500/600N)
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSP-HMI-2
NOTAR) ANTITORQUE SYSTEM DRIVE SHAFTS

1. AntiTorque System Drive Shafts
The Fan Gearbox Drive Shaft connects the
main transmission and the fan gearbox. The
total drive shaft length is approximately 14
inches long. Flanges on each end of the shaft
attach to flexible (Kamatic) type joint coupling
on the main transmission output shaft and fan
gearbox input shaft.
The Fan Inter-Connecting Drive Shaft is
equipped with a kamatic flexible-type joint
and mounting flange (coupling) at each end.
The shaft connects the fan gearbox to the fan
assembly by (two) couplings mounted on the
output shaft of the fan gearbox and input shaft
of the fan assembly. The fan pitch control rod
is routed through the center of the inter-con
nect drive shaft.
2. Fan Gearbox Drive Shaft Replacement
A. Fan Gearbox Drive Shaft Removal
coupling and remove three bolts and

washers that secure fan gearbox drive
shaft to input shaft coupling on fan
transmission gearbox. Support drive
shaft and output shaft coupling on
main transmission.
(6). Remove fan gearbox (Ref. Sec.
63-25-30).
(7). Remove fan gearbox drive shaft by
removing three bolts and washers from
output shaft couping on main transmis
sion.
B. Fan Gearbox Drive Shaft Installation
(Ref. Figure 201) Whenever main transmis
sion, fan gearbox, transmission couplings,
coupling shims, fan gearbox drive shaft
assembly have been replaced, start installation
with step (1). below. If none of these compo
nents have been replaced, and only installa
tion is involved, start with step (3). below.
(Ref. Figure 201)

(1). Remove fan gearbox drive shaft access
doors and covers, upper aft section
fuselage and interior trim panels as
required.
Nomenclature
Grease, aircraft
Primer
(2). Remove tailboom fairing and tailboom

(Ref. Sec. 53-40-30).
Item
CM111
CM112
CM115
CM318
(3). Remove fan pitch control rod (Ref. Sec.

67-20-30).
NOTE: Kamatic couplings do not require fail
(4). Remove fan inter-connecting drive

shaft (Ref. Fan Inter-Connect Drive
Shaft Replacement).
WARNING
D To prevent damage to the engine in
stall F.O.D. cover over engine air in
let.
D To prevent damage to shaft provide
level support for fan transmission
drive shaft during removal or instal
lation.
(5). Gain access thru plenum chamber and
remove drive shaft access panel to aft
safe bolts or sockets. When installing

369D25501-9 Kamatic coupling, install
SKCP2554-15 coupling bolt supplied with
the Kamatic coupling or 369D25503-1 bolt.
If fan gearbox drive shaft is replaced for
torsional buckling, replace and discard
main transmission output gear shaft
coupling, fan gearbox coupling and both
coupling bolts.
assembly. Install coupling onto fan
gearbox input shaft and torque coupling
bolt to 250 - 300 inch-pounds (28.25
- 33.90 Nm) plus drag torque. Check
63-15-30
Page 201
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL

minimum, 200 inch-pounds (22.60 Nm)
maximum.
coupling onto main transmission output
shaft and torque coupling bolt to 250 300 inch-pounds (28.25 - 33.90 Nm)
plus drag torque. Check coupling bolt
for drag torque serviceability of 25
inch-pounds (2.82 Nm) minimum, 200
inch-pounds (22.60 Nm) maximum.
(3). Support drive shaft and position to
align with fan transmission coupling on
main transmission.
(4). Install fan gearbox with four mounting
bolts and torque to 70 - 90 inch
pounds (7.90 - 10.17 Nm); torquestripe bolts.
NOTE: If re-shimming is required, removal

and installation of the fan gearbox is neces
sary to obtain the specified gap between the
coupling flange and flange of drive shaft.
connect fan gearbox coupling to drive
shaft; torque bolts to 80 - 100 inchpounds (9.04 - 11.30 Nm) plus drag
torque.
(6). Align forward end of drive shaft with
gearshaft. Partially install three bolts
as an alignment aid but do not tighten.
(7). Obtain 0.010-0.020 inch (0.254-0.508
mm) gap between forward flange of the
fan gearbox drive shaft and flange of
forward coupling using the following
procedure:
(a). Ensure alignment bolts in previous
step are backed off between
0.050-0.100 inch (1.270-2.540 mm).
Page 202
Revision 43
63-15-30
(b). Pull and hold fan output pinion shaft

rotor brake is installed, ensure that
brake pucks do not restrict axial
travel of fan output shaft.
(c). Remove end play in fan transmission
by applying force to the coupling in
opposite direction of operation while
still holding forward coupling of drive
shaft on main transmission. Do not
push fan drive shaft fwd or aft.
between forward coupling flange and
flange of fan drive shaft using
average of 3 readings. Record the
gap.
(e). Adjust the number of shims
(369A5516-3, -5, -7, or -9). Using
measured gap from step 4 above, add
or remove required number of shims
behind the coupling of main trans
mission output pinion shaft or
between fan gearbox forward cou
pling to obtain specified gap of
0.010-0.020 inch (0.254-0.508 mm).
NOTE: All shims may be removed from forward

or aft coupling if required.
(f). Coat forward coupling splines with
coupling and torque coupling bolt to
250 - 300 inch-pounds (28.25 33.90 Nm) plus drag torque. Check
minimum, 200 inch-pounds (22.60
Nm) maximum.
forward coupling; torque bolts to 80 100 inch-pounds (9.04 - 11.30 Nm)
plus drag torque.
(9). Slowly rotate drive shaft and check for
blower scroll.
MAINTENANCE MANUAL
(10). Install fan gearbox (Ref. Sec.
63-25-30).
(11). Install inter-connecting drive shaft
(Ref. Fan Inter-Connect Drive Shaft
Replacement)
(12). Install fan pitch control; control rod
(Ref. Sec. 67-20-30).
(13). Install tailboom and fairing (Ref. Sec.
53-40-30).
(14). Check anti-torque flight control rigging
(Ref. Sec. 67-20-30).
(15). Install all access doors and covers, and
interior trim panels.
3. Fan Gearbox Drive Shaft Inspection
Inspect shaft as described below.
CSP-HMI-2
(1). Replace bent shaft. Other damage

(scratches, nicks, etc.) that exceeds
repairable limits also requires shaft
replacement.
(2). Inspect for scratches in shaft section
that passes through plenum chamber
fairing tube. Such scratches indicate
possible contact with tube edges at
bulkhead openings.
(3). Inspect for evidence of torsional twist,
buckling or shaft bending as result of
blade strike or hard ground contact.
(4). Inspect for corrosion.
4. Fan Gearbox Drive Shaft Repair
Procedure
For information on repair procedures, refer to
Sec 63-15-10, Tail Rotor Drive Shafts Repair
Procedure.
63-15-30
Page 203
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
BOLT
(NOTE 3)
SHIM
SHAFT
COUPLING
BOLT
(NOTE 3)
WASHER
SPEEDI
SLEEVE
BOLT
WASHER
SHIM
LOCKNUT
COUPLING
BOLT
WASHER
COUPLING
SHIM
(NOTE 1)
LOCKNUT
SHAFT
SPEEDI
SLEEVE
SHIM
(NOTE 1)
NOTE 2
COUPLING
WASHER
BOLT
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.
3. TORQUE 250 - 300 INCH-POUNDS (28.25 - 33.90 NM) PLUS
DRAG TORQUE OF 25 INCH-POUNDS (2.82 NM) MINIMUM,
200 INCH-POUNDS (22.60 NM) MAXIMUM.
G63-1012B
Figure 201. Fan Gearbox and InterConnecting Drive Shafts

Page 204
Revision 20
63-15-30
MAINTENANCE MANUAL
5. Fan InterConnect Drive Shaft
Replacement
(Ref. Figure 201)
A. Fan InterConnect Drive Shaft Removal
(1). Remove fan inlet screen and fan
transmission cover (Ref. Sec.
53-30-30).
(2). Remove tailboom fairing and tailboom
(Ref. Sec. 53-40-30).
67-20-30).
To prevent damage to the shaft
and couplings during and after
removal, provide level support for interconnecting drive shaft.
CAUTION
(4). Remove four mounting bolts and

washers (2 places) and remove shims at
both ends of inter-connect drive shaft,
remove inter-connect drive shaft.
Retain shims for reinstallation.
B. Fan InterConnect Drive Shaft
Installation
Install inter-connect drive shaft to obtain
0.010-0.020 inch (0.254-0.508 mm) gap
between the forward flange of the inter-con
nect drive shaft and the coupling aft flange as
follows:
(1). Install inter-connect drive shaft, install
8 mounting bolts and washers except
leave the 4 mounting bolts on the
forward flange of the inter-connect
drive shaft backed off 0.050-0.100 inch
(1.270-2.540 mm) and torque the four
aft mounting bolts 50 - 70 inchpounds (5.65 - 7.91 Nm).
(2). Pull and hold the coupling on the fan
gearbox Aft to remove end play.
(3). With a feeler gage measure gap (aver
age of 4 readings) between the flange of
the inter-connect drive shaft and the
coupling.
CSP-HMI-2
Do not exceed 0.100 inch (2.540

mm) shim thickness in either of
the two flange locations. Shim thickness in
both locations to be within 0.020 inch (0.508
mm) of each other.
CAUTION
(4). Adjust the shim thickness between the

forward flange and the aft flange of the
inter-connect drive shaft and the two
couplings.
(5). Install shims to obtain the specified
0.010-0.020 inch (0.254-0.508 mm)
gap. Install inter-connect drive shaft
with eight mounting bolts and washers.
Torque forward and aft mounting bolts
50 - 70 inch-pounds (5.65 - 7.91 Nm)
plus drag torque.
(6). Install fan pitch control; control rod
(Ref. Sec. 67-20 -30).
(7). Install tailboom and fairing (Ref. Sec.
53-40-30).
(8). Check control rigging (Ref. Sec.
67-20-30).
(9). Install access panels and covers (Ref.
Sec. 53-30-30).
6. InterConnect Drive Shaft Inspection
Item
Nomenclature
CM318
Primer
(1). Inspect drive shaft coupling for dents,

cracks, scratches, nicks, rust spots and
evidence of joint separation from shaft
or outside edges.
coupling for dents, scratches, cracks or
corrosion pits.
exceed 0.010 inch (0.254 mm) depth
are acceptable. Dents not within
these limits require removal of shaft
from service.
63-15-30
Page 205
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2

corrosion pits or scratches; length
0.005 inch (0.127 mm).
be more than 10 percent of original

material thickness.
surface.

pears, remove coating from area.

finishing, and then polish with crocus
cloth (CM803).

magnetic-particle or dye-penetrant
service.
serviceable condition. Discard and
replace defective hardware.
NOTE: Perform inspection steps (4). and (5).

below only if shaft damage is suspected.
condition, which shall not exceed 0.060
inch (1.524 mm).
patterns.
7. InterConnect Drive Shaft Repair
Item
Nomenclature
CM318
CM801
CM803
Primer
Crocus cloth
(1). Repair of drive shaft Kamatic flexible

type joint is limited. Repairs to spring
area are not allowed. No cracks are
allowed.
(2). Repair drive shaft tube area damage
that is no deeper than 0.005 inch (0.127
mm). Maximum depth after repair is
0.010 inch (0.254 mm). The maximum
Page 206
Revision 20
63-15-30

thickness in repair area.
8. Transmission and Fan Coupling
Inspection
The following procedures is for inspection of
fan gearbox and fan input coupling. For
information on Kamatics coupling inspection,
refer to Sec. 63-10-00.
flange for cracks, scratch, nicks, dent
and corrosion pits. No cracks are
inches.
(2). Inspect coupling speedi-sleeve for wear,
security of attachment to coupling.
9. Gearbox and Fan Coupling Repair
The following procedures is for repair of fan
gearbox and fan input coupling. For informa
tion on Kamatic coupling repair, refer to Sec.
63-10-00.
Item
Nomenclature
CM318
CM801
CM803
Primer
Crocus cloth
(1). Repair damage to splines section and

abrasive paper (CM801) grade 400 600 and crocus cloth (CM803) to
MAINTENANCE MANUAL
(2). After rework, check coupling wall
thickness in repair area. The maximum
be more than 10 percent of original
material thickness.
10. Transmission Coupling / Fan Coupling
Replacement
Item
Special Tools
Nomenclature
ST604
Coupling socket
CSP-HMI-2
A. Transmission Coupling / Fan Coupling

Removal
(1). Remove nut from shaft using coupling
socket (ST604) and coupling holding
fixture tool; remove coupling.
B. Transmission Coupling / Fan Coupling
Installation
(Ref. Figure 202)
(1). Slide coupling onto support shaft.

Item
Nomenclature
CM113
(2). Install nut using anti-seize compound

(CM113) as required. Torque nut to 800
- 1000 inch-pounds (90.39 - 112.98
Nm) plus drag torque using coupling
socket (ST604) and holding fixture.
G63-1023A
Figure 202. Fan Interconnect Drive Shaft Coupling Installation
63-15-30
Page 207
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
Page 208
Revision 43
63-15-30
MAINTENANCE MANUAL
CSP-HMI-2
Section
632000
369D25100 Main
Transmission
(369D/E/FF 500N)
MAINTENANCE MANUAL
CSP-HMI-2
P/N 369D25100
369D25100 MAIN TRANSMISSION

1. Main Transmission
(7). Drain oil from transmission.
The main transmission is secured to the

underside of the main rotor mast support
structure pan by four structure bolts, washers,
and nuts. The transmission is a two-stage
speed reduction unit. The first reduction stage
is for the tail rotor drive system and accessory
drive trains. The second stage is for further
reducing rpm for the main rotor. The transmis
sion housing is magnesium alloy. The accesso
ry gear train drives a rotor tachometer
generator and the transmission oil pump that
are mounted on drive pads at the aft end of the
transmission. The transmission is cooled by air
drawn through a cooling blower and routed
through the transmission oil cooler. Access to
the main transmission is attained by entrance
into the passenger compartment.
(8). Disconnect tail rotor output shaft seal

drain line, input shaft seal drain line
and two hoses that attach to lubrication
pump.
2. Main Transmission Buildup and

Replacement
A. Main Transmission Removal
(9). With assistance, support transmission;

then remove four nuts and washers
from mast support structure studs.
Lower transmission with ex
treme care to prevent contact
between tail rotor drive coupling and sur
rounding structure. Any dents, nicks or
scratches on coupling diaphragm requires
that coupling be scrapped. Use care to pro
tect oil pressure sender and chip detector
terminal studs from damage during handl
ing or when placing transmission on any
surface.
CAUTION
(10). With assistance, carefully lower

transmission from mounting studs.
(Ref. (Ref. Figure 201)

(1). Remove sound insulation and transmis
sion access covers (Ref. Sec. 52-40-00).
(2). Remove main transmission drive shaft
(Ref. Sec. 63-10-00).
(3). Remove cooling blower (Ref. Sec.
63-21-00).
(4). Remove anti-torque drive shaft (Ref.
Sec. 63-15).
NOTE: Removal of main rotor drive shaft (step

e. below) is optional. If help is not available
to rotate rotor hub for spline alignment,
shaft removal simplifies reinstallation of
transmission.
NOTE: Cover top opening of transmission to

prevent entry of foreign material. Residual
operating lubricant is an approved preser
vative for transmission shipment or storage.
(11). Perform the following steps as applica
ble to strip main transmission.
(a). Remove tachometer generator.
(b). Remove coupling bolt, coupling and
shim from tail rotor output shaft.
(12). Remove coupling bolt, coupling, shim,
drive pulley and pulley guard from
main transmission input shaft.

Sec. 63-10-00).
(a). Remove input shaft seal drain

connector (Ref. Figure 202).
(6). Disconnect wires from tachometer

generator, two chip detectors and oil
pressure sender.
(b). Install suitable covers and plugs to

protect all openings, including
threaded holes.
63-20-00
Page 201
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
P/N 369D25100
COUPLING BOLT
COUPLING (KAMATIC)
MAIN ROTOR
DRIVE SHAFT
TAIL ROTOR
DRIVE SHAFT
MAST BASE
FAILSAFE
SOCKET (NOTE 2)
COUPLING
(BENDIX)
OUTPUT SHAFT
FAILSAFE
COUPLING BOLT
DEBRIS
COVER
LAMINATED SHIM
OUTPUT SHAFT
COOLING BLOWER
FILLER
PLUG
O-RING
(NOTE 1)
SEAL
(NOTE 3)
SAFETY WIRE
INPUT SHAFT PULLEY GUARD
SEAL
(NOTE 3)
SEALANT
(NOTE 4)
PULLEY
FILLER SEAL INSTALLATION
LAMINATED SHIM
Revision 20
63-20-00
INTERNALWRENCHING
BOLT
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.
4. FILL CUT IN SEAL WITH SEALANT (CM430).
G63-2004B
Figure 201. 369D25100 Main Transmission Installation

Page 202
COUPLING
MAINTENANCE MANUAL
CSP-HMI-2
P/N 369D25100
B. Main Transmission Installation
(Ref. Figure 201)
Item
Nomenclature
CM111
CM112
CM121
CM125
CM126
CM234
CM417
CM425
CM430
Grease, aircraft
Preservation oil
Oil
Oil, turbine
Cement
Sealing compound
(1). Perform the following steps as applica

ble to build up main transmission prior
to installation.
(a). Install one preliminary 0.010 inch
(0.250 mm) shim on tail rotor output
shaft to prevent coupling bolt from
bottoming in shaft.
(b). Coat coupling splines with grease
(CM111) and coat bolt threads with
assembly. Install shaft coupling and
temporarily tighten coupling bolt to
approximately 250 inch-pounds
(28.25 Nm).
(c). Install tachometer generator. With
rotor brake installed, ensure electri
cal receptacle is at 11 o'clock position.
(d). Install input shaft seal drain connec
tor, bonding it in place with sealing
compound (CM425).
(e). Bond main rotor output shaft O-ring
in place with cement (CM417).
(f). Bond filler seal to transmission with
cement (CM417).
(g). If filler is safetied to case bolt, cut a
small section from seal and bond in
place. After bonding, fill gap in seal
with sealant (CM430).
(2). Use clean, absorbent cloth to clean pan
beneath main rotor mast support,
especially area contacted by O-ring on

top of transmission.
shaft or main transmission
splines can occur during installation. Care
should be taken while meshing drive shaft
splines into transmission output splines to
prevent damage.
CAUTION
(3). With assistance, slowly and evenly lift

and position transmission in place on
mounting studs.
(4). Install four washers and nuts; torque to
60 - 80 inch-pounds (6.78 - 9.04
Nm).
(5). If transmission is new, drain any
residual preservative oil. Service
transmission with lubricating oil
(CM125 or CM126) (Ref. Sec.
12-00-00).
(6). Connect wiring to tachometer genera
tor, two chip detectors and oil pressure
switch.
(7). Install anti-torque drive shaft (Ref.
Sec. 63-15-10/30).
When reinstalling main rotor
drive shaft, check that there is
no gap between shaft mounting flange and
rotor hub before tightening installation
bolts. Gap indicates that shaft splines are
not correctly meshed in transmission.
CAUTION
(8). If main rotor drive shaft has been

removed, apply coating of lubricating
oil (CM121) on shaft before reinstalla
tion and install drive shaft (Ref. Sec.
63-10-00).
(9). Connect tail rotor output shaft seal
drain line and input shaft seal drain
line and two hoses that attach to
lubrication pump.
(10). Install cooling blower (Ref. Sec.
63-21-00).
(11). Coat input drive coupling splines with
grease (CM111) and coat bolt threads
with anti-seize compound (CM112)
before assembly. Install pulley guard,
drive pulley, shim, coupling and
coupling bolt and temporarily tighten
coupling bolt to approximately 250
inch-pounds (28.25 Nm).
63-20-00
Page 203
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
P/N 369D25100
NOTE: Refer to Sec. 63-10-00, Main Transmis
4. Main Transmission Repair Procedure
sion Drive Shaft Installation for coupling
(Ref. Figure 201) Replace electrical compo
shimming, coupling torque and drive shaft
nents, breather-filler, filler screen, externally
installation.
accessible O-rings, lubrication pump, filter,
input shaft oil seal and tail rotor output shaft
oil seal if defective. Dents in outer surface of
(12). Install main transmission drive shaft
transmission housing deeper than 0.10 inch or
(Ref. Sec. 63-10-00).
covering more than 0.60 square inch (3.87 cm2)
area require replacement of transmission (for
repairs not covered in this section, Ref. COM).
(13). Ground run helicopter (refer to appro
This procedure is applicable to dents not
priate PFM) and check drive system for
exceeding specified limits.
excessive vibration and unusual noise.
Verify absence of oil over-temperature
and low pressure indications. Inspect
for oil leakage.
(14). Install access covers and sound insula
tion (Ref. Sec. 52-40-00).
3. Main Transmission Inspection Procedure

(Ref. Figure 201) The following procedures provide
information for checking the main transmission
for oil leakage and mechanical defect.

sion access covers (Ref. Sec. 52-40-00).
(2). Inspect transmission for oil leaks,
cracks, corrosion, secure electrical
connections and correct oil level.
Evaluate oil leakage according to Fluid
Leak Analysis.
Inspect all fluid lines for ade
CAUTION quate clearance between struc
ture and components. Vibration may cause
chafing of lines and subsequent leaking.
(3). Inspect four mounting flanges on main
transmission housing for corrosion and
cracks. Check that transmission
mounting studs and nuts are secure.
This should be accomplished from
fuselage interior as well as exterior at
main rotor mast base.
(4). Check that all safety wiring is intact.
Page 204
Revision 36
63-20-00
Item
CM234
CM318
CM411
CM801
Nomenclature
Primer
Adhesive, epoxy
NOTE: Any evidence of lubricating oil leakage

in a repair area requires replacement of
transmission.
(1). Clean area with solvent (CM234) and
remove sharp edges with grade 320
abrasive paper (CM801).
(2). Apply coat of primer (CM318) on
repaired surface.
(3). If dent is deeper than 0.030 inch (0.76
mm), fill depression with epoxy adhe
sive (CM411) and blend to surrounding
surfaces.
(4). Touch up re-worked area with paint
(Ref. Sec. 20-30).
5. Input Drive Assembly Oil Leakage
Repair Procedure
(Ref. Figure 202) Use the following repair
procedure when oil leakage occurs between the
main transmission housing and the pinion
bearing sleeve flange. Replace the
369D25184-3 O-ring as follows.
Item
CM218
Nomenclature
Alcohol, denatured
MAINTENANCE MANUAL
P/N 369D25100
(1). Remove the shaft interconnect, trans
(12).
mission input coupling, drive pulley
and guard, and cooling blower assembly
(Ref. Sec. 63-21-00).
(2). Drain oil from input drive assembly
through the lower chip detector plug
(Ref. Sec. 12-00-00).
(3). Remove attaching hardware securing
blower mount assembly (Ref. Sec.
63-21-00).
(4). Install four alignment bolts in place of
attaching hardware for blower mount
assembly. (Use any type of 2.00 inch
(5.08 cm) length x 1/4-28 diameter
bolt.)
(5). Install slide hammer tool on input drive
assembly pinion.
NOTE:
D It may be necessary to heat main housing
to move input drive assembly.
D Any movement of more than 0.150 inch
(3.81 mm) may cause disengagement of
scavenge pump drive.
(6). Gently tap input drive assembly away
from main housing no more than 0.150
inch (3.81 mm) to gain access to O-ring
between main housing and input
pattern shim.
(7). Remove slide hammer tool from input
drive assembly pinion.
(8). If required, cut defective O-ring for
removal.
(9). Clean and inspect pattern shim for
distortion and ensure no overlap
condition exists at butt/split line of
shim.
(10). Clean area between main housing and
input drive sleeve with alcohol (CM218)
to remove paint chips or other foreign
matter.
(11). Install new 369D25184-3 O-ring by
slipping over blower mount. Seat
O-ring in contact with the main
housing.
CSP-HMI-2
Remove alignment bolts and install

assembly aid tool halves between
O-ring and input bearing sleeve flange.
(Refer to Figure 203 for locally fabri
cated assembly aid tool.)
(13). Install attaching hardware in blower

mount, input pinion bearing sleeve, and
assembly aid tool.
(14). Tighten attaching hardware as follows:
(a). Maintain an inward preload of the
assembly aid tool halves against the
input pinion bearing sleeve while
tightening the four attaching bolts
equally.
(b). Tighten hardware until attaining a
positive clamp-up between the main
housing, assembly aid tool halves,
and input pinion bearing sleeve
flange.
(15). Remove attaching hardware and slide
out the assembly aid tool halves.
(16). Ensure the O-ring is seated in main
housing groove.
(17). When O-ring is seated correctly,
reinstall input pattern shim between
main housing and input pinion bearing
sleeve flange and reinstall hardware.
(a). Maintain an inward preload on input
pattern shim during the tightening
sequence.
(b). Torque attaching hardware 65 - 75
(19). Inspect pattern shim to ensure no
overlap condition exists at butt/split
line.
(20). Reinstall the shaft interconnect,
transmission input coupling, drive
pulley and guard, and cooling blower
assembly (Ref. Sec. 63-21-00).
(21). Add oil to input drive assembly (Ref.
Sec. 12-00-00).
63-20-00
Page 205
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2
P/N 369D25100
ASSEMBLY AID TOOL

COOLING BLOWER
MOUNTING BRACKET
SCAVENGE
PUMP DRIVE
(NOTE 1)
INPUT DRIVE
PINION
COOLING BLOWER
PULLEY SPACER
CHIP
DETECTOR
INPUT SHAFT
SELF-CLOSING
DRAIN VALVE
INPUT SHAFT
SEAL DRAIN
CONNECTOR
NOTE 2
INPUT PATTERN
SHIM HALVES
NOTE 5
O-RINGS
CHANGE THIS
O-RING ONLY
NOTES:
1. MOVEMENT IN EXCESS OF
0.15 IN. (3.81 MM) MAY CAUSE
DISENGAGEMENT OF SCAVENGE
PUMP DRIVE.
2. INSTALL SLIDE HAMMER ON
INPUT DRIVE ASSEMBLY PINION.
3. INSTALL BETWEEN O-RING AND
FLANGE ON INPUT PINION
BEARING SLEEVE.
4. USE SAME MOUNTING HOLES
FOR ALIGNMENT BOLTS.
5. MOUNT SHIM WITH SPLIT AT
3 AND 9 O'CLOCK POSITION.
0.000-0.030 IN. (0.000-0.762 MM)
MAXIMUM GAP ALLOWED.
CLAMP-UP
SHIM
ASSEMBLY AID
TOOL HALVES
(NOTE 3)
INPUT PINION
BEARING SLEEVE
O-RINGS
MOUNTING
HARDWARE
(NOTE 4)
BLOWER MOUNT
ASSEMBLY
G63-2027A
Figure 202. Input Drive Assembly ORing Replacement

Page 206
Revision 20
63-20-00
MAINTENANCE MANUAL
CSP-HMI-2
P/N 369D25100
1.50 (3.81 CM)

(TYP)
1.50 (3.81 CM)

(TYP)
0.257 (0.653 CM) DIA

(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
(2.92 CM)
(4 PLS)
1.850
4.70 CM)
(4 PLS)
SHIM SPLIT
(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 203. Assembly Aid Tool for Input Drive
63-20-00
Page 207
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
P/N 369D25100
Page 208
Revision 44
63-20-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
632025
369F5100 Main
Transmission
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
P/N 369F5100
369F5100 MAIN TRANSMISSION

1. Main Transmission
The main transmission is secured to the
underside of the main rotor mast support
structure pan by four structure bolts, washers,
and nuts. The transmission is a two-stage
speed reduction unit. The first reduction stage
is for the tail rotor drive system and accessory
drive trains. The second stage is for further
reducing rpm for the main rotor. The transmis
sion housing is magnesium alloy. The accesso
ry gear train drives a rotor tachometer
generator and the transmission oil pump that
are mounted on drive pads at the aft end of the
transmission. The transmission is cooled by air
drawn through a cooling blower and routed
through the transmission oil cooler. Access to
the main transmission is attained by entrance
into the passenger compartment.
2. Main Transmission Replacement
A. Main Transmission Removal
(Ref. Figure 201)
sion access covers.
(Ref. Sec. 63-10-00).
(3). Remove cooling blower (Ref. Sec.
63-21-00).
(8). Disconnect anti-torque output shaft

seal drain line, input shaft seal drain
lubrication pump.
NOTE: The following step will require an assis

tant to hold the transmission mount bolts
from the top of the helicopter and an assis
tant to remove the nuts and washers.
(9). With assistance, support transmission;
then remove hardware securing
transmission to mast support structure.
Lower transmission with ex
treme care to prevent contact
between anti-torque drive coupling and sur
rounding structure. Any dents, nicks or
scratches on coupling requires that coupling
be scrapped. Use care to protect oil pressure
sender and chip detector terminal studs
from damage during handling or when plac
ing transmission on any surface.
CAUTION
(10). With assistance, carefully lower

transmission.
NOTE: Cover top opening of transmission to

prevent entry of foreign material. Residual
operating lubricant is an approved preser
vative for transmission shipment or storage.
B. Main Transmission Installation
(Ref. Figure 201)
(4). Remove anti-torque drive shaft (Ref.

Sec. 63-15-10/30).
NOTE: Removal of main rotor drive shaft is op

tional. If help is not available to rotate rotor
hub for spline alignment, shaft removal sim
plifies reinstallation of transmission.
Sec. 63-10-00).
(6). Disconnect wires from tachometer
generator, two chip detectors and oil
pressure sender.
(7). Drain oil from transmission.
Item
Nomenclature
CM111
CM112
CM121
CM125
Grease, aircraft
Preservation oil
Oil
(1). Use clean, absorbent cloth to clean pan

beneath main rotor mast support,
especially area contacted by O-ring on
top of transmission.
63-20-25
Page 201
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
P/N 369F5100
MAIN ROTOR DRIVE

SHAFT
MAST BASE
COUPLING
(KAMATIC)
COUPLING
BOLT
LAMINATED
SHIM
TAIL ROTOR
DRIVESHAFT
OUTPUT
SHAFT
OUTPUT SHAFT
DEBRIS
COVER
COOLING BLOWER
FILLER
INPUT
SHAFT
O-RING
(NOTE)
COUPLING
PULLEY
GUARD
PULLEY
INTERNAL
WRENCHING BOLT
NOTE:
O-RING MUST BE CEMENTED IN PLACE
BEFORE INSTALLING TRANSMISSION.
Figure 201. 369F5100 Main Transmission Installation

Page 202
Revision 20
63-20-25
G63-2032A
MAINTENANCE MANUAL
CSP-HMI-2
P/N 369F5100
with anti-seize compound (CM112)
CAUTION shaft or main transmission
before assembly.
splines can occur during installation. Care
When installing pulley and
should be taken while meshing drive shaft
CAUTION guard, make sure the spring pin
splines into transmission output splines to
in pulley is fully engaged inside hole in
prevent damage.
pulley guard. If the spring pin does not align
NOTE: The following procedure will require
correctly with hole in pully guard, the
the assistance of another person.
torque will be incorrect.
(2). With assistance, slowly and evenly lift
and position transmission in place.
(3). Install four washers and nuts; torque to
900 - 1100 inch-pounds (101.69 124.28 Nm) plus drag torque.
(4). If transmission is new, drain any
residual preservative oil. Service
transmission with lubricating oil
(CM125) (Ref. Sec. 12-00-00).
(5). Connect wiring to tachometer genera
tor, two chip detectors and oil pressure
switch.
(6). Install anti-torque drive shaft (Ref.
Sec. 63-15-10/30).
When reinstalling main rotor
drive shaft, check that there is
no gap between shaft mounting flange and
rotor hub before tightening installation
bolts. Gap indicates that shaft splines are
not correctly meshed in transmission.
CAUTION
(7). If main rotor drive shaft has been

removed, apply coating of preservative
oil (CM121) on shaft before reinstalla
tion and install drive shaft (Ref. Sec.
63-10-00).
(8). Connect anti-torque output shaft seal
drain line and input shaft seal drain
lubrication pump.
(9). Install cooling blower (Ref. Sec.
63-21-00).
(10). Coat input drive coupling splines with
grease (CM111) and coat bolt threads
(11). Install pulley guard, drive pulley, shim,

coupling and coupling bolt and tempo
rarily tighten coupling bolt to approxi
mately 250 inch-pounds (28.25 Nm).
NOTE: Refer to Sec. 63-10-00, Main Transmis

sion Drive Shaft Installation and for cou
pling shimming, coupling torque and drive
shaft installation.
(Ref. Sec. 63-10-00).
(13). Ground run helicopter (refer to appro
priate PFM) and check drive system for
excessive vibration and unusual noise.
Verify absence of oil over-temperature
and low pressure indications. Inspect
for oil leakage.
(14). Install access covers and sound insula
tion.
3. Main Transmission Stripping
(Ref. Figure 202)
(1). Remove tachometer generator.
(2). Remove coupling bolt, coupling and
shim from anti-torque output shaft.
(3). Remove coupling bolt, coupling, shim,
drive pulley and pulley guard from
main transmission input shaft.
(4). Remove input shaft seal drain connec
tor (Ref. Sec. 12-00-00).
(5). Install suitable covers and plugs to
protect all openings, including threaded
holes.
63-20-25
Page 203
Revision 41
MAINTENANCE MANUAL
CSP-HMI-2
P/N 369F5100
OUTPUT
PINION
OUTPUT
COUPLING
ROTOR
BRAKE
OIL FILLER
ANTI-TORQUE
DRIVE SHAFT
A
OIL COOLER
BLOWER
COUPLING BOLT
CHIP
DETECTORS
DRIVE PULLEY
INPUT
COUPLING
SNUBBER (600N
ADAPTER (369D/E/FF - 500N
PACKING
PRESSURE SWITCH LOCK WIRE
ENGINE-TO-TRANSMISSION
DRIVE SHAFT
TACH GENERATOR
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 BuildUp

Page 204
Revision 28
63-20-25
MAINTENANCE MANUAL
4. Main Transmission BuildUp
(Ref. Figure 202)
CSP-HMI-2
P/N 369F5100
(6). Using a new O-ring, install oil pressure
switch and safety with lockwire
(CM702).
Item
Nomenclature
CM111
Grease, aircraft
CM112
CM417
Cement
CM425
Sealing compound
CM702
Lockwire CRES
(1). Install one preliminary 0.010 inch

(0.254 mm) shim on anti-torque output
shaft to prevent coupling bolt from
bottoming in shaft.
(CM111) and coat bolt threads with
assembly. Install shaft coupling and
temporarily tighten coupling bolt to
approximately 250 inch-pounds
(28.25 Nm).
(3). Install tachometer generator. With
rotor brake installed, ensure electrical
receptacle is at 11 o'clock position.
(4). Install input shaft seal drain connector,
bonding it in place with sealing com
pound (CM425).
NOTE: On the 369F5100 transmission, the oil

pressure switch is mounted on the bottom,
right side, facing down.
(5). 600N: Using a new O-ring, install
147D-2 snubber and torque to 155 165 inch-pounds (17.51 - 18.64 Nm).
369D/E/FF - 500N: Using a new
O-ring, install 369F5195-1 adapter
with teflon tape wrapped around
threads as required and torque to 155 165 inch-pounds (17.51 - 18.64 Nm).
(7). Bond main rotor output shaft O-ring in

place with cement (CM417).
(8). Using two new O-rings, install exten
sion, screen and filler on transmission.
Use 369A5169 shims to ensure filler is
angled no more than 30 from center
facing forward.
5. Main Transmission Inspection Procedure
(Ref. Figure 201) The following procedures
provide information for checking the main
transmission for oil leakage and mechanical
defect.
sion access covers.
(2). Inspect transmission for oil leaks,
cracks, corrosion, secure electrical
connections and correct oil level.
Evaluate oil leakage according to Fluid
Leak Analysis.
Inspect all fluid lines for ade
quate clearance between struc
ture and components. Vibration may cause
chafing of lines and subsequent leaking.
CAUTION
(3). Inspect four mounting flanges on main

transmission housing for corrosion and
cracks. Check that transmission
mounting nuts are secure.
(4). Check that all safety wiring is intact.
6. Main Transmission Repair Procedure
(Ref. Figure 201) Replace electrical compo
nents, breather-filler, filler extension, filler
screen, externally accessible O-rings, scavenge
pump, lubrication pump, filter, input shaft oil
seal and anti-torque output shaft oil seal if
defective. Dents in outer surface of transmis
sion housing deeper than 0.10 inch (2.54 mm)
or covering more than 0.60 square inch (3.87
cm2) area require replacement of transmission
(for repairs not covered in this section, Ref.
CSP-COM-5).
63-20-25
Page 205
Revision 24
MAINTENANCE MANUAL
CSP-HMI-2
P/N 369F5100
This procedure is applicable to dents not
exceeding specified limits.
blower mount assembly.
Item
Nomenclature
CM234
CM318
CM411
CM801
Primer
Adhesive, epoxy
NOTE: Any evidence of lubricating oil leakage

in a repair area requires replacement of
transmission.
(1). Clean area with solvent (CM234) and
remove sharp edges with grade 320
abrasive paper (CM801).
(2). Apply coat of primer (CM318) on
repaired surface.
(3). If dent is deeper than 0.030 inch (0.762
mm), fill depression with epoxy adhe
sive (CM411) and blend to surrounding
surfaces.
(4). Touch up re-worked area with paint
(Ref. Sec. 20-30-00).
7. Input Drive Assembly Oil Leakage
Repair Procedure
A. Input Pinion ORing Replacement
procedure when oil leakage occurs between the
main transmission housing and the pinion
bearing sleeve flange.
Item
Nomenclature
CM218
Alcohol, denatured
(1). Remove the shaft interconnect, trans

mission input coupling, drive pulley
and guard, and cooling blower assembly
(Ref. Sec. 63-21-00).
(Ref. Sec. 12-00-00).
Page 206
Revision 29
63-20-25
(4). Using NAS603-64 jack screws at two

corners of the input quill, begin pulling
the input quill from the transmission
housing. As required, operators may
use 0.5-1.0 inch (12.70-25.40 mm) bar
stock or equivalent as spacers to put
under the jack screws to assist
removing the input quill.
NOTE: It may be necessary to heat main hous

ing to move input drive assembly.
(5). Gently screw input drive assembly
away from main housing no more than
0.150 inch (3.81 mm) to gain access to
O-ring between main housing and
input pattern shim.
(6). Remove jack screws from input drive
assembly pinion.
(7). If required, cut defective O-ring for
removal.
(8). Clean and inspect pattern shim for
distortion and ensure no overlap
condition exists at butt/split line of
shim.
(9). Clean area between main housing and
input drive sleeve with alcohol (CM218)
to remove paint chips or other foreign
matter.
(10). Install new O-ring by slipping over
blower mount. Seat O-ring in contact
with the main housing.
(11). Remove alignment bolts and install
attaching hardware in blower mount
and input pinion bearing sleeve.
(a). Tightening the four attaching bolts
equally.
(b). Tighten hardware until attaining a
positive clamp-up between the main
housing and input pinion bearing
sleeve flange.
(13). Remove attaching hardware.
(14). Ensure the O-ring is seated in main
housing groove.
MAINTENANCE MANUAL
CSP-HMI-2
P/N 369F5100
O-RING
SLEEVE
CRUSH SEAL
INPUT SEAL
O-RING
BEARING RETAINER
BOLT
FAN MOUNT
WASHE
R
BOLT
INPUT LABYRINTH SEAL
WASHE
R
INPUT PINION
LOCKNUT
INPUT
NOSE BEARING
LOCKWASHE
R
INPUT
BEARING
SHIM
SPACER
PULLEY SHIM
INPUT BEARING SHIM

O-RINGS
O-RING
INPUT SHAFT OUTER SLEEVE

INPUT BEARING
INPUT THRUST BEARING
O-RING
G63-2033B
Figure 203. Drive Assembly ORing Replacement

(15). When O-ring is seated correctly,
reinstall input pattern shim between
main housing and input pinion bearing
sleeve flange and reinstall hardware.
(17). Inspect pattern shim to ensure no

overlap condition exists at butt/split
line.

(a). Maintain an inward preload on input
pattern shim during the tightening
sequence.
(18). Reinstall the shaft interconnect,

transmission input coupling, drive
pulley and guard, and cooling blower
assembly.
(b). Torque attaching hardware 50 - 70

drag torque.
(19). Service the transmission (Ref. Sec.

12-00-00).
63-20-25
Page 207
Revision 29
MAINTENANCE MANUAL
CSP-HMI-2
P/N 369F5100
B. Input Pinion Seal Replacement
procedure when oil leakage occurs at the input
pinion seal.
NOTE:
D If replacing a magnetic seal with a la
brynth seal, a speedi-sleeve must be
installed (Ref. COM, Sec. 63-20-25).
D If installing a 369F5165-1 labrynth seal,
seal must be modified (Ref. COM, Sec.
63-20-25).
Item
Nomenclature
CM112
CM218
CM425

Alcohol, denatured
Sealing compound
Item
Special Tools
Nomenclature
N/A
369F5100ATP-1 Locknut removal tool
(c). Insert adapter and breaker bar into

socket.
(d). Turn locknut removal tee counterclockwise, while holding spline socket
stationary, to remove nut.
(6). Using seal removal tool, remove seal
from input quill.
(7). Clean sealant from seal seating surface
in blower mount with denatured alcohol
(CM218).
(8). Allow to air dry.
seal edge and mating surface in blower
mount.
(10). Insert seal into blower mount.
(11). Clean any excess sealant and allow
sealant to cure per manufacturer's
instructions.
(12). Apply anti-seize compound (CM112) to
non-serrated threads on pinion and
install locknut.
NOTE: The following procedure requires two

people to accomplish.
(1). Remove the main transmission drive

shaft (Ref. Sec. 63-10-00, Main
Transmission Drive Shaft Replace
ment).
(a). Insert tee over locknut and put

cheater bar over one ear of tee.
(2). Remove nut from transmission input

coupling, drive pulley and guard (Ref.
Sec. 63-10-00, Main Transmission
Drive Shaft Replacement), keep all
shims with coupling.
(c). Insert adapter and breaker bar into

socket.

(Ref. Sec. 12-00-00).
(4). Remove lockwasher.
(5). Using locknut removal tool, remove
locknut.
NOTE: The following procedure requires two

people to accomplish.
(a). Insert tee over locknut and put
cheater bar over one ear of tee.
(b). Insert socket through center of tee to
engage splines on input shaft.
Page 208
Revision 29
63-20-25
(b). Insert socket through center of tee to

engage splines on input shaft.
(d). Turn input shaft counter-clockwise,

while holding locknut stationary, to
install nut.
(e). Torque nut to 250 foot-pounds (339
Nm). Loosen locknut and re-torque
to 183 - 225 foot-pounds (248 305 Nm).
(13). Install lockwasher.
(14). Reinstall input coupling with shims
previously removed (Ref. Sec.
63-10-00, Main Transmission Drive
Shaft Replacement).
(15). Reinstall main transmission drive shaft
(Ref. Sec. 63-10-00, Main Transmission
Drive Shaft Replacement).
MAINTENANCE MANUAL
(16). Service transmission (Ref. Sec.
12-00-00).
CSP-HMI-2
P/N 369F5100
9. Main Transmission RunIn Procedure
8. Main Transmission Filter Replacement

(Ref. Figure 202)
(1). Remove interior trim and blower access
door.
(2). Position container or cloth to catch
residual oil. Loosen and remove filter
housing by turning counterclockwise.
(3). Remove filter element.
(4). Inspect filter element for metal par
ticles. If metal particles are present,
remove main transmission chip detec
tors and inspect for other evidence of
internal failure in gearbox.
(5). If filter is excessively clogged, flush
system and check filter bypass valve for
operation (Ref. COM).
(6). Install new filter element and new
O-rings.
(7). Install housing and torque to 90 - 100
inch-pounds (10.17 - 11.30 Nm).
(8). If necessary, replenish transmission oil
supply.
(9). Perform ground runup of helicopter and
check for oil leakage.
(10). Reinstall, in order, blower access door
and interior trim.
New (from the factory) transmissions must

have a run-in period to remove the corrosion
preventive coating from the coast-side of the
drive gears. If not done at installation, the
coating will come off, over time, and cause the
impending bypass button to pop.
(1). Fly aircraft normally, monitoring the
transmission chip detectors for metal
particles, for the first 10 hours.
NOTE: Ignore the impending bypass indicator

in the first 10 hours of flight.
(2). During the first 10 hours of flight time,
perform at least three partial autorota
tions (Ref. Pilots Flight Manual) to load
the transmission on the coast side of
the gears.
NOTE: Each autorotation should be at least 30

seconds in duration.
(3). After 10 hours flight time has elapsed,
replace filter element (Ref. Main
Transmission Filter Replacement).
NOTE:
D Coating particles are black in color. Some
silver non-magnetic metallic particles
could be in the filter bowl, which are mag
nesium machining debris from manufac
turing.
D Flushing transmission oil is preferred but
not necessary.
(4). Reset the impending bypass indicator.
63-20-25
Page 209
Revision 29
CSP-HMI-2
MAINTENANCE MANUAL
P/N 369F5100
Page 210
Revision 44
63-20-25
MAINTENANCE MANUAL
CSP-HMI-2
Section
632100
Main Transmission
Lubrication and
Cooling System
(369D/E/FF
500/600N)
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSP-HMI-2
MAIN TRANSMISSION LUBRICATION

AND COOLING SYSTEM
1. Main Transmission Lubrication System
The main transmission lubrication system
consists of a lubrication pump driven by the
transmission, an oil filter, oil cooler, oil cooler
bypass valve, oil temperature sender, oil
pressure sender, liquid level plug, two chip
detectors, a drain line from the tail rotor
output shaft seal and a drain line from the
input shaft seal.
2. Main Transmission Lubrication Pump
Replacement (369D25100 Transmission)
(Ref. Figure 401)
A. Main Transmission Lubrication Pump
Removal (369D25100 Transmission)
sion access covers.
(2). Remove hardware that secure pump
housing to mounting pad.
(3). Remove pump and discard three
O-rings.
B. Main Transmission Lubrication Pump
Installation (369D25100 Transmission)
Item
Nomenclature
CM114
Petrolatum
(1). Install new O-rings in ports and in

groove of pump sleeve. Apply light
coating of petrolatum (CM114) to both
O-rings and mating bores in transmis
sion to prevent damage to O-rings.
(4). Ground run helicopter (Ref. PFM) and

check pump interface for leaks per
Fluid Leak Analysis (Ref. Sec. 63-20).
Verify that pressure warning light is
not on at 55% N2.
(5). Reinstall access covers and sound
insulation.
3. Main Transmission Lubrication Pump
Replacement (369F5100 Transmission)
(Ref. Figure 402)
A. Main Transmission Lubrication Pump
Removal (369F5100 Transmission)
sion access covers (Ref. Sec. 52-40).
(3). Remove pump and discard O-rings.
B. Main Transmission Lubrication Pump
Installation (369F5100 Transmission)
Item
Nomenclature
CM114
Petrolatum

(2). Align square drive of pump with drive

shaft in transmission and carefully
press pump into place.

(3). Install attaching hardware; torque to

50 - 70 inch-pounds (5.65 - 7.91
Nm).

40 - 50 inch-pounds (4.52 - 5.65 Nm)
plus drag torque.
63-21-00
Page 401
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
MAIN TRANSMISSION
LUBRICATION PUMP
O-RINGS
ROTATED
Figure 401. Main Transmission Lubrication Pump (369D25100 Transmission)

Page 402
Revision 20
63-21-00
63-2008
MAINTENANCE MANUAL
CSP-HMI-2
SCAVENGE
OIL PUMP
LUBRICATION
PUMP
LOOKING FORWARD
LUBRICATION
PUMP
MAIN
TRANSMISSION
0-RINGS
DIFFERENTIAL PRESSURE INDICATOR

(IMPENDING BYPASS INDICATOR)
SCAVENGE OIL PUMP
0-RINGS
6G63-002A
Figure 402. Main Transmission Lubrication Pump (369F5100 Transmission)
63-21-00
Page 403
Revision 28
MAINTENANCE MANUAL
CSP-HMI-2

Verify that pressure warning light is
not on at 55% N2.
(5). Reinstall access covers and sound
insulation (Ref. Sec. 52-40).
(369D25100 Transmission)
door.

O-rings.
(7). Install and tighten housing.
supply; then perform ground runup of
helicopter and check split line for oil
leakage.
(9). Reinstall blower access door and
interior trim.
6. Main Transmission Scavenge Pump
Replacement (369F5100 Transmission)
(Ref. Figure 402)
A. Main Transmission Scavenge Pump
Removal (369F5100 Transmission)


sion access covers (Ref. Sec. 52-40).

O-rings.

(7). Install housing and torque to 70 - 100

(3). Remove pump and discard O-rings.

supply; Then perform ground runup of
helicopter and check for oil leakage.
(9). Reinstall, in order, blower access door
and interior trim.
(369F5100 Transmission)
door.
B. Main Transmission Scavenge Pump

Installation (369F5100 Transmission)
Item
Nomenclature
CM114
Petrolatum




40 - 50 inch-pounds (4.52 - 5.65 Nm)
plus drag torque.
Page 404
Revision 20
63-21-00
MAINTENANCE MANUAL
7. Main Transmission Oil Cooler Bypass
Valve Replacement
(Ref. Figure 403) The oil cooler bypass valve
causes main transmission lubrication oil to
bypass the oil cooler when oil temperature is
178 2F (82 1C) or less, or the following
conditions exist: pressure differential of 25 psi
(172 kPa) or higher across oil cooler with oil
temperature of 190F (88C) or higher.
Excessive transmission oil temperature can be
caused by failure of oil cooler bypass valve to
seat in housing. Before installing new valve,
inspect seat within housing. If housing seat is
damaged, housing must also be replaced.
Item
Nomenclature
CM112
(1). Prepare container for draining oil from

transmission oil cooler lines upstream
of bypass valve housing through bypass
valve port. Unscrew valve and drain oil
in container. Install an AN806-12 plug
in housing to eliminate residual drip.
(2). Apply light coat of antiseize compound
(CM112) to valve threads and install
O-ring on valve. Torque valve to 50 60 inch-pounds (5.65 - 6.78 Nm).
(3). Replenish transmission oil lost during
bypass valve removal (Ref. Sec.
12-00-00).
8. Main Transmission Oil Cooler
Replacement
A. Main Transmission Oil Cooler Removal
CSP-HMI-2
NOTE: MDHS Notice DN-72.1 provides in

structions for modifying oil cooler drain sys
tem on early model helicopters to current
configuration.
(3). Remove oil drain tube and drain fitting.
(4). Detach oil cooler outlet duct.
(5). Remove compressor cooling duct and
pull oil cooler outlet duct away from oil
cooler.
(6). Remove hardware that secures oil
cooler and oil cooler inlet duct to
firewall; remove oil cooler.
(7). Remove covers from oil cooler by
breaking lockwire and cutting sealant.
NOTE: MDHS Notice DN-23.2 contains infor

mation relative to installation of oil cooling
lines.
B. Main Transmission Oil Cooler Installation
Item
Nomenclature
CM112
CM408
CM702
CM715

Adhesive, silicone rubber
Lockwire CRES
(1). Scrape old sealant and remnants of

pressure-sensitive tape seals from oil
cooler covers and reinstall covers with
(CM702) lockwire and sealant (CM408).
Use sealant to fill gaps (four places) at
ends of covers.
(2). Make up four 0.125 inch (3.175 mm)
thick and four 0.250 inch (6.35 mm)
thick seals, all 0.750 inch (19.05 mm)
wide, from pressure-sensitive tape
(CM715).
(1). Drain main transmission lubrication

system (Ref. Sec. 12-00-00).
(3). Apply seals, fabricated in previous step,

on oil cooler and oil cooler covers. Cut
holes in seals to accommodate bolts
(eight places).
(2). Remove two tubes that connect oil

cooler to oil cooler bypass valve hous
ing.
(4). Secure oil cooler and oil cooler inlet

duct to firewall with four bolts, washers
and nuts.
63-21-00
Page 405
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
SEALANT
LOCKWIRE
SEALANT
COOLER COVER LOCKWIRE AND
SEALANT (TYPICAL - BOTH ENDS)
OIL COOLER
INLET DUCT
OIL COOLER BYPASS

VALVE HOUSING
SEAL
0.125 X 0.50 X 7.06 IN.
(3.175 X 1.270 X 179.324 MM)
FIREWALL
DOUBLER
OIL COOLER
ELBOW
TEE
DRAIN CAP DRAIN
FITTING
SEAL
0.125 X 0.50 X 5.90 IN.
(3.175 X 1.270 X 149.86 MM)
COMPRESSOR
COOLING DUCT
COVER
(2 PLCS)
SEAL (4 PLCS)
0.250 X 0.75 X 5.75 IN.
(6.35 X 19.05 X 146.05 MM)
SEAL (4 PLCS)
0.125 X 0.75 X 5.25 IN.
(3.175 X 19.05 X 133.35 MM)
OIL COOLER
INLET DUCT
Figure 403. Main Transmission Oil Cooler Installation

Page 406
Revision 20
63-21-00
63-2002A
MAINTENANCE MANUAL
(5). Secure oil cooler outlet duct to oil cooler
with four bolts, washers and nuts.
(6). Install tee (with drain cap), elbow and
tubes that run from oil cooler to oil
cooler bypass valve housing, applying
light coat of antiseize compound
(CM112) to threads.
(7). Install oil drain tube and fitting on tee.
(8). Install compressor cooling duct.
(9). Fill main transmission lubrication
system (Ref. Sec. 12-00-00).
9. Main Transmission Oil Temperature
Sender Replacement
(Ref. Figure 404) The oil temperature sender
for the main transmission lubrication system
is installed in a housing inserted in the 1/2
inch oil line to IN port of lubrication pump.
Switch contacts close when oil temperature
exceeds 240 l0F (116 5C).
Item
Nomenclature
CM112
CM726
Tape, teflon
(1). Remove lockwire and detach electrical

wire from sender terminal post.
Position container for draining trans
mission oil cooler line. Remove two set
screws securing sender within sender
housing. Unscrew sender and drain oil
in container. Plug housing to prevent oil
drainage.
(2). Apply a light coat of antiseize com
pound (CM112) or tightly wrap two or
three turns of teflon tape (CM726) on
tapered threads of sender. Screw
temperature sender into housing;
torque to 30 - 40 inch-pounds (3.39 4.52 Nm). Install set screws until light
contact is made with sender. Lockwire
hex of sender to drilled head of ground
wire screw in sender housing. Connect
electrical wire to sender terminal and
CSP-HMI-2
replenish transmission with oil lost

(Ref. Sec. 12-00-00).
10. Main Transmission Oil Pressure Sender
Replacement
(Ref. Figure 404) The main transmission oil
pressure sender provides a ground to cause the
XMSN OIL PRESS warning light to illumi
nate when oil Pressure is low. It also provides
a ground to the running-time meter. Sender's
normally-closed contacts open when oil
pressure increases to 15 2 psi (103 14 kPa);
simultaneously the sender's normally-open
contacts close.
Item
Nomenclature
CM112
CM726

Tape, teflon
(1). Detach electrical wire or wires and

using absorbent cloth, unscrew sender
from transmission.
(2). Apply light coat of antiseize compound
(CM112) or wrap two or three turns of
teflon tape (CM726) on tapered threads
of sender. Screw in sender; torque to 30
- 40 inch-pounds (3.39 - 4.52 Nm).
Connect wire; make sure that connec
tion is clean and tight. If three wires
are present, for information on connec
tion of third wire refer to wiring
diagram for running time meter.
11. Liquid Level Plug Replacement
(1). Drain oil from transmission until oil
level is well below edge of plug port
(Ref. Sec. 12-00-00).
(2). Remove safetywire from plug.
(3). Remove plug by unscrewing counter
clockwise.
(4). Remove and discard O-ring. Install
new O-ring on plug.
(5). Install plug by screwing clockwise.
Torque plug to 80 - 90 inch-pounds
(9.04 - 10.17 Nm); install safetywire.
63-21-00
Page 407
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
BREATHER-FILLER
SPLINES FOR
MAIN ROTOR
DRIVE SHAFT
O-RING
(NOTE)
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
DRAIN VALVE
NOTE:
O-RING MUST BE CEMENTED IN PLACE
BEFORE INSTALLING TRANSMISSION.
INPUT SHAFT SEAL

DRAIN CONNECTOR
INPUT SHAFT
63-2001
Figure 404. Main Transmission CrossSection View

12. Chip Detector Replacement
(Ref. Figure 404) For removal and installation
instructions, refer to Draining Main Transmis
sion (Ref. Sec. 12-00-00). For functional test
information for detector circuit, refer to Sec.
95-30-00.
13. Cooling Blower Replacement
A. Cooling Blower
(Ref. Figure 405) The cooling blower is
mounted to a bracket on the aft underside of
the main transmission and coupled to the
transmission input shaft by a pulley-driven
Page 408
Revision 42
63-21-00
belt. The blower exhausts air through the

engine oil cooler and the main transmission oil
cooler. Exhaust air from transmission and
engine oil coolers is directed at various
external portions of the engine and engine
accessories.
B. Cooling Blower Removal
(Ref. Figure 405)
and blower access door.
(2). Remove coupling bolt, coupling, shim(s)
and pulley from transmission input
shaft.
MAINTENANCE MANUAL
(3). Disconnect cooling blower drain tube.
Loosen tie-down straps on blower duct
rubber connectors and roll back
connectors to disconnect ducts from
cooling blower.
(4). Cut lockwire and remove four bolts
attaching mounting bracket to trans
mission. Remove two shims inserted
between bracket and transmission pad.
(5). Remove mounting bracket (with blower,
pulley and belt) from helicopter.
NOTE: For 369D25100 transmission installa
tion only; If equipped with 369D25626-11
mount bracket, examine bolts securing
mount bracket to cooling blower assembly. If
safety wired, remove and discard bolts. Re
place with NAS1224-1L self-locking bolts.
(6). Disassemble cooling blower if required.
C. Cooling Blower Installation (369D25100
Transmission)
(Ref. Figure 405)
(1). Install pulley guard on main transmis
sion input shaft.
(2). With belt looped around transmission
input shaft, position mounting bracket
on main transmission pad and loosely
install four bolts and washers. Before
tightening bolts, insert two shims
between bracket and transmission pad.
Verify that blower scroll clears tail rotor
drive shaft by at least 0.190 inch (4.83
mm). Torque bolts to 65 - 75 inchpounds (7.34 - 8.47 Nm). Lockwire
bolt heads after belt tension is checked.
(3). Connect drain tube to cooling blower
scroll fitting. Clamp tube to fitting with
two turns of lockwire.
(4). Roll exhaust duct rubber connectors
onto scroll outlets and secure with
tie-down straps (Transmission oil
cooler duct and engine oil cooler duct).
CSP-HMI-2
In the following step do not use

levers or other tools on belt, or
in any way force belt onto pulley.
CAUTION
(5). Slide pulley onto transmission input

shaft to engage belt in teeth of both
pulleys.
(6). Adjust belt tension.
NOTE: Instructions in step (7). below, apply

only when original shim(s) (same shim
thickness) are installed and drive shaft,
overrunning clutch and couplings remain
unchanged. A distance of 0.010 inch (0.254
mm) between bolt seating surface on cou
pling and transmission input shaft is re
quired to ensure coupling bolt will not bot
tom out shaft and to provide proper
assembly clamp up. (Ref. Sec. 63-10-00).
The 0.010 inch (0.254 mm) mini
CAUTION mum measurement between the
bolt seating surface and the input shaft
must be obtained to ensure proper clamp up.
Warped shims or foreign material could pro
vide a false 0.010 inch (0.254 mm) minimum
measurement and improper clamp up could
result during normal operation which may
damage the main transmission input shaft.
(7). Install laminated shim and coupling on
transmission input shaft. Secure
coupling with coupling bolt; torque to
250 - 300 inch-pounds (28.25 - 33.90
(8). Make sure belt tracks correctly (Ref.
Cooling Blower Belt Tracking).
(.Ref Sec. 63-10-00).
(10). Install access panels.
63-21-00
Page 409
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2
TRANSMISSION
INPUT COUPLING
INTERNAL
WRENCHING BOLT
MOUNTING
BRACKET
0.010 IN. (0.254 MM) MINIMUM
(BETWEEN END OF SHAFT AND
BOLT SEATING ON SURFACE
ON COUPLING)
SHIM
(TYP, 2 PLCS)
MAIN
TRANSMISSION
WASHER
DRIVEN
PULLEY
FAN
MOUNTING
BRACKET
ENGINE OIL
COOLER DUCT
RUBBER
CONNECTOR
TIE WRAP STRAP
(TYP)
COOLING
BLOWER
INPUT SHAFT
WASHER
COOLING
BLOWER
PULLEY
SPACER
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 410
Revision 42
63-21-00
MAINTENANCE MANUAL
D. Cooling Blower Installation (369F5100
Transmission)
CSP-HMI-2
In the following step, do not use

levers or other tools on belt, or
in any way force belt onto pulley.
CAUTION
(Ref. Figure 406)
Item
Nomenclature
CM111
CM112
CM425
CM702
Grease, aircraft
Sealing compound
Lockwire CRES
(1). With belt looped around driven pulley,

install oil cooler fan bracket.
NOTE: NAS1304 series bolts may be used in

place of NAS6604 series bolts.
(a). Install four bolts with washers
through oil cooler mounting bracket
into fan bracket.
(b). Before tightening bolts, displace
cooler toward the transmission flange
to eliminate slack in that direction.
(c). Torque bolts to 70 - 90 inch-pounds
(7.91 - 10.17 Nm) and safety with
lockwire (CM702).
(d). After bolts are torqued, seal around
bolt heads with sealant (CM425).
When installing pulley and
guard, make sure the spring pin
in pulley is fully engaged inside hole in
pulley guard. If the spring pin does not align
correctly with hole in pully guard, the
torque will be incorrect.
CAUTION
(2). Install pulley guard on main transmis

sion input shaft.
(3). With belt looped around transmission
input shaft, position mounting bracket
on main transmission pad and loosely
install two bolts with washers from the
bottom of bracket and two bolts with
washers from top of bracket.
(4). Before tightening bolts, insert two
shims between bracket and transmis
sion pad.
(5). Verify that blower scroll clears antitorque drive shaft by a minimum of
0.190 inch (4.826 mm).
(6). Slide driver pulley onto transmission

input shaft to engage belt in teeth of
both pulleys.
The minimum of 0.010 inch
(0.254 mm) measurement be
tween the bolt seating surface and the input
shaft must be obtained to ensure proper
clamp-up.
CAUTION
D Warped shims or foreign material could

provide a false 0.010 inch (0.254 mm)
minimum measurement and improper
clamp-up could result, which during nor
mal operation, may damage the main
transmission input shaft.
eter of clutch coupling shim is different
than shim used on transmission input
coupling. Incorrect diameters can cause
an improperly seated shim, misalignment
and cocked coupling.
(7.91 - 10.17 Nm).
(8). Coat threads of coupling bolt with
anti-seize compound (CM112).
(9). Lubricate input shaft splines and
coupling splines with grease (CM111).
(10). Install input coupling shim and
coupling on transmission input shaft
with coupling bolt.
(11). Adjust belt tension (Ref. Cooling Blower
Belt Tension Check and Adjustment).
NOTE: Check coupling bolt for a minimum of
25 inch-pounds (2.82 Nm) drag torque.
(12). Torque coupling bolt to 315 - 365
drag torque.
(13). 369D, E, F, and 500N - Make sure belt
tracks correctly (Ref. Cooling Blower
Belt Tracking).
(14). Connect drain tube to cooling blower
scroll fitting. Clamp tube to fitting with
two turns of lockwire (CM702).
(15). Roll exhaust duct rubber connectors
onto scroll outlets (transmission oil
cooler duct and engine oil cooler duct)
and secure with tie straps.
63-21-00
Page 411
Revision 43
MAINTENANCE MANUAL
CSP-HMI-2
BOLT
BOLT
OIL COOLER FAN
BRACKET
FAN BRACKET
BOLT
SHIM
BOLT
PULLEY GUARD
TRANSMISSION
INPUT COUPLING
INTERNAL
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 412
Revision 42
63-21-00
MAINTENANCE MANUAL
E. 369D, E, F, and 500N Cooling Blower
Belt Tracking
(Ref. Figure 407)
(1). Make sure the oil cooler belt tracks
correctly.
(2). Rotate the lower driver pulley with
your hand in a clockwise direction (as
you look at the main rotor transmission
input). Make sure the belt tracks
axially away from the blower on the
upper driven pulley.
CSP-HMI-2
(3). Rotate the lower driver pulley by hand

in a counter-clockwise direction. Make
sure the belt tracks axially towards the
blower on the upper driven pulley.
(4). If the oil cooler belt does not track
correctly, replace with a serviceable
belt.
BLOWER
DRIVEN PULLEY
NOTE 1
DRIVEN PULLEY
NOTE 2
DRIVER PULLEY
(NOTES 1,2)
NOTES;
MAIN TRANSMISSION
DRIVE SHAFT
1. TURN DRIVER PULLEY CLOCKWISE.
VERIFY BELT TRACKS AWAY FROM BLOWER.
2. TURN DRIVER PULLEY COUNTER-CLOCKWISE.
63-2034
VERIFY BELT TRACKS TOWARDS BLOWER.
Figure 407. Cooling Blower Belt Tracking
63-21-00
Page 413
Revision 43
CSP-HMI-2
MAINTENANCE MANUAL
Page 414
Revision 42
63-21-00
MAINTENANCE MANUAL
CSP-HMI-2

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)

(1). Inspect plumbing and system compo
nents from oil cooler to lubrication
pump for leaks, secure attachment and
damage.
(2). Inspect oil cooler, lubrication pump, oil
filter, oil pressure switch, liquid level
plug, and chip detectors for leaks,
secure attachment and damage.
(3). Inspect electrical connections at oil
temperature switch, oil pressure
switch, and chip detectors for absence
of corrosion, secure attachment and
damage.
2. Cooling Blower Inspection
(Ref. Figure 405)
(1). Remove blower access door and inspect
belt for damage or excessive wear. Belt
should be fully seated in pulley grooves.
Limited cracking or separation of belt.
(a). Belt should be fully seated in pulley
grooves.
(b). Limited cracking or separation of belt
between pulley grooves is acceptable.
Visually monitor any propagation.
Belt should be replaced if any one
separation exceeds three inches in
length or if total separation exceeds
50 percent of peripheral length of
belt. (For belt replacement schedule,
refer to Section 05-10-00).
(5). Examine rubber connectors at engine

oil cooler duct and transmission oil
cooler duct where they attach to scroll.
Examine ducts for damage.
(6). Look through hub support legs and, to
extent possible, inspect impeller for
damage. A crack, loose rivet or dis
torted vane is cause for impeller
replacement. Inspect mount screws and
bolts for evidence of broken slippage
mark paint.
(7). Examine scroll drain tube for damage,
secure attachment and clear passage.
(8). Examine mounting bracket and fan
mounting bracket for secure attach
ment. Check for broken lockwire at bolt
heads securing mounting bracket
cooling blower assembly.
3. Cooling Blower Inspection
(Disassembled)
Item
Nomenclature
CM206
CM318
CM801
Chemical coating
Primer
(1). Examine belt for damage or excessive

wear (Ref. Figure 405).
(2). Check belt tension.
(2). Examine driver pulley, spring pin,

pulley guard and driven pulley for
damage or excessive wear.
(3). Hand-rotate main rotor to examine all

visible areas of driven pulley and driver
pulley for damage or excessive wear.
Listen for sounds of defective bearings
or of impeller touching scroll while
rotor is turned.
(3). Check driven pulley retaining nut for a

minimum of 160 inch-pounds (18.08
Nm) plus drag torque. If loss of
torque is indicated, remove pulley nut
and inspect washer for evidence of
elongation and wear.
63-21-00
Page 601
Revision 41
MAINTENANCE MANUAL
CSP-HMI-2
OIL PRESSURE
SENDER
MAIN TRANSMISSION
LUBRICATION PUMP
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 INSTALLED AT THIS LOCATION
(EARLY CONFIGURATION ONLY)
DRAIN CAP
G63-2007A
Figure 601. Main Transmission Cooling Blower and Duct

(4). Check pulley shaft and splines for
condition. Replace damaged flat washer
or ring washer with flat washer. Install
and torque nut to 160 - 190 inchpounds (18.08 - 21.47 Nm) plus drag
torque.
(5). Examine mounting bracket and fan
mounting bracket for cracks and
breaks.
(6). Examine web of mounting bracket for
wear.
(a). Remove nicks, scratches or grooves
leaving sharp impressions in web.
Minimum acceptable web thickness:
0.125 inch (3.175 mm).
(b). Replace mounting bracket if web does
not meet 0.125 inch (3.175 mm)
minimum after repair.
Page 602
Revision 36
63-21-00
(7). Examine scroll (Ref. Figure 801) for

cracks, breaks and distortion.
Handle impeller carefully to
prevent damage that could
cause imbalance and require replacement of
impeller.
CAUTION
(8). Visually (minimum 10X magnification)

examine impeller (Ref. Figure 801) for
cracks, deformation and separation.
(a). Look for foreign material attached to
impeller. None is permitted.
(b). Check for loose rivets at hub.
(c). Use electroprobe or gage of equiva
lent accuracy to measure depth of
scratches or nicks.
(d). Use penetrating dye to examine
suspected cracks.
MAINTENANCE MANUAL
(e). Scratches and nicks not exceeding
0.006 inch (0.152 mm) depth are
repairable by sanding with grade 320
abrasive paper (CM801) to blend
defect into surrounding area.
1). Treat blended areas with chemical
coating (CM206) and touch-up
with primer (CM318).
2). All other defects require replace
ment of impeller.
(9). Examine shaft for damage or excessive
wear. Discard seal (Ref. Figure 801).
4. Cooling Blower Belt Tension Check and
Adjustment
(1). Check that laminated shims are in
position between mounting bracket and
transmission fan mount assembly.
Tighten the four mounting bolts. Rotate
pulley by hand a few turns to even out
belt tension.
(2). Measure belt deflection three times at
approximate center of one of the spans.
The force required to deflect the belt
0.170-0.200 inch (4.32-5.08 mm) must
be 1.75-2.00 pounds (0.7938-0.9072
CSP-HMI-2
Kg). This load is to be applied at a right

angle to the outside face of the belt.
Measure belt deflection without turning
driven pulley, then turn driven pulley
1/2 turn and repeat belt deflection
measurement. Turn driven pulley an
additional 1/4 turn and measure belt
deflection again.
(a). If the tension is too high, greater
than 2.00 pounds (0.9072 Kg),
tension can be reduced by peeling off
a layer of the laminated shim, one at
a time equally from both shims, until
tension falls into proper range.
(b). If the tension is too low: Add layers
from a spare shim in the same
manner as removed in step (2).(a).
above, until tension falls into proper
range.
(3). Make a final check of bolt torque:
For 369D25100 transmission installa
tion, 65 - 75 inch-pounds (7.34 - 8.47
Nm), and then lockwire drilled heads.
For 369F5100 transmission installa
tion, 70 - 90 inch-pounds (7.91 10.17 Nm).
63-21-00
Page 603
Revision 37
CSP-HMI-2
MAINTENANCE MANUAL
Page 604
Revision 36
63-21-00
MAINTENANCE MANUAL
CSP-HMI-2

AND COOLING SYSTEM
REPAIRS
1. 369D25630 Cooling Blower Disassembly
(Ref. Figure 801)
NOTE: Disassemble cooling blower only to ex

tent necessary to perform inspection, re
placement or repair of specific items. Re
place cooling blower bearings and belt per
replacement schedule (Ref. Sec. 05-10-00).
Bolts used to secure mount bracket to cool
ing blower must be self-locking type only.
Discard bolts if safety wired and replace
with self-locking bolts (Ref. Figure 405).
(1). Remove mounting bracket (Ref. Sec.
63-20-00).
(2). Remove scroll cover.
holding device meeting requirements of

caution above, and remove impeller
retaining nut and washer.
Be careful to prevent impeller
damage. Slight impeller defor
mation or damage can cause imbalance.
Protect shaft threads and use nonmetallic
mallet when performing step (8). below.
CAUTION
(8). Manually support impeller and sepa

rate impeller from shaft by carefully
tapping end of shaft. Remove impeller,
scroll, key, spacer and any shimming
present.
(9). Remove bolt, retaining ring and spring
washer from hub.
(5). Remove spacer from impeller shaft.
(10). Use non-metallic mallet on splined end

of shaft to drive impeller-end bearing,
seal, and portion of the shaft from hub.
Do not attempt to remove sleeves from
hub. Sleeves are line-reamed. If either
sleeve is defective, hub must be re
placed. Remove inner retaining ring
from hub. Remove and discard O-ring
in upper sleeve if installed.
(6). Remove four screws and washers that

attach scroll to hub.
(11). If necessary, use pulling device to

extract bearing and seal from shaft.
(3). Hold impeller retaining nut with socket

wrench and remove driven-pulley
(4). Remove driven pulley. Do not forcefully
tap or pry; if necessary, use pulling
device.
In following step, do not use

tools or other devices to hold im
peller. Tool damage can affect impeller bal
ance. Holding device must not damage shaft
splines and must hold shaft with 250 - 300
inch-pounds (28.25 - 33.90 Nm) of torque
applied to impeller retaining nut.
CAUTION
(7). Secure splined end of impeller shaft in
(12). If remaining bearing cannot be driven

from hub by tapping outer race from
inside with nonferrous tube and mallet,
re-insert shaft into bearing, drive
bearing out and remove it from shaft as
described in steps (10). and (11). above.
(13). Discard bearings. They are not to be
re-used.
63-21-00
Page 801
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
SHAFT
HUB
SLEEVE
(NOTE 1)
BEARING
O-RING
SHAFT
BEARING
SLEEVE
(NOTE 2)
HUB
CAVITY FILLED
WITH GREASE
MINIMUM CLEARANCE
TO PREVENT RUBBING
(NOTE 3)
INNER RETAINER
RING
SCREWS AND WASHERS
(4 PLCS)
BOLT
SEAL (PART
OF BEARING)
BEARING
SLEEVE
BLOWER
SCROLL
SEAL
IMPELLER
SCREW AND WASHER
(8 PLCS)
SEALANT
SPRING WASHER
WASHER
KEY
OUTER RETAINING
RING
NUT
LAMINATED
SHIM
COVER
(NOTE 1)
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) MINIMUM.
G63-2009-1
Figure 801. 369D25630 Cooling Blower CrossSection View

Page 802
Revision 22
63-21-00
MAINTENANCE MANUAL
2. 369D25630 Cooling Blower Reassembly
(Ref. Figure 801)
Item
Nomenclature
CM116
CM219
CM220
CM222
CM321
CM425
CM431

Methyl-ethyl-ketone
Naphtha aliphatic
Sealing compound
CSP-HMI-2
(7). Lightly grease (CM116) larger bearing

journal of shaft and bore of remaining
bearing.
On current configuration Cool
ing blowers, apply locking com
pound (CM431) to outer race of lower bear
ing (impeller end) only. Do not apply locking
compound to upper bearing (pulley end).
CAUTION
(8). Apply primer (CM321) and locking

compound (CM431) to faying surfaces of
outer bearing race and sleeve according
to container instructions. Be careful to
prevent compounds from entering
bearing.
NOTE: On newer style bearings, the metal

NOTE: Following procedure covers assembly of
completely disassembled cooling blower, to
gether with those items (belt, brackets, etc)
that form a complete unit. Use only applica
ble steps of procedure when disassembly is
less than complete. New bearings and new
seal are required; those removed are not to
be reused.
(1). Install inner retaining ring in hub and
if removed at disassembly install new
O-ring in upper bearing sleeve.
(2). Lightly grease (CM116) smaller bearing
journal of shaft, and bore of correspond
ing bearing.
NOTE: This bearing does not have a metal

shield.
(3). Place bearing on shaft so that rubber
seal of bearing faces splined end of
shaft.
(4). Using tube that contacts only edge of
inner race of bearing, arbor-press
bearing onto journal until inner race
contacts shaft shoulder.
(5). Clean outer race of both bearings and
faying surfaces of both hub sleeves with
trichloroethane (CM222) and clean
cloth or paper towel.
(6). Arbor-press bearing (with shaft
installed) into sleeve. Exert pressure
only on bearing outer race and on
impeller-end of hub casting (no
pressure on impeller-end sleeve).
shield is replaced by a blue shield.

(9). Insert bearing so that shield side (metal
shield or blue disc) faces interior of hub
and seal side (rubber disc) faces
impeller end of shaft.
(10). Arbor-press bearing simultaneously
onto shaft journal and into sleeve.
Exert pressure equally on both races of
bearing. At same time, exert equal
pressure on splined end of shaft and
pulley end of hub casting. Bearing is to
firmly contact shaft shoulder and inner
retaining ring.

(11). Wipe away excess locking compound.
Use methyl ethyl keytone (CM219) if
hardening begins. Leave assembled
parts undisturbed to permit locking
compound to cure for two hours at
75-100F (24-38C), or for ten
minutes at 220 l0F (105 5C).
(12). Temporarily install lubrication fitting.
(13). Install new seal, spring washer and
outer retaining ring.
(14). Fill hub cavity with grease (CM116)
through lubrication fitting until grease
seeps out around seal of bearing
nearest splined end of shaft. After
lubrication, remove lubrication fitting
and install screw and washer. Lockwire
screwhead.
63-21-00
Page 803
Revision 37
CSP-HMI-2
MAINTENANCE MANUAL
(15). Install hub on scroll with four screws

and washers. Torque screws to 12 - 15
(16). Install spacer and impeller on shaft.
(17). Install washer and locknut on end of
shaft. Using holding device on splined
end of shaft, tighten locknut sufficiently
to remove all end clearance from
stack-up of parts.
(18). Using feeler gage through an air outlet
port, measure minimum clearance
between impeller and scroll lip.
NOTE: If minimum clearance is 0.020-0.040

inch (0.508-1.016 mm), steps (19). and (20).
below may be bypassed.
(19). If clearance is more than 0.040 inch
(1.016 mm), remove impeller and
spacer. Replace spacer with 369H5654
shims as required between impeller and
seal to obtain 0.020-0.040 inch
(0.508-1.016 mm) clearance. Reinstall
impeller, washer and locknut. Tighten
to remove all end clearance, and then
rotate impeller and check for rubbing. If
rubbing occurs, perform step (20).,
otherwise proceed to step (21)..
(20). If clearance is less than 0.020 inch
(0.508 mm), or if rubbing occurs when
performing previous step, disassemble
and install shim(s) between seal and
spacer to ensure 0.020-0.040 inch
(0.508-1.016 mm) minimum clearance
and prevent rubbing.
(21). When clearance is properly adjusted,
remove impeller, install key, impeller,
washer and locknut. Torque locknut to
250 - 300 inch-pounds (28.25 - 33.90
Nm). Use care to avoid placing stress
on impeller or scroll. Hold splined end
of shaft in suitable device.
NOTE: Install two self-locking bolts in place of

safety-wired bolts if not previously in
stalled.
(22). (Ref. Figure 405) Secure fan mounting
bracket on hub with four bolts and
washers on early configurations, or two
self-locking bolts, two screws and four
washers on current versions. Before
Page 804
Revision 36
63-21-00
tightening bolts, fully displace bracket

in direction that causes it to be closest
to main transmission drive shaft when
cooling blower is installed, then torque
bolts to 65 - 75 inch-pounds (7.34 8.47 Nm). Apply slippage mark paint.
(23). (Ref. Figure 405) Install spacer, washer,
pulley, washer and nut on shaft. Hold
nut on impeller end of shaft with socket
wrench and tighten pulley nut to 160 190 inch-pounds (18.08 - 21.47 Nm)
plus drag torque.
(24). (Ref. Figure 405) Install belt on pulley
and secure mounting bracket to fan
mounting bracket with four bolts and
washers. Before tightening bolts, fully
displace bracket in direction that
causes it to be closest to main transmis
sion drive shaft when cooling blower is
installed, then torque bolts to 65 - 75
lockwire drilled heads.
(25). Clean faying surfaces of scroll and
cover with naphtha (CM220); apply
sealant (CM425) according to container
instructions before securing cover to
scroll with eight screws and washers.
3. 600N5630 Cooling Blower Disassembly
(Ref. Figure 802)
NOTE: Disassemble cooling blower only to ex

tent necessary to perform inspection, re
placement or repair of specific items. Re
place cooling blower bearings and belt per
replacement schedule (Ref. Sec. 05-10-00).
(1). Remove mounting bracket (Ref. Sec.
63-20-25).
(2). Hold impeller retaining nut with socket
wrench and remove driven-pulley
(3). Remove driven pulley. Do not forcefully
tap or pry; if necessary, use pulling
device.
(4). Remove spacer from impeller shaft.
(5). Remove two screws and washers that
attach scroll to shroud.
(6). Remove four screws six washers, and
two nuts that attach hub to shroud and
scroll. Retain shim if installed.
MAINTENANCE MANUAL
CSP-HMI-2
SCREW
WASHER
SHROUD
NUT
WASHER
SHAFT
HUB
SCREW
WASHER
BEARING
SCREW
WASHER
LOCKWIRE
O-RING
SCROLL
RETAINING RING
SHIM
(NOTE 3)
SHIM
(NOTE 3)
BEARING
SPRING
WASHER
SEAL
(NOTE 2)
NOTE 3
IMPELLER
RETAINING RING
SHIM
(NOTE 1)
NUT
WASHER
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 CrossSection View
63-21-00
Page 805
Revision 36
CSP-HMI-2
MAINTENANCE MANUAL
In following step, do not use

tools or other devices to hold im
peller. Tool damage can affect impeller bal
ance. Holding device must not damage shaft
splines and must hold shaft with 250 - 300
inch-pounds (28.25 - 33.90 Nm) of torque
applied to impeller retaining nut.
CAUTION
(7). Secure splined end of impeller shaft in

holding device meeting requirements of
caution above, and remove impeller
Be careful to prevent impeller
damage. Slight impeller defor
mation or damage can cause imbalance.
Protect shaft threads and use nonmetallic
mallet when performing step (8). below.
CAUTION
(8). Manually support impeller and sepa

rate impeller from shaft by carefully
tapping end of shaft. Remove impeller,
scroll, key, spacer and any shimming
present.
(9). Remove bolt, retaining ring and spring
washer from hub and shroud.
(10). Use non-metallic mallet on splined end
of shaft to drive impeller-end bearing,
seal, and portion of the shaft from hub.
Do not attempt to remove sleeves from
hub. Sleeves are line-reamed. If either
sleeve is defective, hub must be re
placed. Remove inner retaining ring
from hub. Remove and discard O-ring
in upper sleeve if installed.
(11). If necessary, use pulling device to
extract bearing and seal from shaft.
(12). If remaining bearing cannot be driven
from hub by tapping outer race from
inside with nonferrous tube and mallet,
re-insert shaft into bearing, drive
bearing out and remove it from shaft as
described in steps (10). and (11). above.
(13). Discard bearings. They are not to be
re-used.
Page 806
Revision 37
63-21-00
4. 600N5630 Cooling Blower Reassembly

(Ref. Figure 802)
Item
Nomenclature
CM116
CM219
CM220
CM222
CM321
CM425
CM431

Methyl-ethyl-ketone
Naphtha aliphatic
Sealing compound
NOTE: Following procedure covers assembly of

completely disassembled cooling blower, to
gether with those items (belt, brackets, etc)
that form a complete unit. Use only applica
ble steps of procedure when disassembly is
less than complete. New bearings and new
seal are required; those removed are not to
be reused.
(1). Install inner retaining ring in hub and
if removed at disassembly install new
O-ring in upper bearing sleeve.
(2). Lightly grease (CM116) smaller bearing
journal of shaft, and bore of correspond
ing bearing.
NOTE: This bearing does not have a metal

shield.
(3). Place bearing on shaft so that rubber
seal of bearing faces splined end of
shaft.
(4). Using tube that contacts only edge of
inner race of bearing, arbor-press
bearing onto journal until inner race
contacts shaft shoulder.
(5). Clean outer race of both bearings and
faying surfaces of both hub sleeves with
trichloroethane (CM222) and clean
cloth or paper towel.
(6). Arbor-press bearing (with shaft
installed) into sleeve. Exert pressure
only on bearing outer race and on
impeller-end of hub casting (no
pressure on impeller-end sleeve).
MAINTENANCE MANUAL
(7). Lightly grease (CM116) larger bearing
journal of shaft and bore of remaining
bearing.
Apply locking compound
(CM431) to outer race of lower
bearing (impeller end) only. Do not apply
locking compound to upper bearing (pulley
end).
CAUTION
(8). Apply primer (CM321) and locking

compound (CM431) to faying surfaces of
outer bearing race and sleeve according
to container instructions. Be careful to
prevent compounds from entering
bearing.
(9). Insert bearing so that shield side (metal
disc) faces interior of hub and seal side
(rubber disc) faces impeller end of shaft.
(10). Arbor-press bearing simultaneously
onto shaft journal and into sleeve.
Exert pressure equally on both races of
bearing. At same time, exert equal
pressure on splined end of shaft and
pulley end of hub casting. Bearing is to
firmly contact shaft shoulder and inner
retaining ring.

(11). Wipe away excess locking compound.
Use methyl ethyl keytone (CM219) if
hardening begins. Leave assembled
parts undisturbed to permit locking
compound to cure for two hours at
75-100F (24-38C), or for ten
minutes at 220 l0F (105 5C).
CSP-HMI-2
(15). Install shim on scroll.

(16). Install hub and shroud on scroll with
six screws, eight washers and two nuts.
Torque screws to 12 - 15 inch-pounds
(1.36 - 1.69 Nm).
port, measure for 0.020 inch (0.508 mm)
minimum gap between impeller and
scroll.
(18). Check for proper thread protrusion of
six screws through nutplates and nuts
on inside of scroll.
(19). Install spacer and impeller on shaft.
(20). Install washer and locknut on end of
shaft. Using holding device on splined
end of shaft, tighten locknut sufficiently
to remove all end clearance from
stack-up of parts.
port, measure minimum clearance
between impeller and scroll lip.
NOTE: If minimum clearance is 0.020-0.030

inch (0.508-0.762 mm), steps (19). and (20).
below may be bypassed.
(22). If clearance is more than 0.030 inch
(0.762 mm), remove impeller and
spacer. Replace spacer with 369H5654
shims as required between impeller and
seal to obtain 0.020-0.030 inch
(0.508-0.762 mm) clearance. Reinstall
impeller, washer and locknut. Tighten
to remove all end clearance, and then
rotate impeller and check for rubbing. If
rubbing occurs, perform step (20).,
otherwise proceed to step (21)..
(13). Install new seal, spring washer and

outer retaining ring.

(0.508 mm), or if rubbing occurs when
performing previous step, disassemble
and install shim(s) between seal and
spacer to ensure 0.020-0.030 inch
(0.508-0.762 mm) minimum clearance
and prevent rubbing.
(14). Fill hub cavity with grease (CM116)

through lubrication fitting until grease
seeps out around seal of bearing
nearest splined end of shaft. After
lubrication, remove lubrication fitting
and install screw and washer. Lockwire
screwhead.
(24). When clearance is properly adjusted,

remove impeller, install key, impeller,
washer and locknut. Torque locknut to
250 - 300 inch-pounds (28.25 - 33.90
Nm). Use care to avoid placing stress
on impeller or scroll. Hold splined end
of shaft in suitable device.
(12). Temporarily install lubrication fitting.
NOTE: Install seal with small diameter gap in

rings facing outside of hub.
63-21-00
Page 807
Revision 37
MAINTENANCE MANUAL
CSP-HMI-2
(25). (Ref. Figure 406) Secure fan mounting

bracket on hub with two self-locking
bolts, two screws and four washers.
Before tightening bolts, fully displace
bracket in direction that causes it to be
closest to main transmission drive shaft
when cooling blower is installed, then
torque bolts to 50 - 70 inch-pounds
(5.65 - 7.91 Nm) and screws to 65 - 75
inch-pounds (7.34 - 8.47 Nm). Apply
slippage mark paint.
(26). (Ref. Figure 406) Install spacer, washer,
pulley, washer and nut on shaft. Hold
nut on impeller end of shaft with socket
wrench and tighten pulley nut to 160 190 inch-pounds (18.08 - 21.47 Nm)
plus drag torque.
(27). (Ref. Figure 406) Install belt on pulley
and secure mounting bracket to fan
mounting bracket with four bolts and
washers. Before tightening bolts, fully
displace bracket in direction that
causes it to be closest to main transmis
sion drive shaft when cooling blower is
installed, then torque bolts to 65 - 75
lockwire drilled heads.
(28). Clean faying surfaces of scroll and
cover with naphtha (CM220); apply
sealant (CM425) according to container
instructions before securing cover to
scroll with eight screws and washers.
5. Cooling Blower Cleaning (Disassembled)
Item
Nomenclature
CM234
(1). Clean all usable metal parts with

solvent spray (CM234). Remove
remnants of locking compound with
loctite remover (CM216).
Page 808
Revision 36
63-21-00
6. Transmission and Cooling Blower Drain

Tube Repair and Replacement
Item
CM702
CM717
Nomenclature
Lockwire CRES
(1). Disconnect drain tubes from transmis

sion cooling blower, and from drain
fittings and weld assemblies at firewall.
Release supporting nylon straps and
remove drain tubes (Ref. Figure 601).
(2). Inspect drain tubes, drain fittings, weld
assemblies and connectors for damage
and clear passage.
(3). Repair damaged flexible drain tubes
with tape (CM716).
(4). Install drain tubes as follows:
(a). Attach upper ends of drain tubes to
transmission and cooling blower.
Secure with double wraps of lockwire
(CM702).
(b). Route drain tubes and secure with
nylon straps. Position tubes so that
no drainage traps are formed.
(c). Secure lower ends of drain tubes to
fittings and weld assemblies with
double wraps lockwire (CM702).
(d). Insert lower end of metal drain tube
through grommet in skin and slip
upper end of tube into weld assembly.
Wrap tube with one layer of 1 inch
(2.54 cm) wide tape (CM717) at
clamp-attach point, and install
clamp.
7. Installation of Heating System and Oil
Cooling Line Standoff Clamps (0003D
0539D)
(Ref. Figure 803) The following information
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
oil cooling lines and chafing of the oil cooling
lines by the heating system hose. A protective
bushing is also installed to prevent chafing
between the oil cooling lines.
MAINTENANCE MANUAL
(1). Remove aft compartment interior trim
panels and left Sta. 124.00 bulkhead
access door to gain access to work area.
NOTE: Inspect the 369D292490 heating sys

tem hose and 369D25709 and 369D25710
main transmission oil cooling lines for evi
dence of chafing, kinking or damage at area
of L/H aft section channel assembly.
(2). If not already installed, install
NAS1713D30N clamp on heating
system hose and NAS1713D8N clamp
on 369D25710 oil cooling line. Connect
clamps with screw, washer and nut.
(3). If not already installed, install new
C-SB-16-8 bushing snug against nut
on 369D25709 oil cooling tube assembly
(View A-A). Reposition clamp assembly
securing 369D25709 (lower) and
369D25710 (upper) oil cooling tube
assemblies to accommodate installation
of bushing.
CSP-HMI-2
(4). Check installation of standoff clamps to

ensure adequate clearance between
369D25709 and 369D25710 oil cooling
lines and between oil cooling lines and
369D292490 heating system hose.
NOTE:
D Later Model 369D helicopters have
369D26544-3 closure plate (with grom
met) installed on L/H aft section channel.
Remove plate from channel, if presently
installed, to preclude interference with oil
cooling lines.
D Later model 500D helicopters have
HS4194-6 standoff bracket installed on
channel with MS21919DG30 clamp to se
cure heating hose. Install standoff brack
et and clamp, if not presently installed on
helicopter.
(5). Reinstall bulkhead access door and
interior trim panels.
63-21-00
Page 809
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2
CLAMP ASSY
(RELOCATED)
369D25710 OIL COOLING

TUBE ASSY
369D26544-3 CLOSURE PLATE

(REMOVE IF PRESENTLY INSTALLED
ON AFT SECTION CHANNEL)
(ROTATED)
VIEW

TUBE ASSY
C-5B-16-8 BUSHING
(NOTE 3)
A-A

TUBE ASSY (REF)
HS4194-6 STANDOFF (NOTE 1)

MS20470AD3 RIVET (2)
C-5B-16-8 BUSHING
TUBE ASSY
NAS1713D8N CLAMP (NOTE 2)
NAS1096-7 SCREW
MS21043-3 NUT
369D23024 AFT SECTION

CHANNEL ASSY
(CANT. STA. 124.00)
A
MS21919DG30 CLAMP (NOTE 1)
NAS1096-3-7 SCREW
AN960PD10L WASHER

TUBE ASSY
NAS1713D8N CLAMP (EXISTING)
AN743-12 BRACKET
NAS1096-3-7 SCREW (2)
MS21043-3 NUT (3)
NAS1713D30N CLAMP
(EXISTING)
369D292490 HEATING HOSE
NAS1713D30N CLAMP
(NOTE 2)
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
Revision 22
63-21-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
632200
Rotor Brake
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
ROTOR BRAKE
When working with hydrau
WARNING lic systems, special care

must be taken to prevent entrance of
dust, moisture or other foreign materi
al. System contamination can cause
malfunctions which could cause injury
to personnel or equipment damage.
1. Rotor Brake
The rotor brake enables the pilot to manually
brake the rotor system to a stop by operating a
single brake handle. The handle is installed on
the upper left (or upper right, depending on
helicopter seating configuration) side of the
canted bulkhead 78.50 control tunnel in the
pilot's compartment. Operation of the brake
handle actuates a master cylinder, causing
dual pucks to grip a brake disc installed on the
tail rotor drive shaft. Braking force is trans
mitted through the main transmission to the
main rotor. A friction clip secures the handle in
an out-of-the-way position when the brake is
not in use.
The rotor brake installation includes:
pressure is produced; this pressure is trans

mitted through the tubing to the caliper
assembly where it acts on the pistons. This
causes the pucks to apply clamping pressure
(braking force) to the brake disc. System
pressure is held within safe limits, regardless
of the force applied to the brake handle, by
operation of the pressure-relief valve. When
hydraulic pressure exceeds 500 psig (3447
kPa), the pressure-relief valve opens, venting
excess pressure back to the master cylinder.
When application of force is discontinued,
caliper pistons (and the pucks) are retracted
by return springs in the caliper assembly.
Puck-to-disc clearance is maintained by
action of a self-adjusting mechanism in the
caliper assembly. The original equipment
tachometer generator is replaced by a new unit
that is included in the rotor brake installation
to provide clearance between the tachometer
generator and the brake disc. The original
equipment electrical connector (P202),
installed on the aft fuselage wiring harness
near the main transmission, is replaced with a
new plug which mates with the receptacle on
the new tachometer generator.
(1). A master cylinder with an actuating

handle mechanism (master cylinder
and linkage assembly).
3. Rotor Brake Troubleshooting Procedure
(2). A caliper assembly with dual opposing

pistons to which friction pads (brake
pucks) are attached.
4. Master Cylinder Servicing
(3). A brake disc installed on the tail rotor

drive shaft coupling at the aft end of
the main transmission.
(4). A hydraulic pressure relief valve.
(5). A tachometer generator.
(6). Six stainless steel hydraulic tubing
assemblies and associated fittings.
(7). Attaching and mounting hardware.
(8). A trim panel assembly and installation.
2. Rotor Brake Operation
When manual force is applied to the brake
handle (master cylinder piston), hydraulic
(Ref. Table 201)
(Ref. Figure 401)
Item
CM123
Nomenclature
Hydraulic fluid
Rotor brake installation servicing includes

adding hydraulic fluid (CM123) to the master
cylinder reservoir, and bleeding air from the
system.
(1). Remove interior trim to gain access to
master cylinder.
(2). Disconnect tube assembly from forward
nipple and move end of tube assembly
carefully aside to permit removal of
master cylinder cap.
63-22-00
Page 201
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
(3). Remove attaching screws, cap with

assembled hydraulic parts, and gasket
from master cylinder. Replace gasket.
(4). Fill master cylinder reservoir with
clean hydraulic fluid (CM123) within
1/8 to 1/4 inch (3.175-6.35 mm) of the
top. Install cap with assembled hydrau
lic parts, new gasket, and attaching
screws. Do not tighten screws if
hydraulic system is to be bled.
(5). If hydraulic system has been opened,
e.g. as for replacement of components,
perform procedural steps to bleed the
hydraulic system.
NOTE: It is not necessary to bleed the system if

only a small amount of fluid is required to
fill the reservoir, and if the system has not
been opened.
(6). Tighten attaching screws to secure cap
on master cylinder. Connect tube
assembly to nipple.
(7). Reinstall components removed for
access to the master cylinder assembly.
5. Rotor Brake Hydraulic System Bleeding
Item
Nomenclature
CM123
Hydraulic fluid
The rotor brake hydraulic system must be bled

to remove entrapped air whenever the system
has been opened for any reason.
(1). Remove interior trim for access to the
master cylinder assembly and bleed
screws on caliper assembly (if applica
ble).
(2). Disconnect tube assembly from reducer
in relief valve and nipple in master
cylinder cap.
Page 202
Revision 20
63-22-00
NOTE: Hose material should be resistant to de

terioration from exposure to hydraulic fluid.
A glass container should be used to catch
bleed screw outflow so that bubbles of escap
ing air are clearly visible. The following fill
ing and bleeding procedure is best per
formed by two persons, one to operate the
brake handle, and one to open and close the
bleed screws.
(3). Connect a length of 1/4 inch (6.35 mm)
ID hose on reducer and insert free end
of hose in a container to catch any
hydraulic fluid that may be bypassed by
the relief valve. Connect a second
length of 1/4 inch (6.35 mm) ID hose on
one bleed screw on caliper assembly
and submerge free end of hose in clean
hydraulic fluid (CM123) in a glass
container.
(4). Remove attaching screws and master
cylinder cap. Fill reservoir with clean
hydraulic fluid (CM123) within 1/8 1/4 inch (3.175-6.35 mm) of top of
chamber. Replace cap, do not tighten
attaching screws.
NOTE: Verify that master cylinder reservoir is

kept full of fluid throughout the bleeding
process.
(5). Open one bleed screw and operate
brake handle slowly through a full
down stroke to force hydraulic fluid out
of master cylinder reservoir and into all
other parts of the system. Close bleed
screw and return handle to up
position. Remove cap, refill master
cylinder reservoir, and replace cap.
(6). Repeat step (5). several times to ensure
that entire hydraulic system is filled
with fluid, and that no air remains in
system.
NOTE: The presence of bubbles in the bleed

screw outlet flow indicates air is being
forced out of the system and absence of
bubbles indicates all air has been bled from
the system.
(7). Remove bleeder hose from first bleed
screw and connect it on second bleed
screw.
(8). Repeat steps (5). and (6). until bleed
screw outlet flow is clear of bubbles.
MAINTENANCE MANUAL
(9). Remove fluid catch containers and
hoses. Ensure both bleed screws are
tightly closed. Raise brake handle to
stowed position and engage in handle
retainer assembly. Verify that caliper
pistons (and attached brake pucks) are
retracted when handle is raised.
(10). Make final check of fluid level in
master cylinder reservoir and replen
ish, if necessary. Secure gasket and cap
with attaching screws.
(11). Connect tube assembly to nipple in cap
and to reducer in relief valve and
tighten tube nuts.
CSP-HMI-2
7. Master Cylinder Assembly Overhaul

(1). Remove defective master cylinder
assembly.
(2). Disassemble unit and replace defective
parts with components of overhaul kit
(Vendor PN 12-8310), using manufac
turer's instructions supplied with kit.
(3). Install overhauled master cylinder
assembly.
8. Caliper Assembly Overhaul
6. Rotor Brake Component Repair
(1). Remove defective caliper assembly.
The master cylinder assembly or caliper

assembly may be overhauled as necessary.
Overhaul kits are available from MD Helicop
ters Inc. or an approved MD Helicopter service
center. Other parts must be replaced when
damaged or otherwise unserviceable.
(2). Disassemble unit and replace defective

parts with components of overhaul kit
(Vendor PN 12-11780), using manufac
turer's instructions supplied with kit.
(3). Install overhauled caliper assembly.
63-22-00
Page 203
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Troubleshooting Rotor Brake Installation

Symptom
Isolating Step
Corrective Action
Brake actuating handle creeps

downward under sustained force,
with hydraulic fluid leakage from
master cylinder assembly.
Defective master cylinder assembly.
Remove defective master cylinder

assembly and replace with new unit,
or overhaul and reinstall old unit.
Brake actuating handle creeps

downward under sustained force,
with hydraulic fluid leakage from
caliper assembly.
Defective caliper assembly.
Remove defective caliper assembly

and replace with new unit, or
overhaul and reinstall old unit.
Spongy feel at brake actuating

handle when force is applied.
Air in hydraulic system.
Bleed air from hydraulic system.
Hydraulic fluid at low level in master

cylinder reservoir.
Add fluid to master cylinder

assembly and bleed air from
hydraulic system.
Any of above components or system

faults.
Follow applicable corrective action

procedures.
Brake pucks worn excessively.
Remove defective caliper assembly,

replace defective pucks and reinstall
repaired unit.
Brake pucks create noises, such

as squeals or squeaks, when
brakes are applied.
Glazed or worn brake pucks.
Remove defective caliper assembly,

replace defective pucks and reinstall
repaired unit.
Brake disc creates noises, such

as squeals or squeaks, when
brakes are applied.
Scored or damaged brake disc.
Remove defective brake disc and

replace with new disc.
Rotor brake system fails to slow

rotor effectively.
Page 204
Revision 20
63-22-00
MAINTENANCE MANUAL
CSP-HMI-2
ROTOR BRAKE

dust, moisture or other foreign materi
al. System contamination can cause
malfunctions which could cause injury
to personnel or equipment damage.
1. Rotor Brake Component Access
The following items must be removed to gain
access for removal of rotor brake components.
Removal should be limited to damaged or
defective parts for repair, overhaul or replace
ment, or to remove certain items for access to
other components.
The master cylinder assembly, linkage
assembly and hydraulic relief valve are
installed on or attached to the helicopter
structure. Removal of these components
require access from the crew compartment.
Hydraulic tube assembly is not attached to the
helicopter structure. Access from the passen
ger/cargo compartment is required for removal
of hydraulic tube assembly.
The caliper assembly and related hydraulic
items, caliper mounting bracket, tachometer
generator, brake disc and tail rotor drive
coupling are installed on the main transmis
sion. Removal of these components require
that certain access provisions be made and
that the main transmission, and attached rotor
brake components, be removed from the
aircraft.
NOTE: Component removal can be accom

plished with the doors in place. However, op
erations are facilitated with the doors re
moved.
(1). Remove both crew compartment and
cargo/passenger compartment doors.
(2). Remove crew compartment seats.
(3). Remove map case assembly from
forward side of canted bulkhead 78.50
structure. Remove both (LH and RH)
upper forward panel assemblies from
bulkhead structure. Remove conve
nience panel cover assembly from

convenience panel assembly.
(4). Disconnect electrical wiring and
communications cables from compo
nents on back of convenience panel
assembly. If cabin heating option is
installed on aircraft, disconnect heated
air duct from panel-mounted diffuser.
Remove attaching screws and conve
nience panel assembly from aft side of
canted bulkhead 78.50 structure.
(5). Remove transmission cover panel
assembly from fuselage structure.
(6). Cover exposed trim panels to prevent
damage and soiling.
(7). Remove main transmission from
aircraft (Ref. Sec. 63-20-00/25).
(8). Remove tail rotor (Ref. Sec. 64-20-00),
tail rotor transmission (Ref. Sec.
63-25-10) and tail rotor drive shaft
(Ref. Sec. 63-15-10).
2. Master Cylinder Assembly Replacement
A. Master Cylinder Assembly Removal
The master cylinder assembly is bolted to the
bracket of the master cylinder linkage assem
bly and is connected hydraulically to the
caliper assembly. Remove master cylinder
(1). Remove trim panels to gain access to
master cylinder.
(2). Disconnect tube assembly from nipple,
and tube assembly from elbow, taking
special care to catch any hydraulic fluid
that drains or drips from tube assem
blies or fittings when the system is
opened.
NOTE: If old master cylinder assembly is to be

reinstalled, removal of tube assembly, nip
ples, and elbow may not be necessary unless
the tube assembly or fittings are damaged
or defective.
63-22-00
Page 401
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
MAST SUPPORT PAN
WINDOW SUPPORT
CHANNEL ASSEMBLY
TEE
PRESSURE RELIEF
VALVE
VENT
MASTER CYLINDER
ACTUATING LINKAGE
LEFT-HAND INSTALLATION SHOWN; RIGHT-HAND OPPOSITE
Figure 401. AirframeMounted Rotor Brake Components

Page 402
Revision 20
63-22-00
G63-2003A
MAINTENANCE MANUAL
(3). Remove tube assembly from nipple.
Remove nipples from cap, and elbow
from master cylinder.
(4). Remove nuts, washers, bolts, stop, and
master cylinder assembly from bracket.
Drain residual hydraulic fluid from
(5). Install protective caps or plugs on open
ends of disconnected tube assemblies,
and open ports or fittings in master
cylinder assembly to prevent entry of
contaminants.
B. Master Cylinder Assembly Installation
Item
Nomenclature
CM434
Thread sealant
NOTE: Steps (1). thru (3). below apply only to

installation of a new master cylinder assem
bly.
(1). Remove attaching screws and vendorsupplied cap from master cylinder.
Vendor supplied cap is not used.
(2). Rework vendor-supplied gasket (Ref.
Figure 906).
(3). Replace reworked gasket and new cap
on master cylinder and secure with
attaching screws installed finger tight.
NOTE: Cap must be installed correctly with re

spect to taper of threaded holes.
(4). If new master cylinder assembly is
being installed, or if hydraulic fittings
have been removed from a usable unit,
coat all but first two tapered pipe
threads of nipples and elbow with
thread sealant (CM434). Install nipples
in cap and elbow in master cylinder.
(5). Place one washer and stop on bolts and
insert bolts through master cylinder.
Place two washers on each bolt as
spacers. Position assembled parts on
bracket (Ref. Figure 402) and install
one washer on each bolt. Install nuts
finger tight to hold master cylinder
assembly and stop in position.
CSP-HMI-2
NOTE: Mounting holes in bracket are elon

gated to enable lateral position adjustment
of master cylinder assembly.
(6). With actuating handle in stowed
position, adjust position of master
cylinder assembly so that clearance
(measured with a thickness gage)
between actuating lever (Ref.
Figure 905) and master cylinder piston
is 0.020-0.040 inch (0.508-1.016 mm).
(7). Install tube assembly on aft nipple.
Connect tube assembly to forward
nipple and connect tube assembly to
elbow.
(8). Fill and bleed the hydraulic system.
access to the master cylinder assembly.
3. Master Cylinder Linkage Assembly
Replacement
(Ref. Figure 402)
A. Master Cylinder Linkage Assembly
Removal
The bracket assembly of the master cylinder
linkage assembly is permanently installed on
the canted bulkhead Sta. 78.50 vertical
member by four Jo-bolt blind fasteners. Once
installed, the Jo-bolts cannot be removed
except by destructive procedures. The master
cylinder and linkage assembly may be disas
sembled, leaving the bracket assembly
attached to the structure. Disassembly should
be limited to that necessary for removal of
damaged or defective parts.
(1). Remove master cylinder.
When components are as
WARNING sembled, spring force is con

stantly exerted to inhibit inadvertent
brake application. Care must be exer
cised as the spring is disengaged to
prevent injury to personnel or equip
ment damage.
(2). Manually restrain movement of lever
and attached parts. Carefully disengage
end of spring from under head of clevis
pin. Release spring force carefully.
63-22-00
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Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
STOP
BRACKET
ASSY
NUT
BOLT
WASHER
ACTUATING LEVER
SPACER
GRIP
NUT
WASHER
PIN
COTTER PIN
HANDLE
ROLL PIN
COTTER PIN
SPRING
NUT
WASHER
FITTING
WASHER
CLEVIS PIN
G63-2006
Figure 402. Master Cylinder Linkage Assembly

(3). Remove cotter pin, nut, washer, spring,
and lever with assembled handle parts
from pin.
(4). Remove cotter pin, washers, and clevis
pin, and separate assembled handle
parts from lever. Remove nut, spacer,
and bolt from lever.
(5). Drive two spring pins out of fitting and
handle and separate parts. Remove grip
from handle.
(6). Remove nut and washer from pin, and
remove pin from bracket assembly.
Page 404
Revision 20
63-22-00
B. Master Cylinder Linkage Assembly

Installation
Installation of the master cylinder linkage
assembly will be limited to re-assembly of
components to the bracket assembly.
When the unit is assembled,
WARNING the spring is under restraint

and, if accidentally or inadvertently re
leased, could cause injury to personnel
or equipment damage.
(1). Re-assembly procedures are essentially
the reverse of disassembly procedures,
with special care being given to steps
involving spring.
MAINTENANCE MANUAL
(2). If cotter pins or spring pins have been
removed, use new parts for reassembly.
4. Caliper Assembly, Brake Disc, and Drive
Coupling Replacement (369D25100
Transmission)
(Ref. Figure 403)
A. Caliper Assembly, Brake Disc, and Drive
Coupling Removal (369D25100
Transmission)
The caliper assembly is bolted to a mounting
bracket which is installed on the main
transmission tail rotor cover. The brake disc is
bolted on the drive coupling which is installed
on the transmission output shaft. For clarity,
the brake disc and drive coupling are consid
ered as a single item (disc/coupling unit).
Although the caliper assembly and the
disc/coupling unit are not mechanically
connected, they are installed on the transmis
sion with the outer portion of the disc posi
tioned between the two halves of the caliper
assembly (Ref. Figure 404). This arrangement
makes it necessary to remove both units
(partially, at least) at the same time. Removal
operations require that the main transmission
be removed from the aircraft with the rotor
brake components installed. Proceed as
follows:
(1). Remove main transmission and
attached rotor brake components from
(2). Disconnect tube assembly from caliper
mounted tees. Remove tube assembly
and interconnect tee as a unit.
NOTE:
D It is not necessary to disconnect tube as
semblies from tee except for replacement
of defective and damaged parts.
D New bleed screws are included with the
new caliper assembly.
(3). If caliper assembly is to be replaced by
a new unit, remove two bleed screws
from adapters, remove adapters from
tees, and remove tees from caliper
assembly.
CSP-HMI-2
NOTE: If old caliper assembly is to be rein

stalled, it is not necessary to remove hy
draulic fittings except for replacement of de
fective or damaged parts.
(4). Remove coupling bolt that is used to
secure drive coupling on transmission
output shaft so that disc/coupling unit
is free to slide on shaft splines.
(5). Note and record, for re-assembly
reference, placement of 18 washers
used as spacers between caliper
assembly and mounting bracket, or
under heads of attaching bolts.
The caliper assembly consists of
two identical halves held togeth
er by the attaching bolts. Care should be
used to avoid dropping parts when bolts are
removed.
CAUTION
(6). Hold caliper assembly and unscrew

attaching bolts out of mounting brack
et. Slide disc/coupling unit away from
transmission and remove caliper
assembly and attaching hardware.
(7). If caliper assembly is to be reused and
some time will elapse before re-assemb
ly, remove disc/coupling unit, position
caliper assembly (and assembled parts)
on mounting bracket and screw bolts
into bracket to hold parts until time for
re-assembly.
(8). If disc/coupling unit is to be reinstalled,
and some time will elapse before
re-assembly, slide unit back on trans
mission shaft and install coupling bolt
finger tight to hold parts until time for
re-assembly.
Axial position of the drive
WARNING coupling is critical as it con
trols the mechanical interface between

the coupling and the tail rotor drive
shaft. Out-of-tolerance axial coupling
loads can contribute to coupling fail
ure which could result in injury to per
sonnel and equipment damage. Refer
to Sec. 63-10-00 for coupling reinstalla
tion.
63-22-00
Page 405
Revision 20
CSP-HMI-2
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. TransmissionMounted Rotor Brake Components

Page 406
Revision 20
63-22-00
MAINTENANCE MANUAL
(9). If either disc or coupling is to be
replaced by a new part, slide disc/coup
ling unit off shaft, leaving shim wash
ers in place. Remove nuts, washers, and
bolts and separate disc and coupling. If
coupling is being replaced, measure
(and record for re-assembly reference)
overall length of old coupling at three
separate peripheral locations. Calculate
and record the average value.
B. Caliper Assembly, Brake Disc and Drive
Coupling Installation (369D25100
Transmission)
Item
Nomenclature
CM112
CM117
Grease
CM202
CM434
Thread sealant
CM702
Lockwire CRES
(1). Position brake disc on drive coupling

with raised center side of disc seated
firmly on shoulder of coupling, and with
bolt holes aligned. Insert four bolts
through disc and coupling flange,
install washers and nuts on bolts, and
torque nuts (in an alternating se
quence) to 100 - 140 inch-pounds
(11.30 - 15.82 Nm).
The main transmission must
WARNING be installed in the aircraft
with special care to avoid damage to

rotor brake components. Installation
damage could lead to system failure
which could result in injury to person
nel and equipment damage.
(2). Install transmission in aircraft (Ref.
Sec. 63-20-00/25).
(3). Determine correct shimming for
coupling (Ref. Sec. 63-10-00).
CSP-HMI-2
Molykote metal protector
WARNING contains perchloroethylene.

It should be used in a well-ventilated
area, and the precautions normally fol
lowed when working with the chlori
nated solvent should be implemented.
Solvents used to dilute this material, as
well as metal-cleaning or alkali cleans
ers, should only be used with adequate
ventilation. Follow handling precau
tions on the solvent's container label.
NOTE: Couplings should be treated with moly

kote metal protector (CM202) after each
washing with any solvent or detergent.
(4). Spray molykote metal protector
(CM202) on the interior and exterior
surfaces of Bendix coupling diaphragm
packs. Spray or dip flange in molykote
metal protector. Eliminate excess liquid
by gently blowing with compressed air
(dilute to 10% perchloroethylene). Cure
for 8 hours at room temperature, or 15
minutes at 150F (65C).
(5). Coat, completely but sparingly, splines
of transmission output shaft with
grease (CM117) and threads of coupling
bolt with anti-seize compound
(CM112), or equivalent. Start disc/coup
ling unit on shaft.
To ensure optimum brake opera
tion and minimize equipment
damage, caliper-to-disc clearances on both
sides of disc should be equal, or as nearly
equal as possible. Clearance adjustment is
accomplished by varying number of shim
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
as shims should be placed under bolt heads.
Washer distribution should be the same for
both bolts.
CAUTION
(6). Hold assembled parts with caliper

assembly over edge of disc, slide
disc/coupling unit on shaft, and move
caliper assembly against mounting
bracket at the same time. Screw bolts
into bracket to hold caliper assembly
firmly in position. Screw coupling bolt
into shaft to secure disc/coupling unit.
63-22-00
Page 407
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
DISC
CALIPER
CALIPER
MOUNTING
BRACKET
SHIM WASHERS
CALIPER
ASSEMBLY
BRAKE DISC/BRAKE
PUCK CLEARANCES
NOTE

(KAMATIC)
TAIL ROTOR
DRIVE SHAFT
(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)
MAIN TRANSMISSION
LOCKWIRE
BOL
T
LOCKWIRE
BOL
T
SPECIAL NUT
CALIPER MOUNTING
BRACKET
DRIVE COUPLING
G63-2011
Figure 405. Lockwire Installation (369D25100 Transmission)

Page 408
Revision 20
63-22-00
MAINTENANCE MANUAL
(7). Measure brake caliper housing-to-disc
clearances on both sides of disc with a
thickness gage. If clearances are equal
within 0.032 inch (0.8128 mm), torque
attaching bolts to 160 - 190 inchpounds (18.0821.47 Nm) and secure
with corrosion-resistant lockwire
(CM702) (Ref. Figure 405). Torque
coupling bolt per Section 63-10-00.
NOTE: Clearance differences greater than

0.032 inch (0.8128 mm) can be reduced by
rearranging washers on caliper attaching
bolts.
(8). To adjust clearances, hold caliper
assembly and unscrew bolts from
mounting bracket. Transpose washers
on bolts as required. Reassemble parts,
and recheck clearances.
(9). If new caliper assembly was installed or
if hydraulic fittings were removed from
old unit, coat all but first two threads of
two bleed screws, tees, and plugs with
thread sealant (CM434) or equivalent.
Install plugs and tees in caliper
assembly, screw adapters on tees, and
install bleed screws in adapters.
(10). Connect tube assemblies and tee unit to
tees.
5. Caliper Mounting Bracket Replacement
(Ref. Figure 403)
A. Caliper Mounting Bracket Removal
The caliper mounting bracket is attached to
the main transmission tail rotor cover by
special nuts installed on four of the studs used
for installation of the cover. The caliper
assembly is bolted to the mounting bracket.
Bracket removal requires that the main
transmission be removed from the aircraft
with the rotor brake components installed.
(1). Remove main transmission (and
attached rotor brake components) from
(2). Remove attaching nuts and washers,
and remove mounting bracket from
studs.
CSP-HMI-2
NOTE: It is not necessary to remove washers

used as spacers except for replacement.
Nuts may be replaced on studs until time for
re-assembly to prevent loss of parts.
B. Caliper Mounting Bracket Installation
The following procedures assume that the
transmission has been removed from the
aircraft for removal of the mounting bracket.
Item
CM702
Nomenclature
Lockwire CRES
(1). Place three washers on each of the four

mounting studs (1, 2, 10, and 11 o'clock
positions) as spacers. Position mounting
bracket on studs, install washers and
nuts, and torque nuts to 50 - 75
(2). Secure installation with lockwire
(CM702) (Ref. Figure 405).
(3). Reinstall transmission as required (Ref.
Sec. 63-20-00/25).
6. Caliper Assembly, Brake Disc, and Drive
Coupling Replacement (369F5100
Transmission)
(Ref. Figure 406)
A. Caliper Assembly, Brake Disc, and Drive
Coupling Removal (369F5100
Transmission)
The caliper assembly is bolted to the main
transmission anti-torque cover. The brake disc
is bolted on the drive coupling which is
installed on the transmission output shaft. For
clarity, the brake disc and drive coupling are
considered as a single item (disc/coupling
unit). Although the caliper assembly and the
assembly. This arrangement makes it neces
sary to remove both units (partially, at least)
at the same time. Removal operations require
that the main transmission be removed from
the aircraft with the rotor brake components
installed.
63-22-00
Page 409
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
(1). Remove main transmission (and

attached rotor brake components) from
aircraft (Ref. Sec. 63-25).
(2). Disconnect tube assembly from caliper
mounted tees. Remove tube assembly
and interconnect tee as a unit.
(8). If disc/coupling unit is to be reinstalled,

and some time will elapse before
re-assembly, slide unit back on trans
mission shaft and install coupling bolt
finger tight to hold parts until time for
re-assembly.
Axial position of the drive
NOTE: It is not necessary to disconnect tube
WARNING coupling is critical as it con
assemblies from tee except for replacement

of defective and damaged parts.
trols the mechanical interface between

the coupling and the tail rotor drive
shaft. Out-of-tolerance axial coupling
loads can contribute to coupling fail
ure which could result in injury to per
sonnel and equipment damage. Refer
to Sec. 63-15 for coupling reinstalla
tion.
(3). If caliper assembly is to be replaced by

a new unit, remove two bleed screws
from adapters, remove adapters from
tees, and remove tees from caliper
assembly.
NOTE: If old caliper assembly is to be rein

stalled, it is not necessary to remove hy
draulic fittings except for replacement of de
fective or damaged parts.
(9). If either disc or coupling is to be

replaced by a new part, proceed as
follows:
(a). Slide disc/coupling unit off shaft,
leaving shim washers in place.
(4). Remove coupling bolt that is used to

secure drive coupling on transmission
output shaft so that disc/coupling unit
is free to slide on shaft splines.
(b). Remove nuts, washers, and bolts and

separate disc and coupling.
(5). Note and record, for re-assembly

reference, placement of 18 washers
used as spacers between caliper
assembly and mounting bracket, or
under heads of attaching bolts.
The caliper assembly consists of
two identical halves held togeth
er by the attaching bolts. Care should be
used to avoid dropping parts when bolts are
removed.
(c). If coupling is being replaced, mea

sure (and record for re-assembly
reference) overall length of old
coupling at three separate peripheral
locations.
CAUTION
(6). Hold caliper assembly and unscrew

attaching bolts. Slide disc/coupling unit
away from transmission and remove
caliper assembly and attaching hard
ware.
(7). If caliper assembly is to be reused and
some time will elapse before re-assemb
ly, remove disc/coupling unit, position
caliper assembly (and assembled parts)
on transmission and insert bolts to hold
parts until time for re-assembly.
NOTE: New bleed screws are included with the

new caliper assembly.
Page 410
Revision 20
63-22-00
(d). Calculate and record the average

value.
B. Caliper Assembly, Brake Disc and Drive
Coupling Installation (369F5100
Transmission)
The following procedure is for installation of
the rotor brake caliper assembly. The caliper
assembly should be installed on the transmis
sion before the transmission is installed in the
helicopter.
Item
Nomenclature
CM434
Thread sealant
CM702
Lockwire CRES
MAINTENANCE MANUAL
CALIPER MOUNTING BOSS

ON TRANSMISSION
CSP-HMI-2
AN960-616LL
WASHER
(NOTE 1)
AN960-616LL
WASHER
(NOTE 1)
HS4620C19-29
BUSHING
NAS6606H52
BOLT
(NOTE 3)
CALIPER
ASSEMBLY
DISC
DISC
CALIPER
NOTES:
1. CLEARANCE TO BE ADJUSTED BY VARYING WASHERS FROM EITHER SIDE
OF CALIPER ASSEMBLY.
2. CLEARANCE TO BE EQUAL WITHIN 0.032 IN. (0.8128 MM).
3. TORQUE TO 160 - 190 INCH POUNDS (18.08 - 21.47 NM) AND SAFETY WITH
LOCKWIRE (CM702).
CALIPER
NOTE 2
CSP102-010A
Figure 406. Rotor Brake Caliper Installation (369F5100 Transmission)
63-22-00
Page 411
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
NOTE:
D AN960-616LL washers are to be used for
adjusting caliper-to-disc clearance.
D Nine washers are used on each attaching
bolt; those not used as shims should be
placed under bolt heads. Washer distribu
tion should be the same for both bolts.
(5). Install plugs and tees in caliper

assembly, screw adapters on tees and
install bleed screws in adapters.
(6). Connect tube assemblies and tee units
to tees.
7. Hydraulic Relief Valve Replacement
(Ref. Figure 401)
(1). Insert two bolts with equal number of

washers through the caliper (washers
can be on either side of caliper as
needed) and install two bushings.
NOTE: On the 369F5100 transmission, the

brake caliper bolts directly to the transmis
sion.
(2). Mount the caliper assembly over disc
and thread bolts into transmission.
A. Hydraulic Relief Valve Removal

The hydraulic relief valve is attached by
means of a clamp to the canted bulkhead 78.50
vertical member, and is connected hydraulical
ly between the master cylinder assembly and
the caliper assembly. Remove the relief valve
as follows:
(1). Remove crew compartment hardware
and fittings for access to hydraulic
relief valve assembly.
To ensure optimum brake opera

tion and minimize equipment
damage, caliper-to-disc clearances on both
sides of disc should be equal, or as nearly
equal as possible. Clearance adjustment is
accomplished by varying number of 0.032
inch (0.8128 mm) thick shim washers placed
between the caliper assembly and transmis
sion.
(2). Disconnect tube assembly from reducer

installed in relief valve. Disconnect
tube assembly from relief valve, taking
special care to catch any hydraulic fluid
that drains or drips from tube assem
blies, reducer, or relief valve when the
system is opened. Remove reducer and
O-ring packing from relief valve.
Discard O-ring packing.
(3). Measure brake caliper housing-to-disc

clearances on both sides of disc with a
feeler gage. If clearances are equal
within 0.032 inch (0.8128 mm), torque
attaching bolts to 160 - 190 inchpounds (18.08 - 21.47 Nm) and secure
with lockwire (CM702).
NOTE: Because of limited access, it may be
CAUTION
NOTE: Clearance differences greater than

0.032 inch (0.8128 mm) can be reduced by
re-arranging washers on caliper attach
bolts.
(4). To adjust clearances, hold caliper
assembly and unscrew bolts from
mounting bracket. Transpose washers
on bolts as required. Reassemble parts
and recheck clearances.
NOTE: If new caliper assembly was installed or

if hydraulic fittings were removed from old
unit, coat all but first two threads of two
bleed screws, tees and plugs with thread
sealant (CM434) or equivalent.
Page 412
Revision 20
63-22-00
more convenient to disconnect tube assem

bly from tee before removing tube assembly
from relief valve. If so, remove tube assem
bly from tee; remove relief valve and tube
assembly from helicopter; and remove tube
from relief valve. Reinstall tube assembly on
tee finger tight for storage until required for
replacement of relief valve.
(3). Remove screw, washer, and clamp, and
remove relief valve from canted bulk
head 78.50 structure.
(4). Install protective caps or plugs on open
relief valve ports and open ends of
disconnected tube assembly to prevent
entrance of contaminants.
B. Hydraulic Relief Valve Installation
Installation procedures are essentially the
reverse of removal procedures, with these
special considerations:
(1). Install new O-ring packing on reducer.
MAINTENANCE MANUAL
(2). After relief valve is installed and
connected into the hydraulic system, fill
and bleed the system.
access to the hydraulic relief valve.
8. Hydraulic Tube Assembly Replacement
(Ref. Figure 904)
A. Hydraulic Tube Assembly Removal
The hydraulic tube assembly is attached to the
main rotor mast pan and to the window
channel by four clamps. It is connected
between tees. The assembly removal requires
access from the cargo/passenger compartment.
(1). Remove attaching screws and both (LH
and RH) upper forward trim panel
assemblies. Remove convenience panel
cover assembly. Remove attaching
screws and transmission cover panel
assembly.
(2). Disconnect tube assembly from tees,
taking special care to catch any hydrau
lic fluid that drains or drips from tube
assembly or tees when system is
opened.
(3). Remove (and discard) grommet from
tube assembly and air baffle.
(4). Remove nuts, washers, screws, clamps,
and tube assembly.
(5). If some time is to elapse before re-as
sembly, install protective caps on open
ends of tees to prevent entrance of
contaminants.
CSP-HMI-2
B. Hydraulic Tube Assembly Installation

Tube assembly installation is essentially the
reverse of removal procedures, with these
specific considerations.
Item
CM418
Nomenclature
Cement, epoxy
(1). Make a straight radial cut into center

hole of new grommet and install
grommet on tube assembly. Position
parts and bond grommet into slot in air
baffle with epoxy cement (CM418).
(2). Fill and bleed the hydraulic system.
access to the hydraulic tube assembly.
9. Rotor Brake Forward Cover Assembly
Installation
(Ref. Figure 908)
(1). Position cover assembly on map case
assembly with rotor brake handle and
handle retaining clip through cover
openings. Aft edge of cover must
overlap forward edge of convenience
panel cover assembly. Install attaching
screw through cover assembly and map
case panel into isolation mount on
(2). On the 369D, secure cover assembly
and doublers to angle assembly with
attaching screw. On the 369E/FF,
secure cover assembly to convenience
panel, using shims and attaching
screws.
63-22-00
Page 413
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
Page 414
Revision 44
63-22-00
MAINTENANCE MANUAL
CSP-HMI-2
ROTOR BRAKE
INSPECTION/CHECK

dust, moisture. and other foreign mate
rial. System contamination can cause
malfunctions that could result in inju
ry to personnel and equipment dam
age.
1. Rotor Brake Assembly Inspection
Item
Nomenclature
CM123
Hydraulic fluid
(1). Visually inspect rotor brake compo

nents for general condition, security of
installation, and evidence of hydraulic
fluid leakage.
NOTE: Excessively low fluid level indicates a

system fault that must be isolated and cor
rected.
(2). Disconnect tube assembly (Ref.
Figure 902) from nipple installed in
master cylinder cap. Move end of tube
assembly carefully aside, remove
attaching screws and cap with gasket,
and check that hydraulic fluid level is
1/8 - 1/4 inch (3.175-6.35 mm) from top
of reservoir. If level is low, add hydrau
lic fluid (CM123). Take special care to
avoid getting contaminants into the
hydraulic system.
(3). Visually inspect gasket for tears, cuts,
or other damage; replace gasket, if
defective. Visually inspect sealing
surfaces of cap and master cylinder
body for nicks, cracks, scratches, or
other defects; repair minor damage or
replace defective parts.
(4). Replace cap and gasket on master
cylinder and secure with attaching
screws. Connect tube assembly to
nipple and tighten tube nut securely.
(5). Verify that clip (Ref. Figure 901) on

handle retainer assembly holds brake
handle securely in the stowed (raised)
position.
(6). Actuate brake handle to check that
components of master cylinder linkage
assembly (Ref. Figure 402) operate
freely without binding or excessive play
at pivot points. Verify that spring force
holds lever in BRAKE OFF position.
(7). Visually inspect friction surfaces of
brake disc (Ref. Figure 403) for exces
sive wear, galling, scoring, cracking,
distortion, or other evidence of damage.
(8). Rotate the drive system and check that
caliper brake pucks are not dragging on
the disc.
(9). Apply sufficient force on brake handle
to actuate master cylinder assembly to
pressurize hydraulic system.
NOTE: System pressurization (brake actua

tion) is indicated by the feel of firm resis
tance to handle movement. A cushioned
(spongy) feel indicates that the system con
tains air which must be removed (bled off)
before proceeding with the inspection.
(10). Maintain force on brake handle and
verify that pistons in caliper assembly
operate to force brake pucks against
friction surfaces of brake disc. Visually
inspect brake pucks for extent of wear
and evidence of damage.
Do not apply a side load to brake
handle as damage to support
bracketry may result.
CAUTION
NOTE: Pucks must be extended to the BRAKE

ON position to permit adequate inspection.
If parting line between piston face and puck
is visible, puck is worn excessively and must
be replaced.
(11). Monitor feel of resistance and increase
force applied to brake handle until
hydraulic relief valve opens.
63-22-00
Page 601
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
NOTE: When working properly, the hydraulic

relief valve opens and routes pressurized
hydraulic fluid back to the master cylinder
reservoir when system pressure reaches 500
psig (3447 kPa). Valve opening can be de
tected by a momentary decrease of resis
tance to handle movement. If movement is
solidly resisted, regardless of force applied,
the relief valve is defective and must be re
placed.
(12). Maintain steady force (just short of that
required to initiate relief valve opening)
on brake handle and observe handle
movement. Check that actuating lever
spacer and master cylinder stop do not
contact.
Check for installation of master
cylinder stop to prevent over
travel of piston in master cylinder. If stop is
not installed, damage to master cylinder
components may occur.
CAUTION
NOTE: Continued handle movement indicates

the presence of an internal leak condition
which must be located and corrected.
(13). Release force on brake handle and
verify that caliper pistons (and attached
brake pucks) are retracted.
NOTE: Failure of pistons to retract indicates

that caliper assembly is defective and must
be overhauled or replaced.
(14). Reinstall components that were
removed for access to the rotor brake
system.
Page 602
Revision 20
63-22-00
(15). Raise brake handle to stowed position

and engage it in clip on handle retainer
assembly.
2. Rotor Brake Operational Check
After rotor brake hydraulic system has been
filled with fluid, an operational checkout of the
rotor brake installation must be performed.
(1). Start engine, run up rotor to operating
speed, and then make a normal shut
down (refer to applicable Pilot's Flight
Manual).
Incorrect application of the ro
tor brake can result in sudden
stopping and kick-back of the main rotor, an
action which can cause damage to the rotor
blades and strap packs in the rotor hub. Col
lective pitch must never be applied to slow
rotor rotation as this can cause damage to
the rotor blades and strap packs. Applica
tion of a side load to brake handle may dam
age support bracketry.
CAUTION
(2). When rotor slows to approximately 205

or less rpm, disengage brake handle
from retaining clip and pull handle
down to apply braking force. Make
certain that collective pitch stick is in
full down position, and that cyclic
control stick is in neutral position.
(3). Release brake pressure during last
revolution of rotor.
(4). Raise brake handle to stowed position
and engage it in handle retaining clip.
MAINTENANCE MANUAL
CSP-HMI-2
ROTOR BRAKE

dust, moisture, or other foreign materi
al. Hydraulic system contamination
can cause malfunctions that could re
sult in injury to personnel or equip
ment damage.
1. Rotor Brake Initial Installation
This section provides detailed instructions for
accomplishing initial installation of the rotor
brake components into the aircraft. In general,
procedures are applicable to either left hand or
right hand command configurations. Where
pertinent, differences are specified.
Illustrations are included to provide data
pertinent to aircraft modifications required for
installation of the rotor brake components. All
items and tools required to install the rotor
brake are standard and should be procured
locally. Alternate items of comparable charac
teristics and equal quality may be used.
A. Aircraft Preparation
Preparation for installation of rotor brake
components include removal of certain original
equipment items to gain access, or for replace
ment. Preparations also include permanent
installation of certain rotor brake components.
B. Installation Access
NOTE: The main transmission must be re

moved from the aircraft to permit installa
tion of the transmission-mounted rotor
brake components.
(1). Remove both crew compartment and
cargo/passenger compartment doors.
(2). Remove crew compartment seats.
(3). Remove map case assembly from
forward side of canted bulkhead 78.50
structure. Remove both (LH and RH)
upper forward panel assemblies from
bulkhead structure. Remove conve
nience panel cover assembly from
convenience panel assembly.
NOTE: A new design convenience panel cover

assembly (Ref. Figure 908) must be in
stalled to cover the aft portion of the brake
(4). Disconnect electrical wiring and
communications cables from compo
nents on back of convenience panel
assembly. If cabin heating option is
installed on aircraft, disconnect heated
air duct from panel-mounted diffuser.
Remove attaching screws and conve
nience panel assembly from aft side of
(5). Remove transmission cover panel
assembly from fuselage structure.
(6). Cover exposed trim panels to prevent
damage and soiling.
(7). Remove main transmission from
(8). Remove tail rotor (Ref. Sec. 64-20-00),
tail rotor transmission (Ref. Sec.
63-25-10) and tail rotor drive shaft
(Ref. Sec. 63-15-10).
C. Removing Components to be Replaced
Certain rotor brake and related components
are mounted on the main transmission, and
are installed in the aircraft as a unit with the
transmission. Some of these transmissionmounted components replace similar item
counterparts that were used in the original
installation.
(1). The tail rotor drive coupling installed
on the transmission output shaft must
be replaced by a new drive coupling on
which the brake disc is mounted.
Remove coupling and failsafe device (if
used) from transmission output shaft
(Ref. Sec. 63-15-10). Leave laminated
shim washers on output shaft and
retain coupling bolt for reassembly use.
(2). The tachometer generator installed on
the tail rotor cover assembly on main
transmission must be replaced by a new
unit that provides clearance for the
rotor brake disc. Remove attaching nuts
63-22-00
Page 901
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
and washers, tachometer generator and

gasket from tail rotor cover assembly.
Retain nuts and washers for re-as
sembly use. Tachometer generator will
not be reinstalled. Discard gasket.
(3). The tail rotor cover assembly is in
stalled on the main transmission
housing with nuts and washers in
stalled on twelve studs. Four of the
studs, with special nuts and washers,
will be used for installing the rotor
brake caliper mounting bracket.
Remove four nuts and washers (at 1, 2,
10, and 11 o'clock positions). These nuts
and washers will not be used at
reinstallation.
D. Angle Assembly Installation (500D)
(Ref. Figure 901) The angle assembly must be
installed on canted bulkhead 78.50 shoulder
beam as a means of attachment for the
convenience panel cover assembly and the
rotor brake forward cover assembly.
Item
Nomenclature
CM318
Primer
(1). Lay out and mark location for angle

assembly on portion of forward bulk
head aft panel assembly that covers
canted bulkhead 78.50 shoulder beam.
(2). Insert piece of cardboard (or similar
material) under aft panel assembly to
protect shoulder beam and use a sharp
knife to make panel cut out to accom
modate angle assembly, taking special
care not to cut outside marked area.
(3). Position angle assembly on shoulder
beam as a guide and drill two
0.128-0.132 inch (3.2512-3.3528 mm)
diameter holes through angle assembly
and one wall of shoulder beam, taking
care that point of drill bit does not
penetrate into shoulder beam more
than 1/4 inch (6.35 mm). Deburr holes
in both parts and touch up raw metal
surfaces with primer (CM318).
Page 902
Revision 20
63-22-00
(4). Attach angle assembly to shoulder

beam with blind rivets.
E. Master Cylinder Linkage Assembly and
Mount Bracket Installation
(Ref. Figure 901) The master cylinder linkage
assembly bracket must be installed on canted
bulkhead 78.50 vertical member as a means of
attachment for the master cylinder assembly
and the other components of the master
cylinder linkage assembly.
Item
Nomenclature
CM318
Primer
NOTE: Because of its method of attachment, it

may be more convenient to install the link
age assembly bracket and then assemble
the other components on the bracket. Al
though the procedures given in steps (1).
thru (3). below consider installation of the
assembly, they are also applicable for instal
lation of the bracket. Steps (4). thru (7). be
low describe procedures for assembling com
ponents to the bracket.
(1). Position master cylinder linkage
assembly on canted bulkhead 78.50
vertical member. Hold assembly (with
bracket) firmly in position as a guide
and use a No. 15 drill bit to line drill
four holes in vertical member, taking
care to prevent point of drill bit from
penetrating into vertical member more
than 1/4 inch (6.35 mm).
(2). Line ream holes 0.199-0.202 inch
(5.0546-5.1308 mm) diameter. Remove
linkage assembly, deburr holes in both
parts, and touch up raw metal surfaces
with primer (CM318).
(3). Attach bracket to vertical member with
Jo-bolt blind fasteners.
(4). Secure pin (Ref. Figure 402) in bracket
with nut and washer.
(5). Install grip on handle. Install new roll
pins through handle and fitting.
MAINTENANCE MANUAL
CSP-HMI-2
RIGHT-HAND
INSTALLATION
JO-BOL
T
0.75 IN.
(19.05 MM)
0.50 IN.
(12.70 MM)
NOTE:
LEFT-HAND INSTALLATION SHOWN, RIGHT-HAND
OPPOSITE EXCEPT WHERE NOTED.
G63-2012-1
Figure 901. Locating Permanently Installed Components (Sheet 1 of 2)
63-22-00
Page 903
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
1.00 IN.
(2.54 CM)
0.063 IN.
(1.6002 MM)
(STOCK)
0.50 IN.
(12.70 MM)
1.50 IN.
(3.81 CM)
0.47 IN.
(11.938 MM)
1.00 IN.
(2.54 CM)
0.75 IN.
(19.05 MM)
0.31 IN.
(7.87 MM)
2.00 IN.
(5.08 CM)
0.54 IN.
(13.716 MM)
2.26 IN.
(5.7404 CM)
0.38 IN.
(9.652 MM)
4.80 IN.
(12.192 CM)
1.80 IN.
(4.572 CM)
0.25 IN.
(TYP)
(6.35 MM)
0.70 IN.
(17.78 MM)
0.40 IN.
(10.16 MM)
0.50 IN.
(12.7 MM)
0.38 IN.
(9.652 MM)
(TYP)
3.07 IN.
(7.7978 CM)
0.38 IN.
(9.652 MM)
0.50 IN.
(12.70 MM)
2.38 IN.
(6.0452 CM)
4.57 IN.
(11.6078 CM)
0.32 IN.
(8.128 MM)
0.62 IN.
(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
Revision 20
63-22-00
MAINTENANCE MANUAL
(6). Install bolt, spacer, and nut on lever.
Attach assembled handle parts to lever,
with clevis pin, washers, and new cotter
pin.
When parts are assembled,
WARNING spring force is constantly ex
erted to inhibit inadvertent brake
application. Care must be taken as the
spring is engaged to prevent injury to
personnel or equipment damage.
(7). Install lever with attached parts, and
spring on pin and secure with washer,
nut, and new cotter pin. Engage free
end of spring under head of clevis pin.
F. Handle Retainer Assembly Installation
(Ref. Figure 901) The handle retainer assem
bly must be installed on canted bulkhead 78.50
vertical member to secure the rotor brake
operating handle in the stowed (raised)
position.
Item
Nomenclature
CM318
Primer
Remove retainer assembly and use a

1/8 inch (3.175 mm) drill bit to drill out
marked rivets.
(3). Lay out hole patterns on handle
retainer assembly to match drilled rivet
holes. Use No. 30 drill bit to drill two
holes in retainer.
(4). Cleco retainer assembly in place. Use
retainer as guide and use a No. 15 drill
bit to drill two holes into face of vertical
member. Remove handle retainer
assembly from vertical member.
(5). Deburr holes and touch up with primer
(CM318).
(6). Attach handle retainer assembly to
vertical member with four blind rivets.
G. Rivnut Installation
(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
installation, a rivnut must be installed in the
canted bulkhead 78.50 vertical member for
attachment of the hydraulic relief valve.
NOTE: The master cylinder linkage assembly

must be installed so that the handle retain
er assembly can be positioned correctly.
(1). Position handle retainer assembly on
canted bulkhead 78.50 vertical member
so that when rotor brake operating
handle is in the stowed position,
retainer clip engages handle just below
the rubber grip.
To prevent damage to compo
nents, point of drill bit must not
be allowed to penetrate through wall of ver
tical member more than 1/4 inch (6.35 mm).
CAUTION
NOTE: The tunnel beam web is secured to the

vertical members by a series of rivets. Two
of these rivets must be removed and re
placed by rivets that also attach the handle
retainer assembly.
(2). Mark two rivets on front of vertical
member that most closely match
position of handle retainer assembly.
CSP-HMI-2
Item
Nomenclature
CM318
Primer
Care must be taken when drill

ing the mast pan for rivnut in
stallation to prevent damage to wiring har
nesses which are installed on the upper side
of the pan, or to critical structure members
to which the pan is riveted. A drill stop or
other suitable means should be used to pre
vent point of drill from penetrating more
than 1/4 inch (6.35 mm) into vertical mem
ber.
CAUTION
(1). Lay out location for hole in transmis

sion pan. Use 1/4 inch (6.35 mm) drill
bit to drill hole through pan, deburr
hole, and touch up raw metal surfaces
with primer (CM318). Install rivnut in
accordance with standard shop practice
and manufacturer's instructions.
63-22-00
Page 905
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
BRAKE CALIPER
WASHER
S
BOL
T
BLEED
SCREW
WASHER
S
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
Revision 20
63-22-00
MAINTENANCE MANUAL
CSP-HMI-2
NUT
CLAMP
BLEEDSCREW
SCREW
WASHER
TEE
RIVNUT
CLAMP
TEE
BLEEDSCREW
SPECIAL NUT
SCREW
WASHER
WASHER
SHIM
COUPLING
DISC
MASTER
CYLINDER
TACH
GENERATOR
HANDLE
ASSEMBLY
G63-2013-2A
Figure 902. Rotor Brake Installation (Sheet 2 of 2)
63-22-00
Page 907
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
(2). Lay out location for hole in vertical

member. Use 1/4 inch (6.35 mm) drill
bit to drill hole through outer face of
vertical member. Deburr hole and touch
up raw metal surfaces with primer.
Install rivnut in accordance with
standard shop practice and manufac
turer's instructions.
H. Window Support Channel Modification
(Ref. Figure 903) Three clamps are used to
attach hydraulic tube assembly to the window
support channel. Modifications to the channel
are required to accommodate two of the
clamps.
Item
Nomenclature
CM318
Primer
(1). Use 1/8 inch (3.175 mm) drill bit to

remove one (3rd rivet from front) of the
four rivets used to attach forward
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
bit, deburr hole, and touch up raw
metal surfaces with primer (CM318).
(2). Lay out location for hole in channel as
shown. Use 3/16 inch (4.7625 mm) drill
to drill hole in channel, deburr hole,
and touch up raw metal surfaces with
primer.
I. Caliper Mounting Bracket Initial
Installation
(Ref. Figure 902) The caliper mounting bracket
is installed on four of the twelve studs used to
secure the tail rotor cover assembly on the
main transmission housing.
Item
Nomenclature
CM702
Lockwire CRES
(1). Place three washers on each of the four

studs (1, 2, 10, and 11 o'clock positions)
Page 908
Revision 20
63-22-00
in tail rotor cover assembly for use as

spacers. Position caliper mounting
bracket on studs and secure with
washers and nuts. Torque nuts to 50 70 inch-pounds (5.65 - 7.91 Nm).
(2). Secure installation with lockwire
(CM702).
J. Caliper Assembly, Brake Disc and Drive
Coupling Installation
(Ref. Figure 902) The caliper assembly is
bolted to a mounting bracket which is installed
on the main transmission tail rotor cover. The
brake disc is bolted on the drive coupling
which is installed on the transmission output
shaft. For clarity, the brake disc and drive
coupling are considered as a single item,
herein referred to as the disc/coupling unit.
Although the caliper assembly and the
assembly. This arrangement makes it neces
sary to install both units at the same time.
Item
Nomenclature
CM113
CM117
CM434
CM702

Grease
Thread sealant
Lockwire CRES
Axial positioning of the
WARNING drive coupling is critical as

it controls the mechanical interface be
tween the coupling and the tail rotor
drive shaft. Excessive axial loads can
contribute to coupling failure which
could result in injury to personnel or
equipment damage. Refer to Section
63-15-10 for shimming procedures for
installing coupling disc on shaft.
NOTE: Before installing caliper, brake disc and

drive coupling, install new tachometer gen
erator and gasket. Ensure that mechanical
drive components are correctly engaged and
electrical receptacle is at the 11 o'clock posi
tion.
MAINTENANCE MANUAL
CSP-HMI-2
369D23012-5 REF
369D23012-13 REF
G63-2019
Figure 903. Modifying Window Support Channel

(1). Measure (with a micrometer) and
record thickness of brake disc at four
locations around the disc. Calculate and
record average of thickness measure
ments.
(2). Position brake disc on tail rotor drive
coupling with raised center side of disc
seated firmly on shoulder of coupling
and with bolt holes aligned. Secure disc
to coupling with attaching hardware
and torque nuts (in an alternating
sequence) to 100 - 140 inch-pounds
(11.30 - 15.82 Nm).
(3). Measure (with an inside micrometer)
and record gap between brake puck
faces. Subtract brake disc thickness
calculated in step (1). from gap mea
surement and divide the difference by
two to determine the optimum puck-todisc clearance.
(4). Remove bleed screws from ports in ends
of caliper assembly. Coat all but first
two threads of bleed screws, tees, and
plugs with thread sealant (CM434).
Install plugs in bleed screw ports and
tees in caliper bodies, install adapters
on tees, and install bleed screws in

adapters. Remove and discard hard
ware used to hold caliper halves
together.
NOTE: The caliper assembly consists of two

identical halves. When received, the halves
are held together by commercial hardware.
This hardware is replaced by qualified stan
dard hardware which also secures the cali
per assembly on the mounting bracket.
(5). Insert bolts through one caliper half,
position assembled parts of mounting
bracket and screw bolts into bracket
finger tight to maintain alignment of
caliper half. Use a C-clamp or other
suitable means to clamp caliper half
firm against bracket.
(6). Coat, completely but sparingly, splines
of transmission output shaft with
grease (CM117) and threads of coupling
with anti-seize compound (CM113), or
equivalent. Install coupling/disc unit on
shaft and install bolt into end of shaft
to ensure that coupling is seated firmly
against shim washers on shaft.
63-22-00
Page 909
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
TUBE ASSY
BAFFLE ASSY
MAST SUPPORT
PAN
NOTE:
LEFT-HAND INSTALLATION
RIGHT-HAND OPPOSITE
GROMMET
CHANNEL ASSY
G63-2020
Figure 904. Hydraulic Tube Installation

The caliper assembly must
NOTE: Fore-and-aft positioning of the caliper
to-disc clearances on both sides of disc

are approximately equal. Improper in
stallation can cause malfunctions
nel or equipment damage.
assembly, which determines the puck-todisc clearance relationship, is established by

installing shim washers between the caliper
assembly and the mounting bracket. Nine
washers are provided for each attaching
bolt; those not required for shimming must
be installed under the bolt heads.
WARNING be installed so that caliper-
(7). Measure gap between brake caliper

housing and forward face of disc with a
thickness gage. Subtract desired
caliper-to-disc clearance calculated in
step (3). from this measurement to
determine amount of shimming (wash
ers) to be installed between caliper
assembly and mounting bracket. Divide
the difference by 0.032 inch (0.8128
mm) (washer thickness) to determine
number of shim washers needed.
Page 910
Revision 20
63-22-00
(8). Remove bolts and place the correct

number (nine less the number required
for shimming) of washers on each bolt.
Insert bolts through caliper halves and
screw one bolt finger tight into mount
ing bracket. Release clamped caliper
half and move it away from bracket,
place required number of shim washers
on second bolt as it is pushed through
caliper assembly, and screw bolt into
bracket a few turns. Repeat procedure
MAINTENANCE MANUAL
to install shim washers on other bolt.
Tighten bolts firmly to secure installa
tion.
CSP-HMI-2
4389 GRIP
(1 REQD)
(9). 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
(10). 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.
63-20-00/25).
0.02 IN. (0.508 MM) GAP

0.04 IN. (1.016 MM)
The main transmission must
WARNING be installed in the aircraft
with special care to avoid damage to

rotor brake components. Installation
damage could lead to system failure
nel or equipment damage.
(11). If tachometer generator is installed on
transmission, connect electrical plug
(P202) on aircraft wiring harness to
receptacle on tachometer generator.
K. Master Cylinder Assembly Initial
Installation
(Ref. Figure 902) The master cylinder assem
bly is mounted on the master cylinder linkage
assembly bracket.
Item
Nomenclature
CM434
Thread sealant
(1). Remove attaching screws and vendorsupplied cap from master cylinder.
Vendor cap is not used.
(2). Rework vendor-supplied gasket (Ref.
Figure 906).
G63-2022A
Figure 905. Positioning Master Cylinder

(3). Install new cap and reworked gasket on
master cylinder with attaching screws
installed finger tight.
(4). Coat all but first two tapered pipe
threads of nipples and elbow with
thread sealant (CM434). Install nipples
in cap and elbow in master cylinder.
(5). Place one washer on each bolt, place
stop on bolts and insert bolts through
master cylinder. Place two washers on
each bolt as spacers. Position as
sembled parts on linkage assembly
bracket and secure installation with
washers and nuts. Tighten nuts only
finger tight.
NOTE: Mounting holes in bracket are elon

gated to enable lateral position adjustment
of master cylinder assembly.
(6). With actuating handle in stowed
position, adjust position of master
cylinder assembly so that clearance
(measured with a thickness gage)
between actuating lever (Ref.
Figure 905) and master cylinder piston
63-22-00
Page 911
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
is 0.020-0.040 inch (0.508-1.016 mm).

Tighten nuts to hold master cylinder
assembly firmly in position.
ing hardware loosely to hold clamps

(and tube assembly) to pan and window
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
bulkhead 78.50 vertical member, and is
connected hydraulically, by means of tube
assemblies, between the master cylinder
assembly and the caliper assembly.
(1). Place new O-ring on reducer and screw
reducer into relief valve. Connect relief
valve to tube assembly and tighten tube
nut. Install clamp on relief valve.
(2). Position assembled parts with relief
valve in ``V'' of handle retainer assem
bly. Install attaching hardware loosely
to hold assembled parts on canted
bulkhead 78.50 vertical member.
NOTE: Screw is threaded into nutplate for LH

installation, and into rivnut for RH installa
tion.
M. Hydraulic Tube Assemblies Initial
Installation
(Ref. Figure 902) Two tube assemblies are
installed to connect the master cylinder
assembly and the caliper assembly.
Item
Nomenclature
CM418
Cement, epoxy
(5). With all tube assemblies and fittings

connected, tighten nuts on tube assem
blies. Tighten attaching hardware for
all clamps.
NOTE: It is not necessary to tighten tube as

sembly nuts at this time. The tube assembly
will have to be removed to permit filling the
hydraulic system.
(6). Connect tube assembly to nipple in
master cylinder cap and tighten tube
nut.
N. Rotor Brake Installation Servicing
After all operating components of the rotor
brake system have been installed, the hydrau
lic system must be filled with hydraulic fluid
and have all entrapped air bled off. Refer to
Rotor Brake Hydraulic System Bleeding.
0.50 IN. (12.70 MM) DIA.
0.56 IN.
(14.224 MM)
0.56 IN.
(14.224 MM)
(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
tube assembly on hydraulic relief valve.
(3). Bond grommet into air baffle slot with
epoxy cement (CM418). Install attach
Page 912
Revision 20
63-22-00
EXISTING HOLES
G63-2021A
Figure 906. Reworking Master Cylinder

Gasket
MAINTENANCE MANUAL
O. Installing Interior Furnishings
After the operating components of the rotor
brake installation have been checked out, the
various items of interior furnishings (trim
panels, cover assemblies, seats, etc.) and the
fuselage doors must be reinstalled. This
includes those items that are specific for the
rotor brake installation, and those that were
removed to permit access for installing the
rotor brake components.
P. Map Case Assembly Modification and
Installation
(Ref. Figure 907) Before the map case assem
bly can be reinstalled, it must be modified to
accommodate the rotor brake forward cover
assembly.
(1). Mark map case panel for cutout. Use a
sharp knife to cut out marked area,
taking special care to avoid cutting
outside of marked area.
(2). Install map case assembly on canted
bulkhead 78.50 structure with three
attaching screws.
NOTE: A fourth screw will also be used to at

tach the rotor brake forward cover assembly
(Ref. Figure 908).
Q. Convenience Panel Cover Assembly
Modification and Installation
(Ref. Figure 908) The convenience panel cover
assembly mates with the rotor brake forward
cover assembly to enclose and protect the rotor
brake components installed on the canted
bulkhead 78.50 structure.
(1). Position new convenience panel cover
assembly with the aft edge overlapping
the forward edge of the transmission
cover panel. Install attaching screws to
hold panels in position.
(2). On the 500D, mark location for hole in
the forward corner of convenience panel
cover assembly to line up with nutplate
on angle assembly on canted bulkhead
78.50 shoulder beam. On the others,
mark location for holes in forward
corner of convenience panel cover
assembly to line up parallel with holes
CSP-HMI-2
to be drilled on rotor brake forward

cover panel.
(3). Use No. 42 drill bit to drill holes at
marked location for attaching screws.
NOTE: It may be more convenient to remove

convenience panel cover assembly while
drilling hole.
(4). On the 5000D, secure convenience
panel cover assembly with doublers to
angle assembly with attaching screw.
On the others, the convenience panel
cover assembly will be permanently
fastened down when mated with the
rotor brake forward cover assembly.
R. Rotor Brake Forward Cover Assembly
Installation
(Ref. Figure 908) The rotor brake forward
cover assembly mates with the convenience
panel cover assembly to enclose and protect
the rotor brake components (master cylinder,
etc.) installed on the canted bulkhead 78.50
structure. It is installed over the forward
portion of the master cylinder assembly and
incorporates cutouts to accommodate the
brakes handle and retaining clips.
(1). Position rotor brake forward cover
assembly on map case assembly with
aft edge overlapping forward edge of
convenience panel cover assembly and
with brake and retaining clips extend
ing through cutouts.
NOTE: If aircraft is equipped with optional

particle separator, it may be necessary to
trim the forward cover assembly for clear
ance.
(2). On the 500D, mark location for hole in
upper corner of forward cover assembly
to line up with isolator mount, and in
lower corner to line up with nutplate in
angle assembly on canted bulkhead
78.50 shoulder beam. On the others,
mark location for hole in upper corner
of forward cover assembly to line up
with isolator mount and in upper and
lower outboard corners to line up
parallel with holes previously drilled in
the convenience panel cover assembly.
63-22-00
Page 913
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
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
Revision 20
63-22-00
MAINTENANCE MANUAL
CSP-HMI-2
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 PLCS)
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 PLCS)
369E/FF
G63-2018-1A
Figure 908. Modifying Rotor Brake Cover Panel Assemblies (Sheet 1 of 2)
63-22-00
Page 915
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
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.
Figure 908. Modifying Rotor Brake Cover Panel Assemblies (Sheet 2 of 2)

Page 916
Revision 20
63-22-00
G63-2018-2A
MAINTENANCE MANUAL
(3). Use No. 42 drill bit to drill holes at
marked locations for attaching screws.
NOTE: It may be more convenient to remove

forward cover panel assembly while drilling
holes.
(4). Secure forward cover assembly and
map case panel assembly with attach
ing screws. On the 500D, install screw
through nutplate in angle assembly. On
the others, install screws into shims on
CSP-HMI-2
the outboard edge of forward cover

assembly and convenience panel cover
assembly.
(5). Push panel boot aft on brake handle
approximately 2 inches (5.08 cm) and
secure boot fastener tape.
S. Weight and Balance
(Ref. Table 901) After installing the rotor
brake, incorporate changes in helicopter
weight and balance record.

Configuration
Weight
lb (kg)
Arm
in. (cm)
Moment
inlb (kgcm)
+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)
+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)
+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)
+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)
500D (left side)

Added
500D (right side)

Added
369E/FF 500N (left and right)

Added
600N (left and right)

Added
63-22-00
Page 917
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
Page 918
Revision 44
63-22-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
632510
Tail Rotor
Transmission (Two
and Four Blade)
(369D/E/FF)
MAINTENANCE MANUAL
CSP-HMI-2
TAIL ROTOR TRANSMISSION (TWO AND FOUR BLADE)

1. Tail Rotor Transmission
(Ref. Figure 201) The tail rotor transmission is
a right-angle transmission with a magnesium
alloy housing. A magnetic chip detector is
located on the aft end of the transmission, a
breather-filler is located on the top and a sight
gage is mounted on the aft end (two-bladed) or
on the right side (four-bladed) of the transmis
sion.
2. Tail Rotor Transmission Replacement
A. Tail Rotor Transmission Removal
(1). Disconnect tail rotor driveshaft from
transmission (Ref. Sec. 63-15-10).
(2). Disconnect chip detector wire.
(3). (369D/E) Remove four nuts and
washers from transmission mount
studs.
(4). (369FF) Remove four bolts, eight
washers and four nuts between trans
mission and tailboom extension.
NOTE: Retain any shimming washers that

may be between tail rotor transmission and
tail boom for transmission installation.
tion of coupling and remove tail rotor
drive shaft and transmission as a unit.
(6). Remove tail rotor from tail rotor
(7). Remove tail rotor drive shaft from tail
rotor transmission (Ref. Sec. 63-15-10).
B. Tail Rotor Transmission Installation
Item
Nomenclature
CM318
Primer
Do not carry or otherwise sup

port transmission by coupling,
as coupling diaphragm may be permanently
distorted. During performance of all mainte
nance on transmission, use extra care to
keep contaminants such as paint, dirt, etc
from areas around input and output shaft
seals.
CAUTION
(1). Install tail rotor drive shaft on tail rotor

(Ref. Figure 203) Ensure securi
ty of tail rotor transmission
mount studs. Maximum allowable side play
at end of stud is 0.004 inch (0.102 mm), max
imum allowable axial play is 0.005 inch
(0.127 mm). For stud replacement, refer to
the Structural Repair Manual (SRM).
CAUTION
NOTE: Ensure all paint and sealant is removed

from mating surfaces. Remove excessive
sealant, as required, from transmission to
gain clean mounting surfaces. Ensure that
no gap in sealant coverage exists around the
transmission bearing cover assembly.
(2). Visually inspect mounting studs for
damage or deformation. Replace
damaged or deformed stud (Ref. SRM).
(3). Apply primer (CM318) in holes, on
faying surfaces and on the grip area of
the mounting studs. Install tail rotor
transmission or tailboom extension
while primer is still wet.
tion of coupling and install tail rotor
drive shaft and transmission as a unit
(Ref. Sec. 63-15-10).
NOTE: Note the drag torque for each nut and

it's location on the transmission in the heli
copter for later use.
(a). (369D/E) Secure tail rotor transmis
sion to four tailboom mounting studs
with washers and nuts. Torque nuts
to 75 - 95 inch-pounds (8.47 10.73 Nm) plus drag torque.
63-25-10
Page 201
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2
TRANSMISSION
COUPLING (BENDIX)
(CAUTION: DO NOT LIFT
ASSEMBLY FROM FLANGE)
FAILSAFE
COUPLING BOLT
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 201. Tail Rotor Transmission Stripping/Buildup

Page 202
Revision 20
63-25-10
MAINTENANCE MANUAL
(b). (369FF) Secure tail rotor transmis
sion to tailboom extension with four
bolts, eight washers and four nuts.
(8.47 - 10.73 Nm) plus drag
torque.
(5). Apply torque stripe paint.
(6). Between 2 and 10 hours of helicopter
operation (to allow parts to seat), check
the torque of each mounting nut as
follows:
(a). Using the drag torque previously
measured and noted, apply a torque
load of 75 - 95 inch-pounds (8.47 10.73 Nm) plus the noted drag
torque (noted for each individual
nut) to each mounting nut of the
transmission.
(b). Re-apply torque stripe paint.
(7). Install tail rotor on tail rotor transmis
sion (Ref. Sec. 64-20-00).
(8). Connect chip detector wire. Torque nut
to 12 - 15 inch-pounds (1.36 - 1.69
Nm).
(9). Connect tail rotor drive shaft to main
(10). Drain residual preservative oil and
service transmission with lubricating
oil (Ref. Sec. 12-00-00).
3. Tail Rotor Transmission Inspection
(Ref. Figure 201)
NOTE: If following inspections reveal damage,

repair according to instructions in CSPCOM-5.
(1). Check transmission for leaks, cracks
and corrosion. To evaluate oil leakage,
refer to Fluid Leak Analysis (Ref. Sec.
12-00-00).
(2). Inspect Sta. 284 bellcrank hole for
elongation; if elongation is suspected,
CSP-HMI-2
measure hole diameter. Hole diameter

to be 0.312-0.313 inch (7.9248-7.9502
mm) (Ref. CSP-COM-5 for bolt hole
repair).
(3). Check input shaft for:
(a). Axial play by moving shaft in and
out; transmission must be cold. Axial
play is limited to 0.004 inch (0.102
mm) maximum.
(b). Measure runout; mark high and low
extremes on outer end of shaft with
grease pencil. Total indicated runout
should be less than 0.002 inch (0.051
mm).
(4). Check output shaft for:
(a). Axial play; no axial movement is
permitted.
(b). Measure runout; mark high and low
extremes on outer end of shaft with
grease pencil. Total indicated runout
should be less than 0.0025 inch
(0.0635 mm).
(5). While gently pulling out on input shaft,
check gearset backlash:
(a). Two-bladed gearset backlash should
be 0.004-0.008 inch (0.102-0.203
mm).
(b). Four-bladed gearset backlash should
be 0.0025-0.0050 inch (0.0635-0.127
mm).
NOTE: Although not required, placing marks

on end of output shaft provides guides for
subsequent installation of tail rotor assem
bly in a manner that reduces chances of
high frequency vibrations and lessens possi
bility of requirement for tail rotor balancing.
(6). Inspect all scoring or scratching of
output shaft to determine if marks
penetrate through cadmium plating
and into steel shaft. Penetration of steel
shaft is allowable to maximum depth of
0.010 inch (0.254 mm).
63-25-10
Page 203
Revision 40
MAINTENANCE MANUAL
CSP-HMI-2
LIQUID LEVEL PLUG

(4-BLADED T/R)
BREATHER-FILLER
BREATHER-FILLER
O-RING
O-RING
O-RING
ADAPTER
O-RING
LIQUID
LEVEL PLUG
(2-BLADED T/R)
INPUT SHAFT
OUTPUT SHAFT
0.046 IN. (1.1684 MM)

LINE-WIDTH (TYP)
0.10 IN. (2.54 MM)

LETTER HEIGHT (TYP)
DRAIN HOLE
FULL
0.406 IN. (10.3124 MM)
ADD
BREATHER HOLE
AXIS OUTPUT SHAFT

0.06 IN.
(1.524 MM)
BREATHER-FILLER
LIQUID LEVEL PLUG MARKINGS
INPUT SHAFT
OUTPUT SHAFT
85
85
BREATHER HOLE ORIENTATION

G63-2016A
Figure 202. Replacement of Liquid Level Plug and BreatherFiller

Page 204
Revision 20
63-25-10
MAINTENANCE MANUAL
4. Tail Rotor Transmission Stripping
(Ref. Figure 201) Stripping of the tail rotor
transmission is not required following its
removal from the helicopter. Perform the
following stripping procedure if in preparation
for transmission shipment or storage only.
Item
Nomenclature
CM208
Barrier material
(1). Remove coupling bolt and coupling from

input shaft.
NOTE: For tail rotor transmission replace

ment, further stripping is not required. A re
placement transmission is equipped with all
other accessories.
(2). Drain oil from transmission (Ref. Sec.
12-00-00). Residual operating lubri
cant is approved internal preservative
for shipping or storage.
(3). Wrap transmission in barrier material
(CM208) to protect shaft splines and
chip detector stud during handling,
shipping or storage.
5. Tail Rotor Transmission Buildup
(Ref. Figure 201)
Item
Nomenclature
CM111
CM112
Grease, aircraft

re-assembly.
(2). Install coupling and bolt. Torque
coupling bolt to 250 - 300 inchpounds (28.25 - 33.90 Nm) plus drag
torque. Check coupling bolt for drag
torque serviceability of 25 inchpounds (2.82 Nm) minimum, 200
inch-pounds (22.60 Nm) maximum.
CSP-HMI-2
6. Tail Rotor Transmission Parts

Replacement
(Ref. Figure 202)
Item
CM114
CM222
CM311
CM702
Nomenclature
Petrolatum
Lockwire CRES
NOTE: Replace liquid level plug, chip detector

and breather-filler using torque values in
following paragraphs. Lubricate mating
bores of O-rings with petrolatum (CM114)
to prevent damage to O-rings. Repair other
components or replace tail rotor transmis
sion oil seals (Ref. COM).
(1). Chip Detector Torque valve body 50 60 inch-pounds (5.65 - 6.78 Nm);
detector 40 - 50 inch-pounds (4.52 5.65 Nm). Safety with lockwire
(CM702).
(2). Liquid Level Plug Torque liquid level
plug to 50 - 60 inch-pounds (5.65 6.78 Nm). If level-lines and lettering of
liquid level plug cannot be made
parallel with axis of transmission
output shaft when plug is torqued
within 50 - 60 inch-pound (5.65 - 6.78
Nm) range, clean glass by firmly
rubbing with soft cloth, then mix white
coating (CM311) with equal amount of
thinner and apply lines and lettering.
Safety with lockwire.
NOTE: Some models use an adapter with an

additional O-ring. On those models, install
adapter with O-ring, then install breatherfiller.
(3). Oil Breather-Filler Torque breather-fil
ler to 45 - 55 inch-pounds (5.08 6.21 Nm). If equipped with a 369A5429
breather, hole in breather filler must be
directed rearward at final torque.
Locating vent at any angle aft of output
shaft centerline (viewed from above)
adequately directs vent rearward. One
or two washers may be added between
O-ring and breather flange (one washer
63-25-10
Page 205
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
changes orientation by approximately

100 degrees). Safety with lockwire.
NOTE: If oil breather-filler assembly becomes

clogged, use light air pressure, approxi
mately 5 psig (34 kPa) or a 0.125 inch (3.175
mm) dia. rod applied into the threaded end
to dislodge debris. Ultrasonically clean
breather in solvent (CM222) for ten min
utes.
(3). If contact occurs, rework tail rotor

transmission housing as follows:
(a). Chamfer the web on transmission
housing to dimensions shown in
Figure 204.
Do not remove material in
WARNING excess of specified dimen

sion.
7. Input and Output Gearshaft Cover Oil

Leak Repair
(b). Blend chamfer into existing radius at

the bottom and radius it at the top.
Width of chamfer must be
0.060-0.090 inch (1.524-2.286 mm).
Repair oil leaks at input and output gearshaft

cover by installing a protective sleeve (SpeediSleeve) on the gearshaft area contacted by the
oil seal lip (Ref. COM).
(c). Apply surface touchup treatment

(Ref. Sec. 20-30-00).
8. Tail Rotor Transmission Housing

Assembly Rework (PN 369D25401)
(Ref. Figure 204) An interference condition
may exist between the tail rotor transmission
housing and the tail rotor control bellcrank
with the tail rotor pedal at extreme right
position. The following procedure provides
inspection criteria and rework instructions, if
necessary, for the tail rotor transmission
housing to correct this condition should it
exist.
(1). With assistance, depress and hold right
tail rotor pedal to extreme right
position and inspect web area of tail
rotor transmission housing that comes
in close contact with tail rotor control
bellcrank. If adequate clearance exist
between transmission housing and
control bellcrank, no rework action is
necessary.
(2). Sign off aircraft logbook to indicate
completion of this inspection.
Page 206
Revision 20
63-25-10
(4). Record compliance of this rework in the

aircraft logbook.
AXIAL PLAY 0.005 IN.
(0.127 MM) MAX
SIDE PLAY 0.004 IN.

(0.102 MM) MAX
G63-2023A
Figure 203. Tail Rotor Transmission Mount

Stud Limits
MAINTENANCE MANUAL
CSP-HMI-2

A
0.350 IN. (8.89 MM) MIN.

A
REWORK AREA
(END VIEW)
OUTPUT SHAFT
REWORK AREA
0.500 IN.
(12.70 MM) R
0.060-0.090 IN.
(1.524-2.286 MM) X 45
BLEND INTO
EXISTING RADIUS
TAIL ROTOR
HOUSING
ASSEMBLY
G63-2017A
Figure 204. Rework of Tail Rotor Transmission Housing Assembly
63-25-10
Page 207
Revision 20
CSP-HMI-2
MAINTENANCE MANUAL
Page 208
Revision 44
63-25-10
MAINTENANCE MANUAL
CSP-HMI-2
Section
632530
NOTARr
AntiTorque System
Fan Transmission
(500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
NOTAR ANTITORQUE SYSTEM FAN TRANSMISSION

1. Fan Transmission
The function of the fan transmission is to step
up RPM from the main transmission output to
the fan via fan drive shaft, gears, and intercon
nect shaft. The transmission housing is made
of magnesium, and contains input and output
gear shafts, two angular contact bearings,
coupling, seals, packings, output cover assy,
chip detector, sight glass, and oil breather
assembly.
2. Fan Transmission Replacement
Remove and install fan transmission according
to the following procedures.
A. Fan Transmission Removal
(Ref. Figure 201)
(1). Remove inlet screen, inlet fairing,
engine plenum access cover, and fan
hub transmission fairing (Ref. Sec.
53-30-30).
(2). Remove tailboom (Ref. Sec. 53-40-30).
(3). Drain fan transmission of oil. Discon
nect drain line and cap elbow at bottom
of transmission.
(4). Remove fan drive shaft (Ref. Sec.
63-15-30).
B. Fan Transmission Installation

(Ref. Figure 201)
Do not carry or support trans
mission by coupling as damage
can occur to coupling. During performance
of maintenance on transmission, use extra
care to keep contaminants such as paint,
dirt etc from areas around input and output
shaft seals.
CAUTION
(1). Install fan drive shaft (Ref. Sec.

63-15-30).
(2). Locate and align transmission with
mounting holes on helicopter. Install
four bolts and washers on transmission.
Torque bolts to 70 - 90 inch pounds
(7.90 - 10.17 Nm); torque-stripe bolts.
(3). Connect previously identified chip
detector wires.
(4). Remove cap and connect drain line on
elbow at bottom of transmission.
(5). Install fan interconnect shaft (Ref. Sec.
63-15-30).
(6). Install fan pitch control rod (Ref. Sec.
67-20-30).

67-20-30).
(7). Drain any residual preservative oil (if

new transmission) and service with
lubricating oil (Ref. Sec. 12-00-00).
(6). Remove fan interconnect shaft (Ref.

Sec. 63-15-30).
(8). Install fan hub transmission fairing

(Ref. Sec. 53-30-30).
NOTE: Identify chip detector wires for future

re-installation.
(7). Disconnect chip detector wires.
(8). Remove four transmission mounting
bolts, washers, and transmission from
helicopter.
(9). Install engine plenum access cover (Ref.

Sec. 53-30-30).
(10). Install engine inlet fairing (Ref. Sec.
53-30-30).
(11). Install inlet screen (Ref. Sec.
53-30-30).
63-25-30
Page 201
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2
BOLT
(4 PLS)
WASHER
(4 PLS)
FAN TRANSMISSION
SUPPORT ASSY
FAN TRANSMISSION
BULKHEAD
G63-2024
Figure 201. Fan Transmission Removal/Installation

Page 202
Revision 20
63-25-30
MAINTENANCE MANUAL
3. Fan Transmission Inspection
(1). Check transmission for leaks, cracks,
and corrosion. To evaluate oil leakage
refer to Component Fluid Leak Analy
sis (Ref. Sec. 12-00-00). For further
inspection criteria, please contact
MDHC Customer Support Department.
4. Tube Support Inspection
(1). Inspect mount bolts for security and
corrosion, lockwire intact.
(2). Inspect tube support for dents,
scratches, nicks, gouges and corrosion,
none allowed.
(3). Inspect for visible step in splined area.
(4). If step is evident:
(a). Measure between splines using
0.0864 in. (2.19456 mm) diameter
pins.
(b). Maximum measurement between
pins is 0.390 in. (9.906 mm).
5. Fan Transmission Parts Replacement
(Ref. Figure 202)
Item
CM114
CM222
CM311
CM702
Nomenclature
Petrolatum
Lockwire CRES
CSP-HMI-2
NOTE: Replace liquid level plug, chip detector,

and breather assy using torque values in the
following paragraphs. Lubricate Orings
with petrolatum (CM114) to prevent dam
age to Orings. Repair other components or
replace transmission oil seals if required
(Ref. COM).
(1). Chip Detector Torque valve body (large
hex) to 50 - 60 inch pounds (5.65 6.78 Nm) or 40 - 50 inch pounds
(4.52 - 5.65 Nm) (smaller hex).
(2). Liquid Level Plug Torque liquid level
plug to 50 - 60 inch pounds (5.65 6.78 Nm). If level lines and lettering of
liquid level plug cannot are not parallel
with axis of transmission output shaft
when torqued within 50 - 60 inch
pound (5.65 - 6.78 Nm) range, clean
glass by firmly rubbing with soft cloth,
then mix white coating (CM311) with
equal amount of thinner and apply
lines and lettering. Safety with lockwire
(CM702).
(3). Oil Breather Assy Torque breather
assy to 45 - 55 inch pounds (5.08 6.21 Nm). Ensure breather hole is
facing up. Safety with lockwire
(CM702).
NOTE: If oil breather assy becomes clogged,

use light air pressure, approximately 5 psig
(34 kPa) or a 0.125 inch (3.175 mm) dia. rod
applied into the threaded end to dislodge de
bris. Ultrasonically clean breather in sol
vent (CM222) for ten minutes.
63-25-30
Page 203
Revision 33
MAINTENANCE MANUAL
CSP-HMI-2
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.
(10.3124 MM)
ROTATED VIEW
0.060 IN.
(1.524 MM)
LIQUID LEVEL PLUG MARKINGS

G63-2025A
Figure 202. Fan Transmission Parts Replacement

Page 204
Revision 20
63-25-30
MAINTENANCE MANUAL
CSP-HMI-2
Section
633000
Main Rotor Static
Mast (369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR STATIC MAST

1. Main Rotor Static Mast
(Ref. Figure 201) The main rotor mast provides
support for the main rotor, main transmission
and drive shaft, and consists of an assembled
machined steel tube with a machined alumi
num forged base.
2. Main Rotor Static Mast Replacement
(369D25100 Transmission Installation)
A. Main Rotor Static Mast Removal
(Ref. Figure 201)
Main rotor mast is highly
stressed. Do not allow tools to
strike mast or mast to strike any object. Any
impact damage may require replacement of
mast.
CAUTION
(1). Remove main rotor hub (Ref. Sec.

62-20-00/60).
(2). Remove main rotor controls (Ref. Chap.
67).
(3). Remove main transmission (Ref. Sec.
63-20-00/25).
(4). Remove four studs, washers and nuts.
NOTE: Nuts securing studs have left-hand

threads.
(5). Remove shaft support holddown nuts,
washers and bolts.
(6). Lift main rotor mast from helicopter.
B. Main Rotor Static Mast Installation
(Ref. Figure 201)
Item
Nomenclature
CM306
CM430
Lacquer, clear
(1). Apply silicone sealant (CM430) on

bottom surface of mast tube and base at
drive shaft opening to seal base to mast
support structure at installation.
(2). Position main rotor mast so that holes
in base align with holes in mast support
structure.
(3). Install holddown bolts, washers and
mast mounting nuts; torque nuts to 700
- 820 inch-pounds (79.09 - 92.65
Nm).
(4). Check underside of mast support
structure at left aft stud hole location.
Stud-to-pan doubler surface must be
clean to bare metal for electrical
bonding. Install main transmission
mounting studs, plate spacers and nuts.
Torque studs to 160 - 190 inchpounds (18.08 - 21.47 Nm).
(5). Using 0.0010-0.0015 inch
(0.254-0.0381 mm) feeler gage, check
for gap between self-locking nuts and
plate spacers. No gap is allowed.
(6). If gap exists, remove nut and replace
with new self-locking nut. Torque studs
into replacement nuts to 160 - 190
repeat step (5). above. Continue until
each nut is flush against its spacer.
Seal bare bond area with clear lacquer
(CM306).
(7). Install main transmission (Ref. Sec.
63-20-00/25).
(8). Install main rotor controls (Ref. Chap.
67).
(9). Install main rotor hub (Ref. Sec.
62-20-00/60).
63-30-00
Page 201
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
HUB SLEEVE BEARING

SURFACE
MAIN ROTOR MAST
NUT (LEFTHAND
THREADS)
TAPE
PLATE
SPACER
MAST BASE
RIVET
MAST SUPPORT
STRUCTURE PAN
NOTE 2
DRAIN
HOLE
MAST SUPPORT FITTING
MAST MOUNTING
NUT
MAIN TRANSMISSION
MOUNTING STUD
NOTE 1
AFT BULKHEAD
CHANNEL
TUNNEL BEAM WEB
TUNNEL BEAM
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
TUBE AT BASE) WITH SILICONE RUBBER (CM430).
G63-3000A
Figure 201. Main Rotor Mast and Support Structure (369D25100 Transmission Installation)
Page 202
Revision 20
63-30-00
MAINTENANCE MANUAL
3. Main Rotor Static Mast Replacement
(369F5100 Transmission Installation)
(Ref. Figure 202)
A. Main Rotor Static Mast Removal
Main rotor mast is highly
stressed. Do not allow tools to
strike mast or mast to strike any object. Any
impact damage may require replacement of
mast.
CAUTION
CSP-HMI-2
(4). Using 0.0010-0.0015 inch

(0.0254-0.0381 mm) feeler gage, check
for gap between self-locking nuts and
plate spacers. No gap is allowed.
(5). If gap exists, remove nut and replace
with new self-locking nut. Torque bolts
into replacement nuts to 160 - 190
drag torque and repeat step e. above.
Continue until each nut is flush against
its spacer. Seal bare bond area with
clear lacquer (CM306).
(1). Remove main rotor hub (Ref. Sec.

62-20).
(6). Install main transmission (Ref. Sec.

63-25).
(2). Remove main rotor controls (Ref. Sec.

67-10).
(7). Install main rotor controls (Ref. Sec.

67-10).
(3). Remove main transmission (Ref. Sec.

63-25).
(8). Install main rotor hub (Ref. Sec.

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)
B. Main Rotor Static Mast Installation

Item
Nomenclature
CM306
CM430
Lacquer, clear
(1). Apply silicone sealant (CM430) on

bottom surface of mast tube and base at
drive shaft opening to seal base to mast
support structure at installation.
(2). Position main rotor mast so that holes
in base align with holes in mast support
structure.
(3). Check underside of mast support
structure at left aft stud hole location.
Stud-to-pan doubler surface must be
clean to bare metal for electrical
bonding. Install main transmission
mounting bolts, plate spacers and nuts.
Item
Nomenclature
CM115
CM234
CM235
CM304
CM305
CM318
CM323
CM713
CM802
CM803

Cleaner
Enamel, epoxy
Lacquer, acrylic
Primer
Primer
Crocus cloth
(1). Inspect all areas of main rotor mast for

cracks, nicks, scratches and evidence of
impact damage.
(2). Inspect bearing surfaces for scoring and
galling.
(3). Inspect threads for damage.
(4). Inspect rivets that secure base to mast
tube for security.
63-30-00
Page 203
Revision 36
CSP-HMI-2
MAINTENANCE MANUAL
(5). Check that tape (Ref. Figure 201) on

forward edge of mast tube is secure and
undamaged; replace if defective.
(a). Peel defective tape from mast.
(b). Remove main transmission (Ref. Sec.

63-20-00 or 63-20-25, Main Trans
mission Replacement).
(c). Remove static mast (Ref. Main Rotor
Static Mast Replacement).
(b). As required, polish area to remove

burrs and sharp areas with abrasive
cloth (CM802) or crocus cloth
(CM803).
(d). Thoroughly clean interior tube with

Solvent (CM234).
(c). Clean mast thoroughly with cleaner

(CM235) and allow to dry.
(e). Inspect for any corrosion, none

allowed.
(d). Apply primer (CM318) and paint

(CM305) to affected area.
(f). Remove paint from bad areas and

lightly feather paint edge with crocus
cloth (CM803), remove any residue
from feathering.
(e). Apply pressure sensitive tape

(CM713) to mast.
NOTE: To inhibit corrosion of mast when oper

ating in salt water environment, check tape
at frequent intervals. Also, apply thin
grease film (CM115) to bearing journals.
(6). Inspect internal bore for paint chipping,
orange peeling or flaking, none allowed.
NOTE: Chipping, orange peeling or flaking

paint will normally be at the base of the
static mast tube.
(7). Re-apply finish to mast internal bore
as follows:
(a). Remove main rotor hub (Ref. Sec.
62-20-00 or 62-20-60, Main Rotor
Hub Replacement).
Page 204
Revision 36
63-30-00
(g). Apply primer (CM318), or (CM323),

to repair areas.
(h). Allow to cure per manufacturer's
instructions.
(i). Apply white paint (CM304) to
internal bore of mast.
(j). Allow to cure per manufacturer's
instructions.
(k). Reinstall static mast.
(l). Reinstall main transmission.
(m). Reinstall main rotor hub.
MAINTENANCE MANUAL
CSP-HMI-2
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)
63-30-00
Page 205
Revision 29
MAINTENANCE MANUAL
CSP-HMI-2
AREA
REPAIRABLE
DAMAGE
MAXIMUM REMOVAL
OF
MATERIAL (DEPTH)
CORROSION AND
SCRATCHES
0.010 IN.
(0.254 MM)
CHIPPING OF CAD
MIUM PLATING
THICKNESS OF CAD
MIUM PLATING (0.0035
IN. (0.0889 MM MAXI
MUM)
LONGITUDINAL
SCRATCHES THAT
DO NOT PENE
TRATE THROUGH
NICKEL PLATE.
SCRATCHES MUST
BE A MINIMUM OF
0.25 IN. (6.35 MM)
APART. RADIAL
SCRATCHES ARE
NOT PERMITTED.
CORROSION AND
SCRATCHES
AREA EN
CLOSED
BY MAST
BASE
CORROSION AND
REPLACEMENT OF
TAPE.
MUST NOT PENE

TRATE NICKEL PLAT
ING, 0.003-0.007 IN.
(0.076-0.178 MM)
THICK
MUST NOT PENETRATE

THICKNESS OF SILVER
PLATING BY AN AREA
NO LARGER THAN 0.5
IN.2 (3.2258 CM2). NO
MORE THAN TWO
SUCH AREAS NO
CLOSER THAN 1.5 IN.
(3.81 CM) APART MAY
EXIST. IF WEAR EX
CEEDS LIMITS, CON
TACT MDHS WARRAN
TY REPAIR DEPART
MENT FOR REWORK
DISPOSITION. ONLY
MDHS CAN PERFORM
PLATING REPAIRS.
0.010 IN.
(0.254 MM)
REPAIR PROCEDURE
POLISH DEFECTIVE AREA SMOOTH WITH

ABRASIVE CLOTH (CM802 AND CM803) IF
CADMIUM PLATING HAS BEEN PENE
TRATED. TREAT REWORKED AREA WITH
PRIMER (CM318).
POLISH AREA SMOOTH WITH ABRASIVE
CLOTH (CM802 AND CM803). TREAT RE
WORKED AREA WITH PRIMER (CM318)
AND LACQUER (CM306).
POLISH AREA WITH ABRASIVE CLOTH

(CM802 AND CM803) TO REMOVE BURRS
AND SHARP EDGES ONLY.
WIPE AREA CLEAN USING CHEESE CLOTH

(CM820) DAMPENED IN SOLVENT (CM222).
SPRAY UNIFORM COATING, 0.002-0.005
IN. (0.051-0.127 MM) THICK, ON WORN
AREA WITH LUBRICANT (CM103).
REMOVE DEFECTIVE TAPE. POLISH DE

FECTIVE AREAS TO REMOVE BURRS AND
SHARP SURFACES WITH ABRASIVE
CLOTH (CM802 AND CM803). TOUCH UP
REWORKED AREAS WITH PRIMER (CM318)
AND LACQUER (CM305). REPLACE TAPE
(CM713).
NOTE: FOR MAGNETIC PARTICLE INSPECTION,

REMOVE PAINT FROM APPLICABLE SURFACE
Figure 203. Main Rotor Mast Inspection and Repair

Page 206
Revision 36
63-30-00
G63-3001B
MAINTENANCE MANUAL
Chapter
64
AntiTorque
Assembly
CSP-HMI-2
MAINTENANCE MANUAL
CSPHMI2
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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
64 Contents
Page i
Revision 42
CSPHMI2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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
Page ii
Revision 42
64 Contents
MAINTENANCE MANUAL
CSPHMI2

Para/Figure/Table
5.
Title
Page
Retention Plate and Pitch Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

A. Retention Plate and Pitch Plate Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Retention Plate and Pitch Plate Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
6.
Support Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

A. Support Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Support Shaft Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
7.
Fan Balance Stud Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

A. Fan Balance Stud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Fan Balance Stud Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 402. 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
64 Contents
Page iii
Revision 42
CSPHMI2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
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
4.
Tail Rotor and Pitch Control Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5.
Tail Rotor Pitch Control Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6.
Tail Rotor Blade Stop Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7.
Tail Rotor Pitch Control Link Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8.
Tail Rotor Conical Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9.
Tail Rotor Pitch Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
10. Tail Rotor Swashplate Bearing Regreasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 205. Tail Rotor Swashplate Bearing Regreasing . . . . . . . . . . . . . . . . . . . . .
Figure 206. Tail Rotor Swashplate Bearing Regreasing Tool . . . . . . . . . . . . . . . . .
Figure 207. Tail Rotor Swashplate Holding Block . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 208. Tang Washer Inspection and Application of Torque Stripe . . . . . . . .
Page iv
Revision 42
64 Contents
207
207
208
209
210
MAINTENANCE MANUAL
CSP-HMI-2
Section
640000
AntiTorque
Assembly
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
ANTITORQUE 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,
counteracts main rotor torque and controls
heading of the helicopter. The tail rotor control
system changes the pitch of the tail rotor
blades. The antitorque pedals move a system
of bellcranks and control rods routed through
the fuselage and tailboom to a pitch control
assembly which moves links that attach to
blade-pitch arms on the blades.
The pitch control assembly slides axially on
the tail rotor transmission output shaft.
Pushing forward on the left pedal changes
heading to the left; forward right pedal
movement changes heading to the right.
For two-bladed tail rotor system, blade pitch
movement is -13 degrees to -15 degrees thrust
to the left and +27 degrees to +29 degrees to
the right.
For four-bladed tail rotor system, blade pitch
movement is -13 degrees to -15 degrees thrust
to the left, +31 degrees to +32 degrees thrust
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
with main rotor torque variations, altitude and
airspeed conditions. Control linkage includes a
bungee spring that relieves left pedal forces in
flight.
When the helicopter is on the ground, pedalto-seat distance is adjusted by removing
The two-bladed tail rotor assembly consists

mainly of two tail rotor blades, a hub, drive
fork, two pitch control links, and a pitch
control assembly.
The four-bladed tail rotor assembly consists
of four tail rotor blades, two hubs, drive fork,
four pitch control links and a pitch control
assembly. The blades are held together on the
hub by a laminated tension-torsion strap pack
that permits the blades to rotate axially on the
hub. The hub pivots in the drive fork. Control
of blade pitch is from the pitch control assem
bly through pitch control links that connect to
pitch arms on the blade root fittings.
2. AntiTorque Fan Assembly
The anti-torque fan is an axial fan with
thirteen variable pitch blades. The fan
provides anti-torque by furnishing variable
flow of low pressure high volume air through
the tailboom and thrusters.
During flight, pedal position and pressure
required to maintain a desired heading varies
with main rotor torque variations, altitude and
airspeed conditions. Control linkage includes a
bungee spring that relieves left pedal forces in
flight.
When the helicopter is on the ground, pedalto-seat distance is adjusted by removing
quick-release pins on top of pedal arms and
repositioning pedals.
Table 101. Troubleshooting Tail Rotor and Vibrations

Symptom
Probable Trouble
Heavy mediumfrequency vibration Tail rotor out of balance.

in tail rotor assembly; vibration
sometimes felt in pedals as a
Runout of tail rotor transmission
buzzing sensation.
output shaft excessive.
Corrective Action
Rebalance tail rotor assembly (Ref.
Sec. 182000).
Replace transmission if shaft runout
exceeds 0.0025 inch (0.0635 mm)
T.I.R. No axial play allowed. (Ref.
Sec. 632510).
64-00-00
Page 101
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
Table 101. Troubleshooting Tail Rotor and Vibrations

Symptom
Probable Trouble
Corrective Action
Tail rotor blades slightly out of

balance.
Rebalance tail rotor assembly (Ref.

Sec. 182000).
Tail rotor blade pitch bearings

worn.
Replace tail rotor pitch bearings (Ref.

COM).
Excessive wear in pitch control link

bearings.
Replace pitch control link bearings

(Ref. COM).
Excessive wear of swashplate or

large bearings in housing of pitch
control assembly.
Replace swashplate or repair pitch

control assembly (Ref. COM).
Excessive play in tail rotor fork

bearings.
Replace fork bearings (Ref. COM).
Tail rotor hubtofork play.
Repair (Ref. COM).
Excessive dents in leading edge of

blades.
Replace blade(s) or tail rotor

assembly. (Ref. COM).
Insufficient torque on stabilizer

mount bolts.
Retorque mount bolts (Ref. Chap.

53).
Insufficient torque on tail rotor

assembly retaining nut.
Retorque retaining nut (Ref. Sec.

643000).
Excessive play in pitch control link

assemblies.
Worn pitch control link bearings.
Replace pitch control link bearings

(Ref. COM).
High left pedal forces required in

flight.
Bungee spring (Sta. 63)

disconnected, broken or stretched.
Reconnect or replace bungee spring

(Ref. Sec. 672000).
Pedals binding.
Excessive drag of pitch control

swashplate on transmission shaft.
Clean swashplate bore and

transmission shaft splines.
Relubricate splines.
Snapping noise heard in

nonoperating tail rotor when pitch
angle changed from one extreme
to the other.
Noise is normal action of strap

pack and caused by laminates
twisting and bending when blade is
feathered without centrifugal load
present.
None required.
High frequency vibration, primarily

in pedals as a buzzing sensation.
NOTE: High frequency vibrations in

the helicopter can also be
caused by components of other
systems (Ref. Sec. 182000,
534000, 632510 and
Chap. 71).
Page 102
Revision 34
64-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
640005
FourBladed Tail
Rotor Assembly
Initial Installation
(369D/E)
MAINTENANCE MANUAL
CSP-HMI-2
FOURBLADED TAIL ROTOR ASSEMBLY

1. FourBladed Tail Rotor Initial Installation
This section contains procedures for initial
installation of four-bladed tail rotor kit, which
includes tail rotor; tail rotor transmission; and
parts for modifying over-center trim system
controls and engine/rotor tachometer indicator.
This kit may be installed on all Model 500D
and 500E helicopters at the owner's/operator's
discretion.
(5). Remove existing station 284 bellcrank

and tail rotor control rod (Ref. Sta. 284
Bellcrank Removal).
C. FourBladed Tail Rotor Transmission
BuildUp
(Ref. Figure 901) Build-up the four-bladed tail
rotor transmission as follows.
Item
Nomenclature
CM112
CM305

Lacquer, acrylic
NOTE: Components of the four-bladed tail ro

tor drive system kit are assembled and bal
anced at the factory. Prior to installation of
the kit, some existing equipment must be re
moved from the helicopter, and other equip
ment must be modified.
A. Tail Rotor and Transmission Initial
Installation
Install the four-bladed tail rotor transmission
and tail rotor assembly according to the
following procedures.
B. Existing Tail Rotor and Transmission
Removal
Remove the following equipment from helicop
ter before installing four-bladed tail rotor
transmission and tail rotor assemblies.
(1). Remove existing two-bladed tail rotor
(Ref. Sec. 64-20-00).
(2). Remove tail rotor transmission and
driveshaft (Ref. Sec. 63-25-10).
NOTE: Retain bolt for use when building up

four-bladed tail rotor transmission, cou
pling is a limited-life item. If sufficient ser
viceable life remains on coupling, it may be
reused with four-bladed tail rotor installa
tion. If not, discard and replace coupling
bolt.
(3). Remove bolt, coupling and shims from
transmission output shaft (Ref. Sec.
63-15-10).
(4). Remove index stripe on drive shaft at
Sta. 137.5.
CAUTION
Do not lift transmission assem

bly by coupling flange.
(1). Install shims, coupling and coupling

bolt. Coat threads of bolt with antiseize compound (CM112). Torque bolt to
250 - 300 inch-pounds (28.25 - 33.90
(2). Add stripe of white paint (CM305)
approximately 0.0125 inch (3.175 mm)
wide between ends of decal to allow for
indexing of aft end of drive shaft.
NOTE: To locate new coupling index, use flash

light and look through control tube rod hole
in aft tailboom fitting. Rotate output shaft
until index stripe on coupling is at six o'clock
position.
D. Drive Shaft, Tail Rotor Transmission and
Tail Rotor Installation
(Ref. Figure 901) Install drive shaft, transmis
sion and tail rotor on helicopter as a unit. Do
not install with blades mounted.
Item
Nomenclature
CM305
Lacquer, acrylic
(1). Install existing drive shaft on tail rotor

64-00-05
Page 901
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
TAIL ROTOR
TRANSMISSION
DAMPER
COUPLING
TAIL ROTOR
DRIVESHAFT
STA. 137.50
COUPLING
TAIL ROTOR
TRANSMISSION
(4-BLADED)
WHITE STRIPES 0.125 IN.
(3.175 MM) WIDE
(NEW CONFIGURATION)
WHITE STRIPES 0.125 IN.

(3.175 MM) WIDE
TAIL ROTOR
DRIVESHAFT
WHITE PAINT MARKING

AT 6 0'CLOCK
DOUBLER
STATION 137.50
RING
STA. 137.50
(LOOKING FORWARD)
NOTE: ADD STRIPE OF WHITE PAINT ON COUPLING AT LOCATION
SHOWN, APPROXIMATELY 0.125 IN. (3.175 MM) WIDTH AND
LENGTH, AND AT CONTROL ROD HOLE AT AFT SIDE OF HOUSING.
Figure 901. Tail Rotor Index Stripe Requirements

Page 902
Revision 21
64-00-05
G64-0001A
MAINTENANCE MANUAL
(2). Install assembled unit on helicopter
(Ref. Sec. 63-15-10).
(3). Paint 0.125 inch (3.175 mm) wide and
0.125 inch (3.175 mm) long stripe
(contrasting color to aft tailboom
fitting) at six o'clock position of control
rod in aft tailboom fitting to align stripe
on coupling.
(4). Add white index stripe (CM305) on tail
rotor drive shaft to match stripe on
doubler at Sta. 137.5.
Install bungee installation
WARNING tool (ST508) before discon
necting any pilot's collective stick

hardware. There is strong bungee
spring pressure present in stick link
age. If suddenly released, spring reac
tion in linkage can cause personal inju
ry or parts damage.
(3). Remove bellcranks and collective
bungee spring and bracket; disconnect
and retract lateral cyclic trim actuator
assembly.
(5). Install new tail rotor control rod.

(6). Attach new Sta. 284 bellcrank to new
tail rotor pitch control assembly.
(7). Temporarily install bellcrank to new
control rod assembly.
(8). Install blades on hubs. Install inboard
blades first (Ref. Sec. 64-10-00).
E. Tail Rotor Control OverCenter Trim
System Rework
The tail rotor over-center trim system must be
reworked when four-bladed tail rotor is
installed. Necessary parts for this rework are
included with four-bladed tail rotor kit.
F. TwoBladed OverCenter Trim System
Removal
Prior to rework of over center trim system,
following existing equipment must be removed
and preparations made.
Item
Special Tools
Nomenclature
ST508
Collective bungee installation tool
(1). Remove tail rotor bungee; disconnect

floor-routed tail rotor control rod and
remove and discard spring fitting from
rod. Remove tail rotor idler bellcrank
under pilot seat.
(2). Disconnect tunnel-routed tail rotor
control rod and lateral mixer control
rod at lower rod end.
CSP-HMI-2
Turn off electrical switches
WARNING and disconnect any external

power from helicopter prior to refuel
ing or defueling. Static discharge spark
in presence of fuel vapors can cause
fire or an explosion.
(4). Drain all fuel from fuel cells; purge cells
with dry filtered compressed air.
(5). Fold and displace left fuel cell to permit
bucking of rivets at aft side of canted
wall.
G. FourBladed Over Center Trim System
Initial Installation
(Ref. Figure 902)
Item
Special Tools
Nomenclature
ST508
(1). Locate and clamp fitting (1) and

serrated plate (2) together with serra
tions facing away from fitting. Drill one
0.159 inch (4.0386 mm) diameter rivet
hole with a #21 bit and countersink
hole.
(2). Locate serrated plate (3) and clamp to
seat support structure (4). Ensure
serrations are facing away from seat
support structure. Mark rivet and
screw holes on serrated plate (3) and
seat support structure. Remove ser
rated plate from seat support structure.
64-00-05
Page 903
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
9
7
34
11
35
36
20
21
12
9
(NOTE 2)
14
13
23
15
3 (REF)
2 (REF)
21
NOTE 1
1.00 IN.
(2.54 CM)
1.00 IN.
(2.54 CM)
8
(NOTE 2)
24
26
19
25
0.612 IN.
(15.5448 MM)
0.612 IN.
(15.5448 MM)
22
26
32
2.50 IN.
(6.35 CM)
33
31
10
30
30
29
28
27
5
17
18
1
6
3
CL
1.75 IN.
(4.445 CM)
1.00 IN.
(2.54 CM)
2.00 IN.
(5.08 CM)
16
3.31 IN.
(8.4074 CM)
NOTES:
1. REMOVE 0.12-0.14 IN. (3.048-3.556 MM) ON 369A7304 BRACKET.
2. NOT REQUIRED WHEN 369D27304 BRACKET IS INSTALLED.
Figure 902. Over Center Trim System Installation

Page 904
Revision 21
64-00-05
PILOT'S FLOOR
(REF)
G64-0002A
MAINTENANCE MANUAL
CSP-HMI-2

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
FITTING
SERRATED PLATE
SERRATED PLATE
SEAT SUPPORT STRUCTURE
RIVET
RIVET
BRACKET
BRACE
BRACKET
BELLCRANK
BOLT
BUSHING
WASHER
WASHER
NUT
BOLT
WASHER
NUT
NOTE: Head of rivets not to protrude past base

of serrations.
(3). Attach fitting (1) and serrated plate (2)
together with one rivet (5).
(4). Locate and drill two 0.250-0.254 inch
(6.35-6.4516 mm) diameter screw holes
and two 0.098 inch (2.4892 mm)
diameter rivet holes using a #40 bit
through seat support structure to
match previously marked locations
(step (2).). Countersink rivet holes.
(5). Drill two 0.098 inch (2.4892 mm)
diameter rivet holes with a #40 bit thru
serrated plate (with round bolt holes)
using previously marked locations (step
(2).). Attach serrated plate (3) to seat
support structure using two rivets (6).
NOTE: Check part number of bracket (7). If

bracket is a 369A7304, proceed with step
(6). If 369D27304 bracket is installed, brace
(8) and bracket (9) are not required, proceed
to step (14).
(6). Remove 0.12-0.14 inch (3.048-3.556
mm) maximum material, as required,
from bracket (7) boss lug to achieve a
snug fit between brace (8), bracket (7)
and bellcrank (10).
(7). Temporarily attach bellcrank (10),
brace (8) and bracket (7) with bolt (11),
bushing (12), washers (13, 14) and nut
(15) finger tight.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
RIVET
BOLT
WASHER
NUT
COTTER PIN
BOLT
BUSHING
WASHER
NUT
COTTER PIN
BOLT
WASHER
NUT
COTTER PIN
TAIL ROTOR BUNGEE
SCREW
WASHER
NUT
(8). Install fitting (1) on seat support

structure using bolts (16), washers (17)
and nuts (18).
NOTE: Shim -BSC bracket (9), as required, for

proper fit on canted wall. Shims are not re
quired for -3 bracket (9).
(9). Locate and clamp bracket (9). Drill five
0.193-0.199 inch (4.9022-5.0546 mm)
diameter holes using existing rivet
pattern (Ref. Figure 903).
(10). Attach bracket (9) to canted wall using
five rivets (19) or alternate method of
five screws (34), washers (35) and nuts
(36).
(11). Grasp brace (8) and hold against
bracket (9). Mark mating holes on brace
(8) with those on bracket (9).
(12). Remove brace (8) from bellcrank (10)
and bracket (7). Drill two 0.250-0.254
inch (6.35-6.4516 mm) diameter holes
at locations marked in step (11)..
(13). Install brace (8) on bracket (9) with
bolts (20), washers (21) and nuts (22).
Align opposite end of brace (8) between
bracket (7) and bellcrank (10).
(14). Install bolt (11), bushing (12) and
washers (13, 14) thru bracket (7) and
bellcrank (10). Install nut (15) and
cotter pin (23).
(15). Reinstall tunnel-routed control rods
and floor-routed control rods, with
spring fitting removed.
64-00-05
Page 905
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
Always use bungee installa
WARNING tion tool (ST508) when re

moving attaching hardware. Reaction
of spring when pressure is suddenly re
leased can cause personal injury or
parts damage.
NOTE: Adjust tail rotor pedal force by tighten

ing or loosening the 0.120 inch (3.048 mm)
thread adjustment on bungee female bear
ing assembly. Tighten to maximum 0.120
inch (3.048 mm) thread adjustment on bun
gee female bearing assembly increases ped
al force approximately five pounds; loosen
ing decreases pedal force. Bungee spring
may be attached to any of four holes in fit
ting (1). If excessive left pedal force is re
quired, position spring at lower hole.
H. FourBladed Tail Rotor Controls Rigging
Item
Nomenclature
CM111
Grease, aircraft
Item
Special Tools
Nomenclature
ST508
ST510
ST606

Bungee spring compression tool rod and
channel
T/R swashplate rigging tool
Rigging of four-bladed tail rotor controls is to

be done with tail rotor bungee spring removed.
Tail rotor pitch angles at 3/4 radius shall be:
Full right pedal
14 1
Full left pedal
31 +10
Neutral pedal
7.5 1
Rig tail rotor controls per Tail Rotor Controls

Rigging except use four-bladed tail rotor
control rigging tool (ST606). After rigging,
reinstall tail rotor bungee and carefully
remove bungee installation tool (ST508) using
bungee compression tool rod and channel
(ST510).
(1). Assemble bungee using bungee installa
tion tool (ST508) and instructions for
Page 906
Revision 21
64-00-05
assembly of collective bungee. Coat

parts with grease (CM111) as in
structed. Ensure that 0.120 inch (3.048
mm) of threads are visible between nut
and rod end of bungee female bearing
assembly.
Remove bungee installation
WARNING tool only as instructed.
There is strong bungee spring pressure

present with four-bladed tail rotor
bungee installed. If suddenly released,
spring could cause personal injury
and/or parts damage.
(2). Attach assembled bungee to fitting (1)
using attaching hardware (29 thru 32)
and to bellcrank (10) using attaching
hardware (24 thru 28). Ensure bushing
(25) extends 0.010-0.080 inch
(0.254-2.032 mm) beyond surface of
bungee rod end.
I. Horizontal Stabilizer Tip Weight Removal
Tip weights installed in horizontal stabilizer
for two-bladed tail rotor operation are not
used with four-bladed tail rotor system.
Remove and discard four screws securing tip
plates and weights to horizontal stabilizer.
Reinstall tip plates using four new screws (P/N
NAS1403-15).
J. N2 and NR (Rotor) Tachometer Indicator
Replacement
Remove and replace existing tach indicator
with indicator supplied in four-bladed tail
rotor kit (Ref. Sec. 95-30-00).
K. FourBladed Tail Rotor System
Completion of Installation
Upon completion of kit installation, the
following actions must be completed.
(1). Replace all components, access panels,
covers, etc. removed to gain access to
work area.
(2). Check installation of four-bladed tail
rotor control linkage for discrepancies.
(3). Fill tail rotor transmission with oil (Ref.
Sec. 12-00-00).
(4). Refuel helicopter and perform opera
tional check of four-bladed tail rotor
control system (Ref. PFM).
MAINTENANCE MANUAL
(5). Ensure that Pilot Flight Manual
Supplement is inserted in Section IX,
Rotorcraft Flight Manual.
(6). Ensure that installation of four-bladed
tail rotor kit and appropriate part
numbers, serial numbers and limitedlife data are recorded in helicopter log
book.
CSP-HMI-2
L. Weight and Balance

installation of four-bladed tail rotor kit are
listed in Table 901. After kit installation,
incorporate changes in helicopter weight and
balance record as instructed (Ref. Sec.
08-10-00).

Configuration
Added
Weight
Pounds (kg)
+9.4
Removed
Net Change
(+4.2638)
Arm
inches (cm)
257.2
0.0
+9.4
(+4.2638)
(653.228)
Moment
inlb (kg cm)
+2417.68 (27854.574)
0.0
257.2
(653.228)
0.0
+2417.68 (27854.574)
64-00-05
Page 907
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
BL 0.00
BRACKET
BRACE
OK TO LEAVE
EXISTING RIVETS.
(NOTE)
RIVET (5 REQ'D)
(USE EXISTING
RIVET PATTERN)
WL 13.10
0.032 IN.
(0.8128 MM)
BRACKET
STATION 78.50
CANTED WALL
BL 0.00
BL 6.00 L.H.
-3
NOTE:
OMIT THESE TWO RIVETS WHEN
INSTALLING 369D27003-5 ONLY.
BL 0.00
BRACKET
BRACE
RIVET (4 REQ'D)
(USE EXISTING
RIVET PATTERN)
OK TO LEAVE
EXISTING RIVET
SHIM AS REQUIRED BETWEEN
BULKHEAD AND BRACKET
WL 13.10
BRACKET
0.032 IN.
(0.8128 MM)
SHIM AS REQUIRED BETWEEN

BULKHEAD AND BRACKET
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
Revision 21
64-00-05
MAINTENANCE MANUAL
CSP-HMI-2
Section
641000
Tail Rotor Blades
(369D/E/FF)
MAINTENANCE MANUAL
CSP-HMI-2
TAIL ROTOR BLADES

1. Tail Rotor Blades
Blades are cambered for high thrust to provide
directional control at high altitude. Each
consists of an aluminum honeycomb spar,
aluminum skin, riveted aluminum blade
fittings and an aluminum tip cap; all structur
ally bonded together.
At manufacture, static balancing moments of
all blades are within plus or minus 40 gram
inches of each other by use of a special
balancing fixture and prebalancing with tip
weights. Although erosion or allowable repairs
may cause minor balance moment changes,
such changes are considered negligible enough
to allow direct replacement of any used blade
with a new one and interchangeable use of
blades with remaining service life. In any case
of blade selection or use, inspection, repair and
serviceability requirements must be complied
with. Retirement schedule and remaining
service life of a used blade should always be
considered when making decision to replace a
single blade (Ref. Sec. 04-00-00).
Scratches that do not exceed 0.020 inch

(0.508 mm) depth are permissible if
repaired.
(4). Loose or missing tip weights and
attachment hardware.
(5). Clogged drain openings.
(6). Adhesive separation at exposed edges.
(7). Debonding of tip cap from tail rotor
blade (Ref. Tail Rotor Blade Tip Cap
Repair).
(8). Tip cap rivets for installation and
condition (Ref. Tail Rotor Blade Tip Cap
Repair).
(9). Tail rotor blade pitch bearings for a
maximum 0.250 inch (6.350 mm) play
measured at tip of blade.
3. Abrasion Strip Dye Penetrant and Tap
Test Inspection
(Ref. Figure 202)
2. Tail Rotor Blade Inspection

(Ref. Figure 201) Perform balance check at
intervals specified (Ref. Sec. 05-20-00). If any
of following conditions exist, perform appropri
ate detailed inspections and allowable repairs
(Ref. COM).
(1). Surface cracks, scratches, nicks,
gouges, dents, pits or corrosion.
(2). Leading edge erosion or dents. Visually
check abrasion strip for paint cracking
or chipping along abrasion strip/airfoil
bond line. Use 10X glass to check
abrasion strip/airfoil bond line for
debonding between epoxy adhesive and
abrasion strip. If debonding has
occurred, remove blade from service.
NOTE: If abrasion strip debonding is sus

pected, but cannot be confirmed by visual
inspection, (Ref. Abrasion Strip Dye Pene
trant and Tap Test Inspection).
(3). Root fitting cracks, scratches, nicks and
gouges. No cracks are allowable.
Item
CM729
CM801
Nomenclature
(1). Using a 1/8 inch (3.175 mm) drill bit

and a pencil, fabricate a tapping
hammer by taping drill bit to pencil.
Drill bit should be a minimum of six
inches (15.24 cm) from end of pencil
that is to be held while tapping.
NOTE: Voids are indicated by a dull, dead tone.

Slight tone changes will occur near the tip
cap and along the length of the strip. These
should not be mistaken for voids.
(2). Using the fabricated tapping hammer,
tap test the entire abrasion strip. Hold
end of pencil opposite drill bit and tap
with shank (rounded) end of drill bit. If
void indications are noted, remove
blade from service.
(3). Mask area of blade around abrasion
strip with masking tape (CM729).
64-10-00
Page 201
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
DRAIN OPENING
BALANCE WEIGHT
BLADE
TIP CAP
CLEAR LACQUER
DRAIN OPENING
ROOT FITTING
HUB
RED
TRUNNION
CLEAR LACQUER
O-RING
NUT
WHITE
CRUSH WASHER
BUSHING
BUSHING
CRUSH WASHER
BOLT
3.0 IN. (7.62 CM) RED
3.0 IN. (7.62 CM) WHITE

BLADE
3.0 IN. (7.62 CM) RED
G64-1000A
Figure 201. Tail Rotor Blade

Page 202
Revision 21
64-10-00
MAINTENANCE MANUAL
CSP-HMI-2
SHOWN ABOVE:
UNBONDING OF EPOXY ADHESIVE AND ABRASION STRIP

WITH SEPARATION BETWEEN ABRASION STRIP AND
AIRFOIL SURFACE, BLADE UNACCEPTABLE FOR SERVICE.
SHOWN RIGHT:
UNBONDED AND DISPLACED ABRASION STRIP AT

BLADE TIP; SEPARATION BETWEEN ABRASION
STRIP/AIRFOIL SURFACE ALONG BOND LINE,
BLADE UNACCEPTABLE FOR SERVICE.
DRILL BIT, 1/8 IN.

(3.175 MM)
PENCIL
MIN. 6.0 IN.

(15.24 CM)
TAPE
TAPPING TOOL FOR FABRICATION

G64-1002A
Figure 202. Inspection of Tail Rotor Blade Abrasion Strip
64-10-00
Page 203
Revision 21
CSP-HMI-2
MAINTENANCE MANUAL
Do not use chemical paint re

mover to remove paint from
abrasion strip. Chemicals can attack the
abrasion strip to blade bonding agent.
CAUTION
(4). Using 220 grit abrasive paper (CM801),

sand dry, removing all paint from the
abrasion strip. Ensure abrasion to
airfoil bondline is exposed. Clean paint
dust from blade.
NOTE: Do not remove masking tape from blade

until completion of dye penetrant inspec
tion.
(5). Visually check abrasion strip to blade
bonding using a 10X magnifying glass.
If bond failure is obvious, remove blade
from service.
(6). Dye penetrant inspect, according to
(a). Inspect entire abrasion strip to blade
bond line, including abrasion strip
bond in blade tip cap area.
(b). Apply penetrant using a small brush
or swab to prevent damage to blade
paint, and to minimize clean-up.
(c). Allow penetrant to remain on surface
of abrasion strip bondline for five
minutes minimum.
(d). Use dry lint free cloth or paper towel
to remove excess penetrant.
(e). Apply remover to cloth or lint free
towel to remove remaining surface
penetrant.
NOTE: Never spray or flush area of inspection
ure. Bond failure is indicated by penetrant

bleedout from under the abrasion strip, and
will appear as a line along the edge of the
strip. The 5X magnifying glass will aid dis
tinguishing between porosity voids and
bleedout from under the abrasion strip. It
may be necessary to wipe off, then reapply
the developer to distinguish between poros
ity voids and bond separations. The most
positive indication of bond failure will nor
mally appear during the first one to seven
minutes following developer application.
(8). Using a 5X magnifying glass, examine
bond line to determine if penetrant dye
is indicating a bond separation. If bond
separation is noted, remove blade from
service.
(9). Remove masking tape from blade.
(10). Inspect blade for cleanliness and paint
damage. Clean and repair paint
damage as necessary (Ref. Sec. 20-30).
NOTE: Do not repaint abrasion strip or abra

sion strip to blade bond line.
(11). Check tail rotor balance (Ref. Sec.
18-20-00).
(12). If blade is removed from service
because of separation or voids, notify an
Approved MDHS Service Center or
Distributor for disposition. Those
blades in which voids are found shall be
sent to an approved repair station for
abrasion strip replacement.
4. Tail Rotor Blade Tip Cap Repair
(Ref. Figure 203)
with cleaner.
(f). Ensure thorough penetrant removal
from surface before applying develop
er.
(7). Apply a light film of developer on the
area of examination.
NOTE: The epoxy adhesive used to bond abra

sion strip to blade may have porosity voids.
The penetrant will form a circular pattern
around voids resulting from porosity. These
circular patterns do not indicate bond fail
Page 204
Revision 21
64-10-00
Item
Nomenclature
CM222
CM318
CM411
CM804
Primer
Adhesive, epoxy
Emery cloth, fine
(1). Remove tail rotor blade from helicopter

(Ref. Tail Rotor Blade Replacement
Procedure).
MAINTENANCE MANUAL
CSP-HMI-2
0.60 IN. (1.524 MM)

(NOTE 1)
0.250 IN. (6.35 MM)

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
FIBERGLASS CLOTH & 3135 A & B EPOXY
RESIN (CREST PRODUCTS OR EQUIVALENT)
AS SHOWN.
SURFACE PREPARATION: ABRADE SURFACE
WITH EMERY CLOTH AND WIPE WITH 1, 1,
1-TRICHLOROETHANE SOLVENT. DO NOT
ALLOW RESIN TO BUILD UP IN 0.250 IN. (6.35
MM) DIA. HOLE.
0.390 0.060 IN.

(9.91 1.524 MM)
HOLE LOCATION
0.690 IN. (17.53 MM)

ALONG BLADE CONTOUR
NOTE 2
0.380 IN.
(9.65 MM)
0.250 IN.
(6.35 MM)
0.30 IN.
(7.62 MM)
0.250 IN.
(6.35 MM)
NOTE 2
0.50 IN. (12.70 MM)

ALONG BLADE CONTOUR
(NOTE 2)
NAS 1739B4-2 RIVET
(4 PLACES)
NOTES:
1. FIBERGLASS THIS AREA. DO NOT PLACE FIBERGLASS
CLOTH OVER OPENING FOR BALANCE WEIGHTS.
2. USE NO.27 DRILL AND 1005 COUNTERSINK WITH NO. 30
PILOT. COUNTERSINK TO MAXIMUM 0.035 IN. (0.889 MM) DEPTH.
INSTALL NAS 1739B4-2 RIVET. SEAL RIVET WITH CLEAR
EPOXY (CM411).
G64-1001A
Figure 203. Installation of Tip CapToTail Rotor Blade Rivets
64-10-00
Page 205
Revision 21
CSP-HMI-2
MAINTENANCE MANUAL
Handle blade carefully. Dents,

nicks or scratches may cause
balance problems at reinstallation, or make
blade unserviceable.
CAUTION
(2). With blade on a clean hard surface,

measure and mark locations for rivet
holes.
(3). Using No. 27 drill, carefully drill holes
at locations marked on outboard and
inboard surfaces of blade.
(4). Using 100 1 countersink with No. 30
pilot, countersink holes to 0.035 inch
(0.889 mm) maximum depth.
(5). Apply primer (CM318) to holes and
install rivets while primer is wet.
(6). Coat installed rivets with clear epoxy
(CM411).
(7). Drill a 0.250 inch (6.35 mm) diameter
hole through tip cap (Ref. Figure 203).
Tip cap is 0.070 inch (1.778 mm) thick
at point to be drilled.
(8). Remove FOD from blade interior
through hole.
CAUTION
Trichloroethane may damage

blade paint finish.
(9). Abrade surface surrounding hole using

emery cloth (CM804); wipe clean using
clean cloth dampened with trichloroe
thane (CM222).
CAUTION
Do not allow resin to build-up in

hole.
(10). Bond two plies of 120 fiberglass cloth

over hole with 3135A and B epoxy resin
or equivalent. Allow epoxy to cure
according to manufacturer's instruc
tions.
5. Tail Rotor Blade Replacement Procedure
Item
CM318
Nomenclature
Primer
NOTE: Always record number and location of

existing balance washers when replacing
blade. This record aids in dynamic balance
troubleshooting.
(1). Remove cotter pin, nut, washer and
pitch arm bolt from outboard end of
pitch control link.
Bolt, nut, washers and bushings
may be reinstalled if service
able. If bushing and crush washers are to be
reused, they must be installed in the exact
location from which they were removed. If
either the blade or strap pack assembly from
which they were removed is replaced, re
place crush washers and bushing. Bushings
must be free of nicks and burrs.
CAUTION
NOTE: If same blade is to be reinstalled, retain

intact for reuse. Note and record number
and type of balance washers and attach
ment hardware used on bolt at blade pitch
arm.
(2). Remove bolt that secures blade to
outboard strap pack shoes.
(3). Withdraw blade from hub trunnion.
Do not disassemble strap shoes
from end of strap pack protrud
ing from trunnion. Strap pack parts are not
individually replaceable and must remain
assembled. Avoid damaging strap pack.
Scratches or nicks on strap pack laminates
may make strap pack unserviceable.
CAUTION
NOTE: No axial play is allowed in the strap as

sembly shoes. Rotational movement is per
missible.
(11). Reinstall tail rotor blade on helicopter

(Ref. Tail Rotor Blade Replacement
Procedure).
(4). If strap pack is to remain exposed for

any length of time, wrap exposed end of
strap pack with wax paper or other
similar non-abrasive material to
protect from damage.
(12). Check and adjust tail rotor blade

balance (Ref. Sec. 18-20-00).
(5). If blade being removed is to be rein

stalled, do not remove blade tip screw,
Page 206
Revision 21
64-10-00
MAINTENANCE MANUAL
any balance washers or weight from
blade.
NOTE: Remove old primer from mating sur

faces and attaching hardware prior to reas
sembly.
(6). To install blade, remove any protective
covering from strap pack extending
from hub trunnion.
(7). Install O-ring and slide blade on hub
with blade leading edge facing in
counterclockwise direction. Use care to
keep blade correctly aligned so that hub
trunnion slides into blade pitch bear
ings. Do not use force.
(8). Align bolt holes in root fitting with hole
through bushing in outboard shoes of
strap pack.
(9). Coat contacting surfaces of bushings,
washers, nuts and bolts with unthinned
primer (CM318) and immediately
perform following steps.
(10). Assemble and install bolt, bushings and
washers in sequence (Ref. Figure 201).
Make certain that direction of bolt is
opposite to that of opposing blade. Do
not force bolt; it must have an easy but
snug fit through blade, shoes and
bushings.
NOTE: It is recommended that the MS 21250

bolt be replaced with any of the alternate
bolts with the higher torque at the operators
earliest convenience.
(11). If an MS 21250 bolt is installed, install
nut and torque to 600 - 650 inchpounds (67.79 - 73.44 Nm) while
primer is wet. If an HS5482-6,
HS4441-6, or an LWB22-6 bolt is
installed, torque nut to 750 - 775
inch-pounds (84.74 - 87.56 Nm).
After blade is secured to strap
pack assembly, do not allow
blade pitch travel from neutral to exceed 30
degrees in either direction. Rotating blade
to excessive pitch angles may result in unde
tected damage to strap assembly.
CAUTION
(12). Check that bolthead is flat against

bushing. No gap is permitted. If gap is
found, replace bolt and bushing.
CSP-HMI-2
(13). Install pitch control links (Ref. Sec.

64-30-00).
NOTE: If same blade that was removed is being

reinstalled, install same number of balance
washers on pitch arm bolt that were present
prior to removal of blade. For different
blade, install balance washers required for
static chordwise balance of assembled tail
rotor which have been determined with a
balance fixture.
(14). Balance tail rotor (Ref. Sec. 18-20-00).
6. Tail Rotor Abrasion Strip Riveting
adding rivets at the outboard ends of the
abrasion strip to provide a secondary failsafe
method of attachment.
This procedure is effective on tail rotor blades:
369A1613-7, -503, -505,
369D21606-BSC,
369D21613-11, -31, -41, -51,
369D21615-BSC, -21,
421-088
Nomenclature
Item
CM222
CM318
CM804
N/A
N/A
Primer
Emery cloth, fine
Fiberglass cloth, No. 120
Epoxy resin, Spec. 3135A and B or any 2
part (1:1) clear epoxy resin
Do not attempt to perform this

procedure with the tail rotor
blades installed on the helicopter. Failure to
comply with this caution may result in de
fective rivet installation and possible blade
damage.
CAUTION
(1). Remove tail rotor blades from helicop

ter (Ref. Tail Rotor Blade Replacement
Procedure).
(2). Using a 10X magnifying glass, perform
a visual inspection of the tail rotor
blade abrasion strip bond lines for
debonding.
64-10-00
Page 207
Revision 32
MAINTENANCE MANUAL
CSP-HMI-2
0.60 IN. (1.524 MM)

(NOTE 1)
0.250 IN. (6.35 MM)
HOLE
0.30 IN. (7.62 MM)
CL
NOTE 2
0.390 0.060 IN.
(9.91 1.524 MM)
0.810 0.030 IN.

(20.57 0.762 MM)
HOLE LOCATION
1.160 0.030 IN.

(29.464 0.762 MM)
0.280 0.030 IN. (7.110 0.762 MM)

ALONG CONTOUR (BOTH SIDES)
ABRASION STRIP
BLADE SKIN
VIEW LOOKING
DOWN
NOTE:
1. FIBERGLASS THIS AREA. DO NOT PLACE FIBERGLASS CLOTH OVER OPENING
FOR BALANCE WEIGHTS.
2. COUNTERSINK HOLE 100, DEPTH 0.009-0.011 IN. (0.229-0.2794 MM).
Figure 204. Tail Rotor Blade Abrasion Strip Riveting

Page 208
Revision 21
64-10-00
G64-1005A
MAINTENANCE MANUAL
(3). If abrasion strip debonding is suspected
but cannot be confirmed by visual
inspection, perform Abrasion Strip Dye
Penetrant and Tap Test Inspection.
(e). Inspect hole in abrasion strip.

(11). Remove FOD from interior of blade as
follows:
(a). Drill 0.250 inch (6.35 mm) hole
through tip cap as shown.
NOTE: Tail rotor blades removed for voids

must be removed in ship sets.
(b). Remove FOD from blade interior

through hole (there is space at tip cap
end for debris to pass aft of spar).
(4). If voids are found in blade, remove and

send to an authorized repair station for
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
clean using clean, lint-free cloth
dampened with 1,1,1-trichloroethane
(CM222).
NOTE: When performing the following step,

use drill bit stop to prevent drilling through
both sides of blade.
(6). Using a No. 27 cobalt drill bit, drill
holes at locations shown (light center
punch prior to drilling is allowed).
(7). Deburr holes with a 100 countersink to
a depth of not more than 0.011 inch
(0.2794 mm).
(8). Apply primer (CM318) to holes and
install CS2545-4-1 or CR3555-4-1
rivets while primer is wet.
Installed rivet stems may be de
burred using a file. Do not re
move material from locking collar.
CAUTION
(9). Inspect installed rivets.

(10). If rivet installation is not satisfactory,
remove as follows:
During removal of defective riv
et, observe the following:
Do not damage or enlarge hole.
Do not drive or force rivet stem from hole.
Do not remove rivets common to tip cap.
CAUTION
CAUTION
(c). Using a drill stop, drill through rivet

sleeve using care to prevent hole
enlargement.
(d). Push remaining rivet sleeve through
hole.
Do not allow resin to build up in

hole.
(e). Bond two plies of fiberglass cloth over

hole with epoxy resin.
(12). Repeat inspection of abrasion strip.
(13). Reinstall tail rotor blades.
(14). Perform tail rotor balance (Ref. Sec.
18-20-00, Tail Rotor Blade Balancing).
7. Tail Rotor Blade Abrasion Strip
Modification
application of a 0.0027 inch (0.06858 mm).
thick strip of stainless steel tape over the
inboard end of the abrasion strip.
This procedure is effective on tail rotor blades:
369A1613-7, -503, -505, -509,
369D21606-BSC, -509,
369D21613-11, -31, -41, -51, -71,
369D21615-BSC, -21, -41,
421-088
(a). Carefully grind off locking collar and

upper portion of rivet head.
(b). Carefully push center stem through
rivet sleeve.
CSP-HMI-2
Item
Nomenclature
CM220
CM801
Naphtha aliphatic
NOTE: Abrasion strip must have rivets

installed before applying stainless steel
tape.
64-10-00
Page 209
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
(1). Using a 10X magnifying glass, perform

a visual inspection of the tail rotor
blade abrasion strip bond lines for
debonding.
(2). If abrasion strip debonding is suspected
but cannot be confirmed by visual
inspection, remove blades and perform
Abrasion Strip Dye Penetrant and Tap
Test Inspection.
NOTE: Tail rotor blades removed for voids

must be removed in ship sets.
8. Tail Rotor Blade Protective Tape

Installation
Item
Nomenclature
CM220
CM304
CM801
N/A
N/A
Naphtha aliphatic
Enamel, epoxy
3M aerosol primer MITO-0081
3M mylar tape P/N Y8671-1
(3). If voids are found in blade, remove and

send to an authorized repair station for
repair.
NOTE: This installation is only approved on
(4). Lightly abrade faying surface of tail

installed with 400-grit abrasive paper
(CM801).
In an effort to reduce the amount of erosion in

the area inboard of the abrasion strip, MDHS
has approved the installation of mylar tape to
the blade leading edge. Installation of the tape
is optional.

(CM220) to eliminate grease and dirt
film.

120F (49C).
abraded area.
(7). Remove backing and apply stainless
steel tape to leading edge of tail rotor
blade.
blade equally.
of abrasion strip 0.50 0.03 inch
(12.70 0.762 mm) at the leading
edge of blade.
NOTE: Abrasion tape must be free of surface

wrinkles or air bubbles.
hand.
bonding.
Page 210
Revision 21
64-10-00
tail rotor blades equipped with the new

abrasion strips.
The length of the tape can vary, up to 2.0

inches in length, but must be equal on both
blades.
It is recommended to start with 1.5 inch (3.81
cm) length and increase the length as erosion
occurs by replacing the tape.
Do not cut or trim tape after
installation on blade, damage to
blade will occur.
CAUTION
(1). Measure length of eroded area on blade

with the most erosion.
NOTE: Tape must be of equal length on both

blades to ensure proper balance.
(2). Cut tape long enough to cover erosion
plus approximately 0.50 inch (12.70
mm) overlap on leading edge abrasion
strip.
(3). Round off square corners of tape to
reduce peeling.
(4). Lightly abrade faying surface of tail
installed with 400 grit abrasive paper
(CM801).
film.
MAINTENANCE MANUAL
CSP-HMI-2
1.00 IN.
(2.54 CM)
3.00 IN.
(7.62 CM)
0.50 IN.
(12.70 MM)
1.00 IN.
(2.54 CM)
OLD STYLE ABRASION STRIP

NOTES 1 AND 2
0.50 IN.
(12.70 MM)
0.50 IN.
(12.70 MM)
NEW ABRASION STRIP
NOTES:
1. 304 STAINLESS STEEL OR MYLAR TAPE SHALL BE APPLIED; 0.50 IN. (12.70 MM)
TO ABRASION STRIP AND 0.50 IN. (12.70 MM) TO TAIL ROTOR BLADE.
2. APPLY TAPE EQUALLY TO BOTH SIDES OF BLADE.
G64-1006C
Figure 205. Tail Rotor Blade Abrasion Strip Modification
64-10-00
Page 211
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
(6). Treat any bare metal with epoxy-type

paint (CM304).

120F.
abraded area.
(8). Apply aerosol primer to bonding area
and allow to dry.
(9). Remove backing and apply tape to
blade equally.
of abrasion strip 0.50 0.03 inch
(12.70 0.762 mm) at the leading
edge of blade.
NOTE: Tape must be free of surface wrinkles or

air bubbles.
hand.
bonding.
18-20-00).
9. Tail Rotor Blade Leading Edge Crack
Inspection
(Ref. Figure 206)
Item
Nomenclature
CM220
CM801
Naphtha aliphatic
Do not use any chemicals to re

move the paint and do not pene
trate the metal skin of the blade.
CAUTION
A. Tail Rotor Blades with NewStyle

Abrasion Strips
(1). Inspect leading edge for any evidence of
cracking in the area shown; no cracks
are allowed.
Page 212
Revision 22
64-10-00
(2). If cracks are suspected, perform a dye

penetrant inspection of the suspect area
as follows:
(a). Lightly abrade faying surface of tail
rotor blade in area where tape is to
be installed with 400-grit abrasive
paper (CM801).
(b). Wipe abraded area with naphtha
film.
(c). Perform dye penetrant inspection on
the suspected area per MIL-I-25135,
or equivalent.
(d). Tail rotor blades with evidence of
cracking must be removed from
service.
NOTE: Tail rotor blades with the new abrasion

strip configuration cannot be intermixed
with tail rotor blades that have the old abra
sion strip configuration.
(e). If there is no evidence of cracking,
the blade can be cleaned and touchup epoxy paint applied to the affected
area.
(3). To reduce erosion, apply protective tape
to the blades (Ref. Tail Rotor Blade
Protective Tape Installation).
B. Tail Rotor Blades with OldStyle
Abrasion Strips
(1). Remove stainless steel tape from the
leading edge at the inboard end of the
abrasion strip.
(2). Inspect that area for evidence of cracks;
no cracks are allowed.
(3). If cracks are suspected, perform a dye
penetrant inspection of the suspect area
as follows:
(a). By lightly abrading the blade skin,
carefully remove the paint from the
suspected area.
(b). Perform dye penetrant inspection on
the suspected area per MIL-I-25135,
or equivalent.
(c). Tail rotor blades with evidence of
cracking must be removed from
service.
MAINTENANCE MANUAL
NOTE: Tail rotor blades with the new abrasion

strip configuration cannot be intermixed
with tail rotor blades that have the old abra
sion strip configuration.
(d). If there is no evidence of cracking,
the blade can be cleaned and touchup epoxy paint applied to the affected
area.
(4). Install new 0.0027 inch (0.06858 mm)
thick stainless steel tape in the same
location as follows (Ref. Figure 205):
(a). Lightly abrade faying surface of tail
rotor blade in area where tape is to
be installed with 400-grit abrasive
paper (CM801).
(b). Wipe abraded area with naphtha
film.

120F (49C).
CSP-HMI-2
(c). Using a heat gun, or equivalent, heat

abraded area.
(d). Remove backing and apply stainless
steel tape to leading edge of tail rotor
blade.
1). Apply tape so it overlaps each side
of blade equally.
2). Tape should overlap the inboard
end of abrasion strip 0.50 0.03
inch (12.70 0.762 mm) at the
NOTE: Abrasion tape must be free of surface

wrinkles or air bubbles.
(e). Smooth and press tape into place by
hand.
(f). Re-apply pressure by hand following
bonding.
64-10-00
Page 213
Revision 22
CSP-HMI-2
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
Revision 22
64-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
642000
Tail Rotor Hub and
Fork (369D/E/FF)
MAINTENANCE MANUAL
CSP-HMI-2
TAIL ROTOR HUB AND FORK

1. Tail Rotor Hub and Fork
(Ref. Figure 201) This section covers mainte
nance of the hub, strap pack and fork as an
assembled unit. For all other maintenance
instructions pertaining to hub and fork
assembly, and the hub assembly, strap pack
and fork assemblies as separately-maintain
able components, Ref. COM.
When blades are removed from
hub, exposed ends of strap pack
should be protected with covering (Ref. Sec.
64-10-00). Hub and fork should be handled
carefully to avoid damage to strap pack.
CAUTION
2. Tail Rotor Hub and Fork Replacement

A. Tail Rotor Hub and Fork Removal
Item
Special Tools
Nomenclature
ST607
On four-bladed tail rotor
WARNING system, there is strong
spring pressure in installed tail rotor

linkage. Disconnect the in-line bungee
before beginning disassembly. Failure
to disconnect the bungee can result in
personal injury and/or parts damage.
(1). On four-bladed tail rotor, disconnect
in-line bungee (Ref. Sec. 67-20-10) if
tail rotor is installed on helicopter.
CAUTION
D Whenever blades and hub are removed as
an assembly, or whenever pitch control
links are disconnected, do not allow blade
pitch to exceed 30 degrees from neutral
pitch position. This is equal to blade pitch
control arm movement of approximately
one inch in either direction. Unrestricted

rotation of blades on hub can excessively
bend or stretch strap pack and cause un
detected damage to strap pack and an
out-of-balance tail rotor when reas
sembled.
D To prevent balance problems at reassemb
ly of parts and hardware, mark exact
number, locations and positions of all
items before removal for correct reinstal
lation.
D On two-bladed tail rotor system do not
remove hub-to-drive fork hinge bolt to
remove tail rotor assembly. On fourbladed tail rotor system hub-to-drive
fork hinge bolt removal is required. This
bolt should only be removed according to
instructions Ref. COM. Damage to strap
pack may occur if any other procedure is
used.
(2). Disconnect pitch control links from
blade pitch control arms.
(3). Pull rotating boot out of groove in fork.
(4). On four-bladed tail rotor system
remove inboard and outboard blades
and hubs to access fork tang washer
and nut.
NOTE: Helicopters Serial Nos. D0003 thru

D1024 had a two-piece retaining nut and
stop support. Helicopters subsequent to
D1024 have a one-piece retaining nut and
stop support.
(5). Straighten tang of tang washer.
(6). Using torque wrench adapter (ST607),
loosen retaining nut and slide tail rotor
outward on output shaft of tail rotor
transmission to remove blade stop and
stop support.
(7). Remove nut, tang washer, tapered ring,
and split-ring halves that fit into recess
at inboard end of fork.
64-20-00
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Revision 21
CSP-HMI-2
MAINTENANCE MANUAL
OUTBOARD
STRAP SHOES
FORK
HUB
STRAP PACK
ASSEMBLY
INBOARD STRAP
SHOES
30
30
(SEE CAUTION)
HUB TRUNNION
PITCH CONTROL LINK
DRAIN
OPENING
BALANCE
WEIGHT
TIP CAP
DRAIN
OPENING
CHORDLINE AT
NEUTRAL PITCH
CAUTION:
SHOES NOT TO BE REMOVED FROM STRAP PACK, AVOID DAMAGING
STRAP PACK; SCRATCHES OR NICKS ON STRAP LAMINATES MAY MAKE
STRAP PACK UNSERVICEABLE.
LOOKING AT BLADE
END (TIP)
Figure 201. Tail Rotor Hub and Strap Pack

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64-20-00
G64-2000
MAINTENANCE MANUAL
CAUTION
Tail rotor tang washer must not

be reused.
NOTE: Placing grease pencil mark on drive

fork to key it to transmission output shaft
enables subsequent installation of tail rotor
assembly at same position.
Application of small painted matchmark
next to centerline splined groove on both
pitch control assembly and tail rotor drive
fork aids reassembly at same position on
transmission shaft.
One spline groove of fork is located directly
on centerline passing through centers of the
two fork bearings while, at opposite side of
spline bore, same centerline passes through
a spline tooth. A similar condition exists
with respect to swashplate splines, except
that reference centerline originates between
swashplate arms.
For illustrations showing matchmarks and
additional information, Ref. COM.
(8). Slide tail rotor assembly off output
shaft.
B. Tail Rotor Hub and Fork Installation
Item
Nomenclature
CM115
CM318
Primer
CM702
Lockwire CRES
Item
Special Tools
Nomenclature
ST607
(1). Attach rotating boot; attach to pitch

control assembly using safety wire
(CM702).
(2). Install split ring on output shaft of
transmission.
CSP-HMI-2
It is possible for pitch control

swashplate to be misaligned by
one-half spline in relation to drive fork.
Make sure drive fork, pitch links and swash
plate are in exact alignment with transmis
sion shaft centerline. If incorrectly as
sembled, swashplate will be misaligned
approximately 10 degrees from drive fork.
To correct this condition, remove tail rotor
assembly (leaving pitch control assembly in
stalled), rotate tail rotor assembly 180 de
grees and reinstall it.
CAUTION
(3). Slide tail rotor assembly onto shaft

with drive fork-to-hub pivot bolt
aligned with swashplate lugs. Position
tail rotor assembly on shaft so that
approximately two threads at shaft end
are exposed outboard of drive fork.
(4). Coat tapered ring with primer (CM318)
and install it on shaft, making certain
that tapered edge parallels chamfer in
fork. Perform the following steps while
primer is wet.
NOTE: Pre-assembly of tang washer, nut, stop

support and stop as a unit aids in their in
stallation when performing steps (5). thru
(7). below. Marking outer tang that is next to
inner key on tang washer, before assembly
of parts, simplifies alignment with keyway
on shaft. Teeter blades to start tang washer
on shaft.
(5). Slip new tang washer over exposed
threads of shaft; key tang must face
inboard toward gearbox. Install nut
approximately two full turns on shaft
threads to verify threads engaged.
(6). Slide tail rotor assembly outboard
against nut. Install stop support by
inserting it in drive shaft end.
In next step do not force stop
into position with screwdriver;
this can crack the stop.
CAUTION
(7). Coat contacting surfaces of stop with

grease (CM115) and insert it in stop
support.
(8). Install split ring halves in shaft groove
and slide fork inboard until ring halves
are secured by recess in fork.
(9). Visually align a tang on tang washer
with any convenient reference point.
64-20-00
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Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
PITCH CONTROL ASSEMBLY
NOTE 1
SPLIT RING
(WIRE SPRING)
TAIL ROTOR
ASSEMBLY
ROTATING BOOT
FORK
TRANSMISSION
OUTPUT SHAFT
HINGE
BOLT
FORK BEARING
TANG WASHER
(NOTE 2)
RETAINING NUT
STOP SUPPORT
TAPERED RING
PITCH ARM
STOP
NOTE 3
TORQUE WRENCH
AND ADAPTER
NOTES:
1. CENTERLINE TOOTHSPACE MATCHMARK MUST ALIGN WITH
CENTERLINE TOOTH-SPACE MARK ON FORK WHEN ASSEMBLED ON
OUTPUT SHAFT.
2. DISCARD USED TANG WASHER; BEND TWO TANGS TO SECURE NUT.
3. TOOL PN 369D29823 (ST607).
G64-2001D
Figure 202. Hub and Fork Assembly Installation (TwoBladed)

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64-20-00
MAINTENANCE MANUAL
CSP-HMI-2
NOTE 1
PITCH CONTROL
PITCH ARM
ROTATING BOOT
SPLIT RINGS
FORK
TAIL ROTOR ASSEMBLY
RING, FORK SUPPORT
NOTE 3
NUT, STOP SUPPORT
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).
G64-2002C
Figure 203. Hub and Fork Assembly Installation (FourBladed)
64-20-00
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CSP-HMI-2
MAINTENANCE MANUAL
(10). Torque retaining nut, using torque

wrench adapter (ST607), to:
(a). Torque two-bladed retaining nut to
450 - 500 inch-pounds (50.84 56.49 Nm).
(b). Torque four-bladed retaining nut to
550 - 600 inch-pounds (62.14 67.79 Nm) and ensure wire-spring
split ring halves are firmly imbedded
in fork recess.
NOTE: Tang washer movement of more than

one tang width is an indication that tang
washer inner key tang is sheared. This con
dition requires replacement of tang washer
and reassembly of parts according to initial
installation procedure.
(11). Check that tang has not moved more
than one tang width in relation to
reference point noted in step (9).
(12). Measure clearance between tang
washer and fork.
(0.127 mm), replace tapered ring and/or
fork assembly.
(14). Bend two tangs on tang washer to lock
retaining nut. When bending tangs, do
not force-form tang to match nut
contour; maintain natural bend radius
that develops at tang root.
(15). Apply torque stripe paint across nut,
tang washer and fork assembly in
location that can be checked visually.
(16). Insert edge of rotating boot into groove
of drive fork.
(17). Install pitch control links (Ref. Sec.
64-30-00).
(18). Position tail rotor pedals in neutral
position and recheck that drive fork,
pitch links and swashplate are in exact
alignment with transmission shaft
centerline.
(19). On four-bladed tail rotor system,
reconnect bungee (Ref. Sec. 67-20-10).
(20). Check rigging of tail rotor controls (Ref.
Sec. 67-20-10).
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Revision 44
64-20-00
3. Tail Rotor Hub and Fork Inspection

(Ref. Figure 201) Hub inspection is accom
plished with tail rotor blades removed.
(1). Inspect areas on hub trunnions that
mate with blade pitch bearings for
excessive wear and for damage.
(2). Check hub and fork for axial play or
bearing roughness when hub is pivoted
from one extreme to the other.
(3). Check torque of fork hinge bolt. Apply
125 inch-pounds (14.12 Nm) torque
to nut or bolt. If bolt or nut does not
rotate, preload is correct. If bolt or nut
rotates, retorque. (For repair limit,
torquing requirements and replacement
criteria, Ref. COM.)
(4). Check visible areas of strap pack for
nicks or scratches on strap laminates,
cracked or kinked laminates and sharp
bends or permanent twists in lami
nates. Any one of these defects, except
minor outer surface defects that can be
removed by abrasive polishing, requires
replacement of strap pack. (For infor
mation on allowable repairs, service
ability requirements and replacement,
Ref. COM.)
4. Conical Bearing Inspection
Visually inspect conical bearings installed in
fork assembly, at intervals specified (Ref. Sec.
05-20-00).
(1). Play is not permitted in conical drive
fork bearings.
5. Elastomeric Fork Bearing Inspection
Visually inspect elastomeric bearings installed
in fork assembly, at intervals specified (Ref.
Sec. 05-20-00) for damage and debonding
from fork as follows.
Elastomeric materials can be
damaged by solvents, grease or
oil. If cleaning is necessary, refer to Elasto
meric Bearing - Care and Cleaning.
CAUTION
(1). Apply teetering force by hand to rotor

blades (stop-to-stop). Check for
fork-to-bearing bond failure. Failure is
indicated by any motion between outer
MAINTENANCE MANUAL
bearing cage and fork (bearing turns in
fork). If failure is noted, remove bearing
and rebond in fork according to instruc
tions in the COM.
CSP-HMI-2
pounds (6.672-22.24 N). If load is not

within specified limit, replace bearing.
(8). Reinstall rubber blade stop.
(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
ity in molded ridges indicates bearing
failure and bearing must be replaced.
(3). Check bearing for general condition.
Replace bearing if damaged. Evidence
of light swelling, pock marks and
crumbs are surface conditions and are
not indications of bearing failure.
(4). Elastomeric bearings are suspected of
being unserviceable if visual inspection
reveals rubber deterioration or separa
tion, or a vibration is reported. Perform
following steps to check blade flapping
resistance measurement to determine if
suspected elastomeric bearing has
failed.
(5). To perform measurement, remove
rubber blade stop between tail rotor
hub and fork on inboard hub. The
outboard tail rotor assembly can be
checked without any disassembly.
Do not remove hub-to-drive
CAUTION fork hinge bolt to remove
2-bladed tail rotor assembly. This bolt
should only be removed according to in
structions in the COM. Damage to strap
pack may occur if any other procedure is
used.
(6). The rubber blade stop must be re
moved. Reassemble tail rotor with
rubber blade stop removed.
(7). Measure flapping resistance of blades
using spring scale attached within 1.00
inch (2.54 cm) for 369D/E or 2.00 inch
(5.08 cm) for 369FF inboard of blade tip
(Ref. Figure 204). Block or hold tail
rotor pedal in neutral position. While
pulling 90 degrees from plane of
rotation, record spring scale value when
blade tip is 3.00 inches (7.62 cm)
inboard and outboard from no-load
position. Scale must indicate 1.5-5.0
TAIL ROTOR
STRING
SPRING SCALE
2.00 IN.
(5.08 CM)
1.00 IN.
(2.54 CM)
369F/FF
369D/E
STRING
3.00 IN.
(7.62 CM)
SPRING SCALE
3.00 IN.
(7.62 CM)
ZERO LOAD POSITION
VIEW LOOKING AFT
G64-2003A
Figure 204. Blade Flapping Resistance

Check
6. Elastomeric Bearing Care and Cleaning
Elastomeric bearings are not inherently
resistant to grease, oils or solvents if im
mersed. They are, however, somewhat resis
tant to occasional splash or spoilage of these
materials if exposed on an occasional basis. If
elastomeric materials do come in contact with
these fluids, the elastomer surface should be
immediately cleaned. If cleaning is accom
plished properly, the effect of greases, oils or
solvents on the performance of the elastomeric
material will be minimal. If replacement of
elastomeric bearing is required, refer to COM.
(1). If greases, oils or solvents come in
contact with the elastomeric material,
wipe immediately with clean, dry rag.
(2). If wiping is not sufficient (oil or grease
is too thick), clean the affected area of
the elastomer with a soft bristle brush
and a solution of pure soap and water.
(3). Rinse with tap water.
64-20-00
Page 207
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CSP-HMI-2
MAINTENANCE MANUAL
Page 208
Revision 44
64-20-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
642530
AntiTorque Fan
(500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
ANTITORQUE FAN
1. AntiTorque Fan Assembly
The purpose of the fan is to provide anti-tor
que control using a variable flow of air, across
variable pitch blades, down the tailboom. The
anti-torque fan liner, felt metal seal, provides
a controlled gap between the fan and the felt
metal seal for optimum efficiency of the fan
during flight.
NOTE: The NOTARr anti-torque control sys

tem must be re-rigged immediately after re
placement of any component, control rods,
or linkages, and if helicopter operation re
2. AntiTorque Fan Replacement
Item
Special Tools
Nomenclature
ST605
Fan nut socket
A. AntiTorque Fan Removal

(1). Remove tailboom (Ref. Sec. 53-40-30).
(2). Remove nut and lock washer from aft
tube assembly.
(3). Remove fan pitch control tube (Ref. Sec.
67-20-30, Fan Pitch Control Tube
Removal).
(4). Remove six bolts, washers and pitch
control housing from fan.
(5). Remove lock washer from nut and shaft
by releasing the holding tangs from lock
nut and pull locking ring from support
shaft knurl.
(6). Remove locknut in a counter-clockwise
direction, using coupling socket (ST605)
and coupling holding fixture tool.
(7). Remove washer from shaft.
(8). Remove fan from helicopter.

B. AntiTorque Fan Installation
Item
Nomenclature
CM702
Lockwire CRES
(1). Align and install fan assembly on

support shaft.
(2). Install washer on shaft.
(3). Install locknut and torque nut to 40 42 foot-pounds (54 - 57 Nm). Install
lock washer.
(4). Install pitch bearing housing using six
bolts and washers, Torque bolts to 80 100 inch-pounds (9.04 - 11.30 Nm)
and lockwire (CM702).
(5). Install fan pitch control tube (Ref. Sec.
67-20-30, Fan Pitch Control Tube
Installation).
(6). Install tailboom (Ref. Sec. 53-40-30).
3. AntiTorque Fan Blade Replacement
(Ref. Figure 401)
NOTE: When a blade needs replacement for

any reason, whether it be service related or
at overhaul, replace associated bolt, washer,
and nut.
A. AntiTorque Fan Blade Removal
(1). Remove anti-torque fan from helicopter
(Ref. Anti-Torque Fan Removal).
(2). Remove fan blade from strap assembly
by removing cotter pin, washer and pin.
B. AntiTorque Fan Blade Installation
(1). Install fan blade and align retention
hole with upper strap assembly reten
tion hole.
64-25-30
Page 401
Revision 41
MAINTENANCE MANUAL
CSP-HMI-2
SHELTON CT.USA
S/N LK1014
STRAP ASSY
(NOTE 1)
XX/XX
EXPIRATION DATE
BLADE
ASSY
MDHC P/N 500N53115
11/04
OO7
EXAMPLE OF INK MARK DATE.
WASHER
VIEW LOOKING
FORWARD
STUD
COLLAR
NUT
HUB - BLADE
BUSHING
BOLT
PIN
WASHER
(COUNTERSUNK)
(NOTE 2)
WASHER
COTTER PIN
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.
Figure 401. AntiTorque Fan

Page 402
Revision 42
64-25-30
G64-2005C
MAINTENANCE MANUAL
(2). Install pin, washer and cotter pin.
(3). Reinstall anti-torque fan in helicopter
(Ref. Anti-Torque Fan Installation).
(4). Perform fan balance check (Ref. Sec.
18-20-30, Fan Balance Check).
Item
Nomenclature
CM312
4. Fan Blade Strap and Pitch Horn

Replacement
(Ref. Figure 401) Remove and install the pitch
horn and strap assembly using the following
procedures.
NOTE:
D The following procedure covers the indi
vidual removal of one strap assembly and
pitch horn. If disassembly of all is re
quired, use the following steps for each
one requiring removal.
D When strap is replaced, replace related
bolt, washer, and nut.
A. Fan Blade Strap and Pitch Horn
Disassembly
(2). Remove fan blade(s) (Ref. Anti-Torque
Fan Blade Replacement).
(3). Remove bolt and washer retaining
bottom half of strap assembly between
two retention plates.
(4). Remove strap assembly thru top hole of
fan hub.
(5). Remove pitch horn from fan hub.
B. Fan Blade Strap and Pitch Horn
Reassembly
NOTE: Counterweights on pitch arms are set

by the factory; do not attempt to adjust.
(1). Install pitch horn in fan assembly.
Ensure ball on lower side of pitch horn
is inserted in bushing of pitch plate.
CSP-HMI-2
NOTE: Inspect strap assembly for condition

and expiration date. Pay particular atten
tion to area around the two spools. Inspect
for cracks in the polyurethane coating. If
any cuts or breaks are found that exceed
0.020 inch (0.508 mm) in depth or 0.25 inch
(6.35 mm) in length, replace the strap.
D Tension-torsion straps have a life limit
that starts when their package is opened.
If the date the package was opened is un
known, the 5 year calendar life is based
on the manufacturing cure date.
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
days.
(2). If tension-torsion strap is removed
from package for no more than five
days, do the steps that follow:
(a). Replace desiccant in package, use
desiccant (CM826).
NOTE: If you can not seal package; put, ten
sion-torsion strap, package, and desiccant
(CM826) in new plastic bag.
(b). Put tension-torsion strap in package
and seal package opening with tape.
(c). Put package in box and seal box with
tape.
(3). If replacement strap is new, remove
from package and write the words
EXPIRATION DATE on the strap face
and date five years after the package is
opened. Use permanent ink (CM312).
(4). Make an item component record card
for each tension-torsion strap.
NOTE: Install tension-torsion straps so that
the cure date is in view when fan is as
sembled.
(5). Insert strap assembly thru top of fan
hub and pitch horn until lower (smaller
diameter) hole is aligned between holes
of two retention plates.
(6). Install blade and align spar before
torquing inboard nut, this ensures
proper alignment of strap with blade.
(7). Install new bolt, washers (countersunk
washer against bolt-head), and nut
thru holes of retention plates and of
strap assembly.
(8). Install fan blade(s) and torque bolts to
100 inch-pounds (11.30 Nm) (Ref.
Anti-Torque Fan Blade Installation).
64-25-30
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MAINTENANCE MANUAL
CSP-HMI-2

(Ref. Anti-Torque Fan Replacement).
(10). Perform fan balance (Ref. Sec.
18-20-30, Fan Balance Check).
5. Retention Plate and Pitch Plate
Replacement
(Ref. Figure 401) Remove and install the
retention strap and pitch plate using the
following procedures.
A. Retention Plate and Pitch Plate
Disassembly
A. Support Shaft Disassembly

(2). Remove fan pitch control tube (Ref. Sec.
67-20-30).
(3). Remove fan interconnect driveshaft
(Ref. Sec. 63-15-30).
(4). Remove fan interconnect shaft coupling
from support shaft (Ref. Sec. 63-15-30).
(5). Remove support shaft and fan hub
housing from fan support assembly by
removing four cotter pins, nuts,
washers and bolts.
(6). Remove hub spacer from shaft.
(2). Remove fan blades (Ref. Anti-Torque

Fan Blade Replacement).
(3). Remove strap assemblies and pitch
horns.
(4). Remove pitch plate and retention plates
from fan hub.
B. Retention Plate and Pitch Plate
Reassembly
(1). Position retention plates in fan hub.
NOTE: Install tension-torsion straps so that

the cure date is in view when fan is as
sembled.
(2). Install pitch horn and strap assemblies
(Ref. Strap and Pitch Horn Reassemb
ly).
(3). Place pitch plate over retention plates
within fan hub.
(4). Install fan blades (Ref. Anti-Torque
Fan Blade Installation).
6. Support Shaft Replacement
(Ref. Figure 402) Remove and install the
support shaft using the following procedures.
NOTE: When replacing pitch plate and/or sup

port shaft bearings, do not use 900R bear
ings in the 500/600N helicopters.
Page 404
Revision 41
64-25-30
(7). Remove bearing retainer from support

housing.
(8). Press shaft and fan support bearing out
of support housing.
NOTE: Removal of bearing seal at disassembly

is not required unless seals need replace
ment.
(9). Remove bearing seal from support
housing and bearing retainer.
(10). Press bearing off support shaft using
removal ring.
B. Support Shaft Reassembly
Item
Nomenclature
CM111
CM425
Grease, aircraft
Sealing compound
(1). Install removal ring on support shaft

until firmly seated against shoulder of
support shaft.
(2). Install support bearing on support
shaft.
(3). Install bearing seal in support housing
and bearing retainer using sealant
(CM425).
(4). Fill seal cavity with 3.3-4.0 CCs of
grease (CM111).
MAINTENANCE MANUAL
(5). Install support bearing and shaft in
support housing.
CSP-HMI-2
(2). Removal with Hand Tool:
(6). Install bearing retainer and align bolt

holes on support housing.
(a). Insert the applicable size hex wrench

into the pin wrenching cavity and
hold securely to prevent pin rotation.
(7). Install hub spacer on shaft.
(b). Rotate the collar counterclockwise

with pliers or vise grips to remove.
(8). Install support shaft and housing on

fan support assembly. using four bolts,
washers, and nuts. Torque nuts to 40 50 inch-pounds (4.52 - 5.65 Nm).
Install cotter keys.
(9). Install fan interconnect shaft coupling
on support shaft (Ref. Sec. 63-15-30).
(10). Install fan interconnect driveshaft (Ref.
Sec. 63-15-30).
(11). Install fan pitch control tube (Ref. Sec.
67-20-30).
(12). Install anti-torque fan on helicopter
(13). Check fan balance (Ref Sec. 18-00-30,
Fan Balance Check).
7. Fan Balance Stud Replacement
A. Fan Balance Stud Removal
The following procedure is for removal of the
balance studs when the lock collars have
become loose and allow the stud to rotate.
(1). Removal with Pneumatic Tool: Pneu
matic tools may be used only on
fasteners in interference fit holes and
fasteners with aluminum collars.
(a). Select the applicable removal tool. Fit
removal tool to a 0.375 inch (9.525
mm) square socket drive that will fit
a reversible screwdriver motor.
(b). Place the collar removal tool over the
collar and press firmly.
(c). Rotate the tool counterclockwise by
hand until the teeth bite into the
collar.
(d). Place the motor on the drive socket
and unscrew the collar using reverse
drive.
(e). Tap out the pin with a nonmetallicfaced mallet.
(c). Tap out pin with a nonmetallic-faced

mallet.
B. Fan Balance Stud Installation
Pins may be reused, provided the finish has
not been marred and the threads and wrench
ing cavity are in acceptable condition.
Item
CM409
Nomenclature
Adhesive, epoxy
(1). Apply adhesive (CM409) to pin and

insert, while wet, using a nonmetallicfaced mallet or rivet set into hole.
Ensure Pin is seated flush against fan
hub.
(2). Manually screw the collar onto the pin
a minimum of two threads.
(3). Installation with Pneumatic Tool:
(a). Insert the hex wrench tip of the
power driver into the wrenching
cavity in the pin
(b). Press the power driver socket firmly
against the collar and actuate the
driver until the collar wrenching
device is torqued off.
(c). Withdraw the hex wrench tip from
the wrenching cavity and discard the
wrenching collar.
(4). Installation with hand tool:
(a). Press socket from hand tool firmly
onto collar.
(b). Insert hex wrench though center of
tool and hold pin to prevent it from
rotating.
(c). Turn socket clockwise, while holding
hex wrench, until collar is firmly
seated against fan hub; wrenching
collar will torque off when proper
torque is reached. Discard wrenching
collar.
64-25-30
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MAINTENANCE MANUAL
CSP-HMI-2
AFT CONTROL TUBE

(REF)
SUPPORT SHAFT
COTTER KEY
WASHE
R
NUT
FAN SUPPORT ASSEMBLY

(REF)
FAN SUPPORT
BEARING
BEARING
HOUSING
BEARING
RETAINER
RING
WASHER
BEARING
SEAL
BOLT
FAN
(REF)
WASHER
BEARING
SEAL
LOCKWASHER
HUB
SPACER
LOCKNUT
PITCH
SLIDER
WASHER
BOLT
INNER BEARING
RETAINER
PITCH BEARING
PLATE
LOCKWASHER
PITCH BEARING
RETAINER
PITCH BEARING
HOUSING
NUT
WASHER
BOLT
G64-2006A
Figure 402. AntiTorque Fan Support Shaft

Page 406
Revision 41
64-25-30
MAINTENANCE MANUAL
8. Pitch Horn Counterweight Set Screw
Replacement
(Ref. Figure 403) If, during fan inspection, a
counterweight is found to be loose, the set
screw must be replaced.
Item
Nomenclature
CM216
Loctite remover
CM321
CSP-HMI-2
NOTE: Ensure counterweight-to-pitch horn

index mark aligns correctly. All counter
weights are indexed the same.
(7). Align index mark on counterweight to
match with mark on pitch horn and
install into pitch horn.
(8). Apply grade B locking compound
(CM321) to threads of set screw and
install into pitch horn. Tighten set
screw.
COUNTERWEIGHT
INDEX MARK
COUNTERWEIGHT
(1). Apply heat to loose counterweight.

(2). Remove and discard set screw.
(3). Remove retaining ring and washer.
(4). Inspect threads in counterweight for
condition and cleanliness.
(5). Clean pitch horn threads with Loctite
remover (CM216).
PITCH HORN
INDEX MARKS
SET SCREW
PITCH HORN
G64-2011
(6). Apply grade T primer (CM321) to

threads of new set screw; allow to dry
for 30 minutes at ambient temperature.
Figure 403. Pitch Horn Counterweight Set

Screw Replacement
64-25-30
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Revision 41
CSP-HMI-2
MAINTENANCE MANUAL
Page 408
Revision 34
64-25-30
MAINTENANCE MANUAL
CSP-HMI-2
ANTITORQUE FAN
INSPECTION/CHECK
1. AntiTorque Fan Inspection
Inspect the anti-torque fan for the following
conditions:
(1). All components for cracks, nicks,
corrosion or excessive wear.
(2). Tension-torsion straps for nicks or cuts
in polyurethane coating. No exposed
kevlar fibers allowed. Spools for cracks.
(c). Scoring; axial marks from bearing

installation or removal.
(d). Damaged spines; none allowed.
(e). Corrosion and pitting.
(2). Fan support bearing for free movement
of set.
(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-ofround condition).
(b). Wear.
(5). Counterweights on pitch horn for

security. If loose, perform Pitch Horn
Counterweight Set Screw Replacement.
NOTE: Access the forward counterweights

through the fan inlet. Fan hub fairing must
be removed for access (Ref. Sec. 53-30-30).
(c). Scoring; axial marks from bearing

installation or removal.
(4). Bearing seals for condition.
(5). Hub spacer for cracks and wear.
3. AntiTorque Fan Liner (Felt Metal Seal)
Inspection
(6). Pitch plate bushing for excessive wear,

grooves or cracking.
(1). Inspect for cracks and debonding of

liner material.
(7). Blades for cracks, nicks or impact

damage.
(2). Inspect for cracks around the radius

cutouts of fan support.
(8). Inspect gap between fan blade and tip

seal. Inspect gap between fan blade and
hub (inboard end of the blade). If gap
for any blade end 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.
(3). If cracks are found, stop drill and

inspect every 50 hours (Ref. Sec.
05-20-20).
2. Support Shaft Inspection

Inspect the support shaft and its associated
components as follows:
NOTE: Cracks protruding into the Felt Metal

Seal are unacceptable, replace seal (Ref.
Anti-Torque Fan Liner (Felt Metal Seal)
Replacement).
(4). Inspect aft P-seal for tears, deteriora
tion and debonding.
4. Fan Blade Inspection (100Hour)
NOTE: Ensure proper pitch plate and/or sup

port shaft bearings are installed. 900R bear
ings are not to be used in the 500/600N heli
copters.
Item
CM437
Nomenclature
Sealing compound
(1). Support shaft for:

(a). Cracks; none allowed.
(b). Wear.
(1). Inspect polypropylene portion of fan

blade for nicks, scratches, abrasions
and bulges; pay particular attention to
64-25-30
Page 601
Revision 42
CSP-HMI-2
MAINTENANCE MANUAL
leading edge and area around the pin

near the outboard edge of blade.
(a). Nicks and abrasion pits that are less
than 0.040 inch (1.016 mm) deep and
0.25 inch (6.35 mm) in diameter may
be blended out. (No more than two
such repairs can be made per blade.)
(b). Nicks, scratches and abrasion pits
less than 0.020 inch (0.508 mm) and
1.5 inch (3.81 cm) long may be
blended out. (Total length of all
repairs not to exceed 2.0 inch (5.08
cm).)
(2). Any bulges or blisters over 0.10 inch
(2.54 mm) long in area of pin near
Page 602
Revision 39
64-25-30
outboard end of blade are reason for

blade rejection.
(3). Seal cracks up to 0.10 inch (2.54 mm),
coming from area of pin with sealing
compound (CM437).
(4). If any cracks larger than 0.10 inch (2.54
mm) are found, replace blade.
5. Fan Pitch Slider Inspection
(1). Inspect slider for dents, scratches,
nicks, gouges and corrosion, none
allowed.
(2). Inspect Karon coating on slider for
condition.
(3). Measure across slider, minimum
diameter is 0.805 in. (20.447 mm).
MAINTENANCE MANUAL
CSP-HMI-2
ANTITORQUE FAN
REPAIRS
1. AntiTorque Fan Liner (Felt Metal Seal)
Replacement
(Ref. Figure 801)
A. AntiTorque Fan Liner (Felt Metal Seal)
Removal
(1). Remove tailboom (Ref Sec. 53-40-30).
(2). Disconnect safety wire and remove nut,
lockwasher, 3 bolts, washers and pitch
bearing retainer plate.
(3). Remove pitch bearing and inner pitch
bearing retainer; remove pitch slider
from pitch bearing housing (Ref. Sec.
67-20-30).
(4). Remove fan assembly (Ref. Anti-Torque
Fan Replacement).
(5). Remove sealant around liner edges
with plastic scraper.
(6). Remove four screws that secure the
liner to the aircraft structure.
NOTE: Mark liner to aircraft structure to en

sure proper clocking upon installation. If
liner is not installed in same position, felt
metal seal machining will be necessary for
correct fan clearance.
(7). Carefully slide liner aft through
support structure and fan support
struts.
NOTE: On installation of liner assembly, peel

shim laminates equally among the four
shims to provide a tight fit without deform
ing the liner at screw holes and aircraft
structure.
(2). Install four screws. Torque screws per
standard aircraft practices.
Do not install sealant in butt
splices of liner until after felt
metal is turned/cut to correct clearance. Do
ing so will damage cutting tool and cause in
correct cutting radius to liner seal.
CAUTION
(3). Install sealant (CM425) in mating bores

(cutouts) and around liner edges.
(4). After installing the fan liner and before
installing the fan, trim liner felt metal
seal (Ref. Anti-Torque Fan Liner (Felt
Metal Seal) Machining). Refer to MD
Helicopter Field Service Representative
for additional information.
C. AntiTorque Fan Liner (Felt Metal Seal)
Machining
Item
ST603
Special Tools
Nomenclature
Tip seal cutter
NOTE:
B. AntiTorque Fan Liner (Felt Metal Seal)

Installation
D Do this procedure only after a new fan lin

er is installed.
D Felt metal material can cause FOD con
tamination.
Item
Nomenclature
(1). Apply masking tape and plastic sheet to

fan duct and fan diffuser areas.
CM425
Sealing compound
CAUTION
Use only cutter and equipment

supplied with (ST603) tip seal
tool.
(1). Install fan liner so that the larger
cutouts fit around the fan support
struts and the smaller cutouts fit
around the rivets that secure the fan
inlet fairing.
NOTE: Make sure (ST603) tip seal tool is clean

before you install it.
(2). Install pin (5) and spacer (6) in fan
support assembly.
64-25-30
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Revision 42
MAINTENANCE MANUAL
CSP-HMI-2
FELT METAL SEAL

BEFORE TRIM
FELT METAL SEAL

AFTER TRIM
P-SEAL
SCREW
LINER
P-SEAL
SHIM
FAN
G64-2007
Figure 801. AntiTorque Fan Liner (Felt Metal Seal)

Page 802
Revision 21
64-25-30
MAINTENANCE MANUAL
10
CSP-HMI-2
FAN SUPPORT ASSEMBLY (REF)
21 (4 PL)
20 (4 PL)
20 (4 PL)
19 (4 PL)
11
9
1 (REF)
15 (REF)
16 (REF)
CL
CUTTER
18
5
CUTTING
DIRECTION
12
3
4
22
1
15
13 (2 PL)
14 (2 PL)
16
23 (2 PL)
17
CALIBRATION OF CUTTING TOOL HEIGHT

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
FAN TIP SEAL TOOL (PART 1)

CALIBRATION ARM
CUTTER
MOTOR COLLET
PIN
SPACER
THRUST BEARING
SPACER
NYLON WASHER
THRUST BEARING RETAINER
THREADED KNOB
FAN TIP SEAL TOOL (PART 2)
G64-2008A
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
CAP SCREW
WASHER
POSITION LOCK KNOB
ADJUSTMENT KNOB
SPEED HANDLE
AIR PRESSURE VALVE
BOLT
WASHER
NUT
BALL LOCK PIN
SPACER
Figure 802. AntiTorque Fan Liner Felt Metal Seal Machining
64-25-30
Page 803
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2
(3). Install bolts (19), washers (20), and

nuts (21). Torque nuts.
(4). Put cutter (3) in motor collet (4). Do not
tighten collet.
(5). Apply a thin film of oil to inner side of
pin (5) and outer side of tool (1) shaft.
(6). Put thrust bearing (7) on tool (1) shaft.
Eye protection, a respirator,
WARNING gloves, and protective cloth
ing must be worn during fan liner ma

chining.
(22). Loosen position lock knob (15) and turn
adjustment knob (16) to position cutter
(3) for a cut of not more than one fourth
width of cutter (3). Tighten lock knob.
(23). Connect speed handle (17) to tool (12).
(7). Put tool (1) in pin (5) and push forward.

(8). Turn tool (1) by hand and adjust cutter
(3) to highest point on fan liner. Tighten
collet (4).
(9). Remove tool (1).
(10). Remove thrust bearing (7) from tool (1)
shaft.
(11). Put calibration arm (2) on tool (1).
(12). Measure dimension between cutter (3)
and stop on calibration arm (2).
(13). Loosen motor collet (4) and move cutter
(3) out 0.040-0.050 in. (1.02-1.27 mm)
or until cutter touches stop on calibra
tion arm (2). Tighten collet.
(14). Loosen position lock knob (15) and turn
adjustment knob (16) until cutter (3) is
at aft most position. Tighten position
lock knob.
(24). Connect pneumatic pressure source to

tool (12).
(25). Turn valve (18) to adjust cutter (3)
speed.
(26). Turn speed handle (17) and turn tool (1)
counter-clockwise at a moderate to
slow rate. Do not force cut.
(27). After one full turn, again loosen
position lock knob (15) and turn
adjustment knob (16) to position cutter
(3) for a cut of not more than one fourth
width of cutter (3). Tighten lock knob.
(28). Do step (27). again and again until fan
liner is fully machined.
(29). Disconnect pneumatic pressure source
to tool (12).
(30). Disconnect speed handle (17) from tool
(12).
(15). Put thrust bearing (7) on tool (1) shaft.
(31). Remove cap screws (13), washers (14),

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),

thrust bearing retainer (10), nylon
washer (9), and threaded knob (11).
Tighten knob.
(33). Remove threaded knob (11), nylon

washer (9), thrust bearing retainer (10),
thrust bearing (7), and spacer (8).
(18). Put tool (12) on tool (1) and install ball

lock pin (22).
(19). Install cap screws (13), washers (14),
and spacers (23). Torque cap screws.
(34). Remove tool (1).

(35). Remove thrust bearing (7) from tool (1)
shaft.
NOTE: The following clearance may vary be

cause of variations in blade length.
(20). Make sure there is no radial or axial

movement in tool (1).
(21). Lubricate tool motor, use pneumatic
tool oil.
Page 804
Revision 42
64-25-30
(36). Install fan assembly and check for a

0.10 in. (2.54 mm) maximum clearance
between fan blade ends and felt metal
seal.
MAINTENANCE MANUAL
(37). In step (13). did cutter touch stop on
calibration arm?
(a). No, go to step (11).
(b). Yes, go to step (38).
(38). Remove nuts (21), washers (20), and
bolts (19).
(39). Remove pin (5) and spacer (6) from fan
support assembly.
(40). Clean fan duct and diffuser areas and
remove masking tape and plastic sheet.
CSP-HMI-2
NOTE: The anti-torque control system must be

re-rigged immediately after removal or re
placement of control rods, linkages and com
ponents or if helicopter operation reveals a
rigging deficiency.
(41). Install fan assembly (Ref. Anti-Torque
Fan Replacement).
(42). Install interconnect driveshaft (Ref.
Sec. 63-15-30).
(43). Install fan pitch control rod (Ref. Sec.
67-20-30).
(44). Install pitch slider and inner pitch
bearing retainer (Ref. Sec. 67-20-30).
(45). Install tailboom (Ref. Sec. 53-40-30).
64-25-30
Page 805
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2
2. AntiTorque Fan Bearing Regreasing
Item
Special Tools
Nomenclature
ST614
Fan bearing regreasing tool
(3). Inspect seals for damage; no damage is

allowed.

procedure is for the regreasing of the
500N5364 and 500N7120 bearings.
Item
Nomenclature
CM111
Grease, aircraft
(2). Carefully remove both seals from

bearings (seals will be reused at
reassembly).
(4). Install bearings between regreasing

tools with a 4 inch (10 cm) 10-24
threaded bolt, washers and wing nut.
NOTE: The following procedure provides 100%

grease fill. Normal grease fill is 30 to 50%.
Excess grease will extrude past seals for
several hours of operation until the proper
level is met.
(5). Purge bearing with grease (CM111)
until clean grease protrudes from all
four holes in back of tool.
(6). Remove regreasing tool.
NOTE:
D Ensure proper pitch plate and shaft sup
port bearings are installed. 900R bear
ings are not to be used in the 500/600N
helicopters.
D Refer to Figure 804 for instructions on
the manufacture of a regreasing tool.
(1). Remove bearings from fan assembly
(Ref. Support Shaft Disassembly).
(7). Hand spin bearing to purge excess

grease.
NOTE: Ensure seals are serviceable. If new

seals are required, seals and bearings must
come from the same vendor.
(8). Carefully install seals.
(9). Reinstall bearings (Ref. Support Shaft
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
Revision 42
64-25-30
MAINTENANCE MANUAL
A
CSP-HMI-2
0.50 IN.
(12.7 MM)
0.125 IN. (3.175 MM)

(NOTE 1)
0.188 IN. (4.7752 MM)

DIA THRU HOLE
3.00 IN.
(7.62 CM)
0.580 IN.
(14.732 MM)
1.980 IN.
(5.0292 CM)
1.180 IN.
(2.9972 CM)
0.870 IN.
(22.098 MM)
1.640 IN.
(4.1656 CM)
2.280 IN.
(5.7912 CM)
0.094 IN. (2.3876 MM) DIA

THRU HOLE (8 PL)
EQUALLY SPACED AND
CENTERED BETWEEN
MACHINED GROOVES
0.040 IN.
(1.016 MM)
SECTION A-A
GREASE FITTING
MS15002-1 (2 PL)
1/4-28 TAPER
THREADS
A
PART A
B
0.094 IN. (2.3876 MM) DIA THRU

HOLE (2 PL) EQUALLY SPACED
AND CENTERED BETWEEN
MACHINED GROOVES (NOTE 2)
SEAL MATERIAL (3PL) (PARTS

A AND B) USE LOCALLY
AVAILABLE MATERIAL FIRM
HARDNESS [ 75
SECTION B-B
PART B
NOTES:
1. DIMENSION MAY VARY DEPENDING ON SEAL MATERIAL THICKNESS AVAILABLE.
2. ALL OTHER DIMENSIONS SAME AS PART A.
QUANTITY
STOCK SIZE
1
1
1
2
1
2
1
4 x 4 x .50
4 x 4 x .50
AN23-64
AN960D10L
AN315-3R
MS15002-1
M6855/2
MATERIALS:
1. 6061-T651 ALUMINUM PER QQ-A-250/11 OR EQUIVALENT.
2. SURFACE FINISH 125 RMS.
3. BREAK SHARP EDGES 0.002-0.015 IN. (0.0508-0.381 MM).
4. CHEMICAL FILM TREAT PER MIL-C-5541.
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).
DESCRIPTION
PLATE
PLATE
BOLT
WASHER
NUT
GREASE FITTING
RUBBER
G64-2009B
Figure 804. Fan Bearing Regreasing Tool (ST614)
64-25-30
Page 807
Revision 42
CSP-HMI-2
MAINTENANCE MANUAL
Page 808
Revision 42
64-25-30
MAINTENANCE MANUAL
CSP-HMI-2
Section
643000
Tail Rotor Pitch
Control Assembly
(369D/E/FF)
MAINTENANCE MANUAL
CSP-HMI-2
TAIL ROTOR PITCH CONTROL ASSEMBLY

1. Tail Rotor Pitch Control Assembly
On four-bladed tail rotor
(Ref. Figure 203 and Figure 204) The pitch

control assembly consists of a swashplate that
rotates in a matched set of two bearings
swaged inside a housing. A self-aligning
bearing staked in place at the underside of the
housing provides a pivot for transferring
motion of Sta. 284 bellcrank to the housing.
Clevis ears on end of the swashplate provide
for connection of pitch control links. Movement
of Sta. 284 bellcrank shifts the housing axially
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.
The swashplate is retained in the pitch control
housing by a washer and locknut.
Replacement
A. Tail Rotor Pitch Control Assembly
Removal
WARNING system, there is strong
spring pressure in installed tail rotor

linkage. Disconnect the in-line bungee
before beginning disassembly. Failure
to disconnect the bungee can result in
personal injury and/or parts damage.
(1). Remove tail rotor hub and fork assem
bly (Ref. Sec. 64-20-00).
NOTE: The manner in which the pitch control

assembly is installed determines rotorblade orientation to transmission splined
shaft. Installing rotor blades at 90 degrees
to high and low extremes of shaft runout,
using reference marks placed on shaft at
time of shaft inspection (Ref. Sec. 63-25-10)
reduces chance of high-frequency vibration
and lessens likelihood of having to reba
lance tail rotor.
DIRECTION OF PITCH CONTROL
ASSEMBLY WOBBLE ON OUTPUT SHAFT
0.020 IN.
(0.508 MM)
MAX.
BOLT HOLE
CENTERLINE
PITCH CONTROL
ASSEMBLY
0-10 LB (0-50 N)
SPRING SCALE
(NOTE 1)
TWINE
NOTES:
1. FORCE REQUIRED TO SLIDE PITCH CONTROL
ASSEMBLY INWARD OR OUTWARD ON OUTPUT
SHAFT MUST NOT EXCEED THREE POUNDS (13.4 N)
WITH PITCH LINKS, BELLCRANK AND RUBBER BOOTS
DETACHED FROM PITCH CONTROL ASSEMBLY.
2. ADD ONE OR TWO AN960KD516 WASHERS AS
REQUIRED FOR CLEARANCE AT PEDAL FULL STROKE.
PIVOT
PIN
WASHER
(NOTE 2)
PITCH
CONTROL LINK
STA. 284
BELLCRANK
G64-3000A
Figure 201. Pitch Control Assembly Wobble Check
64-30-00
Page 201
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
install Sta. 284 bellcrank. Rotate

bellcrank back and forth to align
bellcrank bearing with transmission
arm.
0.015 IN. (0.381 MM)

MIN. CLEARANCE
(5). If previously disconnected, reconnect

tail rotor bungee.
HOUSING
SWASHPLATE
3. Tail Rotor Pitch Control Link Replacement

SWASHPLATE-TO-HOUSING
CLEARANCE
Figure 202. SwashplatetoPitch Control

Housing Clearance
(2). Remove Sta. 284 bellcrank from
transmission (Ref. Sec. 67-20-10) so
that pivot pin in bellcrank is disen
gaged from self-aligning pivot bearing
in pitch control housing.
(3). Cut lockwire and pull non-rotating boot
from groove in pitch control housing.
(4). Slide pitch control assembly off trans
mission output shaft.
B. Tail Rotor Pitch Control Assembly
Installation
Item
Nomenclature
CM115
CM702

Lockwire CRES
(1). Insert edge of small end of non-rotating

boot into tail rotor transmission
housing groove. Make certain that
drain holes in boot are downward.
(2). Align spline index marks and slide
pitch control assembly on shaft.
(3). Insert non-rotating boot edge into
groove of pitch control housing and
secure with lockwire (CM702).
(4). Apply grease (CM115) to Sta. 284
bellcrank pivot pin, insert pin into pitch
housing self-aligning bearing and
Page 202
Revision 36
Item
Nomenclature
CM318
Primer
G64-3001A
64-30-00
Prior to removal of pitch control

links, color-code pitch arm bolt
and all washers used at each arm. The bolt,
or an identical one, and same combination of
washers must be reassembled at locations
from which removed, or tail rotor balance
can be seriously affected. Do not allow blade
angles to exceed 30 degrees, approximately
one inch (2.54 cm), in each direction. Unde
tected damage to tension-torsion strap pack
may occur.
CAUTION
(1). Disconnect ends of pitch control link

from clevis ear of swashplate and from
blade pitch control arm.
(2). To install, insert either end of pitch
control link between clevis ears of
swashplate.
(3). Install color-coded attaching hardware
and tighten nut to 30 - 40 inchpounds (3.39 - 4.52 Nm); install cotter
pin with wet primer (CM318).
(4). Pull pitch control assembly inboard or
outboard as required to align pitch
control link bearing with pitch control
arm bushing.
(5). Place special (reduced outside diame
ter) washer and large-diameter spring
washer on pitch arm bolt so that
concave surface of spring washer is
against bolt head. With washers in
place on bolt, insert bolt through
bearing of pitch control link and
bushing in pitch control arm.
MAINTENANCE MANUAL
CSP-HMI-2
PITCH CONTROL
LINK (2) TYPICAL
PITCH ARM
BOLT (STUD)
NUT
BALANCE WASHER(S)
(NOTE 3)
SPRING
WASHER
SPECIAL WASHER
(NOTE 4)
NOTE 1
SPLIT RING
(WIRE SPRING)
TAIL ROTOR
ASSEMBLY
PITCH CONTROL
ASSEMBLY (NOTE 5)
HINGE
BOLT
TRANSMISSION
OUTPUT SHAFT
ROTATING
BOOT
NOTE 2
FORK
FORK BEARING
PITCH ARM
0.255 IN. (6.477 MM)

ORIGINAL THICKNESS
0.070 IN. (1.778 MM) MAX. WEAR

ALLOWED 2 PLACES EACH END
BLADE PITCH ARM
PITCH
CONTROL
LINK
ROOT FITTING
LINK WEAR LIMIT
0.02 IN. (0.508 MM) MAX.
HUB
0.001-0.130 IN.
(0.025-3.302 MM
LINK
BEARING
SWASHPLATE
LINK BEARING AXIAL PLAY
HUB-TO-BLADE PITCH
ARM-CLEARANCE
(TYPICAL 2 PLACES)
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.
G64-3002C
Figure 203. Tail Rotor Pitch Control Assembly (TwoBladed)
64-30-00
Page 203
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
PITCH CONTROL
LINK (2) TYP
COTTER KEY
(NOTE 2)
STATIONARY BOOT
NUT
WASHER
NUT
NOTE 1
WASHER
BOLT
PITCH CONTROL
ASSEMBLY (NOTE 5)
PITCH CONTROL LINK
ROTATING BOOT
PITCH ARM
SPLIT RINGS
BLADE PITCH
ARM
PITCH CONTROL
LINK (2) TYPICAL
ROOT FITTING
TAIL ROTOR
ASSEMBLY
SPECIAL
WASHER
(NOTE 4)
HUB
SPRING
WASHER
PITCH ARM BOLT (STUD)
BALANCE WASHER(S) (NOTE 3)
0.001-0.130 IN.
(0.025-3.302 MM)
NUT
0.020 IN. (0.508 MM)

MAX.
SWASHPLATE
HUB-TO-BLADE PITCH ARM

CLEARANCE (TYP 2 PLCS)
LINK BEARING
LINK BEARING AXIAL PLAY
0.255 IN. (6.477 MM)

ORIGINAL THICKNESS
0.070 IN. (1.778 MM) MAX. WEAR

ALLOWED (2 PLCS) EACH END
LINK WEAR LIMIT

NOTES:
1. CENTERLINE TOOTHSPACE MATCHMARK MUST ALIGN WITH CENTERLINE
TOOTHSPACE MARK ON FORK WHEN ASSEMBLED ON OUTPUT SHAFT.
2. INSTALL WITH WET PRIMER.
3. QUANTITY (IF ANY) DETERMINED BY BALANCE REQUIREMENTS.
4. REDUCE OUTER DIAMETER.
5. FOR DISASSEMBLY, REFER TO CSP-COM-5.
Figure 204. Tail Rotor Pitch Control Assembly (FourBladed)

Page 204
Revision 21
64-30-00
G64-3003C
MAINTENANCE MANUAL
(6). Install washer and nut on end of the
bolt that extends through pitch arm.
(5.65 - 6.78 Nm); install cotter pin with
wet primer (CM318).
(7). Check for clearance between pitch link
and tail rotor hub pivot bolt.
(8). If removed from pitch arm bolt, install
balance washer(s) of same color code as
pitch control arm and secure with nut.
4. Tail Rotor and Pitch Control Assembly
Repair
Item
Nomenclature
CM801
Repair allowable surface defects on fork and

hub that may be reworked by using grade 320
abrasive paper (CM801) to round out and
blend defect. Apply exterior surface touchup
treatment and paint touchup (Ref. Sec.
20-30-00). (Repairable damage limits are
defined in the Component Overhaul Manual.)
Inspection
Item
Nomenclature
CM115
CM234
CM801
CM803

Crocus cloth
(1). If tail rotor control system drag or

friction is suspected, use spring scale
(Ref. Figure 201) to measure drag
(sliding friction) of pitch control
assembly on shaft of tail rotor transmis
sion. Note that pitch control links, Sta.
284 bellcrank and rubber boots must be
detached from the assembly during
CSP-HMI-2
drag check. If drag exceeds three

pounds (13.4 N), remove pitch control
assembly and clean swashplate and
transmission shaft splines. Use solvent
(CM234) and grade 400 abrasive paper
(CM801) or crocus cloth (CM803). Clean
again with solvent (CM234) and coat
output shaft splines with light film of
grease (CM115).
(2). Inspect fork and hub for scratches,
nicks, dents, cracks, corrosion and
similar surface defects. Check for wear
caused by rubbing of aluminum
support. Scratches and nicks that do
not exceed 0.005 inch (0.127 mm)
depth, 0.120 inch (3.048 mm) depth at
inside corner of fork, may be repaired
(Ref. COM). Worn areas resulting from
rubbing of aluminum support up to
0.060 inch (1.524 mm) depth may be
repaired (Ref. COM).
(3). Check wire-spring split ring halves for
damage.
(4). If brinelling wear of inner surfaces of
swashplate clevis ears is detected, 0.003
inch (0.076 mm) depth is allowable
without rework or repair. For wear of
greater depth, Ref. COM, for limits and
allowable repairs.
(5). If there is evidence of swashplate
contact with housing, check that
minimum clearance of 0.015 inch (0.381
mm) exists through 360 degrees of
rotation with axial loading applied. If
contact is apparent or if axial play can
be measured, replace swashplate or
NOTE: Wobble may be accurately measured by

attaching dial indicator support to tail rotor
drive fork, with indicator probe contacting
swashplate clevis ear. Use care not to allow
pitch control assembly to slide on output
shaft while measuring wobble.
(6). If pitch control assembly wobbles on
transmission output shaft, up to 0.020
inch (0.508 mm) is allowable. If greater
amount of wobble is present, replace
swashplate, pitch control housing,
bearings (Ref, COM) or the complete
assembly.
64-30-00
Page 205
Revision 40
CSP-HMI-2
MAINTENANCE MANUAL
(7). Check that hub-to-blade pitch arm

clearance is 0.001-0.130 inch
(0.025-3.302 mm).
(8). Inspect all bolts and nuts for security.
(9). Inspect boots for installation and
deterioration.
(10). Perform following inspections for pitch
control bearings at times specified (Ref.
Sec. 05-20-00) and when bearing
condition is questionable.
(a). Remove cotter pin, nut, washers and
bolt securing Sta. 284 bellcrank to
transmission. Separate pivot pin on
bellcrank from pitch control assem
bly.
(b). Rotate pitch control housing by hand;
check for rough, binding or hard
turning. Inspect for grease leakage. If
any of these conditions exist, remove
pitch control assembly and inspect
for further evidence of damage.
(c). Check that self-aligning bearing on
underside of pitch control housing is
adequately lubricated (packed
approximately 40 percent full) with
grease (CM115), is movable and is
serviceable.
(d). Ensure that pivot pin on Sta. 284
bellcrank is lubricated with grease
(CM115). Position bellcrank to
engage pivot pin with pitch control
assembly. Secure bellcrank to trans
mission with bolt, washers, nut and
cotter pin.
6. Tail Rotor Blade Stop Inspection
NOTE: Change of blade pitch angle when tail

rotor is not rotating can produce audible
snapping noise. Noise results as lamina
tions of blade strap pack are twisted and
bent without a centrifugal load. Such noise
is normal and does not indicate a defect.
(1). Teeter blades back and forth and check
for evidence of abnormal binding. Some
stiffness is normal, especially when
blade stop is newer.
(2). Inspect blade stop for deterioration. Be
sure to check for cracking or splitting in
stem area of stop. Allowable wear for
rubber stop is to surface of aluminum
support. Stop (and support) may be
rotated 90 degrees if stop is excessively
worn at contact point. Replace rubber
stop if damaged, or if worn area cannot
be rotated away from contact point.
NOTE: If replacement of stop support is re

quired, replace with one-piece stop support
and retaining nut.
(3). Check aluminum support for condition
and wear. Replace aluminum support if
damaged, or if excessive wear reduces
clearance between tail rotor blade and
tail boom to less than 0.50 inch (12.70
mm) minimum. Measure allowable
clearance between tip of tail rotor blade
and tail boom while holding hub
against support, and with assistant
applying full right tail rotor pedal.
NOTE: For any questionable items, refer to

complete and detailed inspection, damage,
wear and repair limits, and requirements
for tail rotor assembly in COM.
7. Tail Rotor Pitch Control Link Inspection
NOTE: For more detailed information, refer to

inspection, damage, wear and repair limits,
and requirements for pitch control assembly
(Ref. COM).
(11). Inspect for evidence of rotational
binding by hand-turning tail rotor
assembly a few turns while listening for
unusual sounds. If condition is ques
tionable, perform applicable inspection.
Page 206
Revision 34
64-30-00
Item
Nomenclature
CM318
Primer
(1). Maximum axial play for bearing in

pitch control link is 0.020 inch (0.508
mm).
MAINTENANCE MANUAL
NOTE: Since bearing wear usually occurs only

at blade pitch control arm from displace
ment during operation, links can be re
versed and continued in service until either
or both bearings exceed wear tolerance.
(2). Replace pitch control link if worn
beyond 0.070 inch (1.778 mm) limit. If
wear area(s) are within limits, touchup with primer (CM318) and paint (Ref.
Sec. 20-30-00) at inspection.
8. Tail Rotor Conical Bearing Inspection
(1). Play is not permitted in conical drive
fork bearings (Ref. COM).
9. Tail Rotor Pitch Bearing Inspection
NOTE: In the following step, physical check for

pitch bearing wear that causes root fitting
play on hub can be made by holding one
blade firmly and measuring flapping play at
tip of opposite blade. Measured play indi
cates combined wear of pitch bearings.
(1). Maximum allowable pitch bearings play
is 0.250 inch (6.350 mm).
10. Tail Rotor Swashplate Bearing Regreasing
(Ref. Figure 205)
REGREASE
TOOL
CSP-HMI-2
Item
Nomenclature
CM111
CM217
Grease, aircraft
Isopropyl alcohol
Item
Special Tools
Nomenclature
ST608
ST609
Pitch control assembly holding block

(1). Remove tail rotor from helicopter (Ref.

64-20-00, Tail Rotor Hub and Fork
Replacement).
(2). Remove swashplate from helicopter
(Ref. Tail Rotor Pitch Control Assembly
Replacement).
(3). Remove pitch control links from
swashplate assembly.
Tail rotor swashplate bearings
cannot be removed from hous
ing without damage to the bearings. If bear
ings are removed from housing, install new
bearings.
CAUTION
TAIL ROTOR
SWASHPLATE BEARING
ASSEMBLY
G64-3007
Figure 205. Tail Rotor Swashplate Bearing Regreasing
64-30-00
Page 207
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
NOTE: For 4-Bladed tail rotor swashplates,
NOTE: The following procedure provides 100%
holding block (ST608) will need to be modi

fied. Accomplish modification, or build new
block, as per Figure 207.
grease fill. Normal grease fill is 20 to 40%.

Excess grease will extrude past seals for
several hours of operation until the proper
level is met.
(4). Using wrench (ST609) and holding

block (ST608), Remove nut and tang
washer from threaded end of swash
plate. Discard tang washer.
(5). Carefully remove bearing grease seal at
gearbox end of housing (seal will be
reused at reassembly).
(6). Inspect seal for damage; no damage is
allowed.
(7). Install regreasing tool (Ref. Figure 206)
and plug tang washer groove with
locally fabricated plastic wedge (or
equivalent plug).
0.75 IN. (19.05 MM)
(8). Purge bearings with grease (CM111).

(a). Purge bearings slowly to prevent
damage to outer seal.
(b). Rotate bearings while greasing.
(9). Remove plastic wedge (or equivalent
plug) and regreasing tool.
(10). Hand rotate bearing to remove excess
grease.
NOTE: Ensure seal is serviceable. If new seal is

required, seals and bearings must come
from the same vendor.
(11). Install serviceable seal.
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

1/4-28 TAPER THREADS 0.093 IN.
(2.3622 MM) DIA THRU HOLE
SEAL MATERIAL
0.50 IN.
(12.70 MM)
SECTION A-A
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
CONCENTRIC TO CENTERLINE WITHIN 0.002 IN. (0.051 MM).
Figure 206. Tail Rotor Swashplate Bearing Regreasing Tool

Page 208
Revision 21
64-30-00
G64-3006A
MAINTENANCE MANUAL
NOTE: Using a 5X to 10X magnifying glass, in
(14). Clean surface of locknut and swash

plate with a lint-free cloth dampened
with alcohol (CM217).
spect tang washer center tang to ensure it is

acceptable (Ref. Figure 208).
(12). Install nut with a new tang washer.
Using wrench (ST609) and holding
block (ST608), torque nut to 550 - 600
inch-pounds (62.14 - 67.79 Nm).
NOTE: Avoid getting torque seal in swashplate

splines.
(15). Apply a 0.125 inch (3.175 mm) wide
torque strip, using torque seal or
equivalent, to surface of swashplate
assembly and locknut in two places
(Ref. Figure 208).
(13). Bend one tang of washer into any

aligned slot on nut.
NOTE: Avoid getting alcohol in bearings.
0.62 IN.
(15.748 MM)
7.50 IN.
(19.05 CM)
CSP-HMI-2
0.980-1.010 IN.
(24.892-25.654 MM)
1.50 IN.
(3.81 CM)
0.50 IN.
(12.70 MM)
.31 R - 4 PLACES
75
0.980-1.010 IN.
(24.892-25.654 MM)
5.75 IN.
(14.605 CM)
5.25 IN.
13.335 CM)
2.62 IN.
(6.6548 CM)
2.25 IN.
(5.715 CM)
DIA THRU
0.50 IN.
(12.70 MM)
1.13 IN.
(2.8702 CM)
0.06 R TYP
0.88 IN.
(22.352 MM)
1.50 IN.
(3.81 CM)
3.00 IN.
(7.62 CM)
MODIFICATION OF 369D29822-3 HOLDING BLOCK FOR USE

WITH 4 - BLADED PITCH CONTROL ASSEMBLY (369D21820).
G64-3008A
Figure 207. Tail Rotor Swashplate Holding Block
64-30-00
Page 209
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
TORQUE STRIPE
LOCATIONS
ACCEPTABLE
UNACCEPTABLE
G64-3009
Figure 208. Tang Washer Inspection and Application of Torque Stripe
Page 210
Revision 21
64-30-00
MAINTENANCE MANUAL
Chapter
67
Flight Controls
CSP-HMI-2
MAINTENANCE MANUAL
CSPHMI2
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 101. Troubleshooting Main Rotor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 102. Isolating Main Rotor Control System Troubles . . . . . . . . . . . . . . . . . . .
Table 103. Isolating Tail Rotor Control System Troubles . . . . . . . . . . . . . . . . . . . .
Table 104. Anti-torque Fan System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .
Figure 101. YSAS Electrical Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . .
Figure 102. YSAS Troubleshooting (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 103. YSAS Ground Test Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101
102
103
104
104
105
107
111
67-10-00 Main Rotor Flight Controls (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . . . A

1.
Main Rotor Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

A. Collective Mixer, Lateral and Longitudinal Mixer (Tunnel-Routed)
Control Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Controls Support Bracket and Bellcranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Collective Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Pilot's Collective Pitch Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Copilot's Collective Pitch Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
F. Collective Pitch Stick Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
G. Collective Control Interconnecting Torque Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
H. Collective Bungee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I. Inboard Collective Stick Socket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
J. Cyclic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
K. Pilot's Cyclic Control Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
L. Copilot's Cyclic Control Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
M. Pilot's Compartment Lateral and Longitudinal Cyclic Control Linkage . . . . . . . 3
N. One-Way Lock Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
O. Cyclic Trim Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
P. Roof-Mounted Control Rods (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Q. Roof-Mounted Bellcranks (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1. Main Rotor and Control System (369D/E/FF - 500N) . . . . . . . . . . . . . . 4
Figure 2. Main Rotor and Control System (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
67 Contents
Page i
Revision 42
CSPHMI2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
1.
Tunnel-Routed Control Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

A. Tunnel-Routed Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Tunnel-Routed Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2.
Roof-Mounted Control Rod Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

A. Roof-Mounted Control Rod Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Tunnel-Routed Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 402. Roof-Mounted Controls Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Roof-Mounted Control Rod Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3.
Roof-Mounted Bellcrank Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

A. Roof-Mounted Bellcrank Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Roof-Mounted Bellcrank Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4.
Link Assembly Replacement (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

A. Link Assembly Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Link Assembly Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5.
Controls Support Bracket and Bellcrank Replacement . . . . . . . . . . . . . . . . . . . . . . . . 404

A. Controls Support Bracket and Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 403. Controls Support Bracket, Idler Bellcranks and Cyclic Trim
Actuators Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Controls Support Bracket and Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . 406
6.
Pilot's Collective Pitch Stick Replacement (L/H Command) . . . . . . . . . . . . . . . . . . . . 406

A. Pilot's Collective Pitch Stick Removal (L/H Command) . . . . . . . . . . . . . . . . . . . . . . 406
Figure 404. Dual Collective Controls (L/H Command) . . . . . . . . . . . . . . . . . . . . . . . 407
B. Pilot's Collective Pitch Stick Installation (L/H Command) . . . . . . . . . . . . . . . . . . . 408
7.
Pilot's Collective Pitch Stick Replacement (R/H Command) . . . . . . . . . . . . . . . . . . . . 408

A. Pilot's Collective Pitch Stick Removal (R/H Command) . . . . . . . . . . . . . . . . . . . . . . 408
B. Pilot's Collective Pitch Stick Installation (R/H Command) . . . . . . . . . . . . . . . . . . . 408
Figure 405. Dual Collective Controls (R/H Command) . . . . . . . . . . . . . . . . . . . . . . . 409
8.
Copilot's Collective Pitch Stick Replacement (L/H Command) . . . . . . . . . . . . . . . . . . 410

A. Copilot's Collective Pitch Stick Removal (L/H Command) . . . . . . . . . . . . . . . . . . . . 410
B. Copilot's Collective Pitch Stick Installation (L/H Command) . . . . . . . . . . . . . . . . . 410
Figure 406. CoPilot's Collective Stick Assembly Installation (L/H Command) . 410
9.
Copilot's Collective Pitch Stick Replacement (R/H Command) . . . . . . . . . . . . . . . . . . 411

A. Copilot's Collective Pitch Stick Removal (R/H Command) . . . . . . . . . . . . . . . . . . . . 411
B. Copilot's Collective Pitch Stick Installation (R/H Command) . . . . . . . . . . . . . . . . . 411
Page ii
Revision 42
67 Contents
MAINTENANCE MANUAL
CSPHMI2

Para/Figure/Table
Title
Page
10. Collective Control Interconnecting Torque Tube Replacement . . . . . . . . . . . . . . . . . . 411

A. Collective Control Interconnecting Torque Tube Removal . . . . . . . . . . . . . . . . . . . 411
B. Collective Control Interconnecting Torque Tube Installation . . . . . . . . . . . . . . . . . 412
11. Collective Bungee Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Collective Bungee and Over-Center Fitting - Removal . . . . . . . . . . . . . . . . . . . . . 412
Figure 407. Collective Torque Tube, Gas Producer Torque Tube and
Collective Bungee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Figure 408. Inboard Collective Stick Socket Assembly (L/H Command) . . . . . . . 414
B. Collective Over-Center Fitting and Bungee - Installation and
Preliminary Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
12. Inboard Collective Stick Socket Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . 415
A. Inboard Collective Stick Socket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Inboard Collective Stick Socket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . 415
13. Cyclic Control Stick Replacement (Inboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Cyclic Control Stick Removal (Inboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Cyclic Control Stick Installation (Inboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Figure 409. Cyclic Stick Assembly Installation (Inboard) . . . . . . . . . . . . . . . . . . . . 417
14. Cyclic Control Stick Replacement (Outboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Cyclic Control Stick Removal (Outboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Cyclic Control Stick Installation (Outboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Figure 410. Cyclic Stick Assembly Installation (Outboard) . . . . . . . . . . . . . . . . . . 418
15. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Replacement
(L/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
A. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Removal
(L/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
B. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Installation
(L/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Figure 411. Cyclic Controls (R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
16. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Replacement
(R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Removal
(R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Lateral Control Rods and Sta. 67 Lateral Cyclic Bellcrank Installation
(R/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
17. Cyclic Pitch Interconnecting Torque Tube Replacement (L/H Command) . . . . . . . . 420
A. Cyclic Pitch Interconnecting Torque Tube Removal (L/H Command) . . . . . . . . . . 420
Figure 412. Cyclic Torque Tube and One-Way Lock Installation . . . . . . . . . . . . . 421
B. Cyclic Pitch Interconnecting Torque Tube Installation (L/H Command) . . . . . . . 422
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18. Cyclic Pitch Interconnecting Torque Tube Replacement (R/H Command) . . . . . . . . 422
A. Cyclic Pitch Interconnecting Torque Tube Removal (R/H Command) . . . . . . . . . . 422
B. Cyclic Pitch Interconnecting Torque Tube Installation (R/H Command) . . . . . . . 422
19. One-Way Lock Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
A. One-Way Lock Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
B. One-Way Lock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
20. Cyclic Trim Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
A. Cyclic Trim Actuator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
B. Cyclic Trim Actuator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1.
Cyclic and Collective Control System Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2.
Collective Controls Rigging (L/H Command) (369D/E/FF - 500N) . . . . . . . . . . . . . .

Figure 501. Main Rotor Control System Rigging (369D/E/FF - 500N)
(Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 502. Rigging Main Rotor Control System (600N) (Sheet 1 of 3) . . . . . . . .
Figure 503. Cyclic and Collective Controls Rigging Tools (R/H Command) . . . . .
501
502
505
508
3.
Collective Controls Rigging (R/H Command) (369D/E/FF - 500N) . . . . . . . . . . . . . . 509
4.
Collective Control System Rigging (L/H Command) (600N) . . . . . . . . . . . . . . . . . . . . 509
5.
Collective Controls Rigging (R/H Command) (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . 510
6.
Cyclic Controls Rigging (L/H Command) (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . 510
7.
Cyclic Controls Rigging (R/H Command) (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . 513
8.
Cyclic Controls Rigging (L/H Command) (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
9.
Cyclic Controls Rigging (R/H Command) (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
10. Gas Producer Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515

Figure 504. Gas Producer Drive Backlash Adjustment
(Outboard Collective Stick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Figure 505. Gas Producer Drive Backlash Adjustment
(Inboard Collective Stick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
11. Pipe Plug Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
12. Gas Producer Interconnecting Torque Tube Assembly Shimming
(0003D thru 0929D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
Figure 506. Gas Producer Interconnecting Torque Tube Shimming Procedure
(0003D thru 0929D) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
13. Collective Stick Friction Mechanism Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
Figure 507. Collective Stick Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
14. Collective Bungee Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
15. Cyclic Trim Actuator Bench Testing (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . 524
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16. Cyclic Trim Actuator Bench Testing (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 508. Cyclic Trim Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 509. Cyclic Trim Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 510. Wiring Diagram and Cable Routing (Collective Stick) . . . . . . . . . . . .
Figure 511. Wiring Diagram and Cable Routing (Cyclic Stick) . . . . . . . . . . . . . . .
525
527
528
529
530
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
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
B. Control Tube Straight Area Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Table 802. Control Tube Straight Area Repair Limits . . . . . . . . . . . . . . . . . . . . . . . 805
3.
Controls Support Bracket and Bellcrank Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 805
4.
Controls Support Bracket and Bellcrank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
5.
Controls Support Bracket and Bellcrank Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 805
6.
Pilot's Collective Pitch Stick Disassembly (L/H Command) . . . . . . . . . . . . . . . . . . . . 806

Figure 802. Control Tube Boot Rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
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7.
Pilot's Collective Pitch Stick Repair (L/H Command) . . . . . . . . . . . . . . . . . . . . . . . . . . 807
8.
Pilot's Collective Pitch Stick Reassembly (L/H Command) . . . . . . . . . . . . . . . . . . . . . 807
9.
Pilot's Collective Pitch Stick Disassembly (R/H Command) . . . . . . . . . . . . . . . . . . . . 808
10. Pilot's Collective Pitch Stick Reassembly (R/H Command) . . . . . . . . . . . . . . . . . . . . . 809

11. Copilot's Collective Pitch Stick Disassembly (L/H and R/H Command) . . . . . . . . . . 809
12. Copilot's Collective Pitch Stick Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
13. Copilot's Collective Pitch Stick Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
14. Collective Control Interconnecting Torque Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . 811
15. Collective Bungee Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
16. Collective Bungee Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
17. Inboard Collective Stick Socket Assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 812
18. Inboard Collective Stick Socket Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
19. Inboard Collective Stick Socket Assembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 813
20. Cyclic Control Stick Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
21. Cyclic Friction Mechanism Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
22. Lateral Control Rods and Sta. 67 Bellcrank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
23. Cyclic Pitch Interconnecting Torque Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
24. One-Way Lock Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
25. Cyclic Trim Actuator Spring Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 815
26. Cyclic Trim Actuator Housing or Trim Tube Replacement . . . . . . . . . . . . . . . . . . . . . 815
27. Cyclic Trim Actuator (Motor/Gear Drive Mechanism) Replacement . . . . . . . . . . . . . 816
28. Cyclic Trim Actuator Rework (Calco P/N 8222M6 and 8222M7) . . . . . . . . . . . . . . . . 816
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 201. Collective Pitch Stick Switch Replacement . . . . . . . . . . . . . . . . . . . . . .
Figure 202. Cyclic Stick Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 203. Cyclic Stick Grip Disassembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . .
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202
203
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Page
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 1. Tail Rotor and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.
Sta. 120 Control Rod or Sta. 142 Bellcrank Replacement . . . . . . . . . . . . . . . . . . . . . . 401

A. Sta. 120 Control Rod or Sta. 142 Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Sta. 120 Control Rod or Sta. 142 Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . 401
Figure 401. Upper Fuselage and Boom Tail Rotor Control Linkage . . . . . . . . . . . 402
2.
Sta. 284 Bellcrank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

A. Sta. 284 Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Sta. 284 Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3.
Tailboom Control Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

A. Tailboom Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Tailboom Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4.
Sta. 95 Bellcrank and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

A. Sta. 95 Bellcrank and Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402. Tail Rotor Pedal Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 404
B. Sta. 95 Bellcrank and Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
C. Tail Rotor Pedal Assembly - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
D. 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
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Para/Figure/Table
Title
Page
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
67-20-30 NOTARr Anti-Torque System Flight Controls (500/600N) . . . . . . . . . . . . . A

1.
NOTAR 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
Page viii
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67 Contents
MAINTENANCE MANUAL
CSPHMI2

Para/Figure/Table
4.
Title
Page
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
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
67 Contents
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Para/Figure/Table
Title
Page
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. S.A.S. Rate Gyro and Electronic Control Box (Computer) Replacement . . . . . . . . . 415
A. S.A.S. Rate Gyro and Electronic Control Box (Computer) Removal . . . . . . . . . . . 416
B. S.A.S. Rate Gyro and Electronic Control Box (Computer) Installation . . . . . . . . 416
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1.
Directional Controls Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2.
Fan Pitch Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

Figure 501. Fan Pitch Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
3.
Pilot Pedal Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503

Figure 502. Pilot Pedal Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
4.
Anti-Torque Pedal Friction Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . 505
5.
Thruster Control Rigging (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505

Figure 503. Thruster Control Rigging (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 506
6.
Thruster Control Rigging (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
7.
Left Vertical Stabilizer Assembly Rigging (500N, and 600N with YSAS) . . . . . . . . 508
8.
Stability Augmentation System Rigging Instructions

(500N, and 600N with YSAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
9.
Vertical Stabilizer Assembly Rigging (600N without YSAS System) . . . . . . . . . . . .

Figure 504. Left Vertical Stabilizer Rigging (500N, and 600N with YSAS) . . . .
Figure 505. Stability Augmentation System S.A.S. (Sheet 1 of 2) . . . . . . . . . . . .
Figure 506. Vertical Stabilizer Rigging (600N without YSAS) . . . . . . . . . . . . . . . .
Page x
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509
510
511
513
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CSPHMI2

Para/Figure/Table
Title
Page
10. Vertical Stabilizer Trim Tab Adjustment and Tool Manufacturing

(600N without YSAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
A. Trim Tab Tool Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
B. Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Figure 507. Vertical Stabilizer Trim Tab Bending Tool . . . . . . . . . . . . . . . . . . . . . . 515
Table 501. Flight Controls Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
1.
Upper Fuselage and Tailboom Control Linkage Inspection . . . . . . . . . . . . . . . . . . . . . 601
2.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 601. Isolating Control System Troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 601. Control Cable Coupling Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 602. Forward and Center Cable Relief Area Inspection . . . . . . . . . . . . . . .
Figure 603. Control Cable Telescopic Swivel End Inspection . . . . . . . . . . . . . . . . .
602
603
603
604
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
7.
Fan Pitch Control Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8.
Forward Cable Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
9.
Center Cable Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
67 Contents
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Para/Figure/Table
Title
Page
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
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67 Contents
MAINTENANCE MANUAL
CSP-HMI-2
Section
670000
Flight Controls
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
FLIGHT CONTROLS
FAULT ISOLATION
1. Main Rotor Flight Control System
Troubleshooting
Ensure that rotor controls are
not struck by any object. Many
of the components are highly stressed and
must not be returned to service if surface
damage occurs. When maintenance work is
performed near engine air inlet, comply
with precautions (Ref. Chap. 71) to prevent
entry of foreign objects.
CAUTION
Troubleshooting information is divided into: (1)

investigation of main rotor vibrations (Ref.
Chap. 62); (2) investigation of symptoms (Ref.
Table 101); and (3) isolation of troubles (Ref.
Table 102).
First determine which major installation is
defective. Isolate each linkage installation
from others until area of malfunction is
located. Then investigate and determine exact
location of malfunction and repair or replace
defective component(s). Since first indication of
trouble usually is felt at cyclic or collective
pitch stick, isolation procedures in Table 101
and Table 102 begin with symptoms detected
during operation of these controls.
Sudden onset of excessive
WARNING and/or unusual main rotor

vibrations should be investigated as to
cause, prior to continued flight. Under
no circumstance should main rotor
tracking be attempted to correct the
problem until a thorough inspection of
the main rotor blades, hub assembly
and strap pack assembly has been per
formed.
2. AntiTorque Flight Controls
Anti-Torque flight controls consist of anti-tor
que pedals, torque tube, floor-routed control
tube, tunnel-routed control tube, Sta. 120

control tube and tail boom control rod trans
mitting input through a series of bellcranks
and idlers.
3. AntiTorque and Control System
Troubleshooting
Troubleshooting information is divided into (1)
investigation of operational vibration problems
originating with the tail rotor or symptoms
that can be recognized (Ref. Chap. 64) and (2)
isolation and localization of an unusual
controls malfunction (Ref. Table 103 or
Table 104).
4. Stability Augmentation System
Troubleshooting
Troubleshooting the Yaw Stability Augmenta
tion System (YSAS) shall be performed using
the wiring diagram (Ref. Figure 101) in
conjunction with the fault isolation tree (Ref.
Figure 102) and the ground test box (Ref.
Figure 103).
Troubleshooting the YSAS by field mainte
nance personnel shall be limited to isolating
the trouble to a malfunctioning or defective
system unit/component.
For removal or replacement of YSAS compo
nents refer to applicable section.
Death or injury can occur if
WARNING proper safety precautions

are not taken while performing electri
cal system checks with electrical pow
er on.
Maintenance personnel other
than approved manufacturer's
representative shall not attempt to repair
any part of the YSAS system.
CAUTION
67-00-00
Page 101
Revision 30
MAINTENANCE MANUAL
CSP-HMI-2
Table 101. Troubleshooting Main Rotor Controls

Symptom
Probable Trouble
Cyclic stick pressure in one

Check for continuity between pin S
direction; hands off condition and pins R, U, V, and X of
stick drifts in direction of
connector(s) P109 and/or P130.
pressure.
Corrective Action
If continuity exists, replace cyclic trim
switch, Cyclic Stick Grip Switch
Replacement (Standard Grip).
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

cannot be reduced by
operating trim switch.
Trim actuator inoperative.
Replace actuator.
Defective components in trim actuator

control circuit.
Troubleshoot control circuits: replace

defective electrical component(s).
Trim change is too slow.
Defective trim actuator.
Replace actuator.
Cyclic control sticks have

tendency to move to aft
position.
Low fluid in oneway lock fluid

reservoir.
Add fluid to oneway lock reservoir.
Inadequate cyclic control

during flight.
Helicopter loaded out of center of

gravity range.
Check and correct weight and

balance.
Incorrect cyclic rigging.
Correct cyclic rigging.
Lateral and/or longitudinal friction

device improperly adjusted.
Loosen lateral and/or longitudinal

friction device.
Swashplate spherical bearing surface

damaged.
Replace swashplate bearing assembly

if torque required to rotate bearing
exceeds 32 inchpounds (3.61 Nm).
Scissors crank bearings or hub lower

shoe bearings binding or frozen.
Replace defective bearings.
Lateral and/or longitudinal

interconnecting rod end bearing
binding due to incorrect alignment.
Realign rod end bearing.
Droop stop plungers sticking.
Clean plungers and mating shoe

bushings with isopropyl alcohol
(CM217).
Droop stop followers, rollers and/or

stop ring rusty or corroded.
Apply rust inhibitor and lubricants

(CM204) to followers, rollers and
droop stop ring.
Droop stop striker plate(s) or cam

roller(s) damaged.
Replace striker plate and/or cam roller.
Oneway lock check valve, or push

rod shaft that unseats the valve, is
galled or seized.
Replace oneway lock assembly.
Excessive pressure required

for lateral and/or longitudinal
movement of cyclic control
stick on ground and during
flight. (Some droop friction is
always felt when there is no
rotor rpm.)
Page 102
Revision 21
67-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Table 102. Isolating Main Rotor Control System Troubles

Symptom
Isolating Step
Corrective Action
Binding, lockingup and

erratic action of cyclic control
stick.
Disconnect oneway lock.
If symptom gone, replace oneway

lock.
Symptom remains.
Disconnect upper ends of longitudinal

and lateral control rods.
If symptom gone and rod ends are

serviceable, disassemble and inspect
main rotor mixer controls until
defective part is located.
Symptom remains.
Reconnect upper ends of longitudinal

and lateral control rods, and
disconnect lower ends.
If symptom gone and rod ends are

pilot compartment controls until
Trouble corrected (Reconnect all control linkage).

Binding, lockingup and
erratic action of collective
control stick.
CAUTION: Before disconnecting collective pitch control rod, install collective

bungee installation tool (ST508) to prevent spring reaction on control rod.
Disconnect upper end of collective
pitch control rod and operate stick.
If symptom gone and rod end is

main rotor mixer controls until
Symptom remains.
Leave upper end of collective pitch

control rod disconnected.
Trouble is in pilot compartment

collective control linkage.
Symptom remains.
WARNING: Do not disconnect any hardware from pilots collective stick unless
collective bungee installation tool (ST508) is installed. Strong bungee spring
pressure can cause linkage reaction and severe personal injury, or parts
damage.
Symptom remains.
Disconnect gas producer control rod

from collective stick. Disconnect droop
control override link from collective
controls torque tube.
If symptom gone, trouble is in engine

controls.
Leave gas producer control rod and

droop control override link
disconnected.
Disassemble and inspect pilot

compartment collective control linkage
until defective part is located.
Trouble corrected (Reconnect all control linkage)
67-00-00
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MAINTENANCE MANUAL
CSP-HMI-2
Table 103. Isolating Tail Rotor Control System Troubles

Symptom
Isolating Step
Corrective Action
Binding, locking up and erratic

action of foot pedals. (Do not
force controls)
Disconnect pitch control links from

pitch control assembly.
If symptom gone, replace tail rotor

assembly or repair (Ref. COM).
Symptom remains.
Disconnect Sta. 284 aft boom

bellcrank from pitch control assembly.
If symptom gone, clean swashplate

bore and output shaft splines.
Lubricate splines. Replace swashplate
if necessary. Check for elongation of
bolt hole in support arm portion of
main housing assembly of tail rotor
gear box, caused by looseness of
bellcrank fulcrum bolt and nut. Repair
(Ref. COM).
Symptom remains.
Disconnect floorrouted tail rotor

control rod from foot pedal torque tube
fitting.
If symptom gone, inspect tail rotor

control rods and bellcranks until
Symptom remains.
Loosen foot pedal torque tube

brackets mounted on front of floor
structure.
If symptom gone, pedal torque tube

misaligned; shim for correct alignment.
If symptom remains, disassemble and
inspect tail rotor foot pedal installation
until defective part is located (same
section).
Trouble corrected.
Table 104. Antitorque Fan System Troubleshooting

Symptom
Probable Trouble
Corrective Action
Binding in controls linkage.
Isolate damage or obstruction and

remove.
Restriction against rotating cone.
Isolate restriction or damage and

remove.
Binding, locking up or erratic

action of pedal movement.
Control rod or cable restrictions or

misalignment.
Inspect control rod and control cable

connections, rod end condition and
bearing movement, replace
Pedals feel rachety.
Flat spotting on thruster rollers.
Replace rollers (Ref. Sec. 534030).
Degraded movement or
response of fan control
linkage.
Restriction or malfunction at splitter

assembly.
Inspect splitter range and freedom of

movement.
Degraded travel of force limiting

control rod or diffuser bellcrank
connections.
Isolate damage or malfunction and

replace components.
Incorrect rigging.
Correct rigging.
Incorrect rigging.
Correct rigging.
Excessive resistance against

pedal movements.
Inadequate antitorque/directional movement or response

during flight.
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67-00-00
MAINTENANCE MANUAL
SAS ELECT CONTROL

(COMPUTER)
28VDC OUT
28V RTN
ACTUATOR ENABLE
SERVO CONTROL SIGNAL
SERVO CONTROL RTN
SHIELD
ACTUATOR POSITION
RTN
SHIELD
+15VDC
COM
-15VDC
SHIELD
P1
r
Z
D
H
J
K
L
M
N
P
R
g
h
CSP-HMI-2
TAILBOOM
DISCONNECT
J2P
RING FRAME
DISCONNECT
J3P
J
K
L
S
A
N
B
P
R
C
D
E
G
F
J
K
L
S
A
N
B
P
R
C
D
E
G
F
SAS2A20
SAS9A20
SAS3A22
SAS4A22 WHT
SAS4A22 BLU
SAS5A22 WHT
SAS5A22 BLU
SAS6A22 WHT
SAS6A22 BLU
SAS6A22 ORN
SAS10A22
SAS2B20
SAS9B20
SAS3B22
SAS4B22 WHT
SAS4B22 BLU
SAS5B22 WHT
SAS5B22 BLU
SAS5B22
SAS6B22 WHT
SAS6B22 WHT
SAS6B22 ORN
SAS10B22
E40
P4 (YSAS ACTUATOR)
SAS2C20
SAS9C20
SAS3C22
SAS4C22 WHT
SAS4C22 BLU
J
K
L
S
A
28VDC PWR
PWR END
ACTUATOR ENABLE
COMMAND SIG (L)
COMMAND SIG (H)
SAS5C22 WHT
SAS5C22 BLU
B POSITION FEEDBACK (H)

P POSITION FEEDBACK (L)
SAS6C22 WHT
SAS6C22 BLU
SAS6C22 ORN
C +15VDC
D SIGNAL COMMON
E -15VDC
SAS10C22
F CHASSIS GND
C B A
28VDC RTN B
CHASSIS GRND E
SAS7A20N
SAS8A20N
CB121
YSAS
J1202P
28VDC IN m
ON/OFF RELAY C
SAS1B20
SAS15B22
Z
a
SAS1A20
SAS15A22
5A
YSAS
S12
3
ACTUATOR PCS TP
SERVO COM TP
HARD OVER TP
SIGNAL COMMON
LATERAL ACCEL TP
YAW RATE TP
SAS16A22N
E31
S
e
S
a
W
F
G
P5 (YAW RATE
GYRO)
YAW RATE IN +
YAW RATE IN SHIELD
28VDC OUT
28V RTN
-15VDC
+15VDC
b
c
n
p
q
f
T
SAS11A22 WHT
SAS11A22 BLU
D SIG OUT (H)

C SIG OUT (L)
SAS12A22
SAS13A22
SAS14A22
SAS17A22
A
B
E
F
+28VD
PWR GND
-15VDC
+15VDC
500N
G67-2016-1C
Figure 101. YSAS Electrical Diagram (Sheet 1 of 2)
67-00-00
Page 105
Revision 42
CSP-HMI-2
MAINTENANCE MANUAL
600N
G67-2016-2A
Figure 101. YSAS Electrical Diagram (Sheet 2 of 2)

Page 106
Revision 42
67-00-00
MAINTENANCE MANUAL
CSP-HMI-2
STAR
T
VERIFY ALL YSAS SYSTEM ASSOCIATED

ELECTRICAL CONNECTORS ARE MATED WITH
COMPONENTS. VERIFY CIRCUIT BREAKER IS
PUSHED IN AND YSAS SYSTEM ON/OFF SWITCH IS
ON. IS YSAS STILL INOPERATIVE?
NO
GO TO SHEET
2
YES
SHUT OFF ELECTRICAL POWER. CHECK FOR
CONTINUITY TO A/C GROUND AT PINS B, E AND
C OF SAS COMPUTER PLUG (P1 FOR 500N: P512
FOR 600N). DOES CONTINUITY EXIST?
NO
REPAIR OPEN WIRE(S) BETWEEN PIN B

OF SAS COMPUTER AND GROUND
E40-B OR PIN E AND GROUND E40-A
OR PIN C AND GROUND E31-S.
YES
SHUT OFF ELECTRICAL POWER. DISCONNECT
SAS COMPUTER PLUG (P1 FOR 500N: P512 FOR
600N). REAPPLY ELECTRICAL POWER AND
CHECK FOR 28 VDC AT PIN M. IS VOLTAGE
PRESENT?
NO
REPAIR OPEN WIRE BETWEEN PIN

M OF SAS COMPUTER AND CB121.
YES
DISCONNECT ELECTRICAL POWER. CONNECT
SAS TEST BETWEEN SAS COMPUTER AND SAS
WIRE HARNESS. REAPPLY ELECTRICAL POWER
AND AT SAS TEST BOX, CHECK FOR +15 VDC
AND -15 VDC COMING FROM COMPUTER
POWER SUPPLY. IS VOLTAGE PRESENT?
NO
REPLACE FAULTY SAS
COMPUTER
YES
REMOVE YAW RATE GYRO ATTACHING HARDWARE
AND CAREFULLY ROTATE GYRO IN A CLOCKWISE
DIRECTION. CHECK RIGHT VERTICAL STABILIZER FOR
TRAILING EDGE LEFT (INITIAL MOVEMENT ONLY).
DOES RIGHT VERTICAL STABILIZER MOVE?
NO
GO TO SHEET
3
YES
REMOVE SAS COMPUTER ATTACHING HARDWARE
AND CAREFULLY TILT COMPUTER, CONNECTOR
SIDE UP, CHECK RIGHT VERTICAL STABILIZER
TRAILING EDGE RIGHT MOVEMENT. DOES RIGHT
VERTICAL STABILIZER MOVE?
NO
GO TO SHEET
4
YES
YAW SAS SYSTEM APPEARS TO OPERATE
CORRECTLY.
G67-2017-1A
Figure 102. YSAS Troubleshooting (Sheet 1 of 4)
67-00-00
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Revision 30
MAINTENANCE MANUAL
CSP-HMI-2
FROM SHEET 1
DOES RIGHT VERTICAL STABILIZER MOVE OR

OSCILLATE WITH NO SENSOR INPUTS?
NO
YAW SAS SYSTEM APPEARS TO

OPERATE CORRECTLY.
YES
SHUT OFF ELECTRICAL POWER. CONNECT SAS
TEST BOX BETWEEN SAS COMPUTER AND SAS
WIRE HARNESS. REAPPLY ELECTRICAL
POWER. CHECK FOR SERVO COMMAND
SIGNAL AT TEST BOX BETWEEN SERVO TEST
POINT AND TEST BOX GROUND. IS SIGNAL
VOLTAGE CHANGING?
NO
SHUT OFF ELECTRICAL POWER. CHECK

FOR OPEN WIRES BETWEEN YSAS
COMPUTER AND RIGHT VERTICAL
STABILIZER WIRE HARNESS. DOES
CONTINUITY EXIST?
NO
REPAIR OPEN WIRES BETWEEN YSAS

STABILIZER ACTUATOR.
YES
REPLACE VERTICAL STABILIZER
ACTUATOR.
YES
CHECK FOR YAW RATE GYRO SIGNAL AT TEST
BOX BETWEEN YAW RATE TEST POINT AND
TEST BOX GROUND. IS SIGNAL PRESENT?
NO
REPLACE YSAS COMPUTER.
YES
OPEN WIRES BETWEEN YSAS COMPUTER AND
YAW RATE GYRO WIRE HARNESS. VERIFY GOOD
NO
GROUND MODULES AND GROUND TERMINATIONS.
VERIFY THERE IS NO SHORTED OR CHAFFED
WIRES. APPLY ELECTRICAL POWER AND CHECK
FOR RATE GYRO SIGNAL TO TEST BOX TEST
POINT. IS SIGNAL PRESENT?
YSAS SYSTEM APPEARS TO OPERATE

CORRECTLY.
YES
REPLACE FAULTY YAW RATE
GYRO.
G67-2017-2

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MAINTENANCE MANUAL
CSP-HMI-2
FROM SHEET 1
CHECK YAW RATE GYRO TEST POINT ON THE

YSAS TEST BOX WHILE ROTATING THE YAW RATE
GYRO. IS A VOLTAGE CHANGE PRESENT?
NO

COMPUTER AND YAW RATE GYRO. DOES
CONTINUITY EXIST?
NO
REPAIR OPEN WIRES BETWEEN YSAS

COMPUTER AND YAW RATE GYRO.
YES
YES
REPLACE YAW RATE

GYRO.
CHECK THE SERVO COMMAND TEST POINT ON
THE YSAS TEST BOX WHILE ROTATING THE
YAW RATE GYRO. IS A VOLTAGE CHANGE
PRESENT?
NO
YES
AT THE YSAS TEST BOX, CHECK THE ACTUATOR
POSITION TEST POINT TO TEST BOX GROUND
WHILE ROTATING THE YAW RATE GYRO. IS A
VOLTAGE CHANGE PRESENT?
NO

STABILIZER ACTUATOR. DOES CONTINUITY
EXIST?
NO
REPAIR OPEN WIRES BETWEEN

YSAS COMPUTER AND RIGHT
VERTICAL STABILIZER ACTUATOR.
YES
YES
DISCONNECT THE RIGHT VERTICAL
STABILIZER ACTUATOR PLUG (P4 FOR
500N: P515 FOR 600N). REAPPLY
ELECTRICAL POWER AND PLACE THE
RIGGING SWITCH ON THE YSAS TEST BOX
TO THE EXTEND POSITION. CHECK THE
VOLTAGE AT THE STABILIZER ACTUATOR
PLUG AT TERMINALS S (H) AND A (L). IS
VOLTAGE GREATER THAN 6 VDC?
NO
YES
REPLACE RIGHT VERTICAL STABILIZER
ACTUATOR.
SHUT OFF ELECTRICAL POWER. CHECK RIGHT

VERTICAL STABILIZER FOR PROPER
INSTALLATION OR DAMAGED CONTROL
LINKAGE FROM ACTUATOR TO VERTICAL
STABILIZER. IS STABILIZER PROPERLY
INSTALLED AND FREE FROM DAMAGE?
NO
REPAIR OR REPLACE CONTROL LINKAGE OR

VERTICAL STABILIZER AND VALIDATE THE
CONTROL RIGGING AS REQUIRED.
YES
ACTUATOR.
G67-2017-3A
67-00-00
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MAINTENANCE MANUAL
CSP-HMI-2
FROM SHEET 1
CHECK THE ACCELERATION TEST POINT ON THE

YSAS TEST BOX WHILE TILTING THE YSAS
COMPUTER. IS SIGNAL PRESENT?
NO
REPLACE THE YSAS COMPUTER.
YES
CHECK THE SERVO COMMAND TEST POINT ON
THE YSAS TEST BOX WHILE TILTING THE YSAS
COMPUTER. IS A VOLTAGE CHANGE PRESENT?
NO
YES
AT THE YSAS TEST BOX, CHECK THE ACTUATOR
POSITION TEST POINT TO TEST BOX GROUND
WHILE TILTING THE YSAS COMPUTER. IS
VOLTAGE CHANGE PRESENT?
NO

OPEN WIRES BETWEEN YSAS COMPUTER AND
RIGHT VERTICAL STABILIZER ACTUATOR. DOES
CONTINUITY EXIST?
YES
NO
REPAIR OPEN WIRES BETWEEN

YSAS COMPUTER AND RIGHT
VERTICAL STABILIZER ACTUATOR.
YES
DISCONNECT THE RIGHT VERTICAL STABILIZER
ACTUATOR PLUG (P4 FOR 500N: P515 FOR 600N).
REAPPLY ELECTRICAL POWER AND PLACE THE
RIGGING SWITCH ON THE YSAS TEST BOX TO
THE EXTEND POSITION. CHECK THE VOLTAGE
AT THE STABILIZER ACTUATOR PLUG AT
TERMINALS S (H) AND A (L). IS VOLTAGE
GREATER THAN 6 VDC?
NO
YES
ACTUATOR.
SHUT OFF ELECTRICAL POWER. CHECK RIGHT

VERTICAL STABILIZER FOR PROPER
INSTALLATION OR DAMAGED CONTROL
LINKAGE FROM ACTUATOR TO VERTICAL
STABILIZER. IS STABILIZER PROPERLY
INSTALLED AND FREE FROM DAMAGE?
NO
REPAIR OR REPLACE CONTROL LINKAGE OR

VERTICAL STABILIZER AND VALIDATE THE
CONTROL RIGGING AS REQUIRED.
YES
ACTUATOR.
G67-2017-4A

Page 110
Revision 30
67-00-00
MAINTENANCE MANUAL
ACCEL
CSP-HMI-2
ACTUATOR
POSITION
EXTEND
OFF
YAW
RATE
SERVO
COMMAND
-15
VDC
+15
VDC
RETRACT
GROUND
G67-2018
Figure 103. YSAS Ground Test Box
67-00-00
Page 111
Revision 30
CSP-HMI-2
MAINTENANCE MANUAL
Page 112
Revision 43
67-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
671000
Main Rotor Flight
Controls (369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
MAIN ROTOR FLIGHT CONTROLS

1. Main Rotor Flight Controls
Main rotor flight controls consist of scissors,
rotating swashplate, stationary swashplate,
mixer controls (lateral bellcrank, longitudinal
idler, collective pitch mixer bellcrank, longitu
dinal bellcrank, longitudinal control-mixer
link, longitudinal link, and two mixer links)
and five pitch control rods.
Movement of collective pitch cyclic control
sticks is transferred to mixer controls through
control rods routed up through the controls
tunnel at the center of Sta. 78.50 bulkhead.
Mixer controls transfer required combination
of collective, longitudinal and lateral travel
through swashplates to main rotor blades. The
helicopter may be equipped with either
right-hand or left-hand control configurations
consisting of cyclic, collective and anti-torque
controls. The main rotor hub and blades,
swashplate and control linkage to the crew
compartment controls are identical on either
basic configuration.
NOTE: This section contains information for

both L/H command and R/H command heli
copters. Unless otherwise denoted, the in
formation in this section pertains to both
type helicopters.
A. Collective Mixer, Lateral and Longitudinal
Mixer (TunnelRouted) Control Rods
Tunnel-routed control rods mechanically
transfer displacement of flight controls to
associated bellcranks and the idler at the front
of main rotor mast base. All tunnel-routed
control rods are removed, inspected, repaired
and installed in same manner.
B. Controls Support Bracket and Bellcranks
The controls support bracket is below the
pilot's seat cover, between right and left
inboard sides of the seat structure. The
bracket provides the hingeline for longitudinal
and lateral idler bellcrank, tail rotor bellcrank,
and the engine droop control bellcrank. It also
provides inboard support for the collective

torque tube.
C. Collective Controls
Pilot's compartment collective controls consist
of collective pitch stick, collective bungee, and
the interconnecting shaft and linkage. All
components, except the stick and tunnelrouted collective mixer control rod, are located
within the pilot's seat structure. Dual control
provisions are incorporated into the pilot's
compartment collective controls installation.
D. Pilots Collective Pitch Stick
The pilot's collective pitch stick consists
primarily of a switch housing, throttle grip and
friction mechanism, collective stick tube and
friction mechanism and gas producer control
shaft with right angle (pinion and bevel gear)
drive. Collective pitch stick controls include:
the N1 throttle and idle stop release ring, N2
governor trim switch, landing light switch,
stick friction adjustment grip throttle friction
nut and a starter-ignition switch.
E. Copilots Collective Pitch Stick
The copilot's collective stick consists primarily
of a switch housing, N1 throttle grip, stick
tube, and internal gas producer control shafts
having right angle (pinion and bevel) gear
drive. The gear drive linkage is essentially the
same as in pilot's collective stick housing.
Copilot's collective controls include an N2
governor trim switch.
F. Collective Pitch Stick Friction
Pilot's collective pitch stick friction allows the
pilot to vary amount of effort required to raise
and lower the collective pitch stick as well as
increasing stick resistance to position change
resulting from sudden changes in main rotor
collective forces. The grip is marked with
arrows indicating direction of rotation for
increasing or decreasing friction. Friction can
be applied or released with one hand by
rotating the friction adjustment grip.
67-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
Collective stick friction mecha

nism is designed so that stick
cannot be locked in maximum friction point.
Safety of flight considerations require that
pilot be able to instantly change any estab
lished collective pitch stick position, without
changing friction adjustment in event of a
power failure. There is no suitable check
that pilot can make, with helicopter on the
ground, to determine if maintenance adjust
ment of collective friction is correct. This is
due to large force application necessary to
override collective bungee and blades rest
ing on droop stops. If stick friction is inade
quate during flight, a maintenance check
should be performed. Once friction adjust
ment is determined to be correct at low fric
tion point, any further mechanical adjust
ment to alter (increase) friction at low point
can cause stripping of mechanism when grip
is fully rotated for maximum friction.
CAUTION
G. Collective Control Interconnecting

Torque Tube
The collective interconnecting torque tube
consists of the tube, bungee bracket, bungee
fitting and a tube support bearing. The torque
tube interconnects the pilot's collective pitch
stick and the inboard collective stick socket
assembly. The torque tube is supported at the
left end by a bearing installed in seat struc
ture, and at the right end by the controls
support bracket.
H. Collective Bungee
The collective bungee installation consists of a
male bearing assembly, female bearing
assembly, spring and retainer. This unit
attaches between the bungee over-center
fitting and bungee bracket of collective
interconnecting torque tube. The collective
bungee helps maintain selected collective pitch
stick position in flight by counteracting forces
that are fed back in collective pitch stick(s)
(blade pitching moments, rotor head strap
pack torsion when collective pitch stick is
raised or lowered from mid-position, and
combined imbalance of forces in the controls
system). Flight characteristics of the helicopter
are such that collective forces are relatively
low during most stick travel from low to high
blade pitch. At a point near full pitch, stick
forces reverse and become heavy. The purpose
of the adjustable bungee and the overcenter
Page 2
Revision 21
67-10-00
bracket attachment is to counteract these

forces so that collective stick loads are
relatively constant throughout full range of
travel. There are two adjustments provided to
establish or correct collective flight loads. The
collective bungee spring corrects variation in
collective load from low pitch (level flight) to
high pitch (climb). Setting of overcenter bolt to
raise or lower bungee fitting reduces or
increases overall collective forces in both low
pitch (level flight) and high pitch (climb).
I. Inboard Collective Stick Socket Assembly
Inboard collective stick socket assembly is a
cast magnesium housing that contains gas
producer linkage and provisions for attach
ment of dual collective controls. Internal gas
producer drive gear linkage is essentially the
same as that in the pilot's collective stick
housing with the addition of a splined N1
pinion gear for simplified installation or
removal of a copilot's collective stick. The lower
end of the collective mixer (tunnel-routed)
control rod is attached to the socket housing
and the exterior bellcrank, idler and link
transfer movement of the pilot's collective stick
throttle to the gas producer controls routed
through the fuselage to the engine.
J. Cyclic Controls
The cyclic pitch control system is a fully
mechanical control system. Any combination of
lateral and longitudinal cyclic pitch stick
movement is mixed by cyclic lateral and
longitudinal control mixers and transferred to
the main rotor swashplate, which applies the
combined motion through pitch control rods to
the main rotor blades. Forward and rearward
movement of the cyclic pitch stick causes
helicopter motion in a longitudinal direction,
while side-to-side movement provides motion
in a lateral direction. This action varies lift
developed by main rotor blades and serves as
primary control by horizontal flight. Pilot's
compartment cyclic controls include the control
stick, a lateral interconnecting rod, lateral
cyclic bellcrank, longitudinal cyclic control
interconnecting torque tube and lateral and
longitudinal friction mechanism.
K. Pilots Cyclic Control Stick
The pilot's cyclic control stick consists of a grip
and a tube riveted in a socket. The cyclic grip
contains a toggle switch for cyclic trim control
MAINTENANCE MANUAL
and a trigger switch for radio/interphone
communication. A blank switch socket is
provided at the left of the trim switch for
optional equipment. Coiled, insulated and
open-ended wiring is provided in the grip for
connection to an optional switch.
L. Copilots Cyclic Control Stick
The copilot's cyclic control stick is similar to
the pilot's except electrical wiring exits above
the stick socket. The copilot's cyclic stick is
detachable and may be removed or installed by
use of two quick-release pins.
M. Pilots Compartment Lateral and
Longitudinal Cyclic Control Linkage
Pilot's compartment lateral and longitudinal
cyclic control linkage consists of two control
rods and a bellcrank that interconnect lateral
control movement, and the cyclic torque tube
and one-way lock control system that inter
connect longitudinal control movement of
pilot's cyclic stick to tunnel-routed mixer
control rods. R/H command configuration is
identical to L/H command except for an
additional lateral control rod that attaches
lower end of copilot's cyclic control stick to
lateral cyclic bellcrank.
N. OneWay Lock Control System
The one-way lock of the cyclic control system
is located in longitudinal control linkage
within the pilot's seat structure. The one-way
lock control system is essentially a self-con
tained, closed-loop hydraulic unit - consisting
of a check valve, relief valve and pushrod
mechanism. The check valve is seated when
longitudinal control force (feed-back) origi
nated by main rotor tends to move the
one-way lock (and cyclic stick) in an aft
direction. Seating the check valve prevents
unwanted aft movement of cyclic stick and
shunts feed-back force to helicopter structure.
Normally, only very slight aft movement of the
cyclic stick is required to unseat the check
valve. Should the check valve (or pushrod
shaft that unseats the valve) gall and freeze in
the valve-closed position, a force of approxi
mately 30 pounds is necessary to open the
relief valve and bypass the check valve. This
force is then required for each subsequent aft
movement of the cyclic stick. Conversely,
CSP-HMI-2
should the check valve spring fail, the oneway lock does not function to shunt longitudi
nal feedback forces to structure. The unit is
mounted in two pivoting supports attached to
seat structure, and has a transparent, vented
reservoir with a capacity of approximately 0.67
fluid ounce (20 cc). The one-way lock control
system is serviced through the filler with
hydraulic oil (6, Table 203).
O. Cyclic Trim Actuators
Each of the two cyclic trim actuators consists
of an actuator, housing support, trim tube and
spring assembly. The actuator is essentially a
motor-driven, variable length shaft that
compresses a spring assembly, counteracting
feedback forces from the main rotor and
compensating for imbalance conditions such as
those imposed by crosswinds or unevenly
distributed cargo. Cyclic trim is controlled by
the cyclic trim switch on top of cyclic stick grip.
The cyclic trim switch has five positions:
normally OFF at the center, and momentary
FORWARD, AFT, LEFT, and RIGHT. When
the trim switch is moved off center to any of
the four trim positions, one of the trim motors
operates to provide trim spring force in the
desired direction. By momentarily activation of
the switch, very small trim increments are
obtained. Trim forces cannot be applied in two
directions simultaneously; when both lateral
and longitudinal trim corrections are required,
it is necessary to apply first one, then the
other. Travel of the cyclic pitch control stick is
not limited by the cyclic trim mechanism; trim
spring tension can be overridden at any time.
P. RoofMounted Control Rods (600N)
The roof-mounted control rods transmit cyclic
and collective flight control input from the
tunnel-routed control rods, via the forward
roof-mounted bellcranks, to the link assem
blies, via the aft roof-mounted bellcranks, at
the mixer assembly.
Q. RoofMounted Bellcranks (600N)
The forward roof-mounted bellcrank transfer
controls input from the tunnel-routed control
rods to the roof-mounted control rods. The aft
roof-mounted control rods transfer controls
input from the roof-routed control rods to the
link assemblies.
67-10-00
Page 3
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
1.
2.
3.
4.
5.
6.
7.
MAIN ROTOR DRIVE SHAFT

DAMPER
BLADE ATTACH PIN
MAIN ROTOR BLADE
ROTOR MAST SUPPORT
ROTATING SWASHPLATE
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
4
1
1
10
7
9
6
8
25
27
24
23
26
22
12
15
21
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
COLLECTIVE CONTROL TORQUE TUBE

COPILOT'S COLLECTIVE PITCH STICK
DROOP CONTROL OVERRIDE LINK
COPILOT'S CYCLIC STICK
LATERAL CYCLIC FRICTION KNOB
CYCLIC LATERAL CONTROL ROD
LATERAL CYCLIC TRIM ACTUATOR
LONGITUDINAL CYCLIC TRIM ACTUATOR
LONGITUDINAL CYCLIC FRICTION KNOB
ONE-WAY LOCK
CYCLIC CONTROL TORQUE TUBE
GAS PRODUCER CONTROL ROD
COLLECTIVE CONTROL BUNGEE
ANTI-TORQUE CONTROL ROD (REF)
PILOT'S COLLECTIVE PITCH STICK
14
20
19
16
17
13
18
G67-0000A
Figure 1. Main Rotor and Control System (369D/E/FF 500N)

Page 4
Revision 21
67-10-00
MAINTENANCE MANUAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
MAIN ROTOR DRIVE SHAFT

DAMPER
BLADE ATTACH PIN
MAIN ROTOR BLADE
ROTATING SWASHPLATE
MAIN ROTOR CONTROLS (MIXER, IDLER
BELLCRANKS AND LINKS)
LATERAL MIXER CONTROL ROD (CYCLIC)
LONGITUDINAL MIXER CONTROL ROD (CYCLIC)
COLLECTIVE MIXER CONTROL ROD
COLLECTIVE CONTROL TORQUE TUBE
COPILOT'S COLLECTIVE PITCH STICK
COPILOT'S CYCLIC STICK
LATERAL CYCLIC FRICTION KNOB
CYCLIC LATERAL CONTROL ROD
LATERAL CYCLIC TRIM ACTUATOR
LONGITUDINAL CYCLIC TRIM ACTUATOR
LONGITUDINAL CYCLIC FRICTION KNOB
ONE-WAY LOCK
CYCLIC CONTROL TORQUE TUBE
GAS PRODUCER CONTROL ROD
COLLECTIVE CONTROL BUNGEE
ANTI-TORQUE CONTROL ROD (REF)
PILOT'S COLLECTIVE PITCH STICK
CSP-HMI-2
4
1
5
9
6
8
22
21
12
20
24
19
23
18
10
11
17
16
14
13
15
6G67-035A
Figure 2. Main Rotor and Control System (600N)
67-10-00
Page 5
Revision 21
CSP-HMI-2
MAINTENANCE MANUAL
Page 6
Revision 44
67-10-00
MAINTENANCE MANUAL
CSP-HMI-2

1. TunnelRouted Control Rod Replacement
tube to angle up through the double

hole.
(Ref. Figure 401)

A. TunnelRouted Control Rod Removal
(9). Remove bolt from bottom of 7012 tube

and lower to belly of aircraft and angle
up through the double hole.
Item
Special Tools
Nomenclature
(10). Remove bolts from bottom of 7007 tube

and lower to the belly of aircraft, then
angle up through the double hole.
ST508
Before disconnecting collec
WARNING tive pitch control rod, install

collective bungee installation tool to
prevent spring reaction due to droop
stop load on control rod.
(1). Install collective bungee installation
tool (ST508) and remove collective
bungee.
(2). For access to lower rod ends, remove
controls access door at base of canted
bulkhead in cargo compartment.
(3). Hand turn main rotor blades to align
blue blade to right side of aircraft.
(11). Move 7009 tube to the other side of

center beam and angle up through the
double hole.
B. TunnelRouted Control Rod Installation
To reinstall tunnel-routed control rods,
reverse the sequence of Tunnel-Routed
Control Rod Removal.
2. RoofMounted Control Rod Replacement
(600N)
(Ref. Figure 402)
A. RoofMounted Control Rod Removal
(600N)
Item
Special Tools
Nomenclature
ST508
(4). Disconnect upper end of control rod.

(5). Remove double boot from control tunnel
cover. All tubes will be removed
through the double hole.
Use care during removal of con
trol rods. Any surface damage
caused by hasty removal may result in un
serviceable control rods.
CAUTION

bungee.
(2). For access to roof-mounted control
rods, remove upper fuselage controls
fairing.
(6). Move blue blade pitch housing down as

far as it will go. This will allow the
tubes to go past the housing.
NOTE: If same rods are to be reinstalled, mark
(7). Remove bolts from bottom of 369A7009

and 7011 tubes.
rods for proper positioning upon reinstalla

tion. If new rods are installed, main rotor
flight controls must be re-rigged.
(8). Move cyclic controls so that the 7012

tube moves to its highest point. Place
7009 tube to the far right and lower out
of way. Lower 7011 tube to the left side
of center beam. This will allow 7011
(3). Mark control rod for proper reinstalla

tion.
(4). Remove hardware from control rods
and remove rods from aircraft.
67-10-00
Page 401
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
DOUBLE BOOT
369A7009
369A7011
369A7012
369A7007

VIEW A
DOUBLE BOOT
HOLE
369A7007
DOUBLE BOOT
HOLE
369A7012
369A7011
369A7009

VIEW B
369A7007
369A7012
369A7009

VIEW C
DOUBLE BOOT
HOLE
369A7007
369A7009

VIEW D
DOUBLE BOOT
HOLE
369A7009

VIEW E
G67 1001
Figure 401. TunnelRouted Control Rod Installation

Page 402
Revision 21
67-10-00
MAINTENANCE MANUAL
CSP-HMI-2
LINK ASSEMBLY
AFT ROOF-MOUNTED
BELLCRANKS
ROOF-MOUNTED
CONTROL RODS
FORWARD
ROOF-MOUNTED
BELLCRANKS
ROTATING
SWASHPLATE
MAIN ROTOR CONTROLS

(MIXER, IDLER BELLCRANKS
AND LINKS)
COLLECTIVE MIXER
CONTROL ROD
DIRECTIONAL
CONTROL ROD
LONGITUDINAL MIXER
CONTROL ROD
(CYCLIC)
LATERAL MIXER
CONTROL ROD
(CYCLIC)
6G67-039
Figure 402. RoofMounted Controls Installation

B. RoofMounted Control Rod Installation
(600N)
(1). Install control rods in bellcranks
ensuring RH threaded rod end is
forward.
(2). Install hardware connecting control
rods. Torque nuts to 30 - 40 inchpounds (3.39 - 4.52 Nm) and install
cotter pin.
(3). Remove collective bungee installation
tool.
(4). Reinstall upper fuselage controls
fairing.
(5). Perform flight controls rigging check.
3. RoofMounted Bellcrank Replacement

(600N)
(Ref. Figure 402) Replacement of the roofmounted bellcranks is the same procedure for
the forward and aft bellcranks.
A. RoofMounted Bellcrank Removal (600N)
Item
Special Tools
Nomenclature
ST508

bungee.
(2). For access to roof-mounted control rods
and bellcranks, remove upper fuselage
controls fairing.
67-10-00
Page 403
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
(3). Remove hardware connecting rod from

bellcrank.
(4). Remove hardware from bellcrank pivot
point and remove bellcrank.
B. RoofMounted Bellcrank Installation
(600N)
NOTE: Ensure bellcranks are installed in prop

er position. If bellcranks are install in the
wrong position, rigging will be impossible
(Ref. Illustrated Parts Catalog).
(1). Install bellcrank in mount with word
FORWARD facing up and arrow
pointing towards front of aircraft.
(2). Install hardware connecting bellcrank
to mount. Torque nuts to 30 - 40
install cotter pin.
(2). Ensure bushing protrudes a minimum

of 0.010 inch (0.254 mm) to a maximum
of 0.060 inch (1.524 mm) beyond the
surface of mixer.
tool.
fairing.
5. Controls Support Bracket and Bellcrank
Replacement
(Ref. Figure 403)
A. Controls Support Bracket and Bellcrank
Removal
(3). Reinstall disconnected control rods.

tool.
fairing.
4. Link Assembly Replacement (600N)
(Ref. Figure 402)
A. Link Assembly Removal (600N)
Item
Special Tools
Nomenclature
ST508
(1). Remove foot fairings and controls

access door (Sta. 78.50) and pilot's seat
cover.
Item
ST508
Special Tools
Nomenclature

bungee.

bungee.
(3). Disconnect tunnel-routed control rods.
(2). Remove upper fuselage controls fairing.
NOTE: Upper link bolt has a bushing in the

mixer bellcrank.
(3). Remove hardware from link and
remove link from aircraft.
B. Link Assembly Installation (600N)
(1). Install link between lower bellcrank
and mixer bellcrank with hardware
previously removed.
Page 404
Revision 21
67-10-00
(4). Disconnect upper end of each cyclic

trim actuator.
(5). Disconnect floor-routed tail rotor
control rod from tail rotor bellcrank.
(6). Disconnect Sta. 70 lateral control rod
from lateral idler bellcrank.
(7). Disconnect one-way lock from longitu
dinal idler bellcrank.
MAINTENANCE MANUAL
CSP-HMI-2
COLLECTIVE TORQUE
TUBE
BUNGEE SUPPORT BRACKET
WASHER (SPECIAL)
* * CONTROLS SUPPORT
BRACKET
DROOP CONTROL
OVERRIDE LINK
*
(COUNTERSUNK)
* * TAIL ROTOR
BELLCRANK
BEARING
BEARING
BUSHING
(NOTE 3)
NOTE 2
LATERAL IDLER
BELLCRANK
BEARING
AND SPACER
BUSHING
(NOTE 3)
1/4 IN.
(6.35 MM)
DIA
3/16 IN.
(4.7625 MM)
DIAMETER
FLOOR-ROUTED TAIL
ROTOR CONTROL ROD
*
*
BEARING
STA 70 LATERAL
CONTROL ROD
*
(COUNTERSUNK)
BEARING
SPACE
R
* * LONGITUDINAL
IDLER BELLCRANK
NOTE 6
LATERAL CYCLIC
ONE-WAY TRIM ACTUATOR
LOCK
STA. 72 DROOP
CONTROL BELLCRANK
LONGITUDINAL CYCLIC
TRIM ACTUATOR
NOTE 4
NOTE 6
BOLT INSTALLATION
HOLE
2.
*
NOTES:
1. ASTERISK (*) IDENTIFIES SLOTTED BUSHINGS. EDGE OF BUSHINGS
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.
3.
4.
5.
6.
SHIM WASHERS USED AS REQUIRED TO OBTAIN NO SIDELOAD

ON ONE-WAY LOCK.
BUSHING AND BOLT MUST NOT ROTATE WITH TRIM UNIT
AFTER INSTALLATION.
BOND JUMPER ATTACHMENT TYPICAL FOR BOTH ACTUATORS.
DOUBLE ASTERISK (**) INDICATES PARTS THAT MAY BE EITHER
MAGNESIUM OR ALUMINUM ALLOY.
REPLACEMENT PARTS HAVE NUTPLATE RIVETED IN PLACE.
WASHER, NUT AND COTTER PIN NOT REQUIRED.
G67-1002A
Figure 403. Controls Support Bracket, Idler Bellcranks and Cyclic Trim Actuators Installation
67-10-00
Page 405
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
(8). Remove pilot's collective pitch stick.

(9). Provide support for collective torque
tube. Remove bolts, washers and nuts
securing bungee support bracket and
collective torque tube to controls
support bracket.
(10). Disconnect aft end of droop control
override link from collective torque tube
bracket.
(11). Remove Sta. 72 droop control bellcrank
from support bracket.
(12). Disconnect and remove support bracket
from seat structure. Avoid striking any
bellcranks and pushrods.
B. Controls Support Bracket and Bellcrank
Installation
(1). Carefully position assembled support
bracket and bellcranks between seat
structure bulkheads and secure with
attaching hardware.
(2). Position Sta. 72 droop control bellcrank
in support bracket and install.
NOTE: Cap is matched to cradle of each control

support bracket. Check that numbers on
each part are identical before accomplishing
step (3). below.
(3). Check that two slotted bushings are in
place in bungee support bracket.
Position collective torque tube and
bungee bracket on support bracket
cradle and install cradle bolts, washers
and nuts. Ensure index groove, in edge
of cap that clamps torque tube to
support bracket cradle, mates with
matching index at bracket cradle
parting surface.
(4). Install pilot's collective pitch stick.
(5). Connect aft end of droop control
override link to collective torque tube
droop control bracket.
(6). Connect one-way lock to longitudinal
idler bellcrank.
NOTE: For following steps, ensure that slotted

bushing is in bellcrank ear.
(7). Connect Sta. 70 lateral control rod to
lateral idler bellcrank.
Page 406
Revision 37
67-10-00
(8). Connect floor-routed tail rotor control

rod to tail rotor bellcrank.
(9). Connect upper end of each cyclic trim
actuator.
NOTE: Lateral actuator uses 3/16 inch (4.7625

mm) diameter bolt. The longitudinal actua
tor requires 1/4 inch (6.035 mm) diameter
bolt.
(10). Connect lower ends of tunnel-routed
control rods.
(11). Install collective bungee and remove
collective bungee installation tool.
6. Pilots Collective Pitch Stick Replacement
(L/H Command)
(Ref. Figure 404)
A. Pilots Collective Pitch Stick Removal
(L/H Command)
Item
Special Tools
Nomenclature
ST508
(1). Remove outboard collective stick cover.

(2). Disconnect pilot's collective stick
electrical plug.
(3). Remove attaching hardware that
secures guide to seat structure bracket.
WARNING tive stick, install collective

bungee installation tool to prevent
spring reaction due to droop stop load
on controls.
tool (ST508).
(5). Remove collective bungee and inboard
collective socket. Disconnect droop
control override link (369D/E/FF 500N only), slide bungee bracket to
side, remove cradle cap and slide
collective torque tube inboard.
connects stick housing to torque tube.
MAINTENANCE MANUAL
CSP-HMI-2
COLLECTIVE MIXER
TUNNEL-ROUTED
CONTROL ROD
NOTE 3
INBOARD COLLECTIVE
STICK SOCKET
BUNGEE OVER-CENTER
ADJUSTMENT BOLT
(NOTE 1)
GAS PRODUCER
CONTROL ROD
BUNGEE
GAS PRODUCER
INTERCONNECTING
TORQUE TUBE
COLLECTIVE CONTROL
INTERCONNECTING
TORQUE TUBE
BUNGEE SPRING
ADJUSTMENT NUT
(NOTE 2 - SEE CAUTION)
N2 DROOP CONTROL OVERRIDE

LINK (369D/E/FF - 500N)
COLLECTIVE STICK FRICTION
MECHANISM AND GUARD
THROTTLE
PILOT'S COLLECTIVE
PITCH STICK
NOTE 4
THROTTLE
FRICTION
NOTE 5
SLEEVE
BUSHING
GUIDE
FUSELAGE
SKIN
NOTE 5
NOTES:
1. ROTATED CLOCKWISE TO INCREASE, COUNTERCLOCKWISE TO
DECREASE OVERALL COLLECTIVE DOWNLOADS.
2. ROTATED CLOCKWISE TO INCREASE COUNTERCLOCKWISE TO
DECREASE, BUNGEE PRELOAD.
CAUTION: DO NOT ADJUST BUNGEE SPRING TENSION WHILE BUNGEE
INSTALLATION TOOL IS INSTALLED. USE 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.
G67-1003B
Figure 404. Dual Collective Controls (L/H Command)
67-10-00
Page 407
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
(7). Remove stick by sliding it outboard off

torque tube.
B. Pilots Collective Pitch Stick Installation
(L/H Command)
Item
CM116
Nomenclature
(1). Lubricate stick housing socket with

grease (CM116).
(2). Install stick by sliding housing on
collective control interconnecting torque
tube. Install bolts, washers and nuts.
Tighten nuts equally and by small
increments until correct torque is
applied.
(3). Connect electrical plug.
(4). Install outboard collective stick cover.
Raise and lower stick; verify that
wiring does not foul.
(5). Remove snap plug from exterior skin,
rotate throttle and visually check for
zero backlash between gas producer
interconnect torque tube and hexagonal
interior surfaces of drive gearshaft in
stick housing. Eliminate any backlash
by tightening pipe plug in end of torque
tube; zero backlash is required at both
ends of tube.
(6). Check that inboard stick socket gears
are at mid-travel when pilot's stick
throttle grip is set to mid-travel. If not,
adjust collective stick gas producer
control linkage.
7. Pilots Collective Pitch Stick Replacement
(R/H Command)
(1). Remove stick cover from seat structure.

(2). Disconnect pilot's collective stick
electrical plug.
secures guide to seat structure bracket.
WARNING tive stick, install collective

bungee installation tool to prevent
spring reaction due to droop stop load
on controls.
tool (ST508).
(5). Remove collective bungee and inboard
collective socket. Disconnect droop
control override link (369D/E/FF 500N only), slide bungee bracket to
side, remove cradle cap and slide
collective torque tube inboard.
(6). Disconnect gas producer control rod.
connects stick housing to torque tube.
B. Pilots Collective Pitch Stick Installation
(R/H Command)
Item
Nomenclature
CM116
(1). Lubricate surfaces that are in contact

during rotation with grease (CM116).
(Ref. Figure 405)

A. Pilots Collective Pitch Stick Removal
(R/H Command)
Item
ST508
Special Tools
Nomenclature
Page 408
Revision 21
67-10-00
(2). Ensure that pilot's and copilot's throttle

grips are in same relative positions.
Slide pilot's stick housing on collective
interconnecting torque tube, align
matching holes and secure stick to
torque tube. Connect gas producer
control rod. Align and/or match bell
crank centerline, gearshaft assembly
gear cutout and pilot's throttle.
MAINTENANCE MANUAL
COLLECTIVE
FRICTION GUIDE
CSP-HMI-2
PILOT'S COLLECTIVE
PITCH STICK COVER
FLEXIBLE
CLOSURE
THROTTLE
FRICTION
NUT
PILOT'S
THROTTLE
GRIP
GAS PRODUCER INTERCONNECTING

TORQUE TUBE
COLLECTIVE CONTROL
INTERCONNECTING
TORQUE TUBE
IDLE STOP
RELEASE RING
COLLECTIVE
STICK FRICTION
CONTROL
PILOT'S COLLECTIVE
PITCH CONTROL STICK
N2 DROOP CONTROL
OVERRIDE LINK
(369D/E/FF - 500N)
COPILOT'S
THROTTLE
GRIP
NOTE 3
COPILOT'S
COLLECTIVE PITCH
CONTROL STICK
PLAIN
BUSHING
NOTE 1
NOTE 1
SLOTTED
BUSHING
(NOTE 2)
BUSHING INSTALLATION
NOTES:
1. ARRANGE WASHERS TO LINE UP GUIDE WITH STICK; SPACE LOOSELY WITH
THREE WASHERS.
2. SLOTTED BUSHING MUST PROTRUDE A MINIMUM OF 0.010 INCH (0.254 MM) TO A
MAXIMUM OF 0.060 INCH (1.524 MM) AFTER BOLT IS TIGHTENED.
3. FOUR NUTS TORQUED; EQUALLY AND BY SMALL INCREMENTS.
4. ALLOWABLE FREE PLAY IN CO-PILOT'S TWIST GRIP IS 5.
G67-1004A
Figure 405. Dual Collective Controls (R/H Command)
67-10-00
Page 409
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
(3). Position friction guide in seat structure

bracket with plain bushing, slotted
bushing, and three washers loosely
spaced between bracket ears so guide is
in line (parallel) with stick. Install bolt,
two washers, nut and new cotter pin.
(3). Remove hardware from stick tube

socket adapter and remove pitch stick
assembly by sliding it forward and off
the inboard stick housing.
B. Copilots Collective Pitch Stick
Installation (L/H Command)

(5). Perform operational check of collective
stick friction and adjust friction
mechanism as necessary.
Item
Nomenclature
CM116
(6). Install collective stick cover on seat

structure. Check that wiring is not
fouled when stick is raised and lowered.

grease (CM116).
8. Copilots Collective Pitch Stick

(2). Rotate pilot's or copilot's throttle grips

so that the grip attach bolts are down.
(Ref. Figure 406)
(3). Install copilot's stick socket adapter on

the inboard housing socket extension
and, while moving copilot's throttle
back and forth slightly to get engage
ment of the socket pinion and adapter
splines, slide the adapter into place.
A. Copilots Collective Pitch Stick Removal

(L/H Command)
(1). Remove collective stick cover from seat
structure.
(4). Install attaching hardware to secure

socket adapter.
(2). Disconnect electrical plug.
STICK ASSEMBLY
COLLECTIVE PITCH STICK ASSEMBLY

NOTE 2
NOTES:
1. 0.030-0.150 IN. (0.762-3.81 MM) MUST BE MAINTAINED BETWEEN
STOP AND BRACKET WHEN PILOT COLLECTIVE CONTROL IS IN
FULL DOWN POSITION.
2. LUBE SOCKET WITH GREASE BEFORE STICK INSTALLATION.
0.030-0.150 IN.
(0.762-3.81 MM)
(NOTE 1)
DOWNSTOP CLEARANCE
Figure 406. CoPilots Collective Stick Assembly Installation (L/H Command)

Page 410
Revision 21
67-10-00
G67-1005A
MAINTENANCE MANUAL
(6). Position downstop assembly. Check that
0.030-0.150 inch (0.762-3.302 mm)
clearance exists between downstop and
seat structure with collective pitch stick
in full down position.
(7). Install collective cover on seat struc
ture. Check that wiring is not fouled
when stick is raised and lowered.
(Ref. Figure 404)
backlash is required at both ends of

tube.
NOTE: The R/H command configuration collec

tive friction mechanism is the same as L/H
command except no separate friction guard
is provided, since the pilot's collective pitch
cover also functions as a guard for the fric
tion mechanism.
10. Collective Control Interconnecting Torque
Tube Replacement
(Ref. Figure 407)
A. Collective Control Interconnecting
Torque Tube Removal
A. Copilots Collective Pitch Stick Removal

(R/H Command)
Remove copilot's collective stick according to
instructions in Pilot's Collective Pitch Stick
Removal (L/H Command) except disregard
information on friction guide.
B. Copilots Collective Pitch Stick
Installation (R/H Command)
Item
Nomenclature
CM116

grease (CM116).
(2). Slide stick housing on collective control
interconnecting torque tube. Align
matching holes and install bushings,
bolts, washers and nuts. Tighten
equally and by small increments until
proper torque is applied.
(3). Install outboard collective stick cover.
Secure electrical plug and check that
wiring will not foul when stick is raised
and lowered.
(4). Remove snap plug from exterior skin,
rotate throttle and visually check for
zero backlash between gas producer
interconnect tube and hexagonal ID of
drive gearshaft in stick housing.
Eliminate any backlash by tightening
pipe plug in end of torque tube; zero
CSP-HMI-2
Item
ST508
Special Tools
Nomenclature

bungee.
(2). Remove inboard collective socket
assembly.
(3). Disconnect aft end of droop control
override link (369D/E/FF - 500N only)
from torque tube droop control bracket.
(4). Remove hardware securing bungee
support bracket reinforcement strap
and torque tube to controls support
bracket. Slide bungee bracket aside and
remove controls bracket cradle cap and
reinforcement strap.
(5). Slide collective control torque tube
sufficiently toward right side of seat
structure to remove pilot's collective
pitch stick housing from end of tube.
(6). Remove hardware that connects stick
housing to torque tube.
(7). Remove stick by sliding it outboard and
off torque tube.
67-10-00
Page 411
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
(8). Remove torque tube by sliding it

approximately three inches toward
right side of seat structure to disengage
left end from support bearing inside left
torque tube support. Provide support at
seat structure lightening hole and care,
fully withdraw torque tube from
structure.
Position torque tube, controls bracket

cradle cap, reinforcement strap and
bungee bracket on controls support
bracket. Check that cap-to-cradle
index grooves are matched. Install with
hardware removed. Apply thin layer of
grease (CM116) to sliding surfaces of
bungee overcenter fitting.
(9). Remove gas producer interconnect

torque tube by carefully sliding it out of
collective torque tube.
(7). Install droop control override link

(369D/E/FF - 500N only) to torque tube
droop control bracket.
B. Collective Control Interconnecting

Torque Tube Installation
Item
Nomenclature
CM116
(8). Install inboard collective socket

assembly.
(9). Complete installation of pilot's collec
tive stick.
(10). Install collective bungee.
11. Collective Bungee Replacement
(1). Install gas producer interconnect

torque tube by sliding it carefully into
place in collective control interconnect
ing torque tube.
(2). Insert torque tube into lightening hole
in seat structure. Use care when
inserting tube into place to prevent
scraping on edge of hole. Insert tube
only to a position that provides suffi
cient space between tube end and
fuselage skin for installation of pilot's
stick housing on end of tube.
(3). Lubricate pilot's stick housing with
grease (CM116).
(4). Slide pilot's stick housing on collective
control interconnecting torque tube.
NOTE: Stick housing must be placed on torque

tube before installing torque tube attaching
hardware.
(5). Complete insertion of tube and position
left end of tube in fixed bearing bore.
Rotate torque tube slowly back and
forth until right end bearing rests in
cradle of controls support bracket.
(6). Check that two slotted bushings are in
place in upper lugs of bungee bracket.
Page 412
Revision 29
67-10-00
(Ref. Figure 407)

A. Collective Bungee and OverCenter
Fitting Removal
Item
Special Tools
Nomenclature
ST508

(1). Remove pilot's seat cover from seat
structure.
(2). Raise collective stick and use torque
tube over-center action to compress
bungee spring until bungee installation
tool (ST508) fits over spring retainers.
Secure tool halves in place with clamp.
(3). With stick in over-center position,
remove cotter pin, nut, washer and bolt
that secure male bearing to bungee
over-center fitting.
MAINTENANCE MANUAL
CSP-HMI-2
FUSELAGE SKIN
SNAP PLUG
COLLECTIVE CONTROL INTERCONNECTING

TORQUE TUBE
GAS PRODUCER INTERCONNECT

TORQUE TUBE
NR DISABLE SWITCH
AND BRACKET (NOTE 4)
ACTUATING CAM
(NOTE 4)
BUSHING
(NOTE 1)
CLIP
(3 PLACES)
DROOP CONTROL
OVERRIDE LINK
BRACKET (NOTE 4)
TORQUE TUBE
SUPPORT BEARING
0.30 IN. (7.62 MM)

(NOTE 3)
CONTROLS BRACKET CRADLE

INDEX GROOVE
PIPE PLUG
NOTE 5
GAS PRODUCER
CONTROL ROD
INBOARD
COLLECTIVE
STICK SOCKET
ASSEMBLY
CONTROLS
SUPPORT
BRACKET
THREADED
INSERT
TORQUE TUBE SUPPORT

BEARING
BUNGEE OVER-CENTER
ADJUSTMENT BOLT
BUNGEE OVER-CENTER
FITTING
FITTING
MALE BEARING
NOTE 2
SLOTTED
BUSHING
(NOTE 1)
RETAINE
R
SPRING
BUNGEE
INSTALLATION TOOL
NOTES:
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.
5. WITH COLLECTIVE STICK AT FULL DOWN POSITION,
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).
FEMALE
BEARING
ASSEMBLY
(NOTE 2)
RETAINER
(NOTE 2)
COMPRESSION TOOL
ROD AND CHANNEL
BUNGEE ASSEMBLY-EXPLODED VIEW
G67-1006B
Figure 407. Collective Torque Tube, Gas Producer Torque Tube and Collective Bungee
67-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
SNAP RING
N1 PINION GEAR
GAS PRODUCER INTERCONNECT

TORQUE TUBE
AFT BEARING
(NOTE 4)
SNAP RING
PIPE PLUG
SLOTTED
BUSHING
CLIP
(3 PLCS)
SOCKET HOUSING
SPACER
(NOTE 1)
BEARING (NOTE 4)
BACKLASH SHIM
FORWARD BEARING
(NOTES 2, 4)
SHAFT
ASSEMBLY
BACKLASH SHIM
BEARING
(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.
Figure 408. Inboard Collective Stick Socket Assembly (L/H Command)

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67-10-00
G67-1007B
MAINTENANCE MANUAL
(4). Remove cotter pin, nut, two washers
and bolt that attach female bearing end
of bungee to the bungee bracket.
(5). Remove collective bungee and installa
tion tool as a unit.
(6). Remove cotter pin, nut and washer
from over-center fitting.
(7). Remove bolt that secure over-center
fitting to collective torque tube and
remove fitting.
B. Collective OverCenter Fitting and
Bungee Installation and Preliminary
Adjustment
Item
Nomenclature
CM116
Item
Special Tools
Nomenclature
ST508
(1). Lubricate sliding surfaces of over-cen

ter fitting with grease (CM116) and
position on collective torque tube.
(2). Install bolt and washer though fitting
and torque tube, and adjust to obtain
0.30 in. (7.62 mm) preliminary adjust
ment between upper surface of fitting
and tips on torque tube fitting.
CSP-HMI-2
Do not turn female bearing as

sembly spring retainer while
bungee installation tool is spring loaded.
CAUTION
(6). Raise collective stick so that torque

tube over-center action compresses
spring until bungee installation tool can
be removed; remove tool.
(7). With collective stick at full down
position, preliminary adjustment of
bungee installation is:
369D/E/FF - 500N; 2.2 0.05 inch
(5.588 0.127 cm)
600N; 2.70 0.05 inch (6.86 0.127 cm).
(8). Flight test helicopter and complete
adjustment of collective bungee.
12. Inboard Collective Stick Socket Assembly
Replacement
(Ref. Figure 408)
A. Inboard Collective Stick Socket Assembly
Removal
(1). Remove pilot's seat cover and controls
access door.
(2). Disconnect collective mixer tunnelrouted control rod.
(3). Disconnect gas producer control rod
from idler.
(4). Remove NR disable switch (369D/E/FF
- 500N only) (Ref. Chap. 95).
(5). Remove four nuts and washers that
attach socket assembly to collective
torque tube and remove assembly.
(3). Install washer and nut on bolt and

torque to 30 - 40 inch-pounds (3.39 4.52 Nm); install cotter pin.
NOTE: If disassembly is not intended, install
(4). Position collective bungee, compressed

in installation tool (ST508), so that
female bearing assembly is forward and
aligns with mating hole in bungee
bracket. Check that slotted bushing for
bracket lug is in place, install bolt, two
B. Inboard Collective Stick Socket Assembly

Installation
(5). Position male bearing to align with

mating hole in bungee over-center
fitting. Install bolt, washers, nut and
install cotter pin.
four spacers and reinstall washers and nuts

on protruding bolts to keep assembly intact.
Item
Nomenclature
CM318
Primer
(1). Remove four nuts washers and spacers

from socket assembly mounting bolts.
67-10-00
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CSP-HMI-2
MAINTENANCE MANUAL
(2). With throttle grip on pilot's collective

stick at midtravel, rotate bellcrank
back and forth slightly to engage socket
assembly to gearshaft on hexagonal end
of gas producer interconnect torque
tube. Bellcrank centerline, N1 pinion
gear centerline toothspace and pilot's
throttle must be as shown.
NOTE:
D With pilot's throttle grip at midtravel, two
grip attach bolts should be approximately
straight down. Simultaneously, idler-togas producer control rod bolt holes should
be in line with centerline of inboard stick
assembly housing cap.
D At midtravel, inboard N 1 pinion gear
spline wide toothspace should be at ap
proximately one o'clock as viewed looking
aft into open end of socket.
(3). Install NR disable switch (369D/E/FF 500N only) (Ref. Sec. 95) and secure
socket assembly housing to collective
torque tube.
(4). Rotate pilot's throttle and check for zero
backlash between gas producer inter
connect torque tube and hexagonal
interior of drive gearshaft in socket
assembly housing.
(5). Eliminate backlash by removing
housing cap and gearshaft, and then
removing pipe plug in end of torque
tube.
(6). Coat pipe plug with wet zinc chromate
primer (CM318), reinstall and tighten it
so there is no backlash between torque
tube and control gearshaft at each end
of the tube.
(7). If the normally installed plug does not
sufficiently expand tube, a 1/8-27
internal-wrenching pipe plug 0.38 inch
(9.65 mm) long may be substituted.
Whichever plug is used, it must not
protrude more than 0.030 inch (0.762
mm) when tightened.
(8). Zero degree backlash is required at
both ends of tube.
(9). After plug is tightened, reinstall
gearshaft and housing cap.
Page 416
Revision 29
67-10-00
(10). Connect gas producer control rod to

idler.
(11). Connect collective mixer tunnel-routed
control rod.
(12). Remove bungee installation tool.
(13). Reinstall pilot's seat cover and the
controls access door.
(14). Check that inboard collective pitch stick
socket gears are at midtravel when
pilot's collective pitch stick throttle grip
is set to midtravel. If not, adjust
collective pitch stick(s) gas producer
control linkage.
(15). Adjust NR disable switch (369D/E/FF 500N only) (Ref. Chap. 95).
13. Cyclic Control Stick Replacement
(Inboard)
(Ref. Figure 409)
A. Cyclic Control Stick Removal (Inboard)
(1). Disconnect control stick electrical plug.
(2). Remove hardware that secures pilot's
lateral control rod to stick socket.
(3). Remove hardware that attaches lateral
friction mechanism link to cyclic torque
tube.
(4). Remove hardware that attaches stick
socket to end of cyclic torque tube;
remove stick with lateral friction
mechanism attached.
B. Cyclic Control Stick Installation (Inboard)
(1). Position pilot's cyclic control stick to
align with mating holes in torque tube.
(3). Check that slotted bushing is in place;
then align pilot's lateral control rod
with stick socket. Install attaching
hardware.
(4). Position guide link to align with mating
hole in torque tube. Install bolt, sleeve
bushing three washers, nut and cotter
pin.
MAINTENANCE MANUAL
CSP-HMI-2
LATERAL CYCLIC
BELLCRANK
CYCLIC STICK
ASSEMBLY
STRAP
LATERAL CONTROL ROD

(NOTE 2)
QUICK RELEASE
PIN
QUICK
RELEASE
PIN
SLOTTED BUSHING
(NOTE 1)
NOTES:
OF 0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.060 IN.
(1.524 MM) ABOVE OUTSIDE SURFACES OF PART
AFTER NUT IS TIGHTENED.
2. CONTROL ROD END BEARINGS MUST NOT JAM
THROUGHOUT FULL RANGE OF LONGITUDINAL
TRAVEL (34).
G67-1008A
Figure 409. Cyclic Stick Assembly Installation (Inboard)

14. Cyclic Control Stick Replacement
(Outboard)
(Ref. Figure 410)
A. Cyclic Control Stick Removal (Outboard)
(1). Disconnect control stick electrical plug.
NOTE: Omit steps (2). and (3). below to remove

stick without removing stick socket.
(2). Remove cotter pin, nut, washers and
bolt securing copilot's lateral control rod
to stick socket.
bolt attaching stick socket to end of
cyclic torque tube. Remove stick tube
with stick socket attached.
(4). Remove two quick-release pins attach
ing stick tube to stick socket.
(5). Remove stick tube from socket.

B. Cyclic Control Stick Installation
(Outboard)
(1). Insert stick tube into stick socket and
install two quick-release pins.
NOTE: Omit steps (2). thru (4). when installing

stick without socket.
(2). Position cyclic stick to align holes in
socket with mating holes in torque
tube.
(3). Install bolt, two washers, nut and new
cotter pin.
then align copilot' s lateral control rod
with stick socket. Install bolt, two
washers, nut and new cotter pin.
67-10-00
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CSP-HMI-2
MAINTENANCE MANUAL
CYCLIC PITCH
INTERCONNECTING
TORQUE TUBE
CYCLIC STICK
ASSEMBLY
ONE-WAY
LOCK
ASSEMBLY
WASHE
R
LINK
STA. 67 LATERAL
CYCLIC BELLCRANK
LONGITUDINAL CONTROL
FRICTION MECHANISM
NOTES:
1. EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF
0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.080 IN. (2.032 MM)
ABOVE OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.
2. CONTROL ROD END BEARINGS MUST NOT JAM THROUGHOUT
FULL RANGE OF LONGITUDINAL TRAVEL (34).
SLOTTED
BUSHING
(NOTE 1)
LATERAL CONTROL
ROD (NOTE 2)
SLEEVE
BUSHING
LATERAL CONTROL
FRICTION MECHANISM
G67-1009B
Figure 410. Cyclic Stick Assembly Installation (Outboard)

15. Lateral Control Rods and Sta. 67 Lateral
Cyclic Bellcrank Replacement (L/H
Command)
(Ref. Figure 411)
A. Lateral Control Rods and Sta. 67 Lateral
Cyclic Bellcrank Removal (L/H Command)
(1). Remove large (central) cyclic stick
guard.
(2). Remove pilot's seat cover, and controls
access door from Sta. 78.50 canted
bulkhead.
(3). Remove pilot's lateral control rod, or
Sta. 70 lateral control rod, as applica
ble.
between rod end bearing centers for use

at replacement.
B. Lateral Control Rods and Sta. 67 Lateral
Cyclic Bellcrank Installation (L/H
Command)
(1). Check that slotted bushing is in upper
web of seat structure fitting. Align Sta.
67 lateral cyclic bellcrank and install
attaching hardware.
(2). Check that slotted bushings are in
place and install Sta. 70 lateral control
rod and pilot's lateral control rod.
(4). Remove Sta. 67 lateral cyclic bellcrank

from seat structure fitting.
(3). Move cyclic stick full forward, then full

aft and set pilot's lateral control rod end
bearing angularity so that bearings do
not jam at full travel positions.
(5). If rod or rod ends require replacement,

accurately measure and record distance
(4). If control rod or rod ends are replaced,

perform a cyclic control rigging check.
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67-10-00
MAINTENANCE MANUAL
NOTES:
1. ASTERISK (*) IDENTIFIES SLOTTED BUSHING. 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.
2. WASHERS ARRANGED TO ALIGN LINK WITH TORQUE TUBE,
LOOSELY SPACED WITH FOUR WASHERS.
CLAMP
3. CONTROL RODS MUST NOT JAM THROUGHOUT FULL
FRICTION STUD
RANGE OF LONGITUDINAL TRAVEL (34).
4. INSTALLED WITH LOCKING COMPOUND.
FRICTION DISC
LATERAL GUIDE
CSP-HMI-2
ELECTRICAL
PLUG
CYCLIC STICK SOCKET

AND LATERAL FRICTION
INSTALLATION
RIVET
TUBE
PIN
SOCKET
RETAINER
NOTE 2
NUT
FRICTION
KNOB
PILOT'S CYCLIC
STICK ASSEMBLY
FRICTION
SPRING
*
PILOT'S CYCLIC
STICK GUARD
BUSHING
LONGITUDINAL
CONTROL FRICTION
MECHANISM
CYCLIC STICK GRIP
LATERAL
CONTROL
FRICTION
MECHANISM
COPILOT'S CYCLIC
STICK ASSY
ELECTRICAL PLUG
PILOT'S LATERAL
CONTROL ROD
(NOTE 3)
CYCLIC CONTROLS
CENTER GUARD
FRICTION
KNOB
COPILOT'S CYCLIC
STICK GUARD
QUICK RELEASE PIN
FRICTION SPRING
RETAINER
QUICK RELEASE
PIN
*
COUNTERSUNK
BOLT
COUNTERSUNK
WASHER
FRICTION DISC
NUT
NOTE 2
BEARING
(NOTE 4)
FRICTION STUD
LONGITUDINAL GUIDE
SPRING
PIN
BUSHING
LATERAL
IDLER
BELLCRANK
*
*
STA 70 LATERAL
CONTROL ROD
RIVET
LONGITUDINAL FRICTION INSTALLATION
STA 67 LATERAL CYCLIC

BELLCRANK
PILOT'S LATERAL
CONTROL ROD
LATERAL BELLCRANK CONNECTIONS

G67-1010A
Figure 411. Cyclic Controls (R/H Command)
67-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
16. Lateral Control Rods and Sta. 67 Lateral

Cyclic Bellcrank Replacement (R/H
Command)
(Ref. Figure 411)
A. Lateral Control Rods and Sta. 67 Lateral
Cyclic Bellcrank Removal (R/H
Command)
each end with a bolt, two washers, nut

and new cotter pin.
(3). Move both cyclic sticks full forward,
then full aft and set both lateral control
rods so that rod end bearings do not
jam at full throw positions; hold rod
ends and tighten jam nuts.
(4). If control rod or rod ends were replaced,
perform cyclic control rigging check.
(1). Remove cyclic stick guards.

(2). Install large (central) cyclic stick guard
pilot's seat cover and controls access
door.
(3). Remove pilot's collective pitch stick
cover, and controls access door and left
foot support fairing from Sta. 78.50
canted bulkhead.
(4). Remove cotter pin, two washers and
bolt from each end of pilot's lateral
control rod, copilot's lateral control rod,
or Sta. 70 lateral control rod, as
applicable; remove rod assembly.
and bolt securing Sta. 67 lateral cyclic
bellcrank to seat structure fitting;
remove bellcrank.
(5). Install cyclic stick guards, pilot's

collective pitch stick cover, controls
access door, and foot fairing.
17. Cyclic Pitch Interconnecting Torque Tube
(Ref. Figure 412)
A. Cyclic Pitch Interconnecting Torque Tube
Removal (L/H Command)
(1). Remove pilot's seat cover.
(2). Position pilot's cyclic stick to align holes
in one-way lock support links with bolt
that attaches forward end of one-way
lock to torque tube; tighten longitudinal
friction. Disconnect rod end from torque
tube arm.
(3). Remove pilot's cyclic stick.
(6). If rod or rod ends require replacement,

accurately measure and record distance
between rod end bearing centers for
future reference; use trammel method,
or equivalent.
B. Lateral Control Rods and Sta. 67 Lateral
Cyclic Bellcrank Installation (R/H
Command)
(1). Check that slotted bushing is in upper
web of seat structure fitting. Align Sta.
67 lateral cyclic bellcrank and install
bolt, two washers, nut and new cotter
pin.
place and install Sta. 70 lateral control
rod. Install both lateral control rods at
Page 420
Revision 29
67-10-00
(4). Remove all of cyclic stick guard instal

lation except small guard next to pilot's
cyclic stick.
(5). Remove longitudinal control friction
mechanism.
(6). Remove pilot's lateral control rod from
Sta. 67 lateral cyclic bellcrank.
(7). Cut lockwire and remove support nuts,
support bolts and two wide (L/H)
support spacers from seat structure
fitting lugs and torque tube. Prevent
torque tube from dropping as bolts are
removed.
(8). Remove torque tube and two narrow
(R/H) support spacers.
MAINTENANCE MANUAL
CSP-HMI-2
CONTROLS
SUPPORT
BRACKET
NOTES:
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
SLOTTED BUSHING
SLEEVE
(NOTE 1)
BUSHING
CYCLIC PITCH
INTERCONNECTING
TORQUE TUBE
SHIM WASHER
(NOTE 6)
PIVOT BUSHING
SUPPORT LINK
SUPPORT BEARING
(NOTE 5)
FLANGE
BUSHING
RETAINER
SUPPORT BOLT
(NOTE 2)
SUPPORT SPACER,
0.20 IN. (5.08 MM) WIDE
(NOTE 3)
CYCLIC STICK
PIVOT BEARING
SUPPORT SPACER, 0.430 IN.

(10.29 MM) WIDE
SUPPORT NUT
RIVET
(SEE CAUTION)
SUPPORT BEARING
(NOTE 4)
SUPPORT
NUT
SUPPORT SPACER,
0.260 IN. (6.60 MM) WIDE
(NOTE 3)
RIVET
STUD
SUPPORT BOLT
(NOTE 2)
SPRING PIN
SUPPORT SPACER, 0.520 IN.

(13.21 MM) WIDE
STUD (FRICTION
MECHANISM) (TYPICAL)
G67-1011A
Figure 412. Cyclic Torque Tube and OneWay Lock Installation
67-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
B. Cyclic Pitch Interconnecting Torque Tube

Installation (L/H Command)
one-way lock support links; install

attaching hardware.
(9). Install pilot's seat cover.
Item
Nomenclature

CM702
Lockwire CRES
(Ref. Figure 411)
(1). Align cyclic torque tube support

bearings with holes in structure fitting
lugs. Place narrow support spacer on
right side of each support bearing, and
install two wide support spacers and
support bolts.
NOTE: Support bolts may be installed from ei

ther direction, and two narrowest (R/H) sup
port spacers are to be interchanged for best
alignment of torque tube with one-way lock.
(2). Check that slotted bushing is in torque
tube arm, and fit one-way lock rod end
against unbushed lug of arm. If tighten
ing of attachment bolt will apply
sideload on the rod end, interchange
two narrowest (R/H) support spacers,
and/or adjust lateral position shimming
of longitudinal idler bellcrank or
one-way lock rod ends until there is no
sideload on one-way lock control
system. Check that no structural
interference results from spacer
interchange.
(3). Without sideload on one-way lock,
install and tighten support nuts. Using
lockwire (CM702), safetywire each nut
to hole in threaded end of mating bolt.
When installing lockwire do not
damage aluminum nut and bolt.
(4). Install pilot's lateral control rod (riveted
rod) end to Sta. 67 lateral cyclic
bellcrank.
(5). Install longitudinal control friction
mechanism.
(6). Install cyclic stick guards.
(7). Install pilot's cyclic stick.
(8). Position pilot's cyclic stick to align bolt
holes in torque tube arm with holes in
Page 422
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67-10-00
A. Cyclic Pitch Interconnecting Torque Tube

Removal (R/H Command)
Removal of torque tube is essentially the same
as L/H command except note the following:
(1). Remove pilot's collective pitch stick
cover.
(2). Remove pilot's cyclic stick and copilot's
cyclic stick.
(3). Remove cyclic stick guards.
(4). Remove longitudinal control friction
mechanism.
(5). Remove both lateral control rods from
Sta. 67 lateral cyclic bellcrank.
B. Cyclic Pitch Interconnecting Torque Tube
Installation (R/H Command)
Installation of torque tube is essentially the
same as L/H command except note the
following:
(1). Install pilot's and copilot's lateral
control rods (riveted rod ends) to Sta.
67 lateral cyclic bellcrank.
(2). Install longitudinal control friction
mechanism.
(3). Install cyclic stick guards.
(4). Install pilot's cyclic stick and copilot's
cyclic stick.
(5). Install pilot's collective pitch stick
cover.
19. OneWay Lock Replacement
(Ref. Figure 412)
A. OneWay Lock Removal
(1). Remove pilot's seat cover or inboard
collective pitch stick cover and controls
access door from Sta. 78.50 canted
bulkhead.
MAINTENANCE MANUAL
(2). Remove cyclic stick guard.
in one-way lock support links with bolt
that attaches forward end of one-way
lock to cyclic torque tube; tighten
longitudinal friction. Disconnect rod
end from torque tube arm.
(4). Disconnect one-way lock lower rod end
from longitudinal idler bellcrank.
(5). Disconnect upper end of each support
link from seat structure and remove
one-way lock with links attached.
(6). Remove two cotter pins, washers and
links. Do not remove pivot bushings
from links unless replacement is
necessary.
B. OneWay Lock Installation
(1). Check that rod end bearing center-tocenter distance is correct.
(2). Attach lower ends of links to one-way
lock with bushings, washers and cotter
pins.
(3). Align upper ends of links with mating
holes in seat structure fitting and
attach each link with bolt, sleeve
bushing, washer, nut and cotter pin.
(4). Check that slotted bushing is in place
in longitudinal idler bellcrank; then fit
lower rod end bearing against un
bushed lug of bellcrank to check if
sideloading occurs when attachment
bolt is tightened. There must be no
sideloading of one-way lock mecha
nism. Arrange shim washers, as
necessary, to position longitudinal idler
bellcrank and/or lower rod end for
alignment without sideload.
in support links with hingeline for
upper end of one-way lock and cyclic
torque tube arm; tighten longitudinal
friction.
(6). Repeat check for sideload on one-way
lock, step (4)., and arrange shim
washers, if necessary, to position upper
rod end for alignment without sideload.
CSP-HMI-2
NOTE: Two narrowest (R/H) cyclic torque tube

support spacers may also be interchanged to
align one-way lock.
(7). Without sideload on one-way lock,
secure each rod end bearing with
attaching hardware.
(8). Check reservoir fluid level (Ref. Sec.
12-00-00).
(9). Install cyclic stick guard.
(10). Install pilot's seat cover or inboard
collective pitch stick cover and control
access door.
20. Cyclic Trim Actuator Replacement
(Ref. Figure 403)
A. Cyclic Trim Actuator Removal
(1). Jack helicopter (Ref. Sec. 07-00-00)
until landing gear is fully extended and
clears ground.
(2). Remove foot fairing, controls access
door from Sta. 78.50 canted bulkhead
and open pilot's compartment floor
access door.
(3). Disconnect bonding jumper and
electrical connector from actuator
housing.
(4). Disconnect upper end of trim actuator.
Keep pivot bushing with actuator
unless actuator is being replaced.
(5). Disconnect lower end of trim actuator.
Access to attaching nut is through hole
in under-floor compartment aft
bulkhead, near centerline beam.
(6). Remove trim actuator. Reinstall
original lower end attaching hardware
if actuator is being replaced; new
actuator includes this hardware.
B. Cyclic Trim Actuator Installation
(1). Check trim actuator spring assembly
for free play between spring and spring
adapters. Adjust spring adapter screw
until 0.010-0.050 inch (0.254-1.27 mm)
is felt while pushing or pulling on
spring assembly.
(2). Remove hardware supplied in housing
end of new trim actuator.
67-10-00
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CSP-HMI-2
MAINTENANCE MANUAL

place in actuator housing. Place one
washer around each side of pivot
bearing in center beam support lug and
align actuator housing with bearing.
Install bolt, two washers and nut (and
cotter pin if old style).
(4). Align actuator with idler bellcrank.
Check that slotted bushing is in
bellcrank lug; install actuator pivot
bushing if actuator is a replacement.
Pivot bushing must rotate freely in
actuator. Install bolt, two washers, nut
and cotter pin. After bolt is tightened,
pivot bushing must not rotate in idler
bellcrank.
Page 424
Revision 29
67-10-00
NOTE: Lateral actuator upper hingeline has

3/16 inch (4.7625 mm) bolt hole; longitudi
nal has 1/4 inch (6.35 mm) bolt hole.
(5). Connect bonding jumper. Connect
electrical plug to actuator.
(6). With main rotor blades lifted off droop
stops, perform power-on operational
check of cyclic trim actuator. Actuator
must not bind throughout travel range
in either direction, and must maintain
at least 0.015 inch (0.381 mm)minimum
clearance with center beam structure.
(7). Lower helicopter and remove jacks.
MAINTENANCE MANUAL
CSP-HMI-2

ADJUSTMENT/TEST
1. Cyclic and Collective Control System
Rigging
Rigging of the main rotor control system must
be accomplished immediately after replace
ment of linkage that cannot be accurately
measured (by trameling, etc.) before it is
installed in the main rotor control system, or if
helicopter operation reveals rigging deficiency.
NOTE:
D Cyclic and collective controls must be
rigged in sequence, starting with collec
tive controls. Control rod end bearing ad
justments are to be made to nearest half
turn that produces correct rigging. When
tightening jam nut at adjustable end of
control rods, always hold rod end with
wrench to prevent jamming of bearing.
D On the 600N helicopter, make all rigging
adjustments using the roof-mounted con
trol rods.
D On the 600N helicopter, tunnel-routed
control rods should only be adjusted if a
flight control component, forward of the
roof-mounted bellcranks, has been re
placed.
2. Collective Controls Rigging (L/H
Command) (369D/E/FF 500N)
(Ref. Figure 501)
Item
Special Tools
Nomenclature
ST501

(LH command)
ST503
Mixer rigging plate
(1). Remove main rotor blades, or manually

raise blades off droop stops by simulta
neously lifting blade tips. All five blades
must be off stops during rigging.
Padded supports should be used.
(2). Release friction and raise pilot's

collective stick. Position collective
rigging fixture (ST501) in outboard
lower end of slot in collective friction
guide link (view C).
(3). Lower collective stick on rigging fixture
and tighten friction grip (drive gear).
(4). Position mixer rigging plate (ST503) on
mast support fitting.
NOTE: When installing the mixer rigging plate

on the 500N helicopter, removal of the split
ter bungee and bracket is required. (Ref. Sec
67-20-30).
(5). Measure and record distance from
horizontal centerline of mast support
bracket hingeline bolt (attaching
longitudinal idler bellcrank and
collective pitch mixer bellcrank to mast
support bracket) to surface of mixer
plate (view A). This dimension shall be
used as the basic dimension in rigging
the mixer controls.
(6). Measure distance from horizontal
centerline of bolt that attaches collec
tive pitch mixer bellcrank to longitudi
nal pitch mixer bellcrank (view B) to
surface of mixer rigging plate; it should
be same as basic dimension recorded in
step (5). above. If not, loosen checknut,
disconnect upper end of collective
control rod and adjust rod end (to
nearest half-turn of rod end bearing)
until dimensions are equal.
(7). Reconnect control rod, remove collective
stick rigging fixture and check mixer
travel. With stick at down stop, center
line of collective pitch mixer bellcrank
bolt (view B) should move down so that
dimension recorded in step (5). above
decreases not less than 0.74 inch
(18.796 mm).
67-10-00
Page 501
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
MAST SUPPORT
BRACKET
LONGITUDINAL
PITCH IDLER
BELLCRANK
NOTE 1
BOLT (HEAD LEFT),

WASHERS, NUT,
COTTER PIN
MIXER RIGGING
PLATE
MAST SUPPORT
FITTING
INITIAL RIGGING PLATE MEASUREMENT
LONGITUDINAL PITCH
MIXER BELLCRANK
COLLECTIVE PITCH
MIXER BELLCRANK
COLLECTIVE PITCH
CONTROL ROD
NOTE 1
COLLECTIVE
RIGGING
FIXTURE
RIGGING PLATE MEASUREMENT
FIXTURE INSTALLATION
CONTROL
FRICTION GRIP
(DRIVE GEAR)
NOTES:
1. ACTUAL DISTANCE TO BE MEASURED
AND RECORDED.
2. TO BE SAME AS ACTUAL DISTANCE
MEASURED (VIEW A). (REFER TO TEXT)
3. ELASTOMER RING THIS SIDE ON
CURRENT CONFIGURATION ONLY.
PILOT'S COLLECTIVE
PITCH STICK
COLLECTIVE FRICTION
GUIDE LINK
G67-1012-1
Figure 501. Main Rotor Control System Rigging (369D/E/FF 500N) (Sheet 1 of 3)
Page 502
Revision 21
67-10-00
MAINTENANCE MANUAL
CSP-HMI-2
LONGITUDINAL
PITCH IDLER
NOTE 2
MIXER RIGGING PLATE

MIXER TRAVEL
LONGITUDINAL PITCH
MIXER BELLCRANK
BOLT (HEAD LEFT),

WASHERS, NUT,
COTTER PIN
LONGITUDINAL PITCH
CONTROL MIXER
PITCH CONTROL ROD

ELASTOMER RING
(NOTE 3)
ELASTOMER RING
SLOTTED BUSHING
LATERAL BELLCRANK
LONGITUDINAL
FRICTION GUIDE
LINK
STATIONARY
SWASHPLATE
MIXER LINK
PITCH CONTROL ROD

INSTALLATION (5 PLACES)
NOTE 2
KNURLED THUMBNUT
FRICTION
KNOB
CYCLIC STICK LONGITUDINAL
RIGGING FIXTURE
LONGITUDINAL RIGGING
MIXER TRAVEL
LATERAL PITCH
CONTROL ROD
FRICTION KNOB
LATERAL FRICTION
GUIDE LINK
CYCLIC STICK LATERAL

RIGGING FIXTURE
KNURLED THUMBNUT
LATERAL RIGGING
G67-1012-2
67-10-00
Page 503
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
0.75 IN. (19.05 MM)

0.45 IN. (11.43 MM)
0.74 IN.
(18.796 MM)
UP
0.76 IN. (19.304 MM)
1.190 IN.
(30.226 MM)
2.25 IN.
(57.15 MM)
REF
0.43 IN.
(10.922 MM)
RT
0.43 IN. (10.922 MM)
0.74 IN. (18.796 MM)
NOM
0.75 IN. (19.05 MM)
1.190 IN.
(30.226 MM)
FWD
NOM
NOM
0.50 IN. (12.70 MM)
0.50 IN.
(12.70 MM)
LFT
0.74 IN. (18.796 MM)

0.74 IN.
(18.796 MM)
DN
0.57 IN.
(14.478 MM)
0.57 IN.
(14.478 MM)
AFT
1.92 IN. (48.564 MM) REF
SIDE VIEW
0.32 IN.
(8.128 MM)
FRONT VIEW
0.125 IN.
(3.175 MM)
1.05 IN
(26.67MM)
2.25 IN. (57.15 MM)
1.00 IN.
(25.4 MM)
GENERAL NOTES FOR BUILDING FIELD RIGGING AID:

1. MAKE FROM T-ANGLE STOCK TO DIMENSIONS SHOWN.
2. SCREWS, NUTS AND WASHERS AS REQUIRED.
3. HOLES IN VERTICAL T-ANGLE TO BE SLOTTED TO ADJUST
TO MIXER SUPPORT BOLT NOMINAL DIMENSION.
4. SCRIBE MARKING ON VERTICAL T-ANGLE AS SHOWN.
5. MANUFACTURE FROM 2024-T4 AL ALY PLATE.
6. IMPRESSION STAMP PART NO. AND INSTRUCTIONS.
SURFACE TO BE FLAT AFTER STAMPING.
2.25 IN.
(57.15 MM)
TOP VIEW
0.81 IN. (20.57 MM)
.09 R
0.375 IN. (9.525 MM)
NOTE 5
1.75 IN. (44.45 MM)
6.71 IN. (170.43 MM)

1.12 IN. (28.45 MM)
1.75 IN. (44.45 MM)
NOTE 6
2.75 IN. (69.85 MM)
369A9930
THIS SIDE UP
4.18 IN.
(106.17 MM)
2.18 IN. (55.37 MM)

.09 R
8.56 IN. (217.42 MM)
90
11.38 IN. (289.05 MM)
FIELD RIGGING AID
2.18 IN. (55.37 MM)

0.94 IN. (23.88 MM)
G67-1012-3E
Page 504
Revision 42
67-10-00
MAINTENANCE MANUAL
CSP-HMI-2
MIXER
RIGGING PLATE
MAST
SUPPORT
BRACKET
MAST
SUPPORT FITTING
LONGITUDINAL PITCH
IDLER BELLCRANK
NOTE 1
COLLECTIVE MIXER
CONTROL ROD
MIXER RIGGING
PLATE
INITIAL RIGGING PLATE MEASUREMENT
LONGITUDINAL PITCH
MIXER BELLCRANK
COLLECTIVE FRICTION
GUIDE LINK
COLLECTIVE PITCH
MIXER BELLCRANK
NOTE 2
PILOT'S COLLECTIVE
PITCH STICK
CONTROL FRICTION GRIP
(DRIVE GEAR)
RIGGING PLATE MEASUREMENT

NOTES:
1. ACTUAL DISTANCE TO BE MEASURED AND RECORDED.
2. TO BE SAME AS ACTUAL DISTANCE MEASURED
IN VIEW A (REFER TO TEXT).
3. ELASTOMER RING THIS SIDE ON CURRENT
CONFIGURATION ONLY.
COLLECTIVE RIGGING
FIXTURE
6G67-037-1B
Figure 502. Rigging Main Rotor Control System (600N) (Sheet 1 of 3)
67-10-00
Page 505
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
KNURLED
THUMBNUT
LONGITUDINAL
FICTION GUIDE
LINK
LONGITUDINAL MIXER
CONTROL ROD
(CYCLIC)
LATERAL MIXER
CONTROL ROD
(CYCLIC)
FRICTION KNOB
LONGITUDINAL RIGGING
NOTE 2
LATERAL FRICTION
GUIDE LINK
LONGITUDINAL PITCH
MIXER BELLCRANK
FRICTION KNOB
MIXER RIGGING PLATE
MIXER TRAVEL
CYCLIC STICK LATERAL
RIGGING FIXTURE
KNURLED
THUMBNUT
LATERAL RIGGING
PITCH CONTROL ROD
LATERAL BELLCRANK
ELASTOMER RING
(NOTE 3)
ELASTOMER
RING
SLOTTED
BUSHING
STATIONARY
SWASHPLATE
MIXER LINK
NOTE 2
PITCH CONTROL ROD

INSTALLATION (6 PLACES)
MIXER TRAVEL
MIXER RIGGING PLATE

6G67-037-2A

Page 506
Revision 21
67-10-00
MAINTENANCE MANUAL
1.05 IN.
(26.67 MM)
FWD
0.75 IN. (19.05 MM)

0.48 IN. (12.192 MM)
0.83 IN.
(21.082 MM)
DN
0.37 IN
(9.398 MM)
RT
0.37 IN (9.398 MM)
NOM
0.75 IN. (19.05 MM)
1.05 IN.
(26.67 MM)
2.25 IN.
(57.15 MM)
REF
0.79 IN. (20.066 MM)
0.83 IN. (21.082 MM)
CSP-HMI-2
NOM
NOM
0.52 IN. (13.208 MM)
0.52 IN.
(13.208 MM)
LFT
0.71 IN. (18.034 MM)

0.71 IN.
(18.034 MM)
UP
0.65 IN.
(16.51 MM)
0.65 IN.
(16.51 MM)
AFT
0.50 IN. (12.7 MM)
0.29 IN.
(7.366 MM)
SIDE VIEW
FRONT VIEW
0.125 IN.
(3.175 MM)
2.25 IN. (57.15 MM)
1.00 IN.
(25.4 MM)
GENERAL NOTES FOR BUILDING FIELD RIGGING AID:
1. MAKE FROM T-ANGLE STOCK TO DIMENSIONS SHOWN.
2. SCREWS, NUTS AND WASHERS AS REQUIRED.
3. HOLES IN VERTICAL T-ANGLE TO BE SLOTTED TO ADJUST
TO MIXER SUPPORT BOLT NOMINAL DIMENSION.
4. SCRIBE MARKING ON VERTICAL T-ANGLE AS SHOWN.
5. MANUFACTURE FROM 2024-T4 AL ALY PLATE.
6. IMPRESSION STAMP PART NO. AND INSTRUCTIONS.
SURFACE TO BE FLAT AFTER STAMPING.
2.25 IN.
(57.15 MM)
TOP VIEW
.09 R
0.81 IN. (20.57 MM)

6.71 IN. (170.43 MM)
1.75 IN. (44.45 MM)
0.375 IN. (9.525 MM)

NOTE 5
1.75 IN. (44.45 MM)
1.12 IN. (28.45 MM)
NOTE 6
2.75 IN. (69.85 MM)
369A9930
THIS SIDE UP
4.18 IN.
(106.17 MM)
2.18 IN. (55.37 MM)

.09 R
8.56 IN. (217.42 MM)
90
11.38 IN. (289.05 MM)
2.18 IN. (55.37 MM)
FIELD RIGGING AID
0.94 IN. (23.88 MM)

6G67-037-3B
67-10-00
Page 507
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
COLLECTIVE
FRICTION GUIDE
COLLECTIVE RIGGING
FIXTURE
COLLECTIVE RIGGING
LONGITUDINAL
FRICTION KNOB
FRICTION
KNOB
LATERAL
FRICTION
GUIDE LINK
CYCLIC STICK
LONGITUDINAL
RIGGING FIXTURE
CYCLIC STICK
LATERAL RIGGING
FIXTURE
CYCLIC STICK LATERAL RIGGING

LONGITUDINAL FRICTION
GUIDE LINK

RIGGING FIXTURE INSTALLATION
Figure 503. Cyclic and Collective Controls Rigging Tools (R/H Command)
Page 508
Revision 21
67-10-00
G67-1013
MAINTENANCE MANUAL
NOTE: To facilitate field rigging of the collec

tive control (up and down) and the cyclic
control (both forward and aft, and right and
left) a field rigging aid may be fabricated as
illustrated (Ref. Figure 501, Sheet 3). If the
mixer bellcranks are in dimension with ref
erence to the mixer rigging plate (ST503)
the collective and cyclic controls are proper
ly rigged. The dimension attained in steps
(7). and (8). shall correspond to the dimen
sions marked on the field rigging aid. If the
dimensions attained do not correspond, full
rigging procedures must be performed.
(8). With stick at up stop, centerline of
collective pitch mixer bellcrank bolt
should move up so that dimension
recorded in step (5). above increases
minimum of 0.74 inch (18.796 mm).
Do not adjust control rod end be
yond witness hole. Tighten jam
nut after final adjustment. Failure to ob
serve this precaution can result in parts
damage and/or equipment failure.
CAUTION
(9). If necessary, adjust rod end of collective

pitch control rod to meet limits speci
fied in steps (7). and (8). above. When
adjustment is complete, tighten jamnut
and make certain that length of control
rod does not change.
(10). Remove mixer rigging plate. On the
500N helicopter reinstall the spitter
bungee and bracket. (Ref. Sec
67-20-30).
(11). Reconnect collective pitch control rod.
3. Collective Controls Rigging (R/H
Command) (369D/E/FF 500N)
Item
ST502
Special Tools
Nomenclature
(RH command)
Collective control rigging for the R/H command

helicopter is accomplished according to
instructions for L/H command helicopters,
except collective rigging fixture (ST502) is
CSP-HMI-2
used in inboard lower end of collective friction

guide slot.
4. Collective Control System Rigging (L/H
Command) (600N)
(Ref. Figure 502)
Item
ST501
ST503
ST504
ST506
ST511
Special Tools
Nomenclature
(LH command)
Mixer rigging plate
(LH command)
(LH command)
Test fixture

neously lifting blade tips. All six blades
NOTE: The collective bungee has very high

over-center spring pressure. Ensure collec
tive stick is fully seated on rigging fixture or
rigging may not be correct.
and tighten friction lock.
(4). Adjust longitudinal cyclic trim for
no-load and install longitudinal cyclic
rigging fixture (ST504) (Ref. View D).
(5). Adjust lateral cyclic trim for no-load
and install lateral cyclic rigging fixture
(ST506) (Ref. View E).
NOTE: For both longitudinal and lateral cyclic

rigging fixtures, ensure that the bolt of the
friction lock is engaged in the slot of the rig
ging fixture and that the hook of the fixture
is properly engaged with the checknut tight
ened.
67-10-00
Page 509
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
NOTE: To facilitate field rigging of the collec

tive control (up and down) and the cyclic
control (both forward and aft and right and
left) a field rigging aid may be fabricated as
illustrated (Ref. Figure 502, Sheet 3). If the
mixer bellcranks are in dimension with ref
erence to the mixer rigging plate (ST503)
the collective and cyclic controls are proper
ly rigged. The dimension attained in the fol
lowing paragraphs shall correspond to the
dimensions marked on the field rigging aid.
If the dimensions attained do not corre
spond, full rigging procedures must be per
formed.
(7). Using a six inch (16 cm) scale, measure
and record distance from rigging
plate-to-collective hinge bolt center,
this is your nominal setting, or, position
test fixture (ST511) on rigging plate
and adjust NOM indicator to centerline
of collective hinge bolt.
CAUTION
Do not allow test fixture points

to scribe or mark the bolts.
NOTE: Do not change the setting of the test fix

ture. This setting will be the basic NOMI
NAL for locating, to the nearest half turn of
the respective control rod end fitting, the
height of the bolts.
(a). Adjust collective control rod so
centerline of bolt of the collective
bellcrank (369N2664) is at NOM, to
nearest half-turn on rod end bearing.
(b). Adjust longitudinal control rod so
centerline of bolt of the longitudinal
bellcrank (369N2666) is at NOM, to
nearest half-turn on rod end bearing.
(c). Adjust lateral control rod so center
line of bolt of the lateral bellcrank
(369N2670) is at NOM, to nearest
half-turn on rod end bearing.
(8). Remove collective rigging fixture and
check travel as follows:
NOTE: Adjust rod end, as required, to obtain

the following limits.
Page 510
Revision 24
67-10-00
(a). With collective stick at down-stop,

centerline of bolt in collective bell
crank (369N2664) shall move down a
minimum of 0.71 inch (18.0 mm)
below nominal setting.
(b). With collective stick at up-stop,
centerline of bolt in collective bell
crank (369N2664) shall move up a
minimum of 0.83 inch (21.0 mm)
above nominal setting.
5. Collective Controls Rigging (R/H
Command) (600N)
(Ref. Figure 502 and Figure 503) Collective
control rigging for the R/H command helicopter
is accomplished according to instructions for
L/H command helicopters, except the following
rigging fixtures must be substituted.
Item
ST502
ST503
ST505
ST507
ST511
Special Tools
Nomenclature
(RH command)
Mixer rigging plate
(RH command)
(RH command)
Test fixture
6. Cyclic Controls Rigging (L/H Command)

(369D/E/FF 500N)
(Ref. Figure 501)
Item
ST501
ST503
ST504
ST506
Special Tools
Nomenclature
(LH command)
Mixer rigging plate
(LH command)
(LH command)
NOTE: All cyclic control rigging is done with

collective controls at mid-position.
MAINTENANCE MANUAL
neously lifting blade tips. All five blades
(5). Loosen longitudinal friction knob and
set longitudinal cyclic trim for no load
by neutralizing cyclic stick. Position
cyclic stick so that longitudinal rigging
fixture (ST504) fits in outboard side of
slot in longitudinal friction guide link.
(Index pin of fixture butts against
forward end of slot, and friction knob
stud fits in fixture detent - view F.)
(6). Secure fixture hook in aft end of slot.
Tighten knurled thumbnut to seat
bushing at forward end and tighten
friction knob.
(7). Measure and record distance from
horizontal centerline of bolt at aft end
of longitudinal pitch mixer bellcrank
(view H) to surface of mixer rigging
plate. It should be same as distance
from horizontal centerline of mast
support bracket hingeline bolt to
surface of mixer plate (Ref. Collective
Controls Rigging (L/H Command), step
(5).). If not, loosen jamnut, disconnect
longitudinal pitch control rod and
adjust rod end, to nearest half turn of
rod end bearing, until dimensions are
equal. This will be basic dimension for
cyclic control rigging.
(8). Reconnect control rod, remove longitu
dinal stick rigging fixture and check
mixer travel. With stick at forward
stop, centerline of longitudinal pitch
mixer bellcrank bolt (view B) should
move up so that basic dimension
recorded in step (7). above is increased
minimum of 1.19 inches (3.0226 cm), or
a maximum of 1.22 inches (3.0988 cm).
CSP-HMI-2
NOTE: Field rigging aid (Ref. Figure 501,

Sheet 3) may be used to check dimensions
attained in steps (4). and (5).. If dimensions
attained do not correspond with dimensions
shown on rigging aid, full rigging proce
dures must be performed.
(9). Reposition mixer rigging plate to clear
With stick at aft stop, centerline of
longitudinal pitch mixer bellcrank bolt
(view B) should move down so that
basic dimension recorded in step (3).
above decreases minimum of 0.570 inch
(14.478 mm).
Do not adjust control rod beyond
witness hole. Tighten jamnut af
ter final adjustment. Failure to observe this
precaution can result in parts damage and/
or equipment failure.
CAUTION
(10). If necessary, adjust rod end of longitudi

nal pitch control rod to meet limits
specified in steps (4). and (5). above.
Adjust carefully; tolerance is only 1/2
turn. When adjustment is complete,
tighten jamnut and ensure that length
of control rod does not change.
(11). Reconnect control rod to longitudinal
pitch idler.
(12). Reinstall longitudinal rigging fixture;
reposition and secure mixer rigging
plate.
(13). Loosen friction knob and set lateral
cyclic trim for no load by neutralizing
cyclic stick. Position cyclic stick so that
lateral rigging fixture (ST506) fits in
forward side of slot in lateral friction
guide link. (Index pin of fixture butts
against outboard end of slot, and
friction knob stud fits in fixture detent
- view E.)
(14). Secure fixture hook in inboard end of
slot, tighten knurled thumbnut to seat
bushing at outboard end, and tighten
friction knob.
(15). Measure distance from horizontal
centerline of bolt connecting lateral
bellcrank to stationary swashplate
mixer link to (view D) surface of mixer
rigging plate; it should be same as basic
dimension recorded in step (3).. If not,
67-10-00
Page 511
Revision 38
CSP-HMI-2
MAINTENANCE MANUAL
loosen checknut, disconnect lateral

pitch control rod and adjust rod end (to
nearest half-turn on rod end bearing)
until dimensions are equal.
Check for interference between

rod end bearings and lugs of
pitch control housing. Adjust bearings as re
quired to provide clearance.
CAUTION
NOTE: Next step establishes initial adjust

(16). Reconnect control rod, remove lateral
stick rigging fixture and check mixer
travel. With stick at left stop, centerline
of lateral bellcrank bolt (view D) should
move down so that basic dimension
recorded in step (3). decreases a
minimum of 0.50 inch (12.70 mm) or a
maximum of 0.53 inch (13.462 mm).
NOTE: The field rigging aid (Ref. Figure 501,

sheet 3) may be used to check dimensions
attained in steps (12). and (13).. If the di
mensions attained do not correspond with
dimensions shown on the rigging aid, full
rigging procedures must be performed.
(17). With stick at right stop, centerline of
lateral bellcrank bolt should move up so
that basic dimension recorded in step
(3). increases minimum of 0.43 inch
(10.922 mm).
CAUTION
(18). If necessary, adjust rod end of lateral

pitch control rod to meet limits speci
fied in steps (12). and (13). above. When
adjustment is complete, tighten jamnut
and make certain that length of control
rod does not change.
(19). Reconnect control rod to lateral bell
crank.
(20). Loosen friction control, friction knob,
knurled thumbnuts and hooks of
rigging fixture and remove all three
fixtures.
Page 512
Revision 21
67-10-00
ment of main rotor pitch controls links. Fi

nal adjustment is to be made by tracking
and autorotation rpm setting (Ref. Sec.
18-10-00).
(21). Remove and adjust length of each pitch
control link (view G) so that centerlineto-centerline distance between rod-end
bearings is 6.25 inches (15.875 cm).
Then install the pitch control links.
(22). With collective stick full down and
cyclic stick full forward and full left,
check clearance between the rotating
swashplate and the longitudinal pitch
idler bellcrank. Minimum clearance is
0.125 inch (3.175 mm). Adjust the
collective control rod as required.
(23). With collective stick full up and cyclic
stick full left (any position fore or aft),
check clearance between lateral
bellcrank and, collective pitch mixer
bellcrank of the mixer controls. Mini
mum clearance is 0.030 inch (0.762
mm). Adjust lateral control rod as
required.
cyclic stick full aft, check clearance
between the aft longitudinal bellcrank
and the mast base. Minimum clearance
is 0.030 inch (0.762 mm). Adjust
longitudinal control rod (preferably) or
stick full forward and full left, check
clearance between rotating swashplate
and scissors fitting. Also check clear
ance between scissors rotating link and
lower hub shoe. Minimum clearance in
both cases is 0.030 inch (0.762 mm).
Rotate hub 360 degrees to determine
location of minimum clearance. Adjust
(26). Repeat step (21). above with collective
stick full up and cyclic stick full forward
and full right.
MAINTENANCE MANUAL
stick full aft and full left, check clear
ance between scissors link and edge of
pocket in rotating swashplate. Mini
mum clearance is 0.006 inch (0.1524
mm). Rotate hub 360 degrees to
determine location of minimum clear
ance. Repeat clearance check with
cyclic stick full aft and full right.
(28). Repeat steps (17). thru (22). above to
recheck all clearances.
(29). Repeat steps (7). of Collective Controls
Rigging, step (4)., and steps (9). thru
(15). of Cyclic Controls Rigging, to
recheck mixer control motion travels
and see that minimums are met.
(2). Use lateral rigging fixture (ST507) on

forward side of lateral friction guide,
with fixture cutout positioned over
friction knob stud (view C). Secure
fixture hook in lower inboard end of
slot, tighten knurled thumbnut to seat
bushing at upper outboard end and
tighten lateral friction knob.
8. Cyclic Controls Rigging (L/H Command)
(600N)
(Ref. Figure 502)
Special Tools
Nomenclature
Item
ST501
(30). Install main rotor blades or remove

supports and simultaneously lower all
five blades to normal position.
ST503
ST504
(31). Track main rotor blades and adjust

autorotation rpm (Ref. Sec. 18-10-00).
ST506
7. Cyclic Controls Rigging (R/H Command)

(369D/E/FF 500N)
(Ref. Figure 501 and Figure 503) Rigging of
cyclic controls for the R/H command helicopter
L/H command helicopters except as follows:
Item
Special Tools
Nomenclature
ST505

(RH command)
ST507

(RH command)
(1). Use longitudinal rigging fixture

(ST505) on outboard side of longitudi
nal friction guide, with fixture cutout
positioned over friction knob stud.
Bushing end of fixture butts against
upper end of slot in guide (Ref.
Figure 503, view B). Secure fixture
hook in lower end of slot, tighten
knurled thumbnut to seat bushing at
upper end, and tighten friction knob.
CSP-HMI-2

(LH command)
Mixer rigging plate
(LH command)
(LH command)
NOTE: All cyclic control rigging is done with

collective stick on rigging fixture.
neously lifting blade tips. All six blades
(4). Adjust lateral cyclic trim for no-load
and install lateral cyclic rigging fixture
(ST506).
(6). Check longitudinal travel as follows:

67-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
(a). With cyclic stick at forward stop,

centerline of bolt in longitudinal
bellcrank (369N2666) shall move up
a minimum of 1.05 inches (26.67 mm)
above centerline of collective hinge
bolt. Reposition mixer plate to clear
longitudinal bellcrank.
(b). With cyclic stick at aft stop, center
line of bolt in bellcrank (369N2666)
shall move down a minimum of 0.65
inch (16.51 mm) below centerline of
collective hinge bolt.
(7). Adjust longitudinal cyclic trim for
no-load and install longitudinal cyclic
rigging fixture (ST504).
(8). Remove lateral cyclic rigging fixture.
(9). Check lateral travel as follows:

(a). With cyclic stick at left stop, center
line of bolt head (fwd end) of bolt in
lateral bellcrank (369N2670) shall
move down a minimum of 0.52 inch
(13.208 mm) below centerline of
collective hinge bolt.
(b). With cyclic stick at right stop,
centerline of bolthead in lateral
bellcrank (369N2670) shall move up
a minimum of 0.37 inch (9.398 mm)
above centerline of collective hinge
bolt.
CAUTION
(10). Set pitch change links at nominal 6.25

inch (158.75 mm).
NOTE: Final adjustment of pitch change links

will be accomplished during tracking and
autorotation rpm settings.
(11). Remove all rigging fixtures.
cyclic stick forward and full left, check
and longitudinal pitch idler bellcrank
Page 514
Revision 21
67-10-00
(369N2670). The minimum allowable

clearance shall be 0.125 inch (3.175
mm). Adjust collective control rod as
required.
stick full left (any position fore and aft),
check for interference between lateral
bellcrank (369N2670) and collective
bellcrank (369N2664) of mixer controls.
When there is interference, lengthen
lateral mixer control rod (369A7012) to
maintain a minimum allowable clear
ance of 0.030 inch (0.762 mm).
cyclic stick full aft, check clearance
between aft longitudinal bellcrank
(369N2668) and mast base. The
minimum allowable clearance shall be
0.030 inch (0.762 mm). When clearance
is less than 0.030 inch (0.762 mm),
adjust longitudinal control rod (prefera
ble) or collective control rod.
stick full forward and full left, check
and scissors fitting. Also check clear
ance between scissors fitting and lower
hub shoe. The minimum allowable
clearance in both cases is 0.030 inch
(0.762 mm). Rotate hub 360 degrees to
determine location of minimum clear
ance. Adjust collective mixer control rod
as required.
(16). Repeat above step with collective stick
full up and cyclic stick full forward and
full right.
stick full aft and full left, check clear
ance between scissors link and edge of
pocket in rotating swashplate. Rotate
hub 360 degrees to determine location
of minimum clearance. Minimum
clearance is 0.006 inch (0.152 mm).
(18). Repeat clearance check with cyclic stick
full aft and full right.
(19). Recheck all clearances from previous
steps.
(20). Recheck control motion travels and
check that minimum clearances are
met.
MAINTENANCE MANUAL
(21). Install main rotor blades or remove
supports and simultaneously lower all
six blades to normal position.
(22). Track main rotor blades and adjust
autorotation rpm (Ref. Sec. 18-10-00).
9. Cyclic Controls Rigging (R/H Command)
(600N)
(Ref. Figure 502 and Figure 503) Rigging of
cyclic controls for the R/H command helicopter
L/H command helicopters except as follows:
Item
ST501
ST503
ST505
ST507
Special Tools
Nomenclature
(LH command)
Mixer rigging plate
(RH command)
(RH command)
(1). Use longitudinal rigging fixture

(ST505) on outboard side of longitudi
nal friction guide, with fixture cutout
positioned over friction knob stud.
Bushing end of fixture butts against
upper end of slot in guide). Secure
fixture hook in lower end of slot, tighten
upper end, and tighten friction knob.
(2). Use lateral rigging fixture (ST507) on
forward side of lateral friction guide,
with fixture cutout positioned over
friction knob stud. Secure fixture hook
in lower inboard end of slot, tighten
upper outboard end and tighten lateral
friction knob.
10. Gas Producer Linkage Adjustment
(Ref. Figure 504 and Figure 505) Adjust gas
producer linkage in installed collective pitch
stick(s) and/or inboard socket assembly as
follows:
(1). Remove cap and outboard bearing from
pilot's collective pitch stick housing.
CSP-HMI-2
(2). Remove backlash shims and gear shaft

assembly from socket housing.
NOTE: Note locations, mark and measure re

moved shim thicknesses to ensure reas
sembly at same places.
(3). Ensure that inboard collective pitch
stick socket internal gears are aligned
and mated. If gears are correctly
aligned and mated, do not perform
steps (4). thru (6). and continue with
step (7). If gears are misaligned,
perform steps (4). thru (6).
(4). Disconnect link from idler and remove
link and bellcrank as an assembly from
gearshaft of inboard collective pitch
stick socket by removing bolt, two
washers and nut.
NOTE: During gear shaft rotation to establish

correct mid-position for gearshaft and pin
ion in next step, gearshaft cutout is seen
through hole in rear of socket assembly
housing.
(5). Rotate end of gas producer interconnect
torque tube in pilot's stick socket
housing until gear shaft-to-N1 pinion
gearmesh is at mid-travel and N1
pinion gear wide toothspace is posi
tioned at approximately one o'clock.
View pinion by looking aft into open
end of collective stick socket.
(6). Attach inboard collective pitch stick
socket bellcrank to gearshaft and link
to idler. Bellcrank attachment bolt
must be installed with head slightly
down and forward.
NOTE: Inboard collective N1 pinion gear must

be held in correct position while steps (7).
thru (9). below are performed. If available,
optional copilot's collective pitch stick can be
used to hold gear in position by setting copi
lot's throttle grip attachment bolts at ap
proximately seven o'clock (looking aft) be
fore engaging stick and socket.
(7). With inboard collective pitch stick
socket N1 pinion gear held at position
described in step (5)., rotate pilot's
collective pitch stick throttle grip to
mid-travel position (grip attaching
bolts approximately straight down).
67-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
PINION GEAR MOUNTING DISTANCE

0.699-0.709 IN. (17.7546-18.0086 MM)
PINION GEAR
PINION BEARING
SPLIT SHIMS
(NOTES 1, 3)
GAS PRODUCER TORQUE TUBE
BEARING
DRIVEN GEAR
BEARING
BACKLASH SHIM(S)
(NOTES 2, 3)
GENERAL NOTE:
SHIM SELECTED AS REQUIRED.
STEEL SHIMS PROVIDED IN 0.001, 0.002,
0.005, 0.012 AND 0.032 IN.
((0.025, 0.051,
0.127, 0.305, 0.813 MM) THICKNESS.
TOP VIEW
HOUSING CAP
IDLE STOP
GRIP MID-TRAVEL
N1 CLOSED
N1 OPEN
15
70 40'
15
73 30'
2 50'
(NOTE 5)
CENTERLINE OF GAS
PRODUCER TORQUE TUBE
(NOTE 4)
CUTOUT IN
DRIVEN GEAR
LEFT SIDE VIEW
NOTES:
1. DETERMINES GEAR MOUNTING DISTANCE.
2. DETERMINES GEAR BACKLASH MAXIMUM 0.003 IN. (0.0762 MM).
3. SELECTED AS REQUIRED; STEEL SHIMS AVAILABLE IN 0.001, 0.002, 0.005,
0.0012 AND 0.032 IN. (0.025, 0.051, 0.127, 0.305, 0.813 MM) THICKNESSES.
4. ALSO CENTERLINE OF PINION GEAR AND CUTOUT IN DRIVEN GEAR.
5. CENTERLINE OF CENTER TOOTH ON DRIVEN GEAR.
G67-1014B
Figure 504. Gas Producer Drive Backlash Adjustment (Outboard Collective Stick)
Page 516
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MAINTENANCE MANUAL
CSP-HMI-2
NOTE:
SHIM SELECTED AS REQUIRED.
STEEL SHIMS PROVIDED IN 0.001, 0.002,
0.005, 0.012 AND 0.032 IN. ((0.025, 0.051,
0.127, 0.305, 0.813 MM) THICKNESS.
AFT BEARING
LOCK RING
LOCK RING
FORWARD BEARING
2 50'
70 40'
15
73 30'
15
IDLE STOP
N1 CLOSED
(R/H COMMAND)
6
N1 OPEN
N1 CLOSED
(L/H COMMAND)
GRIP/N1 PINION GEAR

MID-TRAVEL
ROTATED 90 DEGREES
(LINK AND IDLER REMOVED FOR CLARITY)
IDLER
BELLCRANK
LINK
BEARING
WIDE TOOTHSPACE
ON SPLINE
BACKLASH SHIM(S)
(SEE NOTE)
BEARING
LOOKING DOWN
G67-1023A
Figure 505. Gas Producer Drive Backlash Adjustment (Inboard Collective Stick)
67-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
(8). Install backlash shims and gear shaft

in pilot's collective stick socket housing.
Ensure that gearshaft and pinion are
aligned and mated when pilot's throttle
grip is at mid-travel.
NOTE: Make sure that shims are installed in

original locations.
(9). Reinstall outboard bearing and cap on
pilot's stick housing.
(10). Check that both pilot's throttle grip and
inboard collective pitch stick socket N1
pinion gear wide toothspace are correct
at mid-travel.
(11). Remove snap plug from skin, rotate
pilot's throttle grip and visually check
for evidence of backlash between gas
producer interconnect torque tube and
hexagonal interior surfaces of gear
shaft. If necessary, remove cover and
gearshaft from torque tube and elimi
nate any backlash by tightening pipe
plug in end of torque tube. Zero back
lash is required at both ends of tube.
Reinstall snap plug.
11. Pipe Plug Adjustment
(Ref. Figure 407)
(1). Remove pilot seat cover for access to
under seat controls.
(2). Remove snap plug from exterior skin.
(3). Remove bolt securing bellcrank to
inboard gearshaft.
(4). Position throttle midway between idle
stop and full open.
(5). With assistant, tighten pipe plugs at
each end of torque tube simultaneously;
maintain throttle as set in step (4).
Initial torque required to turn pipe
plugs may be high because of dried zinc
chromate primer used at installation.
(6). Reinstall bolt to secure bellcrank to

inboard gearshaft.
(7). Reinstall snap plug in exterior skin.
(8). Reinstall pilot seat cover.
NOTE: If optional dual controls are installed,

perform following rigging and deceleration
checks using copilot throttle.
(9). Check engine gas producer controls
rigging (Ref. Chap. 76).
(10). Perform deceleration check (Ref. Pilot's
Flight Manual).
12. Gas Producer Interconnecting Torque
Tube Assembly Shimming (0003D thru
0929D)
(Ref. Figure 506)
(1). Remove pilot's seat cover and access
door.
(2). Make an index mark on end of collec
tive torque tube fitting flush with
inboard end of pilot's collective stick
assembly housing using a felt pen or
pencil. Do not scribe index mark on
fitting.
(3). Remove four bolts securing pilot's
collective stick assembly to end of
collective torque tube fitting.
(4). Loosen pipe plug in end of gas producer
interconnecting torque tube which
secures it to gas producer gearshaft in
pilot's collective stick assembly.
(5). Remove pilot's collective stick assembly.
NOTE: If the normally installed plug does not
(6). Using rubber mallet or equivalent soft

tool, tap gas producer interconnecting
torque tube assembly toward copilot's
collective socket assembly. Avoid
damage to gas producer interconnecting
torque tube hex end or pipe plug
threads.
sufficiently expand tube, a 1/8-27 internalwrenching pipe plug 0.380 inch (9.652 mm)
long may be substituted. Whichever plug is
used, it must not protrude more than 0.030
inch (0.762 mm) when tightened.
(7). Measure distance between index mark

on collective torque tube fitting and hex
end of gas producer interconnecting
torque tube.
Page 518
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67-10-00
MAINTENANCE MANUAL
CSP-HMI-2
369H7352 PILOT'S COLLECTIVE

CONTROL STICK ASSEMBLY
INDEX MARK OR LINE ON GAS
PRODUCER INTERCONNECTING
TORQUE TUBE END FITTING FLUSH
WITH THE INBOARD END OF THE
PILOT'S COLLECTIVE STICK ASSEMBLY
GAS PRODUCER
INTERCONNECTING
TORQUE TUBE FITTING
INDEX MARKING
MEASUREMENT BETWEEN INDEX MARK

AND HEX END OF GAS PRODUCER
INTERCONNECTING TORQUE TUBE
HEX END
INDEX MARK
369H7355 GAS PRODUCER

INTERCONNECTING TORQUE
TUBE END FITTING
GAS PRODUCER INTERCONNECTING TORQUE TUBE MEASUREMENT
G67-1015-1
Figure 506. Gas Producer Interconnecting Torque Tube Shimming Procedure

(0003D thru 0929D) (Sheet 1 of 2)
67-10-00
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Revision 21
CSP-HMI-2
MAINTENANCE MANUAL
MEASUREMENT BETWEEN INBOARD END OF PILOT'S

COLLECTIVE STICK HOUSING AND END OF GEAR
SHAFT IN PILOT'S COLLECTIVE STICK ASSEMBLY
PILOT'S COLLECTIVE STICK

HOUSING ASSEMBLY
GEAR SHAFT IN PILOT'S

COLLECTIVE STICK ASSEMBLY
GEAR SHAFT RECESSION MEASUREMENT
TOTAL THICKNESS OF AN960C816 WASHERS AND SNAP RING.

EQUAL TO 0.750 IN. (19.05 MM) MINUS ENGAGEMENT LENGTH OF
GAS PRODUCER INTERCONNECTING TORQUE TUBE INTO GEAR
SHAFT IN PILOT'S COLLECTIVE STICK ASSEMBLY ADDED TO
END OF GAS PRODUCER INTERCONNECTING TORQUE TUBE.
ENGAGEMENT LENGTH OF GAS PRODUCER

INTERCONNECTING TORQUE TUBE INTO GEARSHAFT
OF PILOT'S COLLECTIVE STICK ASSEMBLY.
0.750 IN. (19.05 MM) LENGTH OF HEX END ON

THE GAS PRODUCER INTERCONNECTING
TORQUE TUBE.
TORQUE TUBE SHIMMING
G67-1015-2
Figure 506 Gas Producer Interconnecting Torque Tube Shimming Procedure

(0003D thru 0929D) (Sheet 2 of 2)
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MAINTENANCE MANUAL
(8). Measure distance between inboard end
of pilot's collective stick assembly
housing and inboard face of gas produc
er gearshaft in pilot's collective stick
assembly.
(9). Subtract measurement taken in step
(8). from measurement taken in step
(7). Remainder is engagement of gas
producer interconnecting torque tube
with gearshaft in pilot's collective stick
assembly.
(10). Subtract engagement (remainder) from
0.750 inch (19.05 mm). In addition to
thickness of external snap ring, add PN
AN960C816 washers to end of gas
producer interconnecting torque tube to
a total thickness equal to the remainder
from 0.750 inch (19.05 mm) less
engagement. Equivalent washers in
varying thicknesses may be in combina
tion with PN AN960C816 washers.
(11). Reinstall pilot's collective stick assem
bly.
(12). Tighten pipe plug of gas producer
interconnecting torque tube to obtain
zero backlash between torque tube and
gearshaft in pilot's collective stick
assembly.
(13). Reinstall pilot's seat cover and access
door.
13. Collective Stick Friction Mechanism
Adjustment
(Ref. Figure 507)
For collective friction mecha
nism to be correctly adjusted for
maximum friction, three actions must occur
at same time: Drive gear must contact stick
fitting fixed stop; spring retainer housing
washer must contact retainer internal stop;
and gear assembly pin must be at approxi
mate peak of cam. Do not overtighten re
tainer nut so that retainer washer contacts
retainer stop before friction drive gear
reaches stick fitting stop. Adjustment that
does not produce approximately simulta
neous contact will allow excessive addition
CAUTION
CSP-HMI-2
al rotation of drive gear grip and cause ny

lon gears to be stripped.
(1). Remove friction mechanism guard.
(2). Rotate friction drive gear counterclock
wise to maximum friction position.
(3). Remove cotter pin, nut, retainer
assembly, teflon washer and one
phenolic washer.
(4). Slide gear assembly out far enough to
disengage it from idler gear. Use care to
keep other washers and spacer from
dropping.
(5). Remesh gear assembly with idler gear
to position pin on peak of cam. Check
that drive gear is still at maximum
friction stop position.
(6). If gear assembly does not correctly
position pin, reposition idler gear on
drive gear.
NOTE: Ratio of idler gear to gear assembly is

3:1, which permits fine adjustment. When
repositioning idler gear, be sure to reinstall
same number of washers that were removed
from between cotter pin and idler. These
washers limit gear end play to maximum of
0.010 inch (0.254 mm). When reassembled,
gear train must rotate freely.
(7). Reinstall phenolic washer, teflon
washer, retainer assembly and nut.
(8). With drive gear still at maximum
friction position, tighten retainer nut
until it just bottoms on retainer stop.
(9). Rotate friction drive gear clockwise to
minimum friction stop position, release
grip and perform checks in steps (10).
and (11). below.
(10). If pin has overridden low point of cam
(desired minimum friction position),
and grip-to-stick friction prevents
springback of pin to cam low point, turn
grip and move pin to low point.
NOTE: A drive gear that does not rotate freely

on collective stick tube should be replaced.
67-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
GUARD
WASHER(S)
(NOTE 1)
STICK FITTING
COTTER
PIN
FRICTION
DRIVE GEAR
(ROTATING
STOP)
PHENOLIC WASHERS
TEFLON
WASHER
RETAINER HOUSING
COTTER PIN
IDLER
GEAR
MAXIMUM
FRICTION
NUT
STICK FITTING
(FIXED STOP)
FRICTION CONTROL
WASHER
DRIVEN
GEAR
GEAR
ASSEMBLY
(NOTE 2) CAM
STOP
SPACE
R
SPRING
GUIDE
ALUMINUM
WASHER
FRICTION MECHANISM
GUARD
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.
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.
CAM ACTION
Figure 507. Collective Stick Friction Adjustment

Page 522
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67-10-00
G67-1016B
MAINTENANCE MANUAL
(11). With pin on cam low point, rotate
retainer assembly. It should turn freely
on shaft of gear assembly with only
light finger pressure. Adjust retainer
nut to nearest castellation that pro
duces zero friction (no drag on retainer
assembly during rotation). Install cotter
pin.
NOTE: If undesirable collective forces (light,

heavy or creeping) are reported to exist
in collective stick during flight, do not at
tempt to compensate by an increase in col
lective friction. Condition should be cor
rected elsewhere in control system (Ref.
Collective Controls Rigging (L/H Command)
and Collective Bungee Adjustment).
14. Collective Bungee Adjustment
(Ref. Figure 404) Adjustment of bungee system
is only permissible when helicopter is on
ground.
WARNING
D Do not attempt bungee adjustment in
flight, control jamming can result.
D Use all necessary precautions to pre
vent possible entry of any foreign ob
jects into controls linkage exposed
by removal of pilot's seat cover to
make adjustment of bungee system.
Do not attempt bungee adjustment in
flight, control jamming could result.
(1). Collective load forces are affected by
any adjustment made in main rotor
system. Comply with the following.
(a). Bungee adjustment should be made
only when main rotor blades are in
track and autorotation rpm is
established.
(b). Ensure that collective stick friction is
correctly adjusted.
(c). Perform flight evaluation of collective
forces with helicopter takeoff weight
at 2350 pounds (1066 kg), N2 at 103
percent and zero collective stick
friction.
CSP-HMI-2
(2). Prior to test flight, establish half-way

point of collective friction adjustment
grip (drive gear) as follows.
(a). Using soft, colored pencil; index
collective friction adjustment grip at
zero friction.
(b). Roll on maximum friction (approxi
mately 275 degrees rotation). Note
travel and reset friction grip halfway; hold in this position.
(c). Using dot of white paint or similar
method, temporarily mark top of
friction grip and adjacent exposed
area of collective stick. Friction
half-way index mark should be
visible to pilot.
(3). While helicopter is on ground, adjust
bungee to extent necessary to avoid any
upload in flat pitch at normal rpm. This
adjustment must also provide absence
of an excessive download or upload
while in hover and at 120 knots level
cruise. Helicopter must be landed after
each flight check, before making
corrective adjustment.
CAUTION
D After each bungee adjustment is made,
collective stick must be slowly moved
through its full travel range to assure
that there is no binding or restriction of
stick motion, and that spring does not bot
tom at overcenter position.
D Do not turn female bearing assembly
spring retainer while bungee installation
tool is spring loaded.
D When making adjustments to the bungee
over-center fitting, ensure nut turns
when bolt adjustment is made. Cotter pin
can be sheared if nut does not turn with
bolt.
(a). If an upload exists on ground at flat
pitch and normal rpm but a down
load prevails during hover and at 120
knot level cruise, turn bungee
adjustment retainer nut clockwise to
increase preload in bungee system.
67-10-00
Page 523
Revision 29
CSP-HMI-2
MAINTENANCE MANUAL
(b). To correct a download on ground

during flat pitch at normal rpm and
an upload condition during hover and
120 knot level cruise, turn bungee
adjustment retainer nut counter
clockwise to decrease preload in
bungee system.
(c). When a relatively constant upload
condition prevails during flat pitch at
normal rpm on the ground, at hover,
and at 120 knot level cruise, decrease
upload by turning bungee over-cent
er adjustment bolt clockwise.
(d). When a relatively constant download
condition prevails during flat pitch at
normal rpm on the ground, at hover,
and at 120 knot level cruise, decrease
download by turning bungee overcenter adjustment bolt counterclock
wise.
NOTE: Rotation of adjustment bolt head is the

only mechanical operation required to ad
just over-center position of bungee fitting.
(e). After minimum and balanced collec
tive forces are obtained, not more
than one-half of available collective
stick friction (friction grip at halfway index) must cancel collective
forces during flight test at 140 knots
level flight.
(f). If friction applied in step (e). above is
insufficient to cancel collective forces,
repeat adjustment procedure.
15. Cyclic Trim Actuator Bench Testing
(369D/E/FF 500N)
During following tests, do not

retract spring assembly (ram) so
that actuator length is less than 13.50 in
ches (34.29 cm) between attach bolt centers.
CAUTION
(4). With actuator spring assembly (ram)

approximately halfway between travel
limits (actuator length at 14.46 inches
(36.7284 cm) between attach bolt
centers), set up test dial indicator and
measure ram end play. End play must
be within 0.010-0.050 inch (0.254-1.27
mm). While adjusting screw, check that
there is thread-locking friction from
self-locking threaded insert. If end play
is excessive, replace actuator.
NOTE:
D When power is applied to the 8222M6
(369A7014) actuator, it will move in the
commanded direction until it reaches the
end of the stroke. If, during mid-travel,
an opposite power is applied simulta
neously, it will stop and remain stopped
until one or the other input is removed.
D When power is applied to the 8222M7
(369D27001) actuator, it will move, as
commanded, and like the M6, if power is
applied simultaneously in the opposite di
rection, it will stop. Unlike the M6, when
one of the inputs is removed, the M7 ac
tuator may or may not start. If it does not
restart, it has been latched into the off
state by the current surge generated upon
applying the second input. The M7 has a
built-in current limit circuit that latches
it off if the actuator current exceeds 2.7
amp. All power must be removed in order
to unlatch it.
(Ref. Figure 508)

(1). Connect cyclic trim actuator to test
harness and equipment.
(2). Mount actuator in suitable fixture that
allows vertical extension and retrac
tion.
(3). Turn on direct-current power and
adjust output to 25.75 - 26.25 volts.
Page 524
Revision 31
67-10-00
(5). Position test switch to RETRACT and

allow actuator ram to retract to a
length of 13.50 inches (34.29 cm)
between attach bolt centers.
(6). Using stopwatch, check actuator ram
travel time from fully retracted to fully
extended. Check time interval for
actuator motor tested.
MAINTENANCE MANUAL
NOTE: The times in the following charts are

maximum times. Some actuators will travel
at a greater speed than others. Intervals of
less time are acceptable.
Actuator Motor
Part number
Time Interval
(Seconds)
CSP-HMI-2
(0.508 mm) maximum with an overrid

ing (aiding) load; otherwise there must
be no overtravel.
(12). Remove 163 pound (74 kg) load and
repeat step (4). above.
369A7001
58.4
(13). Run actuator until arm is extended 1.75

inches (4.445 cm). Turn power off and
disconnect cyclic trim actuator.
369A7014 (High Speed)
38.0
16. Cyclic Trim Actuator Bench Testing (600N)
369D27001 (Super Fast)
17.5
(Ref. Figure 508)
(7). Measure length of extended ram.

Subtract measured result of step (5).
above from this value. Result must be
1.92 inches (4.8768 cm) minimum.
Do not run actuator against ex
tend limit stop with the
163-pound weight aiding actuation. Actua
tor thrust bearing may be damaged.
CAUTION
(8). Connect a 163 pound (74 kg) load to

actuator. Set switch at RETRACT.
Check time it takes ram to travel
1.72-1.78 inches (4.3688-4.5212 cm) to
retract stop. Check retraction time for
Actuator Motor
Part number
Time Interval
(Seconds)
369A7001
3050
369A7014 (High Speed)
1525
369D27001 (Super Fast)
712
(9). Operating current under load condi

tions must not exceed 1.2 amperes
running and 2.0 amperes stalled.
(10). Reduce voltage input to 21 volts.
Actuator ram must retract and extend.
Overtravel is limited to 0.020 inch
(0.508 mm) with an overriding (aiding)
load; otherwise there must be no
overtravel.
NOTE: It is not necessary to extend or retract

actuator ram more than 1/4 inch (6.35 mm)
for test in steps (10). above or (11). below.
(11). Increase input voltage to 28 volts.
Actuator arm must retract and extend.
(1). Connect cyclic trim actuator to test

harness and equipment.
(2). Mount actuator in suitable fixture that
allows vertical extension and retrac
tion.
(3). Turn on direct-current power and
adjust output to 25.75 - 26.25 volts.
During following tests, do not
retract spring assembly (ram) so
that actuator length is less than 13.50 in
ches between attach bolt centers.
CAUTION
(4). With actuator spring assembly (ram)

approximately halfway between travel
limits (actuator length at 14.46 inches
(36.7284 cm) between attach bolt
centers), set up test dial indicator and
measure ram end play. End play must
be within 0.010-0.050 inch (0.254-1.27
mm). While adjusting screw, check that
there is thread-locking friction from
self-locking threaded insert. If end play
is excessive, replace actuator.
NOTE: When power is applied to the 8222M21

(600N7001) actuator, it will move, as com
manded, and if power is applied simulta
neously in the opposite direction, it will
stop. When one of the inputs is removed, the
actuator may or may not start. If it does not
restart, it has been latched into the off state
by the current surge generated upon apply
ing the second input. The actuator has a
built-in current limit circuit that latches it
off if the actuator current exceeds 3.1 amp.
All power must be removed in order to un
latch it.
(5). Position test switch to RETRACT and
allow actuator ram to retract to a
length of 13.50 inches (34.29 cm)
between attach bolt centers.
67-10-00
Page 525
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2
(6). Using stopwatch, check actuator ram

travel time from fully retracted to fully
extended. Check time interval for
NOTE: The time in the following chart is maxi

mum time. Some actuators will travel at a
greater speed than others. Intervals of less
time are acceptable.
Actuator Motor
Part number
Time Interval
(Seconds)
600N70011 (longitudinal)
6.6
369D270013 (lateral)
11.0
600N70141 (lateral, with

YSAS)
11.0
(7). Measure length of extended ram.

Subtract measured result of step (5).
above from this value. Result must be
1.92 inches (4.8768 cm).
Do not run actuator against ex
tend limit stop with the
163-pound weight aiding actuation. Actua
tor thrust bearing may be damaged.
CAUTION
(8). Connect a 163 pound (74 kg) load to

actuator. Set switch at RETRACT.
Check time it takes ram to travel
1.72-1.78 inches (4.3688-4.5212 cm) to
retract stop. Check retraction time for
Page 526
Revision 36
67-10-00
Actuator Motor
Part number
Time Interval
(Seconds)
600N70011 (longitudinal)
712
369D270013 (lateral)
712
600N70141 (lateral, with

YSAS)
712
(9). Operating current under load condi

tions must not exceed 1.2 amperes
running and 2.0 amperes stalled.
Actuator ram must retract and extend.
(0.508 mm) with an overriding (aiding)
load; otherwise there must be no
overtravel.
NOTE: It is not necessary to extend or retract

actuator ram more than 1/4 inch (6.35 mm)
for test in steps (10). above or (11). below.
Actuator arm must retract and extend.
(0.508 mm) maximum with an overrid
ing (aiding) load; otherwise there must
be no overtravel.
(12). Remove 163 pound (74 kg) load and
repeat step (4). above.
(13). Run actuator until arm is extended 1.75
inches (4.445 cm). Turn power off and
disconnect cyclic trim actuator.
MAINTENANCE MANUAL
CSP-HMI-2
SPRING
ADAPTER
SPRING GUIDE
TEST LOAD
CONNECTION
SPRING ADAPTER SCREW

ADAPTER
TRIM TUBE
ACTUATOR
TRIM DECAL
SELF-LOCKING THREAD INSERT
SPRING
WASHER
NOTE
ACTUATOR
RIVET
(4 PLCS)
SPRING PIN
TRIM TUBE
ACTUATOR HOUSING
ADAPTER
NOTE:
REPLACEMENT PARTS HAVE NUTPLATE RIVETED
IN PLACE. WASHER, NUT AND COTTER PIN NOT REQUIRED.
ITEM
NO.
ACTUATOR
HOUSING
1.00 IN.
(2.54 CM)
PIN INSTALLATION
HOLE
TEST EQUIPMENT
STOPWATCH, MARKED IN 1/10-SECOND

INCREMENTS (MINERVA OR EQUIVALENT).
6 IN. (15.25 CM) SCALE.
DC VOLTMETER, 0-50 VOLTS (WESTON

MODEL 931 OR EQUIVALENT).
ACTUATOR
TUBE
TRIM TUBE - INSTALLATION
SPDT SWITCH
DC MILLIAMMETER, 0-5 AMPERES (WESTON

VARIABLE DC POWER SUPPLY, 10-36 VOLTS

(N.J.E. MODEL SY 36-10 OR EQUIVALENT).
DIAL INDICATOR GAGE (BROWN AND SHARP,

SWITCH, SPDT: CENTER OFF.
26 VDC
ELECTRICAL
POWER
SOURCE
M1
EXTEND
MA
OFF
RETRACT
M2
A
B
C
TEST HOOKUP
CONNECTOR
G67-1017B
Figure 508. Cyclic Trim Actuator Assembly
67-10-00
Page 527
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
P9J
CB102
TRIM
TB1-2
1 5A 2
A
P130J
CYCLIC TRIM
J109
UP
S
TB1-3
V
LAT
P106
TRIM
MOTOR A
DN
S107
B102
RED
RED
BLU
RED
BLU
E6
R
BLU
TB1-9
A
B
TB1-1
U
LONG
P105
TRIM
MOTOR A
B101
B
C
RED
RED
BLU
E25
BLU
E5
LEFT CYCLIC
STICK GRIP
E7
T
RIGHT CYCLIC
STICK GRIP
G67-1000
Figure 509. Cyclic Trim Wiring Diagram

Page 528
Revision 21
67-10-00
MAINTENANCE MANUAL
CSP-HMI-2
P112
L90A16
C110A20
C108E20
C109A20
INCR
S108
RPM
TRIM
D
E
F
H
A
B
C
J
K
DECR
CO-PILOT'S COLLECTIVE
STICK
SPARE PINS
WIRING DIAGRAM
N2 GOVERNOR SWITCH
(NOTE 1)
WIRE GUIDE
AWG SIZE 4
VINYL TUBING
(NOTE 3)
AWG SIZE 12
VINYL TUBING
(NOTE 2)
AWG SIZE 4
VINYL TUBING
NYLON STRAP
GROUND TERMINAL
TAPE
(NOTE 4)
AWG SIZE 8
VINYL TUBING
NOTES:
1. DISCARD 29-761 LOCKING RING BEFORE
INSTALLING SWITCH.
2. ENCASE EACH WIRE FULL LENGTH WITH AWG
SIZE 12 VINYL TUBING.
3. AWG SIZE 4 TUBING SHOULD NOT EXTEND INSIDE
CONTROL STICK MORE THAN 0.060 IN. (1.524 MM).
4. WRAP WIRE BUNDLE WITH CT93C TAPE AS
REQUIRED.
ROTATED
CABLE ROUTING
G67-1018A
Figure 510. Wiring Diagram and Cable Routing (Collective Stick)
67-10-00
Page 529
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
ICS
7
5
6
4
8
V
U
S
R
X
UNUSED PINS
B
A
H
J
K
N
M
L
E
D
C
F
S112
RADIO
SW
WIRE BUNDLE
THRU STICK
XMT
RT
DW
S107
CYCLIC
TRIM
LEFT
UP
WIRE BUNDLE
THRU STICK
CYCLIC CONTROL
STICK GRIP
AWG SIZE 3
VINYL TUBING
(NOTE 1)
WIRING DIAGRAM
AWG SIZE 3
VINYL TUBING
(NOTE 1)
NYLON STRAP
LOCATION OPTIONAL
CYCLIC CONTROL STICK
AWG SIZE 0
VINYL TUBING
(NOTE 2)
NOTES:
1. WIRES FURNISHED WITH GRIP. SPLIT INTO TWO
EQUAL BUNDLES AND RUN EACH BUNDLE THRU
HOLES AS SHOWN. ENCASE EACH BUNDLE IN
AWG SIZE 3 VINYL TUBING.
2. ENCASE TWO BUNDLES IN AWG SIZE 0 VINYL
TUBING. END OF BUNDLE LOCATION IS
OPTIONAL. TAPE END OF TUBING WITH CT93C
TAPE AS REQUIRED.
CABLE ROUTING
G671019
Figure 511. Wiring Diagram and Cable Routing (Cyclic Stick)

Page 530
Revision 21
67-10-00
MAINTENANCE MANUAL
CSP-HMI-2

INSPECTION/CHECK
1. TunnelRouted Control Rod Inspection
(Ref. Figure 601)
(1). Inspect rod end bearings for binding
and excessive wear, 0.040 inch (1.016
mm) maximum axial play.
(2). Inspect control rod for surface damage
and evidence of bending.
(3). Inspect upper two inches (5.08 cm) of
each tunnel routed control rod for wear.
Replace rods with wear depth exceeding
0.020 inch (0.508 mm), or having outer
diameter (OD) less than minimum
which follow.
Control Rod
Minimum OD
Inches (mm)
Collective mixer
0.470
(11.938)
Longitudinal mixer
0.520
(13.208)
Lateral mixer
0.530
(13.462)
Tail rotor
0.470
(11.938))
(4). Inspect for loose rivet at fixed rod end

(lower end).
CAUTION
D When tightening loosened jam nuts on
rod ends as in steps (5). and (6). or (7). be
low, always hold rod end with wrench.
D Do not disconnect rod ends from mixer as
sembly to perform this inspection except
as instructed.
(5). Inspect upper end of tunnel-routed
control rod assemblies for excessive rod
end play.
(a). Loosen jam nut minimum of two
threads.
(b). Preload rod end against either side of
attaching clevis with light finger
pressure to eliminate play other than
in area being inspected and effect of
bearing play.
(c). Lightly deflect tube laterally from
one extreme to other (maintain
preload).
(d). With dial indicator or 6 inch (15.25

cm) rule, measure total horizontal
movement at top of tube where rod
end enters.
(e). If total movement exceeds 1/16 inch
(1.5875 mm) rod assembly must be
replaced with serviceable parts.
(f). Movement less than 3/64 inch
(1.190625 mm) is considered negligi
ble.
(g). If movement is between 3/64 and 1/16
inch (1.5875 and 1.190625 mm),
inspect rod threads, step (6)., or rod
insert, step (7).
(6). Rod Assembly P/N - 369A7007-5,
369A7009-5, 369A7011-5 and
369A7012-5 - For early control tubes
without swaged inserts:
(a). If total lateral movement of upper
end of tube is found to be between
3/64 and 1/16 inch (1.5875 and
1.190625 mm), check rod threads.
(b). Disconnect upper (adjustable) rod
end from control system.
(c). Screw rod end completely out of
control rod.
(d). Use 0.339 inch (8.6106 mm) diameter
drill (size R), free of burrs, to check
rod threads.
1). If drill can be inserted, rod assem
bly is unserviceable and must be
replaced.
2). If drill cannot be inserted, rod is
serviceable.
(e). Reinstall rod end, reconnect rod to
control system and tighten jam nut.
(7). Rod Assembly P/N - 369A7007-9,
369A7009-9, 369A7011-9 and
369A7012-9 - For current control rods
with swaged inserts:
(a). Disconnect upper (adjustable) rod
end from control system.
67-10-00
Page 601
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
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)
LONGITUDINAL MIXER
DIM L
INCH (CM)
56.6
(143.9418)
56.51 (143.5354)
LATERAL MIXER
55.67
(141.4018)
COLLECTIVE MIXER
53.14
(134.9756)
CONTROL ROD
COLLECTIVE PITCH FITTING
2.00 IN. (5.08 CM

(NOTE)
RIVET
L
MAXIMUM ALLOWABLE AXIAL
PLAY 0.040 IN. (1.016 MM)
CONTROLS
SUPPORT BRACKET
LONGITUDINAL IDLER
BELLCRANK
LATERAL IDLER BELLCRANK
NOTE:
INSPECT FOR WEAR. REPLACE RODS WITH WEAR
DEPTH EXCEEDING 0.020 IN. (0.508 MM) OR HAVING
OD LESS THAN ALLOWABLE MINIMUM.
G67-1020A
Figure 601. TunnelRouted Control Rod Inspection

Page 602
Revision 21
67-10-00
MAINTENANCE MANUAL
(b). Back off jam nut sufficiently enough
to inspect insert.
(c). Inspect insert for proper installation,
flush to a maximum of 0.010 inch
(0.254 mm) below the surface of the
rod.
(d). Check that insert is tight inside of
rod.
1). If insert is loose or protrudes above
surface of rod, rod assembly is
unserviceable and must be repla
ced.
2). If insert is tight and swaged flush
to 0.010 inch (0.254 mm) below the
surface of the rod, rod is servi
ceable.
(e). Reconnect rod to control system and
tighten jam nut.
(8). Check rigging of re-connected control
system.
Inspection
(Ref. Figure 403)
(1). Inspect bearings in bellcranks for
binding.
(2). Perform fluorescent dye penetrant
inspection on any suspected part.
NOTE: Parts identified with double asterisk

(**) (Ref. Figure 403) may be either magne
sium or aluminum alloy. (For corrosion con
trol and identification of magnesium and
aluminum alloys, Ref. Sec. 20-40-00.)
3. Pilots Collective Pitch Stick Inspection
(Ref. Figure 602)
(1). Inspect bearings for binding or play.
(2). Inspect all gears for cracks, and
chipped or broken teeth.
(3). Inspect stick tube and gas producer
control tube for corrosion, deformation
and loose rivets.
CSP-HMI-2
NOTE: Pitch stick housing and cap may be ei

ther magnesium or alloy casting. (For corro
sion control and identification of magne
sium or aluminum alloys, Ref. Sec.
20-40-00.)
4. Copilots Collective Pitch Stick Inspection
(Ref. Figure 603)
(1). Inspect bearings for binding or play.
(2). Inspect all gears for cracks, and
chipped or broken teeth.
(3). Inspect stick tube and gas producer
control tube for corrosion, deformation
and loose rivets.
5. Collective Stick Friction Mechanism
Operational Check
(Ref. Figure 602)
(1). Remove guard from collective stick.
(2). Check that teeth of friction drive gear,
idler gear, and driven gear are not
stripped or otherwise damaged.
(3). Rotate friction drive gear grip counter
clockwise to maximum friction stop;
gear train must rotate freely. Check
position of shaft assembly pin. Pin
should be at highest point of cam.
(4). If pin is not at approximate peak of cam
or has overridden peak, friction mecha
nism must be readjusted. If pin is in
correct position, continue with step (5).
below.
(5). Rotate drive gear grip clockwise to
minimum friction position and release
grip; gear train must rotate freely. Pin
should be at approximate low point of
cam.
(6). With pin on low point of cam, hand
rotate spring release housing. If there is
drag on retainer, there is friction on
guide and collective friction must be
readjusted. If retainer rotates freely,
without obvious play, low point friction
setting is correct.
67-10-00
Page 603
Revision 28
CSP-HMI-2
MAINTENANCE MANUAL
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
Revision 39
67-10-00
MAINTENANCE MANUAL
CSP-HMI-2
MOUNTING DISTANCE SHIM

(CUT)
BEARING
(NOTE 2)
COVER
GAS PRODUCER CONTROL TUBE

PINION
HOUSING SOCKET
(NOTE 1)
BEARING
(NOTE 2)
BACKLASH SHIM
GEARSHAFT
BACKLASH SHIM
NYLON STRAP
STICK TUBE
ELECTRICAL
WIRING
BEARING
(NOTE 2)
CONNECTOR
CAP
NOTE 1
SETSCREW
PIN
WIRE GUIDE
SETSCREW
ADJUSTMENT NUT
THROTTLE GRIP
GRIP ATTACH BOLT

SETSCREW
SWITCH HOUSING
NOTES:
1. SURFACES IN CONTACT DURING ROTATION
TO BE LUBRICATED OR OTHERWISE NOTED,
WITH GREASE (CM116).
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)
67-10-00
Page 605
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2

Tube Inspection
(Ref. Figure 404)
(1). Remove pilot's seat cover, control access
door, and left side foot support fairing.
(2). Inspect collective interconnecting
torque tube for cracks, bends or
distortions.
(3). Inspect bungee bracket and bungee
fitting for security and condition.
Ensure cotter pin in over-center
adjustment bolt is not sheared.
(4). Inspect all accessible rivets for play.
inspect support bearings for security
and evidence of binding.
(5). Reinstall pilot's seat cover, controls
access door and foot support fairing.
7. Collective Bungee Inspection
(Ref. Figure 407)
NOTE: Replace any bungee parts in question

able condition.
NOTE: Bungee support bracket may be either

an aluminum or magnesium casting. (For
corrosion control and identification of mag
nesium and aluminum alloys, Ref. Sec.
20-40-00.)
Inspection
(Ref. Figure 408)
(1). Inspect all bearings for binding or play.
(2). Inspect gears for cracks, and chipped or
broken teeth.
(3). Inspect all components for cracks,
corrosion and deformation.
NOTE: Bellcrank and idler may be either an

aluminum or magnesium casting. (For cor
rosion control and identification of magne
sium and aluminum alloy parts, Ref. Sec.
20-40-00.)
9. Pilots Cyclic Control Stick Inspection
(Ref. Figure 604)
NOTE:
D For this inspection, friction stop nut must
be loosened.
D Socket may be either an aluminum or
magnesium casting. (For corrosion con
aluminum alloys, Ref. Sec. 20-40-00.)
(1). Inspect bearings in male and female

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
spring should be approximately 0.580
inch (14.732 mm).
(3). Inspect spring for evidence of deforma

tion. Free length of spring must be;
(a). Effectivity: 369D/E/FF-500N, 3.64
0.06 inches (92.456 1.524 mm)
(b). Effectivity: 600N, 4.50 0.025 inches
(114.30 +0.635 mm)
(3). To check installation, loosen lateral and

longitudinal friction knobs, move cyclic
control stick and check for binding or
unusual noises. Check that rod end
bearings of pilot's lateral control rod do
not jam when stick is full forward and
full aft.
NOTE: Set minimum friction so that phenolic

(4). Inspect male bearing rod for cracks,
evidence of binding, corrosion and
deformation.
Page 606
Revision 39
67-10-00
washers can be slightly turned by hand. If

minimum friction is set too low, stick shake
will occur.
MAINTENANCE MANUAL
10. Copilots Cyclic Control Stick Inspection
(Ref. Figure 604)
CSP-HMI-2
(5). Replace one-way lock if exposed portion

of piston has nicks, scratches or wear
penetrates chrome plating.
Item
Nomenclature
(6). Replace external mounting bushing if

outside diameter is less than 0.4979
inch (12.64666 mm).
CM114
Petrolatum
(7). One-way lock must be replaced if nicks,

dents and scratches to body exceed
0.040 inch (1.016 mm) depth after
repair.
(1). Inspect quick-release pins for secure

fit, also stick tube and socket for
security, distortion and corrosion.
Check for presence of a light coating of
grease in socket and on stick tube end.
Apply thin coating of petrolatum
(CM114), on contact surfaces.
(2). To check controls installation, loosen
lateral and longitudinal friction knobs,
move stick and check for binding or
unusual noises. Check that rod end
bearings of copilot's lateral control rod
do not jam throughout full range of
stick travel.
NOTE: Set minimum friction so that phenolic

washers can be slightly turned by hand. If
minimum friction is set too low, stick shake
will occur.
11. OneWay Lock Inspection
(1). Replace reservoir if cracked, leaking or
has loose or damaged filler cap (Ref.
COM).

to remain on piston as a result of wiping
contact with the piston seal. This should not
be considered leakage or cause for rejection.
(2). Replace forward input rod end bearing
if bearing binds.
Do not attempt to adjust larger
(aft) of two rod ends and do not
remove cotter pin; malfunction of lock will
likely result. (For overhaul and replacement
instructions, Ref. COM).
CAUTION
(3). Replace one-way lock if aft (output) end

bearing binds.
(4). Replace protective boot if it is cracked,
torn or deteriorated.
(8). One-way lock must be replaced if end

play between rod ends exceeds 0.010
inch (0.254 mm) measured at input
(forward) end.
(9). One-way lock must be replaced if
leaking, except as noted for reservoir in
step (1). above.
12. Cyclic Trim Actuator Inspection
(Ref. Figure 508)
(1). Inspect electrical connector for evidence
of damage, and broken or missing
contacts.
(2). Inspect exterior of trim actuator for
evidence of damage and deformation.
(3). When actuator speed (response and/or
travel time) is questionable, perform
bench test (Ref. Cyclic Trim Actuator
Bench Test).
13. Cyclic Control System Operational Check
Excessive slack or free play in the cyclic
control system may result in premature
control stop contact or roughness of the
helicopter and fanning out (out of track) of the
main rotor tip path plane (Ref. Sec.
18-10-00/60). Areas to be checked include
mixer linkages (Ref. Sec. 62-30-00/60) at the
base of the main rotor mast, rotating controls
above the swashplate, trim actuators, and
cyclic control stick in the pilot's compartment.
If total free play at the top of the cyclic grip
exceeds 3/8 inch (9.525 mm) in either longitu
dinal or lateral direction, perform the follow
ing:
67-10-00
Page 607
Revision 39
MAINTENANCE MANUAL
CSP-HMI-2
NOTE 2
SLEEVE BUSHING
NOTE 2
LINK
FRICTION
MECHANISM STUD
KNOB
(NOTE 4)
SPRING
DISC
RETAINER
TORQUE TUBE
CAP NUT
(NOTE 3, 5)
NOTES:
ABOVE OUTSIDE SURFACE OF PART AFTER BOLT IS
TIGHTENED.
2. WASHERS ARRANGED TO ALIGN LINK WITH TORQUE
TUBE; LOOSELY SPACED WITH THREE WASHERS.
3. CAP NUT ADJUSTED TO STOP KNOB WITH SPRING AT
FREE LENGTH 1/32 IN (0.79375 MM).
4. CYCLIC STICK LATERAL FRICTION MECHANISM IS SIMILAR
(SEE MAIN VIEW).
5. IF NUT CAN BE TURNED WITH FINGER PRESSURE, NUT
MUST BE REPLACED.

FRICTION MECHANISM
(NOTE 4)
SCREW
PILOT'S LATERAL
CONTROL ROD
SLOTTED BUSHING
(NOTE 1)
NYLON STRAP AND

MOUNTING PLATE
STA. 67 LATERAL
CYCLIC BELLCRANK
DIM L
ANGLE A
INCH (CM)
12.63
PILOT'S LATERAL
42
(32.0802) 6.65
STA 70 LATERAL
90
(16.891)
PLAY 0.040 IN. (1.016 MM)
(INBOARD END) RIVET
CONTROL ROD
LATERAL CONTROL ROD

INBOARD END ATTACHMENT
G67-1022
Figure 604. Cyclic Stick and Friction Inspection

Page 608
Revision 28
67-10-00
MAINTENANCE MANUAL
When replacing control rod
ends, measure length accurate
ly to ensure that replacement rod is exactly
the same length as the original. Control rods
are factory adjusted at installation to pro
vide necessary clearances.
CAUTION
(1). With the rotor stopped, check for free

play at the cyclic stick grip. While
moving cyclic stick through free play
range, have assistant check controls
mixer area for any free play motion.
(a). Check pivot bolt areas where mixer
bellcranks attach to control rod
bellcranks. If free play is noted,
remove pivot bolts and inspect for
wear and/or play between bolts,
bushings, and bellcranks. Replace
parts as required.
(b). Check control rod assemblies by
Pressing sidewards near the rod end
bearing. Replace rod end as required.
CSP-HMI-2
(c). Check lower end of cyclic stick and

play at attachment of cyclic intercon
necting torque tube. Replace bearings
and bushings as required.
(4). Check for axial play in cyclic trim
actuators.
(a). Disconnect lower end of cyclic control
rods from aft ends of trim actuators
and check for free play. Remove free
play by adjusting spring adjustment
screw located in center recess at aft
end of actuator. If end play exceeds
0.0075 inch (0.1905 mm), replace
actuator. Reconnect control rod.
(b). Check for free play in attachments
and linkages between trim actuators
and cyclic pitch interconnecting
torque tube. Replace parts as re
quired; Install controls tunnel access
door.
14. Main Rotor Flight Control System
600Hour Inspection
(Ref. Figure 508)
(2). Check for free play in blade pitch links

which connect rotating swashplate to
blade pitch housings. Replace rod ends
having free play in excess of 0.040 inch
(1.016 mm) side motion.
NOTE: Rod ends on pitch links should be

checked under a no-load condition which is
best achieved by removing blades.
(3). While moving cyclic stick through free
play range, check lower controls for free
play motion; Remove controls tunnel
access door.
(a). Check control rod assemblies by
pressing sidewards near the rod end
bearings. Looseness indicates axial
play in rod end bearing. Replace rod
end as required.
(b). Check pivot bolt areas of lateral and
longitudinal bellcranks. If free play is
noted, remove pivot bolts and inspect
for wear and/or play between bolts,
bushings, and bellcranks. Replace
parts as required.
(1). With the rotor stopped, check for free

play at the cyclic stick grip.
NOTE: If total free play at the top of the cyclic

grip is 3/8 inch (9.525 mm) or less in either
longitudinal or lateral direction inspection
is not required. If total free play at the top of
the cyclic grip exceeds 3/8 inch (9.525 mm)
in either longitudinal or lateral direction,
(2). While moving cyclic stick through free
play range, have assistant check
controls mixer area for any free play
motion.
(a). Check each pivot bolt area where
lateral mixer bellcranks attach to
collective bellcranks. If free play is
noted at the lateral bellcranks,
remove pivot bolts and inspect for
wear and/or looseness between bolt,
bushings and bellcrank. Replace
parts as required.
(b). Check control rod assemblies by
pressing sidewards near the rod end
bearings; motion here indicates axial
play in rod end bearing. Replace rod
end as required.
67-10-00
Page 609
Revision 39
CSP-HMI-2
MAINTENANCE MANUAL
(3). Check for free play in blade pitch links

which connect rotating swashplate to
blade pitch housings.
NOTE: Both rod ends on each pitch link should

be checked under a no load condition which
is best achieved by removing blades. Re
place rod ends having free play in excess of
0.040 inch (1.016 mm) side motion.
(4). Inspect lower controls for slack between
cyclic stick and attachment of the
longitudinal and lateral control rods to
the mixer mechanisms, located just
forward of the main rotor mast.
(5). Check lower end of cyclic stick for
looseness at the attachment point to
cyclic pitch interconnecting torque tube.
Replace bearings and/or bushings as
required.
(a). Disconnect lower end of longitudinal

cyclic control rod from aft end of trim
actuator and check for axial play.
Remove free play by adjusting spring
adapter screw located in center
recess at aft end of actuator assem
bly.
(b). Check for looseness in longitudinal
and lateral cyclic control rod ends,
located in tunnel. Replace rod ends
as required.
(c). Check for free play in attachments
and linkages between trim actuators
and cyclic pitch interconnecting
torque tube. Replace parts as re
quired. Reinstall access door.
When replacing adjustable rod
ends, measure length accurate
ly to ensure that replacement rod is exactly
same length as original. Mixer control rods
are factory adjusted at original installation
to provide necessary clearances.
CAUTION
(6). Check interconnecting torque tube

bearings for free play; replace bearings
if excessive free play is noted.
(8). Recheck for free play at the top of the

cyclic stick grip; as required, repeat
steps (1). thru (3). until total free play
at top of grip is 3/8 inch (9.525 mm) or
less in either longitudinal or lateral
direction.
(7). Check for axial play in cyclic trim

actuators (remove access door at lower
end of pilot's bulkhead center tunnel in
the cargo compartment).
(9). If replacement of parts is required

perform rigging of main rotor controls
(Ref. Collective Controls Rigging and
Cyclic Controls Rigging).
Page 610
Revision 39
67-10-00
MAINTENANCE MANUAL
CSP-HMI-2

REPAIRS
1. TunnelRouted Control Rod Repair
A. Control Tube End Sleeve Installation
Item
Nomenclature
CM219
CM229
Methyl-ethyl-ketone
Paint remover
CM230
CM231
Paint remover
Plastic bead, spherical 20 - 30 mesh
CM318
CM409
Primer
Adhesive, epoxy
(Ref. Figure 401)

(1). Perform straightness check on control
rod that appears bent or bowed. Total
length of any tunnel-routed rod
(excluding rod ends) must be straight
within 0.050 inch (1.270 mm), with
straightness variation limited to
maximum of 0.010 inch (0.254 mm) in
each foot of length.
Dye-check for cracking
WARNING must always be performed
after cold-straightening. Replace
cracked rod, or cracked or bent rod
end.
(2). Cold-straighten bent rod that is not
within tolerance (step (1). above)
provided there are no nicks or sharp
dents in bent length. Do not use rod
ends to support rod during straighten
ing.
Use care when drilling to re
move or install riveted rod end;
rod end is steel and rod is aluminum.
CAUTION
(3). Replace control rod end if bearing axial

play is more than 0.040 inch (1.016
mm). Set initial control rod length (Ref.
Figure 601).
2. TunnelRouted Control Tube Inspection

and Sleeve Installation
(Ref. Figure 801) The following procedures are
for inspection and installation of reinforcing
sleeves to the tunnel-routed control tubes.
(1). Remove all four control rods (Ref.

Tunnel-Routed Control Rod Replace
ment).
(2). Using paint remover (CM229, CM230
or CM231) remove paint approximately
six inches back from end of each tube,
tape and cover-rap remaining area of
tube.
NOTE: Control tubes that are cracked must be

removed from service.
(3). Dye penetrant inspect external surface
of stripped area for cracks.
(a). Cracked are indicated by heavy bleed
out. It may be necessary to wipe off
and reapply the developer to distin
guish between surface defects caused
during swaging operation.
(b). Light penetrant indications are not
cause for rejection.
(4). If no cracks are found; inspected control
tube can be reworked for sleeve instal
lation. All four control tubes are to be
reworked as follows:
(a). Measure and record length of control
tubes for reinstalling rod ends and to
prevent rerigging after tube rein
stallation.
67-10-00
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Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
0.097-0.102 IN.
(2.4638-2.5908 MM) DIA
0.340 IN. *
(8.635 CM)
SLEEVE
CONTROL TUBE
A DIA
0.750 IN. *
(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
Rod No.
369A7007
369A7009
369A7011
369A7012
Sleeve No.
369D27013
Dim A
inch (mm)
Tube O.D.
inch (mm)
0.5400.545
(13.71613.843)
0.5010.530
(12.725413.462)
0.5100.515
(12.95413.081)
0.4700.500
(11.93812.70)
0.5900.595
(14.98615.113)
0.5510.580
(13.995414.732)
0.5600.565
(14.22414.351)
0.5200.550
(13.20813.970)
0.5700.575
(14.47814.605)
0.5300.560
(13.46214.224)
NOTES:
(1) Material; 2024T351 or T4 (QQA 225/6) bar or round stock
(2) Break sharp edges 0.0050.015 inch (0.1270.381 mm).
(3) Surface finish 125 RMS.
(4) Chemical film per MILC5541.
(5) Tolerance * 0.010 inch (0.254 mm).
Figure 801. Sleeve Fabrication and Installation

Page 802
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67-10-00
MAINTENANCE MANUAL
Drilled out rivets may damage
threads upon removal. Visually
inspect control tube threads for damage
from rivet and rod end removal. Replace
damaged control tubes. Drilled rod ends are
matched drilled to each control tube and
must be reinstalled into control tube end
from which removed.
CAUTION
(b). Remove rod ends, MS20470AD3

rivets must be removed from fixed
end.
(c). Measure outside diameter of control
tube end and select proper sleeve.
(d). Temporarily install sleeve onto
control tubes. Align sleeve and
control tube witness hole. If sleeve
protrudes past end of control tube,
trim end of sleeve flush to 0.000 inch
(0.000 mm) or back 0.080 inch (2.032
mm) from end of tube.
NOTE: Bond integrity is dependent on clean

surfaces.
(e). Thoroughly clean end of control tube
and interior surface of sleeve with
lint free cloth and MEK (CM219) or
equivalent.
(f). Mix epoxy adhesive (CM409) per
(g). Remove excessive adhesive with lint
free cloth moistened with MEK or
equivalent. Do not saturate the
cleaning cloth. Remove adhesive from
witness holes.
CAUTION
CSP-HMI-2
Do not use heat gun. Use of heat

lamp is acceptable.
(i). Allow to cure for 24 hours at mini

mum ambient temperature of 68F
(20C) (alternate cure 4 hours at
115-140F (47-60C)).
(j). Repeat procedure for ends of each
control tube.
(k). Using primer (CM318), touch-up
repaired area(s) of control tube.
(l). Install rod ends into ends in which it
was removed. On fixed rod end, align
witness/rivet hole in sleeve and tube
with rivet hole in rod end. Drill (#40)
thru opposite end of sleeve. Rivet
fixed end with MS20470AD3-15
rivet.
(m). Adjust each control tube to its
previously measured length and
paint the control tube ends with
primer. Paint adjustable ends of
control tube flat black.
(n). Reidentifiy, with permanent ink, the
control tubes that have been re
worked (Ref. Table 801).
Table 801. Control Tube ReIdentification
Old Part Number
New Reworked Part Number
369A7007
369A70075
369A7009
369A70095
369A7011
369A70115
369A7012
369A70125
(o). Rework control tube boot (Ref.

Figure 802).
If control rod is not accurately
measured, flight controls will
require rerigging.
CAUTION
(h). Plug end of control tube to prevent
adhesive from entering threads. Bond
sleeve to control tube. Apply adhesive
to both surfaces and install sleeve.
Align witness/rivet hole in sleeve and
tube.
(p). Reinstall control tubes. Reinstall

trimmed boot with vertical seam
facing aft. Check flight controls for
interference or binding.
67-10-00
Page 803
Revision 21
CSP-HMI-2
MAINTENANCE MANUAL
B. Control Tube Straight Area Sleeve

Installation
This repair is permissible on the straight area
of the tube only and increases the outside
diameter.
Item
CM219
CM229
CM230
CM231
CM318
CM409
Nomenclature
Methyl-ethyl-ketone
Paint remover
Paint remover
Plastic bead, spherical 20 - 30 mesh
Primer
Adhesive, epoxy
NOTE:
D Ensure adequate clearance exists prior to
performing the repair. Determine and re
pair condition that caused damage.
D Maximum length of repair sleeve is 6 in
ches (15.24 cm). Two sleeve repairs per
mitted per control tube.
(1). Remove damaged control rod(s) (Ref.
Tunnel-Routed Control Rod Replace
ment).
Page 804
Revision 21
67-10-00
(2). Tape around area to be repaired.

(3). Using paint remover (CM229, CM230
or CM231), strip paint 1.0 inch (2.54
cm) beyond area of repair.
(4). Polish out burrs and sharp edges.
Ensure defects do not exceed allowable
limits (Ref. Table 801). Dye penetrant
inspect area per MIL-I-25135; no
cracks allowed.
NOTE: Bond integrity is dependent on clean

surfaces.
(a). Thoroughly clean repair area of
control tube and interior surface of
sleeve with lint free cloth and MEK
(CM219) or equivalent.
(b). Mix epoxy adhesive (CM409) per
(c). Apply adhesive to both surfaces and
install sleeve.
(d). Remove excessive adhesive with lint
free cloth moistened with MEK or
equivalent. Do not saturate the
cleaning cloth.
MAINTENANCE MANUAL
CSP-HMI-2
Table 802. Control Tube Straight Area Repair Limits

Nicks and Gouges (2)
Dents and Depressions (2)
Tube
Max. Depth
Max. Depth
Max. Depth
Max. Depth
369A W/O Repair (4) With Repair (1) W/O Repair (4) With Repair (1)
Inch (mm)
inch (mm)
inch (mm)
inch (mm)
Repair Sleeve (3)

O.D.
inch (cm)
Wall
Thickness
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
7011
7012
0.010 (0.254)
0.025 (0.635)
0.010 (0.254)
0.025 (0.635)
1.625 4.1275)
(3.81)
0.049 (1.2446)
0.049 (1.2446)
NOTES:
(1) Sleeve repair not permitted in tapered area. Two sleeve repairs per control tube. Maximum defect area
0.375 in2 (2.41935 cm2) per sleeve.
(2) Must be free of burrs and sharp areas.
(3) Aluminum tube 6061T6 WWT700/6 or 2024T3 WWT700/3. Alternate: field fabricate from
2024T351 or 2024T4 (QQA225/6 or QQA200/3). Inside diameter to be 0.0100.025 inch
(0.2540.635 mm) larger than outside diameter of tube to be repaired. Outside diameter as listed in table,
0.010 inch (0.254 mm) and concentric to inside diameter 0.005 inch (0.127 mm). Maximum length of
repair sleeve 6 inches (15.24 cm). Break sharp edges 0.0050.015 inch (0.1270.381 mm).
(4) Maximum defect area without repair 0.10 in2 (0.64516 cm2) total. For threaded area, last 2 inches (5.08
cm) of both ends, maximum depth of defect 0.020 inch (0.508 mm).
CAUTION
Do not use heat gun. Use of heat

lamp is acceptable.
(e). Allow to cure for 24 hours at mini

mum ambient temperature of 68F
(20C) (alternate cure 4 hours at
115-140F (47-60C)).
(f). Using primer (CM318), touch-up
repaired area(s) of control tube.
Disassembly
(Ref. Figure 403)
NOTE: In following steps, do not remove

slotted bushings unless replacement is nec
essary.
(1). Remove lateral idler bellcrank.
(2). Remove tail rotor bellcrank.
(3). Remove longitudinal idler bellcrank.
NOTE: Shim washers between longitudinal

idler bellcrank and support brackets align
one-way lock for no sideload. Keep shim
washers with bracket for use during reas
sembly.

Repair
(Ref. Figure 403)
Item
CM321
CM431
Nomenclature
(1). Replace unserviceable bearings. Install

new bearing with surface primer
(CM321) and grade A locking compound
(CM431).
NOTE: When idler bellcrank bearings are re

placed, make sure that idler bellcrank
spacers are reinstalled between bearings.
(2). Replace bellcranks or controls support
bracket that has distortion, cracks or
elongated holes.
Reassembly
(Ref. Figure 403)
(1). Install longitudinal idler bellcrank.
Check that slotted bushing is in place
67-10-00
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Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
in support bracket lug, and reinstall

shim washers between bellcrank and
bracket for no sideload of one-way lock.
NOTE: When performing following steps, en

sure that slotted bushing is in support
bracket lug.
(2). Install lateral idler bellcrank.
(3). Install tail rotor bellcrank.
6. Pilots Collective Pitch Stick Disassembly
(L/H Command)
NOTE: Removal of additional setscrew is also

required on helicopters equipped with cargo
release mechanism.
(3). Cut nylon strap or twine that secures
electrical wiring to stick tube. Push
wire slack into stick, carefully pull
housing and wiring from end of stick
tube and disconnect wiring from
switches.
(4). Remove setscrew and wire guide from
forward end of stick. Tie string on each
wire bundle to aid reassembly and
remove wiring.
(5). Remove spring and idle stop release
ring.
(Ref. Figure 602)

(1). Cut two nylon straps, and remove stick
friction mechanism guard.
(6). Remove grip attach bolts. Slide throttle

grip friction washer and discs, and
friction nut from stick tube.
(2). Remove setscrews that secure switch

housing.
(7). Remove friction mechanism and guide

from stick fitting.
SEWN SEAMS
SEWN SEAMS
2 PLACES
0.40-0.50 IN.
(10.16-12.70 MM)
(NOTE 1)
DOUBLE 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.
SINGLE BOOT
G67-1036A
Figure 802. Control Tube Boot Rework

(8). Remove idler gear from stick fitting.
NOTE: In following steps, do not remove bear

ings or pinion unless replacement is neces
sary.
(9). Remove cap from stick housing.
Page 806
Revision 21
67-10-00
(10). Remove gear shaft assembly. Keep

backlash shims with gear shaft.
(11). Remove cover from back of stick
housing.
(12). Remove gas producer control tube
through access hole at back of stick
MAINTENANCE MANUAL
housing. Remove mounting distance
shim only if necessary to adjust pinion
gear mounting distance.
7. Pilots Collective Pitch Stick Repair (L/H
Command)
(Ref. Figure 602)
Item
Nomenclature
CM116
(1). Replace bearings if corroded, excessive

ly worn, or if outer or inner races of
bearings rotate on mating surfaces and
locking compound is inadequate to
prevent rotation.
(2). Replace loose rivets in gas producer
control tube.
(3). Replace friction drive gear or idler gear
with cracked, chipped or broken teeth.
(4). Replace friction drive gear if it does not
rotate freely on stick tube, or if rotating
stop is damaged. To remove gear, drill
out rivets that attach throttle friction
nut fitting to stick.
NOTE: Before replacing drive gear for binding,

clean and relubricate bore with grease
(CM116). Reinstall gear on stick tube and
recheck for free rotation. If gear still binds it
must be replaced.
(5). Replace phenolic friction washers
against guide if worn to less than 1/32
inch thickness.
(6). Replace friction gear assembly if driven
gear has cracked, chipped or broken
teeth or if cam pin is bent.
(7). Replace damaged idle stop release ring.
Ring must slide freely on tube and in
throttle grip.
8. Pilots Collective Pitch Stick Reassembly
(L/H Command)
(Ref. Figure 602)
Item
CM116
CM431
CM807
CM815
CSP-HMI-2
Nomenclature
Twine, nylon
Solder
(1). Check gearshaft bearings in housing

cap a housing for security of outer
races. Use grade A locking compound
(CM431) to install replacement bear
ings. Use care to prevent compound
from entering bearings, and make sure
that each bearing is seated against its
bore shoulder.
(2). Using grease (CM116), lubricate stick
tube interior where gas producer
control tube fitting makes contact.
(3). Attach strings routed through stick
tube during disassembly, and thread
electrical wire bundles from plug
through exit hole, throttle friction nut,
friction washers and discs, throttle grip,
idle stop release ring and spring. Pull
wiring out through front end of stick
tube.
(4). Install wire guide so that it divides
switch wiring: three wires in one cutout
and four in the other. Align guide with
matching hole in stick tube and install
setscrew. When tightened, setscrew
must be flush or not recessed more than
0.010 inch (0.254 mm) below outer tube
surface.
NOTE: Ensure gas producer control tube is in

stalled into stick housing with elongated
area of fitting facing down.
(5). Install gas producer control tube
through access hole in back of stick
housing, and through stick tube until
control tube fitting engages wire guide
bore. Reinstall mounting distance
shims forward side of pinion bearing if
removed during disassembly. (One edge
of shim must be cut for installation.)
NOTE: Steps (6). thru (8). below are used to de

termine gas producer control tube pinion
mounting distance.
67-10-00
Page 807
Revision 21
CSP-HMI-2
MAINTENANCE MANUAL
(6). Install approximate required thickness

of split shims between pinion bearing
and housing to establish gas producer
control tube pinion mounting distance.
(7). Use throttle friction nut to pull gas
producer torque tube forward until not
less than 10 pounds (44.48 N) of force is
applied to compress shims.
(8). Add or subtract shims to provide
0.699-0.709 inch (17.7546-18.0086
mm) dimension (Ref. Figure 504).
Repeat step (7). during each measure
ment.
(9). After mounting distance shimming is
correct, remove gas producer control
tube and apply grade A locking com
pound (CM431) to outside diameter
pinion bearing outer race and stick
housing bore. Reinstall control tube,
and check that compound does not
enter bearing and that bearing outer
race and shims are firmly seated
against housing bore.
(10). Install throttle friction nut, friction
discs and washers.
(11). Using grease (CM116), lubricate
interior of throttle grip and install grip
on stick tube. Align grip and gas
producer control tube fitting and install
grip attach bolts. When tightened, bolts
must be flush or not more than 0.010
inch (0.254 mm) below outer face of
grip.
(12). Establish gas producer control tube
pinion and shaft assembly bevel gear
backlash by temporarily installing
driven gear, shaft, and two bearings,
plus approximate required thickness of
backlash shims in housing. Temporarily
install housing cap. Add or subtract
shims to provide maximum backlash of
0.003 inch (0.076 mm) without bind in
gears. Make certain that bearings are
completely seated in bores while
establishing this backlash adjustment.
(13). After backlash shimming is correct,
remove housing cap and gear shaft.
Page 808
Revision 21
67-10-00
(14). Lubricate teeth of pinion gear and shaft

assembly bevel gear with grease
(CM116).
(CM431) to secure gearshaft to bear
ings. Do not allow compound to enter
bearings. With throttle grip at mid-tra
vel, install driven gear. Note that at
throttle-grip mid-travel, cut out
portion of the driven gear is to be
opposite pinion gear. (Centerline of
center tooth of driven gear is two
degrees and fifty minutes from center of
driven gear cutout.)
NOTE: With throttle grip at mid-travel, two

grip attach bolts are positioned approxi
mately straight down.
(16). Install housing cap on shaft assembly
and seat with hand pressure while
slowly rotating grip back and forth.
Secure cap to side of housing and cover
to back of housing.
(17). Using solder (CM815), connect wiring
to stick switches. Pull electrical wiring
slack out through exit holes in stick
tube, position release ring and. spring
and install switch housing with set
screws. Using nylon strap, or twine
(CM807), secure electrical wiring to
stick tube approximately one inch aft of
exit holes.
(18). Install friction cam and driven gear
assembly on stick fitting. Temporarily
mesh idler gear and driven gear, and
rotate friction drive gear counterclock
wise to maximum stop.
(19). Hold drive gear at stop and remesh
idler gear and driven gear so that gear
assembly pin is at high point of cam.
(20). Use shim washers sufficient to limit
gear end play to maximum of 0.010 inch
(0.254 mm), and secure idler gear with
cotter pin.
(21). Assemble remainder of friction mecha
nism.
(22). Adjust collective friction mechanism.
9. Pilots Collective Pitch Stick Disassembly
(R/H Command)
(Ref. Figure 603)
MAINTENANCE MANUAL
(1). Disassemble collective stick to extent of
removing friction mechanism idler gear
from stick fitting, except also remove
screw and nut to disconnect electrical
terminals from stick housing.
(2). Detach link and idler.
(3). Remove idler from socket housing. Do
not remove idler bearing unless
(4). Remove four bolts and washers that
attach housing cap to socket housing.
Rotate shaft assembly until gear tooth
cutout clears pinion (bellcrank ears at
approximately 195 degrees);, then
separate bellcrank, housing cap and
shaft assembly from housing.
(5). Remove bellcrank from shaft assembly
to separate housing cap from shaft. Do
not press bearings from cap or housing
unless replacement is necessary. Keep
backlash shims with shaft assembly.
(6). Remove link from bellcrank.
through access hole at back of pilot's
collective stick housing.
CSP-HMI-2

that each bearing is seated against its
bore shoulder.
(2). Completely reassemble pilot's collective
stick to the extent of assembling
friction mechanism.
(3). Connect two electrical terminals to
stick housing.
(4). Shim and adjust pinion mounting
distance and backlash.
install bellcrank on shaft assembly and
link to bellcrank; then install, seat and
secure housing cap on stick housing. Do
not adjust collective friction mechanism
at this point of assembly.
(6). Install idler to the stick housing, and
link to the idler.
(7). Adjust the collective friction mechanism
(Ref. Collective Stick Friction Mecha
nism Adjustment).
Disassembly (L/H and R/H Command)
(1). Cut nylon strap or twine securing
wiring to stick tube.
(8). Remove mounting distance shim only if

necessary to adjust pinion gear mount
ing distance.
(2). Remove setscrews that secure the

switch housing.
(9). Remove pinion and bearing from

control tube only if replacement is
necessary.
(3). Push wire slack into stick and carefully

pull switch housing from end of stick
tube; disconnect wiring from N2 switch
(Ref Chap. 96).
10. Pilots Collective Pitch Stick Reassembly

(R/H Command)
(Ref. Figure 603)
Item
Nomenclature
CM431

cap and housing for security of outer
(4). Remove grip attach bolts and grip.

(5). Remove adjusting nut pin and throttle
end play adjusting nut only if stick tube
replacement is necessary, or if end play
must be adjusted.
(6). Remove setscrew and wire guide. Tie a
``fish'' string on end of wire bundle to
aid reassembly, and then remove the
wiring.
(7). Remove cap from stick housing. Do not
remove bearing from cap unless
(8). Remove gearshaft assembly. Keep
backlash shims with gearshaft and do
67-10-00
Page 809
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
not remove bearing from stick housing

unless replacement is necessary.
(9). Remove cover from back of stick
housing.
housing. Remove mounting distance
shim only if necessary to adjust pinion
gear mounting distance. Remove pinion
and bearing from control tube only if
12. Copilots Collective Pitch Stick Repair
(1). Replace bearings if locking compound
does not prevent outer or inner races
from rotating on mating surfaces, if
corroded, or if excessively worn.
(2). Replace loose rivets in gas producer
control tube, or damaged pinion gear.
Reassembly
Item
Nomenclature
CM116
CM431
CM807
CM815

Twine, nylon
Solder

(CM431) to install replacement bearing.
Use care to prevent compound from
entering bearings, and make sure each
bearing is seated against its bore
shoulder.
(2). Using grease (CM116), lubricate stick
tube interior where gas producer
control tube fitting makes contact.
(3). Attach ``fish'' string (routed through
stick during disassembly) and thread
electrical wire bundle from electrical
plug through exit hole in stick tube and
out front end of tube.
Page 810
Revision 21
67-10-00
(4). Install wire guide in stick tube so it

positions wire bundle in right cutout of
guide. Align guide with matching hole
in stick tube, and install setscrew.
When tightened, setscrew must be at
least flush and not recessed more than
0.010 inch (0.254 mm) below outer
surface of tube.
(5). Install gas producer control tube
housing, and through stick tube until
control tube fitting engages wire guide
bore. Reinstall mounting distance
shims at forward side of pinion bearing
if removed during disassembly. (One
edge of shims must lie cut for installa
tion.)
pinion mounting distance (Ref. Gas
Producer Linkage Adjustment).
(7). After mounting distance shimming is
correct, remove gas producer control
tube and apply grade A locking com
pound (CM431) to OD of pinion bearing
outer race, and stick housing bore.
Reinstall control tube and check that
compound does not enter bearing and
that bearing outer race and shims are
firmly seated against housing bore.
(8). Using grease (CM116), lubricate ID of
throttle grip and install grip on stick
tube. Align grip and gas producer
control tube fitting and install grip
attach bolts. When tightened, bolts
must be at least flush and not recessed
more than 0.010 inch (0.254 mm) below
outer surface of grip.
pinion and gearshaft bevel gear
backlash.
remove housing cap and gearshaft.
(11). Lubricate teeth of pinion gear and
gearshaft bevel gear with grease
(CM116).
(CM431) to gearshaft and ID of bear
ings. With throttle grip at mid-travel,
install shaft assembly gear.
MAINTENANCE MANUAL
(13). Install housing cap on gearshaft and
seat with hand pressure while slowly
rotating grip back and forth. Secure cap
on side of housing and cover on back of
housing.
(14). Check throttle grip for zero end play on
stick tube and that not more than 1
pound torque is required to rotate the
grip. If these conditions exist, proceed
with step (18). below. If there is end
play, or too much torque is required to
rotate the grip, perform steps (15)., (16).
and (17).
(15). Remove grip attach bolts and grip.
(16). Insert 3/64 inch (1.190625 mm) diame
ter drift punch into access hole on
forward face of adjusting nut and drive
grooved taper pin from adjusting nut
and threaded fitting of stick tube.
(17). Reinstall grip with grip attach bolts
and establish zero end play and correct
rotational friction, 1 pound (4.448 N)
maximum, between nut and grip. The
match-drill 3/64 inch (1.190625 mm)
maximum diameter stick tube fitting
threads to existing pin groove in nut,
and install pin.
to N2 switch. Pull electrical wiring
slack out through exit hole in stick tube
and install switch housing with set
screws. Using nylon strap or twine
(CM807), secure electrical wiring to
stick tube, approximately one inch (2.54
cm) aft of exit hole.
Tube Repair
(Ref. Figure 407)
(1). Replace loose or binding torque tube
support bearings. Drill out rivets
securing retainer and doubler to seat
structure to replace left support
bearing. Drill out three rivets securing
CSP-HMI-2
right end fitting to torque tube to

replace right support bearing. Install
new bearings and rivets at existing
holes.
(2). Replace torque tube if it is cracked or
has elongated holes.
NOTE: Torque tube droop control bracket may

be either an aluminum or magnesium cast
ing. (For corrosion control and identification
of magnesium and aluminum alloy parts,
Ref. Sec. 20-40-00.)
(3). Replace bent or stripped bungee
adjusting bolt. Torque nut to 30 - 40
(4). Replace scratched, nicked or otherwise
damaged reinforcement strap.
15. Collective Bungee Disassembly
(Ref. Figure 407)
Special Tools
Nomenclature
Item
ST510

channel
(1). Remove male bearing from bungee

clamped in compression by installation
tool.
(2). Install bungee compression tool rod and
channel (ST510) on compressed bungee.
Insert 1/4 inch (6.35 mm) bolt through
channel and female bearing rod end.
(3). Place compression tool and bungee in
vise so that vise jaws make contact with
tool rod and channel. Compress vise
and remove bungee clamp.
(4). Slowly open vise and remove bungee
components.
NOTE: Do not disassemble female bearing as

sembly; if defective, replace as a unit.
67-10-00
Page 811
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
16. Collective Bungee Reassembly
Rotate shaft assembly until gear tooth

cutout clears pinion (bellcrank ears at
approximately 195 degrees); then
separate bellcrank, housing cap and
shaft assembly from housing.
(Ref. Figure 407)
Item
Nomenclature
CM116
Item
Special Tools
Nomenclature
ST508
ST509
ST510

Not used at this time
channel
(1). Lubricate cups of spring retainers and

threads and bore of female bearing
assembly with grease (CM116).
(2). Assemble retainer, spring and female
bearing assembly. Install compression
tool rod and channel (ST510). Insert a
1/4 inch (6.35 mm) bolt through channel
and female bearing rod end.
(3). Position assembly in bench vise.
Compress bungee spring until bungee
installation tool (ST508 or ST509) fits
over retainers. Secure tool halves in
place with clamp.
(4). Open vise slowly and remove bungee
compression tool rod and channel.
(5). Install male bearing in compressed
bungee.
Disassembly
(Ref. Figure 408)
(1). Disconnect link from idler.
(2). Remove idler from socket housing. Do
not remove idler bearing unless
(3). Remove four bolts and washers that
attach housing cap to socket housing.
Page 812
Revision 21
67-10-00
(4). Remove bellcrank from shaft assembly

to separate housing cap from shaft. Do
not press bearings from cap or housing
unless replacement is necessary. Keep
backlash shims with shaft assembly.
(5). Remove link from bellcrank.
(6). Remove snap ring that retains N1
pinion gear aft bearing in housing.
Press pinion gear and aft bearing, as an
assembly, out through access hole at the
back of housing. Disassemble pinion
bearings from pinion and housing only
if replacement is necessary.
Repair
(Ref. Figure 408)
Item
Nomenclature
CM116
(1). Replace bearings if corroded, excessive

ly worn, or if outer or inner races of
bearings rotate on mating surfaces and
locking compound does not prevent
rotation. Install new bearings with
grade A locking compound (CM116).
Check that replacement bearing is
properly seated in mounting bore.
(2). Replace any cracked part.
(3). Replace entire link if bearings are
defective; link bearings are not replace
able.
(4). Replace pinion gear or shaft assembly
bevel gear when correct backlash
cannot be maintained because of tooth
irregularities caused by wear or
deformation.
MAINTENANCE MANUAL
Reassembly
(Ref. Figure 408)
Item
Nomenclature
CM116
CM431

that each bearing is seated against bore
shoulder.
(CM431) to pinion gear aft bearing
outer circumference and matching bore
in socket housing. Install assembled N1
pinion gear and aft bearing; seat
bearing firmly against bore shoulder.
(3). Install snap ring that retains aft-bear
ing in housing bore. Apply locking
compound to bond pinion shaft to
forward bearing and to bond forward
bearing to housing bore. Press bearing
firmly against housing shoulder.
(Housing is machined to provide a light
press-fit.)
(4). Establish N1 pinion and shaft assembly
bevel gear backlash by rotating N1
pinion gear assembly so that wide
toothspace on spline is at about one
o'clock when viewed from socket
(looking aft). Install backlash shims to
obtain maximum backlash of 0.003 inch
(0.076 mm) with bearings firmly seated
in bores.
remove housing cap and gearshaft.
(6). Install bellcrank on shaft assembly, and
link to bellcrank.
CSP-HMI-2
NOTE: Bellcrank attachment bolt must be in

stalled with head slightly down and for
ward.
(7). Lubricate teeth of pinion gear and shaft
assembly bevel gear with grease
(CM116).
(CM431) to bond bevel gearshaft and
bearings. With centerline of wide
toothspace of N1 pinion gear spline up
(on top), install shaft assembly gear at
midtravel position.
NOTE: N1 pinion shaft spline wide toothspace

should be positioned up at approximately
one o'clock position, as viewed looking aft
into open end of socket.
(9). Install four bolts, eight washers, four
spacers and nuts to secure cap to
housing.
(10). Install idler to housing, and link to
idler.
NOTE: When installed, idler to gas producer

control rod bolt holes should be in line with
centerline of stick assembly housing cap
when gearshaft and pinion gears are posi
tioned as outlined in step (8). above.
20. Cyclic Control Stick Repair
(Ref. Figure 411) Disassemble cyclic control
stick only as necessary to replace damaged or
faulty parts. Pilot's stick tube should not be
removed from stick socket; the assembly
should only be replaced as a unit.
21. Cyclic Friction Mechanism Repair
(Ref. Figure 603)
(1). Remove cap nut from friction stud and
disassemble friction mechanism from
stick socket or torque tube.
(2). Replace bent or stripped friction stud.
Drill out rivet and press stud from
socket; install new stud and rivet in
place. Press replacement spring pin
into friction stud until one end of pin is
flush with surface of stud.
(3). Assemble friction mechanism to stick
socket or torque tube.
67-10-00
Page 813
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
(4). Adjust friction knob cap nut to stop

knob when spring extends to free
length, no compression 1/32 inch
(0.79375 mm).
22. Lateral Control Rods and Sta. 67
Bellcrank Repair
(Ref. Figure 411)
Item
Nomenclature
CM431
(1). Replace Sta. 67 lateral bellcrank if it

has elongated holes or is cracked.
Replace pivot bearing if it binds or is
excessively worn; install with grade A
locking compound (CM431). Check free
play of bellcrank with newly installed
pivot bearing by applying light up and
down pressure at forward end of
bellcrank with bearing secured. For
bearing to be acceptable, bellcrank total
play measured at centerline of bolt that
attaches pilot's lateral control rod end
must not exceed 0.024 inch (0.6096
mm).
NOTE: Sta. 67 lateral bellcrank may be either

an aluminum or magnesium machined forg
ing. (For corrosion control and identification
of magnesium and aluminum alloys, Ref.
Sec. 20-40-00.)
rod(s) that appear bent or bowed. Total
length of rod (excluding rod ends) must
be straight within 0.010 inch (0.254
mm). Cold-straightening of rod is
permissible if no nicks or sharp dents
exist in bend length, and rod ends are
not used to support rod during straight
ening process. Dye-check for cracking
is to be performed after cold-straigh
tening. Replace cracked rod, or cracked
or bent rod end.
Page 814
Revision 31
67-10-00

rod end is steel and rod is aluminum. Do not
tighten adjustable rod end jam nut on pilot's
lateral control rod until rod is installed and
cyclic stick longitudinal travel is checked.
CAUTION

mm). Set initial control rod length and
bearing angularity.
Repair
(Ref. Figure 412)
Item
Nomenclature
CM116
CM431

NOTE: Cyclic torque tube may be either a ma

chined magnesium or aluminum casting.
(For corrosion control and identification of
magnesium and aluminum alloys, Ref. Sec.
20-40-00.)
(1). Replace torque tube if it is cracked, has
elongated holes or deformed bearing
supports.
(2). Replace main support bearings or cyclic
stick pivot bearings if they bind or are
excessively worn. Drill out four rivets
and remove bearing retainer to replace
right support bearing. Install cyclic
stick pivot bearing and right support
bearing with grade A locking compound
(CM431).
NOTE: Left support bearing is a slip-fit in

torque tube lug; coat outer circumference of
bearing with grease (CM116) prior to inser
tion in lug.
(3). Replace bent or stripped friction stud.
Drill out rivet; install and rivet new
stud in place. Insert spring pin with one
end flush with stud.
24. OneWay Lock Repair
For overhaul information, Ref. COM.
MAINTENANCE MANUAL
Item
Nomenclature
CM206
CM801
CM803
Chemical coating
Crocus cloth
CSP-HMI-2
(3). Clean inside of trim tube with solvent

(CM234).
(4). Coat outside of replacement spring
assembly tube lightly with grease
(CM116).
(5). Slide replacement spring assembly into
trim tube.
(1). Remove dents, nicks and scratches by

using grade 400 abrasive paper
(CM801) to remove rough edges. Finish
by polishing with crocus cloth (CM803);
maintain smooth transition into
surrounding area. After repair treat
area with chemical film (CM206).
(6). Install spring adapter screw in open

end of spring assembly and tighten
screw until 0.010-0.050 inch
(0.254-1.27 mm) play is felt while
pushing or pulling on spring assembly.
While tightening screw, check that
friction exists from self-locking
threaded insert.
(2). When replacing input (forward) shaft

rod end bearing, with piston at mid
stroke ensure bearing center-to-center
distance is 8.58 0.030 inches (217.932
0.762 mm). Adjust as required. After
correct length is set, tighten and safety
lock nut with lockwire.
(7). Wipe off all excess grease.
NOTE: Support links may be either forged alu

minum or magnesium castings. (For corro
sion control and identification of magne
sium and aluminum parts, Ref. Sec.
20-40-00.)
25. Cyclic Trim Actuator Spring Assembly
Replacement
(Ref. Figure 508)
Item
Nomenclature
CM116
CM234

(1). Insert screwdriver into open end of

spring guide and remove screw that
connects two spring adapters.
NOTE: Identify screw for lateral or longitudi

nal trim; screws are not interchangeable.
Lateral actuator screw is 2-7/8 inches
(73.025 mm) long; longitudinal screw is
2-5/8 inches (66.675 mm) long.
(2). Slide spring assembly out of trim tube.
(8). Perform bench test to check actuator

operation.
26. Cyclic Trim Actuator Housing or Trim
Tube Replacement
(Ref. Figure 508)
Item
Nomenclature
CM318
Primer
(1). Remove actuator spring assembly.

(2). Carefully drill out four rivets attaching
trim tube. Remove trim tube.
(3). Remove actuator from actuator hous
ing. Check housing for condition and
NOTE: Housing may be either aluminum or

magnesium casting. (For corrosion control
and identification of magnesium and alumi
num alloys, Ref. Sec. 20-40-00.)
(4). Use dimensions to assemble replace
ment actuator housing and trim tube. If
replacement part is undrilled, drill #40
- 0.098 inch (2.4892 mm) four attaching
rivet holes.
(5). Coat mating surfaces of trim tube and
actuator housing with primer (CM318).
Assemble while primer is still wet.
67-10-00
Page 815
Revision 31
MAINTENANCE MANUAL
CSP-HMI-2
(6). Install four mechanically expanding

rivets.
(1). Remove cyclic trim actuator from

helicopter.
(7). Reinstall actuator.
(2). If actuator is inoperative, bench test

unit to determine whether mechanical
(stalled), electrical or other mechanical
failures exists.
(8). Reinstall actuator spring assembly.

(9). Perform bench test.
27. Cyclic Trim Actuator (Motor/Gear Drive
Mechanism) Replacement
(Ref. Figure 508)
(1). Remove actuator spring assembly.
(2). Remove trim tube.
(3). Support actuator tube and press out
spring pin.
(4). Unscrew adapter from actuator and
remove actuator from housing.
(5). Screw adapter into replacement
actuator shaft until it bottoms. If spring
pin hole drilled in adapter does not
align with guide hole in adapter,
adapter must be replaced; otherwise
adapter may be reused.
(6). Use 1/16 inch (0.0625) drill to drill
spring pin hole through adapter and
actuator; deburr hole.
(7). Reassemble actuator housing and trim
tube.
(8). Install actuator in housing. Screw
adapter on actuator.
(9). Support actuator shaft; press in spring
pin. Ensure that pin is flush with shaft.
(10). Install actuator spring assembly.
(11). Bench test actuator.
28. Cyclic Trim Actuator Rework (Calco P/N
8222M6 and 8222M7)
The following procedure is for tightening the
trim actuator drive gear retention nut and also
testing stalled actuators.
NOTE: Rework is NOT applicable to actuators

having letter R following vendor part
number on actuator housing.
Page 816
Revision 21
67-10-00
(a). A reading of 0.0 - 0.1 amperes

indicates electrical failure; replace
actuator.
(b). The motor runs, but the output shaft
does not move, indicates a mechani
cal failure; replace actuator.
(c). A reading of 0.7 amperes (approxi
mately), or actuator extends part way
and stalls, indicates stalled failure;
rework actuator per steps (3). thru
(9). below.
(3). Remove lockwire and six screws
securing actuator cover to housing.
When removing housing, note
the location and number of
shims on each gear for reassembly in proper
location.
CAUTION
NOTE: Step (4). not applicable if actuator is op

erative. Perform steps (5). thru (9). below.
(4). Using fingers only, check gear drive
retention (hex) nut for looseness. If nut
is loose, rework per instructions below.
If nut is NOT loose, replace actuator
assembly.
(5). Remove nut and clean threads. Rein
stall nut using Locktight #290 on
threads. Torque nut to 30 - 40 inchpounds (3.39 - 4.52 Nm).
(6). Reinstall actuator cover with existing
screws; lockwire screws.
(7). Add letter R at end of vendor part
number on actuator housing.
(8). As applicable, reinstall trim actuator.
(9). Record rework of trim actuator in
Components Record of helicopter Log
Book.
MAINTENANCE MANUAL
CSP-HMI-2
Section
671020
Collective and
Cyclic Stick Grips
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
COLLECTIVE AND CYCLIC STICK GRIPS

1. Collective Pitch Stick Switches
(Ref. Figure 201) The START, N2 GOV and
LDG LT switches are on the collective stick
assembly. Wiring for the switches is routed
down through the collective stick tube and
interconnects with electrical system wiring
through a connector at the base of the stick.
2. Collective Pitch Stick Switches
Replacement
(Ref. Figure 201)
Item
Nomenclature
CM703
CM807
Tie strap
Twine, nylon
CAUTION
Ensure all electrical power is

OFF.
provided at the left of the trim switch for

optional equipment. Coiled, insulated and
open-ended wiring is provided in the grip for
connection to an optional switch.
NOTE: Cyclic stick grip configurations vary

and may have additional switches. Switch
functions are described in appropriate sec
tions.
4. Cyclic Control Stick Grip Replacement
A. Cyclic Control Stick Grip Removal
(Ref. Figure 203)
(1). Disconnect removable contacts from
electrical plug.
(2). Remove nylon strap that secure wiring
to stick socket. Remove strap mounting
plate only if it is unserviceable.
(3). Remove screw from grip and separate
grip from tube.
(1). Disconnect grounding terminals.

stick grip switch housing. Remove
housing and switchplate.
(3). Disconnect wiring and remove affected
switch.
(4). Install replacement switch in reverse
order of removal. If nylon strap
(CM703) is not available, use twine
(CM807) to secure wiring to collective
pitch stick.
(5). Perform operational check of switch
and associated system or equipment
(Ref. appropriate PFM).
3. Cyclic Stick Grip Switches
(Ref. Figure 202) The pilot's cyclic stick grip
contains a toggle switch for cyclic trim control
and a trigger switch for radio/interphone
communications. A blank switch socket is
(4). Tie a string to each wire bundle to aid

reassembly. Push wire slack into wiring
exit holes in stick socket while pulling
grip wiring from stick tube. Remove
grip and wiring; leave strings in tube.
B. Cyclic Control Stick Grip Installation
(Ref. Figure 203)
(1). Separate grip wiring into approximate
ly equal size color-coded bundles,
according to wiring diagram.
(2). Install an eight inch (20.32 cm) length
of AWG Size No. 3 electrical insulation
sleeving on each bundle and push
sleeving up into grip.
(3). Route wiring through stick tube and
out wiring exit holes with aid of strings
inserted at stick removal. Push wires at
grip end while pulling slack out of
socket.
67-10-20
Page 201
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
KNOB
SETSCREW
PANEL NUT
LOCKWASHER
KNOB
SWITCH IDENTIFICATION
PLATE
PANEL NUT
LOCKWASHER
CHECK NUT
N2 GOV SWITCH
(TYPICAL)
CHECK NUT
LANDING LIGHT
SWITCH
IDLE STOP
RELEASE SPRING
SETSCREW
START SWITCH
(HALF)
RETAINING RING
PILOT'S STICK GRIP

SWITCH HOUSING
THROTTLE
SETSCREW
START SWITCH
(HALF)
SELF-TAPPING SCREW (SUP
PLIED WITH SWITCH)
IDLE STOP
RELEASE RING
G67-1027
Figure 201. Collective Pitch Stick Switch Replacement

Page 202
Revision 21
67-10-20
MAINTENANCE MANUAL
CSP-HMI-2
SWITCH (S102)
(TOGGLE RED)
SWITCH (S4) *(S1)
(RED PUSHBUTTON WITH GUARD)
SWITCH (S103) *(107)

(TRIM BLACK)
SWITCH (S1) *(S4)
(RED PUSHBUTTON WITH GUARD)
SWITCH (S111) *(S112)

(ROCKER, (OLIVE)
SWITCH (S5)
(RED PUSHBUTTON WITH GUARD
TRIGGER SWITCH
WITH GUARD
VENDOR NAME AND
P/N IDENTIFICATION
STANDARD GRIP
OPTIONAL ``T'' GRIP
NOTE:
AN ASTERISK (*) INDICATES - 3 VERSION
OF GRIP AND APPLICABLE SWITCH NUMBER.
OPTIONAL GRIP
G67-1028A
Figure 202. Cyclic Stick Grips
67-10-20
Page 203
Revision 40
MAINTENANCE MANUAL
CSP-HMI-2
CYCLIC TRIM SWITCH (S107)

TRIGGER PIN
HOOK SWITCH (S4)
AND GUARD
FLOAT INFLATE/ HOIST

CUTTER SWITCH (S1/S5)
AND GUARD
XMIT/ICS TRIGGER
SWITCH (S112)
PLUG BUTTON
GRIP ASSEMBLY
G67-1025-1
Figure 203. Cyclic Stick Grip Disassembly (Sheet 1 of 2)

Page 204
Revision 21
67-10-20
MAINTENANCE MANUAL
CSP-HMI-2
GRIP CAP
FOUR-WAY TRIM SWITCH

(S103) *(S107)
BUTTON
TOGGLE SWITCH
(S102)
SWITCH
(S1) *(S4)
RETURN SPRING
TRIGGER GUARD
PIN
PUSHBUTTON SWITCH
(S4) *(S1)
ROCKER SWITCH
(S111) *(S112)
TRIGGER SWITCH
(S101)
SWITCH (S5)
TRIGGER PIN
GRIP ASSEMBLY
NOTE:
ASTERISK (*) INDICATES -3 VERSION OF
GRIP AND APPLICABLE SWITCH NUMBERS.
OPTIONAL T-GRIP
(P/N 369D297846)
G67-1025-2
Figure 203. Cyclic Stick Grip Disassembly (Sheet 2 of 2)
67-10-20
Page 205
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
(4). Install an additional eight inch 20.32

cm) length of insulation sleeving to
protect each wire bundle where routed
through exit holes in socket.
(5). Position grip on stick tube and install
screw.
(6). Push as much wire slack as possible
back into stick. Secure wiring to socket
with new nylon strap, or equivalent.
(7). Cut wiring to correct length and
reinstall replaceable contacts and
electrical plug and wiring diagram.
5. Cyclic Stick Grip Switch Replacement
(Standard Grip)
(Ref. Figure 203)
Item
Nomenclature
CM217
CM425
CM703
CM815
Isopropyl alcohol
Sealing compound
Tie strap
Solder
Ensure that all electrical

WARNING power is OFF.
(1). Disconnect cyclic grip wiring connector
from plug at lower end of cyclic stick.
(2). Remove strap securing wiring to stick
socket; remove strap mounting plate if
it is unserviceable.
(3). Remove exterior sealant from grip
assembly covering switch mounting
hardware and attaching screws.
(4). Drive trigger pivot pin from grip to
release trigger. Pin is removed from
right to left while holding grip in
normal position. Remove trigger.
(5). Remove screw from grip and separate
grip from stick tube.
Page 206
Revision 21
67-10-20
(6). Push slack wiring into wiring exit holes

in stick socket while pulling grip wiring
from stick tube.
(7). Remove trim switch cap by carefully
pulling cap off.
(8). Remove all attaching hardware secur
ing switches to grip, carefully remove
switches and attached harness from
grip assembly.
(9). Tag, identify and un-solder wires of
switch to be disconnected.
(10). Clean grip, wiring and switches with
alcohol (CM217).
(11). Reconnect all electrical wires using
solder (CM815), remove identification
tags from wires.
(12). Carefully position switches to their
approximate location within the grip.
NOTE: Ensure that switches are correctly posi

tioned with any applicable keyway, pin hole,
etc, for proper alignment of mating parts.
(13). Install attaching hardware securing
switches onto grip.
(14). Install trigger and trigger attach pin.
(15). Install cyclic trim switch cap.
(16). Reinstall grip on stick tube, route grip
wiring through stick tube and attach
connector.
(17). Check switch operation and wiring
continuity.
screw holes and insert holes.
(19). Secure wiring to stick with nylon straps
(CM703).
Cyclic trim actuators should be
operated only momentarily to
prevent damage to equipment.
CAUTION
(20). Check operation of switch by momen

tarily cycling in all modes ensuring that
the associated system operates correct
ly.
MAINTENANCE MANUAL
6. Cyclic Stick Grip Disassembly (Optional
TGrip, PN 369D297846 Only)
(Ref. Figure 203)
Ensure that all electrical
WARNING power is OFF.
(1). Remove the grip cap by removing six
screws.
NOTE: The grip is to be disassembled only to

the extent required for replacement of the
switches. The wiring through the grip as
sembly is tied with nylon twine and covered
with a two inch (5.08 cm) insulating sleeve.
Do not remove the twine and sleeves unless
wire replacement is required.
(2). Detach the rocker switch (S111) by
removing two screws.
(3). Unscrew the trigger pin and carefully
withdraw it while holding the trigger
guard and trigger switch (S101) in
place. Then remove the trigger guard
and switch and separate them with care
to prevent distorting or losing the
return spring.
(4). Remove toggle switch (S102). Switch
button is separated from housing by
pressing out the pin.
(5). Unsolder wiring connected to terminals
on the switch to be disconnected. Tag
and identify wires to facilitate correct
reconnection.
7. Cyclic Stick Grip Reassembly and
Modification
Item
Nomenclature
CM217
CM314
CM425
CM703
CM815
Isopropyl alcohol
Sealing compound
Tie strap
Solder
(1). Clean grip, wiring and switches with

alcohol (CM217). Reconnect all electri
CSP-HMI-2
cal wires using solder (CM815) and

reinstall switches as applicable.
NOTE: Ensure that switch is correctly posi

tioned with any applicable keyway, pin hole,
etc, for proper alignment of matching parts.
(2). Insert replacement switch at the
approximate mounting position on the
grip subassembly.
to terminals of the replacement switch.
Remove identification tags from wires.
NOTE:
D Helicopters (369D) S/N 003 thru 480 may
require trigger switch rework to accom
modate replacement switch (Ref.
Figure 204).
D Rework is not necessary for the following
cyclic grip assemblies; PN 369D27133 or
A218-964401-00.
(4). If rework is required, perform steps (a).
thru (c). before continuing.
(a). Press or pull insert from top of grip.
(b). Make template of profile of new
A218-158698-05 trigger switch.
(c). Using file, blade or equivalent
routing tool, remove material from
lower inside edge of hole for trigger
switch to permit installation of new
switch. Use template to determine
amount and location of material to be
removed.
(5). As applicable, secure or attach the
trigger switch, (trigger guard and
return spring for 369D297846 cyclic
grips) to the grip housing using the
original attaching hardware.
open screw holes and insert hole.
(7). Secure the grip cap (for 369D297846
cyclic grips) to the grip subassembly
with six screws; coat the screws with
varnish (CM314) before installation
into grip.
(8). Reinstall grip on stick tube. Using
attached strings, route grip wiring
through stick tube and reconnect at
electrical plug.
67-10-20
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MAINTENANCE MANUAL
CSP-HMI-2
(9). Check switch operation and wiring

continuity.
(10). Secure wiring to stick socket with nylon
strap (CM703).
(11). Energize the electrical system.
Cyclic trim actuators should be

operated only momentarily to
prevent damage to equipment.
CAUTION
(12). Check operation of the switch by

momentarily activating it and ensuring
that the associated system operates
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
Revision 21
67-10-20
MAINTENANCE MANUAL
CSP-HMI-2
Section
672010
AntiTorque Flight
Controls (Two and
Four Blade)
(369D/E/FF)
CSP-HMI-2
MAINTENANCE MANUAL
ANTITORQUE FLIGHT CONTROLS

(TWO AND FOUR BLADE)
1. Tail Rotor Control Configuration
The helicopter may be equipped with either of
two basic pilot's tail rotor foot pedal control
configurations. The tail rotor and control
linkage to the foot pedals are identical on
either basic configuration.
(1). Basic Left-Hand Command Tail Rotor
Controls. Single left position pilot's tail
rotor control pedals. Foot rest can be
installed at right side of crew compart
ment in place of right-hand foot pedals.
(2). Basic Right-Hand Command Tail Rotor
Controls. Right position pilot's tail rotor
control pedals with left copilot's dual

controls. Foot rest not installed.
2. Upper Fuselage and Tailboom Control
Linkage
Upper fuselage tail rotor controls consist of
Sta. 95 bellcrank and support at the front of
the main rotor mast base, Sta. 120 control rod
and Sta. 142 bellcrank inside the boom fairing.
Boom linkage consists of tailboom control rod,
supported by seven bushings (grommets), and
Sta. 284 Bellcrank mounted on the tail rotor
transmission.
67-20-10
Page 1
Revision 21
CSP-HMI-2
MAINTENANCE MANUAL
PITCH CONTROL ASSEMBLY
CONTROL ROD BUSHING

(GROMMET) (7 PLCS)
STA. 284
BELLCRANK
TAILBOOM CONTROL ROD
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 1. Tail Rotor and Control System

Page 2
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67-20-10
MAINTENANCE MANUAL
CSP-HMI-2

1. Sta. 120 Control Rod or Sta. 142 Bellcrank
Replacement
A. Sta. 120 Control Rod or Sta. 142
Bellcrank Removal
(Ref. Figure 401) The Sta. 142 bellcrank and
Sta. 120 control rod must be removed as an
assembled unit.
(1). Remove tail rotor control bellcrank
access door from left side of boom
fairing.
(2). Disconnect tailboom control rod from
lower end of Sta. 142 bellcrank.
(3). Remove hardware that secures Sta. 142
bellcrank to boom fairing brackets.
(4). Open hinge-mounted access door on
engine air inlet aft fairing. Remove
clamp on boot support tube at Sta.
137.50.
(5). Disconnect forward end of Sta. 120
control rod from Sta. 95 bellcrank.
NOTE: Sta. 95 bellcrank must also be detached

from its support for clearance from air inlet
fairing for rod-end bolt removal.
(6). Carefully pull forward end of control
rod and withdraw assembled rod and
bellcrank out through boot support tube
at plenum chamber Sta. 137.50.
(7). Disconnect control rod from upper end
of bellcrank.
B. Sta. 120 Control Rod or Sta. 142
Bellcrank Installation
(Ref. Figure 401) Sta. 142 bellcrank and Sta.
120 control rod must be installed as a unit by
routing assembled end of bellcrank and control
rod through boot support tube at plenum
chamber station (Sta. 137.50).
(1). For access to bellcrank support bracket,
use access door in boom fairing.
(2). Ensure that slotted bushings are in

place at each end of bellcrank; then
position riveted rod end in bellcrank
and install bolt, two washers, nut and
cotter pin. Make sure that hump of
bellcrank faces forward.
(3). Carefully feed assembled control rod
and bellcrank through forward air
intake at left side of control mixer
installation while an assistant guides
the assembly through boot support tube
to bellcrank support bracket.
(4). Position rubber boot in place at Sta.
137.50.
(5). Position Sta. 142 bellcrank in support
bracket and install bolt, two washers,
nut and cotter pin.
Check Sta. 142 bellcrank for
clearance with support struc
ture. Pay particular attention to area above
369A7951-23 bearing when top of bellcrank
is in forward position. If contact is noted,
machine surface of bellcrank (machine sur
face with interference only) (Ref.
Figure 801).
CAUTION

in Sta. 95 bellcrank; then install
forward rod end in bellcrank with bolt
(head to left), two washers, nut and
cotter pin.
(7). Reinstall Sta. 95 bellcrank in its
support with bolt, two washers, nut and
cotter pin.
(8). Secure rubber boot at support tube with
nylon strap. Then clamp tail rotor
pedals in neutral, set free length of
bellows portion of boot at approximately
5.5 inches and secure end to control rod
with nylon strap.
(9). Check rigging of tail rotor controls.
67-20-10
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Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
NOTE 2
STA.
137.50
NYLON
STRAP
BUSHING (GROMMET)
(7 PLACES)
* STA. 142 BELLCRANK
BOOT
BEARING
NOTE 2
STATION 284
BELLCRANK
STA. 120
CONTROL ROD
(NOTE 1)
PIVOT PIN
SPECIAL
WASHER
* STA. 95
BELLCRANK
*
SUPPORT
WASHER
(NOTE 5)
NOTE 2
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
NOTES:
1. MINIMUM OF 0.060 IN. (1.524 MM) CLEARANCE FOR FULL RANGE OF
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.
CONTROL
ROD
STA.
120
TAILBOO
M
DIMENSION
L
INCHES (CM)
45.88
(116.5352)
IN LINE
143.80
(365.252)
63
Figure 401. Upper Fuselage and Boom Tail Rotor Control Linkage
Page 402
Revision 21
67-20-10
ANGLE
A
G672000B
MAINTENANCE MANUAL
2. Sta. 284 Bellcrank Replacement
A. Sta. 284 Bellcrank Removal
(Ref. Figure 401)
(1). Disconnect bellcrank from tailboom
control rod.
(2). Disconnect bellcrank from tail rotor
transmission. Disengage bellcrank
pitch control pin from pitch control
housing and remove bellcrank.
B. Sta. 284 Bellcrank Installation
(Ref. Figure 401)
(1). Insert bellcrank pivot pin into pitch
control housing self-aligning bearing.
(2). Position bellcrank to align with mating
hole in tail rotor transmission arm and
install bolt.
in lower lug of bellcrank; then attach
tailboom control rod to bellcrank with
bolt, two washers, nut and cotter pin.
Tail Rotor Controls Rigging).
3. Tailboom Control Rod Replacement
A. Tailboom Control Rod Removal
(Ref. Figure 401)
(1). Disconnect control rod from Sta. 284
bellcrank.
(2). Remove tail rotor control bellcrank
access door from left side of boom
fairing.
(3). Accurately measure and record distance
between unchamfered edge of forward
rod end bearing jam nut and center of
bearing attach bolt hole. Hold forward
rod end, loosen jam nut and unthread
control rod from rod end by turning aft
end of rod.
CSP-HMI-2
(4). Slowly pull aft end of control rod and

withdraw rod through opening in tail
rotor transmission mounting frame.
B. Tailboom Control Rod Installation
(Ref. Figure 401)
NOTE: Tailboom control rod is routed through

boom with forward rod end removed.
(1). Deleted
(2). Guide control rod through boom aft
frame opening and carefully route
through seven bushings (grommets).
Rotate rod slightly to start it through
each grommet.
in lower lug of Sta. 284 bellcrank; then
attach aft rod to bellcrank.
(4). Using measurement recorded at time of
rod removal, install forward rod end
bearing. Align rod ends so that bearings
have equal space for angular throw;
hold rod end and tighten jam nut.
in lower end of Sta. 142 bellcrank; then
attach forward rod end to bellcrank.
(7). Close plenum chamber access door.
4. Sta. 95 Bellcrank and Support
Replacement
A. Sta. 95 Bellcrank and Support Removal
(Ref. Figure 401)
(1). Disconnect tunnel-routed control rod
from bellcrank.
(2). Disconnect bellcrank from support.
(3). Disconnect bellcrank from Sta. 120
control rod and remove bellcrank.
(4). Remove hardware that secures support
to mast structure; remove support.
67-20-10
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MAINTENANCE MANUAL
CSP-HMI-2
INITIAL CONTROL ROD LENGTH

- BEFORE RIG
CONTROL
DIMENSION L
ROD
INCHES (CM)
TUNNEL-ROUTED
57.95 (147.193)
FLOOR-ROUTED
STA. 95 BELLCRANK
STA. 97.50
(TUNNEL-ROUTED)
CONTROL ROD
30.06 (76.3524)
RIVET
CONTROLS SUPPORT
BRACKET
L
SPRING FITTING

PLAY 0.040 IN. (1.016 MM)
AFT EYEBOLT
BUNGEE
SPRING
STA. 63.00
TAIL ROTOR
IDLER BELLCRANK
NOTE 2
FORWARD EYEBOLT
NOTE 2
NOTE 1
FLOOR-ROUTED
CONTROL ROD
NOTE 3
BUSHING ASSY
(NOTE 4)
TORQUE TUBE
* TORQUE TUBE BRACKET
(NOTE 5)
CONTROL ROD FITTING
NOTE 1
NOTE 3
NOTE 1
PIN
WASHER
* LEFT PEDAL
NOTE 4
NOTE 1
BEARING
STOP
BOLT
JAMNUT
* RIGHT PEDAL
BEARING
NOTE 2
NOTE 3
* PEDAL ARM
BUSHING
(TEFLON-LINED)
* PEDAL ARM
NOTE 4
NOTE 1
NOTE 1
* PEDAL BRACKET
NOTE 2
BUSHING
(TEFLON-LINED)
BUSHING ASSY
(NOTE 4)
NOTE 2
BEARING
LINK
NOTE 2
BELLCRANK
NOTES:
1. SHIM BETWEEN BRACKET AND BULKHEAD WITH AN960PD416
AND/OR -416L WASHERS AS REQUIRED FOR ALIGNMENT WITHIN
0.010 IN. (0.254 MM).
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. DIRECTION OF BOLTS IS OPTIONAL.
4. ADJUSTABLE BUSHINGS MUST HAVE A MINIMUM PROTRUSION OF
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
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67-20-10
MAINTENANCE MANUAL
CSP-HMI-2
STOP BOLT (2)

NOTE 1
ADJUSTABLE
BUSHING ASSEMBLY
(NOTE 4)
JAMNUT
NOTE 2
NOTE 3
TORQUE TUBE
SLEEVE
ADJUSTABLE
BUSHING ASSEMBLY
(NOTE 4)
TORQUE TUBE
RIGHT POSITION TAIL ROTOR
G67-2001-2A
Figure 402. Tail Rotor Pedal Installation (Sheet 2 of 2)

B. Sta. 95 Bellcrank and Support Installation
C. Tail Rotor Pedal Assembly General

(1). Install bellcrank support to mast
structure with three bolts, seven
washers and three nuts. Forward bolt
requires an extra washer under
bolthead; two thin washers are used at
all three locations. Torque nuts to 80 100 inch-pounds (9.04 - 11.30 Nm).
place in bellcrank; then attach Sta. 120
control rod to bellcrank with bolt (head
to left).
(3). Install bellcrank in support.
(4). Attach tunnel-routed control rod to
bellcrank.
(Ref. (Ref. Figure 402) Tail rotor pedal

installation consists of a pair of adjustable
pedals, pedal arms with interconnecting
linkage, pedal mounting bracket for left
control position, torque tube with control rod
fitting and torque tube mounting bracket.
Forward pressure on right pedal rotates torque
tube, moving control system linkage to
increase tail rotor blade pitch. Pressure on left
pedal decreases tail rotor blade pitch. A
bungee spring is installed at aft end of
floor-routed control rod in underseat tail rotor
control linkage. This spring relieves left pedal
forces during flight and causes left pedal to
remain at forward position when helicopter is
on ground and not operating.
67-20-10
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MAINTENANCE MANUAL
CSP-HMI-2
NOTE: Parts identified with an asterisk (*)

may be either magnesium or aluminum
alloy. (Ref. Sec. 20-40-00 for corrosion con
aluminum alloys).
D. CoPilots Pedal Installation
(Ref. Figure 402) The copilot's pedal installa
tion is essentially the same as the pilot's. A
sleeve couples a torque tube extension to the
pilot's torque tube. Dual pedal installation is
also equipped with pedal stop nuts, heel strips,
retaining springs and attachment hardware.
5. Tail Rotor Pedal Assembly Replacement
A. Tail Rotor Pedal Assembly Removal
(Ref. Figure 402)
(1). Pull two hinge pins from pilot's com
partment floor access door hinges and
remove door. Remove access panel from
each side of instrument panel lower
support structure.
(2). Remove battery (Ref. Chap. 96).
(3). Remove pins securing pedals to pedal
arms and remove pedals.
(4). For access to bungee, remove access
cover between pilot's seats and/or by
removing left passenger's footwell on
aft side of canted bulkhead.
(5). Block left tail rotor control pedal at full
forward position to relieve tension on
bungee.
(6). Remove eyebolt and washers at Sta. 63
with bungee attached. Keep washers
with eyebolt for reinstallation.
(7). Disconnect bungee from eyebolt and
fitting at aft end of floor-routed control
rod by using spring tension removal
tool (75, Table 203, 91-00).
and bolt that connect floor-routed
control rod to torque tube fitting.
(9). Remove two nuts, four washers, any
shim washers and two bolts that secure
torque tube bracket to bulkhead. Keep
shim washer selection with bracket to
Page 406
Revision 21
67-20-10
simplify torque tube alignment during

reinstallation.
(10). Remove four nuts, eight washers, any
shim washers and four bolts that secure
pedal bracket to bulkhead. Remove
control pedal installation. Keep shim
washer selection with bracket.
B. Tail Rotor Pedal Assembly Installation
(Ref. Figure 402)
NOTE: Install both left and right pedal brack

ets for right-hand command helicopters.
(1). Install pedal bracket with four bolts,
eight washers and four nuts. Add shim
washers as required at pedal bracket
attachment points to keep centerline
alignment of pedal bracket bearings
within 0.010 inch (0.254 mm). Correct
alignment is indicated by free rotation
al movement of torque tube after nuts
are tightened.
(2). Position torque tube bracket over
mating holes in bulkhead and check
alignment with bulkhead. Add shim
washers as required at bracket attach
ment points to maintain bearing
alignment established in step a above.
Install two bolts, four washers and two
nuts.
(3). Install forward eyebolt, using same
number of washers removed, on bungee
and then hook aft end of bungee into
eyebolt on floor-routed control rod
fitting.
NOTE: If tail rotor pedal forces are not zero

during level flight at 130 to 140 knots, tail
rotor force adjustment may be accomplished
by removing washers as required from the
eyebolt at Sta. 63 bracket.
(4). Using spring tension tool install bungee
into position at Sta. 63 bracket; install
washer and nut on eyebolt.
then install floor-routed control rod in
torque tube fitting and install bolt, two
(6). Check rigging of tail rotor controls and
pedal-to-canopy clearance (Ref. Tail
Rotor Controls Rigging). Pedals should
MAINTENANCE MANUAL
clear windows by a minimum of 0.20
inch (5.08 mm) with 20 pounds (88.96
N) of force applied.
6. Dual Tail Rotor Pedal Initial Installation
(Ref. Figure 402)
NOTE: Before pedal installation, remove the

bushing assembly that secures pilot's left
pedal arm to the torque tube. This will allow
the tube to rotate far enough to install the
bushing assemblies.
(1). Thread a stop nut on each of the two
stop-bolts and install bolts into
threaded inserts of pedal bracket.
(2). Locate pedal bracket and pedal arms
for correct position on torque tube.
CSP-HMI-2
(5). Check that spherical bearings are in

place; then attach bellcrank to pedal
bracket with bolt, two washers, nut and
cotter pin.
place; then fasten each link to bellcrank
with bolt, two washers, nut and cotter
pin.
place; then fasten each link in pedal
arm lugs with bolt, two washers, nut
and cotter pin.
(8). Install pedal bracket assembly with
four bolts, eight washers and four nuts.
Add shim washers as required at pedal
bracket attachment points to keep
centerline alignment of pedal bracket
bearings within 0.10 inch (2.54 mm).
Correct alignment is indicated by free
rotational movement of torque tube
after nuts are tightened.
(3). Fasten left pedal arm to torque tube

with adjustable bushing assembly;
install bushing bolt so that shank of the
bolt head end protrudes at least 0.002
inch. Install nut and torque 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). Check that each end of bushing pro

trudes at least 0.002 inch (0.051 mm). If
not, loosen nut and repeat prior step.
(11). Install heel strips with pins, washers

and cotter pins. Direction of pin head is
optional.
(9). Reinstall bushing assembly previously

removed from the pilot's left pedal arm.
67-20-10
Page 407
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CSP-HMI-2
MAINTENANCE MANUAL
Page 408
Revision 44
67-20-10
MAINTENANCE MANUAL
CSP-HMI-2

ADJUSTMENT/TEST
1. Tail Rotor Controls Rigging
(Ref. Figure 501) The tail rotor control system
must be re-rigged immediately after replace
ment of linkage that cannot be accurately
measured (by trammeling, etc) before it is
installed in the tail rotor control system, or if
helicopter operation reveals a rigging deficien
cy.
Item
Special Tools
Nomenclature
ST606
Remove pilot's pedals and copi

lot's (if installed) to prevent pos
sible contact with lower windshield during
rigging sequence.
CAUTION
NOTE: Control rod end bearing adjustments

are to be made to nearest half turn that pro
duces correct rigging. When tightening jam
nut at adjustable end of a control rod, al
ways hold rod end with a wrench to prevent
jamming of bearing. Never reinstall a used
cotter pin; always install a new one.
(1). Disconnect bungee spring at aft end of
floor-routed control rod (Ref.
Figure 402).
(2). Using two pieces of wood and C-clamp
or rope, secure pilot's foot pedal arms so
they are aligned (A, Figure 501). With
pilot's foot pedals clamped in neutral
and control rod lengths adjusted (Ref.
Figure 401 and Figure 402), control
system bellcrank positions may be
checked as follows:
(a). Tail rotor idler bellcrank (pilot's
compartment): Centerline of aft arm
should be 90 2 degrees to Sta. 78.50
bulkhead.
(b). Sta. 95 bellcrank: Centerline of

tunnel-routed control rod attach bolt
should be 4.30 0.090 inches (109.22
2.286 mm) above mast base struc
ture.
(c). Sta. 142 bellcrank: Centerline of
tailboom control rod attach bolt
should be 4.75-5.09 inches
(120.65-129.286 mm) from aft face of
Sta. 137.50 bulkhead. For access to
bellcrank, remove tail rotor control
bellcrank access door.
(3). Loosen rod end jam nut at forward end
of tailboom control rod.
(4). On tail rotor transmission, remove
hardware attaching tailboom control
rod to inboard end of Sta. 284 bellcrank.
(5). Tie back tail rotor rotating boot. Place
midtravel portion of swashplate rigging
tool (ST606) between swashplate and
tail rotor fork split-ring retainer (B,
Figure 501). Make sure that rigging
tool contacts ring and not fork.
(6). Turn tailboom control rod at aft end.
Adjust rod length to nearest half turn of
rod end that allows swashplate rigging
tool to just slide between split-ring
retainer and swashplate.
(7). Recheck that centerline of tailboom
control rod forward attach bolt remains
4.75-5.09 inches (120.65-129.286 mm)
from aft face of Sta. 137.50 bulkhead.
Also check forward rod end for not less
than one and one-half exposed threads
with jam nut snug against rod. If either
condition does not exist, disconnect
forward end of Sta. 120 control rod and
readjust both control rods until Sta. 142
bellcrank position and exposed threads
of both control rods are within toler
ance.
(8). Ensure that slotted bushing is in place
in bottom ear of Sta. 284 bellcrank and
inboard ear of Sta. 95 bellcrank.
Connect control rods (Ref. Figure 401).
67-20-10
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Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
0.250 IN. (6.35 MM)

MAX. MISALIGNMENT
BETWEEN PEDALS
CLAMPING BLOCKS
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
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
SWASHPLATE
RIGGING TOOL
(NOTE 3)
NON-ROTATING
BOOT
TAILBOOM CONTROL ROD
TAIL ROTOR FORK
(NOTE 2)
SPLIT-RING
RETAINER
BELLCRANK ACCESS DOOR

STA. 120 CONTROL ROD
(NOTE 2)
LEFT PEDAL RIGGING
MID-TRAVEL RIGGING
(NOTES 1, 2)
RIGHT PEDAL RIGGING
G67-2002B
Figure 501. Rigging Tail Rotor Control System

Page 502
Revision 21
67-20-10
MAINTENANCE MANUAL
(9). Check witness holes for proper thread
engagement. Align rod ends to get
approximately equal angular throw in
bellcranks; tighten jam nuts.
(10). Remove clamping device from foot pedal
arms.
(11). Loosen jam nuts on pedal stop bolts (A,
Figure 501). Screw in pedal stop bolts
approximately 0.50 inch (12.70 mm).
Use care when actuating pedals
to avoid possibility of damaging
tool or windshield.
CAUTION
NOTE: Adjust copilot's pedal stop bolts to

match pilot's pedal travel, 0.001-0.003 inch
(0.025-0.076 mm) gap between stop bolts
and pedals.
(12). Adjust right pedal stop bolt (A,
Figure 501) so that when pedal arm is
held against stop, right pedal portion of
swashplate rigging tool just slides
between split-ring retainer and
swashplate (view C). Fit should be tight
enough to support weight of tool.
Without changing adjustment of bolt or
tool fit, tighten jam nut on stop bolt.
(13). Adjust left pedal stop bolt (A,
Figure 501) so that when pedal arm is
held against stop with 20 - 25 pounds
(88.96 - 111.20 N) pressure (or pull on
right pedal), left pedal portion of
swashplate rigging tool just slides
between split-ring retainer and
swashplate (view D). Fit should be tight
enough to support weight of tool.
Without changing adjustment of bolt or
tool fit, tighten jam nut on stop bolt.
Remove swashplate rigging tool and
restore rotating boot to normal installed
position.
(14). Reinstall pedals. Slowly press outboard
pedal to its full forward travel position
against stop bolt. With not more than
20 pounds pressure applied, upper and
lower edges of pedal must clear canopy
glass by not less than 0.20 inch (0.508
mm).
CSP-HMI-2
(15). Operate pedals through full range of

travel. While controls are being moved,
check that there is never less than
0.060 inch (1.524 mm) clearance around
Sta. 120 control rod where it passes
through structure at Sta. 137.50 and
that there is never less than 0.010 inch
(0.254 mm) clearance around tailboom
control rod where it exits between boom
and tail rotor transmission.
(16). Connect bungee spring between aft end
of floor-routed control rod and Sta. 63
bracket (Ref. Figure 402) and check
that pilot's left pedal moves to its
normal forward position.
(17). Install Sta. 142 bellcrank access door.
2. Tail Rotor Bungee Adjustment
(1). 2-Bladed bungee adjustment:
(a). Increase pedal force by removing
washers from under bungee spring
eyebolt.
(b). If tail rotor pedal forces are not zero
during level flight at 130 - 140 knots,
tail rotor force adjustment may be
accomplished by removing a desired
number of AN970-3 washers.
(2). 4-bladed bungee adjustment:
(a). Adjust tail rotor pedal force by
tightening or loosening the 0.120
inch (3.048 mm) thread adjustment
on bungee female bearing assembly.
(b). Tighten to maximum 0.120 inch
(3.048 mm) thread adjustment on
bungee female bearing assembly
increases pedal force approximately
five pounds; loosening decreases
pedal force.
(c). Bungee spring may be attached to
any of four holes in fitting. If exces
sive left pedal force is required,
position spring at lower hole.
67-20-10
Page 503
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
369A2541
BRACKET
STA.
63.00
MS24665-143
COTTER PIN
AN42B-C10A EYEBOLT
AN970-3 WASHER (8 RE
QUIRED) MS21042-3 NUT
AN960-10L WASHER
BUNGEE
ASSEMBLY
MS17826-4
NUT
AN960KD416L
WASHER
369D27521
SPRING
TAIL ROTOR BUNGEE

(2-BLADED)
369DSK83-19
FITTING
AN960KD416L
WASHER
NAS1104-11D
BOLT
TAIL ROTOR BUNGEE

(4-BLADED)
G67-2019
Figure 502. Tail Rotor Bungee Adjustment
Page 504
Revision 21
67-20-10
MAINTENANCE MANUAL
CSP-HMI-2

INSPECTION/CHECK
Linkage Inspection
(Ref. Figure 401)
mm) maximum axial play. Inspect rivet
at fixed rod end.
(3). Inspect rubber boot just forward of Sta.
137.50 bulkhead for condition.
(4). Inspect tailboom control rod surfaces
that pass through all grommets.
Serviceable wear is limited to thickness
of hard anodic coating. Check that all
bushings are secure.
(5). Inspect bellcranks for scratches, cracks,
(6). Inspect bellcrank bearings for looseness
and binding.
(7). Inspect for obstructions in drain slot of
Sta. 284 bellcrank.
(8). Inspect for corrosion or excessive wear
on Sta. 284 bellcrank pivot pin.
(9). Visually inspect doublers on Sta. 142
bellcrank supports for cracking/da
mage.
NOTE: MDHC Notice DN-49 contains infor

mation relative to repair of damaged dou
blers on bellcrank supports. MDHC Notice
DN-102 contains information required to
modify the particle separator fairing and
cover assemblies to prevent possible chafing
of the Sta. 120 tail rotor control rod.
2. Tail Rotor Pedal Assembly Inspection

(Ref. Figure 402)
NOTE: Inspect components at left and right po

sition on the right-hand command models.
Check that corresponding pedals contact
stops simultaneously.
(1). Inspect pedals and pedal arms for
cracks, elongated pedal attach holes
and open drain holes. Inspect teflonreinforced bushing liners for deteriora
tion.
(2). Inspect pedal-to-arm quick-release
locking pin for condition and positive
spring action.
(3). Inspect links and bellcrank for cracks
and bends, and bearings for excessive
play.
(4). Inspect control rod fitting, torque tube
mounting bracket and pedal mounting
bracket for cracks and corrosion. Using
an 8-power magnifying glass, mirror
and flashlight, closely inspect pedal
link bellcrank fitting of pedal bracket in
center forward area where fitting (fork
piece) joins tubular section. If any
cracks are detected, replace bracket
assembly. Inspect bracket bearings for
excessive looseness.
(5). Inspect torque tube for cracks,
scratches, nicks, dents and similar
surface defects.
(6). Inspect pedal brackets for corrosion.
67-20-10
Page 601
Revision 21
CSP-HMI-2
MAINTENANCE MANUAL
Table 601. Isolating Control System Troubles
Symptom
Isolating Step
Corrective Action
Binding, lockingup and erratic

Disconnect pitch control links from
action of foot pedals (Do not force pitch control assembly.
controls).
If symptom is gone, replace tail rotor

assembly. Repair (Ref. COM).
Symptom remains.
Disconnect Sta. 284 aft boom

bellcrank from pitch control
assembly.
If symptom is gone, clean

swashplate 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 gearbox, caused by
looseness of bellcrank fulcrum bolt
and nut. Repair (Ref. COM).
Symptom remains.
Disconnect floorrouted tail rotor

control rod from foot pedal torque
tube fitting.
If symptom is gone, inspect tail rotor

control rods and bellcranks until
Symptom remains.
Loosen foot pedal torque tube

brackets mounted on front of floor
structure.
If symptom is gone, pedal torque

tube misaligned; shim for correct
alignment. If symptom remains,
disassemble and inspect tail rotor
control foot pedal installation until
Trouble corrected.
Page 602
Revision 21
67-20-10
MAINTENANCE MANUAL
CSP-HMI-2

REPAIRS
1. Floor and TunnelRouted Control Rods
(Ref. Figure 401 and Figure 402) The floorand tunnel-routed control rods connect the tail
rotor pedal installation with the upper
fuselage and tailboom control linkage. The two
control rods are linked by a tail rotor idler
bellcrank mounted on the underseat controls
support bracket.
2. FloorRouted Tail Rotor Control Rod
Repair
(Ref. Figure 401) Replace rod end if bearing
axial play is more than 0.040 inch (1.016 mm).
Riveted rod end bearing is replaceable without
rod removal if located at forward end of rod. If
riveted rod end is aft, rod removal is required
to replace rod end bearing.
(5). If removed, install rivet to secure rod

end.
then secure control rod in torque tube
fitting or idler bellcrank with bolt, two
(7). Install bungee spring.
(8). Install access doors.
Linkage Repair
(Ref. Figure 401)
Item
Nomenclature
CM318
CM431
CM802
Primer
NOTE: Floor-routed control rod normally does

not require replacement unless helicopter
receives extensive impact or crash damage.
Remove control rod forward through land
ing light wiring grommet hole after landing
light (if installed) is removed (Ref. Chap.
96).
(1). Disconnect control rod from pedal
torque tube fitting or from tail rotor
idler bellcrank (Ref. Figure 402).
Remove bungee spring (Ref. Sec.
67-10-00).
(2). Accurately measure and record distance
between unchamfered edge of rod end
jam nut and center of rod end bearing
hole.
rod end is steel and rod is aluminum.
CAUTION

rod that appears bent or bowed. Total
length of Sta. 120 control rod, excluding
rod ends, must be straight within 0.040
inch (1.016 mm), with straightness
variation limited to maximum of 0.010
inch (0.254 mm) in each foot of length.
Total length of tailboom control rod,
excluding rod ends, must be straight
A dye check for cracking
(3). If necessary, drill out rivet. Loosen jam

nut and unscrew rod end.
(4). Screw another rod end into rod to
obtain same measurement made in step
(2). above. Align control rod ends so
that bearings have equal space for
angular throw; tighten jam nut.
WARNING must always be performed

after cold-straightening. Replace
cracked rod, or cracked or bent rod
end.
within tolerance (step (1). above)
provided there are no nicks or sharp
67-20-10
Page 801
Revision 21
CSP-HMI-2
MAINTENANCE MANUAL
dents in bend length. Do not use rod

ends to support rod during straighten
ing process.
rod end is steel and rod and bearing adapter
are aluminum.
CAUTION

bearing angularity.
(4). Replace unserviceable control rod
bearing adapter. Trammel method (or
equivalent) may be used to establish
rod length when replacing an adapter.
(a). Measure length and record position
of rod end in adapter; then remove
affected rod end.
(b). Comply with precaution above and
drill out rivets securing adapter to
rod and aft rod end.
(c). Install rod end in replacement
adapter and position at recorded
measurement.
(d). Fit adapter into rod and position to
fit trammel point spacing; pick up
and drill through existing rivet holes
in rod and install rivets to secure
adapter to rod; at aft end, drill and
rivet rod end to adapter.
(5). Replace unserviceable bellcrank and
support pivot bearings. Install bearing
with grade A locking compound
(CM431). Make sure that bearing seats
against bore shoulder.
NOTE:
D Installation direction of Sta. 142 bell
crank bearing may be from either side,
depending on location of bearing shoul
der. There must not be less than 0.010
inch (0.254 mm) protrusion of bearing in
ner race beyond sides of bellcrank after
bearing is installed.
D If contact is noted between Sta. 142 bell
crank and mount bracket, rework bell
crank to clear bracket (Ref. Figure 801).
Page 802
Revision 21
67-20-10

scratches, nicks and corrosion on
bellcranks and support bracket. Use
abrasive cloth, grade 400 - 600
(CM802), to smooth out and blend in
such defects. Following rework limits
represent total limits, including effects
of all previous repairs to any given
area.
NOTE: Parts identified (Ref. Figure 401) with

an asterisk ( * ) may be either magnesium or
aluminum alloy. For corrosion control and
identification of magnesium and aluminum
alloys, refer to Section 20-40-00.
(a). Cast surfaces may be reworked to
depth of 0.020 inch (0.508 mm).
(b). Flat machined surfaces, except clevis
inner ears, may be reworked to depth
of 0.015 inch (0.381 mm). Clevis
inner ear surfaces may be reworked
to depth of 0.020 inch (0.508 mm).
(c). Machined holes may have 0.003 inch
(0.076 mm) removed from bore wall
in an area no greater than 15 percent
of circumference and 50 percent of
depth.
(d). All edges may have 0.030 inch (0.762
mm) removed except around ma
chined holes, which are limited to
0.010 inch (0.254 mm) chamfer.
(e). All rework must be smoothly blended
into adjacent surfaces and finish
must be restored (Ref. preceding
NOTE).
(7). Repair surface abrasion on Sta. 120
control rod by smoothing area with
grade 400 abrasive cloth (CM802) and
restoring protective finish with primer
(CM318). Replace rod if wear or depth
of repair exceeds 0.004 inch (0.102
mm).
(8). Replace tailboom control rod if hard
anodic coating is worn through and
aluminum base metal is visible.
(9). Replace split or torn boot. Remove Sta.
120 control rod. Replace boot and
reinstall Sta. 120 control rod.
MAINTENANCE MANUAL
CSP-HMI-2
BELLCRANK AND SUPPORT

(2 PLS) (NOTE 1)
0.002 IN.
A
(0.508 MM)
NOTES
2&3
0.090 IN. (2.286 MM) R

(TYP)
NOTES
2&3
369A7951-23
BEARING
0.750 IN.
(19.05 MM)
MIN.
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 (TunnelRouted)
Control Rod
All tunnel-routed control rods are removed,
inspected, repaired and installed in same
manner. For initial length and rod end
angularity, Ref. Figure 402. For maintenance
information, Ref. Sec. 67-10-00.
A. Tail Rotor Idler Bellcrank
(Ref. Controls Support Bracket and Bellcrank,
Sec. 67-10-00)
5. Tail Rotor Pedal Disassembly
(Ref. Figure 402)
(1). Before disassembly of tail rotor pedal
installation, matchmark mating pedal
arms, links and bellcranks with pedal
brackets to avoid intermixing compo
nents between locations at reassembly.
(2). Disconnect links from pedal arms and
bellcrank; remove links.
temporarily reinstall washer and nut

on bolt.
(5). Slide pedal bracket and pedal arms off
end of torque tube.
(6). Do not remove two teflon-lined bush
ings from right pedal arm, unless
replacement is required.
(7). Do not remove two stop bolts, jam nuts
on stop bolts or bearings from pedal
bracket unless replacement is required.
(8). Slide torque tube bracket and control
rod fitting off torque tube.
6. Tail Rotor Pedal Repair
(Ref. Figure 402)
Item
Nomenclature
CM425
CM431
Sealing compound
(3). Remove bellcrank from pedal bracket.

(4). Remove nut and washer of two bushing
assemblies that secure left pedal arm
and control rod fitting to torque tube.
Carefully remove bushing bolt and
(1). Replace parts that are cracked or have

elongated attachment holes. Do not
attempt to straighten bent torque tube
or pedal link.
67-20-10
Page 803
Revision 21
MAINTENANCE MANUAL
CSP-HMI-2
(2). Replace unserviceable pedal covers.

Apply sealing compound (CM425) to
approximately 30 percent of upper and
lower edge surfaces that contact pedal.
Cure according to container instruc
tions.
(3). Replace complete pedal link if it is
cracked or contains unserviceable
bearings; bearings are not replaceable.
(4). Replace unserviceable bearings in
mounting brackets or pedal link
bellcrank. Install replacement with
grade A locking compound (CM431).
Right pedal arm bushings are
glass-filled phenolic. Make cer
tain that bushing does not cock during re
placement, and that it is fully seated in arm
bore. Keep tools from contact with bushing
liners to avoid fraying.
CAUTION
(5). Replace bearings in right pedal arm

when teflon-reinforced liner is galled or
frayed. Pull bushing to remove; press to
install.
(6). Remove corrosion from pedal brackets
(Ref. Sec. 20-40-00 and CSP-A-3,
Corrosion Control Manual).
7. Tail Rotor Pedal Reassembly
(Ref. Figure 402)
(1). When reassembling components, check
for correct matchmark identification.
(2). If previously removed, thread jam nut
on each of two stop bolts and install two
stop bolts into threaded inserts of pedal
brackets.
rod fitting onto torque tube.
for correct position on torque tube; slide
bracket and arms onto torque tube.
(5). Fasten left pedal arm and control rod
fitting to torque tube with adjustable
bushing assemblies. Install bushing
bolt so that shank at bolt-head end
protrudes at least 0.002 inch (0.051
Page 804
Revision 21
67-20-10
mm). Torque nut to 50 - 80 inchpounds (5.65 - 9.04 Nm) plus drag

torque. Do not allow bolt to turn.
(6). Check that each end of bushing assem
bly shank protrudes at least 0.002 inch
(0.051 mm). If not, loosen and repeat
step (4). above.
then attach bellcrank to pedal bracket
pin.
place; then fasten each link to bellcrank
pin.
place; then fasten each link in pedal
arm lugs with bolt, two washers, nut
and cotter pin.
(10). Ensure outboard pedals clear windows
by a minimum of 0.20 inch (0.508 mm)
with 20 pounds (88.96 N) of force
applied.
8. Tail Rotor Bungee Spring Forward
Attachment Relocation
(Ref. Figure 802) The information given in this
procedure is for the relocation of the tail rotor
bungee spring forward attachment on 369D
helicopters, Serial No. 003D - 0467D. This
rework allows for the installation of washers,
for bungee adjustment, to adjust for minimum
pedal loads in cruise.
Item
Nomenclature
CM207
CM318
CM411
Chromic acid solution

Primer
Adhesive, epoxy
(1). Remove access cover between pilot's

seats and/or passenger's footwell on aft
side of canted bulkhead.
(2). Block left tail rotor control pedal at full
forward position to relieve tension on
bungee.
MAINTENANCE MANUAL
CSP-HMI-2
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
AN42B-C10A EYEBOLT
AN970-3 WASHER (8 REQUIRED)
MS21042-3 NUT
AN960-10L WASHER
STA
63.00
369A2541 BRACKET
CL SHIP
3.37 IN.
(8.5598 CM)
0.190-0.194 IN.
DIAMETER THRU BRACKET
(4.826-4.9276 MM)
B-B
1.75
369D27521 SPRING
VIEW LOOKING DOWN

VIEW LOOKING INBOARD LH SIDE
G76-2007A
Figure 802. Relocation of Tail Rotor Bungee Spring Forward Attachment
67-20-10
Page 805
Revision 21
CSP-HMI-2
MAINTENANCE MANUAL
(3). Disconnect bungee spring from eyebolt

and remove and retain nut and washer
attaching eyebolt to bracket at Sta. 63,
discard eyebolt.
(4). Locate position and drill new hole using
No. 10 drill, deburr as required.
(5). Seal old eyebolt hole with adhesive
(CM411). Allow to dry per manufactur
er's instructions.
end of 369D27521 bungee spring to

eyebolt. Insert eyebolt in new hole in
369A2541 bracket and secure with
washer and nut retained from prior
step. Torque nut to 20 - 25 inchpounds (2.26 - 2.82 Nm).
NOTE: If tail rotor pedal forces are not zero

during level flight at 130 - 140 knots, tail ro
tor force adjustment may be accomplished
by removing a desired number of AN970-3
washers.
(6). Treat edge of new hole with chromic

acid solution (CM207) and touch up
with zinc chromate primer (CM318).
(8). Remove block from left tail rotor control

pedal.
(7). Install eight AN970-3 washers on one

AN42B-C10A eyebolt and hook forward
(9). Reinstall access cover between pilot's

seats and/or passenger's footwell.
Page 806
Revision 21
67-20-10
MAINTENANCE MANUAL
CSP-HMI-2
Section
672030
NOTARr
AntiTorque System
Flight Controls
(500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
NOTAR ANTITORQUE SYSTEM FLIGHT CONTROLS

1. NOTAR AntiTorque System Control
Linkages Configuration and Description
(1). The helicopter may be equipped with
either of two basic configurations,
single left-hand command or righthand command, (dual control are
optional).
NOTE:
D The 600N helicopter does not have a
spring on the splitter assembly like the
500N helicopter.
D Some 600N helicopters are not equipped
with a YSAS system.
D The 600N helicopter has a Sta. 95 bell
crank instead of a Sta. 97.50 Bellcrank.
(2). The control linkages for the foot pedals
installation are identical to the basic
helicopter, with the exception of a pedal
friction mechanism with a preset
friction tension. The pedal friction
mechanism (500N only) offers the pilot
an artificial feel or workload of a
conventional tail rotor system.
(3). A splitter bungee spring (500N only)
which is incorporated in the flight
control system at the mast base
between the 97.50 bellcrank support
bracket and splitter pinion gear
dampens control feedback.
(4). Fuselage controls linkages consist of
Sta. 97.50 bellcrank and a support at
the front of the main rotor mast base,
fwd control tube, splitter bungee spring,
splitter assembly, intermediate control
tube, Sta. 137.50 support bracket and a
bellcrank at the fan transmission
support assembly, aft control tube and a
two piece cable assembly to the thrust
er.
(5). Empennage controls consist of a
thruster installation, four piece cable
and drum assembly, a control rod,
vertical stabilizer control tubes and
bellcranks and, in the case of the 500N,
a stability augmentation system

(S.A.S.).
2. Stability Augmentation System
NOTE: Aircraft equipped with YSAS cannot be

flown with any component of the system re
moved.
(1). The Yaw Stability Augmentation
System provides increased directional
stability and allows for a lower pilot
workload in the directional axis.
(2). The YSAS adds an actuator that is
located inside the right side of the
horizontal stabilizer and is mechanical
ly bolted to the horizontal stabilizer on
the outboard side.
(3). Two access panels on the horizontal
stabilizer allows access to the actuator,
bellcranks, control rod and electrical
connectors.
(4). A yaw rate gyro is located under the
pilot's seat structure on the foreword
bulkhead. Access to the gyro is through
the rear access panel (footwell) Sta.
78.50 canted bulked.
The yaw rate gyro provides short term
rate signals to the computer, propor
tional to the rate of angular displace
ment about the axis perpendicular to
the gyro's mounting surface damping in
the directional axis signal electronical
ly.
(5). A YSAS electronic control box (comput
er) is installed below the rate gyro. It is
equipped with an internally-mounted
lateral accelerometer.
The lateral accelerometer enhances
direction stability by feeding back to
the YSAS computer signals measured
during flight. The computer processes
the signals received and sends them to
the actuator.
(6). The 600N helicopters come equipped
with an indicator mounted in the
67-20-30
Page 1
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
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
369D2645427
Indicator
500N73053
Vne card set
500N653031
369D245069
Indicator
PFM Flight Manual Supplement
CSP520N1C
369D2645417
Decal
Page 2
Revision 25
67-20-30
MAINTENANCE MANUAL
CSP-HMI-2

1. AntiTorque Flight Controls
NOTE:
D The NOTAR anti-torque control system
must be re-rigged after removal or re
placement of control rods, linkages and
components or if helicopter operation re
D Refer to adjustment and test control rig
ging, during flight control installation.
2. Upper Fuselage Sta. 97.50 (500N) or Sta.
95 (600N) Bellcrank and Support Bracket
Replacement
(Ref. Figure 401)
A. Sta. 97.50 (500N) or Sta. 95 (600N)
Bellcrank and Support Bracket Removal
(1). Disconnect anti-torque control tube
(Sta. 87.50) and Fwd directional control
tube from Sta. 97.50 (Sta. 95) bellcrank.
(2). Remove nuts, washers and bolts from
main rotor mast base support bracket.
Remove bellcrank and support bracket
as an assembly.
B. Sta. 97.50 (500N) or Sta. 95 (600N)
Bellcrank and Support Bracket
Installation
(1). Position bellcrank and support bracket
on mast base structure,and install
three bolts, seven washers and three
nuts. Most forward bolt requires extra
thick washer under head of bolt. Torque
bolt to 80 - 100 inch-pounds (9.04 11.30 Nm) plus drag torque.
3. Forward Directional Control Tube

Replacement
(Ref. Figure 401)
A. Forward Directional Control Tube
Removal
(1). Remove fairings, access covers and
doors necessary to facilitate mainte
nance (Ref. Sec. 53-30-30, Upper Aft
Section Fuselage).
(2). Disconnect forward directional control
tube from Sta. 97.50 (Sta. 95) bellcrank.
(3). Disconnect forward directional control
tube from the lever assembly gear
pinion rack Sta. 113.00 splitter and
remove control tube.
B. Forward Directional Control Tube
Installation
(1). Forward directional control rod initial
length is 15.42 inches (39.17 cm),
measured center of rod end to center of
rod end. Install forward directional
control tube on pinion gear rack lever
assembly Sta. 113.00 splitter and on
Sta. 97.50 (Sta. 95) bellcrank.
(2). Ensure slotted bushings are in place.
Split bushings must protrude 0.010 0.060 inch (0.254 - 1.524 mm) above
surface of bellcranks.
(3). Install washers, bolts and nuts. install
cotter pins and safety wire jamnuts as
required.
(4). Install fairings and panels.
4. Splitter Bungee Spring Replacement
(500N)
(Ref. Figure 401)
(2). Ensure slotted bushings are in place

and connect anti-torque control tube
and fwd rod end of Fwd directional
control tube to bellcrank and cotter pin.
Split bushings must protrude 0.010 0.060 inch (0.254 - 1.524 mm) above
surface of bellcrank.
Item
ST601
ST602
Special Tools
Nomenclature
Rigging pin
Spring tension removal tool
67-20-30
Page 401
Revision 18
MAINTENANCE MANUAL
CSP-HMI-2
A. Splitter Bungee Spring Removal

or rope, secure pilots pedals in mid
position so they are aligned.
(2). Insert rigging pin (ST601) into the
upper hole of bracket assembly and
through the the slot marked ``M'' in the
gear pinion rack. (View B).
Bungee spring is under ten
WARNING sion, use care to prevent per
sonal injuries or damage to aircraft.
(3). Disconnect spring from links, either aft
or fwd., using a spring expansion tool
(ST602).
B. Splitter Bungee Spring Installation
upper hole of bracket assembly and
through the the slot marked ``M'' in the
gear pinion rack Sta. 113.00 splitter.
(2). With a spring expansion tool (ST602),
expand the spring the amount neces
sary to secure the spring to the forward
and aft links.
(3). Remove rigging pin.
5. Upper Fuselage Station 113.00 Splitter
Assembly and Bellcrank Replacement
A. Station 113.00 Splitter Assembly and

Bellcrank Removal
(1). 500N Only: Remove splitter bungee
spring from Sta. 113.00 splitter assem
bly pinion gear (Ref. Splitter Bungee
Spring Replacement (500N)).
(2). Disconnect forward cable assembly
rodend and rodend of forward direction
al control tube from walking lever.
NOTE: Note relationship of index marks on

splitter assembly.
(3). Align index marks on gear teeth.
Remove walking lever from splitter
bracket by removing nut, pivot bolt,
washers and spacer.
Revision 34
(5). Remove four bolts and washers, and

remove splitter assembly.
B. Station 113.00 Splitter Assembly and
(1). Position splitter bracket on structure
and install four bolts and washers.
(2). Position intermediate control tube on
gear pinion stud. Install link, spacer,
washer and nut; install cotter pin.
(3). During installation of walking lever
and bracket, align the index marks
together and install pivot bolt, spacer,
washers and nut and torque to 50 - 60
Ensure bushings and bearings are in
place; install cotter pin.
(4). Install forward cable assembly rodend
and fwd directional control tube rodend.
Ensure bushings are in place. Torque
nuts and install cotter pin.
(5). 500N Only: Install splitter bungee
spring.
6. Intermediate Control Tube Replacement
(Ref. Figure 402)
A. Intermediate Control Tube Removal
(Ref. Figure 402)
Page 402
(4). Remove nut, washer, link assy. and

spacer and disconnect intermediate
control tube from gear pinion stud.
67-20-30
(1). 500N Only: Remove splitter bungee

spring from Sta. 113.00 splitter assem
bly pinion gear (Ref. Splitter Bungee
Spring Replacement (500N)).
(2). Disconnect intermediate control tube
from gear pinion stud by removing nut,
washer, link and spacer.
(3). Disconnect aft end of intermediate
control tube at Sta. 137.50 bellcrank by
depressing pin in head of bolt to release
locking ball while removing nut. With
pin still depressed, remove bolt.
(4). Remove control tube boot ty-strap, and
move control tube carefully forward
through boot, support tube at plenum
chamber inlet.
MAINTENANCE MANUAL
CSP-HMI-2
AFT CONTROL ROD

SECTOR ASSEMBLY
TURNBUCKLE
IDLER PULLEY
DRUM ASSEMBLY
FWD TUBE
ASSEMBLY
MD500N
AFT CONTROL ROD
SECTOR ASSEMBLY
STA. 97.50
BELLCRANK
IDLER PULLEY
TURNBUCKLE
DRUM ASSEMBLY
MD500N
STA. 78.50
CONTROL ROD
FWD TUBE ASSEMBLY
MD600N
VIEW ROTATED 180
DRUM AND SECTOR ASSEMBLY
STA. 95
BELLCRANK
FWD DIRECTIONAL
CONTROL TUBE
SPLITTER SPRING
(MD500N ONLY)
STA. 78.50
CONTROL ROD
MD600N
ROOF-MOUNTED CONTROLS
RIGGING PIN
FWD CONTROL
CABLE
INTERMEDIATE
CONTROL TUBE
SPLITTER ASSEMBLY
G67-2013A
Figure 401. AntiTorque Control System
67-20-30
Page 403
Revision 18
MAINTENANCE MANUAL
CSP-HMI-2
B. Intermediate Control Tube Installation

(1). Carefully feed intermediate control
tube through boot if installed and
forward air inlet to bellcrank at Sta.
137.50.
(2). Connect control tube and check that
bushings are in place.
(3). Install impedance bolt as follows:
NOTE: Install bolt-head up, nut facing down.

(a). Depress pin in head of bolt to install
bolt though clevis assembly.
NOTE: In the following step, pin is to remain

depressed while nut is torqued.
(b). While pin is depressed, install nut
(4.52 - 5.65 Nm).
(c). Release pin and retorque nut to 75 90 inch-pounds (8.47 - 10.17 Nm)
to ensure engagement of locking balls
with nut.
NOTE: Pin must be in the released position

(flush with bolt head) and bolt must pro
trude past the nut for proper installation.
(d). Apply torque stripe.
(4). Install alternate NAS6204-11D bolt
and MS17826-4 nut as follows:
(a). Install bolt, with one AN960KD416L
washer through clevis assembly.
(b). Install AN960KD416L washer and
nut and torque to 20 - 40 inchpounds (2.26 - 4.52 Nm); install
MS24665-134 cotter pin.
(5). Position rubber boot in place. Secure
boot at support tube with nylon strap,
then clamp directional control pedals in
neutral, set free length of bellows
portion of boot at approximately 5.5
inches (13.97 cm) and secure end to
control tube with nylon strap.
(6). 500N Only: Install splitter bungee
spring.
Page 404
Revision 33
67-20-30
7. Station 137.50 Support Bracket and

Bellcrank Replacement
(Ref. Figure 402)
A. Station 137.50 Support Bracket and
Bellcrank Removal
(1). Disconnect intermediate control tube
from upper end of Sta. 137.50 bellcrank
by depressing pin in head of bolt to
disengage and release locking ball and
removing nut. With pin still depressed,
remove bolt.
(2). Disconnect link assembly at clevis,
remove bolt in same manner as in
previous step.
(3). Remove four support bracket assembly
bolts from fan transmission support.
(4). Bellcrank and bracket assembly may be
separated by removing bolt.
B. Station 137.50 Support Bracket and
NOTE: It is recommended to assemble link and

bracket assembly to bellcrank before install
ing bracket assembly on fan transmission
support bracket.
(1). Reassemble bellcrank and bracket
assembly if necessary.
(2). Install impedance bolt as follows:
bolt through bracket and bellcrank.

(b). Install nut and torque to 100 - 120
inch-pounds (11.30 - 13.56 Nm).
(c). Release pin and torque nut to 200 225 inch-pounds (22.60 - 25.42
Nm) to insure engagement of locking
ball with nut.

MAINTENANCE MANUAL
(4). Install lower bolt at link assembly and
bellcrank clevis, and upper bolt inter
mediate control tube Sta. 137.50
bellcrank bolts as follows:
NOTE: Install bolt-head up, nut facing down.

bolt through clevis end of bellcrank.

(4.52 - 5.65 Nm).
with nut.

(6). Install four support bracket assembly
bolts and washers to fan transmission
support. Torque bolts to 70 - 90
inch-pounds (7.91 - 10.17 Nm);
safety wire bolts.
8. Fan Pitch Control Tube Replacement
A. Fan Pitch Control Tube Removal
(1). Remove tail boom fairing and tail boom.
(2). Remove bolt and clevis assembly at Sta.
137.50 bellcrank. Remove convoluted
boot from fan gearbox.
CSP-HMI-2
NOTE: The Fan Pitch Control Tube can be re

moved in either one of the following steps.
The fan assembly pitch bearing slider, pitch
bearing retainer, pitch plate bearings and
bearing retainer nut with aft control tube
can be removed as a unit or individually.
Use extreme care do not damage parts.
(1) Remove locking wire and remove nut and
lock washer from fan pitch control tube.
Remove locking wire and remove three
bolts and washers from pitch bearing re
tainer housing. Pitch bearing slider, pitch
plate bearings and, bearing retainer nut
with aft control tube can be removed as a
unit.
(2) Remove locking wire and remove six pitch
bearing housing assembly bolts. Remove
pitch bearing retainer housing assembly
as a unit.
B. Fan Pitch Control Tube Installation
NOTE:
D Refer to Fan Pitch Control Rigging during
installation.
D Before installing fan pitch control tube,
perform Fan Pitch Control Tube Inspec
tion.
(1). Install the aft control tube.
(2). Install convoluted boot on fan gearbox
or clevis.
NOTE: In the following step, clevis should be

bottomed into control tube, approximately
one thread showing after engagement.
(3). Install clevis assembly on aft control
tube. Ensure that clevis has full thread
engagement on control tube.
(4). Ensure locking washer tang tip is in
slot. Tighten jam nut against locking
washer and safety wire from lock to
nut. Ensure safety wire pigtail is on the
nut.
(5). Install floating bushing in clevis.
(6). Install bolt, bolthead on floating
bushing side of clevis, through clevis
and link assembly as follows:
bolt through clevis end of bellcrank.
67-20-30
Page 405
Revision 38
MAINTENANCE MANUAL
CSP-HMI-2

(4.52 - 5.65 Nm).
with nut.

NOTE: Before installing fan pitch slider, per

form Fan Pitch Slider Inspection.
(8). Install pitch bearing slider and bearing
retainer per rigging instructions.
(9). Install pitch bearing and pitch bearing
retainer housing using three bolts and
inch-pounds (7.91 - 9.04 Nm); safety
wire bolts.
(10). Install lockwasher so that the face of
the tang aligns with the tube assembly
keyway, and the lockwasher aligns with
one of the six slots in the face of the
bearing retainer.
(11). Install jamnut on aft control tube.
(12). Torque nut to 95 -110 inch-pounds
(10.73 - 12.43 Nm) leaving a minimum
Page 406
Revision 34
67-20-30
of three threads protruding beyond the

face of the jam nut.
(13). Install two lockwires on jamnut and
lockwasher.
NOTE: After safety wiring nut and bolts, rotate

fan and ensure that safety wires do not have
interference with each other on rotation.
(14). Install tail boom (Ref. Sec. 53-40-30).
9. Forward Cable Assembly Replacement
(Ref. Figure 402)
A. Forward Cable Assembly Removal
CAUTION
To prevent damage to the engine

install F.O.D. cover over engine
air inlet.
(1). Remove fairings, access doors and
panels necessary to facilitate mainte
nance (Ref. Sec. 53-30-30).
(3). Disconnect the aft end of the antitorque control cable by turning outside
collar sleeve counter-clockwise and
back to expose the inner cable.
(4). Apply sufficient right pedal to expose
inner cables.
(5). Without bending cable, slide male
connector out of female connector.
(6). Disconnect cable assembly forward
rodend from Sta. 113.00 splitter
assembly outboard bellcrank clevis.
(7). Loosen jam nut at rodend and remove
rodend from cable; remove jam nut.
(8). Remove safety wire, jam nuts and
washers from cable assembly support
bracket, remove by pulling or sliding
cable assy. thru conduit and support
bracket.
MAINTENANCE MANUAL
CSP-HMI-2
CABLE ASSY
INTERMEDIATE
TUBE ASSY
SPLITTER ASSY
FORWARD
TUBE ASSY
STA. 137.50
BRACKET
STA. 137.50
BELLCRANK
NOTE 2
NOTE 1
FAN PITCH
CONTROL TUBE
FLOATING
BUSHING
NOTES:
1. CLEVIS FULLY ENGAGED INTO FAN
PITCH CONTROL TUBE.
2. SAFETY FROM LOCKING WASHER TO NUT.
ROTATED
LINK ASSY
G67-2008-1E
Figure 402. Upper Fuselage and Boom Control Linkage (Sheet 1 of 2)
67-20-30
Page 407
Revision 38
MAINTENANCE MANUAL
CSP-HMI-2
CLAMP
STA. 304.00
MD500N
STA. 123.30
FITTING
SUPPORT BRACKETS
STA. 131.50 AND 151.00
SUPPORT BRACKET AND CABLE

ASSY. TAILBOOM STA. 264.00
STA. 303.30
MD600N
RIGHT CONTROL ROD
BELLCRANK
CENTER
BELLCRANK
SHAFT
INNER FEMALE
CONNECTOR
MD600N
INNER MALE
CONNECTOR
FORWARD-TO-CENTER
CABLE CONNECTION
LEFT CONTROL ROD
TORQUE TUBE
HOUSING
MD500N
VERTICAL STABILIZER
CONTROL RODS
G67-2008-2D
Figure 402. Upper Fuselage and Boom Control Linkage (Sheet 2 of 2)

Page 408
Revision 25
67-20-30
MAINTENANCE MANUAL
B. Forward Cable Assembly Installation
Item
Nomenclature
CM702 Lockwire CRES
Before installation of cable, in

spect cable (Ref. Forward and
Center Cable Assembly Inspection).
CAUTION
(1). Install one jam nut and washer on cable

and insert cable assembly through
support bracket and conduit.
(2). Install washer and one jam nut on cable
forward side of support bracket.
(3). Ensure that the threaded portion is
centered in the support bracket.
NOTE: When tightening cable jamnuts, ensure

smooth action of cable and alignment of
cable hex end into cable socket.
(4). Ensure cable hex end and cable socket
are aligned to ensure smooth action.
(5). Slide cable in and out to ensure there is
no binding and tighten jamnuts.
(6). Slide cable in and out again to ensure
there is no binding. If cable slides
smoothly, safety jamnuts (CM702).
(7). Install rodend bearing with locking
device and jamnut.
(8). Ensure that threads protrude past
witness hole. Tighten jamnut and
safety wire nuts.
(9). Connect cable assembly forward rodend
to Sta. 113.00 splitter assembly out
board bellcrank clevis.
CSP-HMI-2
(b). Without bending cable, insert inner

male connector into inner female
connector and ensure they are
properly engaged together.
(c). Slide outside cable collar over
forward cable to engage locking
device and turn clockwise until fully
locked.
(12). Verify rigging of cable assembly from
Sta. 113.00 splitter assembly (Ref.
Adjustment/Test).
(13). Install fairings, access doors and panels
removed for installation.
10. Center Cable Assembly Replacement
(Ref. Figure 402)
A. Center Cable Assembly Removal
Sec. 53-40-30).
Sec. 53-40-30).
bolt from clevis end of control rod
double rodend.
(4). Disconnect cable assembly double rod
end bearing from center tailboom
bellcrank.
(5). Remove double rod end from cable
assembly.
(7). Disconnect the forward end of the
anti-torque control cable by turning
forward cable outside collar sleeve
counter-clockwise and back to expose
the inner cable.
(10). Torque nut and install cotter pin.
(8). Apply sufficient right pedal to expose

inner cables.
(11). Reconnect forward and center control

cable couplings.
(9). Without bending cable, slide male

connector out of female connector.
Failure to properly connect
WARNING thruster cables could result

in uncoupling during flight and loss of
anti-torque authority.
(a). Apply sufficient right pedal to expose
inner cable female connector.
(10). Disconnect cable assembly forward

rodend from Sta. 113.00 splitter
assembly outboard bellcrank clevis.
(11). Remove safety wire and aft jamnut
from cable assembly support bracket.
Cable assembly can be removed by
67-20-30
Page 409
Revision 33
CSP-HMI-2
MAINTENANCE MANUAL
sliding or pulling cable assembly

through support bracket and conduit
and through grommet.
B. Center Cable Assembly Installation
Failure to properly connect
WARNING thruster cables could result

in uncoupling during flight and loss of
anti-torque authority.
(a). Apply sufficient right pedal to expose
inner cable female connector.
Before installation of cable, in

spect cable (Ref. Forward and
Center Cable Assembly Inspection).
CAUTION
(b). Without bending cable, insert inner

male connector into inner female
connector and ensure they are
properly engaged together.
(1). Install one jam nut and washer on cable

and route cable assembly thru conduit
of tailboom and thru support bracket.
(c). Slide outside cable collar over

forward cable to engage locking
device and turn clockwise until fully
locked.
(2). Install washer and jamnut on cable aft

side of support bracket.
(3). Ensure that the threaded portion is
centered in the support bracket.
NOTE: When tightening cable jamnuts, ensure

smooth action of cable and alignment of
cable hex end into cable socket.
(4). Ensure cable hex end and cable socket
are aligned to ensure smooth action.
(5). Slide cable in and out to ensure there is
no binding and tighten jamnuts.
(6). Slide cable in and out again to ensure
there is no binding. If cable slides
smoothly, safety jamnuts (CM702).
(7). Install double rodend bearing with
locking device and jamnut.
(8). Ensure that threads protrude past
witness hole. Tighten jamnut and
safety wire nuts.
NOTE: The split bushing is installed at the top

of bellcrank. A minimum of 0.010 inch
(0.254 mm) and a maximum of 0.060 inch
(1.524 mm) split bushing protrusion re
quired above surface.
(9). Install double rodend bearing and
forward bearing to bellcrank with bolt,
washers and nut. Tighten nut and
install cotter pin.
(10). Reconnect forward and center control
cable couplings.
Page 410
Revision 33
67-20-30
(11). Verify rigging of cable assembly from

Sta. 113.00 splitter assembly to vertical
stabilizers is correct.
(12). Install stationary thruster cone.
(13). Install rotating thruster cone.
11. Aft Control Rod Assembly Replacement
(Ref. Figure 402)
A. Aft Control Rod Assembly Removal
(1). Remove thruster cone (Ref. Sec.
53-40-30).
Sec. 53-40-30).
from sector input shaft.
(4). Remove pan cover.
bolt from clevis end of control rod at
double rodend bearing of tailboom
center cable assembly.
(6). Remove and discard lockwire and then
remove control rod bolt from sector
assembly.
(7). Remove control rod.
B. Aft Control Rod Assembly Installation
Item
Nomenclature
CM702 Lockwire CRES
MAINTENANCE MANUAL
NOTE: Split bushing is installed at the top,

shoulder bushing is installed at bottom. A
minimum of 0.010 inch (0.254 mm) and
maximum of 0.060 inch (1.524 mm) split
bushing protrusion required above surface.
CSP-HMI-2
(6). Remove control rod bolt from sector

assembly and lift sector assembly from
shaft.
(7). Remove clevis pins from sector assem
bly and remove cables.
(1). Connect thruster control rod clevis end

to double rod end aft bearing of center
cable assembly.
B. Sector Assembly and Control Cable

Installation
(2). Install washer and bushing on bolt and

then insert through rod end into sector
assembly.
Nomenclature
(3). Torque bolt to 30 - 40 inch-pounds

(3.39 - 4.52 Nm) and install safety wire
(CM702).
(4). Install bushings, bolt, washer and nut;
(5). Install pan cover.
(6). Install washer and nut on sector input
shaft; torque nut to 95 - 110 inchpounds (10.73 - 12.43 Nm) and install
cotter pin.
(7). Install stationary thruster cone.
Item
CM702 Lockwire CRES
(1). Position the cable assembly around

thruster sector bellcrank, install cable
clevis pins and cotter pins.
(2). Install sector bellcrank on input shaft.
(3). Connect sector assembly aft control rod
to clevis.
(a). Install washer and bushing on bolt
and then insert through rod end into
sector assembly.
(b). Torque bolt to 30 - 40 inch-pounds
(3.39 - 4.52 Nm) and install safety
wire (CM702).
12. Sector Assembly and Control Cable

Replacement
(4). Install bushing, washer on sector input

shaft.
(Ref. Figure 401)
(5). Install pan cover.
A. Sector Assembly and Control Cable

Removal
Sec. 53-40-30).
NOTE: Removed safety clips from turnbuckles

are not to be reused.
(2). Disconnect cables from turnbuckles in
access hole provided (top of stationary
cone).
(3). Remove cotter pin, nut and washers
from sector input shaft.
(4). Remove pan cover.
(5). Remove washer and bushing under pan
cover from sector bellcrank input shaft.
(6). Install washer and nut on sector input

shaft; torque nut to 95 - 110 inchpounds (10.73 - 12.43 Nm) and install
cotter pin.
(8). Perform a rigging check.
13. Drum Assembly and Idler Pulley
Replacement
(Ref. Figure 401)
A. Drum Assembly and Idler Pulley Removal
Sec. 53-40-30).

67-20-30
Page 411
Revision 33
MAINTENANCE MANUAL
CSP-HMI-2
(2). Disconnect cables from turnbuckles in

access hole provided (top of stationary
cone).
(3). Remove cotter pin, nut and two wash
ers, remove drum assembly from shaft.
(4). Remove guard pins to remove cable
assemblies.
B. Drum Assembly and Idler Pulley
Installation (500N)
NOTE: The long cable is 23.07 inches (58.60

cm) and is installed on the aft cable guide of
the drum, or right side, up and around the
right idler pulley. The short cable is 22.82
inches (57.96 cm) long and is installed on
the fwd cable guide of the drum, or left side,
up and round the left idler pulley.
(1). Install cables on drum assembly.
(2). Install drum assembly on shaft and
install guard pins.
(3). Install HS306-233H flat washer
against the bearing.
(4). Install washer and nut; torque nut to
160 - 190 inch-pounds (18.08 - 21.47
Nm) and install cotter pin.
(5). Install turnbuckles and cables.
C. Drum Assembly and Idler Pulley
Installation (600N)
NOTE: The long cable is 23.76 inches (60.35

cm) long and is installed on the aft cable
guide of the drum, or right side, over and
around the left idler pulley. The short cable
is 23.51 inches (59.72 cm) long and is in
stalled on the fwd cable guide of the drum,
or left side, over and round the right idler
pulley.
(1). Install cables on drum assembly as
follows:
(a). Install left cable on forward groove of
drum and cross over to right pulley.
(b). Install right cable on aft groove of
drum and cross over to left pulley.
Page 412
Revision 33
67-20-30
(2). Install drum assembly on shaft and

install guard pins.
(3). Install HS306-233H flat washer
against the bearing.
(4). Install washer and nut; torque nut to
160 - 190 inch-pounds (18.08 - 21.47
Nm) and install cotter pin.
(5). Install turnbuckles and cables.
14. AntiTorque Pedal Friction Replacement
(Ref. Figure 403)
A. AntiTorque Pedal Friction Removal
(1). Remove bolt, washer and bushing from
console support bracket.
(2). Remove nut and washers, remove
spring, retainer, spring and friction
disc, and link.
(3). Remove brace and clamp arm assembly
from anti-torque tube assembly.
B. AntiTorque Pedal Friction Installation
or rope, secure pilot's pedals in mid
position so they are aligned within 0.50
inch (1.27 cm) of each other.
(2). Install washer, bolt, bushing, and link
assembly to bracket assembly on
instrument console.
(3). Install brace and clamp arm assembly
to anti-torque tube assembly.
(4). Install friction disc, link, retainer and
spring, install washer (shim washers if
required) and nut.
(5). Torque brace and arm assembly bolts
30 - 35 inch-pounds (3.39 - 3.95
Nm). Torque nut against washer to
obtain a pedal friction of 5 - 8 pounds
(2.27 - 3.63 kg).
15. AntiTorque Pedal Assembly
Replacement
(Ref. Figure 403)
A. AntiTorque Pedal Assembly Removal
(1). Pull two hinge pins from pilot's com
partment floor access door hinges and
remove door.
MAINTENANCE MANUAL
CSP-HMI-2
STA. 97.50 BELLCRANK
STA. 97.50
(TUNNEL-ROUTED)
CONTROL ROD
CONTROLS SUPPORT
BRACKET
INITIAL CONTROL ROD LENGTH
- BEFORE RIG
CONTROL
DIMENSION L
ROD
INCHES (CM)
TUNNEL-ROUTED
57.95 (147.193)
FLOOR-ROUTED
30.06 (76.3524)
ANTI-TORQUE PEDAL
FRICTION
SPRING FITTING
AFT EYEBOLT
BUNGEE
SPRING
STA. 63.00
TAIL ROTOR IDLER

BELLCRANK
NOTE 2
FORWARD EYEBOLT
RIVET
FLOOR-ROUTED
CONTROL ROD
NOTE 1
L
MAXIMUM ALLOWABLE LOOSENESS

NOTE 2
0.040 IN. (1.016 MM)
TORQUE TUBE
NOTE 3
BUSHING ASSY
(NOTE 4)
NOTE 1
* TORQUE TUBE BRACKET

(NOTE 5)
CONTROL ROD FITTING
PIN
NOTE 1
WASHER
NOTE 3
NOTE 4
BEARING
* LEFT PEDAL
NOTE 1
BEARING
STOP BOLT
JAMNUT
NOTE 2
* RIGHT PEDAL
NOTE 3
NOTE 1
* PEDAL ARM
NOTE 1
BUSHING
(TEFLON-LINED)
* PEDAL BRACKET
* PEDAL ARM
NOTE 4
NOTE 2
BUSHING
(TEFLON-LINED)
BUSHING ASSY
(NOTE 4)
NOTE 2
LINK
BEARING
NOTE 2
BELLCRANK
NOTES:
1. SHIM BETWEEN BRACKET AND BULKHEAD WITH AN960PD416
AND/OR -416L WASHERS AS REQUIRED FOR ALIGNMENT WITHIN
0.010 IN. (0.254 MM).
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. DIRECTION OF BOLTS IS OPTIONAL.
4. ADJUSTABLE BUSHINGS MUST HAVE A MINIMUM PROTRUSION OF
0.002 IN. (0.051 MM) AT EACH END.
5. INSTALLED WITH BEARING RECESS FACING FITTING.
6. ASTERISK (*) INDICATES PART THAT MAY BE EITHER MAGNESIUM OR
ALUMINUM ALLOY. FOR ALLOY IDENTIFICATION AND CORROSION
CONTROL REF. SEC. 20-40-00.
G67-2001-3
Figure 403. Pedal Installation (Sheet 1 of 2)
67-20-30
Page 413
Revision 25
CSP-HMI-2
MAINTENANCE MANUAL
RIGHT POSITION
ANTI-TORQUE PEDALS
STOP BOLT
(2 EACH)
NOTE 1
NOTE 2
JAMNUT
ADJUSTABLE BUSHING
ASSEMBLY (NOTE 4)
NOTE 3
TORQUE TUBE
SLOTTED BUSHING
(TYPICAL) (NOTE 2)
SLEEVE
ADJUSTABLE BUSHING
ASSEMBLY (NOTE 4)
TORQUE TUBE
G67-2001-4
Figure 403. Pedal Installation (Sheet 2 of 2)

(2). Remove access panel from each side of
instruction panel lower support struc
ture.
(3). Remove battery (Ref. Sec. 96-00-00).
(4). Remove pins securing pedals to pedal
arms and remove pedals.
(5). Remove pedal friction mechanism.
and bolt that connect floor-routed
control rod to torque tube fitting.
(7). Remove two nuts, four washers, any
shim washers and two bolts that secure
torque tube bracket to bulkhead. Keep
shim washer selection with bracket to
Page 414
Revision 30
67-20-30
simplify torque tube alignment during

reinstallation.
(8). Remove four nuts, eight washers, any
shims washers and four bolts that
secure pedal bracket to bulkhead.
(9). Remove control pedal installation. Keep
shim washer selection with bracket for
reinstallation.
B. AntiTorque Pedal Assembly Installation
(1). Install pedal bracket with four bolts,
eight washers and four nuts.
(2). Add shim washers as required at pedal
bracket attachment points to keep
centerline alignment of pedal bracket
bearings within 0.010 inch. Correct
alignment is indicated by free rotation
MAINTENANCE MANUAL
al movement of torque tube after nuts
are torqued with no evidence of binding.
(3). Position torque tube bracket over
mating holes in bulkhead and check
alignment with bulkhead.
(4). Add shim washers as required at
bracket attachment points to maintain
bearing alignment established in step
(2). above. Install two bolts, four
washers and two nuts.
(5). Check that slotted bushing is in place,
install floor-routed control rod in
torque tube fitting and install bolt, two
washers and nut; install cotter pin. A
minimum of 0.010 inch (0.254 mm) and
a maximum of 0.060 inch (1.524 mm)
split bushing protrusion required above
surface.
(6). Install anti-toque pedal friction
mechanism.
(7). Check rigging of pedal assembly
controls and pedal-to-canopy clear
ance. Pedals should clear windows by a
minimum of 0.020 inch (0.508 mm) with
20 pounds (9.0718 Kg) of force applied.
16. Stability Augmentation System (S.A.S.)
Actuator Replacement
(Ref. Figure 505)
A. S.A.S. Actuator Removal
CSP-HMI-2
NOTE: Observed and note position of vertical

stabilizer bellcrank for reinstallation pur
poses.
(6). Remove vertical stabilizer torque tube
(Ref. Sec. 53-50-30, Vertical Stabilizer
Torque Tube and/or Bushing Replace
ment).
(7). Disconnect electrical connector from
actuator.
(8). Disconnect S.A.S. actuator from control
rod.
(9). Remove bolts from actuator support
bracket and carefully slide actuator out
of access hole.
B. S.A.S. Actuator Installation
NOTE: Whenever S.A.S. actuator or control

tube is replaced, S.A.S. rigging must be per
formed.
(1). Slide actuator through access panel and
attach actuator to support bracket.
(2). Install vertical stabilizer torque tube
(Ref. Sec. 53-50-30, Vertical Stabilizer
Torque Tube Replacement).
(3). Connect actuator control tube to
vertical stabilizer torque tube bell
crank. Torque nut to 30 - 40 inchpounds (3.39 - 4.52 Nm) and install
cotter pin.
NOTE: Care should be observed to position ver

tical stabilizer bellcrank in the same posi
tion as removed.
(1). Disconnect electrical power from

aircraft. Ensure that battery power is
disconnect.
(4). Reinstall upper and lower R/H vertical

stabilizers (Ref. Sec. 53-50-30, Vertical
(2). Remove horizontal stabilizer center

access panels and R/H end cap access
cover.
(5). Reconnect electrical connector to

actuator.
(3). Remove upper and lower R/H vertical

stabilizers (Ref. Sec. 53-50-30, Vertical
(4). Disconnect actuator control tube from
vertical stabilizer torque tube bell
crank.
(5). Remove R/H vertical stabilizer torque
tube bellcrank.
(6). Perform S.A.S. actuator rigging check

(Ref. Stability Augmentation System
Rigging Instructions).
(7). Install access panels.
17. S.A.S. Rate Gyro and Electronic Control
Box (Computer) Replacement
Access to the rate gyro and electronic control
box (computer) is through the passenger
compartment footwell access panels.
67-20-30
Page 415
Revision 30
CSP-HMI-2
MAINTENANCE MANUAL
The units are mounted on a rack under the

pilot's seat structure against the seat structure
forward panel.
(2). Disconnect and remove electrical plug.
The 500N has the components mounted

approximately 12 inches (30.48 cm) to the
right of centerline.
(4). Carefully remove component from rack.
The 600N has the components mounted

approximately 12 inches (30.48 cm) to the left
of centerline.
A. S.A.S. Rate Gyro and Electronic Control
Box (Computer) Removal
(1). Remove appropriate passenger
compartment footwell fairing (Ref. Sec.
52-50-00).
Page 416
Revision 30
67-20-30
(3). Remove mounting hardware.

B. S.A.S. Rate Gyro and Electronic Control
Box (Computer) Installation
(1). Install component on rack.
(2). Reinstall mounting hardware. Torque
screws to 12 - 15 inch-pounds (1.36 1.69 Nm) plus drag torque.
(4). Reinstall passenger compartment
footwell fairing (Ref. Sec. 52-50-00).
MAINTENANCE MANUAL
CSP-HMI-2

ADJUSTMENT/TEST
1. Directional Controls Rigging
NOTE:
D On the 500N, directional control rigging
is to be accomplished with the (Sta.
113.00) spring on the splitter assembly
disconnected.
D The NOTAR control system must be rerigged after replacement of control rods,
linkages, and components or if helicopter
operation reveals a rigging deficiency.
2. Fan Pitch Control Rigging
(Ref. Figure 501)
Item
Nomenclature
CM702
Lockwire CRES
Item
Special Tools
Nomenclature
ST601
Rigging pin
NOTE: Fan Pitch Control Rigging shall be ac

complished with the tailboom and engine air
inlet fairings removed.
(1). Position Sta. 113.00 splitter assembly
pinion gear so the rigging slot aligns
with lower rigging hole in the bracket
assembly; Insert the rigging pin
(ST601) (View A).
(2). Adjust the bearing retainer so the
flange of bearing retainer is screwed in
on the tube assembly until it just
touches the shoulder of the fan pitchaft control tube (View B).
NOTE: A gap of 0.015-0.025 inch (0.381-0.635

mm) between pitch bearing housing and
bearing retainer plate must exist to ensure
proper clamp-up.
(3). Assemble the pitch plate control

bearing into slider and attach the
bearing retainer plate using three bolts
and three washers.
(7.91 - 9.04 Nm) and safety (CM702).
NOTE: Every 60 turn on bearing retainer is

equivalent to 0.6 degree change in fan pitch
angle.
(5). Using the TICK marks on the fan blade
assembly and on hub housing to
determine blade pitch angle, adjust
bearing retainer to obtain a fan blade
pitch angle of 26 1 (View D).
NOTE:
D The aft control tube keyway should be in
stalled at the 12 O'clock position for ease
of installation.
D Ensure that one of the six slots in the face
of the bearing retainer aligns with fan
pitch-aft control tube key way (View C).
(6). Install lockwasher so that the face of
the lockwasher aligns with one of six
slots of the bearing retainer.
(7). Install jam nut, torque nut to 95 - 110
inch-pounds (10.73 - 12.43 Nm)
leaving a minimum of three threads
protruding beyond the face of the jam
nut.
(8). Check tick marks on fan blade assem
bly and hub housing, ensure that fan
pitch angle is 26 1. If blade pitch is 26
1, proceed to step (9). If not, remove
jamnut and lockwasher and return to
steps (5).
(9). Safety wire (CM702) nut and lockwash
er (2 places required).
(10). Rotate fan to ensure the safety wire
does not interfere.
67-20-30
Page 501
Revision 33
MAINTENANCE MANUAL
CSP-HMI-2
UPPER RIGGING
HOLE
FWD CONTROL
CABLE
SEVENTEEN TO SEVENTYSEVEN
DEGREES AT 5 INCREMENTS
BRACKET
ASSY
PINION GEAR
TICK MARKS
26 1 FAN C/L
FAN HUB ASSY
500N9901
RIGGING TOOL
SPLITTER ASSEMBLY
RIGGING LOCATION
17
77
LOWER RIGGING
HOLE
FAN BLADE ASSY

TICK MARK LOCATION
ON FAN ASSEMBLY
ONE OF
SIX SLOTS
BEARING RETAINER
ASSEMBLY
BEARING
RETAINER
FAN PITCH
CONTROL TUBE
TUBE ASSY
PITCH PLATE
CONTROL BEARING
FAN PITCH CONTROL

KEYWAY TUBE
SLIDER
BEARING RETAINER
LOCATION
BEARING RETAINER SLOT

AND KEYWAY ALIGNMENT
G672010
Figure 501. Fan Pitch Control Rigging

Page 502
Revision 18
67-20-30
MAINTENANCE MANUAL
NOTE:
D If the required adjustment of bearing re
tainer, lockwasher and jamnut cannot be
achieved, adjust the intermediate control
tube to meet requirements of specifica
tions in steps (5). thru (10).
D Do not adjust the control rodend beyond
the witness hole. Do not tighten jam nut
until after final adjustment.
(12). Fan Pitch Control Rigging shall
produce the following results:
(a). 500N:
1). Full left pedal, 69 - 73 degrees.
2). Full right pedal, 50 - 54 degrees.
(b). 600N;
1). Full left pedal, 71 - 75 degrees.
2). Full right pedal, 52 - 56 degrees.
NOTE: On the 600N helicopter, the pedal po

tentiometer rigging must be checked any
time the anti-torque system has been ad
justed.
3. Pilot Pedal Rigging
(Ref. Figure 502)
Item
Nomenclature
CM702
Lockwire CRES
NOTE: Directional control rigging shall be ac

complished with the (Sta.113) splitter
spring assembly disconnected (500N) and
the fan pitch control rigging complete.
(1). Remove left-hand air inlet fairing to
facilitate pedal rigging (Ref. Sec.
53-30-30).
Remove pilot's pedals and copi
CAUTION lot's (if installed) to prevent pos
sible contact with lower windshield during
rigging sequence.
or rope, secure pilot's foot pedal arms so
CSP-HMI-2
they are aligned (View A). Maximum

misalignment between pedals shall be
0.50 inch (1.27 mm).
NOTE: Do not adjust the control rod beyond the

witness hole. Do not tighten the locking
jamnut until after final adjustment.
(3). Anti-torque idler bellcrank position to
be checked as follows:
(a). Position pilot's foot pedals in neutral
and floor-routed control rod length
(initial control rod length is 30.06
inches (76.35 cm) before rigging).
(b). Adjust floor-routed control rod so
that centerline of bellcrank arm is
90 2 degrees to Sta. 78.50 canted
bulkhead (View B).
(c). Sta. 97.50 bellcrank: Adjust the
tunnel-routed control rod so the
centerline of the tunnel-routed
control rod attach bolt in the transfer
bellcrank is 4.21 - 4.39 inches (10.69
- 11.15 cm) above mast base struc
ture (View C).
engagement.
(5). Tighten jamnuts and safetywire
(CM702) as required.
(6). Adjust rodends on the forward control
tube so the rigging pin can be inserted
into the bracket assembly upper hole
and through the slot marked ``M in the
gear pinion rack Sta. 113.00 splitter
assembly (View D).
(7). Remove rigging pin and remove
clamping device from foot pedal arms.
CAUTION
Use care when actuating pedals

to avoid damaging tool or wind
shield.
(8). Loosen jamnuts on pedal stop-bolts
(View A).
(9). Screw in pedal stop-bolts approximate
ly one-half inch (12.7 mm).
(10). Adjust left-hand stop-bolt in the pilot's
pedal support.
67-20-30
Page 503
Revision 20
MAINTENANCE MANUAL
CSP-HMI-2
MID PEDAL
RIGGING HOLE
FWD CONTROL
TUBE
FWD. CABLE
ASSEMBLY
FULL RIGHT
RIGGING HOLE
FULL LEFT PEDAL

RIGGING HOLE
RIGGING PIN
LOWER
RIGGING HOLE
STA 97.50
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

ROUTED CONTROL ROD)
STA 78.50 (TUNNEL

ROUTED CONTROL ROD)
0.50 INCH MAXIMUM

MISALIGNMENT
BETWEEN PEDALS
CONTROLS SUPPORT
BRACKET
CLAMPING BLOCKS
90+ 2
STA 78.50
CANTED BULKHEAD
RIGHT STOP BOLT
JAM NUT
LEFT STOP BOLT
ANTI TORQUE
IDLER BELLCRANK
JAM NUT
FLOOR MOUNTED
CONTROL ROD
PEDAL ARM ALIGNMENT AND

STOP BOLT ADJUSTMENT
G672011
Figure 502. Pilot Pedal Rigging
Page 504
Revision 18
67-20-30
MAINTENANCE MANUAL
CSP-HMI-2
(11). Apply full left pedal until the rigging

pin can be inserted through the bracket
assembly upper hole and into the slot
marked ``L'' in the gear pinion rack Sta.
113.00 splitter assembly (View D).
5. Thruster Control Rigging (500N)
(12). Adjust the left-hand stop-bolt in the

pilot's pedal support so that the stop
just comes in contact with the link
assembly (View A).
Item
CM702
Nomenclature
Lockwire CRES
Item
ST601
Special Tools
Nomenclature
Rigging pin
(13). Remove the rigging pin assembly and

adjust right-hand stop-bolt in the
pilot's pedal support.
(14). Apply full right pedal until the rigging
pin assembly can be inserted through
the bracket assembly upper hole and
into the slot marked ``R'' in the gear
pinion rack Sta. 113.00 splitter assem
bly (View D).
(15). Adjust the right-hand stop-bolt in the
pilot's pedal support so that the stop
just comes in contact with the link
assembly (View A).
NOTE: For dual installation, adjust the stopbolts in the co-pilot's support bracket to
match the pilot's pedal travel. Repeat steps
(11). thru (13).
4. AntiTorque Pedal Friction Installation
and Adjustment
(Ref. Figure 403)
or rope, secure pilot's pedals in mid
position so they are aligned within 0.50
inch (1.27 cm) of each other.
(Ref. Figure 503)
NOTE:
D Thruster control rigging to be accom
plished with the splitter spring installed,
the fan pitch control rigging completed,
the tailboom sector control rod assembly
and stationary thruster cone installed.
the witness hole, do not tighten jamnuts
bracket assembly lower rigging hole
and through the slot on the pinion gear
rack Sta. 113.00 splitter assembly (View
D).
(2). Removed pan cover.
(3). Adjust rodend until it can be attached
to input clevis of sector assembly (View
C).
(4). Connect sector clevis control rod.
(2). Install washer, bolt, bushing, and link

assembly to bracket assembly on
instrument console.
(5). Install bushing, washer and bolt.

Torque bolt 30 - 40 inch-pounds (3.39
- 4.52 Nm). Safety wire (CM702) bolt
(Ref. Anti-Torque Flight Control
Installation).
(3). Install brace and clamp arm assembly

to anti-torque tube assembly.
(6). Remove rigging pin from splitter

assembly.
(4). Install friction disc, link, retainer and

spring, install washer (shim washers if
required) and nut.
(5). Torque brace and arm assembly bolts
30 - 35 inch-pounds (3.39 - 3.95
Nm). Torque nut against washer to
obtain a pedal friction of 5 - 8 pounds
(2.27 - 3.63 kg).

(7). Remove safety clips and adjust the two
turnbuckles until a second rigging pin
(ST601) can be inserted through a slot
in the output drum assembly and
through holes in drum output support
(View A and B).
67-20-30
Page 505
Revision 30
MAINTENANCE MANUAL
CSP-HMI-2
CABLE
SAFETY CLIPS
500N
500N
CABLE
SAFETY CLIPS
600N
600N
G6720141
Figure 503. Thruster Control Rigging (Sheet 1 of 2)

Page 506
Revision 18
67-20-30
MAINTENANCE MANUAL
CSP-HMI-2
RIGGING PIN
INPUT SECTOR
PAN COVER
ROD ASSEMBLY
PAN
RACK GEAR
ROTATING
THRUSTER CONE
STATIONARY
THRUSTER CONE
SLOT
PINION GEAR
RIGGING PIN
0.00 +0.25 IN.

(0.00 +6.4 MM)
600N THRUSTER OPENING

G67-2014-2C
Figure 503. Thruster Control Rigging (Sheet 2 of 2)

(8). Using a cable tensiometer, adjust cable
tension to 20 - 40 pounds (9.07 18.14 kg).

(9). Install safety clips in turnbuckles.
(10). Remove rigging pins.
(11). Install rotating thruster cone using
three bolts and washers. Torque bolts
70 - 90 inch-pounds (7.91 - 10.17
Nm).
(12). Safety wire (CM702) bolts.

(13). Thruster Control Rigging shall produce
the following results:
(a). Full left pedal; rotating thruster cone
to be fully open to the left side of the
tailboom.
(b). Full right pedal; rotating thruster
cone to be open a minimum of 11.80
inches (29.97 cm) when measured
from the lower edge of the right
opening to the upper lip of the
rotating cone.
67-20-30
Page 507
Revision 26
MAINTENANCE MANUAL
CSP-HMI-2
6. Thruster Control Rigging (600N)

(Ref. Figure 503)
Item
CM701
Nomenclature
Lockwire CRES
Item
Special Tools
Nomenclature
ST601
Rigging pin
NOTE: Do not adjust the control rodend beyond

the witness hole, do not tighten jamnuts un
til after final adjustment.
(1). Insert rigging pin (ST601) into bracket
assembly lower rigging hole and
through slot on the pinion gear Sta.
113.00 splitter assembly (Ref.
Figure 503).
(2). Removed pan cover.
(3). Adjust rodend until it can be attached
to input clevis of sector assembly and
the rigging slot in input sector assem
bly aligns with the rigging hole in pan.
(4). Connect sector clevis control rod.
(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 Flight
Control Installation).
(6). Reinstall pan cover ensuring rigging
pin hole in pan cover aligns with
rigging hole in sector assembly. If pin
cannot be inserted through fan cover,
sector assembly and pan, repeat above
steps.
(7). Adjust the two turnbuckles until a
second rigging pin can be inserted
through a slot in the output drum
assembly and through holes in drum
output support.
Page 508
Revision 30
67-20-30
(8). Using a cable tensiometer, adjust cable

tension to 20 - 40 pounds (9.07 18.14 Kg) by adjusting the two turn
buckles.
(9). Remove rigging pins.
(10). Install rotating thruster cone using
three bolts and washers.
(11). Push full left pedal and verify bottom
edge of rotating thruster opening is
within 0.00 0.25 inch (0.0 6.4 mm) of
edge of stationary thruster cone (Ref.
Figure 503); adjust turnbuckles as
necessary.
(12). Remove rotating thruster cone.
(13). Verify cable tension.
(14). Reinstall rotating thruster cone; Torque
rotating thruster cone bolts to 70 - 90

justed.
(15). Safety bolts with lockwire (CM701).
(16). Safety turnbuckles with clips.
7. Left Vertical Stabilizer Assembly Rigging
(500N, and 600N with YSAS)
(Ref. Figure 504)
Item
ST601
Special Tools
Nomenclature
Rigging pin
NOTE:
D Rigging to be accomplished with the tail
boom and vertical stabilizers, splitter as
sembly bungee spring and engine air inlet
fairings installed.
(1). 500N helicopters: Insert rigging pin
(ST601) into the bracket assembly
upper hole and into the slot marked
MAINTENANCE MANUAL
``R'' in the gear pinion rack Sta. 113.00
splitter assembly (View A) splitter
assembly upper hole.
(a). Adjust the left vertical stabilizer to
6.5 0.5 degrees on the horizontal
stabilizer degree plate (View C).
(b). Remove rigging pin.
(2). 600N helicopters: With pedals set to full
right position, adjust tip of the left
vertical stabilizer trailing edge to 12
degrees.
engagement. Rodends are to be
installed equal distance on torque tube
to within 0.020 inch (0.508 mm) of each
other.
8. Stability Augmentation System Rigging
Instructions (500N, and 600N with YSAS)
(Ref. Figure 505)
Item
Special Tools
Nomenclature
ST1013
Yaw S.A.S. test box
(1). Turn OFF power supply, turn S.A.S.

switch on the instrument panel to the
OFF position.
(2). Install the Yaw S.A.S (ST1013). Test
Box to the computer located and
mounted on the co-pilot's seat structure
forward bulkhead, the test box is now
in series with the computer and
actuator.
(3). Using the aircraft power supply or an
external power source, activate S.A.S.
switch.
CSP-HMI-2
NOTE: The actuator and control tube can be

slid out the horizontal stabilizer end panel
far enough to remove safety wire and loosen
the jamnuts. The control tube can be rotated
and adjusted similar to a turnbuckle.
(6). 500N helicopters: Using the top rig
plate, adjust right vertical stabilizer to
4.0 0.5 degrees.
(7). 600N helicopters: Using the top rig
plate, adjust top right vertical stabilizer
to -1.75 0.25 degrees.
(8). After adjustment, slide actuator and
control tube out far enough to tighten
and safety jamnuts.
(9). Reinstall actuator and control tube.

justed.
9. Vertical Stabilizer Assembly Rigging
(600N without YSAS System)
(Ref. Figure 506)
Item
Special Tools
Nomenclature
ST601
Rigging pin
NOTE:
D Rigging to be accomplished with the tail
boom and vertical stabilizers installed.
bracket assembly upper hole and into
the slot marked ``R'' in the gear pinion
rack Sta. 113.00 splitter assembly.
(4). Adjust actuator to the fully extended

position using the Yaw S.A.S. test box.
(2). Push trailing edge of left vertical

stabilizer to the right using only enough
force to eliminate freeplay (5-lb (0.3
Kg) max).
(5). Turn aircraft power OFF, actuator

should remain in fully extended
position.
(3). Adjust control rod for the left vertical

stabilizer to 10.5 0.5 degrees on the
horizontal stabilizer degree plate.
67-20-30
Page 509
Revision 37
MAINTENANCE MANUAL
CSP-HMI-2
HORIZONTAL
STABILIZER
6.5 0.5
INCIDENCE
ANGLE
VERTICAL STABILIZER
(LEFT)
(TOP VIEW)
500N9901
RIGGING PIN
500N SHOWN
CONTROL TUBE
(LEFT)
AFT CONTROL
ROD
STA 273.00
BELLCRANK
(TOP VIEW)
G67-2012A
Figure 504. Left Vertical Stabilizer Rigging (500N, and 600N with YSAS)
Page 510
Revision 30
67-20-30
MAINTENANCE MANUAL
CSP-HMI-2
4.00.5 DEGREES
COMPUTER AND
RATE GYRO
RIGHT CONTROL ROD
VIEW LOOKING DOWN
S.A.S. ACTUATOR
STABILITY AUGMENTATION
SYSTEM
RIG PLATE
(VIEW LOOKING DOWN)
500N
G67-2015-1A
Figure 505. Stability Augmentation System S.A.S. (Sheet 1 of 2)
67-20-30
Page 511
Revision 30
MAINTENANCE MANUAL
CSP-HMI-2
-1.75 0.25 DEGREES
BL 0.00
COMPUTER AND
RATE GYRO
VIEW LOOKING DOWN
RIGHT CONTROL ROD
37.07 IN.
(94.15 CM)
3
2
3
3 2 1 0 -1 -2 -3
S.A.S. ACTUATOR
STABILITY AUGMENTATION
SYSTEM
RIG PLATE
(VIEW LOOKING DOWN)
BL 0.00
600N
G6720152A
Figure 505. Stability Augmentation System S.A.S. (Sheet 2 of 2)

Page 512
Revision 36
67-20-30
MAINTENANCE MANUAL
CSP-HMI-2
14.5+0.5
DEGREES
10.5+0.5
DEGREES
RIGHT
CONTROL
TUBE
LEFT
CONTROL
TUBE
CL
LH
RH
INCREASE PRESSURE L PEDAL
INCREASE PRESSURE R PEDAL
DECREASE PRESSURE R PEDAL
DECREASE PRESSURE L PEDAL
DECREASE PRESSURE L PEDAL
DECREASE PRESSURE R PEDAL
BOTTOM VIEW
TRIM TAB ADJUSTMENT

6G67-092-1A
Figure 506. Vertical Stabilizer Rigging (600N without YSAS)
67-20-30
Page 513
Revision 30
MAINTENANCE MANUAL
CSP-HMI-2
(4). Push trailing edge of right vertical

stabilizer to the right using only enough
force to eliminate freeplay, 5 lbs (0.3
Kg) maximum.
(5). Adjust control rod for the right vertical
stabilizer to 14.5 0.5 degrees on the
horizontal stabilizer degree plate.

justed.
10. Vertical Stabilizer Trim Tab Adjustment
and Tool Manufacturing (600N without
YSAS)
A. Trim Tab Tool Manufacturing
(Ref. Figure 507)
(1). Manufacture guide as follows:
(a). Cut guide from 0.130 inch (3.30 mm)
2024-T3 aluminum sheet 7.00 inch
(17.78 cm) x 4.50 inch (11.43 cm).
(b). Measuring 1.73 inch (4.39 cm) from
bottom, make V-cut in guide 1.030
inch (2.62 cm) wide and 3.79 inch
(9.63 cm) deep.
(c). File 0.070 inch (1.78 mm) wide x
0.260 inch (6.60 mm) deep slot in aft
end of V-cut.
(d). File smooth all surfaces of guide.
NOTE: Note the difference in the degree mark

ings between the top and bottom of the
guide.
(e). Etch degree marks in guide as
indicated in Figure 507.
(2). Manufacture angle tool as follows:
(a). Cut two plates from 0.130 inch (3.30
mm) 2024-T3 aluminum sheet 9.00
inch (22.86 cm) x 2.00 inch (5.08 cm).
(b). Cut a spacer from 0.040 inch (1.016
mm) 2024-T3 aluminum sheet 9.00
inch (22.86 cm) x 1.00 inch (2.54 cm).
Page 514
Revision 30
67-20-30
(c). File smooth all surfaces of spacer and

plates.
(d). Chamfer one 9.00 inch (22.86 cm)
edge of each plate, 0.060 x 0.100 inch
(1.524 x 2.54 mm) (this will be the
front of the tool) as indicated in
Figure 507.
(e). Stack plates, chamfered edges facing
each other with spacer between
plates and flush with aft side of
plates (un-chamfered edge).
(f). Drill and rivet angle tool together,
size and type of rivets optional.
B. Trim Tab Adjustment
(Ref. Figure 506) Adjust vertical stabilizer trim
tabs to improve directional handling character
istics and to minimize pedal forces in forward
flight.
For best results, aircraft should be weighted
down to normal operating weight during test
flights while doing tab adjustments.
NOTE:
D Ensure vertical stabilizers are rigged cor
rectly (Ref. Vertical Stabilizer Assembly
Rigging (600N)).
D Ensure there is no play between the
500N7213-5 bellcrank assembly and the
500N7212-3 shaft.
D Ensure there is minimal play between the
upper and lower vertical stabilizers.
D When installing new upper vertical stabi
lizers, if previous tab settings were not re
corded, left trim tab should be set to zero
degrees and right trim tab should be set
to 10 right (viewed looking forward from
the rear).
D The right vertical stabilizer tends to af
fect pedal pressure more than the left.
The left vertical stabilizer tends to affect
flight characteristics more than the right.
Left Vertical Tab
Right Vertical Tab
10 Right
(1). Determine which pedal requires excess

pressure to attain proper trim during
straight flight.
MAINTENANCE MANUAL
CSP-HMI-2
20
10
0
0.050 IN.
(12.70 MM)
10
20
RIVETS
(4 PLCS)
THIS SIDE UP
3.79 IN.
(9.63 CM)
9.00 IN.
(22.86 CM)
4.05 IN.
(10.29 CM)
4.50 IN
(11.43 CM)
20
10
1.03 IN. (2.62 CM)
0.07 IN.
(1.78 MM)
1.73 IN.
(4.40 CM)
0
10
20
R
THIS SIDE DOWN
7.00 IN.
(17.78 CM)
0.040 IN.
(1.016 MM)
GUIDE
0.060-0.100 IN.
(1.524-2.54 MM)
2.00 IN.
(5.08 CM)
0.130 IN.
(3.302 MM)
MAX
1.00 IN.
(2.54 CM)
6G67-092-2
Figure 507. Vertical Stabilizer Trim Tab Bending Tool
NOTE:
D Always adjust right vertical stabilizer
trim tab first. If tab is bent to a maximum
of 20 before correct pedal pressure can be
achieved, go to left tab and continue ad
justments.
D Limit tab adjustments to 5 increments
between flights.
D Exceeding 20 tab adjustments may cause
a tail wag condition.
(2). Position guide on right vertical stabiliz
er over trim tab.
(3). Position angle tool on trim tab.
Do not bend tabs beyond 20 in

either positive or negative direc
tion. Tabs and/or vertical stabilizer skin can
be damaged.
CAUTION
NOTE:
D Bending tabs to the right will decrease
left pedal pressure.
D Tab angles are acceptable when left pedal
forces are between 2 and 5 lbs. (0.91 and
2.27 Kg) in stabilized flight and the flight
characteristics are acceptable.
(4). Bend tab in direction needed to relieve
pedal pressure and improve flight
characteristics.
(5). Remove tab tools and fly aircraft, see
chart below, to determine if pedal
pressure was relieved.
67-20-30
Page 515
Revision 30
MAINTENANCE MANUAL
CSP-HMI-2
(6). Repeat above steps until pedal pressure

and handling characteristic are cor
rected.
NOTE: After trim tab adjustments, position

guide on both the top and bottom of trim tab
to ensure tab is straight.
Pedal Position
Pedal Force
Hover
*60 KIAS
*80 KIAS
*100 KIAS
*120 KIAS
(7). Log trim tab setting in log book.
*130 KIAS
NOTE: *Level flight
Handling: Low pedal forces might require bending
tabs in opposite directions.
Table 501. Flight Controls Troubleshooting

Pedal KickThru or Binding
Noticeable hump in pedals (kickthru) in flight.
yes
Are control cables Binding?
no
Is there binding in control rod at

fan transmission?
yes
no
Is there pedal binding in flight?
yes
Replace worn or binding

control cable(s).
yes
Adjust control rod for proper

clearance.
Check for dry roller bearings at

rotating cone.
Dutch Roll
Is there relative movement
between upper and lower
verticals?
no
Is there play when holding cone

and moving the vertical
stabilizers?
yes
no
Bend left tab to the left, starting

with 5 left.
yes
Check for loose attaching

hardware for the upper and
lower verticals (NOTE).
Check for loose bellcrank at

control shaft.
NOTE: When tightening hardware, do not torque fasteners beyond specified torque limits.
Page 516
Revision 30
67-20-30
MAINTENANCE MANUAL
CSP-HMI-2

INSPECTION/CHECK
Linkage Inspection
(Ref. Figure 401)
and excessive wear (0.040 inch (1.016
mm) maximum axial play). Inspect
rivet at fixed rod end.
(3). Inspect rubber boot just forward of Sta.
137.50 bulkhead for condition.
(4). Inspect control rod surfaces serviceabil
ity, wear is limited to thickness of hard
anodic coating.
(4). Inspect control rod fitting, torque tube

mounting bracket and pedal mounting
bracket for cracks and corrosion. Using
an 8X magnifying glass, mirror and
flashlight, closely inspect pedal link
bellcrank fitting of pedal bracket in
center forward area where fitting (fork
piece) joins tubular section. If any
cracks are detected, replace bracket
assembly. Inspect bracket bearings for
excessive looseness.
(5). Inspect torque tube for cracks,
scratches, nicks, dents and similar
surface defects.
(6). Inspect pedal brackets for corrosion.
3. Sta. 97.50 (500N) or Sta. 95 (600N)
Bellcrank and Support Bracket Inspection
(5). Inspect bellcranks for scratches, cracks,

Check that all bushings are secure.
(1). Inspect bellcrank and support bracket

for cracks, corrosion and other similar
surface defects.
(6). Inspect bellcrank bearings for looseness

and binding.
(2). Check that all bushings are secure.

Check bellcrank bearings for looseness
and binding.
(7). Visually inspect bellcrank supports for

cracking/damage.
2. AntiTorque Pedal Assembly Inspection
(Ref. Figure 502)
NOTE: Inspect components at left and right po

sition on the right-hand command models.
Check that corresponding pedals contact
stops simultaneously.
(1). Inspect pedals and pedal arms for
cracks, elongated pedal attach holes
and open drain holes. Inspect teflonreinforced bushing liners for deteriora
tion.
(3). Inspect rod ends bearings for binding

and excessive wear (0.040 inch (1.016
mm) maximum axial play). Inspect
control rod surface serviceability, wear
is limited to thickness of hard anodic
coating. Inspect for safety wire at
rodends and lockwasher as required.
Bolts for cotter pins as required.
4. Forward and Intermediate Directional
Control Tube, and Link Inspection
(1). Inspect rodend and link bearings for
binding and excessive wear (0.040 inch
(1.016 mm) maximum axial play).
(2). Inspect pedal-to-arm quick-release

locking pin for condition and positive
spring action.
(2). Inspect control tubes and link for

surface damage and wear. Inspect
control tubes surface serviceability,
wear is limited to thickness of hard
anodic coating.
(3). Inspect links and bellcrank for cracks

and bends, and bearings for excessive
play.
(3). Inspect for safety wire at rodends and

lockwasher as required. Bolts for cotter
pins as required.
67-20-30
Page 601
Revision 34
CSP-HMI-2
MAINTENANCE MANUAL
5. Splitter Bungee Spring Inspection (500N)

(1). Inspect spring support bracket for loose
rivets, loose screws, corrosion and
cracks and general condition.
(2). Check link assemblies for cracks, bends
and dents.
(3). Inspect spring for condition and a
positive spring action.
6. Sta. 113.00 Splitter Assembly and
Bellcrank Inspection
(1). Visually inspect bellcrank and support
bracket for cracks and damage using 5X
power magnifying glass.
(2). Inspect for cracks, corrosion and other
similar surface defects.
(3). Check that all bushings and bearings
are secure.
(4). Inspect rodend bearings for binding and
excessive wear (0.040 inch (1.016 mm)
maximum axial play). Inspect control
rod surface serviceability, wear is
limited to thickness of hard anodic
coating. Inspect for safety wire at
rodends and lockwasher as required.
Bolts for cotter pins as required.
7. Forward and Center Cable Assembly
Inspection
(1). Inspect for freedom of movement and
no binding.
(2). Check rodend bearings for corrosion,
and wear.
(3). Cable housing for fraying, and security.
(4). Inspect cable couplings for wear,
deformation or damage (Ref.
Figure 602).
(5). Inspect inner cable coupling hex for
proper alignment with outer cable
coupling.
(6). Inspect cable inner couplings for
deformation or obvious damage.
(7). Using a bright light and 10X magnify
ing glass, inspect inner coupling male
Page 602
Revision 35
67-20-30
and female connectors for corrosion

pitting or cracks; none allowed.
(8). Inspect center cable hex end for wear
beyond allowable tolerance (Ref.
Figure 601).
(9). Inspect collar for wear in locking
groove.
(10). Inspect relieved area, at Sta. 123.30,
between threads and swage for crack or
(11). Inspect relieved area, at Sta. 164.00
(500N) or Sta. 292.00 (600N), between
threads and swage for crack or evidence
of corrosion.
(12). Inspect forward cable coupling opening
for proper dimension (Ref. Figure 601).
(13). Using a bright light and 10x magnify
ing glass, inspect the swaged area of
the telescopic swivel end for cracks
(Ref. Figure 603).
(14). Inspect for any evidence of swivel ball
separation.
8. YSAS Actuator, Rate Gyro and Electronic
Control Box Inspection
(1). Inspect YSAS actuator for damage, no
damage allowed.
(2). Inspect mounting hardware for proper
installation and general condition.
(3). Inspect wiring for condition, no fraying,
cracking of insulation or chafing
allowed.
(4). Inspect grommet for proper installation
and deterioration, replace if deterio
rated.
(5). Inspect mounting bracket for cracks
(pay particular attention to area around
four rivet attach holes) no cracks
allowed.
(6). Inspect rate gyro and electronic control
box for damage, security in mount and
ensure electrical plugs are secure.
(7). Inspect mounting bracket for cracks, no
cracks allowed.
9. Fan Pitch Control Tube Inspection
(1). Inspect tube for dents, scratches, nicks,
gouges and corrosion, none allowed.
MAINTENANCE MANUAL
CSP-HMI-2
(b). Minimum measurement across pins

is 0.640 in. (16.256 mm).
(2). Inspect for visible step in splined area.

(3). If step is evident:
(a). Measure across splines using 0.096
in. (2.4384 mm) diameter pins.
Table 601. Isolating Control System Troubles

Symptom
Isolating Step
Corrective Action
Binding, lockingup and erratic

Disconnect fwd control tube from
action of foot pedals (Do not force Sta. 113.00 splitter assembly.
controls).
If symptom is gone, check from

splitter assembly aft.
0.250 INCH (6.35 MM)

HEX (REF)
CLOSED
POSITION
OPEN
POSITION
(REF TABLE)
HEX CONFIGURATION
FORWARD CABLE FEMALE END
ROUND CONFIGURATION
ACCEPTABLE DIMENSIONS
CENTER CABLE (-5) (INSIDE TAIL BOOM)
SLOT DIMENSION
IN (MM)
0.450 (11.43)
0.260 IN. (6.604 MM) MIN.

(NOTE)
0.685 (17.40)
0.450 (11.43)
0.250 IN.
(6.35 MM)
MALE CONNECTOR
HEX CONFIGURATION
ROUND
CONFIGURATION
ROUND CONFIGURATION
UNACCEPTABLE DIMENSIONS
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
67-20-30
Page 603
Revision 39
MAINTENANCE MANUAL
CSP-HMI-2
TAILBOOM FAIRING
CABLE ASSY
RELIEF AREA
INSPECT FOR CRACK
INNER FEMALE
CONNECTOR
CABLE END RELIEF AREA
OUTSIDE COLLAR SLEEVE

(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
Revision 24
67-20-30
MAINTENANCE MANUAL
CSP-HMI-2
FORWARD CABLE
TAILBOOM FAIRING
CENTER CABLE
ASSY
INSPECT TELESCOPIC SWIVEL END

FOR CRACKS AND/OR TELESCOPIC
SWIVEL SEPARATION FROM
THRUSTER CABLE CONDUIT CAP
TELESCOPIC SWIVEL END

CONDUIT CAP
88_777
Figure 603. Control Cable Telescopic Swivel End Inspection
67-20-30
Page 605
Revision 24
MAINTENANCE MANUAL
CSP-HMI-2
10. Sector Assembly, Control Cables and

Drum Assembly Inspection
(a). Fraying or corrosion; no fraying or

corrosion allowed.
(Ref. Figure 402)
(b). Proper installation of turnbuckle

safety clips.
(1). Inspect sector assembly for:

(a). Proper installation of mounting
hardware.
(b). Remove access cover from pan
assembly.
(c). Center cable mounting bolt for
security and proper installation of
safety wire.
In the following step, ensure
WARNING the anti-torque pedals are
not moved, personal injury can occur.
(d). Check sector assembly for excess
up-and-down play.
(e). Damage, cracks or corrosion; no
damage, cracks or corrosion allowed.
(f). Reinstall access cover on pan assem
bly.
(2). Remove tip cap (500N).
(3). Remove rotating cone assembly.
(4). Remove access cover from top of
stationary thruster assembly (600N).
(5). Inspect control cables for:
Page 606
Revision 39
67-20-30
(c). Corrosion or cracking on turnbuckles;

no corrosion or cracking allowed.
(d). Proper cable tension.
(6). Reinstall access cover on top of station
ary thruster assembly (600N).
(7). Inspect control cable pulleys for:
hardware.
(b). Guard pins installed.
(c). Excessive groove in pulleys; evident
in out-of-round pulley.
(8). Inspect drum assembly for:
hardware.
(b). Damage, cracks or corrosion; no
damage, cracks or corrosion allowed.
(c). Guard pins installed.
(9). Reinstall rotating cone assembly.
(10). Reinstall tip cap (500N).
MAINTENANCE MANUAL
CSP-HMI-2

REPAIRS
1. AntiTorque Flight Control Repair
General
rod end is steel and rod and bearing adapter
are aluminum.
CAUTION
2. Sta. 97.50 (500N) or Sta. 95 (600N)

Bellcrank and Support Bracket Repair
Item
Nomenclature
CM321 Surface primer locking compound

CM431 Sealing, locking and retaining compound
(1). Replace unserviceable bearings.

(2). Install new bearings with surface
primer (CM321) and grade A locking
compound (CM431).
NOTE: When idler bellcrank bearing are re

placed, ensure idler bellcrank spacers are
reinstalled between bearings.
(3). Replace bellcranks or control support
brackets that have cracks or enlongated
holes.
3. Forward Directional Control Tube Repair
bearing angularity.
(2). Initial length forward directional
control tube is 15.42 inches (39.17 cm).
Rod end angularity is 0 degrees
straight line within 2 degrees.
rods that appear bent or bowed.
(4). Drill out rivet. Loosen jamnut and
unscrew rodend.
(5). Screw replacement rodend into rod to
obtain same measurement made in step
b. Align control rodends so bearings
have equal space for angular throw;

tighten jamnut.
(6). If removed, install rivet to secure
rodend.
(7). Ensure slotted bushing is in place.
(8). Secure control rod in torque tube fitting
or idler bellcrank with bolt, two
4. Upper Fuselage Sta. 113.00 Splitter
Assembly Repair
Refer to Field Service Department for repairs.
5. Intermediate Control Tube Repair
(1). Perform straightness check on inter
mediate control rod that appears bent
or bowed. Total length of control rod
(excluding rod ends) must be straight
NOTE:
D A dye check for cracking must always be
performed after cold-straightening. Re
place cracked rod, or cracked or bent rod
end.
D Do not use rod ends to support rod during
straightening process.
within tolerance provided there are no
nicks or sharp dents in bend length.
bearing angularity.
(4). Replace unserviceable control rod
bearing adapter if installed.
(a). Measure length and record position
of rod end in adapter.
(b). Remove affected rod end. Initial
installation length of intermediate
control rod is 23.68 inches (60.15 cm).
Rod end angularity is 40 2 degrees.
67-20-30
Page 801
Revision 18
MAINTENANCE MANUAL
CSP-HMI-2
(c). Drill out rivets securing adapter to

rod and aft rod end.
(d). Install rod end in replacement
adapter and position at recorded
measurement.
6. Sta. 137.50 Support Bracket and Bellcrank
Repair
Item
Nomenclature
CM318
CM321
CM431
CM802
Primer
(1). Replace unserviceable bearings.

scratches, nicks and corrosion on
bellcranks and support bracket.
(9). Use abrasive cloth (CM802), grade 400
- 600, to smooth out and blend in such
defects.
(10). Cast surfaces may be reworked to depth
of 0.020 inch (0.508 mm).
(11). Repair surface abrasion on control rod
by smoothing area with grade 400
abrasive cloth (CM802) and restoring
protective finish with primer (CM318).
(12). Replace rod if wear or depth of repair
exceeds 0.004 inch (0.102 mm).
(13). Replace tailboom control rod if hard
anodic coating is worn through and
aluminum base metal is visible.
(14). Replace split or torn boot.
(2). Install new bearings with surface

primer (CM321) and grade A locking
compound (CM431).
7. Fan Pitch Control Tube Repair


0.015 inch (0.381 mm).
8. Forward Cable Assembly Repair
(4). Clevis inner ear surfaces may be

mm).
9. Center Cable Assembly Repair


10. Aft Control Rod Repair
11. Thruster Sector Assembly Repair

holes, which are limited to 0.010 inch
(0.254 mm) chamfer.

be restored.
13. AntiTorque Pedal Disassembly
NOTE: Installation direction of Sta. 137.50

bellcrank bearing may be from either side,
depending on location of bearing shoulder.
There must not be less than 0.010 inch
(0.254 mm) protrusion of bearing inner race
beyond sides of bellcrank after bearing is in
stalled.
Page 802
Revision 18
67-20-30
12. Drum Assembly and Idler Pulleys Repair

(Ref. Figure 403)
NOTE: Before disassembly of pedal installa

tion, matchmark mating pedal arms, links
and bellcranks with pedal brackets to avoid
intermixing components between locations
at reassembly.
(1). Disconnect links from pedal arms and
bellcrank; remove links.
MAINTENANCE MANUAL
(2). Remove bellcrank from pedal bracket.
(3). Remove nut and washer of two bushing
assemblies that secure left pedal arm
and control rod fitting to torque tube.
(4). Carefully remove bushing bolt and
temporarily reinstall washer and nut
on bolt.
(5). Slide pedal bracket and pedal arms off
end of torque tube.
NOTE:
D Do not remove two teflon-lined bushings
from right pedal arm unless replacement
is required.
D Do not remove two stop bolts, jam nuts on
stop bolts or bearings from pedal bracket
unless replacement is required.
rod fitting off torque tube.
14. AntiTorque Pedal Repair
Item
Nomenclature
CM425 Sealing compound

CM431 Sealing, locking and retaining compound
(1). Replace parts that are cracked or have

elongated attachment holes.
CAUTION
Do not attempt to straighten

bent torque tube or pedal link.
(2). Replace unserviceable pedal covers.

Apply sealing compound (CM425) to
approximately 30 percent of upper and
lower edge surfaces that contact pedal.
Cure according to container instruc
tions.
(3). Replace complete pedal link if cracked
or contains unserviceable bearings;
bearings are not replaceable.
(4). Replace unserviceable bearings in
mounting brackets or pedal link
bellcrank.
(5). Install replacement with grade A
locking compound (CM431).
CSP-HMI-2
Right pedal arm bushings are

glass-filled phenolic. Do not
cock bushings during replacement; ensure
bushing is fully seated in arm bore. Keep
tools from contact with bushing liners to
avoid fraying.
CAUTION
(6). Replace bearings in right pedal arm

when teflon-reinforced liner is galled or
frayed. Pull bushing to remove; press to
install.
(7). Remove corrosion from pedal brackets
(Ref. Sec. 20-40-00 and CSP-A-3,
Corrosion Control Manual).
15. AntiTorque Pedal Reassembly
(Ref. Figure 403)
(1). When reassembling components, check
for correct matchmark identification.
(2). If previously removed, thread jamnut
on each of two stop bolts and install two
stop bolts into threaded inserts of pedal
brackets.
rod fitting onto torque tube.
for correct position on torque tube; slide
bracket and arms onto torque tube.
(5). Fasten left pedal arm and control rod
fitting to torque tube with adjustable
bushing assemblies.
(6). Install bushing bolt so shank at
bolt-head end protrudes at least 0.002
inch (0.051 mm).
(5.65 - 9.04 Nm) plus drag torque; do
not allow bolt to turn.
(8). Ensure each end of bushing assembly
shank protrudes a minimum of 0.002
inch (0.051 mm). If not, loosen and
repeat above steps.
(9). Ensure slotted bushing is in place; then
attach bellcrank to pedal bracket with
(10). Ensure slotted bushings are in place;
then fasten each link to bellcrank with
67-20-30
Page 803
Revision 18
MAINTENANCE MANUAL
CSP-HMI-2
(11). Ensure slotted bushings are in place;

then fasten each link in pedal arm lugs
pin.
(12). Ensure outboard pedals clear windows
by a minimum of 0.20 inch (5.08 mm)
with 20 pounds (9.07 kg) of force
applied.
16. YSAS Actuator Regrease Procedure
A. YSAS Actuator Disassembly
(Ref. Figure 801)
Do not attempt to loosen or
tighten nut by grasping actua
tor housing, damage to spline housing can
occur.
CAUTION
(1). Cut and remove lockwire from lock

washer and nut.
(2). Hold hex end of output shaft and loosen
nut.
(3). Remove rod end, nut and lockwasher.
(4). Record output shaft orientation by
marking the notch on the connector
side of the shaft with a pencil.
(5). Measure endplay of the actuator as
follows:
(a). Push the output shaft in towards the
actuator housing by applying a load
of 20 -100 lbs (9.07 - 45.36 kg).
(b). Using a depth gage, measure and
record dimension ``C''.
(c). Screw the rod end into the output
shaft a few turns.
(d). Pull on the output shaft by applying
a load of 20 -100 lbs (9.07 - 45.36
kg).
(e). Unscrew and remove the rod end
without changing dimension ``C''.
NOTE: If the variation in dimension ``C'' ex

ceeds 0.013 inch (0.3302 mm), the actuator
should be returned to the manufacturer for
repair rather than regrease.
Page 804
Revision 42
67-20-30
(f). Remeasure and record dimension

``C''.
(6). Cut lockwire and remove the four
screws that hold the seal housing and
splined housing.
NOTE: It may be necessary to grasp the cylin

drical portion of the seal housing or splined
housing with a rubber-tipped clamping tool
to loosen the housing because of primer ap
plied to the screws at assembly.
(7). If there is an inspection seal at the
housing joint, remove enough of the
label so that it cannot get pinched
between the housings when the actua
tor is re-assembled. Leave some of the
label on the actuator to aid in re-as
sembly. If there is no inspection seal,
use pieces of tape.
NOTE: Belleville spring, spacer and shims (if

installed) are installed between the seal
housing and splined housing.
(8). Remove seal housing and splined
housing.
(9). Note the order of assembly of these
parts.
(10). Measure and record the thickness of the
spacer and the total thickness of the
shims (if installed) to avoid confusion
with the spacer and shims on the other
side of the splined housing.
NOTE: The teflon washer attached to the end of

the LVDT core is a close fit to the bore
through the LVDT housing, it may be neces
sary to carefully tug a little to fully remove
the shaft.
(11). Unscrew and remove the output shaft.
This shaft has the LVDT core and
associated hardware attached to it; Do
not unscrew the nylon screw or the
LVDT core.
(12). Note the orientation of the belleville
spring, spacer and shims (if installed).
Measure and record the thickness of the
spacer and shims.
MAINTENANCE MANUAL
Do not use any cleaning sol
vents. Damage to the motor
bearings and the molybdenum disulfide fin
ish on the acme nut and spline surfaces may
occur.
CAUTION
(13). Wipe off old grease from all parts using

lint-free cloth.
(14). Using cotton swabs, remove grease
from acme nut area. Be sure to reach
into the cavity just beyond the acme
nut threads to remove grease deposits.
(15). Use the acme screw to remove grease
from the acme nut threads.
(a). Run screw in and out, then wipe
threads clean.
(b). Repeat above step until no more
grease appears on screw threads.
B. YSAS Actuator Regrease and
Reassembly
(Ref. Figure 801)
Item
Nomenclature
CM109
CM111
CM127
CM318
CM731
Molybdenum disulfide powder lubricant

Grease, aircraft
Grease, YSAS Actuator
Primer
Lockwire CRES
NOTE: Use YSAS actuator grease (CM127) or

mix aircraft grease (CM111) and molybde
num disulfide powder (CM109) to regrease
the actuator.
(1). Prior to applying new grease, re-as
semble the output shaft with attached
hardware (splined housing, belleville
spring, spacer and shims (if installed))
to the actuator to avoid confusion at
re-assembly.
(2). Remove and weigh output shaft with
LVDT core and associated hardware
attached; Record weight.
(3). Adjust scale up 2.5 grams.
CSP-HMI-2
NOTE: If you mix grease, only use Mobil

Grease 28 which meets MIL-G-81322.
(4). If necessary, mix 95% aircraft grease
(CM111) with 5% molybdenum disulfide
powder (CM109) by weight.
(5). Apply special grease (CM127) to acme
screw threads until scale is balanced
again.
(6). Evenly distribute grease around the
acme screw threads to form a fairly
even cylinder in order to fit through the
belleville spring without scraping off
too much grease.
(7). With belleville spring, spacer and shims
(if installed) in place within end bore in
motor housing, carefully assemble
greased output shaft to actuator.
(a). Screw in the shaft until the leading
edge of the spline on the shaft is
about flush with the end of the motor
housing and oriented so that the
splined housing can be put on in it's
proper orientation.
(8). Apply grease (CM127) to splined
surfaces of splined housing until
grooves are completely full. Install
splined housing as originally oriented.
(9). Apply film of grease (CM127) to
smallest inside diameter of seal
housing.
(10). With belleville spring, spacer and shims
(if installed) in place within end bore of
seal housing, slide seal housing into
position over output shaft as originally
oriented.
(11). Replace four screws which hold down
seal housing; Use only
NAS1352-04H8P screws.
(a). Install screws with wet primer
(CM318).
(b). Torque screws to 9 inch-pounds
(1.02 Nm).
(c). Using lockwire (CM731), safety
screws.
67-20-30
Page 805
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2
(12). Re-install rod end, nut and lockwasher

with rod end face (surface `À'') oriented
at 90 2 with respect to surface ``B''.
(19.21 - 22.60 Nm).
SPLINED
HOUSING
(13). Using lockwire (CM731), safety nut to

lockwasher, washer may be oriented
with lockwire end up or down.
MOTOR
HOUSING
SEAL
HOUSING
LVDT CORE
OUTPUT
SHAFT
1.10 0.03 IN
(27.9"0.76 MM)
ROD
END
LOCKWASHER
LOCKWIRE
SHIMS
SPACERS
BELLEVILLE
SPRING
SHIMS
SPACERS
SCREW
A
B
SAFETY
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Figure 801. YSAS Actuator (CrossSection View)

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Chapter
71
Power Plant
CSP-HMI-2
MAINTENANCE MANUAL
CSPHMI2
TABLE OF CONTENTS
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Title
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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. Allison 250-C20B and 250-C20R/2 Engine Removal and
Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Removal of Disconnected Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
2.
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

A. Engine Installation in Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Connecting an Installed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 402. Model 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 . . . . . . 413
71-00-30 Power Plant (250-C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1.
2.
3.
Model 250-C30 Power Plant Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Table 1. 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
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B. Connecting an Installed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

Figure 402. Engine Mounts and Structural Fittings . . . . . . . . . . . . . . . . . . . . . . . . 406
3.
Engine Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407

Figure 403. Model 250-C30 Engine Build-Up (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 408
4.
Engine Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
71-00-47 Power Plant (250-C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1.
2.
3.
Model 250-C47 Power Plant Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1. Power Plant Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1. Starter/Generator System Wiring Diagram (Sheet 1 of 2) . . . . . . . . . .
Figure 2. Engine Wire Harness Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
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

1.
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.
Air Inlet Screen Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

A. Air Inlet Screen Removal (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Engine Air Inlet Screen Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . 202
B. Engine Inlet Screen Removal (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
C. Air Inlet Screen Installation (369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . 204
D. Engine Inlet Screen Installation (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3.
Air Inlet Bell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

A. Air Inlet Bell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Air Inlet Bell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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4.
Firewall Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5.
Air Intake System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Figure 202. Firewall Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6.
Firewall Seal Ring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7.
Air Inlet Bell Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8.
Plenum Chamber Drain Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Figure 203. Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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

1.
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1. Engine Air Particle Separator Configurations . . . . . . . . . . . . . . . . . . . . . .
Figure 1. Particle Separator Operating Principle - Early Type
(Donaldson Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2. Particle Separator Operating Principle - Current Type
(APM Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
3
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

1.
Air Bypass Door System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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2.
Solenoid Air Valve Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.
Air Pressure Sensing Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.
Air Bypass Door Rigging (369D/E/FF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.
Air Bypass Door Rigging (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6.
Particle Separator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
7.
Mist Eliminator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Figure 201. Air Bypass Door System (369D/E/FF) (Sheet 1 of 3) . . . . . . . . . . . . . 204
Figure 202. Air Bypass Door System (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.
PLM Particle Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

A. PLM Particle Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. PLM Particle Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2.
PLM Scavenge Ejector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

A. PLM Scavenge Ejector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. PLM Scavenge Ejector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3.
PLM Ejector Nozzle and Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
4.
Mist Eliminator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

A. Helicopters With Mist Eliminator Access Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Helicopters Without Mist Eliminator Access Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 402
C. Mist Eliminator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
5.
Donaldson Particle Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

A. Donaldson Particle Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Donaldson Particle Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
1.
Engine Air Inlet Bypass Door 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
B. Displaced Vortex Generator Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801. Vortex Generator Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
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C. Damaged Or Missing Vortex Generator Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803

D. Damaged Or Missing Vortex Generator and Outlet Tubes . . . . . . . . . . . . . . . . . . . 803
E. PLM Particle Separator Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
F. Fairing Modifications (369D Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 802. Fairing Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
2.
Mist Eliminator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
3.
Particle Separator Alignment and Joint Surface Repair (369D/E/FF) . . . . . . . . . . . 805
4.
Donaldson Particle Separator Repair (369D Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805

Figure 803. Donaldson Particle Separator Gasket Replacement . . . . . . . . . . . . . . 806
Figure 804. Mist Eliminator Bolt Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
5.
Donaldson Particle Separator Auxiliary Fairings and Seals Installation . . . . . . . .

Figure 805. Auxiliary Fairings and Seals Installation (Sheet 1 of 2) . . . . . . . . . .
Figure 806. Auxiliary Fairings and Supports Fabrication (Sheet 1 of 2) . . . . . . .
Figure 807. Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
808
810
812
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
L. Post-Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 923
M. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 923
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Para/Figure/Table
Title
Page
71-10-60 Engine Air Particle Separator (600N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1.
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
71-20-00 Engine Mounts (250-C20B, 250-C20R/2, 250-C30 and 250-C47) . . . . . . . . A

1.
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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CSPHMI2

Para/Figure/Table
2.
Title
Page
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 and Airframe Fittings . . . . . . . . 402
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 and Airframe Fittings . . . . . 405
Inspection/check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1.
Engine Mounts and Fittings Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2.
Upper Engine Mounts Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1.
Engine Mount Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2.
Mount Hole Repair (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)

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
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
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Para/Figure/Table
Title
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 401. Auto Re-ignition System Equipment (Sheet 1 of 3) . . . . . . . . . . . . . .
Figure 402. Auto Re-ignition Wiring Diagram (Sheet 1 of 6) . . . . . . . . . . . . . . . . .
Figure 403. Auto Re-ignition Schematic (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . .
402
403
406
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
E. Relay and Switch Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
F. Relay and Switch Assembly Installation (T-Panel with Center Console) . . . . . . 903
G. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
71-60-00 Engine Cooling System (250-C20B, 250-C20R/2, 250-C30 and 250-C47)

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
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CSPHMI2

Para/Figure/Table
Title
Page
Figure 202. Engine Air Cooling System - 250-C30 and 250-C47 (Sheet 1 of 2) 204
71 Contents
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MAINTENANCE MANUAL

Para/Figure/Table
Title
Page x
Revision 36
71 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
710000
Power Plant
(250C20)
MAINTENANCE MANUAL
CSP-HMI-2
POWER PLANT
1. Power Plant Description
consist of a combined four stage axial

and single stage centrifugal flow
compressor, an annular combustion
chamber and a four stage turbine
system to extract power from the gas. A
two-stage gas producer turbine drives
the compressor, gas producer fuel
control, accessory gear train and N1
tachometer-generator. A two-stage
power turbine drives the helicopter
rotor system, governor control and N2
tachometer-generator. A start counter
is standard and part of the engine
ignition system
(1). MDHI 369D/E helicopters may be

powered by either a 250-C20B or
250-C20R/2 turboshaft engine man
ufactured by the Allison Engine
Company Inc.
(2). MDHI 500N helicopter is powered by a
250-C20R/2 turboshaft engine man
ufactured by the Allison Engine
Company Inc.
(3). The engine is secured in the helicopter
by three mount assemblies and ac
cessed through two hinged, air-sealed
doors.
(4). A belt-driven blower provides external
cooling air through strategically
positioned ducts that direct air onto
engine exterior surfaces and through
the engine and transmission oil cooler
heat exchangers. Spent blower air is
exhausted aft through an annular
opening between the engine exhaust
pipes and fuselage.
(5). Engine intake air may be filtered
through a standard screen or optional
air particle separator/mist eliminator
assembly. Intake air is drawn through a
plenum chamber and into the engine
intake bell-mouth by the compressor.
Engine compartment air is separated
from compressor intake air by a seal
ring.
2. Power Plant Operation
(1). Allison turboshaft engines installed in
369D/E - 500N model helicopters
(2). Allison Engine Operation and Mainte

nance Manuals are the primary
information source for engine fault
isolation and maintenance data (Ref.
Sec. 01-00-00). Refer to these manuals
for specific engine maintenance proce
dures.
(3). Starter operational limitations are in
the applicable Pilot's Flight Manual.
3. Models 250C20B and 250C20R/2 Power
Plant Fault Isolation
(Ref. Table 1)
(1). Check engine support systems, i.e.; chip
detectors, instruments, fuel supply,
electrical systems, etc., to ensure that
helicopter equipment is functioning
correctly before disassembling engine
systems for an indicated fault.
(2). Inspect and isolate engine problems per
the applicable Allison Engine Operation
Table 1. Power Plant Fault Isolation

Symptom
High frequency vibration (1)
Probable Trouble
Loose engine mount bolts.
Corrective Action
Retorque engine mount bolts to 100
140 inchpounds (11.30 15.82
Nm).
NOTES:
(1) High frequency vibrations may be caused by other drive and rotor system components.
71-00-00
Page 1
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 2
Revision 44
71-00-00
MAINTENANCE MANUAL
CSP-HMI-2
POWER PLANT
1. Engine Removal
A. Engine Disconnecting for Removal
After each opening, removal
WARNING or replacement of any part

of the engine and/or aircraft fuel sys
tem between the aircraft fuel tank and
the engine fuel nozzle, the fuel system
must be bled to remove trapped air.
Failure to comply with this procedure
can result in engine flameout or power
loss.
Cap fluid lines and fittings with
approved devices. Do not use
tape to cover fuel and oil openings. Tape
adhesives loosened by fuel or oil can con
taminate systems.
CAUTION
(1). Set all switches OFF. Disconnect

external power. Disconnect battery.
NOTE: Tag all hardware, wire terminals, fuel

and oil lines before removal to expedite en
gine installation. Identify and bag loose
parts to prevent loss or damage.
(e). Disconnect ground jumper at center

firewall stud.
(f). Unclamp and remove electrical
harness from right engine mount
(369D only).
(5). Remove combustion chamber drain line
from burner drain valve.
(6). Disconnect fuel inlet line from engine.
(7). Disconnect fuel pump seal drain line.
(8). Disconnect compressor cabin air bleed
outlet tube from tee fitting on engine
compressor scroll.
(9). Loosen compressor cooling air ducts at
firewall coupling and engine oil cooler
deflector coupling (Ref. Sec. 71-60-00).
(10). Disconnect duct support bracket at
hoisting eye. Remove ducts from engine
compartment (Ref. Figure 401, view B).
(11). Disconnect torque-meter oil line from
firewall.

(Ref. Sec. 63-10-00).
(12). Disconnect oil pressure indicator line

from firewall.
(3). Remove engine exhaust pipes (Ref. Sec.

78-20-00). Cover engine exhaust
outlet.
(13). Disconnect N2 control rod from idler

bellcrank. Secure control rod to fire
wall.
(4). Disconnect electrical wiring from

engine;
(14). Disconnect anti-icing system as follows:
(a). Disconnect engine electrical harness

ground lead and plug from recep
tacle.
(b). Disconnect thermocouple wire leads
from terminal studs on engine
compartment door frame (Ref.
Figure 401, view C).
(c). Remove thermocouple lead clamps
from door frame and exhaust pipe
clamp.
(d). Disconnect terminals E, C, and B
from starter-generator.
(a). Model 250-C20B;

Disconnect anti-ice control valve
lever (Ref. Figure 401, view A).
(b). Model 250-C20R/2:
Remove electrical connector from
anti-ice solenoid valve. Unclamp and
remove wiring harness from horizon
tal firewall shield.
(15). Disconnect N1 control rod from gas
producer lever. Secure control rod to
firewall.
(16). Disconnect accessory drive vent tube.
71-00-00
Page 401
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
CONTROL CABLE
CLEVIS
AIR INLET BELL
CONTROL VALVE
LEVER
SCREW (5 PLCS)
(NOTE 1)
NUT (5 PLCS)
(NOTE 1)
ENGINE HOIST
NO. 1 BEARING
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
DRAIN LINE
BRACKET
FUEL CONTROL
DRAIN LINE
FUEL SUPPLY
HOSE
COMBUSTION CHAMBER
DRAIN LINE
ROTATED
COMPRESSOR CASE
COOLING AIR DUCT
TURBINE CASE
COOLING AIR DUCT
NOTES:
1. C20R/2 ENGINE (6 PLCS)
2. C20B ENGINES ONLY.
3. C20R/2 ENGINES ONLY.
G71-0000-1
Figure 401. Allison 250C20B and 250C20R/2 Engine Removal and Installation (Sheet 1 of 2)
Page 402
Revision 22
71-00-00
MAINTENANCE MANUAL
CSP-HMI-2
INSTALLATION
G71-0000-2
Figure 401. Model 250C20B and 250C20R/2 Engine Removal and Installation (Sheet 2 of 2)
71-00-00
Page 403
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
(17). Disconnect fuel control drain line.

The oil cooler is fragile. Unless
otherwise required, disconnect
oil supply and return lines only at engine.
Support oil cooler port boss with a backup
wrench when oil line removal is required.
Do not strain or bend unsupported tubes.
CAUTION
(18). Disconnect and cap engine oil inlet,

outlet and vent lines.
B. Removal of Disconnected Engine
Item
Special Tools
Nomenclature
ST401
Engine stand
ST402
Engine hoist
(6). Slowly lower engine out of helicopter.

Align engine side mount fittings
between fixed and adjustable support
shafts.
(7). Screw in adjustable support shaft until
engine mount fittings are securely
engaged with support shaft sockets.
(8). Insert detent pin through adjustable
support shaft.
(9). Remove hoist from engine lift fitting.
2. Engine Installation
D Do not remove engine mounts or disturb

engine mount adjustments to remove the
engine (Ref. CSP-SRM-6).
D Engine-transmission alignment must be
inspected and realigned whenever one or
more engine mount assemblies is re
placed or the existing engine-transmis
sion alignment adjustment is disturbed.
Do not disturb adjustable engine mount
fittings unless an engine-transmission
alignment check is planned.
(1). Install engine hoist apparatus (ST402)
between airframe hoist fitting and
engine hoist eye.
(2). Have an assistant apply tension to
engine with hoist.
(3). Maintain downward pressure on rear of
engine during mount bolt removal.
Unbolt lower engine mount assembly
from engine fitting.
(4). Unbolt left and right engine mount
assemblies from engine fittings.
Revision 22
(5). Align engine stand (ST401) under

engine with adjustable support shaft on
left side (Ref. Figure 402).
(10). If engine is to be stored or transported,

secure upper end of engine stand
transport and storage bar to engine
lifting eye fitting.
CAUTION
Page 404
Do not use fuel or oil lines as

hand holds. Do not allow engine
to strike airframe while maneuvering it out
of the helicopter.
CAUTION
71-00-00
A. Engine Installation in Mounts

Item
CM702
Nomenclature
Lockwire CRES
Item
ST402
Special Tools
Nomenclature
Engine hoist

(2). Position engine to line up engine lifting
eye under airframe lift fitting.
(3). Remove detent pin from adjustable
support shaft on engine stand. Detach
transport and storage bar from engine
lift fitting.
(4). Install engine hoist (ST402) between
airframe fitting and engine hoist
fitting.
MAINTENANCE MANUAL
(5). Have an assistant tension hoist to
support engine. Unscrew engine stand
adjustable support shaft.
(6). Move engine to disengage fixed shaft.
Roll stand away from engine.
CAUTION
D Do not use tubes or hoses as hand holds.
Do not allow engine to strike airframe.
Avoid damaging engine intake bell.
D Prevent FOD, ensure that no foreign ob
jects are trapped in firewall seal ring.
(7). Have hoist operator raise engine while
while pushing down to maintain correct
helicopter and engine alignment.
(8). Align left and right engine mount
assemblies with engine mount fittings
and install bolts and washers (Ref.
Figure 403). Torque bolts to 100 - 140
inch-pounds (11.30 - 15.82 Nm).
Safety bolts to engine mounts using
lockwire (CM702).
(9). Align hole in lower engine mount
assembly with engine mount fitting and
install bolt and washer. Torque bolt to
100 - 140 inch-pounds (11.30 - 15.82
Nm). Safety bolt to engine mount using
lockwire (CM702).
(10). Ensure engine air inlet firewall seal
ring contacts firewall seal around its
entire circumference.
(11). Remove hoist from helicopter.
B. Connecting an Installed Engine
Item
Nomenclature
CM702
Lockwire CRES
CSP-HMI-2
Proper tightening of engine
WARNING tubing connections is criti
cal to flight safety. Correct torque val

ues must be used at all times. Excessive
torque on fuel or pneumatic sensing
system connections can result in crack
ing of the flare causing an air leak
which can cause flameout, power loss,
or overspeed.
(1). Connect torque-meter oil line to
firewall.
(2). Connect oil pressure gauge line to
firewall.
(3). Connect engine oil vent line. Torque
line nut to 120 - 140 inch-pounds
(13.56 - 15.82 Nm) (Ref. Figure 401).
Do not bend oil return line.
Bending loads are transferred to
oil cooler port and may fracture cooler.
CAUTION
(4). Connect engine oil inlet and outlet

lines. Hand-tighten until snug.
Wrench-tighten approximately 1/4 turn
or until definite resistance is felt.
(5). Position accessory drive vent elbow and
connect with vent tube. Torque elbow
(16.95 - 28.25 Nm). Torque tube nut to
20 - 30 inch-pounds (2.26 - 3.39 Nm)
(Ref. Figure 402, detail B).
(6). Connect Nl control rod to lever with
bolt, two washers and nut. Install bolt
with head outboard, one standard OD
washer under nut and one large 0.80
inch (20.32 mm) diameter washer
under bolt head. Torque nut to 40 - 45
inch-pounds (4.52 - 5.08 Nm). Install
a new cotter pin.
(7). Connect short N2 control rod to gover
nor lever with bolt head up, one
standard OD washer under head and
one large 0.80 inch (20.32 mm) OD
washer under nut. Install a new cotter
pin. Connect long N2 control rod with
bolt head forward, two washers and
nut. Install a new cotter pin.
(8). Connect engine fuel pump seal drain
line. Torque tube nut to 20 - 30 inchpounds (2.26 - 3.39 Nm).
71-00-00
Page 405
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE MOUNT
FITTING
ANGLE
(NOTE 1)
SCREW (5 PLCS)
(NOTE 2)
ENGINE AIR
INLET BELL
VENT ELBOW
WASHER
(NOTE 2)
O-RING
JAM NUT
VENT ELBOW INSTALLATION
ACCESSORY DRIVE
GROUND JUMPER
(NOTE 1)
ENGINE MOUNT FITTING
INSTALLATION (TYP)
N2 TACHOMETER
GENERATOR
NUT (5 PLCS)
(NOTE 2)
N1 TACHOMETER
GENERATOR
IGNITION EXCITER
LEAD
OIL INLET COUPLING

OIL OUTLET COUPLING
START COUNTER
KNIFE SPLICE
ELECTRICAL
HARNESS
CHIP DETECTOR
CONNECTORS
FUEL INLET REDUCER
FUEL FILTER SWITCH

KNIFE SPLICE
D WIRE LEAD
STARTER-GENERATO
R
REDUCER
A WIRE LEAD
O-RING
OIL PRESSURE
SNUBBER
O-RING
OIL PRESSURE REDUCER
FITTING INSTALLATION
ENGINE
STAND
NOTES:
1. APPLIES ONLY TO LOWER MOUNT.
2. C20R/2 ENGINES (6 PLCS).
3. C20B ENGINES ONLY.
4. REMOVE CLUTCH ASSEMBLY WITH SEAL, COUPLING
AND ASSOCIATED HARDWARE INTACT.
G71-0001-1B
Figure 402. Model 250C20B and 250C20R/2 Engine Stripping and Buildup (Sheet 1 of 2)
Page 406
Revision 30
71-00-00
MAINTENANCE MANUAL
HOSE
CSP-HMI-2
AIR INLET
BELL
FIREWALL SEAL RING
SPECIAL TEE FITTING

SCREW
(5 PLCS)
JAM NUT
O-RING
NUT
(5 PLCS)
CABIN AIR FITTING
INSTALLATION
FUEL PUMP SEAL ELBOW NUT AND O-RING

BEFORE FILTER PORT
(BF)
REDUCER O-RING
ANTI-ICE VALVE
(NOTE 3)
O-RING
FIREWALL
SEAL
OVERRUNNING
CLUTCH
(NOTE 4)
SPARK IGNITER
LEAD
AFTER FILTER
PORT (AF)
FITTING
PRESSURE SWITCH
BUSHING
HOSE ASSEMBLY
FUEL CONTROL
DRAIN UNION
HOSE
FUEL PRESSURE SWITCH

INSTALLATION
3/8 IN. (9.525 MM)
DIA. BOLT
DETENT PIN
LIFT FITTING
5/16 IN. (7.9375 MM)
DIA. BOLT (2)
ENGINE LIFT FITTING
INSTALLATION
GOVERNOR CONTROL IDLER
SUPPORT, BELLCRANK AND N2
CONTROL ROD ASSEMBLY
REDUCER
O-RING
SNUBBER
O-RING
ACCUMULATO
R
TORQUE OIL PRESSURE FITTING

INSTALLATION
G71-0001-2
Figure 402. Model 250C20B and 250C20R/2 Engine Stripping and Buildup (Sheet 2 of 2)
71-00-00
Page 407
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
(9). Connect fuel inlet line to fuel pump.

Torque hose nut to 230 - 260 inchpounds (25.99 - 29.38 Nm).
NOTE: Ensure burner drain valve and plug are

installed in combustion chamber with an Oring on each part. Ensure drain valve is in
the aft (lowest) position.
(10). Install combustion chamber drain line
on drain valve.
(11). Connect fuel control drain line. Torque
drain line nut to 20 - 30 inch-pounds
(2.26 - 3.39 Nm) (Ref. Figure 401).
(12). Connect anti-ice system as follows:
(a). Model 250-C20B:
Connect anti-icing control cable to
anti-icing control valve lever with
clevis pin and washer. Secure with
cotter pin (Ref. Figure 401, detail A).
(b). Model 250-C20R/2:
Install connector P307 to anti-ice
solenoid valve and secure anti-icing
wiring harness with clamps.
(13). Install cooling air ducts and air duct
support bracket on hoisting eye above
engine. Connect and tighten ducts on
firewall coupling and oil cooler deflec
tor.
(14). Secure engine electrical harness to
engine mount with cushioned loop
clamp. Connect harness plug to recep
tacle and safety with lockwire (CM702).
located on right upper engine door

frame with chromel and alumel nuts.
(Ref. Sec. 63-10-00).
(18). Remove all identifying tags from wires
and hardware.
Misrigging of throttle controls
can cause inadvertent flameout
when throttle is rapidly closed to the idle po
sition.
CAUTION
(19). Rig gas producer (N1) and power

turbine (N2) controls (Ref. Chap. 76).

loss.
(20). Perform fuel system bleed.
(21). Perform an engine deceleration check
per the Pilot's Flight Manual.
NOTE: Make engine adjustments per the Alli

son Engine Operation and Maintenance
Manual.
(22). Perform an anti-icing system opera
tional check (Ref. Sec. 75-10-00).
(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
with washers and nuts.
(Ref. Figure 402)
(c). At lower engine mount fitting; install

bonding jumper on engine compart
ment firewall stud. Torque bolt to 100
- 140 inch-pounds (11.30 - 15.82
Nm). Safety bolt to engine mount
using lockwire (CM702).
Item
ST401
ST402
(15). Install engine exhaust pipes and

thermocouple clamp support.
(16). Attach thermocouple clamps in frame
and leads to terminal block studs
Page 408
Revision 22
71-00-00
Special Tools
Nomenclature
Engine stand
Engine hoist
(1). Install engine in engine stand (ST401).

(2). Disconnect wire leads from generator A
and D terminals.
(a). Loosen mounting clamp and remove
starter-generator.
MAINTENANCE MANUAL
(b). Remove mounting flange and gasket.
(c). Install cover on generator mounting
pad.
(3). Disconnect electrical connectors from:
(a). Chip detectors.
(b). Tachometer generators.
(c). Ignition exciter.
(d). Start counter.
(e). Fuel filter pressure switch.
(f). Unclamp and remove electrical
harness from overrunning clutch and
lower engine mount fitting.
(g). Remove entire engine electrical
harness.
NOTE: Discard all used O-ring packings.

(4). Remove fuel supply and return reduc
ers/unions.
(5). Remove oil supply and return reducers/
unions.
(6). Remove accessories drive vent elbow
and jamnut.
(7). Remove compressor bleed air hose, tee
and jamnut (Ref. Figure 402. view C).
(8). Remove oil pressure reducer/snubber.
(9). Remove torque-meter reducer/snubber.
(10). Remove N1 and N2 tachometer genera
tors and gaskets.
(11). Remove fuel pressure switch installa
tion as follows:
CSP-HMI-2
(a). Remove hose, reducer and O-ring

from before filter (BF) port (Ref.
Figure 402, view D).
(b). Remove bushing, fuel pressure
switch, fitting and O-rings from after
filter (AF) port.
(12). Remove engine air inlet bell and
firewall seal.
(13). Model 250-C20B Only:
Remove anti-icing valve lever assembly
from poppet guide (Ref. Figure 401,
view A).
(14). Remove fuel pump seal drain port
elbow and jamnut.
(15). Remove governor control idler support,
bellcrank and short N2 control rod as
an assembly. Install vacuum/hydraulic
pump pad cover.
(16). Remove overrunning clutch and
firewall seal. Install cover on engine
pad.
(17). Remove fuel control drain fitting.
(18). Remove pneumatic line accumulator
per Allison installation bulletin (Ref.
Sec. 01-00-00).
(19). Hoist (ST402) engine out of engine
stand.
(20). Unbolt and remove engine mount
fittings.
(21). Install engine in shipping container.
(22). Remove engine hoist fitting.
71-00-00
Page 409
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE HOIST
FITTING
BULKHEAD SPLICE
FITTING
FIREWALL BULKHEAD
STA 124.00
BULKHEAD SPLICE
FITTING
LOWER ENGINE
MOUNT
LOWER ENGINE
MOUNT ATTACH
FITTING
LOWER ENGINE MOUNT INSTALLATION
ENGINE
FITTING
UPPER ENGINE
MOUNT ASSY
AIRFRAME
FITTING
LANDING GEAR
DAMPER FITTING
UPPER ENGINE MOUNT INSTALLATION
NOTE:
THICK WASHERS ARE USED IN LOCATIONS
Figure 403. Model 250C20B and 250C20R/2 Engine Mounts and Airframe Fittings
Page 410
Revision 22
71-00-00
G71 0002
MAINTENANCE MANUAL
4. Engine Buildup
or overspeed.
CSP-HMI-2
(3). Hoist engine clear of shipping contain

er.
(4). Inspect engine as follows:
(a). If shipping container moisture
indicator was other than a light blue
color, examine engine for corrosion.
Perform corrosion corrective mainte
nance per Allison Operation and
Maintenance Manual as required.
(b). Inspect inlet guide vanes for damage.
(c). Exhaust and inlet openings for FOD.
Item
Nomenclature
CM113
CM114
CM118
CM502
CM702
CM808

Petrolatum
Grease
Sleeving, fiberglass
Lockwire CRES
Lacing cord
Item
Special Tools
Nomenclature
ST401
Engine stand
(1). Review Allison instructions for remov

ing engine from shipping container in
Allison Operation and Maintenance
Manual.
Prevent FOD Inspect and clean
all accessories and hardware
prior to installing parts on engine.
CAUTION
NOTE: Replace O-rings and gaskets with new

parts. Lubricate fuel line packings with
clean jet fuel or petrolatum (CM114) prior to
installation. Lubricate oil line packings with
clean engine oil prior to installation. Apply a
thin coating of anti-seize compound
(CM113) to the male threads of unions and
fittings before torquing.
(2). Install engine hoist lift fitting and bolts.
Torque 3/8 inch-diameter bolt to 160 190 inch-pounds (18.08 - 21.47 Nm).
Torque 5/16 inch-diameter bolts to 140
- 160 inch-pounds (15.82 - 18.08
Nm).
(d). Turbine blades for damage.

(e). Install covers over intake and
exhaust ports.
(f). All fasteners for security, slippage
marks for alignment, potting com
pound and, or correctly installed
lockwire where applicable.
(g). Tubes and hoses for damage.
(5). Record engine serial number and
start-counter reading in appropriate
log.
Prevent damage to machined
surfaces and contamination. Re
move covers from engine one at a time as re
quired by the installation sequence.
CAUTION
(6). Install lower engine mount fitting with

angle and ground wire under aft bolt
head. Install side engine mount fittings,
Install lockwire (CM702).
(8). Install accumulator in pneumatic line
per Allison installation bulletin (Ref.
Sec. 01-00-00).
(9). Install fuel control drain fitting and
O-ring.
(10). Remove overrunning clutch pad cover.
Install overrunning clutch, firewall seal
and engine electrical harness angle and
clamp (Ref. Sec. 63-10-00).
(11). Install oil pressure gauge reducer/snub
ber and O-ring.
71-00-00
Page 411
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
(12). Install torque-meter reducer/snubber

and O-ring.
Engine spark igniter wire lead
may obstruct governor arm on a
new or overhauled engine.
CAUTION
(13). Reroute engine spark igniter lead below

governor as shown (Ref. Figure 402).
Support igniter lead only with cush
ioned clamps and existing fasteners.
Replace and, or add clamps as required.
(14). Remove vacuum/hydraulic pump pad
cover from gear case.
(15). Install governor control idler support,
bellcrank and short N2 control rod as
an assembly. Do not connect control rod
to governor lever.
Only high temperature all met
al self locking nuts shall be used
to fasten governor control idler support
bracket to engine accessory pad.
CAUTION
(16). Install elbow with O-ring and jamnut

in fuel pump seal drain port.
Install anti-icing valve lever with
attaching hardware on poppet guide.
Position poppet guide so that lever is
parallel with top of engine.
(18). Install engine air inlet bell and firewall
seal.
(19). Install fuel pressure switch fitting and
O-ring in fuel pump AF port (Ref. Sec.
28-00-00).
Ensure both halves of the fuel
filter pressure switch are
gripped by wrench when torquing the in
stallation. An asymmetrical wrench grip
may cause shearing motion between assem
bly halves. Such damage may result in leak
age or failure to operate FUEL FILTER
caution/warning light, or both.
CAUTION
(a). Install fuel filter pressure switch and

O-ring.
(b). Install bushing and O-ring on
switch.
Page 412
Revision 26
71-00-00
(c). Install reducer and O-ring in BF

port.
(d). Install hose assembly between AF
and BF fittings.
(20). Lubricate splines with grease (CM118)
and install N1 and N2 tachometer
generators. Install washers and nuts.
(7.91 - 10.17 Nm).
(21). Install special tee, jamnut and O-ring
in compressor scroll bleed air port. Do
not torque at this time.
(22). Install hose between special tee and
compressor bleed air elbow. Torque tee
jamnut. Torque hose nuts to 150 - 250
inch-pounds (16.95 - 28.25 Nm).
(23). Install accessory gear case vent elbow,
jamnut and O-ring. Do not torque at
this time.
(24). Install oil inlet and outlet couplings and
O-rings.
(25). Install fuel inlet reducer and O-ring.
(26). Install starter/generator.
Always support the weight of
the starter/generator during re
moval/installation. Damage can occur if
weight is supported by the shear shaft.
CAUTION
(a). Remove starter/generator pad cover.

Install starter/generator mount with
gasket, washers and nuts. Torque
nuts to 100 - 140 inch-pounds
(11.29 - 15.81 Nm).
(b). Install starter/generator with Vclamp. Torque clamp nut to 50
(c). Tap around clamp with a rawhide
mallet to seat clamp on flange.
Retorque clamp nut to 50 inchpounds (5.64 Nm).
(d). Continue tapping around clamp and
retorquing clamp nut until nut no
longer turns when specified torque is
applied.
(27). Clamp engine electrical harness to
lower engine mount and starter-gener
ator.
MAINTENANCE MANUAL
(28). Connect ignition exciter wire lead and
starter-generator A and D wire leads.
(1). Disconnect accessory drive overboard

vent tube from elbow on engine accesso
ry case; remove vent tube from helicop
ter.
(29). Attach electrical connectors to both chip

detectors and safety with lockwire
(CM702).
(2). Install extension tube to existing vent

tube as follows:
(30). Connect N1 and N2 tachometer genera

tors connectors.
(a). Position extension tube over vent

tube. Drill rivet holes in line thru
tubing.
(31). Connect start counter lead and fuel

pressure switch wire lead splices.
Install fiberglass sleeving (CM502) over
splices and secure with high tempera
ture lacing cord (CM808).
(b). Apply sealant (CM425) between

tubes. Install two NAS1738B4-2
rivets. Fillet seal around circumfer
ence of tubes.
5. Modification of Accessory Drive Gearbox

Overboard Vent Tube (SN 0004D 0519D)
(Ref. Figure 404) The following procedure adds
a four inch extension tube to the existing
engine accessory drive gearbox vent tube to
reduce oil spattering onto the lower fuselage.
Item
Nomenclature
CM425
Sealing compound
CSP-HMI-2
(3). Remove existing grommet at lower

fuselage Sta. 127.00 and install new
MS35489-22 grommet.
(4). Insert extension tube thru grommet
and connect vent tube to elbow on
engine accessory case. Torque line nut
to 120 - 140 inch-pounds (13.56 15.82 Nm).
FUSELAGE SKIN
STA. 127.00
NAS1738B4-2 RIVET
(2 REQD.)
MS35489-22 GROMMET
NOTE
EXTENSION TUBE
369A8010-615
TUBE ASSY.
0.250 IN.
(6.35 MM)
0.84 IN.
(21.34 MM)
NOTE: SEAL BETWEEN TUBES

BEFORE ASSEMBLY AND FILLET
SEAL ABOUT CIRCUMFERENCE.
4.85 IN.
(12.319 CM)
88-295A
Figure 404. Extension of Engine Accessory Drive Overboard Vent Tube
71-00-00
Page 413
Revision 26
CSP-HMI-2
MAINTENANCE MANUAL
Page 414
Revision 44
71-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
710030
Power Plant
(250C30)
MAINTENANCE MANUAL
CSP-HMI-2
POWER PLANT
sor, N1 tachometer-generator and

accessory gear train, and a two-stage
power turbine driving the spare
accessory pad, governor, N2 tachome
ter-generator and helicopter rotor
system. An overrunning clutch, drive
shaft, starter generator, fuel, oil, drain
and bleed air lines, exhaust ducting,
mounting and hoist fittings and control
levers adapt the engine to the helicop
ter.
(1). MDHI 369FF helicopter is powered by a

250-C30 turboshaft engine manufac
tured by the Allison Engine Company
Inc.
cessed through two hinged, air-sealed
doors.
(3). A belt-driven blower forces external
positioned ducts that direct the air onto
heat exchangers. Spent cooling air is
duct and fuselage.
air particle separator/mist eliminator
assembly. Intake air is drawn through a
plenum chamber and into the engine
intake bell-mouth by the compressor.
Engine compartment air is separated
from compressor intake air by a seal
ring.
(1). The Allison 250-C30 turboshaft engine
consists of a single stage centrifugal
flow compressor, a can-annular
combustion chamber, a two-stage gas
producer turbine driving the compres

dures.
3. Model 250C30 Power Plant Fault
Isolation
(Ref. Table 1)

Symptom
Probable trouble
Loose engine mount bolts
Corrective action
140 inchpounds (11.30 15.82
Nm).
NOTES:
71-00-30
Page 1
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 2
Revision 44
71-00-30
MAINTENANCE MANUAL
CSP-HMI-2
POWER PLANT
1. Engine Removal

loss.
taminate systems.
CAUTION

external power. Disconnect battery.

and oil lines before removal to expedite in
stallation. Identify and bag loose parts to
prevent loss or damage.
(Ref. Sec. 63-10-00).
(3). Remove engine exhaust duct (Ref. Sec.
outlet.
(4). On left engine compartment door
frame; unclamp and disconnect thermo
couple wire leads from terminal studs
(Ref. Figure 401, view B).
(5). Unplug engine-airframe electrical
harness connector from engine recep
tacle.
(6). Disconnect thermal switch plug from
firewall.
(7). Loosen and remove remaining engine

cooling air ducts from engine compart
ment (Ref. Figure 402, views A and D).
(8). Remove combustion chamber drain line
from burner drain valve.
(9). Disconnect fuel inlet line at enginemounted fuel pump and cap line.
(10). Disconnect and remove fuel pump seal
drain line.
(11). Disconnect and remove fireshield drain
line.
(12). Disconnect fuel control vent line and
cap line.
(13). Disconnect customer bleed line at
firewall.
(14). Disconnect torque-meter oil line from
firewall.
(15). Disconnect oil pressure indicator line
from firewall.
(16). Disconnect N2 control rod from idler
bellcrank. Secure control rod to fire
wall.
(17). Disconnect N1 control rod from gas
producer lever. Secure control rod to
firewall.
(18). Disconnect and remove starter-genera
tor cooling air duct from starter and
fuselage bracket.
CAUTION
(19). Disconnect and cap engine oil inlet,

outlet and vent lines.
71-00-30
Page 401
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
COMBUSTION
CHAMBER DRAIN LINE
STARTER-GENERATOR
COOLING DUCT
LONG RANGE FUEL

TANK LINE
ENGINE GEARCASE
COOLING DUCT
FUEL PUMP
INLET
UPPER ENGINE MOUNT

LH SIDE SHOWN
RH SIDE OPPOSITE
UPPER ENGINE
MOUNT FITTING
N1 CONTROL ROD
GENERATOR
TERMINALS
(E, C, B ONLY)
THERMOCOUPLE
LEAD STUD (2)
ENGINE MOUNTING
PAD ASSY
THERMOCOUPLE LEAD
UPPER ENGINE MOUNT
LANDING GEAR
DAMPER FITTING
ENGINE DOOR
FRAME
THERMOCOUPLE LEAD - INSTALLATION
G71-0003-1
Figure 401. Model 250C30 Engine Removal and Installation (Sheet 1 of 2)

Page 402
Revision 22
71-00-30
MAINTENANCE MANUAL
CSP-HMI-2
LOWER ENGINE MOUNT

INSTALLATION
HOISTING EYE
FITTING
BRACKET
LOWER ENGINE
MOUNT
CLAMP
FIRESHIELD DRAIN
TUBE ASSY
LOWER ENGINE
MOUNT FITTING
FUEL PUMP SEAL

DRAIN TUBE ASSY
POWER TURBINE COOLING

DUCT INSTALLATION
ENGINE AIR
INLET BELL
ENGINE OIL
INLET LINE
BLEED DUCT
ENGINE OIL
OUTLET LINE
MAIN TRANSMISSION
DRIVESHAFT
TORQUEMETER
OIL PRESSURE
N2 CONTROL ROD
ENGINE HARNESS
DISCONNECT
ENGINE MOUNTING
PAD ASSY
G71-0003-2
Figure 401. Model 250C30 Engine Removal and Installation (Sheet 2 of 2)
71-00-30
Page 403
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2

Item
Special Tools
Nomenclature
ST401
Engine stand
ST402
Engine hoist

shafts.
support shaft.
(9). Remove hoist from engine lift fitting.
CAUTION
engine mount adjustments to remove en
gine.
D Engine-transmission alignment shall be
inspected whenever one or more engine
mount assemblies is replaced or the exist
ing alignment is disturbed. Do not disturb
adjustable engine mount fittings unless
an engine-transmission alignment check
is planned.

lifting eye fitting.
2. Engine Installation
A. Engine Installation in Mounts
Item
Nomenclature
(1). Install engine hoist apparatus (ST402)

between engine hoist eye and airframe
hoist fitting.
CM702
Lockwire CRES
(2). Have an assistant apply tension to

engine with hoist.
Item
Special Tools
Nomenclature
ST402
Engine hoist
(3). Maintain downward pressure on rear of

engine during mount bolt removal.
Unbolt engine at lower engine mount
fitting. Take care not to damage rod end
bearings.
(4). Unbolt left and right engine mount
assemblies from engine fittings.
of the helicopter.
CAUTION

(2). Position engine to line up engine lifting
eye under airframe lift fitting.
lift fitting.
fitting.

left side.
(5). Have an assistant tension hoist to

support engine. Unscrew engine stand
adjustable support shaft.


Page 404
Revision 22
71-00-30
MAINTENANCE MANUAL
CSP-HMI-2

firewall.
CAUTION
Do not allow engine to strike airframe or
components. Avoid damaging engine in
take bell.
D Prevent FOD ensure that no foreign ob
jects are trapped in firewall seal ring.
(7). Have hoist operator slowly raise engine
while pushing engine down to maintain
correct engine and transmission
alignment.
assemblies with engine fittings. Install
bolts and washers (Ref. Figure 403).
(24.86 - 40.67 Nm); Safety bolts to
engine mounts using lockwire (CM702).
assembly with engine fitting. Install
bolt, washers and nut. Torque nut to 95
- 110 inch-pounds (10.73 - 12.43
Nm); install cotter pin as required.
(10). Ensure engine air inlet firewall seal
ring contacts firewall seal around its
entire circumference.
B. Connecting an Installed Engine
Item
Nomenclature
CM702
Lockwire CRES

or overspeed.
(1). Connect torque-meter oil line to
firewall.

line nut to 120 - 140 inch-pounds
(13.56 - 15.82 Nm).
CAUTION
(4). Connect engine oil outlet and inlet

lines. Hand-tighten until snug.
Wrench-tighten approximately 1/4 turn
or until definite resistance is felt.
(5). Position accessory drive vent elbow and
connect with vent tube. Torque elbow
(16.95 - 28.25 Nm). Torque tube nut to
20 - 30 inch-pounds (2.26 - 3.39
Nm).
(6). Connect N1 control rod to lever with
bolt, two washers and nut. Install bolt
with head outboard, one standard OD
washer under nut and one large 0.8
inch diameter washer under head.
(4.52 - 5.08 Nm). Install a new cotter
pin.
(7). Connect short N2 control rod to gover
nor lever with bolt head up, one
standard OD washer under head, one
large 0.80 inch (20.32 mm) OD washer
under nut and a new cotter pin.
Connect long N2 control rod with bolt
head forward, two washers, nut and a
new cotter pin.

on drain valve.
71-00-30
Page 405
Revision 34
MAINTENANCE MANUAL
CSP-HMI-2
ROTATED
UPPER ENGINE MOUNT INSTALLATION
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)
LOWER ENGINE MOUNT INSTALLATION
ENGINE FITTING
LOWER ENGINE MOUNT
LOWER ENGINE MOUNT

ATTACH FITTING
(REF. SEC. 71-20-00)
G71-0004A
Figure 402. Engine Mounts and Structural Fittings

Page 406
Revision 34
71-00-30
MAINTENANCE MANUAL
(11). Secure engine electrical harness to
engine mount with cushioned loop
clamp. Connect harness plug to recep
tacle and safety with lockwire (CM702).
(a). Install engine harness ground lead.
(b). Install E, C, and B generator leads on
starter-generator terminal block
with washers and nuts.
(c). Attach thermocouple leads to termi
nal block studs located on right upper
engine door frame with chromel and
alumel nuts.
support bracket on airframe hoist
fitting. Connect and tighten ducts on
firewall coupling and oil cooler deflec
tor.
CSP-HMI-2

tional check (Ref. Sec. 75-10-00).
3. Engine Stripping
(Ref. Figure 403)
Item
ST401
ST402
Special Tools
Nomenclature
Engine stand
Engine hoist

(2). Disconnect wire leads from generator A,
E and D terminals.

(Ref. Sec. 63-10-00).
(3). Loosen mounting clamp and remove

starter-generator.
(14). Install exhaust duct (Ref. Sec.

78-30-00).
(4). Remove mounting flange and gasket.
(15). Remove all identifying tags from wires

and hardware.
Improper rigging of throttle con
trols can cause inadvertent
flameout when throttle is rapidly closed to
the idle position.
CAUTION
(16). Rig gas producer (N1) and power

turbine (N2) controls (Ref. Chap. 76).

loss.
(17). Perform fuel system bleed.

Manual.
(5). Install cover on generator mounting

pad.
(6). Disconnect electrical connectors from:
(a). Chip detectors.
(b). Tachometer generators.
(c). Fuel filter pressure switch.
(d). Unplug electrical harness connector
from front of engine.
(e). Unclamp and remove engine electri
cal harness.

(7). Remove oil vent line and associated
hardware.
(8). Remove fuel inlet fitting.
(9). Remove oil supply, return and vent
reducers/unions.
(10). Remove oil pressure reducer/snubber.
(11). Remove torquemeter reducer/snubber.
(12). Unclamp and remove compressor bleed
service line, fitting and associated
clamps.
71-00-30
Page 407
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
SCREEN
ASSEMBLY
FITTING
NUTPLATE
FITTING
SPACER
(NOTE)
INLET
SEAL
ENGINE OIL
OUTLET
ENGINE OIL
PRESSURE
INLET
BELL
ENGINE OIL
INLET
NUTPLATE
PLUG
ENGINE MOUNT
PAD ASSEMBLY
GAS PRODUCER
TURBINE
TACH/GEN (N1)
POWER TURBINE
TACH/GEN (N2)
SUPPORT
ASSEMBLY
ENGINE OIL
TANK VENT
TORQUEMETER
OIL PRESSURE
PACKING
SEAL
BACKING
BOLT
COUPLING
SHIM
CLUTCH
ASSEMBLY
NOTE:
SPACER BONDED TO INLET SEAL.
Figure 403. Model 250C30 Engine BuildUp (Sheet 1 of 2)

Page 408
Revision 22
71-00-30
G71-0005-1A
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE BLEED AIR

ASSEMBLY
REF.
FITTING
HI
POINTER
LO
VIEW LOOKING AFT
FUEL FLOW STOP ADJUSTER
TUBE ASSEMBLY
STARTER/GENERATOR
ENGINE MOUNTING
PAD ASSEMBLY
GASKET
FITTING
SWITCH
REDUCER
HOSE ASSEMBLY
G71-0005-2A
Figure 403. Model 250C30 Engine BuildUp (Sheet 2 of 2)
71-00-30
Page 409
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
(13). Remove compressor bleed duct from

bleed valve.
(14). Unfasten and remove N1 and N2
tachometer generators and gaskets.
(15). Remove hose and reducer from fuel
pump after filter (AF) port.
(16). Remove fuel pressure switch and fitting
from fuel pump before filter (BF) port
(Ref. Figure 403).
firewall seal. Cover engine inlet.
(18). Remove fuel pump seal drain port
union/reducer.
(19). Remove governor control idler support
complete with bellcrank, short N2
control rod and lever. Do not dismantle
assembly.
(1). Review Allison instructions for remov

ing engine from shipping container in
Manual.
Prevent FOD Inspect and clean
all accessories and hardware
prior to installing parts on engine.
CAUTION
NOTE: Replace O-rings and gaskets with new

parts. Lubricate fuel line packings with
clean jet fuel or petrolatum (CM114) prior to
installation. Lubricate oil line packings with
clean engine oil prior to installation. Apply a
thin coating of anti-seize compound
(CM113) to the male threads of unions and
fittings before torquing.
(20). Remove overrunning clutch and clutch

firewall seal. Install cover on gear case.
(2). Install engine hoist fitting and bolts.

Torque 3/8 inch diameter bolt to 160 190 inch-pounds (18.08 - 21.47 Nm).
Torque 5/16 inch-diameter bolts to 140
- 160 inch-pounds (15.82 - 18.08
Nm).
(21). Hoist (ST402) engine out of engine

stand.
(3). Hoist engine clear of shipping contain

er.

fittings.

(24). Unbolt and remove hoist fitting.
4. Engine Buildup
(Ref. Figure 403)
(b). Inspect inlet guide vanes for damage.
Item
Nomenclature
CM113
CM114
CM118
CM502
CM702
CM808

Petrolatum
Grease
Sleeving, fiberglass
Lockwire CRES
Lacing cord
Item
Special Tools
Nomenclature
ST401
Engine stand
Page 410
Revision 22

71-00-30

(d). Turbine blades for damage.
(e). Install covers over intake and
exhaust ports.
(f). All fasteners for security, slippage
(g). Tubes and hoses for damage.
log.
MAINTENANCE MANUAL
CAUTION
(6). Install side engine mount fittings with

bolts and washers. Torque bolts to 140 160 inch-pounds (15.82 - 18.08 Nm);
lockwire bolts.
(8). Set fuel flow stop adjuster as follows:
(a). For Bendix P/N 2524944-5 or
2524922-7 and subsequent, set
pointer at LO position.
(b). For Bendix P/N 2524944-1, -2, -3,
-4 or 2524922-3, -4, -5, -6, set
pointer midway between LO stamped
mark and the middle scribed mark.
(c). Torque jam nut to 20 - 25 inchpounds (2.26 - 2.82 Nm); lockwire
nut.
(9). Remove cover from gearcase clutch
mounting pad.
(10). Install overrunning clutch on gearcase
mount pad with wire harness support
angle between 4 and 5 o'clock position
looking aft (Ref. Sec. 63-10-00).
(11). Loosely attach wire harness clamp to
support angle with screw, washer and
nut.
(12). Attach clutch firewall seal to clutch
flange with one washer under each bolt
head and nut. Torque nuts to 25 - 35
NOTE: Use new O-ring packings and gaskets

on all installations where the parts are re
quired. Lubricate O-rings with clean sys
tem fluids prior to installation.
(13). Remove tachometer-generator cover
plates from gearcase mount pads.
(14). Install a gasket under each tachome
ter-generator.
(15). Lubricate splines with grease (CM118)
and install N1 and N2 tachometer
generators. Install washers and nuts.
CSP-HMI-2

(7.91 - 10.17 Nm).

or overspeed.
(16). Inspect torquemeter and engine oil
pressure snubber and reducer bores for
metal shavings and debris. Clean
hardware as required. Preassemble
both snubbers as follows:
(a). Thread torquemeter snubber onto
reducer and O-ring. Torque assembly
to 65 - 75 inch-pounds (7.34 - 8.47
Nm).
(b). Thread oil pressure snubber onto
reducer and O-ring. Torque assembly
to 95 - 105 inch-pounds (10.73 11.86 Nm).
(c). Apply a thin coat of engine oil to
snubber threads and O-rings and
install in gearcase ports (Ref.
Figure 403)
The gear case is magnesium
alloy. Using relatively high
torque values applicable to threaded fittings
and fasteners in metals other than magne
sium may result in stripped threads. Refer
to Allison Engine Maintenance Manual for
additional fastener torque information.
CAUTION
(d). Torque oil pressure snubber assembly

to 50 - 65 inch-pounds (5.65 - 7.34
Nm).
(e). Torque torquemeter snubber assem
bly to 25 - 35 inch-pounds (2.82 3.95 Nm).
(f). Install union and O-ring in gearcase
oil supply (inlet) port. Torque union
to 450 - 500 inch-pounds (50.84 56.49 Nm).
(g). Install union and O-ring in gearcase
oil return port. Torque union to 180 200 inch-pounds (20.34 - 22.60
Nm).
71-00-30
Page 411
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
(17). Install compressor bleed air duct with

screws washers and clamp (Ref.
Figure 401).
(18). Install inlet bell with one washer under
each bolt head and nut. Install service
bleed air tube support bracket on aft
surface of engine inlet bell mounting
flange at the 2 o'clock position looking
aft. Torque nuts to 5 - 7 inch-pounds
(0.56 - 0.79 Nm).
Only high-temperature self
CAUTION locking all metal nuts shall be
used to fasten governor control idler support
bracket to engine accessory pad.
(19). Install governor control idler support
complete with bellcrank, short N2
control rod and lever.
(20). Attach short control rod to N2 governor
lever. Stack hardware with bolt head on
top, large washer under bolt head and
washer under castellated nut; Install
cotter pin.
(21). Install compressor bleed air service
fitting on compressor case with engine
supplied washers and bolts. Lockwire
bolts.
(22). Attach bleed air tube to service fitting.
(23). Install clamp on bleed air tube and
secure to support bracket with bolt,
washer and nut. Torque bleed air tube
nut on compressor case fitting to 450 500 inch-pounds (50.84 - 56.49 Nm).
Install a protective cap on tube end.
(24). Install union and O-ring in engine oil
tank vent gearcase boss. Torque union
to 180 - 200 inch-pounds (20.34 22.60 Nm).
(25). Preassemble oil tank vent tube, clamp,
union and hose. Torque union, hose and
tube end nuts to 450 - 500 inch
pounds (50.84 - 56.49 Nm).
(26). Attach vent tube assembly to oil tank
vent gearcase union. Install tube clamp
with screw, washer and nut. Using a
backup wrench to hold union, torque
tube nut to 450 - 500 inch-pounds
(50.84 - 56.49 Nm).
Page 412
Revision 26
71-00-30
(27). Assemble differential pressure switch.

(28). Install elbow with O-ring and jamnut
in fuel pump seal drain port.
(29). Install oil inlet and outlet couplings and
O-rings.
(30). Install fuel inlet reducer and O-ring.
CAUTION

(11.29 - 15.81 Nm).
applied.
(32). Clamp engine electrical harness to
lower engine mount and starter-gener
ator.
(33). Connect ignition exciter wire lead and
starter-generator A and D wire leads.
(34). Attach electrical connectors to both chip
detectors and safety with lockwire
(CM702).
(35). Connect N1 and N2 tachometer genera
tors.
(36). Connect start counter lead and fuel
pressure switch wire lead splices.
Install fiberglass sleeving (CM502) over
splices and secure with high tempera
ture lacing cord (CM808).
(37). Inspect engine connections for security
and proper routing.
MAINTENANCE MANUAL
CSP-HMI-2
Section
710047
Power Plant
(250C47)
MAINTENANCE MANUAL
CSP-HMI-2
POWER PLANT
centrifugal flow compressor section, a

can-annular combustion section, a
two-stage gas producer turbine section
and power and accessory gearbox. The
gas producer geartrain drives the
compressor, hydromechanical control
unit, fuel pump and internal pressure
and scavenge oil pumps. An overrun
ning clutch, drive shaft, starter genera
tor, fuel, oil, drain and bleed air lines,
exhaust ducting, mounting and hoist
fittings and control levers adapt the
engine to the helicopter.
(1). MDHI 600N helicopter is powered by a

250-C47M turboshaft engine manufac
tured by the Allison Engine Company
Inc.
cessed through two hinged air-sealed
doors.
(3). A belt-driven blower forces external
positioned ducts that direct the air onto
heat exchangers. Spent cooling air is
duct and fuselage.
air particle separator assembly. Intake
air is drawn through a plenum chamber
and into the engine intake bell-mouth
by the compressor. Engine compart
ment air is separated from compressor
intake air by a seal ring.
(5). The engine is equipped with a full
authority digital engine control (FA
DEC) system. A hydromechanical
control manual system is provided for
backup if the electronic system fails.
(1). The Allison 250-C47M turboshaft
engine consists of a single stage

dures.
3. Model 250C47 Power Plant Fault
Isolation
(Ref. Table 1)

Symptom
Probable trouble
Loose engine mount bolts
Corrective action
140 inchpounds (11.30 15.82
Nm).
NOTES:
71-00-47
Page 1
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
P / J1202
IMS27466T25F2451
P1067A16
GCUI
GENERATOR CONTROL UNIT
P1203
4
3
T
J
L
G
P1068B16
P1053A16N
P1055A22N
E1
2 1
CURRENT
LIMIT
POWER IN
POWER GND
NEGATIVE SENSE
P1203 (200 AMP GEN WIRING SHOWN)

E38
GCU1A22N WHT
GCU1A22N ORN
#1 CURRENT SENSE
K
R
B
F
D
FIELD
BUS SENSE
M
A
P1054A16
P1050A22
#3 CURRENT SENSE
#4 CURRENT SENSE
GENERATOR SENSE
#2 CURRENT SENSE
P / J1201
W1250B22
P1049A22
P1069B22
70
S
H
P
GEN OUT LT.

LINE CONTACTOR
GEN DISABLE
P1051A22
P1052A22
GCU1A22N BLU
(369D24284-3)
2
52
51
64
AS301 1
BLU
WHT
P1125A22
B
U
S
CR204
TB1001
CR201
4
K1047B22
E37
P20003A10
FEEDER
A1
X1
X2
P1049C22
5
K308
FWD. LINE
CONTACTOR
A2
CR202
JUMPER
12 GA
CR2003
P1048A22N
CB301
2
1
P1067A16
JUMPER 16AWG
15A
CB302
STARTER /
GENERATOR
JUMPER 22AWG
1A
G300
E12
P1063AON
A
B
P1059AO
A2
A1
P1065AO
P1060A22
P1063AO
X1
X2
CR301
K312
AFT LINE
CONTACTOR
E13
P1066A22N
TB201-1
D
K1
FADEC
START RELAY
3
5 8
P / J 113
K1057B22
E38
A
S106
START
SWITCH
A2
A1
K1047A22
A
2
1
CR33
B
K1058A22N
TB200-7
ECU053A22N
1K1006D22
1K1006G22
ECU034B22
K1057A22
ECU035A22
4
2
7
ECU049D22
P1049B22
K4
FADEC
IGN RELAY
P1049A22
X1
X2
K1062A0
K301
START
RELAY
J / P 112
2K1006D22
2K1006G22
P1069B22
S106
START SW.
P1203-P
FROM AUTO RE-IGNITION RELAY
J1072B22
P1060A22
L
M
K312-X1
J / P 1301
5 8
E13
IGNITION
EXCITER
IGN.
GAP
E13
4
2
7
GENERATOR / STARTER CIRCUIT
Figure 1. Starter/Generator System Wiring Diagram (Sheet 1 of 2)

Page 2
Revision 22
71-00-47
6G71-064-1
MAINTENANCE MANUAL
CSP-HMI-2
K309
APU
RELAY
P1029A2
P2004A10
CR30
X1
X2
CR
29
TB1001
J100
APU
37
A1
FEEDER
E4
P1028A2N
P / J 1201
A2
JUMPER
12GA
CR2002
P1030A22
P108
BATT
BATT 160 o
P1032A2
P1033A2N
W1036A22
5
E
W1043C22
4
P2005A10
A1
X1
X2
CR
28
JUMPER
12GA
FEEDER
CR2001
K200
W1038A22N
A
E37
TB200-8
CR205
23
W1037A22
TB200-9
W1046B22
A2
2
7
BATT
HI TEMP
RELAY
TB1003
CR206
K310
BATT
RELAY
W1045C22
35
E1
W1045A22
BATT 140 o
3
P1035A22
36
W1043B22
GENERATOR / STARTER CIRCUIT
6G71-064-2
Figure 1. Starter/Generator System Wiring Diagram (Sheet 2 of 2)
J1202-K
( # 8 LUG )
J1202-N
( # 10 LUG )
J1201-54
E1140B22
TC300
( AIRFRAME MTD. )
( CHROM )
E1141AA16 ( ALUML )
TC3002
( ENGINE MTD )
THERMOCOUPLE
FUEL
FILTER
SW.
A B
SP123
ENGINE ACCESSORY HARNESS

ALLISON P/N 23064231
J1301 ( MS27466T21F41P / MW P1301 MS27467T21F41S )

TB200-7S
J1072B22
L
IGNITION
EXCITER
E13
J1201-55
J1201-53
JMPR 22GA
JMPR 22GA
2
3
H1163A22
E1142B22
SP73
B A
IGN. GAP
ANTI-ICING
SOLENOID
VALVE
ENG CHIP
DET UPPER
ENG CHIP
DET LOWER
6G71-079
Figure 2. Engine Wire Harness Wiring Diagram
71-00-47
Page 3
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 4
Revision 44
71-00-47
MAINTENANCE MANUAL
CSP-HMI-2
POWER PLANT
1. Model 250C47 Engine Replacement
(5). Loosen clamps and remove engine

cooling air ducts from engine compart
ment.
(6). Loosen clamps and remove compressor
bleed hose from engine compartment.
(7). Detach engine electrical connections.

loss.
(a). Detach engine electrical harness

connector.

taminate systems.
(8). Disconnect fuel inlet line at engine

mounted fuel pump.
CAUTION

external power. Disconnect battery (Ref.
Sec. 96-05-00).

and oil lines before removal to expedite in
stallation. Identify and bag loose parts to
prevent loss or damage.
(Ref. Sec. 63-10-00).
(3). Remove engine exhaust duct (Ref. Sec.
outlet.
(4). Loosen clamps and remove starter
cooling air duct from engine compart
ment.
(b). Detach electrical connections from

starter/generator.
(c). Detach splice connector from fuel
filter bypass switch.
(9). Disconnect hydromechanical unit

(HMU) vent line and drain line.
(10). Disconnect customer bleed air line at
firewall elbow.
(11). Disconnect torquemeter oil line at
firewall.
(12). Disconnect oil pressure indicator line at
firewall.
(13). Disconnect engine control cable from
engine control box on HMU.
CAUTION
(14). Disconnect engine oil inlet, outlet and

vent lines.
71-00-47
Page 401
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
INLET SEAL
ENGINE HOIST FITTING
INLET
BELL
SEAL
ASSEMBLY
LEFT SIDE SHOWN

CLUTCH
ASSEMBLY
ENGINE MOUNT PAD
6G71-066-1A
Figure 401. Engine Buildup Assembly (Sheet 1 of 2)

Page 402
Revision 22
71-00-47
MAINTENANCE MANUAL
CSP-HMI-2
CUSTOMER
BLEED AIR
LINE
HYDROMECHANICAL
FUEL CONTROL UNIT
ENGINE
OIL TANK
VENT LINE
ENGINE OIL
PRESSURE
PERMANENT
MAGNET
ALTERNATOR
ENGINE OIL
INLET
FUEL FILTER
ASSEMBLY
ENGINE
CONTROL
BOX
ENGINE OIL
OUTLET
STARTER/
GENERATOR
FUEL DIFFERENTIAL
PRESSURE SWITCH
OIL FILTER
ASSEMBLY
VIEW LOOKING AFT
REF. CLUTCH
ASSEMBLY
O-RING
O-RING
BOLT
POWER TAKEOFF
PAD COVER
LOOKING INBOARD-LEFT SIDE
6G71-066-2A
Figure 401. Engine Buildup Assembly (Sheet 2 of 2)
71-00-47
Page 403
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
EXHAUST DUCT
EXHAUST
SUPPORT
ASSEMBLY
COMBUSTOR DRAIN
ENGINE DOOR
ASSEMBLY
ELECTRICAL HARNESS
PRESSURE TRANSDUCER
BULKHEAD UNION
WASHER (2X)
NUT
ENGINE OIL PRESSURE LINE
ENGINE TORQUEMETER LINE
6G71-067-1A
Figure 402. Engine Installation (Sheet 1 of 2)

Page 404
Revision 22
71-00-47
MAINTENANCE MANUAL
FUEL
FILTER
CSP-HMI-2
FUEL IN PORT
OIL OUT PORT

OIL
FILTER
FUEL OUT PORT
OIL IN PORT
(EXISTING HOSE)
OIL TANK
ENGINE VENT
CONNECTION
CUSTOMER
BLEED AIR
CONNECTION
ENGINE OIL IN
CONNECTION
ENGINE OIL OUT

CONNECTION
(EXISTING HOSE)
6G71-067-2
Figure 402. Engine Installation (Sheet 2 of 2)
71-00-47
Page 405
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2

Item
Special Tools
Nomenclature
ST401
ST402
Engine stand
Engine hoist

hoist fitting.
C. Engine Installation in Mounts
Item
CM702
Nomenclature
Lockwire CRES
Item
ST401
ST402
Special Tools
Nomenclature
Engine stand
Engine hoist
CAUTION
engine mount adjustments to remove en
gine.
D Engine to transmission alignment shall
be inspected whenever one or more en
gine mount assemblies is replaced or the
existing alignment is disturbed. Do not
disturb adjustable engine mount fittings
unless an engine-transmission align
ment check is planned.
(1). Install engine hoist tool (ST402)
between engine hoist fitting and
airframe hoist fitting.
(2). Apply tension to engine with hoist and
remove engine mount bolts.
of the helicopter.
CAUTION

left side.
shafts.
support shaft.
(7). Remove hoist from engine hoist fitting.
Page 406
Revision 22
71-00-47

(2). Position engine to line up engine hoist
fitting under airframe hoist fitting.
hoist fitting.
fitting.
(5). Apply tension to engine hoist to support
engine. Unscrew engine stand adjust
able support shaft.
CAUTION
Do not allow engine to strike airframe or
components. Avoid damaging engine in
take bell.
D Prevent FOD. Ensure that no foreign ob
jects are in the engine plenum area.
(7). Slowly raise engine while pushing back
of engine down to maintain correct
engine and transmission alignment.
assemblies with engine mount fittings.
Install bolts and washers (Ref.
Figure 403). Torque bolts to 220 - 360
MAINTENANCE MANUAL
inch-pounds (24.85 - 40.66 Nm).
Safety bolts with lockwire (CM702).
assembly with engine fitting. Install
bolt, washers and nut. Torque nut to 95
- 110 inch-pounds (10.73 - 12.43
Nm).
(10). Ensure inlet seal assembly contacts
firewall around its entire circumfer
ence.
(12). Perform engine to transmission
alignment if applicable (Ref. CSPSRM-6, Section 53-30-00).
(13). Using a mirror and light, check for
clearance between airframe and bleed
valve, any clearance is acceptable.
(14). If bleed valve contacts firewall, readjust
engine mounts for clearance.
(a). Move engine back by adjusting the
left and right mounts, increasing the
top and decreasing the bottom.
(b). Only make adjustments one flat at a
time until bleed valve clears firewall.
NOTE: One flat will move the engine approxi

mately 0.020 inch (0.508 mm) aft.
(c). Adjust lower mount to insure no
preload exists.
(d). Perform engine to transmission
alignment if applicable (Ref. CSPSRM-6, Section 53-30-00).
D. Connecting an Installed Engine

or overspeed.
(1). Connect torquemeter indicator oil line
to bulkhead union on firewall. Torque
CSP-HMI-2
tube nut to 75 - 85 inch-pounds (8.47

- 9.60 Nm).
bulkhead union on firewall. Torque tube
nut to 75 - 85 inch-pounds (8.47 9.60 Nm).
hose nut to 230 - 260 inch-pounds
(25.98 - 29.36 Nm).
CAUTION
(4). Connect engine oil out line to elbow.

(5). Connect engine oil in line to union.
(6). Connect customer bleed air line to
elbow. Torque hose nut to 460 - 500
inch-pounds (51.96 - 56.48 Nm).

on drain valve. Torque tube nut to 50 65 inch-pounds (5.64 - 7.34 Nm).
(10). Attach engine electrical connectors.
(a). Attach engine electrical wire harness
to to airframe connector at firewall.
(b). Attach fuel pressure bypass switch
splice connector.
(c). Attach starter/generator electrical
connections (Ref. Figure 403).
(Ref. Sec. 63-10-00).
71-00-47
Page 407
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2
2. Model 250C47 Engine Stripping
STARTER / GENERA
TOR
(Ref. Figure 401)
D
E
P1063A0N
E12
Item
Special Tools
Nomenclature
ST401
ST402
Engine stand
Engine hoist
A
B
C
K1062A
0P1061A0
P1054A18
P1052A22
6G71-085
Figure 403. Starter/Generator Electrical

Connections
support bracket on airframe hoist
fitting. Connect ducts and tighten
clamps on firewall coupling and oil
cooler deflector.
(13). Install compressor bleed hose and
tighten clamps.
(14). Install starter cooling air duct and
tighten clamps.
(15). Install exhaust duct (Ref. Sec. 78-00).
(16). Connect and rig engine control cable
(Ref. Chap. 76).

loss.
(17). Perform fuel system bleed (Ref. Chap.
28).

Manual.
tional check (Ref. Chap. 75).
Page 408
Revision 29
71-00-47

taminate systems.
CAUTION

(1). Remove engine control box from HMU.
(2). Remove reducers from HMU.
(3). Remove starter/generator.
CAUTION
(a). Loosen V-clamp and remove starter/

generator.
(b). Remove bolts, washers, mounting
flange and gasket.
(4). Remove oil vent line and associated
hardware.
(5). Remove fuel inlet fitting.
(6). Remove unions from oil in port and oil
tank vent unions from gearcase.
(7). Remove oil pressure tube, clamps and
attaching hardware and reducer/snub
ber.
(8). Remove torquemeter tube, clamps and
attaching hardware and expander.
(9). Remove customer bleed air line,
associated clamps and hardware and
fitting.
(10). Remove N1 and N2 tachometer genera
tors and gaskets.
MAINTENANCE MANUAL
(11). Remove hose, fuel pressure switch,
reducers, tee fitting and union from fuel
filter assembly.
firewall inlet seal. Cover engine inlet.
(13). Remove overrunning clutch and clutch
firewall seal. Install cover on gear case.
(14). Hoist engine and remove engine stand.
fittings.
(17). Unbolt and remove hoist fitting.
3. Model 250C47 Engine Buildup
(Ref. Figure 401)

or overspeed.
CSP-HMI-2
CAUTION
D Prevent FOD. Inspect and clean all acces
sories and hardware prior to installing
parts on engine.
D The gear case is magnesium alloy. Using
relatively high torque values applicable to
threaded fittings and fasteners in metals
other than magnesium may result in
stripped threads. Refer to Allison Engine
Maintenance Manual for additional fas
tener torque information.
(b). Install engine hoist fitting and bolts.
Torque bolts to 140 - 160 inchpounds (15.81 - 18.07 Nm).
(c). Install engine hoist tool (ST402)
between engine hoist fitting and
airframe hoist fitting.
(d). Raise engine off shipping container
base.
(b). Inlet guide vanes for damage.
Item
Nomenclature
(d). Install covers over intake and

exhaust ports.
CM111
CM126
CM702
Grease, aircraft
Oil, turbine
Lockwire CRES
(e). All fasteners for security, slippage

(f). Tubes and hoses for damage.
Item
Special Tools
Nomenclature
ST401
ST402
Engine stand
Engine hoist
(1). Prepare engine for buildup as follows:

(a). Review Allison instructions for
removing engine from shipping
container in Allison Operation and
Maintenance Manual.

log.
CAUTION
(4). Install engine mount fittings with bolts

inch-pounds (15.81 - 18.07 Nm).
Safety bolts with lockwire (CM702).
71-00-47
Page 409
Revision 29
MAINTENANCE MANUAL
CSP-HMI-2

(6). Install clutch assembly.
(a). Remove engine power take off pad
cover from aft side of engine gearbox
and protective cover from forward
side of engine gearbox.
(b). Lubricate clutch assembly and
engine power output shaft splines
before assembly. Pack all voids and
gaps with grease (CM111).
(c). Install clutch assembly with angle,
washers and nuts. Torque nuts to 50
- 70 inch-pounds (5.64 - 7.90 Nm).
Use caution when installing bolt
to avoid cutting O-ring. Liberal
ly coat O-ring with grease and install with
twisting motion.
CAUTION
NOTE: Use new O-ring packings and gaskets

on all installations where the parts are re
quired. Lubricate O-rings with clean sys
tem fluids prior to installation.
(8). Install expander with O-ring on

existing engine torquemeter line fitting.
Torque expander to 50 - 70 inchpounds (5.64 - 7.90 Nm).
(9). Install engine oil tank vent line.
(a). Install union with O-ring in engine
gearcase oil tank vent port. Torque
union to 280 - 305 inch-pounds
(31.62 - 34.45 Nm).
(b). Install oil tank vent tube on union.
Torque tube nut to 230 - 260 inchpounds (25.98 - 29.36 Nm).
(c). Install union on oil tank vent tube.
Torque union to 230 - 260 inchpounds (25.98 - 29.36 Nm).
(d). Install vent hose on union. Torque
hose nut to 230 - 260 inch-pounds
(25.98 - 29.36 Nm).
(10). Install union with O-ring in engine
gearcase oil inlet port. Torque union to
550 - 600 inch-pounds (62.12 - 67.77
Nm).
(11). Install customer bleed air line.
(d). Lubricate O-rings with grease

(CM111) and install on bolt. Install
bolt in aft end of engine power output
shaft. Thread bolt into clutch shaft
and torque bolt to 250 - 300 inchpounds (28.24 - 33.88 Nm).
(a). Install customer bleed air fitting with

engine supplied gasket, washers and
engine supplied bolts. Torque bolts to
20 - 25 inch-pounds (2.25 - 2.82
Nm). Safety bolts with lockwire
(CM702).
(e). Reinstall engine power take off pad

cover. Torque nuts to 50 - 70 inchpounds (5.64 - 7.90 Nm).
(b). Install bleed hose assembly on bleed

air fitting. Torque hose assembly to
230 - 260 inch-pounds (25.98 29.36 Nm). Clamp line to strap
attached to inlet bell mount bolt.
NOTE: Install firewall seal with split at 6

O'clock position.
(12). Install fuel switch.
(f). Install seal at end of clutch assembly

screws to 15 - 20 inch pounds (1.69
- 2.25 Nm).
To avoid contamination of en
gine oil system, inspect reducer
and snubber bores for metal shavings and
debris.
CAUTION
(7). Install engine oil pressure snubber,

reducer and O-ring on engine gearbox.
Connect oil pressure tube to snubber.
Torque tube nut to 20 - 30 inchpounds (2.25 - 3.38 Nm). Clamp tube
to existing engine line.
Page 410
Revision 29
71-00-47
(a). Install union with O-ring in fuel

filter housing. Torque union to 95 105 inch-pounds (10.73 - 11.86
Nm).
(b). Install tee on union with O-ring and
jam nut. Torque jam nut to 38 - 42
(c). Install reducer with O-ring on end of
tee. Torque reducer to 95 - 105
inch-pounds (10.73 - 11.86 Nm).
(d). Install union with O-ring on 90
degree fitting of tee. Torque restrictor
to 95 - 105 inch-pounds (10.73 11.86 Nm).
MAINTENANCE MANUAL
(e). Install fuel switch with O-ring on
reducer. Torque switch to 65 - 75
(f). Install reducer with O-ring in fuel
filter housing. Torque reducer to 95 105 inch-pounds (10.73 - 11.86
Nm).
(g). Install hose between fuel switch and
reducer. Torque hose nuts to 20 - 30
CSP-HMI-2

applied.
(15). Install engine control box on HMU.
(a). Hold engine control box in position
against HMU.
(13). Install inlet bell and inlet seal with

bolts, washers and nuts. Torque nuts to
60 - 85 inch-pounds (6.77 - 9.60
Nm).
(b). Insert 0.1535-0.1545 inch

(3.8989-3.9243 mm) rig pin (#23 drill
blank) through engine control box,
indexed HMU pointer and into HMU.
(c). Rotate serrated washer on shaft for

micro-adjustment until rig pin
inserts without interference.

CAUTION

(11.29 - 15.81 Nm).
(d). Install mounting bolts, washers and

use shim washers as required
between engine control box and HMU
to prevent binding on rig pin. Torque
(e). Check rig pin fit again and repeat
previous steps as required.
(16). Install reducers with O-rings on HMU.
Torque reducers to 550 - 600 inchpounds (62.12 - 67.77 Nm) and 50 55 inch-pounds (5.64 - 6.21 Nm).
71-00-47
Page 411
Revision 29
CSP-HMI-2
MAINTENANCE MANUAL
Page 412
Revision 44
71-00-47
MAINTENANCE MANUAL
CSP-HMI-2
Section
711000
Engine Air Intake
System (369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE AIR INTAKE SYSTEM

1. Description and Operation
(1). The engine air intake system consists of
an air inlet screen, plenum chamber,
engine inlet bell, engine inlet firewall
seal, and engine firewall seal ring.
(2). Air enters the inlet fairing, passes
through the inlet screen, plenum
chamber and air inlet bell into the
engine compressor.
intake air from accumulating in the

plenum chamber cavity.
2. Air Inlet Screen Replacement
A. Air Inlet Screen Removal (369D/E/FF
500N)
(Ref. Figure 201)
NOTE: The following procedures are to be used

for all MDHI model helicopters. The differ
ent steps are noted for the 500N installa
tion.
(3). The engine inlet screen assembly is

made of a lightweight 1/4 inch (6.35
mm) mesh metal screen material
secured to a metal frame along its outer
edge. The engine air particle separator
option, when installed, replaces the
inlet screen.

fairings (Ref. Sec. 53-30-00/30).
(4). The inlet screen edge is 1-1/2 inches

(3.81 cm) from the top of air inlet
fairing to provide an intake air-bypass
area in the event that debris clogs the
screen. The firewall seal separates
plenum chamber intake air from engine
compartment air.
(4). On 500N installation, remove the

engine plenum fairing attachment
hardware, open bypass door and
remove fairing assembly.

mounted with a reference to both sides
of the engine inlet screen. Blockage of
the inlet screen will cause a pressure
decrease on the engine plenum side and
the switch will activate a warning light
in the cockpit.
(6). A cable from the cockpit is manually
operated to open a bypass door which
allows unfiltered air into the engine
inlet plenum if the engine inlet screen
is blocked.
(7). The molded nylon air inlet bell is
retained on its mounting flange with
three flat springs and is required to
smooth air flow into the compressor.
(8). A plenum chamber drain system
prevents water condensed out of engine
(2). Open plenum chamber bypass door.

(3). Install a suitable cover over engine air
inlet bell though bypass door opening.
Avoid FOD. Cover compressor

inlet prior to working in plenum
chamber. Vacuum all FOD debris out of ple
num chamber before removing protective
cover from engine inlet bell. Severe damage
to engine may result from entry of foreign
objects.
CAUTION
(5). Remove clamps or tie-down straps

securing tail rotor control rod boot to
inlet screen fairing.
(6). Disconnect Sta. 120.00 tail rotor control
rod forward end. (Ref. Chap. 67).
(7). On 500N disconnect the intermediate
anti torque tube forward end. (Ref. Sec.
67-20-30).
(8). Remove blower air inlet screen (Ref.
Figure 201).
(9). Remove attaching hardware and engine
air inlet screen.
71-10-00
Page 201
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
FAIRING
ENGINE AIR INLET SCREEN

BOLT
PLENUM CHAMBER
ACCESS DOOR
WASHER
SCREW
SCREW
WASHER
WASHER
BLOWER AIR
INLET SCREEN
ANTI-TORQUE CONTROL
ROD BOOT SUPPORT
FAIRING
369D/E/FF INSTALLATION
PLENUM CHAMBER
ACCESS DOOR
ENGINE AIR INLET SCREEN
BOLT
WASHER
SCREW
WASHER
BLOWER AIR
INLET SCREEN
WASHER
ANTI-TORQUE CONTROL
ROD BOOT SUPPORT
500N INSTALLATION
G71-1021B
Figure 201. Engine Air Inlet Screen Installation (Sheet 1 of 2)

Page 202
Revision 22
71-10-00
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE INLET
SCREEN ASSEMBLY
ENGINE PLENUM
ACCESS COVER
INLET FRAME
600N INSTALLATION
6G71-074
Figure 201. Engine Inlet Screen Installation (Sheet 2 of 2)
71-10-00
Page 203
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
B. Engine Inlet Screen Removal (600N)

(Ref. Figure 201)
4. Firewall Seal Removal

(Ref. Figure 202)
(1). Remove screws, washers and inlet

screen from inlet frame.
C. Air Inlet Screen Installation (369D/E/FF
500N)
(Ref. Figure 201)
Vacuum all FOD debris out of
plenum chamber before remov
ing protective cover from engine inlet bell.
Severe damage to engine may result from
entry of foreign objects.
CAUTION
(1). Install engine air inlet screen in reverse

order of removal.
D. Engine Inlet Screen Installation (600N)
(Ref. Figure 201)
(1). Install inlet screen on inlet frame with
washers and screws. Torque screws to
20 - 25 inch-pounds (2.25 - 2.82
Nm).
3. Air Inlet Bell Replacement
A. Air Inlet Bell Removal
(1). Remove engine.

(2). Remove attaching hardware, air inlet
bell and firewall seal ring.
(3). Remove firewall seal ring from inlet
bell.
B. Air Inlet Bell Installation
(Ref. Figure 202)
On early installations; attach firewall
seal ring to inlet bell by lifting and
positioning leaf springs over bell flange.
(2). Position engine air inlet bell and seal
assembly on compressor inlet mounting
flange and secure.
(3). Install engine.
Revision 22
CM219
CM411
Methyl-ethyl-ketone
Adhesive, epoxy
(1). Remove engine.

(2). Pull seal from firewall.
Use Methyl ethyl ketone
WARNING (MEK) in a well ventilated

(3). Remove seal debris from firewall with a
wooden or plastic scraper.
(4). Remove residue from firewall with
MEK (CM219).
(5). Apply adhesive (CM411) to installation
per manufacturers instructions. Center
seal over firewall opening and bond in
place.
(6). Install engine.
5. Air Intake System Inspection
(Ref. Figure 202)
Page 204
Item
Nomenclature
71-10-00
(1). Inspect air inlet screen for security,

deformation,inspect screen for cleanli
ness, clogged areas and foreign particle
accumulation. (Cleaning of engine air
inlet screens Ref. Sec. 20-20-00).
(2). Inspect screen for tears, cuts, breaks
and missing pieces.
(3). Inspect anti-torque control rod boot for
condition and secure attachment (Ref.
Chap. 67).
(4). Inspect air inlet bell for cracks, breaks
and missing pieces. No cracks or
missing pieces allowed.
On early installations; inspect engine
firewall seal ring for cracked or weak
springs.
MAINTENANCE MANUAL
SCREW
CSP-HMI-2
WASHER
AIR INLET BELL

FIREWALL SEAL
FIREWALL SEAL RING
WASHER
NUT
ENGINE
SPACER
MOUNTING FLANGE
250-C30 AND 250-C47 ENGINES
SCREW
FIREWALL SEAL RING
SCREW
WASHER
ENGINE AIR INLET BELL
NUT
FIREWALL
WASHER
AIR INLET BELL
NUT
FIREWALL SEAL
FIREWALL SEAL
FIREWALL SEAL RING
EARLY CONFIGURATION
250-C20B AND 250-C20R/2 ENGINES
G71-1020A
Figure 202. Firewall Seal Installation
71-10-00
Page 205
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
(6). Inspect engine-to-firewall seal ring at

the firewall for cracks, corrosion or
damage preventing a positive and
complete seal. Repair or replace seal
installation as required.
6. Firewall Seal Ring Repair
(7). Inspect air inlet-to-firewall seal for

cracks, corrosion or damage preventing
a positive and complete seal. Repair or
replace seal installation as required.
Engine air inlet bell repairs are not autho

rized; replace a defective bell.
(8). Inspect plenum chamber drain tubing

for deformation and corrosion. Ensure
drain is open.
Replace damaged or broken springs on early

installations.
7. Air Inlet Bell Repair
8. Plenum Chamber Drain Tube Replacement

(Ref. Figure 203)
(1). Replace drain tubing using standard
practices and procedures.
PLENUM CHAMBER
PLENUM CHAMBER
DRAIN TUBE
FIREWALL FITTING
FIREWALL
LOCKWIRE
FIREWALL
NYLON TWINE
DRAIN TUBE ATTACHMENT
GROMMET
G71-1022
Figure 203. Drain System
Page 206
Revision 22
71-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
711005
Engine Compressor
Water Wash Kit
(369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE COMPRESSOR WATER WASH KIT

1. Engine Compressor Water Wash Kit
Maintenance
Replace hoses, clamps and other hardware
only when necessary.
Whenever working in the en
gine plenum area, cover engine
with cardboard or other suitable object to
prevent foreign objects from entering en
gine.
CAUTION
(1). Remove appropriate access panels to

gain access to area of water wash kit to
be worked on.
2. Engine Compressor Water Wash Kit

Inspection
(1). Inspect hoses for chafing, damage and
deterioration.
(2). Inspect all clamps for damage and
security.
(3). Inspect elbow for damage and security.
(4). Inspect spray assembly for loose rivets,
secure hose and clamp, no damage to
grommet and silicone sealant around
tube intact.
(5). Inspect all mounting brackets for loose
rivets.
(6). Inspect lanyard for security and
damage; cap installed.
71-10-05
Page 201
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 202
Revision 44
71-10-05
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE COMPRESSOR WATER WASH KIT

1. Engine Compressor Water Wash Kit Initial
Installation
A. Gaining Access to Work Area
(1). In aft compartment, remove seat
assemblies, L/H bulkhead trim, access
cover and insulation; gearbox access
cover.
fairing; open plenum chamber access
door.
Install temporary cover of card
board or suitable material over
engine air intake.
CAUTION
(3). Remove engine air shield screen or

engine air inlet screen, as applicable;
remove access cover from mast support
structure panel.
(4). Open L/H engine compartment door.
B. Airframe Modification and Installation
(Ref. Figure 901)
Item
Nomenclature
CM318
CM430
Primer
(4). Drill or cut 0.4531 inch (11.50874 mm)

hole in firewall assembly at dimension
shown in view A-A. Position and install
AN848-4D hose elbow in firewall with
hardware as shown.
(5). Cut hole for MS35489-11 grommet in
forward wall of plenum chamber per
dimensions shown; install grommet
with sealant (CM430).
(6). Position 369H3042 spray assembly on
inner side of plenum chamber forward
wall, view B-B, with tube inserted
forward through grommet. Mark and
drill rivet holes and install spray
assembly with eight NAS1738M4-2
rivets. Install rivets with primer.
(7). Install 369H3048-5 hose on spray
assembly tube and on hose elbow at
firewall; secure hose at each end with
AN737TW22 clamps.
(8). Mark and drill No. 8 hole in 369H3024
channel and install MS25281-4 clamp
and hardware as shown. Secure -5 hose
with clamp.
(9). Install 369H3048-3 hose on elbow at
left side of firewall and on hose adapter
at forward side of lower section ring.
Secure hose at each end with
AN737TW22 clamps.
2. Installation Inspection
(1). Position 369H3047 support on Sta.

137.50 lower section ring at dimensions
shown in view E-E. Mark and drill
rivet holes and install support with six
NAS1398B4-2 rivets. Install rivets
with Primer (CM318).
(2). Drill No. 8 hole in ring assembly; locate
from existing hole in support.
(3). Install AN807-4D hose adapter in
support with hardware as shown;
install lanyard clip in hole with hard
ware as shown. Install 369H3046 cap
on hose adapter.
(1). Carefully check and/or vacuum the

plenum chamber for any foreign objects
or debris. Remove protective cover from
engine air intake.
NOTE: Spray kit using 369H3042 nozzle re

quires 60 PSI (414 kPa) to establish water
flow rate of one quart (0.946 L) in 9-10 sec
onds. A bypass valve or equivalent installed
at source hose connection is recommended
in order to relieve pressure and facilitate
disconnection at hose adapter.
(2). Perform operational check of water
wash kit installation.
71-10-05
Page 901
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
(3). Reinstall removed components and

assemblies; install and secure access
covers and doors.
(4). Record installation of 369H92537

engine compressor water wash kit in
helicopter Log Book.
STA.
127.00
STA.
137.50
0.22 IN.
R
(5.588 MM)
TYPICAL
BL
0.00
B
MS35489-11
GROMMET (1 REQD)
(DO NOT SPLIT)
0.76 IN.
(19.304 MM) 0.60 IN.
(15.24 MM)
WL
50.00
B
0.38 IN.
(9.652 MM)
NOTE
HOLE FOR
GROMMET
AN737TW22
CLAMP (2 REQD)
CL ENGINE
AN848-4D HOSE ELBOW

AN960PD716L WASHER
AN924-4D NUT
1.75 0.10 IN.

(44.45 2.54 MM)
369H3048-5 HOSE
D
D
369H3046 CAP AND
LANYARD ASSEMBLY
AN807-4D HOSE ADAPTER
AN960PD716L WASHER
AN924-4D NUT
AN737TW22 CLAMP
(2 REQD)
AFT SECTION ASSEMBLY

FUSELAGE STRUCTURE
369H3048-3 HOSE
AN737TW22 CLAMP
NOTE: SEAL WITH SILICONE SEALANT.
Figure 901. Engine Compressor Water Wash Kit Installation (Sheet 1 of 3)

Page 902
Revision 22
71-10-05
E
G71-1023-1A
MAINTENANCE MANUAL
CSP-HMI-2
BL
10.00
FIREWALL ASSEMBLY
BL
20.00
15
APPROX.
TRACE
WL 40.00
0.453 IN.
(11.5094 MM)
0.79 IN.
(20.066 MM)
3.00 IN.
(76.2 MM)
A-A
TRACE
WL 30.00
CL ENGINE
BL
0.00
0.78 IN.
(19.812 MM)
INLET ASSEMBLY,
ENGINE AFT SECTION
369H3042 SPRAY ASSEMBLY
NAS1738M4-2 RIVET
MFD. HEAD FAR SIDE
LOCATED FROM 369H3042
(8 REQD) (NOTE)
B-B
NOTE: ALTERNATE MS20615-3M5 RIVET
MAY BE USED IN PLACE OF NAS1738M4-2.
G96-1023-2A
71-10-05
Page 903
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
BL
0.00
WL
50.00
INLET ASSEMBLY,
ENGINE AFT SECTION
RING ASSEMBLY,
LOWER SECTION STA.
137.50
C-C
0.198-0.204 IN.
(NO. 8) DIA. HOLE
(50.292-5.1816 MM)
NAS623-3-3 SCREW
AN960PD10L WASHER (2 REQD)
MS25281-4 CLAMP
MS21042-3 NUT
WL
34.50
0.50 IN.
(12.7 MM)
369H3024 REF
0.50 IN.
(12.7 MM)
NAS1398B-4-2 RIVET
LOCATE FROM
369H3047 (6 REQD)
1.18 IN.
(29.972 MM)
369H3047 SUPPORT
E-E
LBL
8.45
STA.
124.00
CANT
D-D
0.198-0.204 IN.
(50.292-5.1816 MM) (NO. 8) DIA. HOLE (LOCATED FROM 369H3047)
NAS623-3-3 SCREW
AN960PD10L WASHER
MS21042-3 NUT

Page 904
Revision 22
71-10-05
G96-1023-3A
MAINTENANCE MANUAL
CSP-HMI-2
Section
711010
Engine Air Particle
Separator
(369D/E/FF 500N)
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE AIR PARTICLE SEPARATOR

(Ref. Figure 1)
(1). MDHI 369/500 helicopters may be
equipped with an optional engine inlet
air particle separator filter installation
in place of the standard engine air inlet
screen.
(2). Later model helicopters are equipped
with a Aircraft Porous Media (APM)
filter. Earlier 500D helicopters were
fitted with a Donaldson particle
separator. The APM unit is equipped
with provisions for an optional mist
eliminator installation.
(3). Both the APM and Donaldson particle
separators are installed inside the front
of the aft intake fairing above the
plenum chamber and utilize the same
operating principle. The particle
separator installation consists of vortex
tubes, a collection chamber, a nozzle
manifold, ejectors, flapper valve, seals
and attaching hardware. A scavenge air
system is used to remove trapped
particles from the collection chamber
with engine bleed air. The scavenge air
system consists of a solenoid air valve,
tubes, an air pressure switch, SCAV
AIR circuit breaker switch, AIR
FILTER CLOGGED caution light,
wiring, and attaching hardware. An air
bypass door system is included to allow
the particle separator to be bypassed in
the event the unit becomes clogged. The
air bypass door system includes a
hinged plenum chamber door, door
latches, door actuating forward and aft
cables, cable return spring, two retain
ers, three cable pulleys, adjustable
cable stop, handle and attaching
hardware.
(4). An optional mist eliminator may be
fitted to the back of APM separators to
filter liquid sprays out of engine inlet
air. Nine self retaining bolts secure
early mist eliminator installations to
the aft face of the particle separator.
Later installations feature a system of

clips that retain the mist eliminator in
sealed contact with the particle separa
tor. The mist eliminator consists of a
welded stainless steel frame and wire
mesh screens on the fore and aft faces.
(5). Air drawn through the particle separa
tor by the engine passes through the
parallel vortex tubes. Each tube is
fitted with vanes and an opening to the
particle collection chamber. The vanes
spin the incoming air so that centrifu
gal force separates heavier solid bits
from the air flow. A smaller diameter
tube directs particle free center vortex
tube air through the collection chamber
rear plate into the plenum chamber.
When the scavenge air system is
switched ON, trapped particles are
drawn out of the collection chamber by
scavenge air vacuum and discharged
overboard through an opening in the
right side of the aft inlet fairing of APM
equipped helicopters and the left side
on Donaldson equipped machines. The
nozzle manifold is fitted with an engine
bleed air inlet port and air jets to
discharge contaminants. The ejector
assembly consists of a mounting flange
with tubes, duct assembly and flapper
valve.
(6). The scavenge air system is supplied
compressor bleed air controlled by the
solenoid air valve. Bleed air is delivered
to a duct-mounted nozzle-manifold
that ejects contaminants from the
particle separator. The electrically
actuated solenoid air valve is mounted
on the left forward side of the Station
124.00 bulkhead. The valve is con
trolled by the SCAV AIR circuit breaker
switch on the instrument panel.
(7). An increase in plenum chamber
vacuum (reduced plenum chamber
pressure) caused by reduced airflow
through a clogged filter/mist eliminator
is sensed by a differential pressure
switch ported to the plenum chamber
and particle separator inlet. Sufficient
71-10-10
Page 1
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
pressure differential causes the switch

to close. Switch closure lights an AIR
FILTER CLOGGED caution indicator
on the instrument panel. A cable
actuated filter bypass door on the
plenum chamber wall may be opened by
the pilot to allow the engine to operate
on unfiltered air.
(8). Pulling the FILTER BYPASS CON
TROL handle in the crew compartment
disengages two door latches inside the
engine air inlet aft fairing and opens
the door inward. A spring and two
retainers on the aft end of the forward

cable returns the handle to the stowed
position. An adjustable stop provides
for cable travel adjustment and air
bypass door rigging.
On 500N installation, the FILTER
BYPASS CONTROL handle in the crew
compartment disengages one door latch
inside the air inlet aft fairing and opens
the door inward. Adjustment of this
cable installation is limited by reposi
tioning the cable assembly.
Table 1. Engine Air Particle Separator Configurations

Model
500N
Part Number
500N901483
500N901481
Cabin Heat
Principal Features
No
Yes
APM filter with new pressure switch and Tpedestal electrical

installation.
530FF 369H90148543
369H90148541
369H90148529
369H90148527
No
Yes
No
Yes
APM filter with generic wire harness and no cabin heat

APM filter with generic wire harness and cabin heat
APM filter with new pressure switch and Tpedestal electrical
installation.
500E
369H90148545
369H90148539
369H90148537
369H90148535
369H90148521
369H90148519
Yes
No
No
Yes
No
Yes
APM filter for C20R engine with generic wire harness

APM filter for C20R engine with generic wire harness
APM filter for C20B engine with generic wire harness
APM filter for C20B engine with generic wire harness
APM filter with Tpedestal electrical installation.
500D
369H90148509
369H90148507
No
Yes
APM filter with electrical controls bracket on side of slimline pedestal.
369H90148505
369H90148503
No
Yes
Donaldson filter with electrical controls bracket on side of slimline

pedestal. No mist eliminator option.
Page 2
Revision 36
71-10-10
CSP-HMI-2
(VIEW LOOKING DOWN)
TYPICAL FILTER FUNCTION
MAINTENANCE MANUAL
G71-1000-1A
Figure 1. Particle Separator Operating Principle Early Type (Donaldson Unit)
71-10-10
Page 3
Revision 22
FILTER BY-PASS CONTROL

PULL HANDLE FWD
PULL HANDLE
SWIRL GUIDES
EJECTOR MANIFOLD
LOCATED ON BOTTOM
OF PARTICLE SEPARATOR
AIR
FILTER
CLOGD
INDICATOR
LIGHT
EJECTOR
MANIFOLD
SCAV AIR OUTLET

FLAPPER VALVE
AIR PRESSURE SWITCH

(PRESSURE ACTIVATED)
AIR BLEED SOLENOID

(SHUTOFF) VALVE
FILTER SCREEN
FILTERED
AIR TO
ENGINE
AIR INLET
CONTAMINATED AIR
TO SCAVENGE EJECTOR
SWIRL GUIDES
FILTER TUBE DETAIL VIEW
SWIRL GUIDES
TO ENGINE
AIR INLET
ENGINE AIR INLET

AFT FAIRING
ATMOSPHERIC AIR
FILTERED AIR
CONTAMINATED AIR
ENGINE COMPRESSOR BLEED AIR
MECHANICAL ACTUATION
ELECTRICAL ACTUATION
Figure 2. Particle Separator Operating Principle Current Type (APM Unit)
TYPICAL FILTER FUNCTION

(VIEW LOOKING DOWN)
PLENUM CHAMBER
ACCESS (FILTER
BYPASS) DOOR
NORMALLY CLOSED
ENGINE COMPRESSOR BLEED AIR
SCAVENGE EJECTOR NOZZLE
FILTER TUBE
(SEE DETAIL VIEW)
SCAV
AIR
OFF
Revision 22
71-10-10
Page 4
MAINTENANCE MANUAL
CSP-HMI-2
G71-1000-2
MAINTENANCE MANUAL
CSP-HMI-2

FAULT ISOLATION
1. Engine Air Particle Separator Fault
Isolation
Table 101. Engine Air Particle Separator Fault Isolation
Symptom
Probable Trouble
Corrective Action
Turbine outlet temperature (TOT)

gage indicates a moderate
temperature increase with all other
indications normal.
Partially blocked particle separator

and, or mist eliminator.
Clean and service particle separator

installation.
FILTER CLOGGED caution light

on. Light goes out when air bypass
door is opened.
Clogged filter.
Clean and service particle separator

installation.
Filter requires frequent cleaning.

Loads up with SCAV AIR, ON and
functioning.
Inadequate scavenge air flow;

leaking scavenge air bleed air
lines.
Inspect scavenge air system for

leakage. Repair system as required.
Solenoid air valve blocked.
Clean solenoid air valve.
Lamp failed.
Replace lamp.
Disconnected, open or loose

wiring.
Check continuity, repair or replace

wiring.
Faulty air pressure switch.
Replace pressure switch.
Defective light assembly.
Replace light assembly.
Defective air pressure switch.
Replace air pressure switch.
Wiring problem.
Repair wiring.

fails to come on when air filter is
clogged but works when tested.
Defective wiring.
Repair wiring.
Defective air pressure switch.
Replace air pressure switch.

handle is pulled but bypass door
fails to open.
Disconnected or broken cable.
Repair or replace cables.
Air bypass door does not open all

the way when FILTER BYPASS
CONTROL handle is pulled to
forward limit.
Cable stop out of adjustment.
Adjust cable stop.

handle fails to return to full aft
position after control actuation.
Defective return spring.
Replace return spring.
Cable kinked, worn or binding.
Repair or replace cable assembly.
No air is exhausted through outlet

duct with SCAV AIR circuit breaker
ON and engine running.
Defective wiring.
Repair wiring.
Disconnected or damaged
scavenge air line.
Connect or replace scavenge air line.
Defective solenoid air valve.
Replace solenoid air valve.

fails to come on when filter is
clogged.

stays on regardless of bypass door
position.
71-10-10
Page 101
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2
UTILITY
CB117
2
1
LINE
P16B20
SCAVENGE AIR
CB15
1
2
LINE 3A LOAD
P206
P16C20
SPLICE
DC
BUS
P16D20
(NOTE 3)
369A8462 SCAV.
AIR SOLENOID
P17A20N
(NOTE 3)
E45
P16E22
P16J22
FILTER CLOGGED LIGHT (AMBER)

AND PRESS-TO-TEST SWITCH
SPLICE
2
SPLICE
P16F22
P16K22N
SPLICE
SPLICE
P16G22
P16H22
TB6
AIR
PRESSURE
SWITCH
GND
E15
GND
NOTES:
1. THIS WIRING DIAGRAM SHOULD BE USED WITH THE
ELECTRICAL SYSTEM WIRING DIAGRAM IN CSP-HMI-3
FOR COMPLETE CIRCUIT INTERCONNECT AT INSTALLATION.
2. ASTERISK ( * ) INDICATES WIRE IS CUT TO LENGTH AT
INSTALLATION.
3. PART OF WIRE HARNESS 369D24163.
G71-1002-1A
WIRE LIST
WIRE NO.
P17A20N
P16K22N
P16J22
P16H22
P16G22
P16F22
P16E22
P16D20
P16C20
P16B20
LENGTH
72.0*
10.0
72.0*
204.0*
12.0
3.0
240.0*
72.0*
FROM
P206B
SPLICE
LIGHT 3
SPLICE
SPLICE
LIGHT 2
CB15 LINE
SPLICE
CB15 LOAD
CB117 LINE
TERMINATION
32445
SOLDER
32445
32445
SOLDER
MS25036149
MS25036149
MS25036149
TO
E45
TB6
SPLICE
E15
SPLICE
SPLICE
LIGHT 1
P206A
SPLICE
CB15 LINE
TERMINATION
MS25036101
32445
MS25036103
32445
32445
SOLDER
32445
MS25036149
Figure 101. 369H90148503, 505, 507, 509 Particle Separator

Installation Wiring Diagram (SlimLine Panel)
Page 102
Revision 36
71-10-10
MAINTENANCE MANUAL
CB15
1
TB700-3
N-P
J-K
P16A22
P16B22
CSP-HMI-2
P618J
a
P16M22
P16AA22
TB103
1
FILTER
BYPASS
LIGHT
SCAV-AIR
SOLENOID
P16E22
E72
3
2
P16J22N
P16L22
P9J
f
P16MM22
P206
A
B
P17D20N
M
T-W
P618J
d
P16F22
P16C20
P16FF22
P9J
k
E45
P16G22
SP207
E15
P16H22N
B
A
SP206
A B
BYPASS
AIR SW
NOTES:
1. APPLICABLE TO 369D MODEL, S/N 1222 AND SUBS. WITH
T-PANEL AND CENTER ELECTRICAL CONSOLE.
2. EXISTING WIRING IS SHOWN PHANTOMED. WIRE TO BE
INSTALLED IS SOLID.
G71-1002-2
Figure 102. 369H90148503, 505, 507, 509 Particle Separator Installation

Wiring Diagram (TPanel with Center Console)
71-10-10
Page 103
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2
KNIFE SPLICE
VARISTOR
(NOTE 2) P206
A
P16D20
P16C20
(NOTE 1)
P17A20N
E45
CB11
9
2
WIRE HARNESS
(NOTE 4)
369H90148-101 ALTERNATE CONFIGURATION
TERMINAL LUG
(REF)
CB15
P514D20
SCAV AIR
SOLENOID
P16MA20
(NOTE 1)
1 3A 2
SP207
B A
P16G22
SP206
A B
E15
P16H22N
AIR PRESSURE SWITCH
P16F20
P16M20
P9J
f
q
P206
P16C20
(NOTE 1)
TB503-4 (REF)
A 369A8462
SCAV AIR
B SOLENOID
P17D20N
E45
G
K
SEE ALT.
CONF.
J
L
VARISTOR
P12 (REF)
E508A20
L532A20
MS3106R10SL-4S
CONNECTOR
P514C20
TB503-6 (REF)
CB104
1 5A 2
VARISTOR
(NOTE 2)
P206 (REF)
E559A20
B DIMMER
B
SOLDER
CONNECTIONS
SHRINK TUBING
VARISTOR
INSTALLATIO
N
P514B20
TB503-12 (REF)
3
C
4
NOTE 1
M531C20
TB505-1/2 (REF)
F
E511BB2
0
E511B2
0
LIGHT ASSY
(NOTE 3)
VIEW LOOKING AT
REAR
NO
NC
E15
C
P514A20
P514G20
LAMP TEST
NOTES:
1. ALL EXISTING WIRES ARE PHANTOMED. WIRES TO BE INSTALLED ARE
IN SOLID LINES.
2. VARISTOR WIRES TO BE AS SHORT AS POSSIBLE.
3. USE 20 GAGE BUSS WIRE AND SHRINK TUBING AS REQUIRED.
4. P16D20 MAY BE TRIMMED TO APPROXIMATELY 16 IN. (41 CM) LENGTH.
G71-1001A
Figure 103. 369H90148519, 521, 527, 529 Particle Separator

Installation Wiring Diagram
Page 104
Revision 36
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2
CB150
(SCAV-AIR)
P1201J
P/J1203A
1
P1008AA22
3A
P206
P1008B22
CR201
10
P1008A22
D10
SCAV-AIR
SOLENOID
E18
A F
P1150A22N
P527
P
1
1
P1154A22
S2001
AIR FILTER
1 BYPASS SW 2
SP207
A B
P1154B22
NOTE:
ALTERNATE CONFIGURATION
FOR T-PANEL WITH CENTER
CONSOLE.
CB150
(SCAV-AIR) 1
20 GA JMPR
P1201J
P1008A22
3A
P206
P1008B22
CR201
10
SCAV-AIR
SOLENOID
E18
A F
P1150A22N
WARNING
PRESS-TO-TEST
N
N
C
N
O
N
C
O
S1
W1040C22N
P1154C22
N
SP206
A B
P1154B22
1
1
E33
B
S2001
AIR FILTER
1 BYPASS SW 2
SP207
A B
SP206
A B
P1154C22
N
20 GA JMPR
S2
P1154A22
W1237B22
TB503-1/2
W1237A22
W1237C22
W1040F22
E F G H
J K L M
TB503-2
G
H
A
B
J
K
P1233B22
D TB503-8
P1233C22
AIR FILTER
CLOGGED LIGHT
2
1
C
3
4
P
D
R
E
W1040E22
P12
DIMMER CONTROL UNIT
D WARNING LTS BRT/DIM

B DC GROUND TEST
NOTES:
1. APPLICABLE TO 369E S/N 384 &
SUBS AND 369FF S/N 076 & SUBS.
2. EXISTING WIRING IS SHOWN
PHANTOMED. WIRE TO BE
INSTALLED IS SOLID.
3. THIS WIRING DIAGRAM SHOULD
BE USED WITH THE ELECTRICAL
SYSTEM WIRING DIAGRAM IN
CSP-HMI-3 FOR COMPLETE
IDENTIFICATION.
G71-1002-3
Figure 104. 369H90148535,537, 539, 541, 543, 545 and 500N901481, 3

Particle Separator Installation Wiring Diagram
71-10-10
Page 105
Revision 36
CSP-HMI-2
MAINTENANCE MANUAL
Page 106
Revision 36
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2

1. Air Bypass Door System Maintenance
2. Solenoid Air Valve Cleaning
Item
Nomenclature
Item
Nomenclature
CM106
Fluorocarbon dry lubricant
CM112
CAUTION
D Prevent engine FOD. Secure a cover over
the engine intake prior to working inside
plenum chamber. Remove cover after
completing work.
D Loose, missing or improperly installed air
bypass door hardware may cause engine
damage.
NOTE: Maintain door system equipment per

FAA publication, EA-AC43.13-1A and 2A.
(1). Disconnect cable from door.
(2). Inspect and replace loose or worn door
hinge pins with 0.091 inch (2.3114 mm)
diameter corrosion resistant wire.
(3). Inspect all door hardware for wear,
corrosion, correct installation, secure
attachment and proper operation.
(4). Connect cable to door.
(5). Close door. Check for positive latching
and correct alignment. Peel or add latch
clip shims to align door flush with
fairing surface.
(6). Rig air bypass door (Ref. Air Bypass
Door Rigging) after replacing either
forward or aft cable, or changing cable
travel.
(7). Spray gasket and door edge with S-122
fluorocarbon dry lubricant (CM106) if
operating in temperatures below 40F
(4.5C).
(8). Remove engine intake cover.
NOTE: Maintain scavenge air equipment per

FAA publication, EA-AC43.13-1A and 2A.
Use anti-seize compound
(CM112) on all male threaded
fittings prior to installation.
CAUTION
(1). To access solenoid air valve; remove

lower and center air duct trim from
forward left side of aft passenger
compartment bulkhead.
NOTE: Solenoid air valve water flush proce

dure may be accomplished with valve in
stalled or removed from helicopter. In either
case, a 28 Vdc power supply is required to
actuate valve for cleaning.
(2). Connect a low pressure, clean water
source to valve inlet fitting. Connect a
hose to the outlet fitting to route
discharged water to a drain. Connect a
28 Vdc external power source to
helicopter or the valve, as required.
(3). Turn on water. Alternately open and
close valve with SCAV AIR circuit
breaker switch to flush valve poppet
seat.
(4). Reverse air valve water connections.
Repeat flushing procedure.
Compressor bleed air is hot
enough to char tube identifica
tion tapes that may cause FOD. Remove
identification tapes from compressor bleed
air tubes prior to installation.
CAUTION
(5). Install solenoid air valve. Torque valve

mounting bolts to 22 - 27 inchpounds (2.49 - 3.05 Nm). Torque tube
nuts to 110 - 130 inch-pounds (12.43
- 14.69 Nm).
71-10-10
Page 201
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
3. Air Pressure Sensing Switch Maintenance

Air pressure switch and AIR FILTER
CLOGGED caution light circuit function may
be quick-checked as follows:
(1). Open air bypass door.
Prevent engine FOD. Secure a
cover over the engine intake
prior to working inside plenum chamber.
Remove cover after completing work.
CAUTION
(2). Attach a suitable length of 3/16 inch

(4.76 mm) ID hose to pressure switch
nipple. Connect a vacuum source to the
hose.
(3). Connect 28 Vdc power to the helicopter.
(4). Apply vacuum to pressure switch. The
AIR FILTER CLOGGED caution light
should come on. Release the vacuum
and the light should go out.
(b). Have an assistant press hard against

the air bypass door in an attempt to
keep the latch-bolts from moving up
out of their clips.
(c). Grasp FILTER BYPASS CONTROL
handle and slowly move it forward.
The distance the handle travels
before meeting the solid resistance of
the latch-bolts gives an indication of
cable slack and lost motion due to
wear.
(4). Remove cable slack as follows:
(a). Break lockwire between door latch
center crank threaded swivel fitting
and cable end fitting (Ref.
Figure 201, detail D). Remove
attaching hardware and swivel
fitting from door latch center crank.
Thread swivel fitting up swaged
cable terminal end 2 - 3 turns.
Reassemble all door hardware except
lockwire.
4. Air Bypass Door Rigging (369D/E/FF)
(b). Repeat previous steps as required

until slack is removed. Do not
preload cable.
Rig air bypass door installation after replacing

forward or aft cables or when door operation or
opening angle is incorrect. Rig door as follows:
(c). Lockwire cable end fitting to door

latch center crank swivel fitting.

CAUTION cover over the engine intake
(1). Cycle air bypass door control handle
and door mechanism several times to be
certain system does not bind at any
point. Isolate problem and repair a
binding cable or door latch system
before continuing.
(2). With door open, make sure FILTER
BYPASS CONTROL handle is returned
full aft against cable housing and
spring resistance is immediately felt as
handle is started forward.
(3). Determine if there is excess slack in the
cable system as follows:
(a). Close air bypass door. Try door to
make sure latch-bolts are bottomed
in latch-clips.
Page 202
Revision 22
71-10-10
(5). Adjust door opening angle as follows:

(a). Thread cable-stop in or out of stop
sleeve until top of cable-stop is 1.65
inches (4.19 cm) below cable swaged
ball.
(b). Pull FILTER BYPASS CONTROL
handle forward until aft cable
swaged ball bottoms in cable stop.
Maintain cable tension to keep cable
ball against stop.
(c). Pull air bypass door outboard to
maintain cable tension.
Avoid an erroneous cable adjust
ment. Maintain a constant cable
ball contact with cable stop as stop is ad
justed.
CAUTION
(d). Adjust cable stop until air bypass

door opens to a minimum 45 angle
relative to fairing exterior surface.
Measure angle between door and
fairing exterior surface at Sta. 136.00
(Ref. Figure 201, details G and H).
MAINTENANCE MANUAL
(e). Release FILTER BYPASS CONTROL
handle. Inspect handle for freedom of
movement, full retraction and contact
with forward fitting.
(f). Close air bypass door.
(g). Check that aft cable is tight and
cable swaged ball rests against top of
cable-stop.
(h). Inspect pulley alignment. All pulleys
must line up within 0.13 inch (3.302
mm).
(i). Inspect cable for correct routing
around pulleys. Rotate each pulley
90 to distribute wear.
(j). Peel cable-stop support bracket
laminated shim as required to center
cable inside cable-stop to within
0.060 inch (1.524 mm).
(k). Torque cable-stop jam-nut to 10 - 30
(6). Check all components of FILTER
BYPASS CONTROL system for correct
operation. Inspect all fasteners for
security.
5. Air Bypass Door Rigging (500N)
(Ref. Figure 202)
CAUTION cover over the engine intake
(1). The bypass door cable length is deter
mined on the initial installation.
NOTE: The control cable assembly shall actu

ate with one pound pull.
CSP-HMI-2
(2). Cycle air bypass door control handle

and door mechanism several times to be
certain system does not bind at any
point. Isolate problem and repair a
binding cable or door latch system
before continuing.
(3). Minor repositioning of the cable
assembly can be performed by loosening
the installation hardware to reposition
the cable.
6. Particle Separator Cleaning
Item
CM226
Nomenclature
Cleaning compound, alkaline waterbase
(1). Submerge separator in a solution of

detergent soap (CM226) and water for
at least 15 minutes. Clean screens and
vortex tubes with a soft, long-bristle
brush.
(2). Flush with clean water. Drain and blow
out ejector nozzle with dry, low pressure
compressed air.
7. Mist Eliminator Maintenance
(1). Remove mist eliminator and clean with
solvent or steam.
NOTE: Mist eliminator is all stainless steel.

The assembly will not be harmed by conven
tional metal cleaning solutions.
(2). Examine plenum chamber. A dust
accumulation indicates leakage which
must be identified and eliminated.
(3). Spray 15 milliliters of engine oil on
each face of the mist eliminator prior to
installation.
71-10-10
Page 203
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
UPPER RIGHT PULLEY

DOOR OPERATING AFT
CABLE
ENGINE AIR INLET
AFT FAIRING
RETAINER (2)
CLIP
CABLE CONNECTOR
DOOR OPERATING
FORWARD CABLE
RETURN SPRING
GROMMET
CLAMP
GROMMET
FORWARD AND AFT CABLE - INSTALLATION
BYPASS AIR CONTROL

RELEASE HANDLE
PULLEY GUARD
PLATE
BUSHING
AFT
FAIRING
AFT FAIRING
UPPER PULLEY
BRACKET
PULLEY
(NOTE 1)
LOWER PULLEY
BRACKET
LOWER PULLEY - INSTALLATION

BUSHING
PULLEY
(NOTE 1)
UPPER PULLEY - INSTALLATION (TYPICAL)
G71-1003-1
Figure 201. Air Bypass Door System (369D/E/FF) (Sheet 1 of 3)

Page 204
Revision 22
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2
CABLE
CLIP
LINK
GASKET
CENTER
CRANK
LATCH ASSY
LAMINATED SHIM
(NOTE 3)
CLIP
FILTER BYPASS DOOR - INSTALLATION
WASHER
WASHER
BOLT
NUT
(NOTE 2)
AFT FAIRING
CABLE STOP
CABLE STOP
SLEEVE
TYPICAL LINKAGE - INSTALLATION

(4 PLCS)
NOTES:
1. PULLEYS TO BE IN ALIGNMENT WITHIN 0.13 IN. (3.302 MM).
2. TIGHTEN NUT TO GET 0.005-0.015 IN. (0.127-0.381 MM) GAP BETWEEN
BOLT HEAD AND WASHER; 4 PLACES.
3. ADJUST LAMINATED SHIM THICKNESS TO GET CORRECT DOOR
LATCHING AND ALIGNMENT.
4. SHIM TO ALIGN CABLE WITH CABLE STOP WITHIN 0.060 IN. (1.524 MM).
CABLE STOP
BRACKET
SHIM
(NOTE 4)
SLEEVE NUT
CABLE STOP JAMNUT
CABLE STOP - INSTALLATION
G71-1003-2B
71-10-10
Page 205
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
DOOR
LATCHED
SWAGED BALL
1.65 IN. (4.191 CM)

CABLE TRAVEL
CABLE STOP
DOOR
OPEN
CABLE STOP JAMNUT

QUICK-DISCONNECT
DOOR STOP - ADJUSTMENT
COTTER PIN
MINIMUM DOOR
OPENING
45
VIEW
369A8442-3 LATCH ASSEMBLY
G71-1003-3B

Page 206
Revision 22
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2
GROMMET
ENGINE INLET
BYPASS DOOR
LATCH ASSY
BYPASS DOOR
CLIP
BYPASS AIR CONTROL

RELEASE HANDLE
HINGE
LINK
CABLE ASSY
PIVOT
FITTING
BRACKET
G71-1024
Figure 202. Air Bypass Door System (500N)
71-10-10
Page 207
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 208
Revision 44
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2

1. PLM Particle Separator Replacement
A. PLM Particle Separator Removal
(1). Remove forward engine air inlet
fairings.
(2). Pull FILTER BYPASS CONTROL
handle to open filter bypass door.
CAUTION
(3). Remove engine air cooling inlet screen.

(4). In crew compartment; remove map case
trim panel from control channel (Ref.
Chap. 25).
(5). Disconnect forward cable from aft cable
at quick-disconnect fitting. Remove
spring retainers and spring.
(6). Remove handle plug button. Separate
retainers and remove handle.
(7). Remove attaching hardware and cable
retaining clamps. Remove cable forward
fitting nut and washers.
(8). Pull cable assembly forward into crew
compartment far enough to clear
particle separator.
(9). Disconnect and remove pressure switch
tubes, jam-nut, washers and union.
(10). Remove particle separator fairing
retaining screws and washers.
NOTE: Left fairing installations without re

movable lower cover require the tail rotor
control rod be disconnected at Sta. 95.00
bellcrank to remove fairing from helicopter.
(11). Remove tail rotor control rod boot
forward clamp.
(12). Slide boot and left fairing forward and
clear of particle separator.
(13). Unfasten and remove ejector duct
assembly.
(14). Disconnect and remove ejector scavenge

air line between particle separator and
bracket mounted elbow.
(15). If installed, remove mist eliminator.
(16). Unbolt, then tilt top of particle separa
tor forward and remove from fairing.
B. PLM Particle Separator Installation
Install particle separator in reverse order of
removal and per the following procedures:
Item
CM112
Nomenclature
(1). Center and clamp tail rotor control

pedals in neutral position. Install
forward boot on tail rotor pitch control
rod. Adjust boot free length between
7.13 and 7.22 inches (18.1102 and
18.3388 cm). Install ty-rap.
(2). Use the same number of washers under
forward cable fitting as were removed.
Washer stack height variances will
affect door rigging.
Use anti-seize compound on all
male threaded fittings prior to
installation.
CAUTION
(3). Apply anti-seize compound (CM112) to

fitting threads and particle separator
attaching hardware.
(4). Check air bypass door rig (Ref. Air
Bypass Door Rigging).
(5). Perform an operational check of air
bypass door and scavenge air systems
(Ref. Scavenge Air Operational Check).
2. PLM Scavenge Ejector Replacement
A. PLM Scavenge Ejector Removal
(1). Remove lockwire and unbolt ejector
assembly support bracket.
(2). Remove lockwire and bolts attaching
ejector assembly hold down plates to
particle separator ejector box.
71-10-10
Page 401
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
(3). Remove ejector assembly.

B. PLM Scavenge Ejector Installation
(1). Install ejector in reverse order of
removal.
3. PLM Ejector Nozzle and Manifold
Replacement
(1). Remove ejector assembly (Ref. PLM
Scavenge Ejector - Removal).
(2). Remove lockwire and two nuts securing
nozzle and manifold assembly to
particle separator ejector box.
(3). Remove nozzle and manifold assembly.
(4). Clean mating surfaces between ejector
box and nozzle and manifold assembly.
(5). Install nozzle and manifold assembly in
reverse order of removal.
(6). Install ejector assembly.
4. Mist Eliminator Replacement
A. Helicopters With Mist Eliminator Access
Panel
CAUTION
D Prevent engine FOD. Secure a cover over
the engine intake prior to working inside
plenum chamber. Remove cover after
completing work.
D If mist eliminator is NOT to be rein
stalled, remove 4504 tape from particle
separator. If not removed, tape may come
loose and be ingested by the engine.
NOTE: Mist eliminator access panel installa

tion replaces nine mist eliminator mount
bolts with a system of permanently installed
clips to secure mist eliminator.
(1). On top of aft inlet fairing; unfasten two
1/4-turn panel fasteners. Lift panel
trailing edge, then entire panel clear of
access opening.
(2). Lift mist eliminator out of access panel
opening.
Page 402
Revision 37
71-10-10
B. Helicopters Without Mist Eliminator

Access Panel
CAUTION

handle to open air bypass door.
(2). On 500N installation, remove the fan
inlet screen and engine plenum access
fairing attachment hardware. Proceed
with step (5).
(3). Remove four screws securing door hinge
upper halves to inlet fairing (Ref.
Figure 201, detail D).
NOTE: Do not disturb established cable length.

from cable end-fitting. Remove cable
from door. Remove door.
Nine mount bolts are retained
in mist eliminator frame. Do not
attempt to remove bolts from frame.
CAUTION
(5). Unbolt mist eliminator from particle

separator.
(6). Pull mist eliminator aft to clear particle
separator frame. Tilt mist eliminator
lower edge up and remove unit through
bypass door opening.
C. Mist Eliminator Installation
(1). Install mist eliminator in reverse order
of removal.
5. Donaldson Particle Separator
Replacement
A. Donaldson Particle Separator Removal
fairings.
handle to open the air bypass door (Ref.
Figure 201, detail A).
CAUTION
MAINTENANCE MANUAL
(4). In crew compartment; remove map case
trim panel from control channel (Ref.
Chap. 25).
(5). Disconnect forward cable from aft cable
at quick-disconnect fitting. Remove
handle plug button. Separate retainers
and remove handle.
(15). Remove exit port screen attaching

hardware and duct.
B. Donaldson Particle Separator Installation
Install particle separator assembly in reverse
order of removal and as follows:
(6). Remove spring retainers and spring.

(7). Remove attaching hardware and cable
retaining clamps. Remove cable forward
fitting nut and washers. Pull cable
assembly into crew compartment.
(8). Remove pressure switch tubes and
union.
NOTE: It is not necessary to disconnect tail ro

tor control rod to remove left fairing if fair
ing is equipped with a removable cover.
(9). Disconnect forward end of tail rotor
control rod at Sta. 95.00 bellcrank.
(10). Remove fairing retaining screws and
washers. Remove tail rotor control rod
boot forward.
clamp. Slide left fairing forward on tail rotor
control rod to clear particle separator.
NOTE: Paint an alignment mark across ejector

and nozzle manifold flanges prior to disas
sembly as a reference for later assembly.
(11). Remove bolts and washers securing
nozzle manifold to particle separator.
(12). Unbolt particle separator. Tilt top of
particle separator forward and remove
from fairing.
(13). Disconnect upper air tube assembly
from nozzle manifold. Move forward
O-ring from ejector to rubber sleeve.
Remove nozzle manifold and ejector
from aft fairing.
(14). Remove sleeve and O-rings from duct.
CSP-HMI-2
Item
CM112
Nomenclature
NOTE: Apply antiseize compound (CM112) to

male threads of fittings, nozzle manifold
bolts and particle separator attaching hard
ware before installation.
(1). Bench assemble rubber sleeve and
O-ring on grooved end of ejector.
(2). Align nozzle manifold and ejector inside
aft fairing.
(3). Position ejector so that top flapper
valve vertical hinge line angle is 10 to
20 degrees counterclockwise from
ejector vertical centerline.
(4). Torque ejector and nozzle manifold
(5). Install tail rotor control rod forward
boot with a free length of 7.13 to 7.22
inches (18.1102 and 18.3388 cm) with
tail rotor pedals centered.
(6). Use the same number of washers under
forward cable fitting as were removed.
Hardware position changes or washer
stack height variances will affect door
rigging.
(7). Rig air bypass door (Ref. Air Bypass
Door Rigging).
(8). Perform air bypass door and scavenge
air system operational checks (Ref.
Scavenge Air Operational Check).
71-10-10
Page 403
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 404
Revision 44
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2

INSPECTION/CHECK
1. Engine Air Inlet Bypass Door 300Hour
Inspection
(Ref. Figure 201)
Item
Nomenclature
CM425
Sealing compound

Use extreme care when working around en
gine inlet to prevent any foreign object from
entering engine. Remove cover after com
pleting work.
CAUTION
NOTE: Inspect Engine Air Inlet Bypass Door

per FAA publication, EA-AC43.13-1B.
(1). Remove engine inlet bypass door and
inspect air bypass door gasket seal for
condition and secure attachment. No
gasket seal deterioration or debonding
allowed. Replace door gasket as
required.
(2). Inspect door surfaces for cracking,
chaffing or damage. Repair door per
Structural Repair Manual (CSPSRM-6).
(3). Remove and replace the latch retention
cotter pin (located inside the attach
cable `Ù'' clamp). Seal cotter pin with
sealant (CM425).
(4). Replace latch assembly if:
(a). The cotter pin hole in the latch stem
is elongated more than 0.080 inch
(2.032 mm).
(b). The cotter pin has worn into the
surface of the cable attach `Ù'' clip,
more than 1/2 the thickness of the
clip, 0.025 inch (0.635 mm) deep.
(c). The latch engagement faying surface,

where it contacts the plenum, is worn
more than 0.050 inch (1.270 mm)
below the original surface.
(5). Inspect door hinges for wear and hinge
fastening hardware for security. Repair
or replace hinges as required.
(6). Inspect door for worn or damaged
latching and attachment hardware.
(7). Check insert assembly and latch
linkages for wear and lost motion.
Repair or replace latch hardware as
required.
(8). Inspect door system cable and cable
ends for corrosion, fraying, chaffing and
freedom of movement.
(9). Inspect door system cable pulleys,
pulley bushings and brackets for wear,
damage, freedom of movement and
security.
(10). Reinstall engine inlet bypass door. Seal
all cotter pins with sealant (CM425).
(11). Inspect door for proper alignment when
closed. Door must fit snug against seal
with obvious seal compression.
(12). Inspect latches for positive latching.
handle. Action to be a smooth, positive
door opening with no binding. Release
handle. Handle should snap back to
stowed position.
2. PLM Particle Separator Inspection
(1). Inspect vortex generator tubes for
broken, loose or missing vanes and
center pins.
(2). Inspect outlet tube for security and
damage.
(3). Inspect inlet plate for dents punctures
and cracks.
(4). Inspect vortex tube particle discharge
openings for clogging.
(5). Inspect separator and mist eliminator
mounting seals for secure attachment
and damage. Replace damaged seals.
71-10-10
Page 601
Revision 39
MAINTENANCE MANUAL
CSP-HMI-2
Left fairing inspection and re

work or replacement is manda
tory for particle separator installations, part
numbers 369H90148-507, and -509. Early
installations were fitted with left forward
fairings, PN 369D290128-11 equipped with
a single screw and nutplate securing a re
movable
fairing
section,
PN
369D290128-31 over the tail rotor control
rod.
CAUTION
(6). Inspect tail rotor control rod for

abrasion or gouging caused by contact
with particle separator fairing or
fairing hardware. Modify, repair or
replace fairing (Ref Fairing Modifica
tion (369D Only)). Inspect, repair or
replace control rod if damaged beyond
limits (Ref. Sec. 67-20-10).
(7). Inspect ejector flapper valve and hinge
for wear and corrosion. Repair or
replace valve parts as required.
(8). Inspect ejector tubes for cuts, breaks
and distortion. Inspect flange condition.
(9). Inspect tube nuts and fittings for
crossed or stripped threads.
(10). Inspect scavenge air discharge duct for
damage.
(11). Inspect entire assembly for cracks,
holes and distortion. Cracks may
indicate that assembly is subject to
distortion loads when installed.
(4). Inspect gasket tapes for deterioration

and security. Replace damaged gasket
tapes.
(5). Inspect entire particle separator
assembly for cracks, holes and distor
tion. Cracks may indicate filter preload,
misalignment or distortion when
installed. Align filter (Ref. Particle
Separator Alignment and Joint Surface
Repair).
(6). Inspect rubber sleeves for cuts, holes or
deterioration.
(7). Inspect O-rings for nicks, cuts, wear or
deterioration.
(8). Inspect ejector tube for cuts, breaks or
distortion.
(9). Inspect flapper valve for condition and
free movement.
NOTE: Ejectors with a missing flapper valve

may be continued in operation until a re
placement is installed.
(10). Inspect nozzle manifold for cracks and
distortion.
(11). Inspect fitting for crossed or stripped
threads. See that the seven nozzle air
passages are open, clean and undam
aged.
(12). Inspect ejector exhaust duct screen for
damage or clogging.
4. Scavenge Air Operational Check
Engine operation or helicop
3. Donaldson Particle Separator Inspection

(1). Inspect filter inlet screens for damage
and secure attachment. Remove
damaged inlet screens.
NOTE: Particle separator may be operated

without inlet screens.
(2). Inspect vortex tubes for for security and
broken or missing vanes.
NOTE: Up to five damaged vortex tubes may be

blocked off with patches.
(3). Inspect vortex tube particle separator
openings for clogging.
Page 602
Revision 22
71-10-10
WARNING ter flight must be accom
plished in accordance with require

ments and limitations specified in the
Pilot's Flight Manual and applicable
supplements.
(1). Ensure air bypass door is closed.
(2). Ground run engine per Pilot's Flight
Manual.
(3). Switch SCAV AIR circuit breaker ON.
NOTE: A slight increase in turbine outlet tem

perature (TOT) is normal when SCAV AIR
circuit breaker is switched ON.
(4). Have an assistant check for scavenge
air exhaust from outlet duct. Airflow
MAINTENANCE MANUAL
from duct indicates that solenoid air
valve has opened.
(5). Switch SCAV AIR circuit breaker OFF.
(6). Check that no scavenge air flows from
outlet duct.
(7). Shut down engine per Pilot's Flight
Manual.
5. Air Pressure Sensing Switch Calibration
Check
(1). Assemble test equipment (Ref.
Figure 601).
(2). Attach pressure switch to test equip
ment. Connect a suitable vacuum
source to pressure switch nipple and
u-tube.
(3). Connect an ohmmeter or continuity
tester to pressure switch electrical
leads.
(4). Cycle switch from open to close several
times with vacuum. Watch meter for
indication of switch closure. Release
vacuum.
(5). Slowly apply vacuum. Note u-tube
water height differential in both legs of
CSP-HMI-2
the tube relative to the switch closing

point. The total of the differential
heights of both legs of the u-tube is
equal to switch actuation pressure.
(6). Switch closing pressures shall be per
the applicable particle separator
installation dash number shown (Ref.
Figure 601).
6. Mist Eliminator Inspection
(1). Check mist eliminator serial number
for APM serial numbers 005 thru 069.
Remove the wire staples from a mist
eliminator so identified.
(2). Inspect frame and screens for security
and condition. Replace mist eliminator
if screens are partially detached, or
assembly distortion prevents joint seal
contact with the particle separator.
(3). Inspect all nine bolts, where installed,
for security in mist eliminator frame.
Repair or replace bolts as required (Ref.
Page 803).
(4). Examine outlet side of mist eliminator.
Surface should be slightly oily but
clean. Dirt on the outlet side signals the
need to clean the assembly.
71-10-10
Page 603
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
TO L.H. FAIRING
ATTACHING UNION
SUCTION SOURCE
HOSE TEE
POWER LEAD
RETURN LEAD
24 IN (61 CM)
SCALE
OHMMETER OR
CONTINUITY
TESTER
24 IN (61 CM)
STRAIGHT
SECTION
12 IN (30.5 CM)
H2O STATIC
HEIGHT
369A8402
OPEN
CLOSE
-15
2.0
12.500.25
-13
2.0
18.500.25
-7
2.0
10.500.25
-3
2.0
4.80.4
TYGON TUBING (OR EQUIVALENT)

BENT AND FILLED WITH H2O TO
STATIC HEIGHT AS SHOWN
G71-1004E
Figure 601. Air Pressure Sensing Switch Calibration Check

Page 604
Revision 38
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2

REPAIRS
1. PLM Particle Separator Repairs
Item
Nomenclature
CM234
CM728
NOTE:
D The following particle separator repair/
replacement items and, or kits are avail
able from Pall Land Marine (PLM) or
through your local distributor (Ref. Sec.
01-00-00).
D AA-A224-1D1KF1 Repair kit, Centrisep
scavenge ejector Assy. (Ejector, two plate
halves, four bolts).
D AA-224A-1D1KF2 Repair kit, Centrisep
nozzle and manifold Assy.
Permanent repairs or particle

separator replacement should
be accomplished as soon as possible. Do not
use repair kit if mounting plate holes are en
larged or distorted so as to prevent the re
pair plug snap-lock lip from fully engaging
plate hole edge.
CAUTION
(a). Repair plugs, AA-9500-D929 are

used to seal pushed-in but otherwise
undamaged vortex generator tubes.
(b). Stems, AA-9500-D930 are used with
repair plugs to seal the vortex
generator tube hole when the the
tube is missing or removed.
(c). Stems, AA-9500-D931 are used with
repair plugs when both the vortex
generator tube and outlet tube are
missing or removed.
No more than 30 of the 292
WARNING vortex generator tubes may

be plugged. Plugged tubes shall be
widely distributed over particle sepa
rator. Not more than 15 plugged tubes
may be concentrated in any one area.
B. Displaced Vortex Generator Tube
The following procedures are for

CAUTION Pall Land Marine (PLM) par
ticle separators only.
A. Vortex Tube Plug Installation
NOTE: Procedures are per Pall Land Marine

Corporation publication, PLM-TM-80-1.
Contact PLM direct for additional informa
tion. A vortex generator tube replacement
kit may be available that will supersede use
of Tube Repair Kit AA-8101-1KF1 required
to accomplish the following temporary re
pairs.
(1). The AA-8101-1KF1 repair kit contain
parts required to plug holes created by
displacement of, or damage to, the
vortex generator and outlet tubes.
(Ref. Figure 801)

(1). Inspect displaced vortex generator tube
for missing center pin and extensive
rim damage. Should either condition
exist, refer to Damaged Or Missing
Vortex Generator Tube.
(2). Position particle separator on a table
with front surface of vortex tube plate
up.
(3). Press damaged tube assembly all the
way in. Ensure that vortex tube
bottoms on outlet tube per illustration
(4). Insert repair plug AA-9500-D929 in
the hole. Align plug with vortex
generator center pin.
(5). Press plug into inlet tube plate until
plug snaps in place.
71-10-10
Page 801
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
INLET TUBE
PLATE
REPAIR PLUG
AA-9500-D929
INLET TUBE
PLATE
VORTEX GENERATOR
TUBE
OUTLET TUBE
OUTLET TUBE
PLATE
OUTLET TUBE
A.
OUTLET TUBE
PLATE
SERVICEABLE INSTALLATION
INLET TUBE
PLATE
B.
REPAIR PLUG
AA-9500-D929
DISPLACE VORTEX GENERATOR

TUBE REPAIR
REPAIR PLUG
AA-9500-D929
INLET TUBE
PLATE
STEM
AA-9500-D930
OUTLET TUBE
PLATE
OUTLET TUBE
C. MISSING VOTEX GENERATOR

TUBE REPAIR
OUTLET TUBE
PLATE
STEM
AA-9500-D931
D. MISSING VORTEX GENERATOR

AND OUTLET TUBE REPAIR
G71-1005
Figure 801. Vortex Generator Repairs

Page 802
Revision 22
71-10-10
MAINTENANCE MANUAL
C. Damaged Or Missing Vortex Generator
Tube
(1). Remove remaining vortex generator
tube material without damaging plate
hole.
(2). Insert center pin of stem
AA-9500-D930 into plug
AA-9500-D929 and install in hole per
illustration (Ref. Figure 801, view C).
Ensure stem free end is inside outlet
tube.
(3). Press plug into hole until it snaps in
place.
D. Damaged Or Missing Vortex Generator
and Outlet Tubes
(1). Remove remaining vortex generator
and outlet tube material. Do not
damage either plate hole.
(2). Insert center pin of stem
AA-9500-D931 into plug
AA-9500-D929 and install in hole per
illustration (Ref. Figure 801, view D).
Ensure stem free end protrudes from
outlet tube plate.
(3). Press plug into hole until it snaps in
place.
E. PLM Particle Separator Gasket
Replacement
(1). Remove old gasket and clean joint
surfaces with P-D-680 dry cleaning
solvent (CM234) on a clean cloth.
(2). Cut 1/8 inch (3.175 mm) thick pressure
sensitive tape (CM728) to 3/8 inch
(9.525 mm) width.
NOTE:
D Note that the particle separator/aft inlet
fairing seal tape is not installed on the
bottom.
D The inner seal tape is the mist eliminator
joint seal.
CSP-HMI-2
F. Fairing Modifications (369D Only)
Item
Nomenclature
CM501
CM505
Fiberglass cloth
NOTE: Modification procedures apply to 500D

series helicopters
equipped with
369H90148-507 or -509 particle separator
installations and APM (now PLM) particle
separators. Early installations were fitted
with
left
forward
fairings,
PN
369D290128-11 equipped with a single
screw and nutplate securing a removable
fairing section, PN 369D290128-31 over the
tail rotor control rod. Modify the -11 and
-31 fairing components as follows.
(1). Remove fairings (Ref. PLM Particle
Separator Removal).
(2). Drill out rivets and remove nutplate
from 369D290128-11 left fairing
assembly (Ref. Figure 802, detail A).
(3). Patch nutplate rivet and screw holes
with fiberglass cloth (CM501) and resin
(CM505) per structural repair manual
(SRM).
NOTE: A
replacement
cover,
PN
369D290128-51 may be installed in lieu of
reworking 369D290128-31 cover assembly.
(4). Rework cover, PN 369D290128-31 per

illustration using fiberglass cloth and
resin. Laminate one layer of fiberglass
cloth on top of cover and two layers on
bottom surface (Ref. Figure 802, detail
B).
(5). Drill two 0.250 inch (6.35 mm) diameter
screw holes through cover to match
holes in PN 369D290128-11 fairing
assembly.
(3). Cut tape to length, peel off backing and

apply to surface.
(6). Install 369D290128-55 and -57 seals

on cover.
(4). Ensure gasket tape is firmly attached

to surface.
(7). Install reworked fairings (Ref. PLM

Particle Separator Installation).
71-10-10
Page 803
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
SCREW, WASHER
(REMOVED)
NUTPLATE
(REMOVED)
NOTE 1
1.40 IN.
(35.56 MM)
0.60 IN.
(1.524 MM)
RIVETS
(REMOVED)
FAIRING
MODIFICATIONS
-31 COVER
(BEFORE REWORK)
0.80 IN.
(20.32 MM)
-57 SEAL
EXISTING -39 SEAL

(REMOVED)
-55 SEAL
BUILDUP
(NOTE 2)
NOTE 1
2.40 IN.
(60.96 MM)
0.61 IN.
(15.494 MM)
-55 SEAL
ONE LAYER
181 FIBERGLASS
(TOP) (TYP)
-31 COVER
COVER MODIFICATION
-55 SEAL
NOTES:
1. DRILL 0.250 IN (6.35 MM) DIAMETER HOLES IN
COVER TO MATCH -11 FAIRING.
2. SHADED AREA DENOTES FIBERGLASS BUILDUP.
TWO LAYERS
181 FIBERGLASS
(BOTTOM) (TYP)
-41 SEAL
-57 SEAL
VIEW A-A
G71-1019A
Figure 802. Fairing Modifications

Page 804
Revision 22
71-10-10
MAINTENANCE MANUAL
2. Mist Eliminator Repair
(1). The mist eliminator is a non-repairable
all welded assembly except for the
mounting bolts required for some
installations. Repairs are limited to bolt
repair or replacement.
NOTE:
D The following mist eliminator repair/re
placement items and, or kits are available
from Pall Land Marine (PLM) or through
your local distributor.
D AE-A224-1D2 Mist eliminator Assy.,
complete.
D AA-A224-1D2KF1 Repair kit, mist elimi
nator (nine mounting bolts).
(2). Remove mist eliminator assembly per
`Mist Eliminator Replacement'.
(3). Chase mounting bolt threads with a
10-32 die, as required.
(4). Remove mounting bolts from mist
eliminator frame by pulling bolt aft
while unscrewing.
(5). Replace mounting bolts.
(6). Flatten an area 0.160-0.170 inch
(4.064-4.318 mm) wide by 0.125 inch
(3.175 mm) long, maximum, across the
first three to four threads adjacent to
the bolt shank to inhibit removal.
3. Particle Separator Alignment and Joint
Surface Repair (369D/E/FF)
Item
Nomenclature
CM504
Epoxy resin with catalyst
(1). Draw an outline of the particle separa

tor on smooth, parallel surfaced, 1/2
inch (12.7 mm) thick phenolic or close
grained plywood. Cut template from
material. Drill mounting bolt holes.
(2). Position template against engine air
inlet fairing-to-filter mounting surface
and install three bolts and nuts finger
tight. Ensure template is secure and
undistorted.
CSP-HMI-2
(3). Using a 0.030 inch (0.762 mm) feeler

gage, check for gaps at the three
mounting bolt attach points. Install
shims in areas where gaps exceed 0.030
inch (0.762 mm) width per the next
step.
(4). Bond an aluminum or fiberglass shim
thickness to the fairing that is equiva
lent to the gap.
(a). Bond aluminum shims to the fairing
with epoxy resin (CM504).
(b). Laminate and bond fiberglass cloth
per Structural Repair Manual
procedures (CSP-DEF-6).
4. Donaldson Particle Separator Repair
(369D Only)
Item
CM234
CM503
CM728
Nomenclature
Fiberglass repair kit
NOTE: Particle separator repairs are accom

plished per standard fiberglass repair meth
ods using fiberglass repair kit (CM503). En
sure that no potential for engine foreign
object damage occurs as a result of filter re
pair.
(1). Rebond loose or missing fiberglass
attachment spacers.
(2). Rebond front and back wall to center
section seams as required.
(3). Rebond manifold nozzle attachment
tube.
(4). Patch repair or fill any other damaged
or cracked areas.
(5). Replace damaged vortex tubes.
NOTE: Up to five damaged vortex tubes may be

temporarily blocked.
(6). Install not more than five aluminum
patches over vortex tube outlet holes.
Install patches with at least three
mechanically expanded rivets.
(7). Replace worn or loose gasket tapes as
follows:
71-10-10
Page 805
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
MOUNTING
STRUCTURE
AFT AIR INLET

FAIRING
SCREEN
(TYPICAL)
PARTICLE
SEPARATOR
GASKET
(NOTE)
PARTICLE SEPARATOR
NOTE:
INSTALL GASKET AS SHOWN ON AFT FACE
OF PARTICLE SEPARATOR
Figure 803. Donaldson Particle Separator Gasket Replacement

Page 806
Revision 22
71-10-10
G71-1017
MAINTENANCE MANUAL
CSP-HMI-2
MIST ELIMINATOR
ROTATED 180
SECTIONAL VIEW
FLATTENED THREADS
(NOTE)
0.160-0.170 IN.
(4.064-4.318 MM)
NOTE:
FLATTEN THREADS TO DIMENSION SHOWN.
DO NOT EXCEED MAXIMUM DIMENSION.
DETAIL
0.125 IN. MAX.

(3.175 MM)
G71-1018A
Figure 804. Mist Eliminator Bolt Repair
71-10-10
Page 807
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
(a). Remove tape debris. Wipe tape

contact surfaces with a clean cloth
and P-D-680 dry-cleaning solvent
(CM234).
(b). Cut tape 0.380 inch (9.652 mm) wide
from 0.125 inch (3.175 mm) thick
Y-3192-B material (CM728).
(c). Install tape across the top and down
right and left sides of the fairing
contact area. Do not apply seal tape
across the bottom (Ref. Figure 803).
Install particle separator.
(8). Perform particle separator alignment
procedures and the following steps.
(a). Remove ejector-to-outlet duct rubber
sleeve. Use a straight edge to check
for misalignment between the ejector
and outlet duct. Maximum allowed
misalignment is 1/4 inch (6.35 mm).
(b). Install tapered shims between duct
and screen rubber rim to repair
ejector-to-outlet duct misalignment.
Use at least two attachment screws
to retain shim.
NOTE: Existing screen and duct attachment

screws are long enough to allow addition of
1/4 inch (6.35 mm) thick shim.
(9). Install particle separator.
NOTE:
D Installation of sealed fairings around the
particle separator to protect the engine
from FOD is required for early Donaldson
particle
separator
installations
369H90148-503 and -505 used on some
369D series helicopters.
D Donaldson particle separator installa
tions are identified by the scavenge air ex
haust port on the left side of the aft inlet
fairing.
D Procedures
cover
fairing
kit,
PN369D290140 and pressure switch,
PN369A8402-7 installation.
D PN369A8402-3 pressure switch modifi
cations to -7 specifications using a Jensen
#800-174 kit are provided. Modification
of a -3 switch to a -7, or procurement and
installation of a -7 switch is mandatory
when auxiliary fairings are installed.
(1). Remove air inlet forward fairings.
(2). Remove particle separator (Ref.
Donaldson Particle Separator Remov
al).
(3). Clean particle separator (Ref. Particle
Separator Cleaning).
(4). Inspect particle separator (Ref. Donald
son Particle Separator Inspection).
(5). Repair unit (Ref. Donaldson Particle
Separator Repair).
NOTE: 369D290140-5 and -7 supports and

369D290140-11 and -12 fairing assemblies
may be manufactured using drawings pro
vided (Ref. Figure 806). Apply a coat of
primer (CM318) after making the parts.
(6). Install LH fairings and seals as follows:
5. Donaldson Particle Separator Auxiliary

Fairings and Seals Installation
(a). Locate 369D290140-5 seal support

forward of aft fairing filter mounting
frame as indicated (Ref. Figure 805,
detail A and section B-B).
Item
Nomenclature
(b). Use -5 support as a guide and drill

two rivet holes through fairing.
CM234
(c). Install support with two

NAS1738B4-2 rivets.
CM318
Primer
CM430
Page 808
Revision 22
71-10-10
(d). Install 369D290140-13 and -25 seals

on support (Ref. Figure 805, view
A-A and section B-B).
MAINTENANCE MANUAL
(e). Position and mark 369D290140-11
fairing (Ref. Figure 805, view E-E).
Drill 0.250 inch (6.35 mm) diameter
hole through -11 to match inlet
fairing existing nutplate.
(f). Split grommet and install on wire
and controls bundle (Ref. Figure 805,
view E-E). Slip -11 fairing into
grommet groove.
(g). Trial fit 369D290140-11 fairing on
aft inlet fairing with washer and
screw. Remove fairing assembly.
(h). Install 369D290140-17, -19 and -23
seals on underside of 369H90151-31
fairing. Trim -19 and -23 seals to
match fairing contour (Ref.
Figure 805, view A-A).
(7). Install RH fairings and seals as follows:
(a). Locate 369D290140-7 seal support
forward of aft fairing filter mounting
frame as indicated (Ref. Figure 805,
view A-A and section C-C).
(b). Use -5 support as a guide and drill
three rivet holes through fairing.
(c). Install support with three
NAS1738B4-2 rivets.
(d). Install 369D290140-15 seal on
support (Ref. Figure 805, view A-A
and section C-C).
(e). Position and mark 369D290140-12
fairing (Ref. Figure 805, view E-E).
Drill 0.250 inch (6.35 mm) diameter
hole through -11 to match inlet
fairing existing nutplate.
(f). Split grommet and install on wire
and controls bundle (Ref. Figure 805,
view E-E). Slip -12 fairing into
grommet groove.
(g). Trial fit 369D290140-12 fairing on
aft inlet fairing with washer and
screw. Remove fairing assembly.
CSP-HMI-2
(h). Install 369D290140-17 and -23 seals

on underside of 369H90151-41
fairing. Trim -23 seal to match
fairing contour (Ref. Figure 805, view
A-A).
(8). Disconnect and remove 369A8402-3
pressure switch.
(a). Remove screws and separate switch
halves. Remove diaphragm-magnet
and return spring (Ref. Figure 807).
(b). Clean parts with P-D-680 dry
cleaning solvent (CM234).
(c). Reassemble switch with new diaph
ragm-magnet and return spring per
illustration.
(d). Align screw holes, magnet-diaph
ragm, spring and switch halves and
assemble unit with screws. Lockwire
screws.
(e). Install new name plate over existing
name plate.
(9). Check pressure switch operation (Ref.
Air Pressure Sensing Switch Calibra
tion Check). Switch closing should occur
between 10.25-10.75 inches
(26.035-27.305 cm) of water.
(10). Install pressure switch.
(11). Install particle separator (Ref. Donald
son Particle Separator Installation).
(a). Install 369H90151-31 and -41
fairing halves with washers and
screws (Ref. Figure 805, view A-A).
(b). Install 369D290140-11 and -12
fairings with washers and screws
(Ref. Figure 805, view E-E).
(c). Apply sealing compound, RTV732
(CM430) around all gaps between -11
and -12 fairings, grommets, wire
bundles, aft fairing and mast fitting
(Ref. Figure 805, detail A).
71-10-10
Page 809
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
-12 FAIRING ASSY

TRIM -12 FAIRING AS REQUIRED TO CLEAR
EXISTING STRUCTURE IN 369A3053
TYP. FOR INSTL. OF -11 FAIRING
-17 SEAL
-23 SEAL
369H90151-41
MOUNTING FRAME FOR

369H90152 FILTER AT
STA. 124.00
TRIM -19 AND -23 SEALS

TO MATCH CONTOURS
OF 369H90151 FAIRINGS
W.L. 67.00
B.L. 865 RN
3.31 IN.
(8.4074 CM)
369H90151-31
FAIRING
SEE DETAIL A
STA.
124.00
369A3053
FAIRING
-11 FAIRING ASSY

-17 SEAL
NAS173884-2 RIVET
-15 SEAL
(3 REQD)
DRILL 369A3053 TO
-7 SUPPORT
MATCH HOLES IN
SUPPORT SECTION C - C
ROTATED 90 CCW
SEAL ALL OPENINGS OR

GAPS USING SILASTIC
NO. 732 OR EQUIV.
VIEW A
-A
-11 FAIRING ASSY

MOUNTING FRAME FOR
369H90152 FILTER AT
STA. 124.00
W.L. 68.36
B.L. 8.70 LH
-13 SEAL
-25 SEAL
-5 SUPPORT
1.25 IN.
(3.175 CM)
APPLY SILASTIC NO. 732 OR

EQUIV. BETWEEN FLANGE
OF FAIRING AND 369H3003
NAS173884-2 RIVET
(3 REQD)
DRILL 369A3053 TO MATCH
HOLES IN SUPPORT
SECTION B
-B
ROTATED 90 CCW
0.19 IN.
(4.826 MM)
E
SEAL ALL OPENINGS OR
GAPS USING SILASTIC
NO. 732 OR EQUIV.
STA.
124.00
DETAIL A
TYP. FOR INSTAL. OF -12 FAIRING
G71-1014-1A
Figure 805. Auxiliary Fairings and Seals Installation (Sheet 1 of 2)

Page 810
Revision 22
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2
-4 FAIRING FOR -12 ASSY (NOTE)

-3 FAIRING FOR -11 ASSY (NOTE)
MS20470AD2 RIVET (2)
-9 PLATE
-7 SUPPORT
0.19 IN.
(4.826 MM)
-15 SEAL
0.44 IN.
(11.176 MM)
0.19 IN.
(4.826 MM)
2.03 IN.
(5.1562 CM)
SECTION D ROTATED 180
369H90151-41 FAIRING
MS35489-19 GROMMET
SPLIT GROMMET APPROX.
AS SHOWN PRIOR TO INSTL.
369D23011
369H3003 FAIRING
0.250 IN. (6.35 MM) DIA.

THRU -11 FAIRING ASSY
TO MATCH EXISTING
NUTPLATE LOCATIONS
-11 FAIRING ASSY
VIEW E - E
ROTATED 90 CCW TYP. FOR
INSTL. OF -12 FAIRING ASSY
NOTE:
DRILL 0.063 IN. (1.6002 MM) DIA. HOLES IN
-3 AND -4 FAIRINGS TO MATCH HOLES IN
-9 PLATE (2 PLCS)
G71-1014-2A
Figure 805. Auxiliary Fairings and Seals Installation (Sheet 2 of 2)
71-10-10
Page 811
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
3.51 IN.
(8.9154 CM)
0.098 IN. (2.4892 MM) DIA.
(3 PILOT HOLES)
3.20 IN.
(8.128 CM)
1.70 IN. (4.318 CM)
0.12 IN. (3.048 MM)
0.40 IN. (10.16 MM)
0.80 IN. (20.32 MM)
0.31 IN.
(7.874 MM)
0.43 IN. (10.922 MM)
0.68 IN. (17.272 MM)

0.37 IN.
(9.398 MM)
5
(4 PLCS)
BEND UP X 0.09 IN. (2.286 MM) R
(2 PLCS)
-7 SUPPORT (FLAT PATTERN)
BEND UP X 0.09 IN. (2.286 MM) R

2.02 IN.
(5.1308 CM)
1.70 IN. (4.318 CM)
0.098 IN. (2.4892 MM) DIA.
(2 PILOT HOLES)
0.31 IN.
(7.874 MM)
6 30' (4 PLCS)
0.12 IN. (3.048 MM)

0.35 IN. (8.89 MM)
0.77 IN. (19.558 MM)
0.23 IN. (5.842 MM)
0.80 IN. (20.32 MM)
0.40 IN. (10.16 MM)
0.37 IN. (9.398 MM)
0.31 IN. (7.874 MM)
3.50 IN.
(8.89 CM)
0.18 IN. (4.572 MM)
BEND DN X 0.09 IN. (2.286 MM) R
BEND UP X 0.09 IN. (2.286 MM) R
-5 SUPPORT (FLAT PATTERN)
2.03 IN.
(5.1562 CM)
0.19 IN.
(4.826 MM)
0.75 IN. (19.05 MM)
0.31 IN.
(7.874 MM)
0.44 IN.
(11.176 MM)
0.0635 IN (0.16129 MM)
(#52 DRILL)
-9 PLATE
G71-1015-1A
Figure 806. Auxiliary Fairings and Supports Fabrication (Sheet 1 of 2)

Page 812
Revision 22
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2
30
0.95 IN.
(24.13 MM)
0.17 IN.
(4.318 MM)
1.70 IN.
(4.318 CM)
1.56 IN.
(3.9624 CM)
0.93 IN.
(23.622 MM)
0.81 IN.
(20.574 MM)
2.00 IN.
(5.08 CM)
0.12 IN. (3.048 MM) R

(2 PLCS)
0.06 IN. (1.524 MM) R
(2 PLCS)
5.63 IN.
(14.3002 CM)
0.18 IN.
(4.572 MM)
1.44 IN.
0.40 IN. (3.6576 CM)
(10.16 MM)
1.06 IN. (2.6924 CM)
1.50 IN.
(3.81 CM)
2.13 IN.
(5.4102 CM)
0.31 IN.
(7.781 MM)
BEND DN 30 OPEN X
0.12 IN. (3.048 MM) R
0.92 IN. (23.368 MM)

(2 PLCS)
0.12 IN. (3.048 MM) R
(2 PLCS)
30
BEND DN X
0.12 IN. (3.048 MM) R
(2 PLCS)
-4 FAIRING (FLAT PATTERN)

SHOWN -3 OPP.
G71-1015-2A
Figure 806. Auxiliary Fairings and Supports Fabrication (Sheet 2 of 2)
71-10-10
Page 813
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
NAMEPLATE
RETAINING SCREWS
SWITCH BODY
DIAPHRAGM RETURN
SPRING
DIAPHRAGM MAGNET
ASSEMBLY
SWITCH BODY
G71-1016
Figure 807. Pressure Switch

Page 814
Revision 22
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2

1. Engine Air Particle Separator Initial
Installation
Item
Nomenclature
CM206
CM318
Chemical coating
Primer
(1). 369H90148-519, -521, -527 and -529

particle separator installations are
covered by procedures in this section.
NOTE: Tag components as they are removed,

including attaching hardware. Protect loose
parts from damage, dirt or loss.
(2). Ensure that battery switch and all
other helicopter switches are OFF.
(10). On helicopters with cabin heat, remove

cabin heat control valve to facilitate
installing part number
369H90148-507, -519, or -527 particle
separators.
cover over the engine intake be
fore working in or around plenum chamber.
CAUTION
(11). Remove engine air inlet forward fairing

and aft fairing access cover.
(12). Remove plenum chamber access door.
(13). Disconnect forward end of tail rotor
control rod at Sta. 95.00 bellcrank (Ref.
Sec. 67-20-10). Remove forward boot.
(15). Modify engine air cooling inlet screen
(3). Open crew compartment left floor

access door and disconnect battery
connector J108.
(16). Remove engine intake air inlet screen

(Ref. Sec. 71-10-00).
(4). Remove fairings from instrument panel

(Ref. Chap. 95).
(17). Prepare airframe electrical ground

points per FAA publication, EAAC43.13-1A and 2A.
(5). Remove rotor brake cover, where

installed.
(6). Remove map case and interior trim
panel (Ref. Sec. 25-30-00).
(7). Remove map case cover upper left
support bracket.
(18). Using chemical film (CM206) treat

reworked areas as required and apply
primer (CM318) except on electrical
ground or bonding points.
A. Filter Bypass Door and Aft Cable
(Ref. Figure 901)
(8). Remove transmission oil cooler inlet

duct (Ref. Sec. 63-21-00).
NOTE: Installation of bleed air extraction el

bow, tee and hose with the engine in the he
licopter can be done; however, clearance is
minimal.
(9). On helicopters without cabin heat,
remove engine to ease bleed air extrac
tion hardware installation prior to
installing part numbers
369H90148-509, -521, or -529 particle
separators.
Item
Nomenclature
CM410
Adhesive, epoxy (parts A & B)
(1). Modify the plenum chamber access door

as follows:
(2). Install clip and insert assembly on door
with screws, washers and nuts.
(3). Install latch assemblies on door with
71-10-10
Page 901
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
HINGE (2 PLCS)
FAIRING
0.63 IN. (16.002 MM)

SCREW
A
1.250 IN. (3.175 CM)
SCREW
WASHER
NUT
LINK (2 REQD)
A
PLENUM CHAMBER ACCESS DOOR
SCREW
WASHER
NUT
BOLT
NUT
WASHER
(NOTE 10)
BOLT
NUT
WASHER
(NOTE 10)
DOOR
1.250 IN. (3.175 CM)
0.63 IN. (16.002 MM)
PLATE
CLIP
DOOR
(NOTE 1)
REMOVE
REMOVE
PLATE (2 REQD)
1.00 IN. (2.54 CM)
A-A
SCREW
WASHER
NUT
0.53 IN. (13.462 MM)
DOOR
NUTPLATE (4
PLCS) (NOTE 4)
RIVET (8 PLCS)
(NOTE 3)
HINGE
CLIP
(NOTE 13)
SHIM
(NOTE 9)
B-B
COVER
(NOTE 6)
RIVET (4 PLCS)
(NOTE 5)
0.62 IN. (15.748 MM) (TYP)
0.50 0.03 IN.

(12.70 0.762 MM)
1.250 IN. (3.175 CM) (TYP)
FIBERGLASS
CLOTH (1 PLY)
(NOTE 8)
C-C
0.50 0.03 IN. (12.70 0.762 MM)

0.56 0.03 IN. (14.224 0.762 MM)
FAIRIN
G
STA.
141.00
GASKET
(NOTE 7)
DOOR INSTALLATION
STA.
131.00
0.19 0.03 IN. (4.826 0.762 MM)

(NOTE 3)
G71-1006-1A
Figure 901. Air Bypass Door Installation (Sheet 1 of 2)

Page 902
Revision 22
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2
LATCH
CLIP
1.450 IN. (3.683 CM)

(NOTE 1)
SHIM
0.56 IN. (14.224 MM)

LATCH
CLIP
0.56 IN.
(14.224 MM)
SHIM
0.68 IN. (17.373 MM)
PLATE
DOOR
0.68 IN. (17.373 MM)
(REF)
PLATE
1.450 IN. (3.683 CM)
(NOTE 1)
1.62 IN. (4.1148
CM) (NOTE 12)
1.62 IN. (4.1148

CM) (NOTE 12)
D-D
STA.
136.00
GASKET
4.12 IN.
(10.4648 CM)
8.42 IN.
(21.3868 CM)
0.91 IN. (23.114

MM)
2.00 IN. (5.08 CM)

CLIP
DOOR
INSERT ASSY
E-E
NOTES:
1. DOOR PN 369A2099, 369H2087 AND 369D22087.
2. INSTALL COVER. TRIM DOOR TO MATCH CONTOUR OF COVER SO AFT
EDGE OF COVER OVERLAPS DOOR BY 0.19 IN. (4.826 MM) NOMINAL.
REWORK NOT REQUIRED ON 369D290134 DOOR.
3. INSTALL MS20426A03-5 RIVETS FLUSH ON HINGE NEAR SIDE.
4. CENTER NUTPLATES ON EXISTING 0.196-0.210 IN. (4.9784-5.334 MM) DIA.
HOLES IN HINGE. POSITION NUTPLATES AS SHOWN ON FAR SIDE IF HINGE.
5. DRILL FAIRING TO MATCH HOLE PATTERN IN COVER. INSTALL FOUR
MS20470AD-3 RIVETS.
6. BOND COVER TO AFT FAIRING (REF. CSP-DEF-6).
7. MAKE GASKET FROM DE41 CLOSED CELL NEOPRENE RUBBER. BOND TO
DOOR WITH ADHESIVE (CM418).
8.
9.
10.
11.
12.
13.
APPLY ONE PLY OF FIBERGLASS TO COVER-TRIMMED DOOR

EDGE PER DIMENSION SHOWN.
PEEL SHIM, AS REQUIRED, TO ALIGN DOOR AND FAIRING
EXTERNAL SURFACES FLUSH WHEN DOOR IS LATCHED.
TIGHTEN NUT TO GET 0.005-0.015 IN. (0.127-0.381 MM) GAP
BETWEEN BOLT HEAD AND WASHER.
DIMENSION TO MATCH LATCH AND BE CENTERED WITHIN
0.060 IN. (1.524 MM) WITH CLIP.
DIMENSION TO MATCH CLIP AND BE CENTERED WITHIN 0.060 IN.
(1.824 MM) WITH LATCH.
CHAMFER UPPER EDGE TO EASE DOOR LATCH ENGAGEMENT.
G71-1006-2A
Figure 901. Air Bypass Door Installation (Sheet 2 of 2)
71-10-10
Page 903
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
ORIGINAL BRACKET
LOCATION
FAIRING BRACKET
BOSS
NOTE 2
NEW BRACKET
LOCATION
SCREW (2 PLCS)
(NOTE 1)
1.65 IN. (4.191 CM)

CABLE TRAVEL
DOOR LATCHED
DOOR OPEN
11
30
FAIRIN
G
0.29 IN. (7.366 MM)
B.L. 5.83 RH
0.39 IN. (9.906 MM)
CABLE STOP
1.375 IN.
(3.4925 CM)
SLEEVE
VIEW LOOKING DOWN

EXISTING SCREWS,
WASHERS, NUTS
BRACKET
FAIRING MODIFICATION,
UPPER RIGHT PULLEY
BRACKET
SCREW (2 PLCS)
GUARD PLATE
FAIRING
SPACER
WASHER
NUT
SHIM
(NOTE 4)
WASHER
JAMNUT
PULLEY
(NOTE 3)
BUSHING
CABLE STOP
INSTALLATION
LOWER PULLEY
BRACKET
SCREW (2 PLCS)
G71-1007-1A
Figure 902. Aft Cable Installation (Sheet 1 of 2)

Page 904
Revision 22
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2
DOOR CRANK
WASHER
EXISTING SCREWS,
WASHERS, NUTS
NUT
CABLE TERMINAL
BRACKET
AFT FAIRING
COTTER PIN
CABLE
CONNECTION
BOLT
NUT
FITTING
NOTES:
1. DRILL TWO 0.217-0.229 IN. (5.5118-5.8166 MM) DIAMETER HOLES.
COUNTERSINK 100 TO 0.43 IN. (10.922 MM) MINOR DIAMETER.
2. FILL HOLES WITH ADHESIVE (CM410) OR EQUIVALENT.
3. PULLEYS TO BE IN ALIGNMENT WITHIN 0.13 IN. (3.302 MM).
4. SHIM TO ALIGN CABLE WITH CABLE STOP WITHIN 0.060 IN. (1.524 MM).
WASHER (2
PLCS)
UPPER PULLEY
INSTALLATION
(TYP 2 PLCS)
BUSHING
PULLEY
(NOTE 3)
G71-1007-2A
Figure 902. Aft Cable Installation (Sheet 2 of 2)

(4). Attach links to latch and insert assem
bly with bolts, washers and nuts.
Tighten nuts to get a 0.005-0.015 inch
(0.127-0.381 mm) clearance between
bolt-heads and washers.
(10). Install sleeve assembly in bracket.

Secure with washer and nut.
(5). Install door hinge nut-plates with

rivets.
(11). Install door latch shims, clips, plates,

screws, washers and nuts (Ref.
Figure 901, view D-D).
(6). Relocate upper right pulley bracket

mount holes (Ref. Figure 902, view B).
Drill 0.217-0.229 inch (5.5118-5.8166
mm) diameter holes. Countersink 100
to 0.430 inch (10.922 mm) diameter. Fill
original holes with EA9314 epoxy
adhesive (CM410) mixed per manufac
turers instructions.
(12). Install bushing in lower pulley. Attach

pulley assembly to bracket with shim
between pulley and bracket. Install
guard plate, spacer, screws and washers
over pulley. Attach the assembled
pulley bracket to fairing with screws,
washers and existing nuts (Ref.
Figure 902 detail C).
(7). Install upper pulley brackets using

existing fasteners. Insert bushings in
two upper pulleys. Route cable assem
bly over pulleys.
(13). Install air bypass door on aft fairing

with screws, washers and nuts.
(8). Install pulleys and cable assembly in

brackets; install pulley bracket bolts,
washers and nuts.
(9). Install cable-stop bracket and shim
using existing fasteners. Thread cable
stop into sleeve. Install washer and

cable-stop jamnut.
(14). Screw fitting (Ref. Figure 902, detail E)

onto cable terminal. Install fitting in
insert assembly crank arm with washer
and nut. Tighten nut to get a
0.005-0.015 inch (0.127-0.381 mm) gap
between crank and fitting head. Install
cotter pin. Bend cotter pin only enough
to keep it in place. Door rigging adjust
71-10-10
Page 905
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
ments will be required later to complete

the installation.
(15). Add or peel latch clip shims to align
door and fairing external surfaces flush
with door closed and latched (Ref.
Figure 901).
(3). Cover saw cut with a single ply of glass

cloth (Ref. Figure 901, detail C-C) and
per Structural Repair Manual, CSPDEF-6.
C. Handle and Forward Cable Installation
(Ref. Figure 903)
(16). Check pulley alignment. Pulleys shall

line up within 0.130 inch (3.302 mm) of
each other.
(17). Locate seal supports on fairing. Drill
fairing to match holes in supports.
Install rivets (Ref. Figure 904, detail A).
(18). Install seals on supports. Align LH
seals (Ref. Figure 904, detail A, sections
A-A and C-C).
(19). Remove coax, anti-ice and wire harness
cable support hardware, including clip
(Ref. Figure 904, views H-H and J-J).
(20). Locate and rivet ty-rap base in posi
tion. Tie coax, anti-ice and wire
harness in one bundle. Secure bundle to
base with ty-raps.
B. Cover Installation
Item
Nomenclature
CM418
Cement, epoxy
NOTE: 369D series helicopters equipped with

engine inlet fairings other than part num
bers 369A3053-505, -507 and -509 require
modification of the air bypass door to clear
particle separator and the installation of a
cover on the fairing (Ref. Figure 901, detail
B).
(1). Use cover as a template and drill a
0.098 inch (2.4892 mm) diameter hole
in four places. Bond cover to fairing
using bonding adhesive (CM418).
Install rivets.
(2). Trace aft edge of cover onto bypass door.
Remove door and cut away material
0.190 inch (4.826 mm) forward of trace
line.
Page 906
Revision 22
71-10-10
Item
Nomenclature
CM318
Primer
Item
Special Tools
Nomenclature
ST2007
ST2008
Rivnut installation speed header

Rivnut keyway cutter
(1). Remove 369H6524-835 bracket (Ref.

Figure 903).
(2). Remove oil pressure sender tube
assembly from frame hole at canted
Sta. 78.50.
(3). Enlarge oil pressure sender tube
bulkhead hole to 0.042 inch (1.0668
mm) diameter. Install grommet.
(4). Modify map case or rotor brake cover
(Ref. Figure 903, Sheet 3). Use fly-cut
ter as required.
(5). Attach control handle identification
decal to map case.
(6). Drill and deburr rivet holes in angle,
brackets and mount. Install brackets
and mount.
(7). Insert cable end into handle. Fit two
retainer halves over swaged ball. Pull
assembly back into handle to secure.
Install button plug.
(8). Route cable assembly through bracket
and secure with nut and washers. Stack
washers as required to adjust handle
protrusion into cabin.
(9). Trim fairing to get a 0.120 inch (3.048
mm) diameter gap between main rotor
mast and fairing (Ref. Figure 903, view
F).
MAINTENANCE MANUAL
CSP-HMI-2
D. Bleed Air System Installation (Helicopters

Without Cabin Heat)
(10). Locate rivnut installation point (Ref.

Figure 903, view A). Drill one
0.250-0.256 inch (6.35-6.5024 mm)
diameter hole through pan. Use a
C-3576 key cutting tool (ST2008) to
make a 0.062-0.065 inch (1.5748-1.651
mm) wide by 0.056-0.058 inch
(1.4224-1.4732 mm) deep rivnut
keyway. Apply primer (CM318) to hole.
Install rivnut with a C-6000 speed
header (ST2007) while primer is wet.
Item
Nomenclature
CM112
(11). Inspect rivnut installation. Rivnut

length measured from upper surface of
head to blind end shall be between
0.365-0.415 inch (9.271-10.541 mm).
Rivnut shall be tight.
NOTE:
(12). Secure cable to rivnut with a clamp,

washer and screw.
(13). Install grommet in fairing (Ref.
Figure 903, view D). Route cable
through grommet.
(14). Locate and drill 0.390 inch (9.906 mm)
diameter hole through left fairing for
pressure switch tube union (Ref.
Figure 904, Sheet 1). Do not install
union at this time.
(15). Locate pressure switch support angle
position (Ref. Figure 904, Sheet 1). Drill
and deburr rivet holes. Install angle
with rivets. Do not install pressure
switch at this time.

CAUTION
D Helicopters without Cabin Heating re

quire the installation of compressor bleed
air hardware on the engine for the par
ticle separator scavenge air system.
D Installation of bleed air extraction elbow,
tee and hose with the engine installed in
the helicopter can be done; however,
clearance is minimal.
D Apply high temperature anti-seize com
pound (CM112) to male threads of all fit
tings prior to installation.
(1). Remove engine (Ref. Sec. 71-00).
(2). Continue with `Scavenge Air System
Installation'.
E. Bleed Air System Installation (Helicopters
With Cabin Heat)
Item
Nomenclature
CM112
NOTE: Ground connection (E45) requires mini

mum resistance to current flow for reliable
solenoid air valve operation.
(16). Prepare electrical ground (E45) stud
installation per FAA publication,
EA-AC43.13-1A and 2A.
(17). Install ground stud screw through
existing tool hole in stringer with
washers, jamnut and nut. Install decal
(Ref. Figure 907, detail B).

CAUTION
NOTE: Apply high temperature anti-seize

compound (CM112) to male threads of all fit
tings prior to installation.
(1). Remove cabin heat control valve.
Remove existing control valve elbow
and O-ring.
71-10-10
Page 907
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
0.250 IN. (6.35 MM) DIA. HOLE

TO MATE WITH EXISTING
NUTPLATES (6 PLCS)
PARTICLE SEPARATOR
RIGHT FAIRING
MAP CASE
LEFT FAIRING
5.55-5.68 IN.
(14.097-14.4272 CM)
FORWARD CABLE
5.55-5.68 IN.
(14.097-14.4272 CM)
RIVNUT, CLAMP,
ENGINE INLET SCREW, WASHER
FAIRING
TOP VIEW LOOKING DOWN
ENGINE AIR COOLING

INLET SCREEN
GRIND OFF SHADED AREA IN
SEPARATOR INTERFERES WITH FITTING
0.25 IN.
(6.35 MM)
45 ANGLE
1.00 IN.
(2.54 CM)
MAST SUPPORT FITTING
ENGINE AIR COOLING INLET

SCREEN MODIFICATION
G71-1008-1A
Figure 903. Handle and Forward Cable Installation (Sheet 1 of 3)

Page 908
Revision 22
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2
CABLE
PULLEY
6.56-6.80 IN. (16.6624-17.272 CM)
0.88-1.12 IN.
(22.352-28.448 MM)
CABLE CONNECTOR
RETAINER
SPRING
RETAINER
GROMMET
SCREW
CABLE
CLIP
LEFT FAIRING
CLAMP
WASHER
MAST SUPPORT
NUT
CABLE HOUSING
FAIRING
0.12 IN. (3.048 MM) DIA.

CLEARANCE
G71-1008-2A
71-10-10
Page 909
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
0.70 IN. (17.78 MM) DIA. HOLE

IN TRIM PANEL TO MATCH
CABLE FITTING
TORQUE GAGE
TUBE (REF)
OIL PRESSURE TUBE
ENLARGE HOLE TO 0.42 IN.
(10.668 MM) DIA.,
INSTALL GROMMET
FILTER BY-PASS CONTROL

PULL HANDLE FWD
OPTIONAL ROTOR
BRAKE HANDLE (REF)
HEATER CONTROL
CABLE
DECAL
0.22 IN. (5.588 MM) DIA.
HOLE IN TRIM PANEL TO
MATCH SHOCK MOUNT
EXISTING RIVET
LOCATION
0.096 IN. (2.4384 MM)

DIA. HOLE (8 PLCS)
OPTIONAL ROTOR
BRAKE COVER (REF)
CANTED STA. 78.50
0.22 IN. (5.588 MM)

RIVET EDGE
DISTANCE
(TYP)
MAP CASE OR OPTIONAL
ROTOR BRAKE COVER
TORQUE GAGE TUBE

(REF)
GROMMET
WASHERS, AS REQUIRED, TO
ADJUST HANDLE PROTRUSION
FORWARD CABLE
MAP CASE OR OPTIONAL

ROTOR BRAKE COVER
OIL PRESSURE SENDER

TUBE (REF)
CABIN HEAT CONTROL
CABLE (REF)
CABLE END FITTING
NUT
RETAINER HALVES
BRACKET
SHOCK MOUNT
0.73 IN. (18.542 MM)

0.096 IN. (2.4384 MM)
DIA. HOLE (2 PLCS)
BUTTON
0.44 IN.
(11.176 MM)
BYPASS
DOOR
HANDLE
ANGLE
RIVET (2 PLCS)
0.28 IN. (7.112 MM) RIVET EDGE

DISTANCE (TYP), PICK UP EXISTING
RIVET LOCATIONS
0.95 IN.
(24.13 MM)
HANDLE SUPPORT BRACKET

INST
G71-1008-3A

Page 910
Revision 22
71-10-10
MAINTENANCE MANUAL
(2). Install special three-port elbow and
O-rings with existing fasteners. Torque
three-port elbow flange self-locking
nuts up to 18 inch-pounds (2.03 Nm).
Install cabin heat control valve. Torque
(3). Install universal elbow, O-ring and
jamnut on engine compressor scroll.
Torque jamnut to 145 - 155 inchpounds (16.38 - 17.51 Nm) (Ref.
Figure 905).
(4). Install tee, jamnut and O-ring on
compressor diffuser duct. Torque tee
(32.20 - 35.59 Nm).
(5). Install hose assembly between elbow
and tee. Torque hose nuts to 150 - 250
inch-pounds (16.95 - 28.25 Nm).
(6). Install cover, spacer and gaskets on
special three-port elbow with bolts,
washers and nuts.
(7). Loosely install special three-port elbow
on canted firewall with bolts, washers
and nuts.
(8). Install nut and O-ring on 0.750 inch
(19.05 mm) universal elbow and install
in three-port elbow. Torque three-port
elbow flange self-locking nuts up to 18
inch-pounds (2.03 Nm). Torque
universal elbow jamnut 285 - 315
inch-pounds (32.20 - 35.59 Nm).
(9). Install engine (Ref. Sec. 71-00).
(10). Install tube assembly between firewall
mounted universal elbow and tee-fit
ting. Torque tube nuts to 460 - 500
inch-pounds (51.97 - 56.49 Nm).
F. Scavenge Air System Installation
(Ref. Figure 905)
(1). The scavenge air system consists of a
solenoid air valve, tubes, air pressure
switch, SCAV AIR circuit breaker
switch, AIR FILTER CLOGGED
caution light, wiring, and attaching
hardware.
CSP-HMI-2
(2). Attach one end of compressor bleed air

tube to special three-port elbow. Torque
tube nut to 110 - 130 inch-pounds
(12.43 - 14.69 Nm).
(3). Bolt solenoid valve to bracket. Attach
free end of bleed air tube assembly to
solenoid valve. Torque tube nut to 110 130 inch-pounds (12.43 - 14.69 Nm).
CAUTION
Do not scratch or gouge firewall

surface when trimming heat
shield.
(4). Mark solenoid valve bracket position on
firewall heat shield pad. Remove
bracket, valve and tube. Cut an 0.125
inch (3.175 mm) oversize opening
through heat shield pad for the valve
mounting bracket.
(5). Drill and deburr valve bracket rivet
holes.
(6). Install bracket on firewall with six
rivets.
(7). Mount solenoid valve on bracket.
Torque valve mounting bolts to 20 - 25
(8). Install scavenge air tube between the
valve and elbow. Torque tube nuts 110 130 inch-pounds (12.43 - 14.69 Nm).
(9). Install elbow on scavenge air line
support bracket (Ref. Figure 904, view
G-G) with one washer on each side.
Install and torque jamnut to 120 - 150
inch-pounds (13.56 - 16.95 Nm).
(10). Trim away up to 0.050 inch (1.270 mm)
of bracket outboard edge to clear
intersecting angle and rivet heads.
Install support assembly on shelf with
washers and screws.
(11). Locate scavenge air line elbow doubler
on plenum chamber bulkhead. Fasten
doubler to structure with rivets.
(12). Install elbow, washer and nut on
doubler. Torque elbow jamnut to 120 150 inch-pounds (13.56 - 16.95 Nm).
(13). Install upper scavenge air tube between
elbows. Torque tube nuts 110 - 130
inch-pounds (12.43 - 14.69 Nm).
71-10-10
Page 911
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
SEALING COMPOUND
(NOTE 6)
SCREW,
WASHER
(NOTE 1)
SEAL
(NOTE 7)
TRIM
(NOTE 8)
SCREW,
WASHER
SPACER
SEAL
0.84 IN.
(21.336 MM)
RIVET (2 REQD)
DETAILA
PARTICLE
SEPARATOR
SUPPORT
MIST ELIMINATOR
TAIL ROTOR SHAFT

TUNNEL (REF)
CL
5.21 IN.
(13.2334 CM)
2.94-3.06 IN.
(7.4676-7.7724 CM)
1.11 IN.
(2.8194 CM)
D
1.36-1.48 IN.
(3.4544-3.7592 CM)
C
D
SCREEN
BYPASS
FAIRING ASSY
DOOR
CABLE
0.39 IN. (9.906 MM)
DIA. HOLE THRU
FAIRING
TAIL ROTOR PITCH

CONTROL ROD (REF)
C
GROMMET
SCREW,
WASHER
(NOTE 2)
STA.
127.00
STA.
SEE
DETAIL 131.00
A
TOP VIEW
G71-1009-1A
Figure 904. Modifications and Installation (Sheet 1 of 4)

Page 912
Revision 22
71-10-10
MAINTENANCE MANUAL
PARTICLE SEPARATOR
MOUNTING FRAME
CSP-HMI-2
PARTICLE SEPARATOR
MOUNTING FRAME
PARTICLE
SEPARATOR (REF)
SEAL
(NOTE 3)
FORWARD FLANGE,
PARTICLE SEPARATOR
SUPPORT
SUPPORT
SCREW,
WASHER
0.43 IN.
(10.922 MM)
FAIRING
DRILL FAIRING
TO MATCH
SUPPORT
SEAL
0.31 IN. (7.874 MM)
DRILL FAIRING TO
MATCH SUPPORT
NUTPLATE
PARTICLE
SEPARATOR
SECTION B-B
SECTION A-A
SEAL
(NOTE 3)
SECTION C-C
SEALING COMPOUND
(NOTE 6)
FAIRING
MAST
SUPPORT
FITTING
GROMMET
(NOTE 5)
0.250 IN. (6.35 MM)

DIA. HOLE
(NOTE 4)
INLET FAIRING
VIEW D-D
G71-1009-2A
71-10-10
Page 913
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
E
F
F
TAPE
(NOTE 9)
0.38 IN.
(9.652 MM)
TUBE ASSY,
TORQUE TO
25-35 IN. LB
(2.82-3.95 NM)
UNION, WASHERS,
JAMNUT, TORQUE
TO 65-80 IN. LB
(7.34-9.04 NM)
H
MIST ELIMINATOR
MOUNTING CLIPS
E- E
VIEW
H
MAST SUPPORT
FITTING (REF)
G
SUPPORT
TUBE ASSY
SWITCH ASSY
WASHER
, ELBOW
ENGINE INLET
ASSY (REF)
SIDE VIEW
WASHER
, NUT
SCREW,
WASHER
(NOTE 10)
TRIM
(NOTE 12)
SUPPOR
T
SCAVENGE AIR TUBE

ASSY
TRIM
(NOTE 11)
VIEW G - G
JAMNUT, TORQUE TO
120-150 IN. LB
(13.56-16.95 NM)
INLET
FAIRING (REF)
TUBE, TORQUE TO
110-130 IN. LB
(12.43-14.69 NM)
MAST
SUPPORT (REF)
SCREW,
CLAMPS
(REMOVE)
CLIP
(REMOVE)
FWD
STA.
127.00
BASE,
RIVET
INLET
FAIRING
(REF)
STA.
127.00
MIST ELIMINATOR
ACCESS PANEL
VIEW F- F
MAST SUPPORT
(REF)
BASE,
RIVET
(INSTALL)
VIEW H- H
(RH SIDE
ONLY)
0.38-0.50 IN.
(9.652-12.7 MM
VIEW J - J
G71-1009-3A

Page 914
Revision 22
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2
FAIRING
K
JAMNUT, TORQUE
TO 240-280 IN. LB
(27.12-31.64 NM)
DOUBLER
L
FLAPPER VALVE
PARTICLE SEPARATOR
ELBOW, FITTING,
O-RING, NUT
K
EJECTOR
VIEW LOOKING AFT
RIVET (2 PLCS)
(NOTE 14)
0.16 IN.
(4.064 MM)
NUTPLATES, RIVETS
(6 PLCS), FAR SIDE
(NOTE 13)
TUBE, TORQUE
TO 110-130 IN. LB
(12.43-14.69 NM)
FAIRING
DUCT
1.13 IN. (2.8702 CM)
0.33 IN.
(8.382 MM)
0.63 IN.
(16.002 MM)
(TYP)
RIVET
(NOTE 15)
DOUBLER
(NOTE 16)
RIVET
(NOTE 15)
VIEW k-k
LOOKING INBOARD
DOUBLER
0.63-0.69 IN.
(16.002-17.526 MM)
SCREW,
WASHER (6
PLCS)
VIEW L-l
LOOKING INBOARD
G71-1009-4A
71-10-10
Page 915
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2

1. 0.250 IN. (6.35 MM) DIAMETER HOLE THROUGH
FAIRINGS TO MATCH EXISTING NUTPLATE
LOCATION.
2. 0.250 IN. (6.35 MM) DIAMETER HOLE THROUGH
FAIRING TO MATCH LOWER FAIRING ASSEMBLY
NUTPLATE LOCATION; LEFT AND RIGHT SIDES.
3. INSTALL SEAL AFTER SUPPORT INSTALLATION.
4. DRILL 0.250 IN. (6.35 MM) DIAMETER HOLE
THROUGH FAIRING ASSEMBLY TO MATCH EXISTING
NUTPLATE LOCATION.
5. SPLIT GROMMET ON TANGENT SHOWN PRIOR TO
INSTALLATION.
6. APPLY SEALING COMPOUND (CM430) TO ALL
OPENINGS AND GAPS.
7. ALIGN BOTTOM EDGES OF SEALS.
8. TRIM LOWER FAIRING AS REQUIRED TO CLEAR AFT
FAIRING STRUCTURE.
(14). Install tee on solenoid air valve. Install

cap on tee.
(15). Install tube assembly between solenoid
valve tee and elbow. Torque tube nuts
110 - 130 inch-pounds (12.43 - 14.69
Nm).
(16). Install scavenge air tube clamp support
bracket, spacer, clamp, screws, wash
ers, and nuts (Ref. Figure 905, detail
C).
(17). Clamp tube assembly to air duct with
clamps, screw, washers and nut (Ref.
Figure 905, detail B).
G. Solenoid Valve and Pressure Switch Wire
Harness Installation
Item
Nomenclature
CM815
Solder
part number 369A4163, go to step (6). If not

using prefabricated wire harness, proceed
as follows:
(1). Do not clamp wiring until routing and
connections are complete. Install wires
per FAA publication, EA-AC43.13-1A
and 2A. Where possible, route added
wiring along existing wire harness.
Revision 22
(2). Install varistor across connector P206

pins A and B (Ref. Figure 103, detail A).
Solder (CM815) connections per
standard shop practices.
(3). Connect wire P17D20N to solenoid
valve connector P206 pin B and ground
lug E45 with washers and nut.
(4). Solder wire P16C20 to connector P206,
pin A.
(5). Route solenoid air valve wire harness
through airframe (Ref. Figure 907).
(6). Install wire harness, part number
369A4163 as follows:
(7). Solder varistor between pins A and B of
connector P206 (Ref. Figure 103, detail
A).
(8). Route wire harness through airframe
(Ref. Figure 907).
(9). Connect wire P17A20N to ground lug
E45.
NOTE: If using prefabricated wire harness,
Page 916
9. IF INSTALLING MIST ELIMINATOR; APPLY 0.125 IN.

(3.175 MM) THICK BY 0.380 IN. (9.652 MM) WIDE
PRESSURE SENSITIVE TAPE (CM728) OR
EQUIVALENT TO PARTICLE SEPARATOR PRIOR TO
INSTALLATION.
10. USE EXISTING NUTPLATES.
11. TRIM SUPPORT AS REQUIRED TO CLEAR RIVET
HEADS.
12. TRIM OUTBOARD EDGE OF SUPPORT 0.050 IN.
(1.270 MM), MAXIMUM, TO CLEAR ANGLE.
13. DRILL 0.2170.229 IN. (5.51185.8166 MM) DIAMETER
SCREW HOLES TO MATCH DOUBLER HOLES.
14. EQUALLY SPACE RIVETS BETWEEN NUTPLATES.
15. PICK UP EXISTING RIVET LOCATIONS.
16. CUT HOLE THROUGH AFT FAIRING TO MATCH
DOUBLER. BOND DOUBLER TO EXTERIOR FAIRING
SURFACE WITH ADHESIVE (CM410) PER
MANUFACTURERS INSTRUCTIONS.
71-10-10
(10). Splice solenoid valve wire P16D20 to

airframe wire P16C20.
(11). Determine correct pressure switch wire
length. Trim wires as required.
(12). Install knife splice halves on pressure
switch pigtails. Install knife splice
halves on airframe wires P16G22 and
P16H22N.
MAINTENANCE MANUAL
CSP-HMI-2
NUT
CLAMP
TO EJECTOR
NOZZLE (REF)
WASHER
TUBE ASSY
DOUBLER
(NOTE 1)
CLAMP
TUBE ASSY, TORQUE
TO 110-130 IN. LB
(12.43-14.69 NM)
(NOTE 4)
BOLT
COVER
SCREW
RIVET
(6 PLCS)
WASHE
R
GASKET
SPACER
GASKET
NUT, TORQUE TO
120-150 IN. LB
(13.56-16.95 NM)
STRINGER
WIRE HARNESS
WASHER
CLAMP
BOLT
TRANSMISSION
OIL COOLING
DUCT (REF)
WASHER
TUBE ASSY,
TORQUE TO
110-130 IN. LB
(12.43-14.69 NM)
(NOTE 2)
NUT, TORQUE
TO 20-25 IN. LB
(2.26-2.82 NM)
ELBOW
HOSE ASSY, TORQUE

TO 150-250 IN. LB
(16.95-28.25 NM)
ELBOW
SOLENOID
VALVE
BOLT
WASHER
BRACKET
ASSY
(NOTE 2)
NUT, TORQUE TO
145-155 IN. LB
(16.38-17.51 NM)
5.65 IN. (14.351 CM)
O-RING
NUT
ENGINE
COMPRESSOR
SCROLL (REF)
TEE
WASHER
NUT, TORQUE
TO 18 IN. LB
(2.03 NM)
TEE
SPACER
BRACKET
(NOTE 3)
HEAT SHIELD
PAD (NOTE 2)
WASHER NUT, TORQUE TO

285-315 IN. LB
(32.20-35.59 NM)
SCREW
CAP
TUBE, TORQUE TO
460-500 IN. LB
(51.97-56.49 NM)
NUT
SCREW
WASHER
NUT, TORQUE TO
285-315 IN. LB
(32.20-35.59 NM)
O-RING
O-RING
ELBOW
CLAMP
G71-1010A
Figure 905. Scavenge Air Equipment Installation
71-10-10
Page 917
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2

1. LOCATE DOUBLER ON PLENUM CHAMBER WALL AT
THE INTERSECTIONS OF STA. 126.25 AND W/L 52.50.
CENTER DOUBLER ON A POINT 1.50 IN. (3.81 CM)
BELOW PLENUM CHAMBER ANGLED FLOOR PAN.
DRILL ONE 0.578 IN. (14.6812 MM) DIAMETER HOLE
THROUGH CENTER. DRILL SIX EQUALLY SPACED
RIVET HOLES AROUND DOUBLER. MAINTAIN A 0.220
IN. (5.588 MM) MINIMUM RIVET EDGE DISTANCE.
NOTE: Ensure electrical continuity and mini

mum resistance between ground wire
P16H22N and airframe.
(13). Connect either switch pigtail to air
frame wire P16G22. Connect remaining
lead to airframe ground wire P16H22N.
(14). Install clamps and ty-raps.
(15). Refer to Instrument Panel Modifica
tions; T-Pedestal or Slimline Panel
Modification for crew compartment
wiring information.
(16). Vacuum all debris from work area.
(17). Inspect all tube connections for correct
torque values. Inspect all components
and attaching hardware for correct
installation and security.
H. Ejector Duct Doubler and Rib Installation
Item
Nomenclature
CM418
Cement, epoxy
NOTE: Doubler is required for all installations.

Rib installation is required for helicopters
not equipped with 369A3053-505, -507, or
-509 engine inlet fairing assemblies.
(1). Drill out required rivets (Ref.
Figure 904, view K-K and Figure 906).
(2). Locate and bond doubler to fairing
exterior with adhesive (CM418).
(3). Install rivets through doubler and
fairing.
(4). Back-drill from inside of engine inlet
fairing through existing rivet holes and
doubler.
Page 918
Revision 22
71-10-10
2. BOLT SOLENOID VALVE TO MOUNTING BRACKET.

ATTACH TUBE BETWEEN VALVE AND ELBOW TO
LOCATE VALVE ASSEMBLY ON FIREWALL. TRIM
AWAY HEAT SHIELD PAD BENEATH BRACKET PRIOR
TO RIVETING BRACKET TO FIREWALL.
3. USE EXISTING STRINGER TOOLING HOLE.
4. HAND FORM AS REQUIRED TO CLEAR
STRUCTURES.
(5). Cut hole in aft engine inlet fairing to

match hole in doubler.
(6). Bond rib in position (Ref. Figure 906).
(7). Drill six holes through fairing to match
holes in doubler, Install nut-plates and
rivets (Ref. Figure 904, view K-K).
(8). Install ejector duct (Ref. Figure 904,
view L-L) with screws and washers.
I. Particle Separator Installation
Item
CM106
CM112
CM234
CM405
CM425
CM430
Nomenclature
Adhesive
Sealing compound
(1). Position particle separator inside

engine air inlet aft fairing. Coat
mounting bolt threads with anti-seize
compound (CM112).
(a). Temporarily attach separator to
mount boss with bolts and washers.
Stack washers under right bolt head
as necessary. Check fit.
NOTE: Do not grind mast support fitting un

less particle separator cannot be installed
due to interference with fitting.
(2). Remove particle separator and grind
material from corner of mast support
fitting (Ref. Figure 903, detail C).
(3). Drill 0.250 inch (6.35 mm) diameter
holes through horizontal fairings to
match auxiliary fairing nut-plates (Ref.
Figure 904, Sheet 1).
MAINTENANCE MANUAL
CSP-HMI-2
PARTICLE SEPARATOR
MOUNTING FRAME
1.19-1.44 IN.
(3.0226-3.6576 CM)
0.50-0.75 IN.
(12.7-19.05 MM)
TRIM FIBERGLASS
CLOTH TO PREVENT
OVERLAP INTO
COUNTERBORE
RIVET, WASHER
(2 PLCS)
0.75 IN.
(19.05 MM)
0.63-0.88 IN.
(16.002-22.352 MM)
OVERLAP
(NOTE 4)
RIVET,
WASHER
(7 PLCS)
1.03-1.25 IN.
(2.6162-3.175 CM)
RIB
(NOTE 1, 2)
FAIRING
DOUBLER
(FAR SIDE)
1.13-1.25 IN.
(2.8702-3.175 CM)
FIBERGLASS CLOTH
(NOTE 3)
EJECTOR DUCT OPENING

LOOKING OUTBOARD
NOTES:
1. RIB INSTALLATION ONLY REQUIRED FOR HELICOPTERS NOT EQUIPPED
WITH 369A3053-505, -507 OR -509 ENGINE INLET FAIRING ASSEMBLY.
INSTALL RIB AND FIBERGLASS CLOTH PRIOR TO INSTALLING NUTPLATES
AND NUTPLATE RIVETS.
2. BOND RIB TO FAIRING WITH ADHESIVE (CM410) PER MANUFACTURERS
INSTRUCTIONS.
3. APPLY A MINIMUM OF TWO PLIES OF FIBERGLASS CLOTH (CM501) WITH
RESIN (CM506) OR EQUIVALENT PER MANUFACTURERS INSTRUCTIONS.
4. FIBERGLASS CLOTH TO OVERLAP HOLE EDGE 0.09-0.19 IN. (2.286-4.826 MM)
ON FAR SIDE.
G71-1011A
Figure 906. Ejector Duct Doubler Installation
71-10-10
Page 919
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
STRINGER (REF)
TUBE (REF)
GROMMET
(NOTE 2)
GROUND
(E45)
MAIN ROTOR WIRE

HARNESS (REF)
ENGINE INLET ASSY
SOLENOID
VALVE
STRUT
STRAP
P16G22 WIRE
P16H22N WIRE TO
PRESSURE SWITCH
(NOTE 1)
P16C20 WIRE,
WASHER, STRAP
(NOTE 3)
CHANNEL ASSY (REF)
FRAME, CANTED
STA. 124.00
P16C20 WIRE
P17D20N WIRE
CLAMP
GROMMET
(NOTE 2)
NOTES:
1. P16H22N WIRE FROM PRESSURE SWITCH
TO GROUND E15.
2. INSTALL GROMMET IN EXISTING TOOLING
HOLE.
3. SECURE WIRE TO FRAME USING WASHERS
AND STRAPS THROUGH EXISTING TOOLING
HOLES (2 PLCS).
Figure 907. Wiring Harness Installation

Page 920
Revision 22
71-10-10
G71-1012
MAINTENANCE MANUAL
(4). Drill 0.250 inch (6.35 mm) diameter
holes through auxiliary fairing vertical
plates to match aft inlet fairing nutplates (Ref. Figure 904, view D-D).
NOTE: Do not install auxiliary fairings at this

time.
(5). If installation does not include mist
eliminator, install bolts and washers in
the three lowest particle separator mist
eliminator attachment holes. Torque
Nm).
(6). If installation includes mist eliminator,
wipe rear surfaces of particle separator
clean with dry cleaning solvent
(CM234) on a clean cloth. Wipe dry.
(7). Attach 0.125 inch (3.175 mm) thick by
0.380 inch (9.652 mm) wide pressure
sensitive seal tape to particle separator
aft surface around mist eliminator
frame and fairing frame contact areas
(Ref. Figure 904, view E-E).
(8). Install rubber seal (Ref. Figure 904,
section B-B) on the forward lower shelf
edge of the particle separator as
follows:
(a). Apply one heavy brush coat of
adhesive (CM405) to seal and particle
separator joint surfaces. Let surfaces
dry 15 minutes.
(b). Apply a second coat of adhesive.
Immediately press seal in place.
Allow assembly to air dry a minimum
of eight hours.
NOTE: Do not install mist eliminator support

channels if helicopter is not equipped with a
mist eliminator access panel on top of the aft
fairing (Ref. Figure 904, view F-F).
(9). Install mist eliminator support chan
nels on particle separator lower aft face
with screws (Ref. Figure 904, view
E-E).
(10). Install scavenge air line special elbow,
O-ring and nut on particle separator
ejector assembly. Do not torque elbow
jamnut at this time (Ref. Figure 904,
Sheet 4).
CSP-HMI-2
(11). Install particle separator with washers

and bolts.
(12). Install scavenge air supply tube
between ejector nozzle and shelf
mounted elbows. Torque ejector nozzle
elbow jamnut 240 - 280 inch-pounds
(27.12 - 31.64 Nm). Torque tube nuts
110 - 130 inch-pounds (12.43 - 14.69
Nm).
(13). Modify two grommets as shown (Ref.
Figure 904, view D-D). Install grom
mets over left and right wire bundles.
Insert left and right auxiliary fairing
assemblies into grommet grooves.
Install screws and washers through
auxiliary fairing vertical plates.
(14). Install pressure switch sensing tube
union on left fairing with one washer on
each side of fairing. Torque union
jamnut 65 - 80 inch- pounds (7.34 9.04 Nm).
(15). Attach tail rotor control rod cover, if so
equipped, to left fairing with existing
fasteners. Complete all fairing installa
tions.
(16). Install pressure switch. Torque pres
sure switch jamnut 65 - 80 inchpounds (7.34 - 9.04 Nm).
(17). Install upper and lower pressure switch
tubes. Torque tube nuts to 25 - 35
(18). Seal all gaps around auxiliary fairing
installations with sealant (CM430)
(Ref. Figure 904, view D-D).
(19). Use existing screw to attach clip to
structure (Ref. Figure 903, detail E).
Install clamp on cable with clip, screw,
washer and nut.
(20). Install cable return spring and retain
ers (Ref. Figure 903, detail D). Secure
spring assembly with cable connector.
(21). Close and latch air bypass door.
Connect forward and aft cable sections.
Distance between center of forward
cable swaged ball terminal and aft face
of fairing should be between 6.56 and
6.80 inches (16.662 and 17.272 cm) with
no cable slack (Ref. Figure 903 detail
D).
71-10-10
Page 921
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
(22). On helicopters without mist eliminator

access panel, remove air bypass door.
Spray 15 milliliters, total, of engine oil
on mist eliminator front and rear
surfaces. Insert mist eliminator,
forward face up, through bypass door
opening and move to engage nine mist
eliminator mount bolts with particle
separator. Start all bolts by hand.
(2.82 - 3.95 Nm).
(23). Install door gasket on aft fairing with
adhesive (CM405) per manufacturers
instructions.
(24). For operation below 40F (4.5C), spray
door gasket and door edge with fluoro
carbon dry lubricant (CM106).
rod forward boot free length to between

7.130 and 7.250 inches (18.1102 and
18.4150 cm). Secure with ty-raps.
J. Instrument Panel Modifications;
TPedestal
(1). Do not install clamps or ty-raps on
wiring until wiring installation is
complete. Install wires per FAA
Where possible, route added wiring
along existing wire bundles.
(2). Remove plug button from SCAV AIR
switch panel hole.
(25). Install air bypass door.
(3). Connect wire P514D20 between pin 1 of

SCAV AIR (CB15) circuit breaker
switch and pin 1 of POS LT circuit
breaker switch CB119 (Ref.
Figure 103).
(26). Rig bypass door (Ref. Air Bypass Door

Rigging).
(4). Connect wire P16MA20 (stowed inside

console) to pin 2 of CB15.

door cable fitting cotter pin (Ref.
Figure 902, detail E).
(5). Install SCAV AIR circuit breaker switch

in panel.
(28). On helicopters equipped with mist

eliminator access panel disengage two
1/4-turn fasteners and remove access
panel (Ref. Figure 904, view F-F).
(29). Use locking pliers to pull while turning
nine mounting bolts, if so equipped, out
of mist eliminator frame. Discard bolts.
(30). Pass mist eliminator through access
opening into engagement with lower
support channels. Hold mist eliminator
against particle separator and install
access panel. Lock panel fasteners.
(31). Inspect mist eliminator installation
through bypass door opening. Check
that mist eliminator is firmly in
position against particle separator.
Adjust as required.
(32). Remove mist eliminator and spray a
total of 15 milliliters of clean engine oil
on front and rear surfaces. Reinstall
mist eliminator.
(33). Clamp tail rotor control pedals in
mid-position. Adjust tail rotor control
Page 922
Revision 22
71-10-10
(6). Remove third from right dummy block

from caution and warning light panel.
(7). Connect stowed wires P514C20 to pin 2
of light assembly and wire P514B20 to
pin C.
(8). Install AIR FILTER CLOGGED caution
light assembly.
K. Slimline Panel Modification
(1). Use switch and light subpanel bracket
as a template. Locate and drill a 0.219
inch (5.5626 mm) diameter hole
through instrument panel hood and left
fairing above existing hole.
(2). Cut a 0.50 inch (12.70 mm) wide slot,
2.98 inches (7.5692 cm) long with full
radius at forward end in instrument
panel left fairing.
(3). On helicopters equipped with
369H90022 anti-ice fuel filter (airframe
filter) installation; remove plug buttons
from AIR FILTER CLOGGED and
SCAV AIR subpanel positions. Wire and
install switch and light (Ref.
Figure 103).
MAINTENANCE MANUAL
L. PostInstallation Inspection
CSP-HMI-2
(5). Clean all debris from mast area.
Item
Nomenclature
CM209
Zinc chromate putty
(1). Inspect all installation brackets, clamps

and fasteners for security.
(2). Check electrical wiring connectors,
clamps and attaching hardware for
proper installation and security.
Failure to inspect and thorough
ly clean debris from engine inlet
areas will result in engine FOD.
CAUTION
(3). Inspect plenum chamber for cleanli

ness. Remove all traces of debris with a
vacuum cleaner.
(4). Remove engine inlet covers.
(6). Install modified engine cooling air inlet

screen (Ref. Figure 903, detail B).
(7). Install engine air inlet forward fairings.
Seal gap between reworked area of left
fairing and door cable with zinc
chromate putty (CM209) as required.
(8). Install all interior trim.
(9). Check bypass door rigging (Ref. Air
Bypass Door Rigging).
(10). Perform a particle separator operation
al check (Ref. Scavenge Air Operational
Check).
(11). Revise weight and balance records.
M. Weight and Balance
installation of the particle separator are listed
in Table 901. Incorporate changes in helicopter
weight and balance records.

Configuration
Weight
Pounds (kg)
Arm
inches (cm)
Moment
inlb (kg cm)
369H90148503
10.8
(4.8987968)
124.2
(315.468)
13.4
(154.38408)
369H90148505
13.5
(6.123496)
125.1
(317.754)
16.9
(194.70828)
369H90148507
10.8
(4.8987968)
122.6
(311.404)
13.2
(152.07984)
369H90148509
12.3
(5.5791852)
122.8
(311.912)
15.2
(175.12224)
369H90148519
17.0
(7.7110691)
124.8
(316.992)
21.3
(245.40156)
369H90148521
18.6
(8.4368167)
125.4
(318.516)
23.3
(268.44396)
369H90148527
17.0
(7.7110691)
124.8
(316.992)
21.3
(245.40156)
369H90148529
18.6
(8.4368167)
125.4
(318.516)
23.3
(268.44396)
500N901481 /3
18.6
(8.4368167)
125.4
(318.516)
23.3
(268.44396)
71-10-10
Page 923
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 924
Revision 44
71-10-10
MAINTENANCE MANUAL
CSP-HMI-2
Section
711060
Engine Air Particle
Separator (600N)
MAINTENANCE MANUAL
CSP-HMI-2

(1). The optional engine air particle separa
tor is mounted above the engine air
inlet plenum. Intake air is cleaned by
the particle separator to prevent dirt or
foreign objects from entering the
engine.
(2). Dirt is separated from the intake air by
centrifugal force created by the particle
separator vortex tubes. Clean air passes
through the tubes to the engine inlet
plenum.
(3). The separated dirt is removed from the
inside of the particle separator with
pressurized engine compressor bleed
air. A solenoid shutoff valve is activated
from a switch in the cockpit and bleed

air comes from the cabin heat system.
Pressure from the bleed air draws the
dirt out of the particle separator and
exhausts it through the ejectors.
mounted with a reference to inside and
outside of the particle separator.
Blockage of the particle separator will
cause a pressure decrease on the engine
plenum side and the switch will
activate a warning light in the cockpit.
(5). A cable from the cockpit is manually
operated to open an engine bypass door
which allows unfiltered air into the
engine inlet plenum if the particle
separator is blocked.
71-10-60
Page 1
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 2
Revision 44
71-10-60
MAINTENANCE MANUAL
CSP-HMI-2

FAULT ISOLATION
1. Engine Air Particle Separator Fault
Isolation
Table 101. Engine Air Particle Separator Fault Isolation
Symptom
Air Filter Clogged warning light.
Probable Trouble
Corrective Action
Inlet screen or air particle separator Clear obstruction from screen or
obstructed.
panel.
Replace panel (Ref. Sec. 760000).
Decrease in performance with

scavenge air activated.
S2001 (REF)
AIR FILTER
BYPASS SW.
E1
8
J1201-1
0
D C B A
1
2
Faulty scavenge air solenoid valve.
Replace scavenge air solenoid.
Faulty wiring.
Test and repair wiring (Ref. Sec.

960000).
SP20
B 7A
B A
SP20
6
J1201-1
1
F E G
P1154B2
2
P1154C22
N
P1008B2
2
P1150A22
N
P20
6
A
CR208
E1
8
SCAV AIR
SOLENOID
B
6G71-078
Figure 101. Air Intake and Particle Separator Circuits Wiring Diagram
71-10-60
Page 101
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 102
Revision 44
71-10-60
MAINTENANCE MANUAL
CSP-HMI-2

1. Particle Separator Replacement
(Ref. Figure 401)
A. Particle Separator Removal
(1). Remove left and right particle separator
access panels.
(3). Remove bolts, washers and solenoid

valve.
B. Scavenge Air Solenoid Valve Installation
(1). Install solenoid valve with bolts and
(2). Disconnect left and right bleed air

tubes from particle separator.
(2). Connect tube nuts to solenoid valve.

Torque tube nuts to 110 - 130 inchpounds (12.42 - 14.68 Nm).
(3). Remove screws and washers attaching

left and right ejectors to particle
separator.
(3). Attach electrical connector to solenoid

valve.
(4). Remove screws and washers and lift

particle separator from top of engine
inlet frame.
B. Particle Separator Installation
3. Air Filter Bypass Switch Replacement

A. Air Filter Bypass Switch Removal
(1). Detach electrical wires at splices.
(2). Disconnect tube nut from switch.
(1). Install particle separator on top of

engine inlet frame with screws and
washers. Torque screws to 20 - 25
(2). Attach left and right ejectors with
screws and washers. Torque screws to
20 - 25 inch-pounds (2.25 - 2.82
Nm).
(3). Connect left and right bleed air tubes to
particle separator. Torque particle
separator tube nuts to 460 - 500
inch-pounds (51.96 - 56.48 Nm).
(4). Install left and right particle separator
access panels. Torque screws to
(3). Remove jam nut, washer and switch.

B. Air Filter Bypass Switch Installation
(1). Install switch with jam nut and washer.
Torque jam nut to 65 - 80 inchpounds (7.34 - 9.03 Nm).
(2). Connect tube nut to switch. Torque nut
to 25 - 35 inch-pounds (2.82 - 3.95
Nm).
(3). Attach electrical wires with splices.
4. Bypass Door Assembly Replacement
A. Bypass Door Assembly Removal
2. Scavenge Air Solenoid Valve

Replacement
(1). Remove cotter pin and clevis pin and

disconnect bypass door linkage.
(Ref. Figure 401)
(2). Drill out rivets and remove bypass door

assembly.
A. Scavenge Air Solenoid Valve Removal
B. Bypass Door Assembly Installation
(1). Detach electrical connector from

solenoid valve.
(1). Install bypass door assembly with

rivets.
(2). Disconnect tube nuts from solenoid

valve.
(2). Connect linkage with clevis pin and

cotter pin.
71-10-60
Page 401
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
5. Bypass Door Cable Assembly

Replacement
(2). Remove access door from side of

particle separator.
A. Bypass Door Cable Assembly Removal
NOTE: There area eight rivets securing the
(1). Remove cotter pin and clevis pin from

bellcrank and cable end.
manifold in place. Four rivets secure the

flange and four rivets, two per side, secure
the tubes.
(2). Disconnect mounting clamps and

remove cable assembly.
B. Bypass Door Cable Assembly Installation
(1). Install cable assembly and connect
mounting clamps.
(2). Install clevis pin through cable end and
bellcrank. Safety clevis pin with cotter
pin.
6. Bypass Door Seal Repair
(1). Drill out rivets attaching door stop and
seal to frame. Remove door stop with
seal.
(2). Remove damaged seal.
(3). Clean faying surfaces.
(4). Install new seal on door stop.
(3). Remove rivets securing manifold and

remove from particle separator.
Debris left in particle separator
must be removed to prevent
damage to engine.
CAUTION
(4). Clean area thoroughly of any metal

shavings.
(5). Thoroughly wipe rework area with
clean cloth dampened with solvent
(CM234) and allow to air dry.
(6). Install new manifold is particle separa
tor.
(a). Secure with eight CR3212-4-2 (or
equivalent) rivets wet with primer
(CM318).
(5). Install door stop and seal with rivets.

7. Particle Separator Manifold Replacement
(Ref. PA CD-01062-1D8L/R)
field replacement of the Pall Aerospace
particle separator manifold.
Item
Nomenclature
CM234
CM318
CM425
Primer
Sealing compound

CAUTION
(1). Remove particle separator (Ref. Particle

Separator Replacement).
Page 402
Revision 29
71-10-60
CAUTION
Ensure rivets are properly

installed to prevent damage to
engine.
(b). Thoroughly clean heads of rivets and
surrounding area with solvent
(CM234) and allow to air dry.
(c). Apply a small amount of sealing
compound (CM425) to seal rivet head
to particle separator.
(d). Allow sealing compound to cure
before reinstalling particle separator
on helicopter.
(7). Reinstall access door on side of particle
separator.
(8). Remove cover from engine inlet.
(9). Reinstall particle separator (Ref.
Particle Separator Replacement).
MAINTENANCE MANUAL
CSP-HMI-2
WASHER
EJECTOR
SCREW
PARTICLE
SEPARATOR
SCREW
EJECTOR
WASHER
REDUCER
WASHER
SCREW
MANIFOLD
TEE
WASHER (2X)
NUT
CLAMP
ELBOW
CABIN HEAT
SYSTEM
REF.
PLENUM
PLENUM
CLAMP
SCREW
(2X) WASHER
NUT
SCREW
WASHER
WASHER
SCREW
REF. STRUCTURE
SPACER
BRACKET
CLAMP
REF.
CABIN HEAT
SYSTEM
NUT
WASHER
WASHER
NUT
BOLT
REF. FIREWALL
WIRE HARNESS
SOLENOID
VALVE ASSEMBLY
BOLT
(2X) WASHER
CLAMP
TEE
BRACKET ASSEMBLY
6G71-062B
Figure 401. Engine Air Particle Separator Installation
71-10-60
Page 403
Revision 29
MAINTENANCE MANUAL
CSP-HMI-2
DOOR ASSEMBLY
SEAL
HINGE
(2 PLCS)
SEAL
DOOR SHOWN OPEN
COTTER PIN
DIFFERENTIAL
PRESSURE SWITCH
RIVET (3 PL)
PIN
PIVOT
REF. FRAME
BELLCRANK
GROMMET
COTTER
PIN
CABLE
ASSEMBLY
TUBE ASSY
RIVET (4 PL)
PIN
REF. HINGE
COTTER PIN
CRANK
PIN
LINK
Figure 402. Bypass Door Installation

Page 404
Revision 29
71-10-60
6G71-068A
MAINTENANCE MANUAL
CSP-HMI-2

INSPECTION/CHECK
1. Engine Air Particle Separator Inspection
(1). Visually inspect particle separator for
damage and security of installation.
(a). Inspect particle separator panel for
damage to axial flow dust separator
tubes. No damage allowed.
(b). Inspect particle separator for security
of installation. Torque or replace
loose or missing hardware.
(c). Open access panels and inspect bleed
air tubes for security. Torque tube
nuts.
(d). Inspect ejectors for security. Torque
or replace loose or missing hardware.
(2). Visually inspect bypass door for damage
and security of installation.
(a). Open bypass door and inspect seal for
damage or leakage. None allowed.
(b). Inspect bypass door for security of
installation. Torque or replace loose
or missing hardware.
(3). Visually inspect air filter bypass switch
for damage and security of installation.
2. Bypass Door Inspection

(1). Visually inspect bypass door stop for
damage to seals. Replace damaged
seals.
(2). Inspect bypass door hinges for opera
tion and security. Replace or repair as
required.
3. Bypass Door Cable Inspection
(1). Visually inspect bypass door cable for
operation and security. Replace inoper
able cable. Torque or replace loose or
missing hardware.
(2). Visually inspect linkage for cracks,
deformation and security of hardware.
Replace damaged linkage. Replace
missing hardware.
4. Air Pressure Sensing Switch Calibration
Check
(1). Assemble test equipment (Ref.
Figure 601).
(2). Attach pressure switch to test equip
ment. Connect a suitable vacuum
source to pressure switch nipple and
u-tube.
(a). Inspect switch for security. Torque

loose hardware.
(3). Connect an ohmmeter or continuity

tester to pressure switch electrical
leads.
(b). Inspect electrical wiring for chafing

or cuts. None allowed. Ensure
connections are secure.
(4). Cycle switch from open to close several

times with vacuum. Watch meter for
indication of switch closure. Release
vacuum.
(4). Visually inspect scavenge air solenoid

valve for damage and security of
installation.
(a). Inspect solenoid valve for security of
installation. Torque or replace loose
or missing hardware.
(b). Inspect electrical wiring for chafing
or cuts. None allowed. Ensure
connections are secure.
(5). Slowly apply vacuum. Note u-tube

water height differential in both legs of
the tube relative to the switch closing
point. The total of the differential
heights of both legs of the u-tube is
equal to switch actuation pressure.
(6). Switch closing pressures shall be per
the applicable particle separator
installation dash number shown (Ref.
Figure 601).
71-10-60
Page 601
Revision 29
MAINTENANCE MANUAL
CSP-HMI-2
TO R.H. FAIRING
SUCTION SOURCE
HOSE TEE
POWER LEAD
RETURN LEAD
24 IN (61 CM)
SCALE
OHMMETER OR
CONTINUITY
TESTER
24 IN (61 CM)
STRAIGHT
SECTION
12 IN (30.5 CM)
H2O STATIC
HEIGHT
OPEN
2.0
CLOSE
18.500.25
TYGON TUBING (OR EQUIVALENT)

BENT AND FILLED WITH H2O TO
STATIC HEIGHT AS SHOWN
G71-1029A
Figure 601. Air Pressure Sensing Switch Calibration Check

Page 602
Revision 33
71-10-60
MAINTENANCE MANUAL
CSP-HMI-2
Section
712000
Engine Mounts
(250C20B,
250C20R/2,
250C30 and
250C47)
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE MOUNTS
1. Description
(1). The engine is bolted to the helicopter
airframe with one lower and two upper
tubular steel, welded mount assem
blies. Engine loads are transferred
through the mounting system into the
airframe through six fittings and
special attaching fasteners. Left and
right upper engine mount assemblies
effect engine-transmission alignment
and may be adjusted by means of
threaded fittings that are a part of each
mount leg.
CAUTION
D Engine-transmission alignment shall be
inspected and adjusted whenever one or
more of the engine mount assemblies is
replaced or the existing adjustment is dis
turbed.
D Do not remove engine mounts to remove
the engine.
D Unless otherwise required, remove and

replace only one engine mount at a time.
D Do not disturb adjustable engine mount
fittings unless an engine-transmission
alignment check is planned.
D Use box-end and socket wrenches on
mounting system hardware. Do not nick
or scratch any of the mounting system
fasteners.
2. Airframe Fittings
(1). Airframe-engine mount structural
attach fittings and hoist fitting are
removed or replaced per the Structural
Repair Manual (SRM).
NOTE: Structural attach fittings shall not be

removed unless structural damage is evi
dent or engine-transmission misalignment
is suspected as a result of a damaged struc
tural fitting. Prior to attempting fitting re
placement perform an engine-transmission
alignment check per the SRM.
71-20-00
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CSP-HMI-2
MAINTENANCE MANUAL
Page 2
Revision 44
71-20-00
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE MOUNTS
1. Airframe Fittings Replacement
Remove/install airframe structural attach
fittings only if structural damage is present
per the Structural Repair Manual (SRM).
2. Lower Engine Mount Replacement
(250C20/C20R/2)
A. Lower Engine Mount Removal
(250C20/C20R/2)
(Ref. Figure 401)
Item
Special Tools
Nomenclature
ST402
Engine hoist
(1). Remove hardware attaching air duct

support bracket to overhead engine
hoist fitting.
(2). Install engine hoist (ST402). Back off
mount nuts 1/2 turn. Tension hoist to
relieve engine weight on lower mount
until bolts will turn freely.
(3). Release cargo compartment trim and
upholstery to gain access to bolt-heads
at bulkhead fitting.
(4). Disconnect left and right forward ends
of lower engine mount. Discard both
nuts.
(5). Detach lower engine mount from engine
fitting.
B. Lower Engine Mount Installation
(250C20/C20R/2)
(Ref. Figure 401)
NOTE: All engine mount fitting bolts, washers

and nuts are corrosion resistant steel.
(1). Install lower engine mount on bulkhead
fittings with two bolts, four washers
and two new nuts.
(2). Install engine-mount attach bolt and
washer. Torque bolt to 100 - 140
inch-pounds (11.30 - 15.82 Nm);
Lockwire installation.
(3). Torque airframe fitting hardware at
firewall to 50 - 70 inch-pounds (5.56
3. Upper Engine Mounts Replacement
(250C20/C20R/2)
A. Upper Engine Mounts Removal
(250C20/C20R/2)
(Ref. Figure 401)
(1). On upper right engine mount; unclamp
and move wire harness.
(2). Remove gear case cooling duct clamp
from left engine mount.
(3). Disconnect upper mount forward attach
points from airframe fittings. Discard
nuts.
(4). Disconnect aft ends of mounts from
engine fittings.
B. Upper Engine Mounts Installation
(250C20/C20R/2)
(Ref. Figure 401)
Do not tighten airframe-mount
bolts until engine fitting-mount
bolt is tightened.
CAUTION

CAUTION
D Do not tighten airframe-mount bolts un
til engine fitting-mount bolt is torqued.
D If a new engine-mount fitting has been
installed; retorque engine-mount attach
bolt after 3 to 5 hours of flight time.
(1). Install two bolts, four washers and two

new nuts to fasten mounts to airframe
fittings.
NOTE: Retorque engine attach bolt after 3 to 5

hours flight time following a new engine
mount fitting installation.
71-20-00
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MAINTENANCE MANUAL
CSP-HMI-2
ENGINE HOIST
FITTING
BULKHEAD SPLICE
FITTING
FIREWALL BULKHEAD
STA 124.00
BULKHEAD SPLICE
FITTING
LOWER ENGINE
MOUNT
LOWER ENGINE
MOUNT ATTACH
FITTING
LOWER ENGINE MOUNT - INSTALLATION
ENGINE
FITTING
UPPER ENGINE
MOUNT ASSY
AIRFRAME
FITTING
LANDING GEAR
DAMPER FITTING
UPPER ENGINE MOUNT - INSTALLATION
NOTE:
THICK WASHERS ARE USED IN LOCATIONS
MARKED WITH ASTERISK (*)
Figure 401. 250C20/C20R/2 Engine Mounts and Airframe Fittings

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71-20-00
G71-2000
MAINTENANCE MANUAL
(2). Install engine-mount washer and bolt.
Torque bolt to 100 - 140 inch-pounds
(11.30 - 15.82 Nm).
CSP-HMI-2
B. LowerAft Engine Mount Installation

(250C30/C47)
(Ref. Figure 402)
(3). Torque upper engine mount fitting

hardware at firewall and landing gear
damper support to 30 - 40 inchpounds (3.39 - 4.52 Nm) plus drag
torque.
(4). Repeat the appropriate steps to install
the remaining upper engine mount.
(5). Remove engine hoist.
CAUTION

(6). Install wire harness clamp on right

engine mount.
(7). Install compressor air duct support
bracket on airframe hoist fitting. Install
gear case cooling duct clamp on left
engine mount (Ref. Sec. 71-60-00).
4. LowerAft Engine Mount Replacement
(250C30/C47)
A. LowerAft Engine Mount Removal
(250C30/C47)
(Ref. Figure 402)
Item
Special Tools
Nomenclature
ST402
Engine hoist
(1). Place ends of lower engine mount

against bulkhead fittings.
(2). Install aft engine mount as shown; use
two bolts, four washers and two new
nuts at bulkhead attach fittings.
(3). Install engine-mount attach bolt
washers and new nut. Torque nut to 95
- 110 inch-pounds (10.73 - 12.43
Nm) plus drag torque. Install cotter
pin as required.
(4). Torque airframe fitting hardware at
Sta. 137.50 to 95 - 110 inch-pounds
5. Upper Engine Mounts Replacement
(250C30/C47)
A. Upper Engine Mounts Removal
(250C30/C47)
(Ref. Figure 402)
(1). Remove hardware attaching upper

cooling air duct support bracket to
overhead engine hoist fitting.
(2). Install engine hoist (ST402). Back off
mount nuts 1/2 turn. Tension hoist to
relieve engine weight on aft mount
until bolts will turn freely.
(3). Detach aft engine mount from engine
fitting.
(4). Disconnect left and right forward ends
of aft engine mount. Discard nuts.
(1). Remove gear case cooling duct clamp

from left side engine mount.
(2). Disconnect upper mount forward attach
points from airframe fittings. Discard
nuts.
(3). Disconnect aft ends of mounts from
engine fittings.
B. Upper Engine Mounts Installation
(250C30/C47)
(Ref. Figure 402)
71-20-00
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CSP-HMI-2
MAINTENANCE MANUAL
CAUTION

(1). Install two bolts, four washers and two
new nuts to fasten mounts to airframe
fittings.
Page 404
Revision 34
71-20-00
(2). Install engine-mount washer and bolt.

Torque bolt to 220 - 360 inch-pounds
(24.86 - 40.67 Nm); lockwire bolt.
(3). Torque upper engine mount fitting
hardware at firewall and landing gear
damper to 60 - 85 inch-pounds (6.78
(4). Repeat the appropriate steps to install
the remaining upper engine mount.
(5). Remove engine hoist.
(6). Install gear case cooling duct clamp on
left engine mount.
MAINTENANCE MANUAL
UPPER ENGINE
MOUNT FITTING
(REF. SEC. 71-20-00)
CSP-HMI-2
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. Model 250C30/C47 Engine Mounts and Airframe Fittings
71-20-00
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MAINTENANCE MANUAL
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71-20-00
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE MOUNTS
INSPECTION/CHECK
1. Engine Mounts and Fittings Inspection
(1). Inspect painted surfaces of engine
mounts for condition.
(2). Inspect all engine mount tubes for
straightness. Hold steel straight edge
against tubes to reveal any warps or
bends in tubes.
(3). Check that jam nuts and lockwire on
mounts with adjustable fittings are
secure and not disturbed. If not secure
or adjustment is disturbed, a check of
engine-to-transmission alignment is
required per the Structural Repair
Manual (SRM).
(4). Visually inspect all tubes and welded
joints for cracks and evidence of
corrosion. Magnetic-particle inspect
suspected engine mount assemblies. If
crack(s) are evident, mount is unser
viceable.
(5). Inspect flanges and bosses of engine
mount fittings and lifting eye for
flatness, cracks and corrosion. Replace
defective fittings.
(6). Inspect threaded steel insert for
damaged threads, corrosion and for full
bottoming to seat of insert hole.
2. Upper Engine Mounts Adjustment
NOTE: Do not disassemble upper engine

mounts except for spares replacement or
magniflux inspection.
(1). Engine realignment is required when:
(a). Mount assembly is from another
helicopter.
(b). One upper mount has been replaced.
(c). One upper mount adjustment has
been disturbed.
(2). Check engine-transmission alignment
per the Structural Repair Manual
(SRM) and realign a reassembled or
cannibalized mount assembly.
(3). Engine transmission realignment is
accomplished by adjusting the upper
engine mounts using the tool specified
by SRM instructions and as follows:
(a). Adjust mounts to align engine with
transmission. Tighten jamnuts and
recheck alignment.
(b). Lockwire jamnuts.
(c). Paint a slippage mark across both
jamnuts on each leg.
71-20-00
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MAINTENANCE MANUAL
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71-20-00
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE MOUNTS
REPAIRS
1. Engine Mount Repairs
Accomplish minor repairs as instructed below;
otherwise, replace defective engine mounts
that are cracked, twisted, bent or exceed
acceptable attach hole tolerances.
2. Mount Hole Repair (250C20/20R/2)
Upper engine mounts incorporate close
tolerance holes. Hole tolerances must be
maintained within limits to get correct
engine-transmission alignment.
(1). Engine attachment hole diameter
normally is 0.3122-0.3132 inch
(7.92988-7.95528 mm).
(2). Ream a damaged hole to 0.3170 inch
(8.0518 mm) diameter maximum.
(3). Perform an engine-transmission

alignment check per the Structural
Repair Manual (CSP-SRM-6).
(4). A repaired mount shall be replaced
when engine-transmission misalign
ment occurs as a result of repair.
NOTE:
D Drilling one mount hole to the maximum
0.3170 inch diameter does not normally
cause misalignment beyond tolerance.
D If both mounts are reworked, enginetransmission alignment must be checked.
3. Painted Surfaces Repair
(1). Repaint otherwise undamaged surfaces
as necessary (Ref. Sec. 20-30-00).
71-20-00
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MAINTENANCE MANUAL
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71-20-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
713000
Engine Ignition
Control System
(250C20B,
250C20R/2 and
250C30)
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE IGNITION CONTROL SYSTEM

1. Engine Ignition System Description and
Operation
(1). The engine ignition system consists of
switches, wiring, ignition exciter and an
igniter plug.
(2). Engine ignition power may be provided
by the helicopter battery or external
auxiliary power as selected by battery
switch position. Later helicopters are
equipped with a standard start circuit
breaker that may be installed on earlier
machines.
CAUTION
Refer to the Pilot's Flight Manu

al for specific engine start proce
dures.
Secondary ignition circuit
WARNING voltage is lethal. Set battery
switch OFF, disconnect battery and ex

ternal power before working on sys
tem. Insulate all bare wires and cable
as required.
2. Automatic Reignition System
(Ref. Figure 401) Engine automatic re-ignition
equipment is installed on all Model 369D
helicopters subsequent to S/N 1149 and all
369E/FF and 500N helicopters. The equipment
consists of a two-switch, four-lamp, indicating
latching cluster (XDS9), and a toggle switch
(S11) for operational testing of the re-ignition
system, mounted on the lower left side of the
instrument panel face. Relays K104 and K304,
and a diode isolator assembly (CR1 and CR2)
is located in the engine bay on the aft oleo
support fitting.
NOTE:
(3). Placing the battery switch in either
EXT PWR or BAT with the key switch
on, arms the start system. Pressing the
START switch on the collective stick
applies 24 Vdc to the starter/generator
and ignition exciter. The starter/genera
tor motors the engine gas producer to
start speed while the exciter simulta
neously provides a high voltage spark
across the igniter plug gap. At about
15% rpm, fuel is added to the sequence
by moving the throttle out of cutoff to
idle. START button release de-ener
gizes the ignition exciter and starter/
generator.
(4). See the Allison Engine Operation and
Maintenance manual for specific
ignition system maintenance informa
tion.
(5). Refer to Auto Re-ignition for wiring
data on the standard and automatic
ignition system option.
D For information relative to optional auto

matic re-ignition equipment installed on
369D helicopters prior to S/N 1150, refer
to Auto Re-ignition Initial Installation.
D For Instructions on modification to re-ig
nition equipment for full time operation
(Applicable to 369D helicopters, S/N 003 949 only), refer to Auto Re-ignition Modi
fication.
D On 369E helicopters 384 and subs, and
369FF helicopters 076 and subs auto reignition system has new design and op
erational differences.
D On 369E helicopter S/N 384 - 508, 369FF
helicopter S/N 076 - 091, and 500N heli
copters S/N 001 - 044 addition of air/
ground switch S522 and terminal boards
TB1001 and TB1003 are used. Relay
K304 and diodes CR1 and CR2 (located in
the engine bay on the oleo panel) isolators
are not used.
D On 369E helicopters 509 & subs, 369FF
helicopters 092 & subs, and 500N helicop
ters 045 & subs the air/ground switch has
been removed.
71-30-00
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CSP-HMI-2
MAINTENANCE MANUAL
(1). The Automatic re-ignition is initiated

when the Engine Power Out Warning
(EPO) Unit senses an N1 speed of less
than 55 percent or an NR speed of less
than 98 percent (369D/E model helicop
ters) or 95 percent (369FF and 500N
model helicopter).
(2). When the EPO unit senses one or both,
re-ignition relay (K104) closes, which
completes a 28 volt circuit to the
ignition exciter (SQ300), generating
high voltage across the igniter. In
addition, audible and visual warning
circuits are energized.
(3). The auto re-ignition relay is de-ener
gized when the EPO unit senses the
appropriate N1 and NR speeds.
(4). Pressing a reset button resets the
warning light circuit (relay K304
opens).
(5). Automatic re-ignition is prevented
during normal start-up and shutdown
by an NR disable switch which senses
throttle position.
Page 2
Revision 22
71-30-00
(6). Rotor/oil pressure switch S203 auto

matically arms the audio circuitry with
pressure.
(7). As the throttle is increased to the flight
idle position, the NR sensing function is
enabled after a time delay of 3.5
seconds. The NR sensing function
remains enabled until the throttle is
decreased through the ground idle
position.
(8). A re-ignition test switch, S11, provides
a ground test of the auto re-ignition
circuit. RE-IGN TEST switch S11
provides ground test of the auto
re-ignition circuit by bypassing the
main transmission pressure switch,
closing relay K104 to energize the
igniter.
(9). ENG OUT audio alarm only is disabled
when the generator switch is OFF (On
369E helicopter S/N 384 - 508, 369FF
helicopter S/N 076 - 091, and 500N
helicopters S/N 001 - 044 audio
warning is disabled by air/ground
switch S522).
MAINTENANCE MANUAL
CSP-HMI-2

FAULT ISOLATION
1. Engine Ignition System Fault Isolation
(Ref. Table 101)
Before removing or install
WARNING ing components of the elec
trical system, ensure all electrical pow
er is OFF. Serious injury or death can
result from voltage potentials in the ig
nition exciter. Voltages in other electri
cal system components can injure per
sonnel.
NOTE: All troubleshooting presumes wire seg

ment continuity checks for OPEN or
SHORT circuit conditions have been com
pleted and indicator lamps are known to be
good.
Table 101. Ignition System Fault Isolation

Symptom
Engine will not start (starter
operation normal)
Starter/generator does not motor

engine when START switch is
pressed
Probable Trouble
Corrective Action
Oil fouled igniter plug
Attempt a second start.
Faulty ignition circuitry
Listen for spark igniter operation.

Check for fuel vapor from exhaust.
No power to ignition exciter due to

faulty key switch, start switch or
wiring
Replace defective switch or wiring.
Spark igniter fouled, grounded or

open
Clean or replace igniter plug.
Faulty high tension lead
Replace lead.
Igniter plug firing intermittently
Check exciter input voltage. Install

an operational exciter and test
ignition system.
Circuit breaker open
Reset/replace circuit breaker.
Low battery voltage
Crank engine with an APU or charge

battery.
Defective start relay
Replace relay.
71-30-00
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MAINTENANCE MANUAL
CSP-HMI-2
2. Automatic Reignition System Fault

Isolation
(Ref. Table 102 and Table 103)
Before removing or install
WARNING ing components of the elec
trical system, ensure all electrical pow
er is OFF. Serious injury or death can
result from voltage potentials in the ig
nition exciter. Voltages in other electri
cal system components can injure per
sonnel.
NOTE: All troubleshooting presumes wire seg

ment continuity checks for OPEN or
SHORT circuit conditions have been com
pleted and indicator lamps known to be
good.
Table 102. Automatic Reignition System Fault Isolation (369D)

Symptom
Probable Trouble
Corrective Action
Defective lamp
Replace lamp XDS9.
Defective switch XDS9
Replace indicator switch XDS9.
Defective relay K304
Replace relay K304.
Start relay (K301) is energized

during automatic reignition
Diode CR2 defective, or START

switch (S106) closed
Replace diode CR2 or diode isolator

assembly or check START switch
and wiring for short circuit.
Equipment fails to function with 28

Vdc present at terminals D and E
of terminal board TB5033 and
ARMED lamps illuminated
Relay K104 defective
Replace relay K104.
ARMED lamps not illuminated and

equipment fails to function with 28
Vdc at terminals D and E of
terminal board TB5033
Switch S11 defective
Replace switch S11.
ARMED lamps not illuminated, but

equipment functions
Relay K304 and/ or lamps

defective
Replace lamps and/or relay K304.
ARMED and REIGN lamps

illuminated, 28 Vdc present at
terminal 1 of diode CR1, but less
than 26 Vdc at terminal 2 of diode
CR1 and automatic reignition fails
Diode CR1 defective
Replace diode CR1 or diode isolator

assembly.
System functions normally, but

REIGN lamps do not illuminate
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71-30-00
MAINTENANCE MANUAL
CSP-HMI-2
Table 103. Automatic Reignition System Fault Isolation (369E/FF 500N)

Symptom
Probable Trouble
REIGN TEST switch ON, REIGN Faulty diode CR1

P RST indicator lit, 28 Vdc present
at pin 1 of CR1 (diode isolator
assembly) but less than 28 Vdc
present at pin 2 of CR1. Automatic
reignition does not occur
REIGN TEST switch ON, 28 Vdc
present at pin L of TB5039.
Automatic reignition does not
occur
Replace diode or diode isolator

assembly.
Faulty reignition relay K104
Faulty REIGN TEST switch S11

REIGN TEST switch ON, 28 Vdc
present at pin 6 of TB50310.
Automatic reignition does not
occur and REIGN P RST indicator
does not light
Auto reignition system functions
normally but REIGN P RST
indicator does not light
Corrective Action
Replace reignition relay K104.
Replace REIGN TEST switch S11.
Defective lamp
Replace lamp XDS9.
Defective switch XDS9S2
Replace indicator switch XDS9.
Defective relay K304
Replace relay K304.
71-30-00
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CSP-HMI-2
MAINTENANCE MANUAL
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Revision 44
71-30-00
MAINTENANCE MANUAL
CSP-HMI-2

1. Automatic Reignition System
Component Replacement
(Ref. Figure 401 thru Figure 403) Replace
affected components of the automatic re-igni
tion system as indicated in the following
procedures.
Ensure all electrical power
WARNING is OFF during removal and

replacement of electrical components.
Lampholder assembly has a po

larizing key, and can only be in
stalled one way. Do not attempt to force it to
seat.
CAUTION
(4). Insert new lamp into lampholder and

reinstall lampholder assembly into
housing.
D. Armed Lights/Switch (XDS9) Display
Screen Replacement
A. Automatic Reignition Test Switch (S11)

Replacement
(1). Pull screen and lampholder assembly

out of housing.
Replace switch per Control Switches Replace

ment (Ref. Sec. 96-30-00).
(2). Remove screen by sliding it to left or

right.
B. Armed Light/Switch (XDS9) Assembly

Replacement
(1). Remove four screws and washers
securing adapter plate to instrument
panel.
(2). Pull entire assembly away from panel.
(3). Remove nut, washer and screw secur
ing clamp to switch and push housing
through adapter plate.
(4). Hold switch with one hand and housing
with other hand and apply breakaway
pressure to force two spring fingers on
housing to release switch.
(5). Remove wires from defective compo
nents and reconnect to replacement
component as required.
(6). Reassemble components in reverse
order of disassembly.
C. Armed Light/Switch (XDS9) Lamps
Replacement
(1). Pull display screen and lampholder
assembly out of housing.
(3). Slide replacement screen into position.

Lampholder assembly has a po
larizing key, and can only be in
stalled one way. Do not attempt to force it to
seat.
CAUTION
(4). Re-insert screen and lampholder

assembly into housing.
E. K104/K304 Relay Replacement
Replace relays K104 and/or K304 as follows:
Item
Nomenclature
CM815
Solder
(1). Remove nuts, four washers and two

screws attaching relay to mounting
bracket.
(2). Pull relay forward until wiring at back
of relay is accessible.
(3). Note location of each wire and remove
from back of relay.
(2). Slide defective lamp out of lampholder.
(4). Using solder (CM815) connect wires to

new relay.
(3). Remove filter from defective lamp and

slip it over glass envelope of new lamp.
(5). Reinsert wiring and relay, and attach to

bracket with screws, washers and nuts.
71-30-00
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MAINTENANCE MANUAL
CSP-HMI-2
F. CR1/CR2 Diode Replacement
Item
CM313
Nomenclature
Insulation varnish

(2). Remove lead wire from diode to be
replaced by removing nut, two washers
and screw.
(3). Remove nut, lockwasher and terminal
(CR1) from diode. Holding flat washer,
mica washer, and insulating ring under
bus, remove diode and mica washer
from opposite side of bracket. Remove
washers and ring from under bus.
(4). Install mica washer on threaded end of
replacement diode and hold insulating
Page 402
Revision 22
71-30-00
ring, mica washer and flat washer in

place between bus and bracket.
(5). Insert threaded end of diode through
bracket, ring, washers and bus. Install
terminal (CR1 only) and lockwasher on
threaded end of diode and secure with
AN316-4 nut. Do not use nut supplied
with diode.
(6). Reinstall terminal on diode with screw,
two washers and nut.
(7). Perform operational test of system
(refer to applicable Pilot's Flight
Manual.
(8). After successful test, apply glyptol
(CM313) to exposed threads and tip of
new diode.
(9). Close and secure engine access doors.
MAINTENANCE MANUAL
CSP-HMI-2
INSTRUMENT
PANEL
INST. CB101
ENG. OUT CB106
CIRCUIT BREAKER
PANEL
AUTO RE-IGNITION
(NOTES 2, 3)
RE-IGNITION PANEL
(NOTE 1)
LOWER SWITCH AND CIRCUIT

BREAKER PANEL
INSTRUMENT PANEL (SLIM LINE)
RELAY
K304
RELAY
K104
BRACKET
(NOTES 1, 2)
RELAY
K103
RELAY
K304
REAR VIEW (NOTE 3)
RELAY
K104
NOTES:
1. EFFECTIVE SHIPS 369D SERIAL NOS. 3 THRU 949.
2. EFFECTIVE SHIPS 369D SERIAL NOS. 950 THRU 1148.
3. EFFECTIVE SHIPS 369D SERIAL NOS. 1150 AND SUBS
(WITH AUTO RE-IGNITION INSTALLED).
4. EFFECTIVE SHIPS 369E/FF - 500N.
5. EFFECTIVE SHIPS 369FF ONLY.
6. SWITCH ASSEMBLY ARRANGEMENT VARIES WITH
HELICOPTER MODEL.
7. EFFECTIVE 369E, 001 THRU 383; 369FF, 001 THRU 075.
8. EFFECTIVE 369E, 384 AND SUBS; 369FF, 076 AND SUBS;
500N, 001 AND SUBS.
9. NOT USED ON 369E, 384 AND SUBS; 369FF, 076 AND SUBS;
500N, 001 AND SUBS.
G96-1005-1A
Figure 401. Auto Reignition System Equipment (Sheet 1 of 3)
71-30-00
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MAINTENANCE MANUAL
CSP-HMI-2
RE-IGN PRST
WARNING LT
(NOTE 5)
RE-IGN PRST
WARNING LT
10
120
110
100
90
80
70 60
RE-IGN
TEST SWITCH
20
30
40
50
K104
(NOTE 7)
6 ALTITUDE
5 4
EDGE-LIGHTED PANEL-TOP VIEW

(NOTE 4)
SWITCH
XDS9
ANTI-COLL
LT
PITOT
HTR
OFF
SCAV
AIR
OFF
POS
LTS
ANTI-ICE
UTIL
PWR
OFF
OFF
OFF
OFF
START PUMP
RE IGN
TEST
HOUSING
PULL
FOR
AIR
OFF
OVSPD FAULT
TEST
TEST
OFF
OFF
SCREEN
ASSEMBLY
RE-IGN
TEST SWITCH
CIRCUIT BREAKER
PANEL
PNL LT
CB104
ENG. OUT
CB106
INSTRUMENT PANEL
(NOTE 4)
SWITCH
S11
SUPPOR
T
RE-IGNITION
SWITCH ASSY XDS9
(TYPICAL) (NOTE 6)
RE-IGNITION PANEL
(369D294201-705)
RELAY
K204
RE-IGNITION PANEL
(369D294201-703)
RELAY
K304
RELAY
BRACKET
TB501
MODULE (NO. 20)
INSTRUMENT T-PANEL
(WITH CENTER CONSOLE)
TB502
CENTER CONSOLE (RIGHT SIDE)

(NOTES 1, 2)
G96-1005-2

Page 404
Revision 22
71-30-00
MAINTENANCE MANUAL
CIRCUIT BREAKER
PANEL 369H92143
DE-ICE
TRIM
N2
GOV
ENG
CYCLIC
START
CARGO
CIG
HOOK
LTR
AUTO
RE-IGN
ENG
AUTO
ATT
TRIM
TEST
OUT
N2
GOV
ENG
ENG
CYCLIC START
OUT
DIR
RE-IGN
LDG
LIGHTS
ANN
HOVER
PANEL
COVER EXISTING MARKINGS

WITH BLACK DECALS
INST
GYRO
AUTO
COVER EXISTING
MARKINGS WITH
BLACK DECALS
RE-IGN
AUTO RE-IGN
XPDR
GYROS
CIRCUIT BREAKER
PANEL 369D294566
ENG. OUT
CB105
ENG. OUT
CB106
HEAT
CSP-HMI-2
ADF
ICS
TOW
ANN PANEL
CB104
CENTER CONSOLE PANEL
(WITH T-SHAPE INSTRUMENT PANEL)
VHF
UHF
VHF
FM
AM
AM
LDG
LIGHTS
ANN
INST
HOVER
PANEL
ADD AUTO
RE-IGN DECAL
INST
CB124
ANN PANEL
CB123
K104
TB1001
IGNITER
TB1003
TERMINAL BOARD AND RELAY
ASSEMBLY
IGNITION
EXCITER
J1201
STATION
137.50
WIRE BUNDLE
TB200
WIRE
BUNDLE
ENGINE POWER OUT
DIODE ISOLATOR
ASSEMBLY
(CR1, CR2)
(NOTES 7, 9)
TO
P303
START RELAY
(K301)
BATTERY COMPARTMENT (NOTE 8)
OLEO
SUPPORT
FITTING
LOWER
RING
SECTION
SP17
ENGINE COMPARTMENT
SP18
G96-1005-3
71-30-00
Page 405
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
P19 ENGINE OUT WARNING

B
N
SP71
A
E25
S199
AUTO RE-IGN TEST
CB106
DISABLE SW
NO
2 OUT
1
J616 P616
3
(NOTE 3)
J615 P615
STOW
PUSH TO RESET
1
1
D
C
2
2
2
2
A
B
1
NC 1
C
4
6
S11
5A
6
(NOTE 3)
E
A
REF SEC
95 - 00
ARMED
GROUND
N TACH IN
1
TACH IN
R
AUTO RESTART
28VDC OUT
S1
RE -IGN
NC
NO
DIMMER
P12 INDICATOR
PNL
LTS
DISABLE
R
WHEN GROUNDED
TB6
S2
NO
CB104
NC
ENG
5A
1
+ 28VDC IN
P9 J9
SP70
B A
DS11
XDS9
E2
GEN OUT
+2
7
E2
TB502-13
7
-
3
XDS18
2
4
K304
A
D
J9 P9
B
8
K104
RH COMMAND WITH 389D294201-703

INSTRUMENT PANEL CONFIGURATION
5A
ENG
2 OUT
CB104
B
C
28/14 VDC
PNL
LTS
5A
TB502-20
DIMMER
P12 INDICATOR
D
DS11
1
START RELAY
IGNITION
EXCITER
IGNITER
LT COLLECTIVE
STICK(PILOT)
D
X2
ENG
J112 P112
A
START
S108
P527 IND-CAUT
2 OUT
SQ300
TB1 - 8
CB106
J303 P303
CR2

SP17
CR1
SP18
A
B
XDS18
28VDC
BUS
5A
2
S3
GEN OUT
KEY
SWITCH
TB101
CB106
3
D
J618 P618
(NOTE 3)
(NOTE 3)
J
X1
A
P526 MAST / CAUT
DS118
E13
B
A
EE
P618 J618
CB124
INST
LTS
5A
1
J617 P617
14 VDC
(IN)
2
CB123
PNL
LTS
5A
1
2
D
S6
2 NO 1C
28 VDC
(IN)
DS119
NOTES:
1. SOLID LINES (
) INDICATE WIRES
SUPPLIED WITH OPTIONAL EQUIPMENT
2. DASHED LINES (---) INDICATE HELICOPTER WIRING
OR COMPONENTS OF ELECTRICAL SYSTEM
3. RIGHT HAND COMMAND HELICOPTERS ONLY
EFFECTIVITY: 369D; 003-949, 956,

965, 977 AND 989
G96-1006-1
Figure 402. Auto Reignition Wiring Diagram (Sheet 1 of 6)

Page 406
Revision 22
71-30-00
MAINTENANCE MANUAL
CB101
P9 J9
5A
AUTO RE-IGN TEST
HOUR METER
+
-
SP38
A B
INSTR
CSP-HMI-2
SP37
A B
NO
M5
1
C
2
2
SP91
A B
A
1
C
C
LT COLLECTIVE
STICK(PILOT)
+
P112 J112
START
S106
S11
CB108
5A
B3
A3
S1
CR5
E2
X2
K104
D
CB104
REF SEC
96-10
5A
P12 DIMMER IND
PNL
LTS
TB502-13
E13
X2
X301
X1
IGNITER
GEN OUT
E
3
SQ300
XDS18
2
7
SP17
B
CR2
K304
1
SP16
E2
(NOTE 3)
KEY
SW

AUTO RESTART
28 VDC OUT
GROUND
N TACH IN
1
TACH IN
R
N DISABLE
R
WHEN GROUNDED
S3
28VDC
BUS
REF SEC
96-45
CB106
REF SEC
96-00
TB101
2
5A
+28 VDC IN
CR1
B
E2
ENG OUT
WARNING
P19
+
P303 J303
A2 X1
(NOTE 3)
REF SEC
96-10
B2
B1
NO
XDS9
IGNITION
EXCITER
NC
NO
1
D
RE -IGN
2
2
ARMED
B
1
ENG 2
OUT
NC
S2
NO
E2
CR3
A1
TB1 - 8
CR4
DS10
TB1-20
J618 P618
1
2
A
B
P618 J618
(NOTE 3)

(NOTE 3)
CB105
1
5A
1
2
SP71
E25
DISABLE
R
SWITCH
NO
C
1
S199
SP70
B
P9 J9
I
J618 P618
T
STOW
EFFECTIVITY: 369D; 950-955, 957-964, 966-976,

978-988, 990-1149,
G96-1006-2
71-30-00
Page 407
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
CB101
P9 J9
INSTR
1
5A
P19
ENG OUT
WARNING
AUTO RE-IGN TEST
CR4
CR3
4
1
1
D
RE -IGN
2
2
ARMED
B
1
NC
S2
NO
C
CB106
1
5A
2
2
TB503-5
ENG TB503-7
OUT
A
2
B
B3
B2
B1
A
B
C
D
1
C
C
A3
A2
NC
A1
S11
B3
B1
TB503-3
A3
C
A
A1
S1
B2
A2
X1
CR5
NO
X2
X1
X2
XDS9
E
K304
REF SEC
96-30
C
E
D
K104
1
S3
KEY
SW
REF SEC
96-45
TB101
1
HOUR METER
1
E15
NO
NC
REF SEC
95-30
M5
S203
A2
REF SEC
96-10
E13
A1
X2
G N DISABLE
R
WHEN GROUNDED
U AUTO RESTART
28 VDC OUT
CASE GND
REF SEC
96-10
B +28 VDC IN
E2
TB6
X301
CR2
2
IGNITION
EXCITER
P303 J303
1
START
RELAY
X1
28VDC
BUS
ROTOR OIL
PRESS SW
3
GND BUS
IGNITER
CR1
SQ300
TB1 - 8
J112
REF SEC
95-00
B
C
VOLTAGE
REGULATOR
GEN
DISABLE
SP70
A B
J113 P113
STOW
A N TACH IN
1
L N
TACH IN
DS10
LT COLLECTIVE
STICK(PILOT)
P6
F
N
5
E GROUND
START
S106
DISABLE SW
SP71
NO
B
NC
E25
S199
EFFECTIVITY: 369D; 1150, 1185 & SUBS

G96-1006-3

Page 408
Revision 22
71-30-00
MAINTENANCE MANUAL
INSTR
1
5A
CB106
1
5A
TB505-1/2
J
N
TB503-8
L
C
CB101
ENG
OUT
D
E
F
TB503-9
B
S11
RE-IGN
P RST
A
C
NC
REF SEC
95-30
M5
S203
TB503-10
G
H
J
CASE
GND
3
2
G
K
A1
A2
REF SEC
96-10
REF SEC
96-10
E13
X2
K304
6
TB10
CR51
3
L
START
RELAY
X301
X1
TB503-3
B
K104
1
S3
SP17
B A
CR1
E
D
KEY
SW
REF SEC
95-00
CR5
CR2
A
5
2
5A
E15
TB503-11
WARN
PNL
LTS
XDS9
CB104
ROTOR OIL
PRESS SW
HOUR METER
TB503-4
3 NC 4
S2
C
NO
P9 J9
NO
AUTO RE-IGN
TEST
1
2
E31
CSP-HMI-2
SP70
A B
DISABLE SW
SP71
B A
NO
NC
STOW
E25
S199
J303 P303
1
SP60
A B
(NOTE 2)
14
(NOTE 2)
(NOTE 2)
(NOTE 2)
EVENTS
COUNTER
(NOTE)
P303A J303A
AUTO RESTART
U 28 VDC OUT
B +28 VDC IN
IGNITER
SQ300
G N DISABLE
R
WHEN GROUNDED
IGNITION
EXCITER
E33
IGNITER
SQ301
IGNITER
ENG OUT
WARNING
P19
E GROUND
SQ300
REF SEC
95-00
LT COLLECTIVE
STICK(PILOT)
J113 P113
P6
F
VR1
EFFECTIVITY:
3
369E;
TACH IN
DS10
B
C
GEN
DISABLE
5
VOLTAGE
REGULATOR
L N
J112
TB1-6
D
A N TACH IN
1
START
S106
NOTES:
1. REFER TO MANUFACTURER'S INSTRUCTION
MANUAL, TABLE 201, SEC. 01-00
2. 369FF MODEL HELICOPTERS ONLY
001-38
G96-1006-4
71-30-00
Page 409
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
ENG OUT
CB106
B
F
PNL LTS
CB104
NO
XDS21
C
NC
G
T
Y
TB503-2
E31
TB505-5/6
F
A
F
G
H
TB503-5
K
J
TB503-2
TB503-3/4
A
F
B
E
C
S11
(SW POSITION
SHOWN OFF)
WARN PRESS
TO TEST
G E31
E31 D
AUTO RE-IGN
TEST SW
TB503-1
P1
E
D
P2
B
C
C E38
P12
+ 28 VDC
DIMMER
S522
2
1
SP201
BA
RE-IGN
PRESS TO RESET
+ 28 VDC TEST
ENG OUT
WARN SIGNAL
NO
XDS9
C
NC
TB503-5
J L M
BA
SP200
42
P1201J
31
33
30
32
34
73
72
71
24
47
26
25
TB1003
F E G H
TB200-9
A2
A3
A1
B3
J1301P
SP70
BA
ROTOR
TACH
GEN
P19
E
F
H
G
F
E
SQ301
(NOTE 2)
IGNITION
EXCITER
SQ300
IGNITION
EXCITER
NR DISABLED
WHEN GROUNDED
N2
TACH
GEN
E37
IGNITER
PLUG
IGNITER
PLUG
+ 28 VDC FROM
START SW
S203
TB1001
4
3
CR201
XMSN OIL
PRESS SW
P306
B
A
AUTO RE-IGN 28 VDC OUT

@ 2.5 AMPS
N1 TACH IN
NR TACH IN
+ 28 VDC IN
GROUND
CASE GROUND
AUDIO DISABLE - WHEN

NOT GROUNDED
FLASHER 1 ENG OUT
E
H
J1301P
TB200-7
(NOTE 2)
P1302J
1
B2
B1
TB1001 TB200-7
R SP
L K J
10
9
CR2
TB200-7
P305
NO
BA
SP701
B
A
NC
ENGINE OUT WARNING
+28 VDC TO K308-X1

FWD LINE CONTACTOR
TO K301-X1
START RELAY
S199
TB200-9
T Z
X1
X2
SP71
BA
22G
JUMPER
8
10
TB1001
9
TB1003
TB200-8
E37
N S R
TB200-8
M5
HR METER
TB1003
8
7
K104 AUTO RE-IGN

RELAY
A B D
TB200-9
28 VDC BUS
A
B
D
TB503-5
DUAL
TACH
IND
N1
TACH
IND
AIR/GND SW
(POSITION SHOWN
ON GROUND)
E38
J
TB200-9
Revision 22
71-30-00
Page 410
NOTES:
1. APPLICABLE TO HELICOPTERS
369E S/N 384 - 508
369FF S/N 076 - 091
500N S/N 001 - 045
2. APPLICABLE TO 369FF
S/N 076 - 091 ONLY
SP81
_
AB
+ AB
SP82
NR DISABLE SW
SHOWN ACTIVATED
G96-1006-5
71-30-00
N1
TACH
IND
DUAL
TACH
IND
AUTO RE-IGN
TEST SW
3
1
GEN 5
SWT
S4 6
NC
P1
E
D
P2
B
C
S11
3
2
E31-C
C E38
G E31
E31-D
E31
NC
TB503-5
J L M
NO
SP81
AB
AB
SP82
TB505-5/6
RE-IGN
PRESS TO RESET
+ 28 VDC TEST
ENG OUT
WARN SIGNAL
XDS9
+ 28 VDC
V
S
DIMMER
P12
Y
TB503-2
TB505-5/6
TB503-5
F
G
H
TB503-3/4
F
E
J K L M
A
B
C
TB503-2
REF START/
GENERATING
SYSTEM
96-10
WARN PRESS
TO TEST
NO
XDS21
NOTES
1. APPLICABLE TO HELICOPTERS
369E S/N 509 & SUBS
369FF S/N 092 & SUBS
500N S/N 045 & SUBS
2. APPLICABLE TO 369FF
S/N 092 & SUBS ONLY
A
B
D
TB503-5
PNL LTS
CB104
TB503-1
ENG OUT
CB106
28 VDC BUS
J M
TB200-9
26
25
47
24
73
34
33
38
32
31
42
P1201J
TB1003
TB200-9
FG H
A B D
TB200-9
10
E37
N S
TB200-8
TB200-8
X1
B2
A2
SP71
AB
22G
JUMPER
TB1003
TB1001
M5
HR METER
K104 AUTO RE-IGN

RELAY
B1
NC
S199
NO
C
T Z
TB200-9
TB200-7
RSP
P1203
NR DISABLE SW
SHOWN ACTIVATED
X2
A1
B3
A3
GEN DISABLE
GENERATOR
CONTROL UNIT
AB
SP701
SP70
BA
B
A
P202
TB1001
10
9
CR2
J1301P
E
H
P19
ROTOR
TACH
GEN
IGNITER
PLUG
NR TACH IN
GROUND
CASE GROUND
NR DISABLED
WHEN GROUNDED
AUDIO DISABLE - WHEN

NOT GROUNDED
FLASHER 1 ENG OUT
+ 28 VDC IN

@ 2.5 AMPS
N1 TACH IN
N1
TACH
GEN
E37
S203
CR201
TB1001
4
3
ENGINE OUT WARNING
B
A
P305
XMSN OIL
PRESS SW
J1301P
F
E
SQ300
IGNITION
EXCITER
IGNITER
PLUG
TB200-7
E
F
+ 28 VDC FROM
H
START SW
G
+28 VDC TO K308-X1

FWD LINE CONTACTOR
TO K301-X1
START RELAY
TB200-7
L K M J
(NOTE 2)
P1302J
1
SQ301
(NOTE 2)
IGNITION
EXCITER
MAINTENANCE MANUAL
CSP-HMI-2
G96-1006-6A
Page 411
Revision 43
MAINTENANCE MANUAL
CSP-HMI-2
28 VDC BUS
CB106
INSTR
CB101
ENG OUT
XDS9
J
TB505 1/2
H
CR1
K304
PRESS TO TEST
+
IGNITION
EXCITER
AUTO REIGN
RELAY
HR
METER
K104
M5
_
SQ300
A
CR51
B
IGNITER
PLUG
AUTO REIGN
SW S11
P19
ENGINE POWER OUT BOX
AUTO RESTART 28 VDC/.5 A OUT
28 VDC IN
EFFECTIVITY: 369D; ALL

369E; 001-383
369FF; 001-075
G96-1009-1
Figure 403. Auto Reignition Schematic (Sheet 1 of 3)

Page 412
Revision 22
71-30-00
MAINTENANCE MANUAL
CSP-HMI-2
TB505-3/4
28 VDC BUS
XDS9
CB106
ENG
OUT
A3
A2
A1
B2
IGNITION
EXCITER
SQ300
B1
NC
IGNITER
PLUG
B3
PRESS TO TEST
(NOTE 2)
IGNITION
EXCITER
SQ301
10
TB1001
IGNITER
PLUG
CR2
REF START
GENERATING
TB1001
4
CR201
P19
X1
K104
AUTO
RE-IGN
RELAY
NR DISABLED WHEN
GROUNDED
S11
TB1001
A
X2
ENG POWER OUT BOX
TB505-5/6
M5
S203
NO
HR METER
XMSN OIL
PRES SW
DS105
2
5
1
2
REF SEC
96-00
(N1/NR TACH'S)
AUTO RE-IGN
TEST SWITCH
NC
_
WARN
HORN
+
S522
3
TB1003
1
DIMMER
AIR GND
SWITCH
NR DISABLE
S199
C
NO
NC
(SWITCH POSITION
SHOWN - ACTIVATED)
P12
AUDIO DISABLE WHEN

NOT GROUNDED
FLASHER 1 ENG OUT
DS14
S
C
ENG OUT
NOTES:
1. EFFECTIVITY; 369E;
369FF;
500N;
2. EFFECTIVITY: 369FF;
28 VDC IN
384-508
076-091
001-044
076-091 ONLY
G96-1009-2C
71-30-00
Page 413
Revision 26
MAINTENANCE MANUAL
CSP-HMI-2
TB505-3/4
28 VDC BUS
XDS9
GENERATOR
CONTROL UNIT
CB106
P1203
GEN DISABLE
ENG
OUT
A3
A2
A1
B2
IGNITION
EXCITER
SQ300
B1
NC
IGNITER
PLUG
B3
PRESS TO TEST
(NOTE 2)
IGNITION
EXCITER
SQ301
10
TB1001
IGNITER
PLUG
CR2
TB1001
4
CR201
REF START
GENERATING
P19
X1
K104
8
9
AUTO
RE-IGN
RELAY
TB1001
TB1003
10
X2
TB505-5/6
REF START/
GENERATING
SYSTEM
96-10
TB505-5/6
ENG POWER OUT BOX
M5
NO
DS105
2
NC
NR DISABLED WHEN
GROUNDED
S11
XMSN OIL
PRES SW
3
2
S203
HR METER
U
5 GEN
SWT
6
S4
1
6
WARN
HORN
2
5
4
+
REF SEC
96-00
(N1/NR TACH'S)
AUTO RE-IGN
TEST SWITCH
2
TB1003
NR DISABLE
S199
NO
NC
(SWITCH POSITION
SHOWN - ACTIVATED)
DIMMER
P12
S
AUDIO DISABLE WHEN

NOT GROUNDED
FLASHER 1 ENG OUT
DS14
C
ENG OUT
B
NOTES:
1.
EFFECTIVITY 369E;
369FF;
500N;
2.
EFFECTIVITY 369FF;
28 VDC IN
509 AND SUBS

092 AND SUBS
045 AND SUBS
092 AND SUBS ONLY
G96-1009-3A

Page 414
Revision 26
71-30-00
MAINTENANCE MANUAL
CSP-HMI-2

INSPECTION/CHECK
1. Automatic Reignition System Check
(with Ground/Air Switch)
369E
369FF
500N
384 - 508
076 - 091
001 - 044
NOTE: Helicopters equipped with the ground/

air switch can be modified to eliminate the
switch (Ref. Sec. 96-10-00, Generator Con
trol Unit Upgrade to Eliminate Squat
Switch).
(1). The RE-IGN TEST switch (S11)
provides for an OFF and two test
positions; GND (up) and FLT (center).
(2). Both horn and audible warnings are
disabled by ground/air switch (S522)
when the helicopter is on the ground,
except when RE-IGN TEST switch is
placed in the GND position.
NOTE: Conducting test with engine motoring

will require pushing the RE-IGN P RST in
dicator to reset the system (Refer to appro
priate PFM for in-flight test of system).
A. Normal Start
Verify system operation of normal starting
circuit by performing a normal start as
described in appropriate Pilot's Flight Manual.
2. Automatic Reignition System Check
(without Ground/Air Switch)
369E
509 & subs
369FF
092 & subs
500N
045 & subs
Verify system operation of automatic re-igni
tion circuit as follows:
(1). Set BATTERY/OFF/EXT PWR (master)
switch to OFF.
(3). The FLT position provides a complete

in-flight systems test by simulating a
fault of the N1 input to the EPO.
(2). Connect external 28 Vdc power.
(4). Both on-ground and in-flight tests can

be accomplished by selecting GND
position.
(4). Close ENG OUT circuit breaker.
(5). On-ground test requires RE-IGN

TEST switch in the GND position.
(3). Set master switch to EXT PWR.
NOTE: Closing ENG OUT circuit breaker pro

vides power at re-ignition relay K104.
(5). Set RE-IGN TEST switch to ON.
(a). With power applied, the ENG OUT

indicator should be flashing.
(6). Verify audible spark across engine

igniter gap.
(b). Press the press-to-test button and

all warning lights should illuminate
momentarily.
(7). Verify Re-ignition indicator lights.
(c). Set RE-IGN TEST switch to GND.
(9). Press Re-ignition indicator. Verify

indicator lamps go out.
(d). Verify horn, audio warning, RE-IGN

P RST indicator is illuminated and
engine igniter firing.
(e). Return switch to OFF, the system
should reset.
(8). Set RE-IGN TEST switch to OFF.
(10). Open ENG OUT circuit breaker.

(11). Set master switch to OFF.
(12). Disconnect external power.
71-30-00
Page 601
Revision 32
CSP-HMI-2
MAINTENANCE MANUAL
Page 602
Revision 32
71-30-00
MAINTENANCE MANUAL
CSP-HMI-2

REPAIRS
1. Auto Reignition System Modification
2. Instrument Panel Modification
This section provides for modification instruc

tions of the 369H900118-513 and -515 engine
automatic re-ignition equipment (369D
helicopters S/N 003 - 949 only). These
instructions cover relocation of re-ignition
controls on the instrument panel and neces
sary rewiring to provide full-time operation of
the system.
(Ref. Figure 801)
A. Preparation for Modification

Preparing for modification of installed engine
automatic re-ignition equipment includes the
following:
(master) switch in OFF position.
(2). Disconnect wires from auto re-ignition
switches as follows:
Item
CM302
CM305
Nomenclature
Lacquer, acrylic
(1). Fabricate cover, as required, for hole

vacated by switch XDS9.
(2). Install cover on instrument panel.
(3). Install plug button on instrument
panel.
(4). Paint out lettering at previous auto
re-ignition switch location with acrylic
lacquer (CM305).
(5). Fabricate plate as follows:
(a). Remove J501A20 from circuit break

er (CB106-2) and ARM-OFF switch
(S11-1) and discard wire.
(b). Disconnect J501AE20, J502E20,
J501B20, J502A20 and J502D20 at
switch (S11).
(c). Remove ARM-OFF switch (S11) from
instrument panel.
(a). Make plate from 0.062 inch (1.5748

mm) thick aluminum alloy sheet as
shown in Figure 801.
(b). Apply one coat primer (CM302) and
dry for 1 to 2 hours.
(c). Apply topcoat of acrylic lacquer
(CM305) and air dry 4 hours mini
mum.
(d). Remove J503D20 and J503EE20

from terminal board (TB502-13A and
13C).
(6). Install plate and auto re-ignition

switches (XDS9) and (S11, PN 882GK15
- Cutler Hammer or equivalent) at new
location on instrument panel.
(e). Remove J505A20N and J508A20N

from stud (E2).
(7). Fabricate and install decal on instru

ment panel.
(f). Remove J507AA20 from terminal

board (TB502-13E).
3. Electrical System Modification

(Ref. Figure 802)
(g). Remove E559AC22 from splice

(MS25181-1).
(3). Remove relays (K304 and K104) and
switch (XDS9). Remove all wires from
relays and switch and retain relays and
switch for reuse.
(1). Revise wiring as follows:

(a). Install diode at circuit breaker
CB101.
(b). Install diodes CR3 and CR4 on
switch S11.
71-30-00
Page 801
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
(c). Install transzorb CR5 on relay K104.
(d). Rewire switches (S11 and XDS9) and

relays (K104 and K304) as shown.
(e). Reinstall relays K104 and K304 in

original position.
(2). Perform check of modified auto re-igni
tion system (refer to the appropriate
PFM).
369H6416 INSTRUMENT
PANEL ASSEMBLY
COVER (SEE VIEW D-D)

HS1957-2 SCREW NAS620A6L
WASHER MS21043 NUT
(OR EQUIVALENT)
REMOVE AUTO RE-IGN SWITCHES AND

BLACK OUT LETTERING AND COVER UP
HOLES AFTER RELOCATION
SS48152 PLUG BUTTON OR EQUIVALENT
(CARR FASTENER COMPANY)
USE EXISTING HOLE IN PANEL,

USE 6-32 X 0.50 IN. (12.7 MM) LS
SCREW AND WASHER (4 PLACES)
369H90118-105 SWITCH ASSEMBLY (RE).

EXISTING SWITCH MAY BE REWIRED
DRILL0.218-0.221 IN. (5.5372-5.6134 MM) DIA

HOLES IN PANEL TO USE TINNERMAN NUT
`Ù'' TYPE NC, C42332BE-632 OR TAP DRILL
THREADS FOR 6-32 SCREW (REF)
PLATE
882GK15 SWITCH (CUTLER HAMMER)

INSTALL DECAL (SEE VIEW E-E)
G96-1007-1A
Figure 801. Relocation of Auto Reignition Controls (Sheet 1 of 2)

Page 802
Revision 22
71-30-00
MAINTENANCE MANUAL
USE EXISTING CLAMP

AND HARDWARE
CSP-HMI-2
1.125 IN.
(2.8575 CM)
0.562 IN.
(14.2748 MM)
1.00 IN. 2.54 CM)

0.125 IN. (3.175 MM)
DIA. HOLE
0.87 IN. (22.098 MM)
MODIFY EXISTING
SUPPORT TO FIT
IF REQUIRED
1.12 IN. (2.8448 CM)
B-B
1.44 IN.
(3.6576 CM)
0.500-0.505 IN.
(12.7-12.827 MM)
DIA. HOLE
1.76 IN.
(4.4704 CM)
0.175 IN.
(4.445 MM)
DIA.
0.375 IN.
(9.525 MM)
0.32 IN. (8.128 MM)

0.30 IN. (7.62 MM)
0.50 IN.
(12.7 MM)
0.15 IN. (3.81 MM)
PRESS TO
RESET
1.18 IN.
(2.9972 CM)
0.59 IN.
(14.986 MM)
0.12 IN.
1.00 IN. (3.048 MM)
(2.54 CM)
0.12 IN.
(3.048 MM)
6 POINT GOTHIC
LETTERS
1.06 IN.
(2.6924 CM)
3.00 IN. (7.62 CM)

AUTO
RE-IGN
12 POINT GOTHIC
LETTERS
0.87 IN. (22.098 MM)

TEST
OFF
0.50 IN.
(12.7 MM)
0.130-0.143 IN.
(3.302-3.6322 MM)
DIA. HOLE
0.03 in. (0.762 MM)
R (TYP 4 PLCS)
0.88 IN.
(22.352 MM)
DECAL
MADE FROM 3650 SCOTCH CAL BRAND FILM, BLACK
BACKGROUND (COLOR NO. 37038) WITH WHITE
LETTERS (COLOR NO. 37875) PER FED-STD-595.
E-E
0.53 IN.
(13.462 MM)
COVER
(FOR 369H6416 INSTRUMENT PANEL)
MADE FROM ALUMINUM ALLOY SHEET, 2024-T3, QQ-A-250/5,
TEMP T-3 0.03 X 1.062 X 1.187 IN. (0.762 X 26.9748 X 30.1498 MM).
APPLY ONE COAT HMS-15-1082 PRIMER AND DRY FOR 1 TO 2
HOURS. APPLY TOPCOAT HMS-15-1083 ACRYLIC LACQUER AND
AIR DRY 4 HOURS MINIMUM.
D-D
G96-1007-2A
Figure 801. Relocation of Auto Reignition Controls (Sheet 2 of 2)
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MAINTENANCE MANUAL
CSP-HMI-2
34130 SPLICE (AMP INC)

IN5402 DIODE
(CRIMP AND SOLDER)
NO. 2 SLEEVING (MIL-I-631)
MS17821-4-9 STRAP, A/G
P12 (D11
)
D DIMMER
E559A22
E559AC20
3 XDS18
S11
TEST SW (8826K15)
E2
M5
J505A20N
E559AD20
E503H20
1
3
E503K20
2
4
J508C20
CR3 CR4
IN4003 DIODE
TS25181-1
SPLICE
J9
+
X
HOUR
METER
-
CB106
E559AE20
B3
B2
B1
A3
A1
SP
A2
E559AF20
E503M20
E503J20
X1
X2
K304
(NOTE 1)
SP
E507AD20
1 2
3
BUS
K301
SP17
1 CR2 2
E503N20
P9
A
B J503E20 D
C
P503C20
J503B20
1 CR1
SP18
P303
M
E503AE20
B2
EXITER
A3
A2
X1
IGN
J507AC20
TB502-13
CR5 (IN6055 TRANSORB)
X2
K104
(NOTE 1)
J507AB20
D
E
F
J507A20
E3
NOTES:
1. DO NOT RELOCATE RELAYS, EXISTING RELAYS MAY BE USED (REWIRED).
2. DASHED LINES (- - -) INDICATE EXISTING HELICOPTER WIRING.
Figure 802. Auto Reignition Rewiring Diagram
Revision 22
TO STARTER
TO STARTER SW
E13
TB502-13
J503D20
E15
S203
TO RCR
JUMPERS 20GA WIRE

USE MIL-W-16878/4
TYPE E OR EQUIVALENT
A1
Page 804
XMSN OIL
PRESS SW.
SP
B3
B1
BUS
CB101
J501B20
PUSH TO RESET
1
1
A RE-IGN A
2
2
2
2
ARMED
G
G
1
1
XDS9
NC
C
NO
S2 NC
C
S1 NO
+
-
E503L20
GEN OUT
WARN LT.
71-30-00
P19
U
E
EPO
G96-1007-3A
MAINTENANCE MANUAL
CSP-HMI-2

1. Auto Reignition Initial Installation
This section provides instructions for installa
tion of the 369H900118-513 and -515 engine
automatic re-ignition equipment. These
instructions cover removal or modification of
existing equipment to accommodate re-igni
tion equipment.
NOTE: 369D helicopters S/N 003 - 949 did not

provide full time operation. Refer to Auto
Re-ignition Rework for converting system
to full time operation.
A. Reference Data
The consumable and expendable materials
listed are of a commercial nature that could be
procurable locally. Alternate, but equivalent,
items might be available, but consultation
with MDHI Customer Service Department is
recommended.
B. Preparation for Installation
Preparing for installation of engine automatic
re-ignition equipment includes the following:
(master) switch in OFF position.
(2). Open engine right access door.
attaching hardware removed to gain
access to work areas. Protect compo
nents from damage and contamination
until installed.
C. Automatic Reignition System
Installation
NOTE: The engine automatic re-ignition kits

are supplied with as many parts assembled
as practical, however. some parts may re
quire assembly at installation. The follow
ing procedures provide complete assembly
instructions. The operator should omit those
steps which may have already been accom
plished.
D. Diode Isolator Assembly Installation
Item
CM313
CM612
CM703
CM808
Nomenclature
Insulation varnish
Tube, silicone
Tie strap
Lacing cord
NOTE: When providing ground for electrical

components, clean contacting surfaces to
bare metal per Maintenance of Electrical
Bonding Connections (Ref. Chap. 96). Do
not tighten electrical clamps or secure elec
trical wiring to existing harnesses until all
electrical wiring and components are in
stalled.
(1). Remove nut and washer securing
forward end of K301 start relay to
369A2537 oleo support.
(2). Clean area for electrical bonding
around large hole in bracket and that
portion of K301 start relay bracket
exposed by removal of nut and washer
in step (1). above.
(3). Using nut and washer removed in step
(1). above, install diode isolator assem
bly so that lug type diode connectors
are aft.
(4). Locate wire J503C20 (open end) in
harness running vertically, just forward
of Sta. 135.50 bulkhead and approxi
mately 6 inches (15.24 cm) aft of diode
isolator assembly. Place a 2.50 inch
(6.35 cm) length of silicone tubing
(CM612) on wire for use in step (6).
below.
(5). Connect wire J503B20 from diode CR1
of diode isolator assembly to the B-end
of knife splice SPl8. Connect A-end of
same splice to wire J503C20 located in
step (4). above.
(6). Slide silicone tubing over SPl8 splice
and secure with tie-strap (CM703) at
each end of splice.
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MAINTENANCE MANUAL
CSP-HMI-2
(7). Remove existing wire K502D20 from

terminal X2 of K301 start relay. Cut off
existing terminal, remove and save
existing terminal protector, slip 2.50
inch (6.35 cm) length of silicone tubing
on wire, and connect wire to B-end of
knife splice SPl7.
(8). Connect A-end of SP17 splice to
K502CB20 wire from common connec
tor 2 of CR1 and CR2 diodes of diode
isolator assembly.
(9). Slide silicone tubing over splice and
secure with tie-strap at each end of
SP17 splice.
(5). On left side of instrument panel

structure, install relay K104 in center
position and relay K304 in aft position,
on bracket with screws, washers and
nuts.
NOTE: Bracket is installed in upper half of

largest lightening hole in left side structure
of instrument panel.
(6). Clean area around ARM-OFF switch
(S11) mounting hole in lower switch
and circuit breaker panel, to prepare
bonding surface for switch support;
clean all surfaces around holes in
support.
(10). Place terminal protector removed in

step (7). above, on wire K502CA20 of
diode isolator assembly. Connect wire to
X2 terminal of K301 start relay and
slide terminal protector into place.
(7). Insert threaded shank of ARM-OFF

switch through half-inch (12.7 mm)
hole in support followed by key washer
with washer tang toward switch
actuator arm.
(11). Secure wiring with lacing cord (CM808)

as required. making certain that
sufficient wire slack remains so that
connectors are not stressed.
(8). Insert ARM-OFF switch through half

inch (12.7 mm) mounting hole in lower
switch and circuit breaker panel; install
washer and nut making certain tang is
positioned in small hole adjacent to
half-inch (12.7 mm) hole in panel.
(12). After assembly and test apply insula

tion varnish (CM313) to exposed
threads and tips.
(13). Close engine access door.
E. Relay and Switch Assembly Installation
Item
Nomenclature
CM703
CM812
Tie strap
Splice, knife
(2). Remove ash tray and edge lighted panel

from lower switch and circuit breaker
panel.
(3). Remove screws and loosen lower switch
and circuit breaker panel.
(4). Remove and discard square cutout and
adjacent round hole button covers
located above PRESS TO RESET
placard.
Revision 22
(10). Secure housing of switch (XDS9) to

support with clamp, screw, washers and
nut.
(11). Install electrical wiring as follows:
(1). Remove instrument panel left and right

side covers to expose lightening holes.
Page 902
(9). Clean portion of cylindrical (coil)

housing to contact clamp; insert switch
assembly (XDS9), from front side of
panel. into square cut out mounting
hole in lower switch and circuit breaker
panel.
71-30-00
(a). Route wire J502A20 from relay K104

to ARM-OFF switch and connect to
contact 3 of switch (S11).
(b). Route wire J503EE20 from relay
K104 and insert pin in contact C of
terminal block 502, module 13
(TB502-13).
(c). Route wire J508A20N from relay
K104 and connect to ground stud E2.
(d). Route wire J507AA20 from relay
K104 and insert pin in contact E of
TB502-13.
MAINTENANCE MANUAL
(e). Route wire E559AC22 from relay
K304 to closest proximity of GEN
OUT wire E559A22; connect wires
E559AC22 and E559A22 with splice
(CM812).
(f). Route wire J501AE2O from relay
K304 to contact 1 of ARM-OFF
switch (S11); install terminal
(MS25036-102) on wire J501A20;
connect terminals of wires J501AE20
and J501A20 to contact 1 of ARMOFF switch (S11). Route wire
J501A20, install terminal
(MS25036-149) and connect to
contact 2 of circuit breaker CB106.
(g). Route wire J502E20 from relay, K304
and connect to contact 4 of ARMOFF switch (S11).
(h). Arrange relay wires to form smooth
flow integrating with existing wire
bundles; use tie-straps (CM703) as
required to secure wire bundles.
Ensure sufficient wire slack to avoid
stress on solder joints.
(i). If bracket has been removed for
installation ease, clean bracket panel
contact areas to ensure positive
ground; install bracket with screws
and washers.
(j). Route ground wire J505A20N from
switch (XDS9) coil housing and
connect to ground stud E2.
(k). Route wire J502D20 from RE-IGN
ARMED switch (XDS9) and connect
to contact 6 of ARM-OFF switch
(S11).
(l). Route wire J503D20 from switch
(XDS9) and insert pin in contact A of
TB502-13.
(m). Route wire J501B20 from switch
ARM-OFF switch (S11).
(12). Install instrument panel left side cover.
(13). Clean screw attach areas of lower
switch and circuit breaker panel to
ensure positive grounding bond; install
panel.
CSP-HMI-2
(14). Install edge-lighted panel and ash tray

on lower switch and circuit breaker
panel.
(15). Perform Operational Check of engine
automatic re-ignition electrical system.
F. Relay and Switch Assembly Installation
(TPanel with Center Console)
Item
Nomenclature
CM612
CM703
CM812
CM815
Tube, silicone
Tie strap
Splice, knife
Solder
NOTE: T-panels (-703 and -705) with center

console are identical except the -705 is
equipped with 14 caution indicators.
(1). Remove console right side cover.
(2). Remove additional panels as required
to facilitate installation of engine
automatic re-ignition switches and
wiring.
(3). Remove ARM-OFF and RE-IGN
ARMED switch hole covers from
instrument panel.
(4). Locate relay bracket (for relays K104
and K304) on right side of console inner
panel.
(5). Install relays K104 and K304 as
follows:
(a). Install relay K104 in outboard
position, and relay K304 in inboard
position on relay bracket, with
(b). Arrange relay wires to form a smooth
flow, integrating with existing wire
bundles; use tie-straps (CM703) as
required to secure wire bundles.
Ensure sufficient wire slack to avoid
stress on solder joints.
(6). Install ARM-OFF switch (S11) and
RE-IGN/ARMED switch assembly as
follows:
71-30-00
Page 903
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
(a). Clean area around ARM-OFF (S11)

switch-hole in instrument panel to
prepare bonding surface for switch
(XDS9) support; install AUTO
RE-IGNITION decal
(369H90118-27). Clean all surfaces
around holes in support.
(b). Insert threaded shank of ARM-OFF
switch (S11) through half-inch
mounting hole in support followed by
key washer with washer tang toward
switch actuator arm.
(c). Insert ARM-OFF switch (S11)
through half-inch mounting hole in
instrument panel; install washer and
nut making certain key washer tang
is in small hole adjacent to half-inch
(12.7 mm) hole in panel.
(d). Clean portion of cylindrical (coil)
housing to contact clamp; insert
switch assembly (XDS9) into square
cutout mounting hole in instrument
panel.
(e). Secure housing of switch (XDS9) to
support with clamp, screw, washers
and nut.
(7). Install electrical wiring as follows:
(a). Route wire J502A20 from relay K104
to ARM-OFF switch (S11) and
connect to contact 3 of ARM-OFF
switch (S11).
(b). Route wire J503EE20 from relay
K104 and insert pin in contact C of
terminal block 502, module 13
(TB502-13).
(c). Route wire J508A20N from relay
K104 and connect to ground stud
E31.
(d). Route wire J507AA20 and insert pin
in contact E of TB502-13.
(e). On aircraft equipped with
369D294201-703 instrument panel
face, install wire E559AC22 as
follows:
1). Install module No. 20 on TB502.
Page 904
Revision 22
71-30-00
2). Route wire E559AC22 from relay

K304 to TB502 and insert pin in
contact C of TB502-20.
3). Install pin (MPCM20M-H2) on
wire E559AB22; insert pin in
contact A of TB502-20 and route
wire to plug P12. Crimp pin on
opposite end of wire E559AB22
and insert pin in contact D of P12.
4). Install pin (MPCM20M-H2) on
wire E559AA22; insert pin in
contact B of TB502-20. Route
opposite end of wire E559AA22 to
GEN OUT (XDS18) warning light
and solder (CM815) to contact 3.
(f). On aircraft equipped with
369D294201-705 instrument panel
face; install wire E559AC22 as
follows:
1). Route wire E559AC22 to closest
proximity of wire E17A22 (routed
between P526-EE and P527-A).
2). Cut wire E17A22; install 2.50 inch
(6.35 cm) length of silicone tubing
(CM612) and splice (CM812) wires
E559AC22 and E17A22. Slide
tubing over splice and secure with
tie-straps (CM703).
(g). Route wire J5017E20 from relay
K304 and connect to contact 1 of
(h). Route wire J502E20 and connect to
contact 4 of ARM-OFF switch (S11).
(i). Route ground wire J505A20N from
switch (XDS9) and connect terminal
to ground stud E31.
(j). Route wire J502D20 from switch
(XDS9) and connect terminal to
contact 6 of ARM-OFF switch (S11).
(k). Route wire J503D20 from switch
TB502-13.
(l). Route wire J501B20 from switch
(XDS9) and connect to contact 3 of
(m). Relocate wire J501A20 as follows:
MAINTENANCE MANUAL
1). On aircraft equipped with 369D
294201-703 instrument panel face,
disconnect wire J501A20 from
CB124 on circuit breaker panel,
2). On aircraft equipped with 369D
294201-705 instrument panel face,
disconnect wire J501A20 from
CB119 on circuit breaker panel,
(8). Install black cover decals
(369H90118-35 and -37) over AUTO
RE-IGN markings of previously used
circuit breaker position on edge lighted
circuit breaker panel; install new
AUTO RE-IGN decal (369H90118-33).
CSP-HMI-2
(9). Install console right cover.

(10). Secure all panels loosened or removed
for access.
(11). Perform Operational Check of engine
automatic re-ignition system (refer to
appropriate PFM).
installation of engine automatic re-ignition
equipment are listed in Table 901. After
installation of the engine automatic re-igni
tion system equipment, incorporate changes in
helicopter weight and balance record.

Weight
Pounds (kg)
Added
1.5
Removed
Change
(0.6803884)
Arm
inches (cm)
91.5
0.0
1.5
(0.6803884)
(232.41)
Moment
in.lb (kg cm)
1.4
0.0
91.5
(232.41)
(16.12968)
0.0
1.4
71-30-00
(16.12968)
Page 905
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 906
Revision 44
71-30-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
716000
Engine Cooling
System (250C20B,
250C20R/2,
250C30 and
250C47)
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE COOLING SYSTEM

1. Engine Cooling System Description and
Operation
(Ref. Figure 201 and Figure 202) Helicopter
engine and transmission oil cooler blower air is
used to cool engine exterior surfaces. After
passing through the oil coolers, the relatively
temperate air is redirected by a system of
supports, clamps, and ducts onto the ignition
exciter, engine gearcase, and compressor and
turbine section external surfaces. Exhaust air
is discharged overboard through a gap
between the engine exhaust pipe and engine
access doors.
3. Engine Cooling System Repair and

Replacement
Item
Nomenclature
CM107
Fluorocarbon release agent
CM712
2. Engine Cooling System Inspection
(1). Unclamp and remove ducts.
(2). Patch duct damage with tape (CM712).
(1). Inspect ducts for holes, tears, cracks,

fraying and security. Repair duct
damage as required.
(2). Inspect duct supports and clamps for
condition and security. Repair support
system as required.
NOTE: Apply dry film lubricant (CM107) to

duct and seal mating surfaces prior to as
sembly.
(3). Assemble duct, seals, clamps and
attaching hardware.
71-60-00
Page 201
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE AIR COOLING

INLET SCREEN
ENGINE OIL
COOLER DUCT
WIDE AREA
WASHER
BLOWER
TRANSMISSION OIL
COOLING DUCT
COMPRESSOR
COOLING DUCT
POWER TURBINE
COOLING DUCT
TRANSMISSION
OIL COOLER
IGNITION EXCITER
COOLING DUCT
CLAMP
ENGINE GEARCASE
COOLING DUCT
(FLEX-HOSE)
G71-6000-1
Figure 201. Engine Air Cooling System 250C20B and 250C20R/2 (Sheet 1 of 2)
Page 202
Revision 22
71-60-00
MAINTENANCE MANUAL
CSP-HMI-2
CLAMP
HOISTING
EYE FITTING
CONNECTO
R
SUPPORT
BRACKET
DUCT CONNECTION
POWER TURBINE
COOLING DUCT
COMPRESSOR
COOLING DUCT
9/32 INCH (7.14 MM)
SPACER
OVERHEAD DUCT SUPPORT
5010
1/4 INCH (6.35 MM)

SPACER
CLAMP
COOLING
DUCT
DUCT SUPPORT
RING
SEAL
CLAMP
GEARCASE COOLING DUCT ATTACHMENT
COOLING DUCT ATTACHMENT
CLIP
LOWER TRANSMISSION
OIL COOLER DUCT
CLAMP
(NOTE)
STA. 124.00 LOWER

SECTION FRAME
CLAMP
(NOTE)
ENGINE MOUNT
CLAMP
GEARCASE COOLING DUCT SUPPORT
NOTE:
INSTALL CHAFFING STRIP TO INSIDE SURFACE
OF CLAMP PRIOR TO INSTALLATION
G71-6000-2B
Figure 201. Engine Air Cooling System 250C20B and 250C20R/2 (Sheet 2 of 2)
71-60-00
Page 203
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
BLOWER
TRANSMISSION OIL
COOLING DUCT
ENGINE OIL
COOLER DUCT
ENGINE OIL
COOLER
COMPRESSOR
COOLING DUCT
TRANSMISSION OIL
COOLER
IGNITION EXCITER
COOLING DUCT
ENGINE GEARCASE
COOLING DUCT
RIVET (2)
BRACKET
ENGINE DOOR
FRAME
STARTER-GENERATOR
COOLING DUCT
CLAMP
POWER TURBINE COOLING

DUCT INSTALLATION
G71-6001-1
Figure 202. Engine Air Cooling System 250C30 and 250C47 (Sheet 1 of 2)
Page 204
Revision 22
71-60-00
MAINTENANCE MANUAL
CSP-HMI-2
CLAMP
HOISTING EYE
FITTING
COOLING DUCT
SEAL
BRACKET
COOLING DUCT ATTACHMENT
CLAMP
(NOTE)
COMPRESSOR COOLING
DUCT INSTALLATION
9/32 INCH (7.14 MM)
SPACER
5010
1/4 INCH (6.35 MM)

SPACER
CLAMP
CONNECTO
R
DUCT SUPPORT
RING
CLAMP
DUCT CONNECTION
GEARCASE COOLING DUCT ATTACHMENT
CLIP
LOWER TRANSMISSION
OIL COOLER DUCT
CLAMP
(NOTE)
STA. 124.00 LOWER

SECTION FRAME
CLAMP
(NOTE)
ENGINE MOUNT
CLIP
CLAMP
NOTE:
INSTALL CHAFFING STRIP TO INSIDE SURFACE
OF CLAMP PRIOR TO INSTALLATION
G71-6001-2B
Figure 202. Engine Air Cooling System 250C30 and 250C47 (Sheet 2 of 2)
71-60-00
Page 205
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 206
Revision 44
71-60-00
MAINTENANCE MANUAL
Chapter
75
Engine AntiIce
System
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
75-10-00 Engine Anti-Icing System (250-C20B, 250-C20R/2, 250-C30

and 250-C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1.
Engine Anti-Icing System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.
Engine Anti-Icing System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Table 201. 250-C20B Engine Anti-icing System Fault Isolation . . . . . . . . . . . . . 201
Table 202. 250-C20/R2, 250-C30 and 250-C47 Engine Anti-icing System
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3.
250-C20B Engine Anti-Icing Valve Control Cable Replacement . . . . . . . . . . . . . . . 202

A. 250-C20B Engine Anti-Icing Valve Control Cable Removal . . . . . . . . . . . . . . . . . 202
B. 250-C20B Engine Anti-Icing Valve Control Cable Installation . . . . . . . . . . . . . . 202
Figure 201. 250-C20/R2, 250-C30 and 250-C47 Engine Anti-Icing
System Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.
250-C20/R2, 250-C30 and 250-C47 Engine Anti-Icing System Controls

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.
250-C20B Engine Anti-Icing System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6.
250-C20/R2, 250-C30 and 250-C47 Engine Anti-Icing System Inspection . . . . . 204
7.
250-C20B Engine Anti-Icing System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8.
250-C20/R2, 250-C30 and 250-C47 Engines Anti-Icing System Test . . . . . . . . . . 204
9.
250-C20B Engine Anti-Icing System Control Cable Repair . . . . . . . . . . . . . . . . . . . 204
10. 250-C20/R2, 250-C30 and 250-C47 Engine Anti-Icing Valve Repair . . . . . . . . . . . 204
Figure 202. 250-C20B Engine Anti-Icing System . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 203. 250-C20/R2, 250-C30 and 250-C47 Engine Anti-Icing
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
75 Contents
Page i
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page ii
Revision 43
75 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
751000
Engine AntiIcing
System (250C20B,
250C20R/2,
250C30 and
250C47)
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE ANTIICING SYSTEM

1. Engine AntiIcing System Description and
Operation
(1). Compressor inlet guide vanes and the
front bearing hub are the only compo
nents supplied anti-icing air on the
helicopter engines.
(2). Model 250-C20B Engines: The anti-ice
system consist of a manually operated
push-pull control cable, mechanical
anti-icing valve, air distribution tubing
and, attaching hardware. The poppettype anti-icing valve is mounted on the
engine compressor scroll and controls
compressor bleed air used for engine
anti-icing. The control cable is as
sembled of rigid and flexible sections
clamped along the right side of the
overhead cabin heat duct. Moving the
control handle forward opens the
anti-icing valve. Control handle travel
is approximately 1.44 inches (3.66 cm)
from OFF to ON. A detent holds the
handle in both ON and OFF positions.

There is no intermediate heat position.
(3). Model 250-C20/R2, 250-C30 and
250-C47 Engines: The engine installa
tions use an electrically controlled
anti-ice system. Compressor bleed air,
supplied to the inlet guide vanes and
the number one bearing housing, is
controlled by the ANTI-ICE circuit
breaker/switch, CB143 on the 369FF 500/600N, and CB122 on 369D/E
helicopters fitted with a 250-C20/R2
engine. Moving the console mounted
switch to ANTI-ICE de-energizes a
solenoid fastened to the engine heat
shield that controls the anti-icing
system.
(4). Refer to the applicable Allison engine
manual for additional engine anti-ice
information.
2. Engine AntiIcing System Fault Isolation
Table 201. 250C20B Engine Antiicing System Fault Isolation

Symptom
Probable Trouble
Corrective Action
Antiice ON does not restore

normal engine operation when
compressor icing occurs.
System not rigged correctly.
Check rigging.
Lack of antiicing air.
Defective antiice air lines.
Check engine air lines for leaks.
Antiicing air valve stuck closed.
Replace valve.
Cable wire sheared.
Replace cable.
Cable clevis pin sheared or

missing.
Replace clevis pin.
Antiice OFF has no effect. Inflight Antiicing air valve stuck open.
symptom is continuation of
Corroded, pinched or crushed
approximately 10% reduction in
cable.
available power or torque.
Cable clevis pin sheared or
missing.
Replace valve.
Replace cable.
Replace clevis pin.
Cable wire sheared.
Replace cable.
Antiice air valve compressor scroll adapter nut

overtightened.
Loosen adapter nut. Torque nut to 10

inchpounds (1.13 Nm).
75-10-00
Page 201
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. 250C20B Engine Antiicing System Fault Isolation

Symptom
Antiicing control drags or binds.
Probable Trouble
Control cable rigid sleeve kinked.
One or more flexible cable section
bend radii less than 3 inch (7.62
cm) minimum.
Corrective Action
Check operation with cable clevis
disconnected from antiice valve lever.
Replace kinked or corroded cable.
Increase flexible cable bend radius.
Control handle creeps open or

closed.
ONOFF detentspring weak or

broken.
Replace detentspring assembly.
Handle detent grooves worn or

dirty.
Clean, repair or replace cable.
Table 202. 250C20/R2, 250C30 and 250C47 Engine Antiicing System Fault Isolation
Symptom
Probable Trouble
System ON fails to restore normal

engine operation in compressor
icing conditions.
Corrective Action
Lack of antiicing air.
Inspect air lines for leaks.
Inoperative/defective antiicing valve.
Replace valve.
Faulty switch or wiring.
Repair or replace switch/wiring as

required.
Switching antiice OFF has no

Antiicing air valve stuck open.
effect. Inflight symptom is
continuation of approximately 10%
reduction in available power or
torque.
3. 250C20B Engine AntiIcing Valve

Control Cable Replacement
A. 250C20B Engine AntiIcing Valve
Control Cable Removal
(2). Remove right half of engine air inlet
forward fairing.
(3). Remove heater duct outer box attaching
hardware.
(4). Remove clamps and straps attaching
the control cable to structure.
(5). Remove valve lever cable clevis attach
ing hardware.
Replace valve.
B. 250C20B Engine AntiIcing Valve

Control Cable Installation
Item
CM430
CM707
Nomenclature
Tape, fastener
CAUTION
Do not kink cable rigid sleeve

section.
(1). Position bulkhead hole grommet on

rigid sleeve section.
(2). Install Velcro tape (CM707) on mating
surfaces of forward clamp, and block.
(3). Route cable assembly through bulk
head, flexible cable bend radius shall
be, not less than 3.00 inches (7.62 cm),
minimum.
NOTE: Check valve lever travel before tighten

ing clamp nearest anti-icing valve.
(6). Remove the heater duct box, and

control cable.
Page 202
Revision 22
75-10-00
(4). Install cable clamps, straps, and

attaching hardware.
MAINTENANCE MANUAL
CB122
3A
P9J
2
Q516G20
CSP-HMI-2
P307
SP888
Q516F20
Q516E20
1
3
P535F20N
ANTI-ICE
SOLENOID
VALVE
E12
G751002
Figure 201. 250C20/R2, 250C30 and 250C47 Engine AntiIcing System Wiring
tional check.
(a). Determine that control operates
valve through full range of travel
from ON to OFF.
(6). Secure clamp nearest anti-icing valve.
(15). Install right half of engine air inlet

forward fairing.
(16). Close and latch engine access doors.
4. 250C20/R2, 250C30 and 250C47
Engine AntiIcing System Controls
Replacement
(7). Apply sealant (CM430) around engine

side of air inlet pan cable hole (Ref.
Figure 202).
(1). Refer to the applicable Allison Mainte

nance and Operation Manual for
anti-ice system maintenance instruc
tions (Ref. Sec. 01-00-00).
(8). Move anti-ice handle to OFF. Ensure

handle is locked in OFF position by
detent.
(2). Refer to Figure 201 for airframe wiring.
(9). Move engine anti-ice valve lever to the

closed position (poppet plunger down).
(10). Loosen cable clevis jamnut.
NOTE: Do not push, or pull actuator cable to

get lever-arm and clevis-pin hole align
ment.
(a). Screw clevis up or down cable
end-fitting threads to align cable
clevis with valve lever-arm pin holes.
(b). Check hole alignment by inserting
clevis pin. Remove pin.
(c). Extend cable length by 1 to 2 full
counterclockwise turns of clevis.
(11). Install clevis-pin, washer, and cotterpin.
5. 250C20B Engine AntiIcing System

Inspection
(1). Inspect anti-ice system controls as
follows:
(a). Controls for freedom of movement,
and control handle detent-spring for
positive lock.
(2). Isolate stiff control operation problems
as follows:
(a). Disconnect cable clevis from valve
lever. Check for binding as control
lever is moved from ON to OFF.
1). If control binds, inspect flexible
cable length for bend radii less
than the three inch minimum.
Look for kinks, a crushed outer
sleeve, and corrosion.
(12). Tighten clevis jamnut.
2). Inspect rigid cable section for

corrosion, kinks, and dents.
(13). Install heat duct outer box.
3). Repair or replace damaged cable.
(14). Adjust handle position parallel to

windshield glass using handle set
screw, as required.
(3). Inspect anti-icing valve lever assembly

for wear, lost motion, and freedom of
movement.
75-10-00
Page 203
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
(4). Repair or replace system components as

required.
6. 250C20/R2, 250C30 and 250C47
Engine AntiIcing System Inspection
(1). Inspect solenoid valve for secure
attachment.
(2). Check wire insulation for abrasion, and
connections for security. Repair as
required.
(3). Inspect tubes for cracks, and connec
tions for security.
7. 250C20B Engine AntiIcing System Test
(1). Test system operation as follows:
(a). Pull control handle ON.
(b). Check control detent locks handle in
ON position and does not creep
toward OFF.
(c). In engine compartment, check
anti-icing air valve as follows:
1). Valve lever is at aft travel limit
(valve open), and cable is not
distorted by overdrive.
(2). Return control handle to OFF position.
(a). Check control detent locks handle in
OFF position and does not creep
toward ON.
(b). In engine compartment, check
anti-icing valve position:
Page 204
Revision 37
75-10-00
1). Valve lever is at forward travel

limit (valve closed).
(3). Adjust cable to correct insufficient
anti-icing valve lever travel or cable
distortion.
NOTE: Check that poppet guide, and lever as

sembly are parallel with top of engine (Ref.
Figure 202, view B).
8. 250C20/R2, 250C30 and 250C47
Engines AntiIcing System Test
(1). Perform anti-icing system test per the
appropriate Pilot's Flight Manual (Ref.
Sec. 01-00-00).
9. 250C20B Engine AntiIcing System
Control Cable Repair
(1). The control cable assembly is normally
replaced as a unit. However, disassem
bly to the extent shown in the illustra
tions can be accomplished for inspection
purposes (Ref. Figure 202). No repairs
are recommended except for replace
ment of lever mechanism parts.
10. 250C20/R2, 250C30 and 250C47
Engine AntiIcing Valve Repair
(Ref. Figure 203)
(1). Repair or replace engine anti-icing
valve per Allison Engine Operation and
Maintenance Manual.
MAINTENANCE MANUAL
CSP-HMI-2
FLEXIBLE SLEEVE
NYLON STRAP
(TYP)
GROMMET
(TYP)
RIGID SLEEVE
CONTROL HANDLE
INSTALLATION
2 PLCS
RIGID SLEEVE
HANDLE
SETSCREW
1 PLS
TAPE
(NOTE 2)
CONTROL HANDLE
CANOPY FRAME
HANDLE DETENT
SPRING
CLEVIS ATTACHING
POINT
FLEXIBLE SLEEVE
PLENUM CHAMBER
AIR INLET PAN
NOTE 1
CABLE SPLICE
RIGID TUBING
120
ANTI-ICING VALVE
CABLE SUPPORT
BLOCK (3 PLCS)
OUTER BOX
6 PLCS
OPEN
CLOSED
LEVER ASSY
CABLE CLEVIS
ANTI-ICING VALVE
POPPET VALVE
HEAT DUCT
MOUNTING
SCREW
VERTICAL CENTERLINE OF
ENGINE (LOOKING AFT)
INSTALLATION ANGLE
(ANTI-ICING VALVE)
CONTROL CABLE TO
VALVE ATTACHMENT
NOTE:
1. SEAL HOLE ON ENGINE SIDE OF PAN WITH ADHESIVE.
2. APPLY VELCRO TAPE TO FORWARD BLOCK AND CLAMP
MATING SURFACES.
G75-1000
Figure 202. 250C20B Engine AntiIcing System
75-10-00
Page 205
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
COIL
SCREW
CONNECTOR
COVER
SPRING
PLATE
O-RING
PLUNGER
BACKUP RING
SEAL
DISC
LOCKPIN
LOCKPIN
O-RING
SEAT
SEAT
O-RING
BODY
SOLENOID VALVE ASSY

G75-1001
Figure 203. 250C20/R2, 250C30 and 250C47 Engine AntiIcing Control Valve
Page 206
Revision 22
75-10-00
MAINTENANCE MANUAL
Chapter
76
Engine Power
Controls
CSP-HMI-2
MAINTENANCE MANUAL
CSPHMI2
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
76-00-00 Engine Power Controls (250-C20B, 250-C20R/2 and 250-C30) . . . . . . . . . A

1.
Engine Power Controls Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

A. Power Turbine Governor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Power Turbine Governor Trim Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Gas Producer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Engine Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.
Engine Power Controls Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Table 101. Engine Control Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101. N2 Trim Actuator Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
76-10-00 Power Turbine Governor Controls (250-C20B, 250-C20R/2

and 250-C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1.
Engine Governor Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Figure 201. Power Turbine Governor Controls Rigging . . . . . . . . . . . . . . . . . . . . . . 203
2.
Governor Lever Pointer Rigging for 250-C20B (P/N 2524769-10 and Prior) . . . . . 204
Figure 202. Power Turbine Governor Adjustments
(P/N 2524769-10 and Prior) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.
Governor Lever Pointer Rigging for 250-C20B / -C20R2 (P/N 2524769-11, -12) 206
Figure 203. Power Turbine Governor Adjustments (P/N 2524769-11, -12) . . . . 207
4.
Governor Lever Pointer Rigging for 250-C20B / -C20R/2 (P/N 2524667-13) . . . . 208
Figure 204. Power Turbine Governor Adjustments (P/N 2524667-13) . . . . . . . . 209
5.
Governor Lever Pointer Rigging for 250-C20B (P/N 2524667-14 and Higher,
P/N 2524769-13 and Higher and P/N 2549170-1 and Higher) . . . . . . . . . . . . . . . . 210
Figure 205. Power Turbine Governor Adjustments (P/N 2524667-14 and Higher,
P/N 2524769-13 and Higher and P/N 2549170-1 and Higher
on 250-C20B Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
6.
Governor Lever Pointer Rigging for 250-C20R/2 (P/N 2524667-14 and Higher,
P/N 2524769-13 and Higher and P/N 2549170-1 and Higher) . . . . . . . . . . . . . . . . 212
Figure 206. Power Turbine Governor Adjustments (P/N 2524667-14 and Higher,
P/N 2524769-13 and Higher and P/N 2549170-1 and Higher
on 250-C20R/2 Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
7.
Governor Lever Pointer Rigging for 250-C30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Figure 207. Power Turbine Governor Adjustments (250-C30 Engine) . . . . . . . . 215
8.
Governor Controls Final Check and Adjustment (250-C20B, -C20R/2) . . . . . . . . . 216
9.
Governor Controls Final Check and Adjustment (250-C30) . . . . . . . . . . . . . . . . . . . . 217
76 Contents
Page i
Revision 44
CSPHMI2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
10. Governor Controls Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

11. Control Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
12. Bellcrank Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
13. Droop Compensation Link Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
14. Droop Control Override Link Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Figure 208. Power Turbine Governor Controls (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 220
15. Control Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
16. Bellcrank and Support Fitting Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
17. N2 Trim Actuator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Figure 209. N2 Trim Actuator Test Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
18. N2 Trim Actuator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
19. Sta. 68.00 Bellcrank Rework, P/N 369A7717-3 and 369N2606 Only . . . . . . . . . . . 223
Figure 210. Station 68.00 Bellcrank Rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
76-20-00 Gas Producer Controls (250-C20B, 250-C20R/2 and 250-C30) . . . . . . . . . A
1.
Gas Producer Controls Rigging (250-C20B and 250-C20R/2) . . . . . . . . . . . . . . . . . . 201
2.
Gas Producer Controls Rigging (250-C30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Figure 201. Gas Producer Controls Rigging (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . 204
A. Gas Producer Fuel Control De-richment Valve Adjustment . . . . . . . . . . . . . . . . . 210
B. Power Controls Operational Test/Final Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 210
3.
Gas Producer Controls Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
4.
Sta. 124.00 Support Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

A. Sta. 124.00 Support Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
B. Sta. 124.00 Support Fitting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
5.
Gas Producer Controls Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
6.
Gas Producer Control Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
7.
Bellcrank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Figure 202. Gas Producer Controls Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
76-47-00 Engine Power Controls (250-C47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1.
Engine Controls Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.
Engine Controls Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.
Engine Controls Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Table 201. Engine Controls Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Engine Control Unit Wiring Diagram (Sheet 1 of 2) . . . . . . . . . . . . . 202
Page ii
Revision 37
76 Contents
MAINTENANCE MANUAL
CSPHMI2

Para/Figure/Table
4.
Title
Page
ECU (Electronic Control Unit) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

A. ECU Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. ECU Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5.
Engine Control Potentiometer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

A. Collective Potentiometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Collective Potentiometer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
C. Directional Potentiometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
D. Directional Potentiometer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6.
CIT (Compressor Inlet Temperature) Sensor Replacement . . . . . . . . . . . . . . . . . . . . . 206

A. CIT Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. CIT Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7.
Engine Control Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

A. Engine Control Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Engine Control Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8.
Engine Control Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

A. Engine Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Engine Control Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 202. Engine Controls Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 208
9.
Engine Throttle Control Cable Mounting Bracket Replacement . . . . . . . . . . . . . . . . 210

A. Engine Throttle Control Cable Mounting Bracket Removal . . . . . . . . . . . . . . . . . . 210
B. Engine Throttle Control Cable Mounting Bracket Installation . . . . . . . . . . . . . . . 210
10. Engine Control Cable Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

11. Engine Controls Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 203. Engine Control Cable Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
12. Engine Control Cable Shipping and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
A. Control Cable Removal From Shipping Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 204. Effective Bend Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
B. Control Cable Installation into Shipping Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
76 Contents
Page iii
Revision 37
CSPHMI2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page iv
Revision 37
76 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
760000
Engine Power
Controls (250C20B,
250C20R/2 and
250C30)
MAINTENANCE MANUAL
CSP-HMI-2

1. Engine Power Controls Description and
Operation
(1). The engine control system consists of
gas producer (N1) throttle controls and
power turbine (N2) governor controls.
The throttle twist grip mechanically
actuates a lever on the gas producer
fuel control that establishes a base line
from which the unit schedules metered
fuel to the gas producer portion of the
engine. An electrically operated trim
actuator and mechanical rpm droop
compensator in the main rotor collec
tive pitch control mechanism changes
power turbine governor lever position
when collective is increased or reduced
and when N2 speed increase or decrease
is commanded with the beep switch on
the collective stick. Either, or both
actions regulate power output by
biassing the gas producer fuel control to
increase or decrease fuel flow to
compensate for rotor system torque
requirements.
(2). Refer to the applicable Allison Engine
additional engine fuel system theory,
operation and maintenance data.
A. Power Turbine Governor Controls
(1). Power turbine governor (N2) controls
include the N2 trim actuator controlled
by the beep switch on the pilot's
collective stick. Governor trim droop
control override components and
linkages are installed within the pilot's
seat structure. A fuselage routed
control rod assembly, engine compart
ment linkages, bellcranks and supports
transfer motion to the power turbine
governor. A droop control override
spring compensates for over-travel in
maximum collective pitch/speed
conditions.
B. Power Turbine Governor Trim Actuator
(1). The actuator consists of a reversible
continuous duty 26Vdc motor and gear
train driving a ram equipped with an

adjustable rod-end. The actuator,
operated by an N2 trim (beep) switch on
the collective pitch stick, moves gover
nor linkage that varies engine N2 speed
from 94 to 105% rpm. Operating stroke
of the actuator ram is approximately
1.00 inch (2.54 cm); speed is 0.15 inch
(3.81 mm) per second; travel time from
full retraction to full extension is
approximately 7 seconds. The actuator
is lubricated when manufactured and
requires no further lubrication service.
C. Gas Producer Controls
(1). The gas producer portion of the engine
is controlled by the pilot's throttle twist
grip which effects gas producer fuel
control lever position through a system
of torque tubes, gears, push-rods,
bellcranks, bellcrank support fittings,
levers and attaching hardware (Ref.
Figure 1).
(2). Refer to Allison Engine Operation and
Maintenance Manual for engine fuel
system theory, operation and mainte
nance data.
D. Rigging
(1). Rig engine control system prior to the
next flight when engine operation
reveals a rigging problem, or after
replacing any system component.
NOTE: Perform a deceleration time check per

pilot's flight manual after rigging and test
ing power turbine controls. Refer to Allison
Operation and Maintenance Manual for ad
justment procedures if deceleration time is
less than allowable minimum.
(2). Rig gas producer controls per (Ref. Sec.
76-20-00).
(3). Rig power turbine governor controls per
(Ref. Sec. 76-10-00).
76-00-00
Page 1
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
N2 CONTROL
IDLER BELLCRANK
N2 IDLER BELLCRANK
CONTROL ROD
GOVERNOR LEVER
CONTROL ROD
STA 124.00 CONTROL SUPPORT
RPM GOVERNOR CONTROL

IDLER SUPPORT FITTING
POWER TURBINE GOVERNOR

FUSELAGE-ROUTED CONTROL ROD
GAS PRODUCER LEVER

CONTROL ROD
N2 TRIM SWITCH
COLLECTIVE PITCH STICK
STA 124.00 BELLCRANK

STA 129.00 BELLCRANK
INTERCONNECT
TORQUE TUBE
GAS PRODUCER
CONTROLS SUPPORT
FITTING
DROOP CONTROL
OVERRIDE LINK
STA 68.00 BELLCRANK
GAS PRODUCER
FUSELAGE-ROUTED
CONTROL ROD
STA 73.00 GAS PRODUCER
CONTROL ROD
STA 70.00 BELLCRANK
N2 TRIM ACTUATOR
STA 72.00 BELLCRANK
G76-0001
Figure 1. Engine Control Systems
Page 2
Revision 22
76-00-00
MAINTENANCE MANUAL
CSP-HMI-2

FAULT ISOLATION
1. Engine Power Controls Fault Isolation
Table 101. Engine Control Fault Isolation
Symptom
Throttle movement springy;
response lags behind control
movement.
Probable Trouble
Corrective Action
Lost motion; gas producer

interconnect torque tube loose in
collective stick gear shafts.
Tighten torque tube pipe plug for

zero backlash.
Worn rodends; worn bellcrank

bearings.
Replace worn parts.
Stiff control action.
Rodends binding/jammed.
Realign rodend bearings to

eliminate jamming.
Low power; improper idling speed;

improper acceleration; variable
power output at constant setting.
Incorrectly adjusted gas producer

or power turbine governor controls.
Adjust gas producer or power turbine

governor controls for correct
operation.
Defective gas producer or power

turbine governor assembly.
Replace faulty unit per Allison

Engine Operation and Maintenance
Manual.
Stagnated or hot engine starts.
Fuel control derichment valve out

of adjustment.
Adjust derichment valve.
Excessive TOT readings during

engine shutdown.
Engine controls out of adjustment.
Adjust engine controls per the

applicable Allison manual.
Fuel cutoff valve not closing.
Adjust, repair or replace gas

producer control per Allison manual.
76-00-00
Page 101
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
REF CHAP 96
CB101
5A
1 2
P9J
H
LEFT COLLECTIVE
STICK (PILOT)
INCR
N2 GOV
CONT
DECR
P113J
J
RIGHT COLLECTIVE
STICK (COPILOT)
J112P
J
INCR
WHT
WHT
BLU
BLU
N2 GOV
CONT
DECR
S104
S108
P107
A
N2 GOV
A MOTOR
RED
B
E6
B103
TB1-5
RED
BLU
RED
TB1-7
C
D
Figure 101. N2 Trim Actuator Wiring Schematic
Page 102
Revision 22
76-00-00
G76-0002
MAINTENANCE MANUAL
CSP-HMI-2
Section
761000
Power Turbine
Governor Controls
(250C20B,
250C20R/2 and
250C30)
MAINTENANCE MANUAL
CSP-HMI-2
POWER TURBINE GOVERNOR CONTROLS

1. Engine Governor Control Rigging
(Ref. Figure 201)
NOTE: The rigging procedures for the C20B,

C20R/2 and C30 engine controls are similar,
differing mostly in adjustments.
CAUTION
D Do not make any adjustments to governor
stops, adjustment screws or nut positions.
D Replace worn linkage components prior to
rigging engine controls or adjusting en
gine fuel controls. Several worn rod-end,
fitting and bellcrank bearings in the gov
ernor control system compound otherwise
minimal lost motion. Loose control sys
tems will not hold rigging adjustments,
and if continued in service may result in
engine power creep, hunting or flame out.
NOTE: Gas producer throttle control tube, in

terconnect torque tube, collective pitch
stick, interconnecting collective pitch torque
tube and linkage maintenance practices are
covered under `Main Rotor Flight Controls'
(Ref. Sec. 67-10-00) and `Gas Producer Con
trols' (Ref. Sec. 76-20-00).
(1). Disconnect control rod between idler
bellcrank and governor lever at idler
bellcrank. Secure rod to avoid damage.
CAUTION
D 250-C20R/2 engines equipped with a
2524667-13 engine governor require re
moval of the 369A7717-5 droop compen
sation adjustment fork and installation of
the longer 369A7717-3 fork to achieve
the necessary 1/2% to 1% droop com
pensation (approximately 2% for 500N).
D 250-C30 engine installations may re

quire replacement of the 369A7717-3
droop compensation adjustment fork to
the longer 369A7717-7 fork to achieve
the necessary 1/2% to 1% droop compen
sation. Upon installation of the longer
369A7717-7 fork assembly, ensure that
no interference occurs between the collec
tive torque tube and the 369A7712 link
assembly. Also check between the pro
truding end of the droop fork and N2 ac
tuator.
D To identify forks with obscured part num
bers, measure distance between threaded
shank end-flat to clevis bolt hole center:
369A7717-3 fork:
3.00 inches (76.20 mm)
369A7717-5 fork:
2.63 inches (66.802 mm)
369A7717-7 fork:
3.87 inches (98.298 mm).
(2). Set the initial reference dimension
between center of Sta. 68.00 bellcrank
pivot bolt and droop compensation fork
clevis bolt-center.
Droop Fork Settings
Engine
Installation
Length
In. (mm)
250C20B
2.20 0.03 (55.880 0.762)
250C20R/2
2.20 0.03 (55.880 0.762)
250C20R/2 (1)
2.50 0.03 (63.500 0.762)
250C30
(2)
(1) With 2524667-13 governor

(2) 3.40 0.03 inches (86.360 0.762 mm) with
369A7717-7 ext. fork and 369A7704 bell
crank
2.60 0.03 inches (66.040 0.762 mm) with
369A7717-3 ext. fork and 369A7704-7 bell
crank
76-10-00
Page 201
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
NOTE:
D Make control rod-end adjustments to the
nearest half turn that produces correct
rigging.
D Stabilize rod-end with a backup wrench
when torquing rod-end jamnut.
D Inspect rod-end thread engagement
through witness hole to ensure a safe, se
cure installation.
proper engine installation as indicated

below.
Idler Bellcrank Control Rod Setting
Engine
Installation
Length
In. (mm)
250C20B, R/2
14.38 0.03 (365.252 0.762)
250C30
13.70 0.03 (347.980 0.762)
(3). Connect 28Vdc external power. Reset

N2 GOV circuit breaker. Set battery
switch to EXT PWR.
(7). Verify that collective is FULL DOWN

and governor trim actuator is at
maximum extension.
(4). With pilot's collective stick the FULL

DOWN position, beep N2 actuator to
maximum extension. Adjust actuator
ram as required to get 5.47 0.03 inches
(138.938 0.762 mm) measured be
tween pivot bolt-centers.
(8). Check governor lever and pointer

position, as follows.
(5). Adjust fuselage-routed governor control

rod length to move Sta. 124.00 bell
crank. The lower arm pivot bolt-center
measurement from the firewall should
be set to the applicable engine installa
tion as indicated below.
Station 124 Bellcrank Setting
Engine
Installation
Setting
In. (mm)
250C20B, R/2
(MultiEngine)
3.63 0.03 (92.20 0.762)
250C30
(Current)
3.34 0.03 (84.84 0.762)
250C30
(Early)
3.75 0.03 (95.25 0.762)
(6). In engine compartment; set idler

bellcrank control rod length to the
Page 202
Revision 22
76-10-00
Governor and fuel control levers

can be installed on the wrong
fuel system component shaft. Governor le
ver is relatively short with an offset angle of
about 65. Fuel control lever offset angle is a
more moderate 38.
CAUTION
NOTE:
D Specified pointer/lever angular relation
ships are standard production settings.
Slight variations in position may be re
quired to obtain proper travel and satis
factory engine operation. Such variation
is acceptable provided all other rigging
and engine performance requirements
are met.
D Governor lever travel produced by trim
actuator operation, from forward travel
point (trim actuator retracted and collec
tive stick down) to aft travel point (trim
actuator extended and collective stick
down), is 31 to 32. Approximately 36 to
38 of governor lever travel from mini
mum N2 stop is unused.
MAINTENANCE MANUAL
CSP-HMI-2
GOVERNOR
LEVER
GOVERNOR LEVER
CONTROL ROD
IDLER
SUPPORT
RODEND ANGULAR RELATIONSHIPS
CONTROL ROD
ANGLE
FUSELAGE ROUTED
IN LINE
N2 IDLER BELLCRANK
90
GOVERNOR LEVER
90
COLLECTIVE
TORQUE TUBE
DROOP CONTROL
OVERRIDE LINK
NOTE 4
DROOP COMPENSATION
ADJUSTMENT FORK
STA. 124.00
BELLCRANK
STA. 124.00
FIREWALL
STA 68.00
BELLCRANK
NOTE 1
NOTE 3
STA. 124.00 SUPPORT

FITTING
STA. 72.00
BELLCRANK
250-C30 ENGINE
INSTALLATION
FUSELAGE-ROUTED
CONTROL ROD
5.47 +0.03 (138.938 7.62 MM)

(NOTE 2)
MULTI-ENGINE
POWER TURBINE CONTROL LINKAGE
NOTES:
INITIAL SETTINGS.
1. DROOP FORK.
2. N2 ACTUATOR RAM.
3. STA. 124.00 BELLCRANK.
4. IDLER BELLCRANK CONTROL ROD.
G761002B
Figure 201. Power Turbine Governor Controls Rigging
76-10-00
Page 203
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
2. Governor Lever Pointer Rigging for

250C20B (P/N 252476910 and Prior)
and D of the word SPEED on the

governor.
NOTE:
(Ref. Figure 202)

(1). Reposition the lever arm only, not the
pointer, one serration (15) counter
clockwise from pointer centerline.
Do not overtorque governor con
trol lever nut. Exceeding nut
torque limit may cause binding.
CAUTION
(2). Torque lever nut to 40 - 50 inchpounds (4.52 - 5.65 Nm) while

holding lever center screw with a hex
wrench. Apply a torque stripe.
(3). Verify collective stick is FULL DOWN
and governor actuator is at maximum
extension.
D The pointer control arm shall not hit the

mechanical stops.
D As stick is raised, the Sta. 124.00 bell
crank will bottom out on the support and
until it reaches FULL UP travel, the
droop control override spring will com
press.
(6). Bottom collective stick and beep N2
trim to minimum; The governor pointer
shifts back to approximately the first
vertical leg of the letter N of N2 on the
governor.
If any interference exists at gov
ernor lever, check that correct
lever is installed.
CAUTION
(4). Connect short control rod between idler

bellcrank and governor control arm.
Adjust the rod to locate the N2 pointer
between the letters P and E of the word
SPEED embossed on the governor.
(7). Verify that all jamnuts, bolts, nuts,

lockwire and cotter pins are properly
installed and secured.
(5). Raise the pilot's collective stick until

the Sta. 124.00 bellcrank bottoms on
support and ensure the governor
pointer shifts to between the letters E
(9). Set the battery switch OFF.
Page 204
Revision 22
76-10-00
(8). Pull the N2 GOV circuit breaker reset

button, as required.
(10). Shut down and disconnect external

power.
MAINTENANCE MANUAL
MINIMUM N2 ACTUATOR EXTENSION

COLLECTIVE DOWN
POINTER AT THE FIRST VERTICAL LEG
OF THE LETTER ``N'' OF N2 (94-98%)
CSP-HMI-2
86
36 - 38
31 - 32
68
UNUSED TRAVEL
MAXIMUM N2 ACTUATOR EXTENSION
COLLECTIVE DOWN
POINTER BETWEEN ``P'' AND `È'' OF THE
WORD SPEED (103-105%)
GOVERNOR LEVER
CONTROL ROD
TORQUE NUT
40-50 IN. LBS.
(4.52-5.65 NM)

COLLECTIVE RAISED
POINTER BETWEEN `È'' AND ``D'' OF THE
WORD SPEED
POINTER CL
GOVERNOR LC
ONE SERRATION 15
NOTE:
DROOP CONTROL OVERRIDE LINK SPRING STARTS TO
COMPRESS; ARM IS NOT REQUIRED TO HIT MAXIMUM STOP
WITH FULL COLLECTIVE AND ACTUATOR EXTENDED.
G76-1004A
Figure 202. Power Turbine Governor Adjustments (P/N 252476910 and Prior)
76-10-00
Page 205
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL

250C20B / C20R2 (P/N 252476911, 12)
NOTE:
(Ref. Figure 203)

(1). Position the governor lever arm in line
with the pointer.
CAUTION

extension.
between the letters S and P of the word
pointer shifts to a position approxi
mately aligning with the vertical leg in
Page 206
Revision 22
the first letter E in the word SPEED on

the governor.
76-10-00

mechanical stops.
press.
shifts back to approximately the first
vertical leg of the letter R of INCR on
the governor.
lever is installed.
CAUTION

power.
MAINTENANCE MANUAL
CSP-HMI-2
N2 GOVERNOR ARM
PARALLEL TO POINTER
L C

COLLECTIVE UP
APPROXIMATE POINTER LOCATION
TORQUE NUT
40-50 IN. LBS.
(4.52-5.65 NM)
COLLECTIVE DOWN
POINTER GREATER THAN LETTER ``S'' IN SPEED

COLLECTIVE UP
POINTER APPROXIMATELY AT LEADING
EDGE OF LETTER ``S'' IN SPEED

COLLECTIVE DOWN
POINTER APPROXIMATELY AT VERTICAL
LEG OF LETTER ``R'' IN INCR
POINTERLC
NOTE:
DROOP CONTROL OVERRIDE LINK SPRING
STARTS TO COMPRESS; ARM IS NOT REQUIRED
TO HIT MAXIMUM STOP WITH FULL COLLECTIVE
AND ACTUATOR EXTENDED.
ACCORDING TO STA. 124.00 BELLCRANK
INSTALLATION, POINTER LOCATIONS ARE
APPROXIMATE.
G76-1005B
Figure 203. Power Turbine Governor Adjustments (P/N 252476911, 12)
76-10-00
Page 207
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL

250C20B / C20R/2 (P/N 252466713)
(Ref. Figure 204)
(1). Position the governor lever arm in line
with the pointer.
CAUTION

extension.
greater than the letter P in the word
pointer is greater than the second letter
E in the word SPEED on the governor.
Page 208
Revision 22
76-10-00
NOTE:
mechanical stops.
press.
shifts back to approximately the aft end
of the letter R of INCR on the governor.
lever is installed.
CAUTION

power.
MAINTENANCE MANUAL
CSP-HMI-2
N2 GOVERNOR ARM
PARALLEL TO POINTER
L C

COLLECTIVE UP
APPROXIMATE POINTER LOCATION
TORQUE NUT
40-50 IN. LBS.
(4.52-5.65 NM)
COLLECTIVE DOWN
POINTER GREATER THAN LETTER ``P'' IN SPEED

COLLECTIVE UP
POINTER APPROXIMATELY AT LEADING EDGE
OF LETTER ``S'' IN SPEED

COLLECTIVE DOWN
POINTER APPROXIMATELY AT AFT END
OF LETTER ``R'' IN INCR
POINTERLC
NOTE:
DROOP CONTROL OVERRIDE LINK SPRING
STARTS TO COMPRESS; ARM IS NOT REQUIRED
TO HIT MAXIMUM STOP WITH FULL COLLECTIVE
AND ACTUATOR EXTENDED.
ACCORDING TO STA. 124.00 BELLCRANK
INSTALLATION, POINTER LOCATIONS ARE
G76-1010B
Figure 204. Power Turbine Governor Adjustments (P/N 252466713)
76-10-00
Page 209
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL

250C20B (P/N 252466714 and Higher,
P/N 252476913 and Higher and P/N
25491701 and Higher)
(Ref. Figure 205)
(1). Position the governor lever arm, not the
pointer, to the first serration counterclockwise from pointer centerline.
CAUTION

extension.
at 69 3.
Page 210
Revision 44
76-10-00

pointer is approximately at 81.
NOTE:
mechanical stops.
press.
shifts back to 38 3.
lever is installed.
CAUTION

power.
MAINTENANCE MANUAL
CSP-HMI-2
N2 GOVERNOR ARM POSITION TO FIRST

SERRATION COUNTER-CLOCKWISE
FROM POINTER CENTERLINE
10
POINTER LC
N2 ACTUATOR EXTENDED
COLLECTIVE UP 1/3 TO 1/2 TRAVEL
APPROXIMATE POINTER LOCATION 81
COLLECTIVE DOWN
POINTER AT 69 +3
NOTE:
COMPRESS; ARM IS NOT REQUIRED TO HIT MAXIMUM
STOP WITH FULL COLLECTIVE AND ACTUATOR
EXTENDED.
N2 ACTUATOR RETRACTED
COLLECTIVE DOWN
POINTER AT 38 +3
COLLECTIVE UP
POINTER AT 63 +3
ACCORDING TO STA. 124.00 BELLCRANK INSTALLATION,

POINTER LOCATIONS ARE APPROXIMATE.
-14GOV - C20B
Figure 205. Power Turbine Governor Adjustments (P/N 252466714 and Higher,
P/N 252476913 and Higher and P/N 25491701 and Higher on 250C20B Engine)
76-10-00
Page 211
Revision 44
CSP-HMI-2
MAINTENANCE MANUAL

250C20R/2 (P/N 252466714 and Higher,
P/N 252476913 and Higher and P/N
25491701 and Higher)
(Ref. Figure 206)
(1). Position the governor lever arm, not the
pointer, to the first serration counterclockwise from pointer centerline.
CAUTION

extension.
at 77 3.
Page 212
Revision 44
76-10-00

pointer is approximately at 94.
NOTE:
mechanical stops.
press.
shifts back to 44 3.
lever is installed.
CAUTION

power.
MAINTENANCE MANUAL
CSP-HMI-2
N2 GOVERNOR ARM POSITION TO FIRST

SERRATION COUNTER-CLOCKWISE
FROM POINTER CENTERLINE
10
POINTER CL
APPROXIMATE POINTER LOCATION 94
COLLECTIVE DOWN
POINTER AT 77 +3
COLLECTIVE DOWN
POINTER AT 44 +3
COLLECTIVE UP
POINTER AT 63 +3
NOTE:
COMPRESS; ARM IS NOT REQUIRED TO HIT MAXIMUM STOP
WITH FULL COLLECTIVE AND ACTUATOR EXTENDED.
ACCORDING TO STA. 124.00 BELLCRANK INSTALLATION,
POINTER LOCATIONS ARE APPROXIMATE.
-14GOV - C20R2
Figure 206. Power Turbine Governor Adjustments (P/N 252466714 and Higher,
P/N 252476913 and Higher and P/N 25491701 and Higher on 250C20R/2 Engine)
76-10-00
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Revision 44
CSP-HMI-2
MAINTENANCE MANUAL

250C30
(Ref. Figure 207)
(1). At the governor unit position the
governor lever to within 10 degrees
parallel with the pointer arm.
CAUTION
(2). Torque lever nut to 40 - 50 inchpounds (4.52 - Nm) while holding

lever center screw with a hex wrench.
Apply a torque stripe.
(3). Verify that collective is FULL DOWN
and governor trim actuator is at
minimum extension.
(4). Adjust governor lever control rod link
so that the governor pointer points to
20 mark on the N2 governor plate.
(5). Raise the pilot's collective stick,
minimum beep, and check that pointer
is at is at the 35 mark on the in the N2
governor plate.
NOTE:
D If pointer is above 35 mark, lengthen the
369A7706 rod. If the pointer is below the
35 mark, shorten the rod. After adjusting
rod, repeat steps (3). and (4)..
D Specified pointer/lever angular relation
ships are standard production settings.
Slight variations may be required to ob
tain proper travel and satisfactory engine
operation. Variations are acceptable pro
vided all engine performance require
ments are met.
Page 214
Revision 22
76-10-00
(6). Move collective stick FULL DOWN.

Beep governor trim actuator to maxi
mum extension. The pointer will point
to approximately the 50 mark.
(7). Raise the collective stick until Sta.
124.00 bellcrank bottoms on support,
the pointer will point approximately the
58 mark.
NOTE: The control arm of the pointer should

not hit the mechanical stops.
(8). Continue raising the pilot's collective
stick; droop control override spring
compression continues to increase until
the stick reaches FULL UP. The
governor pointer should remain
approximately stationary on the 58
mark.
(9). Verify that all jamnuts are torqued to
25 - 30 inch-pounds (2.82 - 3.39
Nm). Check all bolts, nuts and cotter
pins for proper installation and securi
ty.
power.
MAINTENANCE MANUAL

COLLECTIVE UP
POINTER AT THE 35 MARK
COLLECTIVE DOWN
POINTER AT THE 20 MARK
CSP-HMI-2

COLLECTIVE DOWN
POINTER TO BE AT THE 50 MARK
POINTER TO BE APPROXIMATELY AT THE 58 MARK
TORQUE NUT
40-50 IN. LBS.
(4.52-5.65 NM)
LEVER ARM
POINTER PARALLEL TO WITHIN 10
G76-1006C
Figure 207. Power Turbine Governor Adjustments (250C30 Engine)
76-10-00
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Revision 35
MAINTENANCE MANUAL
CSP-HMI-2
8. Governor Controls Final Check and

Adjustment (250C20B, C20R/2)
Make all engine compart
WARNING ment control rod adjust

ments with engine shut down.
(1). Have an assistant move collective

through full range of travel while
inspecting all movable linkage for
clearance with adjacent parts. Check
that control rod, N2 actuator and
override link bearings are not jammed
when linkage is at extreme control
positions.
(2). Start and operate engine at idle with
main rotor blades in flat pitch per
Pilot's Flight Manual.
(10). Mark N2 lever position on governor

quadrant.
(11). Connect external electric power.
(12). With collective at bottom stop, beep N2
trim to maximum rpm.
(13). Adjust governor lever control rod (105%
N2 maximum: 369D/E) (104% N2
maximum: 500N).
(4). Throttle up to maximum rpm.
(14). Start engine. With main rotor blades in

flat pitch, beep N2 trim to (102% rpm:
369D/E) (100% rpm: 500N). Lift off and
hover.
(5). Observe N2 tachometer pointer for (98%

or less rpm: 369D/E) (94% or less:
500N) when rotor rpm pointer is
superimposed on N2 pointer and Nl
tachometer pointer is stabilized.
(15). Observe N2 tachometer pointer when

pointer of Nl tachometer is stabilized.
N2 pointer indication, that is, droop
compensation, should be (1/2% to 1%
rpm: 369 D/E) (1% to 2% rpm: 500N)
above indication in previous step.
(6). Check for the following engine power

out (EPO) indications:
(16). Land and shut down engine.
(3). Decrease N2 trim to minimum.
(a). Engine-out flashing light.

(b). Audio signal in headset.
(c). Horn; sounds when N2 pointer on
dual indicator is stable.
(7). With collective stick down, increase N2
trim to (104% to 105% rpm: 369D/E)
(103% to 104% rpm: 500N). Observe N2
tachometer pointer when rotor rpm
pointer is superimposed on N2 pointer
and N1 tachometer pointer is stabilized.
(8). Without decreasing N2 trim, rotate
pilot's throttle to ground idle.

PFM after rigging and testing power tur
bine controls. Refer to Allison Operation
and Maintenance Manual for adjustment
procedures if deceleration time is less than
allowable minimum.
Manual.
Page 216
Revision 42
76-10-00
(17). If droop compensation occurred as

required, no further adjustments are
required.
(18). If droop compensation did not occur per
step (15)., check and re-rig power
turbine and gas producer linkage
systems as required.
(19). Where Nl and N2 linkage are correctly
adjusted, additional adjustment may be
made to droop compensation adjust
ment fork; as follows:
NOTE: Three to five turns of droop compensa

tion fork may be necessary to change droop
compensation approximately 0.5% rpm.
(a). Shorten droop compensation adjust
ment fork to increase compensation.
(b). Lengthen fork extension to decrease
compensation.
(c). Align fork with override link rod-end
before tightening fork jamnut.
(20). Move collective through full travel after
adjustment and check for clearance
MAINTENANCE MANUAL
between movable linkage and adjacent
parts.
(21). When full power is demanded in flight
and high N1 and TOT operating range
cannot be reached, gas producer fuel
control maximum throttle stop may
require adjustment. Refer to Allison
adjustment procedure.
9. Governor Controls Final Check and
Adjustment (250C30)
(1). Have an assistant move collective
through full range of travel while
inspecting all movable linkage for
clearance with adjacent parts. Check
that control rod, N2 actuator and
override link bearings are not jammed
when linkage is at extreme control
positions.
main rotor blades in flat pitch per
Pilot's Flight Manual.
(3). Rotate pilots throttle counterclockwise
up to maximum rpm.
(4). Decrease N2 trim to minimum.
(5). Observe N2 tachometer pointer for 94%
or less rpm and N1 tachometer is
stabilized.
(6). With collective stick down, increase N2
trim to maximum.
(7). Observe N2 tachometer pointer for
103% to 104% rpm and N1 tachometer
pointer is stabilized.
Make all engine compart
WARNING ment control rod adjust

ments with engine shut down.
(8). Stop engine. Adjust length of governor
control lever rod until N2 trim is within
limits specified in steps (5). and (7).
above. Adjust one rod end not more
than one turn at a time.
CSP-HMI-2
(9). Restart engine. With main rotor blades

in flat pitch, actuate N2 trim for 100
percent, liftoff and hover.
(10). Observe N2 tachometer pointer when
pointer of N1 tachometer is stabilized.
N2 pointer indication (droop compensa
tion) should be 1 to 2 percent above N2
setting in step (9).
(11). Land and shut down engine.
NOTE: If droop compensation occurs as re

quired in (10). above, skip steps (12). and
(13). below.
(12). If droop compensation does not occur as
required in step (10). above, recheck
entire power turbine governor (N2
RPM) control linkage rigging and gas
producer (N1 fuel control) linkage
adjustment.
Any change to initial droop com
pensation fork length may re
sult in interference between N2 trim actua
tor case and fork threaded end. Move
collective through full travel after adjust
ment and check for clearance between mov
able linkage and adjacent parts.
CAUTION
(13). If N1 and N2 linkage are correctly

installed, an additional adjustment may
be made at droop compensation adjust
ment fork. Shorten droop compensation
adjustment fork to increase compensa
tion. Lengthen fork extension to
decrease compensation. Align fork with
override link rod end before tightening
fork jam nut. Three to five turns of
droop compensation fork may be
necessary to change droop compensa
tion fork approximately 0.5 percent.

allowable minimum.
76-10-00
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MAINTENANCE MANUAL
CSP-HMI-2
10. Governor Controls Replacement

(Ref. Figure 208)
(1). Remove and replace control rods,
bellcranks and supports as required,
except as follows:
Only high temperature all
WARNING metal self-locking nuts are

to be used for attaching control idler
support to engine gearcase accessory
pad.
NOTE: Remove droop control override link, N2

trim actuator, and Sta. 72.00 bellcrank from
airframe as a unit.
(2). Leave Sta. 72.00 bellcrank attached to
N2 trim actuator and remove as a unit.
(3). Disconnect the bonding jumper and
electrical connector from the actuator.
(4). Disconnect the actuator from Sta. 68
bellcrank.
(5). Disconnect Sta. 72 bellcrank from the
fuselage-routed control rod end.
(6). Remove the pivot bolt that attaches
Sta. 72 bellcrank to structure rib and
controls support bracket; remove
actuator and bellcrank.
(7). Disconnect the trim actuator from Sta.
72 bellcrank. Use care to keep sleeve
bushings with bellcrank.
(11). The sleeve bushings in Sta. 68 bell

crank arm must rotate freely, without
any binding, after the actuator is
attached and the connecting hardware
is tightened.
(12). Connect replacement droop control
override link to collective torque tube.
(13). Push on rod end and check that the link
assembly plunger head is free to slide
back and forth in the link housing end
fitting.
(14). Connect rod end to droop compensation
fork; the rod end should align with the
fork.
(15). Connect the bonding jumper and
electrical connector to the actuator.
NOTE: Replacement trim actuator may have a

tab or use a bonding strap/clamp for connec
tion of the bonding jumper.
(16). Rig power turbine governor controls if
any linkage components have been
removed and replaced.

allowable minimum.
11. Control Rod Inspection
(Ref. Figure 208)
(8). Check replacement actuator for a

maximum extended length of 5.44-5.50
inches (13.82-13.97 cm) measured
between bolt hole centers. Test actuator
for proper operation (Ref. N2 Trim
Actuator Test).

mm) maximum axial play).
(9). Assemble original or replacement trim

actuator to original or replacement Sta.
72 bellcrank with a bolt, two washers,
nut and new cotter pin.
(3). When necessary, perform straightness

check on control rods that appear bent
or bowed. Total length of gas producer
control rods (excluding rod ends) must
be straight within the following
tolerances, with straightness variation
limited to maximum of 0.010 inch
(0.254 mm) in each foot of length.
(10). Check that both sleeve bushings are in

place in Sta. 68 bellcrank arm before
connecting the actuator; then install
assembled unit in controls support
bracket and connect linkage as shown
in Figure 208.
Page 218
Revision 35
76-10-00

(a). Fuselage-routed control rods: 0.050

inch (1.27 mm).
MAINTENANCE MANUAL
(b). Governor lever control rod: 0.020
inch (0.508 mm).
CSP-HMI-2
14. Droop Control Override Link Repair

(Ref. Figure 208)
(c). Idler bellcrank control rod: 0.020 inch

(0.508 mm).
(4). Inspect for loose rivet at fixed rod ends.
(5). Inspect bearings in bellcranks for
binding.
(6). Perform fluorescent dye penetrant
inspection of any suspect part.
Control rods, part number
369A7706-3, between the idler
bellcrank and governor control lever were
made of aluminum and must be replaced
with a steel part, P/N 369A7706-5, or the
complete assembly, P/N 369A7706-11.
CAUTION
NOTE: After replacement and inspection of the

power turbine governor controls linkage,
perform a deceleration check in accordance
with procedures found in the PFM. If con
firmed deceleration time is less than the al
lowable minimum, refer to the appropriate
Allison Operation and Maintenance Manu
al.
12. Bellcrank Inspection
(Ref. Figure 208)
(1). 369D Only: Inspect droop compensation
bellcrank for installation of a spacer
between fork extension jamnut and
bellcrank threaded insert.
As required, install spacer.
(2). Perform a fluorescent penetrant crack
inspection on all suspected parts.
13. Droop Compensation Link Inspection
(Ref. Figure 208)
(1). Inspect droop compensation spring
cartridge for condition and wear.
Cartridge total end play is not to exceed
0.015 inch (0.381 mm).

allowable minimum.
Item
Nomenclature
CM117
CM321
CM431
Grease
(1). Install link end-fitting bearing (detail

B) using surface primer (CM321) and
locking compound (CM431) per contain
er instructions.
(2). Replace rod-end or spring as follows:
(a). Remove four retaining rivets from
housing rod-end.
(b). Drill out rod-end rivet and dismantle
spring assembly. Discard rod-end
and plunger.
(c). Assemble plunger, retainers, spring
and jam nut. Thread jamnut onto
plunger until there is minimum
spring free-play.
(d). Thread rod-end onto plunger until it
contacts jamnut.
Plunger must be free to travel to
bottom of end-fitting oblong slot
without binding.
CAUTION
(e). Align plunger-head hex-flats so that

two parallel flats are at a right angle
(90) to rod-end bearing. Tighten jam
nut.
(f). Using No. 50 drill, drill through
rod-end and plunger at witness hole.
Install rivet.
(g). Lubricate interior of housing, spring
retainers and plunger with grease
(CM117). Install spring assembly in
housing so that plunger hex enters
end fitting slot and rod-end aligns
vertically with housing bearing.
(h). Install four plunger retaining rivets.
76-10-00
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Revision 35
MAINTENANCE MANUAL
CSP-HMI-2
COLLECTIVE TORQUE TUBE
NOTE 3
GROUND JUMPER
DROOP
COMPENSATION
FORK
AIRFRAME
STRUCTURE
*
N2 TRIM ACTUATOR
JAM NUT
STA. 68.00 BELLCRANK
BEARING
SPACER
SLEEVE BUSHING
LOCKED
THREAD
INSERT
AIRFRAME
STRUCTURE
BRACKET
*
FLANGED
BUSHING
SLEEVE
BUSHING
STA. 72.00
BELLCRANK
STA. 64.00 SEAT

STRUCTURE
BRACKET
NOTES:
1. BUSHINGS AND BEARINGS MUST ROTATE
FREELY AFTER ASSEMBLY.
2. ASTERISK ( * ) INDICATES CORROSION
RESISTANT STEEL.
ROD END
JAM NUT
RIVET
BEARING
STA. 124.00
BELLCRANK
FUSELAGE-ROUTED
CONTROL ROD
RETAINER
SPRING
NOTE 3
RETAINER
HOUSING END
FITTING
BEARING
PLUNGER
DROOP CONTROL OVERRIDE LINK
LINK HOUSING
Figure 208. Power Turbine Governor Controls (Sheet 1 of 2)

Page 220
Revision 22
76-10-00
G76-1007-1
MAINTENANCE MANUAL
CSP-HMI-2
NOTE 3
IDLER
BELLCRANK
SUPPORT
GOVERNOR LEVER
CONTROL ROD
GASKET
NUT
(NOTE 5)
IDLER BELLCRANK
BEARING
(NOTE 2)
RIVET
IDLER BELLCRANK
CONTROL ROD
STA. 124.00
SUPPORT FITTING
STA. 124.00
BELLCRANK
250-C30 ENGINE
INSTALLATION
BEARING
NOTES: (CONT.)
3. SPECIAL ALUMINUM ALLOY WASHER;
0.25 IN. (6.35 MM) ID X 0.80 IN. (20.32 MM) OD.
4. MAXIMUM OF 3 WASHERS ALLOWED TO
CORRECT PIN GRIP.
5. ONLY HIGH TEMPERATURE ALL-METAL
NUTS MUST BE USED.
COLLAR
WASHER
(NOTE 4)
PULL-TYPE
LOCKBOLT PIN
FUSELAGE-ROUTED
CONTROL ROD
ENGINE COMPARTMENT LINKAGE

(POWER TURBINE CONTROL)
G76-1007-2A
Figure 208. Power Turbine Governor Controls (Sheet 2 of 2)
76-10-00
Page 221
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
15. Control Rod Repair

(Ref. Figure 208)
(1). Repair rod assemblies as follows:
Fluorescent penetrant crack in
spection shall be performed af
ter cold-straightening control rods. Replace
a cracked rod. Replace a cracked or bent
rod-end.
CAUTION
(2). Cold-straighten bent rods provided

there are no nicks or sharp dents in
bend length. Do not use rod-ends to
support rod during straightening
process.
move or install riveted rod-end.
Tighten jam nut before drilling or riveting.
CAUTION

mm).
(3). With actuator ram approximately

halfway between stops, measure ram
end-play with dial indicator. End-play
total indicator reading when measured
under 10 pound (4.5 kg) reversing load.
(4). Set test switch to RETRACT and allow
actuator ram to fully retract. Using end
of ram sleeve as reference point,
measure portion of ram that remains
out of sleeve to nearest 1/64 inch
(0.3968 mm). Record this measurement
for use in the following step.
(5). Set test switch to EXTEND and run
ram to extend stop. Measure length of
extended ram. Subtract result of step
(4). from extended ram value. Result
should be 0.97-1.03 inches
(24.638-26.162 mm).
(6). Actuator current draw at 26.0Vdc shall
be:
16. Bellcrank and Support Fitting Repair
(a). Under no-load; 0.60-1.25 amperes.
(Ref. Figure 208)
(b). Stalled; 2.0 amperes, maximum.
Item
Nomenclature
CM321
CM431

(1). Install replacement bearings using

surface primer (CM321) and grade A
locking compound (CM431) per contain
er instructions.
(2). Replace distorted or cracked bellcranks
and support fittings. Replace parts that
have elongated holes.
17. N2 Trim Actuator Test
(Ref. Figure 209)
(1). Connect N2 trim actuator to test
equipment.
(7). Operate actuator motor in both extend

and retract directions. Over-travel
maximum when power is switched off.
Actuator ram must retract and extend
to stops without binding on or between
stops.
Actuator ram must retract and extend
to stops without binding on stops or
between stops.
(10). Run actuator to full extended position.
Extended actuator overall length shall
be 5.47-5.50 inches (13.894-13.970 cm)
between pivot bolt centers.
(11). Torque rod-end jamnut to 30 - 40
(12). Turn off power.
(2). Turn on dc power and adjust output to

25.75 to 26.25 volts.
Page 222
Revision 35
76-10-00
(13). Disconnect actuator.
MAINTENANCE MANUAL
CSP-HMI-2
19. Sta. 68.00 Bellcrank Rework, P/N

369A77173 and 369N2606 Only
MS3106-10L-3S
CONNECTOR
SPDT
SWITCH
M1
+
MA
26 VDC
POWER
EXTEND
RETRACT
M2
A
B
C
ITEM
NO.
1
2
3
4
5
6
(Ref. Figure 210)
Item
CM318
N/A
N/A
EQUIPMENT DESCRIPTION
6-INCH SCALE
DC VOLTMETER, CALIBRATED 0-5 VOLTS.
(WESTON MODEL 931 OR EQUIVALNET)
DC MILLIAMMETER, CALIBRATED 0-5AMPERES.
(WESTON MODEL 931 OR EQUIVALENT)
VARIABLE DC POWER SUPPLY, 10-36 VOLTS,
(N.J.E. MODEL SY36-10 OR EQUIVALENT)
DIAL INDICATOR GAGE
(BROWN AND SHARP MODEL 740 OR EQUIVALENT)
SWITCH, SPDT, CENTER OFF
Item
N/A
N/A
Special Tools
Nomenclature
Spotface cutter, 0.687 inch (17450 mm)
dia., 0.030 inch (0.762 mm) corner radius
Spotface cutter pilot, 5/16-24 UNF-3A
thread
(1). Remove panels required to get at power

turbine governor controls linkage.
G76-1008
Figure 209. N2 Trim Actuator Test Hookup
18. N2 Trim Actuator Repair

(1). N2 actuator repairs are limited to
actuator ram rod-end replacement. Set
distance between pivot-bolt centers to
5.44-5.50 inches (13.818-13.970 cm)
with ram fully extended. Torque
rod-end jamnut to 30 - 40 inchpounds (3.39 - 4.52 Nm).
All other actuator repairs are to

be performed by an authorized
overhaul station or the actuator manufac
turer.
CAUTION
Nomenclature
Primer
Dichromate
Anodizing compound
(2). Unbolt and remove Sta. 68.00 bellcrank

assembly.
(3). To expedite reassembly, measure and
note distance between the center of
droop compensation fork clevis bolt hole
and bellcrank pivot bolt hole. Remove
droop compensation fork from bell
crank.
(4). Screw spotface cutter pilot into bell
crank. Cut away only enough material
to provide a 360 flat surface around
hole. Do not cut into thread insert.
(5). Coat bare metal surface with Dow #7 or
#17 chemical treatment per manufac
turers instructions.
(6). Apply primer (CM318) over reworked
surfaces. Allow primer to dry.
(7). Assemble locknut, spacer and droop
compensation fork on bellcrank. Get as
close to previously noted dimension as
possible.
(8). Rig power turbine governor controls.
(9). Note compliance in helicopter log book.
76-10-00
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Revision 35
MAINTENANCE MANUAL
CSP-HMI-2
0.687 IN. (17.45 MM)

DIA SPOTFACE
(NOTE)
NOTE
BELLCRANK
THREAD INSERT
DROOP
COMPENSATION
FORK
JAM NUT
SPACER
STA. 68.00
BELLCRANK
ASSEMBLY
ASSEMBLY ARRANGEMENT
NOTE:
DO NOT SPOTFACE BELOW INSERT
G76-1009
Figure 210. Station 68.00 Bellcrank Rework

Page 224
Revision 22
76-10-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
762000
Gas Producer
Controls (250C20B,
250C20R/2 and
250C30)
MAINTENANCE MANUAL
CSP-HMI-2
GAS PRODUCER CONTROLS

1. Gas Producer Controls Rigging
(250C20B and 250C20R/2)
(Ref. Figure 201)
Item
ST404
ST501
ST502
Special Tools
Nomenclature
Wrench, ground idle adjusting
(LH command)
(RH command)
NOTE:
D The following throttle control rigging pro
cedures are applicable to Allison
250-C20B and 250-C20R/2 engines
equipped with Bendix or Chandler Evans
(CECO) fuel control systems.
D Make fuel flow metering adjustments per
nance Manual except for 369/500 series
helicopter specific idle speed variances
explained in the following steps.
Failure to bleed fuel supply
WARNING system after opening system

to atmosphere can result in power loss
or engine flameout. Bleed trapped air
after opening any fuel lines between
fuel tank and combustion chamber
nozzle. Bleed fuel system following re
moval and replacement of any part of
the engine or aircraft fuel system (Ref.
Sec. 28-00-00).
Do not exceed adjustable rodend maximum extension/thread
engagement. Inspect rod-end thread en
gagement through witness hole.
CAUTION
NOTE:
D Refer to Collective Controls (Ref. Sec.
67-10-00) for information on rigging
throttle gas producer control tube, inter
connect torque tube and associated link
age.
D Rigging check/adjustments are required

when pilot's compartment linkage, or con
trol rod lengths have been disturbed, or
when there is less than a 0.010 inch
(0.254 mm) gap between Sta. 129.00 fire
wall bellcrank upper arm and its support
fitting with the throttle in CUT-OFF.
(1). Remove gas producer lever control rod
(Detail B).
(2). Position pilot's collective stick at
mid-travel. Insert rigging fixture
(ST501) or (ST502) in collective friction
guide link slot. Rest collective stick on
fixture (Detail A).
(3). On dual control installations; check for
asynchronous motion between collective
stick throttle assemblies with the
throttle wide open and in CUT-OFF.
Dual control throttle movement should
be synchronized, but with the pilot's
(command position) throttle dominating
the copilot's throttle at idle.
(4). Position pilot's throttle twist grip so
that twist grip set-screws are at six
o'clock.
(5). Remove gearbox inspection plate on the
bottom of the collective stick. Ensure
that the centerline of the cutaway on
the large bevel gear is aligned on the
collective stick lengthwise centerline. If
gear is not properly positioned, remove
gearbox side plate and reposition the
gear.
NOTE: When a ring adjustment is made, check

engagement of ring gear and pinion. Cutout
in ring gear should face aft with throttle in
CLOSED position. When dual controls are
in installed, check for override or interfer
ence between collective stick assemblies
with with the throttle grip in the CLOSED
and FULL OPEN position. Return throttle
grip to MID travel position.
(6). Find and remove all lost motion in the
throttle system before making rigging
adjustments.
76-20-00
Page 201
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
NOTE: It is important that all assembly toler

ances between the gas producer intercon
nects and torque tube assemblies are correct
and all backlash removed to assure accurate
rigging of the fuel control system.
(7). Check idler for interference with its
support.
(8). Adjust Sta. 73.00 control rod length so
that lower arm of Sta. 70.00 bellcrank
is parallel to seat structure (Detail B).
(9). Adjust fuselage-routed control rod
length so that bolt center in lower arm
of Sta. 129.00 bellcrank is 4.97-5.03
inches (12.624-12.776 cm) from Sta.
124.00 firewall bulkhead.
(10). Move throttle to CUT-OFF.
(11). Adjust the fuselage routed control rod
to provide a gap of 0.010-0.050 inch
(0.254-1.270 mm) between Sta. 129.00
bellcrank upper arm and support
fitting. Push the rod and bellcrank
toward the firewall bulkhead to remove
all friction errors before checking gap.
NOTE:
D Bendix Fuel Control: Pointer position
may range from 0 to 10 when contacting
the CUT-OFF stop, depending on calibra
tion settings peculiar to the fuel control.
D Bendix fuel control lever and shaft serra
tions are at 15 intervals.
(12). Set fuel control lever against CUT-OFF
stop. Pointer position should range
between the 0 and 10 quadrant
marks. Set the fuel control throttle
shaft lever, without moving the pointer,
15 counterclockwise from parallel with
the engine compartment door frame
while keeping the pointer at CUT-OFF
and inboard lever half in contact with
stop.
(13). Torque fuel control lever nut to 40 - 50
inch-pounds (4.52 - 5.65 Nm). Do not
over-tighten nut. Apply a torque stripe.
Page 202
Revision 22
76-20-00
Governor and fuel control levers

can be erroneously installed on
the wrong fuel system component shaft.
Governor lever is relatively short with an
offset angle of about 65. Fuel control lever
offset angle is a more moderate 38.
CAUTION
(14). Move throttle twist grip from wide open

to CUT-OFF to ensure that the throttle
lever is contacting open and closed fuel
control mechanical stops. Adjust gas
producer lever control rod as required
to cause lever contact. Do not adjust
stops.
(15). Turn pilot's throttle to maximum rpm,
then to idle.
(16). Bendix Fuel Control: With pilot's
throttle held at idle, adjust gas produc
er lever control rod until gas producer
pointer is at 30 (View C).
(17). CECO Fuel Control: With pilot's
throttle held at idle, adjust gas produc
er lever rod until gas producer pointer
is at 30 to 32.
CAUTION
D Do not alter gas producer lever position or
control linkage to adjust idle speed. Idle
speed is to be checked during engine op
erational test and adjusted with fuel con
trol idle screw, not with the linkage.
D Check linkage at extreme travel posi
tions. Ensure gas producer lever hits fuel
control mechanical stops before throttle
twist grip stops are contacted.
D Interference or binding anywhere in link
age is not allowed.
D Be sure that linkage movement is clear of
wires, tubes and hoses.
(18). Rotate pilot's throttle counterclockwise
to maximum rpm.
(19). Make sure gas producer lever strikes
maximum speed stop.
(20). Raise collective stick to up stop.
(21). Gas producer lever must remain in
contact with maximum speed stop; if
lever comes off stop, check gas producer
controls for binding.
(22). Release idle detent and roll pilot's
throttle to CUT-OFF. Make sure that
MAINTENANCE MANUAL
gas producer lever strikes CUT-OFF
stop.
(23). Lower collective stick. Ensure gas
producer lever does not move off
CUT-OFF stop.
(24). When dual controls are installed, move
copilot's throttle twist grip to its idle
stop. Fuel control pointer shall not be
more than 5/64 inch (1.9844 mm) below
the idle degree mark specified for a
Bendix fuel control (30) or a CECO
fuel control (30 to 32) as applicable.
(25). Have an assistant cycle the throttle
from CUT-OFF to wide open. Ensure
control rods do not roll over or jam
when linkage is at extreme travel
positions.
NOTE: Refer to your Allison Operation and

Maintenance Manual for complete gas pro
ducer fuel control rigging procedures to
make the following adjustments.
CSP-HMI-2
fault isolation procedures per Allison

Manual.
(29). Accelerate and decelerate engine three
times to ensure repeatability.
Throttle snap to idle must be
WARNING performed to ensure that en

gine will not flame out.
(30). Accelerate engine to to normal operat
ing rpm with pilot's throttle; then snap
clockwise to idle. Repeat this check
using copilot's throttle where installed.
If flameout occurs, adjust engine idle
speed per the applicable Allison
Perform a deceleration time

check per PFM following gas
producer or linkage replacement or adjust
ment. Refer to Allison Engine Operation
procedures when deceleration time is less
than allowable minimum.
CAUTION
(31). Shut down engine.

main rotor in flat pitch per Pilot's
Flight Manual (PFM).
Operating requirements de
mand that idle rpm be adjusted
within minus 1% of the Allison specified up
per limit of 65% rpm. Achieving required
idle rpm is particularly important for heli
copters equipped with dual controls.
2. Gas Producer Controls Rigging (250C30)

(Ref. Figure 201)
CAUTION
(27). With pilot's throttle at idle, observe Nl

tachometer indicator. Ensure Nl speed
stabilizes between 64 - 65 %. To adjust
idle rpm, proceed as follows:
(a). Bendix: Adjust idle speed with
adjusting tool (ST404) per the
applicable Allison Operation and
Maintenance Manual.
(b). CECO: Adjust idle speed with a 5/32
hex-wrench per the 250-C20 Allison
(28). Accelerate engine to 100%, stabilize,
then decelerate to idle after each
adjustment. If idle adjustments do not
consistently stabilize rpm within 64% 65% limit, follow engine fuel control
Special Tools
Nomenclature
Item
ST404
ST405
ST406
ST407
ST501
ST502
Wrench, ground idle adjusting

Rigging fixture, collective stick
Alignment fixture
Rigging pin
(LH command)
(RH command)
NOTE:
D The following throttle control rigging pro
cedures are applicable to Allison 250-C30
engines equipped with Bendix fuel control
systems.
D Make fuel flow metering adjustments per
nance Manual except for 369/500 series
helicopter specific idle speed variances
explained in the following steps.
76-20-00
Page 203
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
RIGGING
FIXTURE
TORQUE TUBE
ASSEMBLY
GEARBOX
INSPECTION
PLATE
COLLECTIVE FRICTION
CONTROL
GEARBOX
SIDE PLATE
PILOT'S COLLECTIVE
PITCH STICK
FRICTION
GUIDE LINK
G76-2000-1
Figure 201. Gas Producer Controls Rigging (Sheet 1 of 3)

Page 204
Revision 22
76-20-00
MAINTENANCE MANUAL
CSP-HMI-2
IDLE POSITION
(NOTES 10, 11)
GAS
PRODUCER
LEVER
CUT-OFF
POSITION
(NOTE 8)
MID POSITION
(NOTE 1
TORQUE NUT
40-50 IN. LBS.
(4.52-5.65 NM)
CUT-OFF
(NOTE 7)
GAS PRODUCER
LEVER CONTROL
CL
OF
CONTROL ROD
POINTER
CECO FUEL CONTROL
QUADRANT
IDLE RANGE
(NOTES 9, 11)
OVERTRAVE
L (NOTE 1)
BENDIX FUEL CONTROL
POINTER
(NOTE 12)
LEVER CONTROL
ROD
LEVER POSITION
QUADRANT
250-C30 FUEL CONTROL

FUEL CONTROL LEVER
AND POINTER
SUPPORT
FITTING
GAS PRODUCER
LEVER CONTROL ROD
STA. 129.00
BELLCRANK
STA.
74.87
GAP
(NOTE 6)
STA. 73.00
CONTROL ROD
IDLER
ASSY.
STA. 70.00
BELLCRANK
(NOTES 2, 3)
DISTANCE
(NOTES 4, 5)
STA. 124.00
FIREWALL
FUSELAGE-ROUTED
CONTROL ROD
LINKAGE INSTALLATION
(NOTE 1)
G76-2000-2A
76-20-00
Page 205
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
COLLECTIVE STICK
(NOTE 1)
CL COLLECTIVE
TORQUE TUBE
VERTICAL (PARALLEL)
WITH FORWARD SEAT
STRUCTURE
STA. 70.00
BELLCRANK ASSY.
(NOTE 2)
STA. 73.00 CONTROL

ROD ASSY.
WL
14.47
THROTTLE
OPEN
WL
13.10
THROTTLE
CUT-OFF
54 30'
STA.
78.21
COLLECTIVE STICK LINKAGE RIGGING, 250-C20B
AND 250-C20R/2 ENGINE EQUIPPED HELICOPTERS
FUSELAGE-ROUTED
CONTROL ROD ASSY.
COLLECTIVE
(NOTE 1)
THROTTLE TWIST GRIP
IN FLIGHT IDLE
99 55' 12
(REF)
PILOT'S SEAT
STRUCTURE
(REF)
38 (REF)
WL
20.03
ALIGNMENT
FIXTURE
VERTICAL
IDLER
STA.
74.87
STA. 70.00
BELLCRANK
(NOTE 3)
CL COLLECTIVE
TORQUE TUBE
STA. 73.00
CONTROL ROD
ASSY.
WL
14.47
THROTTLE
OPEN
WL
13.10
IDLE
5 45'
37 30'
54 30'
THROTTLE
CUT-OFF
STA.
78.21
FUSELAGE-ROUTED
ROD ASSY.
MID
STA.
70.35
COLLECTIVE STICK LINKAGE RIGGING

250-C30 ENGINE EQUIPPED HELICOPTERS

Page 206
Revision 22
76-20-00
G76-2000-3A
MAINTENANCE MANUAL
CSP-HMI-2

1. EXCEPT AS NOTED, GAS PRODUCER AIRFRAME
CONTROL LINKAGE RIGGING ADJUSTMENTS AND
MEASUREMENTS ON ALL 369/500 SERIES
HELICOPTER MODELS ARE NORMALLY STARTED
WITH FUEL CONTROL LEVER CONTROL ROD
DISCONNECTED, COLLECTIVE STICK AT
MIDTRAVEL; I.E., RIGGING FIXTURE (ST501) OR
(ST502) INSTALLED, AND THE PILOTS THROTTLE
TWIST GRIP ROTATED TO MIDPOSITION; I.E., TWIST
GRIP SETSCREWS AT SIX OCLOCK.
2. ON 250C20B AND 250C20R/2 ENGINE EQUIPPED
HELICOPTERS; ADJUST STA. 73.00 CONTROL ROD
SO LOWER ARM OF STA. 70.00 BELLCRANK IS
VERTICAL WHEN THROTTLE TWIST GRIP IS AT IDLE
POSITION.
3. FOR 250C30 ENGINE EQUIPPED HELICOPTERS;
ALIGN FORWARD FACE OF STA. 70.00 BELLCRANK
WITH AFT EDGE OF FIXTURE (ST406).
4. FOR 250C20B AND 250C20R/2 ENGINE EQUIPPED
HELICOPTERS; WITH THROTTLE AND COLLECTIVE
IN MIDPOSITION, ADJUST FUSELAGE ROUTED
CONTROL ROD SO CENTER OF STA. 129.00
BELLCRANK LOWER ARM PIVOT BOLT IS 4.975.03
INCHES (12.62412.776 CM) FROM FIREWALL
BULKHEAD.
5. FOR 250C30 ENGINE EQUIPPED HELICOPTERS;
WITH THROTTLE AND COLLECTIVE IN
MIDPOSITION, ADJUST FUSELAGE ROUTED
CONTROL ROD SO CENTER OF STA. 129.00
BELLCRANK LOWER ARM PIVOT BOLT IS 5.47 5.50
INCHES (13.89413.970 CM) FROM FIREWALL
BULKHEAD.
6. ON ALL ENGINE INSTALLATIONS: ROLL THROTTLE

TO CUTOFF AND PUSH CONTROL ROD AND
BELLCRANK TOWARD FIREWALL TO ELIMINATE
PLAY. ADJUST FUSELAGE ROUTED CONTROL ROD
TO GET A GAP OF 0.0100.050 INCH (0.2541.270
MM) BETWEEN UPPER BELLCRANK ARM AND
SUPPORT FITTING.
7. BENDIX FUEL CONTROL CUTOFF POINTER
POSITION NORMALLY RANGES BETWEEN 0 10
WITH FUEL CONTROL LEVER AGAINST CUTOFF
STOP. CUTOFF RANGE IS DUE TO FACTORY SET
CALIBRATION VARIATIONS BETWEEN FUEL
CONTROL UNITS.
8. CECO FUEL CONTROL CUTOFF POINTER
POSITION IS 2 TO MINUS, 1/32 INCH (0.7938 MM)
FROM QUADRANT EDGE, WITH FUEL CONTROL
LEVER AGAINST CUTOFF STOP.
9. WITH PILOTS THROTTLE TWIST GRIP HELD AT IDLE:
BENDIX FUEL CONTROL IDLE POINTER POSITION IS
30.
10. CECO FUEL CONTROL IDLE POINTER POSITION IS
30 32.
11. MAXIMUM ALLOWABLE POINTER MOVEMENT
BELOW THE OPTIMAL IDLE POSITION ON ALL
ENGINE INSTALLATIONS FROM ALL CAUSES IS, 5/64
INCH (1.9844 MM).
12. NORMAL SETTING IS 40 WITH PILOTS THROTTLE
AT IDLE.
Failure to bleed fuel supply
D Rigging check/adjustments are required

when pilot's compartment linkage or fuse
lage-routed control rod length adjust
ments have been disturbed, or when there
is less than a 0.010 inch (0.254 mm) gap
between Sta. 129.00 firewall bellcrank
upper arm and its support fitting with the
throttle in CUT-OFF position.
WARNING system after opening system

to atmosphere can result in power loss
or engine flameout. Bleed trapped air
after opening any fuel lines between
fuel tank and combustion chamber
nozzle. Bleed fuel system following re
moval and replacement of any part of
the engine or aircraft fuel system (Ref.
Sec. 28-00-00).
Do not exceed adjustable rodCAUTION end maximum extension/thread
engagement. Inspect rod-end thread en
gagement through witness hole.
NOTE:
D Refer to Collective Controls (Ref. Sec.
67-10-00) for information on rigging
throttle gas producer control tube, inter
connect torque tube and associated link
age.
(1). Remove gas producer lever control rod

(Detail B).
(2). Position pilot's collective stick at
mid-travel. Insert rigging fixture
(ST501) or (ST502) in collective friction
guide link slot. Rest collective stick on
fixture.
(3). On dual control installations; check for
a synchronous motion between collec
tive stick throttle assemblies with the
throttle wide open and in CUT-OFF.
Dual control throttle movement should
be synchronized, but with the pilot's
(command position) throttle dominating
the copilot's throttle at idle.
76-20-00
Page 207
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
(4). Position plot's throttle twist grip so that

twist grip set screws are at six o'clock.
(15). Torque control rod jamnuts to 25 - 30

(5). Remove gearbox inspection plate on the

bottom of the collective stick. Ensure
that the centerline of the cutaway on
the large bevel gear is aligned on the
collective stick lengthwise centerline. If
gear is not properly positioned, remove
gearbox side plate and reposition the
gear.
CAUTION
(6). Find and remove all lost motion in the

throttle system before making rigging
adjustments.
(7). Put throttle in idle position and secure
with friction lock.
(8). Locate and secure alignment fixture
(ST406) on the pilot's seat structure.
The forward face of the Sta. 70.00
bellcrank should align with the aft edge
of the fixture. Adjust Sta. 73.00 control
rod as required to align bellcrank with
fixture. Remove the rigging fixture.
(9). Bottom the collective stick and check
the idler assembly for clearance with
support.
(10). Set collective and throttle at mid-tra
vel.
(11). Adjust fuselage-routed control rod
length so bolt center through lower arm
of Sta. 129.00 bellcrank is 5.50 0.03
inches (139.7 0.762 mm) from Sta.
124.00 firewall bulkhead.
(12). Rotate throttle twist grip to CUT-OFF.
(13). Adjust the fuselage routed control rod
to provide a gap of 0.010-0.050 inch
(0.254-1.270 mm) between Sta. 129.00
bellcrank upper arm and support
fitting. Push the rod and bellcrank
toward the firewall bulkhead to remove
all friction errors before adjusting gap.
NOTE: It will be necessary, during the rigging

procedure to remove and reinstall the rig
ging fixtures as required.
(14). Move collective through full range of
travel. Ensure throttle movement is
unrestricted in all collective stick
positions.
Page 208
Revision 22
76-20-00
D Adjusting fuel control mechanical stop

settings for any reason is not allowed.
D Governor and fuel control levers can be
erroneously installed on the wrong fuel
system component shaft. Governor lever
is relatively short with an offset angle of
about 65. Fuel control lever offset angle
is a more moderate 38.
NOTE:
D Pointer position may range from 0 to 10
when contacting the idle CUT-OFF stop,
depending on calibration settings pecul
iar to the fuel control unit.
D The Bendix fuel control features a double
serrated washer between the lever and
fuel control input shaft. There are 24 (15
each) serrations on the lever side and 25
(14.4 each) serrations on the fuel control
side that allow coarse or fine lever posi
tion adjustments to be made. Make 0.6
incremental adjustments by moving the
washer one serration in one direction and
the lever one serration in the opposite di
rection. Fifteen degree adjustments are
made by moving the lever against the
washer; 14.4 adjustments by moving the
washer and lever together against the fuel
control shaft.
(16). Rotate the throttle twist grip to idle.

(17). Insert rigging pin (ST407) through fuel
control lever. Position the lever on the
fuel control throttle shaft so that lever
is close to parallel to, or a maximum of
5 forward of the Sta. 137.50 engine
compartment bulkhead. Torque lever
nut to 40 - 50 inch-pounds (4.52 5.65 Nm). Do not over-tighten the nut.
Apply a torque stripe.
(18). Set gas producer lever control rod to a
preliminary length of 16.4 inches (41.66
cm) measured between rod-end bolt
hole centers.
(19). Set throttle twist grip in the idle
position. Connect gas producer lever
control rod. Adjust rod length as
required to align it with the fuel control
lever.
MAINTENANCE MANUAL
To prevent flameout, the fuel
control pointer should not move
more than 5/64 inch (1.9844 mm) below the
fuel control quadrant 40 mark with throttle
at idle and commanded by either the pilot's
or copilot's twist grip.
CAUTION
NOTE:
D When dual controls are installed, move
copilot's throttle twist grip to its idle stop.
Fuel control pointer shall not be more
than 5/64 inch (1.9844 mm) below the idle
degree mark.
D Throttle twist grip stopped at idle setting
must produce a 40 pointer/quadrant
alignment on the fuel control with the rig
ging pin inserted.
(20). Remove rigging pin and operate pilot's
throttle twist grip from CUT-OFF to
wide open while an assistant deter
mines that the fuel control lever
contacts the max open and CUT-OFF
mechanical stops and the following
pointer positions are indicated.
(a). With pilot's throttle wide open, fuel
control pointer shall align with
quadrant 100 mark and fuel control
max stop shall be in contact with
lever.
(b). With pilot's throttle in CUT-OFF;
fuel control pointer shall be between
0 and 10 quadrant marks with
lever in contact with fuel control
minimum stop.
(21). Adjust the gas producer lever control
rod length as required to move lever
into stop contact. If the Sta. 124.00
bellcrank bottoms on its support fitting,
adjust fuselage routed control rod one
turn away from the bellcrank bottoming
problem.
(22). Return pilot's throttle twist grip to idle
detent. Ensure fuel control pointer
aligns with 40 mark.
(23). Bottom the pilot's collective stick.
Rotate throttle to wide open. Check for
stop/lever contact.
CSP-HMI-2
(24). Move and hold throttle at idle. Check;

gas producer pointer is at 40 quadrant
position.
CAUTION
D Do not alter gas producer lever position or
control linkage to adjust idle speed. Idle
speed shall be adjusted by the fuel control
idle screw, not the linkage.
D Check linkage at travel extremes to en
sure that the linkage does not bind at any
point and the gas producer lever hits the
fuel control mechanical stops before the
throttle twist grip stops make contact.
(25). Set pilot's throttle wide open. Raise
collective stick to upper stop. Check
that fuel control lever remains on max
speed stop. Inspect the fuel control
linkage for binding if the fuel control
lever comes off the max speed stop.
(26). Leave throttle wide open and bottom
pilot's collective stick. Check that fuel
control lever remains in contact with
the max stop.
(27). Have an assistant move throttle and
collective stick through entire range of
travel while inspecting installation for
operating clearances, control rod
bearing jamming and rod roll-over.
(28). Check that the copilot's throttle
operates N1 fuel control the same as the
pilot's with the following exception:
(a). When the copilot's throttle twist grip
is rotated to its idle stop, the fuel
control pointer shall move no more
than 5/64 inch (1.9844 mm) below the
quadrant 40 mark (Detail C).
(29). Inspect all bolts, nuts, control rod
jamnuts, cotter pins and lockwire
installations for security.
NOTE: Refer to your Allison Operation and

Maintenance Manual for complete gas pro
ducer fuel control rigging procedures to
make the following adjustments.
main rotor in flat pitch per Pilot's
Flight Manual.
76-20-00
Page 209
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
Operating requirements de
mand that idle rpm be adjusted
within minus 1% of the Allison specified up
per limit of 65% rpm. Achieving required
idle rpm is particularly important for heli
copters equipped with dual controls.
CAUTION
(31). With pilot's throttle at idle, observe Nl

tachometer indicator. Ensure Nl speed
stabilizes between 64% - 65%.
(a). Adjust idle speed with adjusting tool
(ST404) per the applicable Allison
(32). Accelerate engine to 100%, stabilize,
then decelerate to idle after each
adjustment. If idle adjustments do not
consistently stabilize rpm within 64% 65% limit, follow engine fuel control
fault isolation procedures per Allison
Manual.
(33). Accelerate and decelerate engine three
times to ensure repeatability.
Throttle snap to idle must be
WARNING performed to ensure that en

gine will not flame out.
(34). Accelerate engine to to normal operat
ing rpm with pilot's throttle, then snap
to idle. Repeat this check using copilot's
throttle where installed. If flameout
occurs, adjust engine idle speed per the
applicable Allison Operation and
Maintenance Manual.

CAUTION check per PFM following gas
producer or linkage replacement or adjust
ment. Refer to Allison Engine Operation
procedures when deceleration time is less
(35). Shut down engine.
A. Gas Producer Fuel Control Derichment
Valve Adjustment
(1). Refer to Allison Engine Operation and
Maintenance Manual.
Page 210
Revision 22
76-20-00
B. Power Controls Operational Test/Final

Adjustments
(Ref. Sec. 76-10-00)
3. Gas Producer Controls Linkage
Replacement
(Ref. Figure 202)
(1). Disassemble linkage only to point
required to make repairs.
(2). Measure and note control rod length
before removing rod-ends to expedite
reassembly and rigging.
4. Sta. 124.00 Support Fitting Replacement
(Ref. Figure 202)
A. Sta. 124.00 Support Fitting Removal
(1). Remove lockbolt from Sta. 124.00
support fitting as follows:
(2). Split collar axially with a sharp chisel.
Have an assistant support opposite side
with a bucking bar to prevent hole
deformation or breakout. Drive pin out
with a drift.
NOTE: Lockbolt hole enlargement beyond

0.1870 inch (4.7498 mm) diameter requires
an oversize lockbolt pin installation.
B. Sta. 124.00 Support Fitting Installation
Item
Special Tools
Nomenclature
ST2009
Inspection gauge
(1). Position support fitting on Sta. 124.00

lower frame. Install standard bolts,
washers and nuts. Do not tighten.
NOTE: A standard size pin may be used where

pin hole does not exceed 0.1870 inch (4.7498
mm) diameter; otherwise, proceed as fol
lows:
(2). Use a No.7 drill to enlarge a damaged
hole to 0.2015 inch (5.1181 mm)
maximum diameter. Use a 3/16 inch
(4.7625 mm) diameter replacement pin.
MAINTENANCE MANUAL
NOTE: Up to three washers may be used under

pin head to establish correct lockbolt grip.
CSP-HMI-2
1). Bearing wear is limited to 0.040

inch (1.016 mm) maximum axial
looseness.
(3). Install lockbolt pin and collar; best fit

results when pulling gun air pressure is
90-125 psi (621-862 kPa).
(b). Surface damage.
(4). Inspect lockbolt installation with gauge

(ST2009) or equivalent.
(d). Gouges
(a). No gap is allowed under either pin

head or collar. If pin grip length or
collar swage quality is questionable,
replace lockbolt.
(5). Torque control support fitting/Sta.
124.00 attaching hardware.
Do not jam bearing against fit
ting. Hold rod-end with a
wrench when tightening adjustable end jam
nut. Ensure bearing misalignment is di
vided equally between each control rod
bearing assembly.
CAUTION
(6). Rig gas producer controls (Ref. Model

250-C20B and 250-C20R/2 Gas
Producer Controls Rigging).
5. Gas Producer Controls Inspection
(Ref. Figure 202)
(1). Check gas producer linkage for lost
motion due to wear as follows:
(a). Open throttle to maximum speed
stop, then slowly back to to idle stop.
(b). Mark pointer position on gas produc
er fuel control quadrant.
(c). Use light finger pressure to move gas
producer lever toward CUT-OFF.
Mark pointer position on quadrant.
Relax pressure.
(d). Measure distance between lever
position marks. Measurement
exceeding 5/64 inch (1.9844 mm)
indicates unacceptable wear in
throttle control linkage. Inspect
individual linkage components for
loose fasteners and wear.
(2). Inspect control rods for:
(a). Worn or binding end bearings.
(c). Cracks
(e). Nicks
(f). Loose end rivets
(g). Misalignment, bent or bowed
Control rod variation from a
straight line is limited to 0.010
inch (0.254 mm), maximum, in each foot.
CAUTION
(3). Bent or bowed gas producer control

rods, excluding rod-ends, must fall
within the following tolerances:
(a). Fuselage-routed control rods: Not
more than 0.050 inch (1.270 mm),
total variation.
(b). Sta. 73.00 control rod: Not more than
0.010 inch (0.254 mm), total varia
tion.
(c). Gas producer lever control rod: Not
more than 0.020 inch (0.508 mm),
total variation.
(4). Inspect bellcrank and support fitting
bearings for binding.
(5). Fluorescent penetrant inspect sus
pected parts for cracks.
Check control system rig
WARNING and engine operation follow

ing any repair that required gas pro
ducer control or linkage disassembly
or replacement; prior to releasing heli
copter for flight.
check per pilot's flight manual
after adjusting or replacing gas producer
fuel control or linkage parts. Make adjust
ments per Allison Operation and Mainte
nance Manual if deceleration time is less
CAUTION
6. Gas Producer Control Rod Repair

(Ref. Figure 201)
76-20-00
Page 211
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
Item
Nomenclature
CM321
CM431
7. Bellcrank Repair
(Ref. Figure 202)
(1). Replace bellcranks or control supports
that are distorted, cracked or have
elongated holes.
(2). Replace unserviceable bellcrank
bearings.
Fluorescent penetrant crack in

spection shall be performed af
ter cold-straightening. Replace a cracked or
bent rod, or rod-end.
CAUTION
(1). Cold-straighten a bent rod provided

there are no nicks or sharp dents in
bend length. Do not use rod-ends to
support rod during straightening
process.
move or install riveted rod-end.
Tighten jam nut before drilling and riveting
to prevent hole enlargement.
CAUTION
(2). Replace control rod-end if bearing axial

bearing angularity as shown.
Page 212
Revision 22
76-20-00
CAUTION
Do not get primer or locking

compound on bearing surfaces.
(a). Apply surface primer and grade A

locking compound (CM321 and
CM431) to bearing outer race and
installation hole per manufacturers
instructions. Install bearing.
Check control system rig
WARNING and engine operation follow

ing any repair that required gas pro
ducer control or linkage disassembly
or replacement; prior to releasing heli
copter for flight.
check per pilot's flight manual
after replacing or adjusting gas producer
fuel control or linkage parts. Make adjust
ments per Allison Operation and Mainte
nance Manual if deceleration time is less
CAUTION
MAINTENANCE MANUAL
CSP-HMI-2
COLLECTIVE STICK
GAS PRODUCER IDLER
GAS PRODUCER
LEVER
GAS PRODUCER
LEVER CONTROL ROD
COUNTERSUNK
WASHER
COUNTERSUNK
SCREW
RIVET
WASHER
(NOTE)
STA. 73.00
CONTROL ROD
STA. 129.00
BELLCRANK
SUPPORT
FITTING
BEARING
THIN
WASHERS
COLLAR
STA. 124.00
FIREWALL
PULL-TYPE
LOCKBOLT PIN
BEARING
STA. 70.00
BELLCRANK
FUSELAGE-ROUTED
CONTROL ROD
NOTE:
SPECIAL ALUMINUM ALLOY WASHER, 0.25 IN.
(6.35 MM) ID X 0.80 IN. (20.32 MM) OD.
GAS PRODUCER CONTROL LINKAGE

G76-2001
Figure 202. Gas Producer Controls Replacement
76-20-00
Page 213
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 214
Revision 44
76-20-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
764700
Engine Power
Controls (250C47)
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE CONTROLS
1. Engine Controls Description
modulates fuel flow to the engine in

conjunction with the position of the
power lever angle (PLA) which is
connected to the throttle grip on the
collective stick by a control cable. The
PLA will be set with the throttle grip to
either the Cutoff, Ground Idle or Flight
Idle position. The ECU provides hot
start and overspeed protection, over
speed test function and auto-reignition
and rotor speed trim capability.
(1). The 250-C47 engine control system

consists of a full authority digital
engine control (FADEC) system for
automatic operation and a hydrome
chanical backup system for emergencies
or manual operation.
(2). Refer to the 250-C47M Rolls-Royce
Engine Operation and Maintenance
Manual for additional engine fuel
system theory, operation and mainte
nance data.
2. Engine Controls Operation
(1). Engine control mode is selected by the
Auto/Manual Switch. In the Auto Mode,
the Electronic Control Unit (ECU)
(2). In the Manual Mode, the fuel flow is

modulated by the PLA on the Hydrome
chanical Control Unit with the throttle
grip and control cable. The ignition
exciter operates continuously in this
mode.
3. Engine Controls Fault Isolation
Table 201. Engine Controls Fault Isolation

Symptom
Probable Trouble
Corrective Action
ECU FAIL on Warning/Caution

panel.
Faulty ECU.
Replace ECU.
Faulty wiring.
Test and repair wiring.
Flight controls unresponsive.
Faulty ECU.
Replace ECU.
Faulty collective potentiometer.
Replace Collective Potentiometer.
Faulty directional potentiometer.
Replace Directional Potentiometer.
Faulty wiring.
Test and repair wiring.
76-47-00
Page 201
Revision 44
CSP-HMI-2
MAINTENANCE MANUAL
6G76-065-1B
Figure 201. Engine Control Unit Wiring Diagram (Sheet 1 of 2)

Page 202
Revision 37
76-47-00
MAINTENANCE MANUAL
CSP-HMI-2
6G76-065-2B
Figure 201. Engine Control Unit Wiring Diagram (Sheet 2 of 2)
76-47-00
Page 203
Revision 37
MAINTENANCE MANUAL
CSP-HMI-2
4. ECU (Electronic Control Unit)

Replacement
5. Engine Control Potentiometer

Replacement
(Ref. Figure 202)
(Ref. Figure 202)
A. Collective Potentiometer Removal

collective potentiometer.
A. ECU Removal
(1). Disconnect engine harness and air
frame harness connectors from ECU.
(2). Remove screw, lockwasher and washer
and disconnect bonding jumper from
ECU.
(3). ECU P/N - 23068338, 23070259,
23072949 and 23080491 - Remove
bolts, washers, large area washers and
bushings and remove ECU from
mounting bracket.
(4). ECU P/N - 23088905, 23089311 Remove bolts and washers and remove
ECU from mounting bracket.
(2). Loosen potentiometer mounting screws

and remove drive belt.
(3). Remove screws and washers and
remove potentiometer assembly from
mounting bracket.
B. Collective Potentiometer Installation
Item
Special Tools
Nomenclature
ST1010
N/A
Volt-ohmmeter
Laptop computer with MT35 program
(1). Prepare potentiometer mounting

surfaces for electrical bonding (Ref.
CSP-HMI-3, Section 96-00-00).
(2). Install potentiometer with screws and
B. ECU Installation
(1). ECU P/N - 23068338, 23070259,
23072949 and 23080491 - Install
ECU on mounting bracket with bush
ings, large area washers, bolts and
washers. Torque bolts to 36 - 46 inch
pounds (4.06 - 5.19 Nm).
(2). ECU P/N - 23088905, 23089311 Install ECU on mounting bracket with
bolts and washers. Torque bolts to 36 46 inch pounds (4.06 - 5.19 Nm).
(3). Rig potentiometer to collective stick.

(a). Place collective stick in full down
position and connect an ohmmeter
(ST1010) between pins 1 and 2. Turn
potentiometer gear until resistance is
between 1000 and 1175 ohms.
or
Attach electrical connector to poten
tiometer. Connect MT35 to the ECU
and apply power to aircraft. Reading
on MT35 should be 0.0% - 5.0%.
CAUTION
(3). Connect bonding jumper to ECU with
screw, lockwasher and washer. Torque
screw to 20 - 25 inch-pounds (2.25 2.82 Nm).
(4). Connect engine harness and airframe
harness connectors to ECU.
Page 204
Revision 44
76-47-00
Excessive tension on drive belt

may damage potentiometer.
(b). Install drive belt over both pulleys

with teeth fully engaged. Tension belt
with potentiometer mounting screws
so that the belt does not noticeably
sag over the span. Retorque screws to
20 - 25 inch-pounds (2.25 - 2.82
Nm).
MAINTENANCE MANUAL
(c). Place collective in full up position
and verify that potentiometer resis
tance is between 4500 and 4675
ohms.
or
With electrical connector attached to
potentiometer and MT35 connected
apply power to aircraft, reading
should be 98.6% - 105.0%.
(d). If necessary, belt may be adjusted one
tooth on either pulley (one tooth
equals 450 ohms).
(e). If more adjustment is required,
loosen pulley to bracket bolts on
collective (view B) and rotate pulley
to obtain desired resistance. Retor
que bolts to 20 - 25 inch-pounds
(2.25 - 2.82 Nm).
(4). If not already connected, attach
electrical connector to potentiometer.
C. Directional Potentiometer Removal
directional potentiometer.
(2). Loosen potentiometer mounting screws
and remove drive belt.
(3). Remove screws and washers and
remove potentiometer assembly from
mounting bracket.
D. Directional Potentiometer Installation
Item
Special Tools
Nomenclature
ST1010
N/A
Volt-ohmmeter
Laptop computer with MT35 program
(1). Prepare potentiometer mounting

surfaces for electrical bonding (Ref.
CSP-HMI-3, Chap. 96).
CSP-HMI-2
(2). Install potentiometer with screws and

(3). Rig potentiometer to directional
controls.
(a). Place directional control pedals to full
left pedal position and connect
ohmmeter (ST1010) between pins 2
and 3. Turn potentiometer gear until
resistance is between 1000 and 1250
ohms.
or
Attach electrical connector to poten
tiometer. Connect MT35 to the ECU
and apply power to aircraft. Reading
on MT35 should be 0.0% - 7.1%.
CAUTION
Excessive tension on drive belt

may damage potentiometer.
(b). Install drive belt over both pulleys

with teeth fully engaged. Tension belt
with potentiometer mounting screws
so that the belt does not noticeably
sag over the span. Retorque screws to
20 - 25 inch-pounds (2.25 - 2.82
Nm).
(c). Place directional control pedals to full
right pedal position and verify that
potentiometer resistance is between
4500 and 4675 ohms.
or
With electrical connector attached to
potentiometer and MT35 connected
apply power to aircraft, reading
should be 98.6% - 105.0%.
(d). If necessary, belt may be adjusted one
tooth on either pulley (one tooth
equals 400 ohms).
(e). If more adjustment is required,
loosen pedal pulley bolt and rotate
pulley to obtain desired resistance.
Retorque bolt to 20 - 25 inchpounds (2.25 - 2.82 Nm).
(4). If not already connected, attach
electrical connector to potentiometer.
76-47-00
Page 205
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
6. CIT (Compressor Inlet Temperature)

Sensor Replacement
(Ref. Figure 202)
A. CIT Sensor Removal
(1). Detach electrical connector from CIT
sensor.
(2). Remove bolts, washers and CIT sensor.
B. CIT Sensor Installation
(1). Install CIT sensor with bolts and
(2). Attach electrical connector to CIT
sensor.
7. Engine Control Box Replacement
A. Engine Control Box Removal
(1). Disconnect engine control cable nut
from engine control box and remove
cable end from control box coupling.
(2). Remove bolts, washers and engine
control box from the engine hydrome
chanical control unit.
B. Engine Control Box Installation
NOTE: A 0.1540 in. (3.9116 mm) rig pin or stan

dard #23 drill must be inserted in rig hole
during installation of the engine control box
to the engine hydromechanical control unit
to maintain proper alignment.
(1). Install engine control box to engine
hydromechanical control unit with
600N7717-1 nut. Torque nut to 60 - 85
drag torque. Minimum drag torque is
15 inch-pounds (1.69 Nm).
(2). Measure gap between engine control
box and HMU.
(3). Peel MHS5079-2346 shim washer for
gap in step (2). and ensure alignment to
maintain full engagements of the
serrations without binding the controls.
(4). Install bolt, washer and shim washer.
Torque bolt to 36 - 46 inch pounds
Page 206
Revision 44
76-47-00
(4.06 - 5.19 Nm). A slip fit of the rig

pin through the control box, HMU lever
and HMU rig pin hole must be main
tained after final torque of bolt.
(5). Install control cable end into engine
control box coupling and connect cable
nut. Torque nut to 50 inch pounds
(5.64 Nm).
(6). Rig engine control cable (Ref. Section
76-00-00).
8. Engine Control Cable Replacement
(Ref. Figure 202)
A. Engine Control Cable Removal
(1). Disconnect control cable nut from
engine control box and remove cable
end from control box coupling.
(2). Remove screw, washers, spacer, clamp
and nut from control cable in engine
compartment.
(3). Remove cotter pin, nut, bolt and
washers and disconnect control cable
from engine throttle bellcrank.
(4). Cable with Cable Bulkhead Swivel Remove screws, nuts and washers
attaching control cable bulkhead swivel
to bracket.
(5). Loosen jam nut. Remove rod end
bearing and jam nut.
(6). Loosen jam nuts above and below
bracket and remove top jam nut and
flat washer.
(7). Pull engine control cable out of bracket.
(8). Cable with Cable Bulkhead Swivel Remove cable bulkhead swivel from
engine control cable.
(9). Remove bottom jam nut from cable.
(10). Pull engine control cable aft through
control cable conduit and remove from
engine compartment.
(11). After cable is removed from helicopter,
refer to Engine Control Cable Shipping
and Handling.
MAINTENANCE MANUAL
B. Engine Control Cable Installation
NOTE: When replacing 600N7714-1 or -3 en

gine control cable with 600N7714-7 cable,
doubler 600N7720-1 and doubler
600N7720-3 must be installed on engine
control cable bracket 600N7718-1.
(1). Before installing a new engine control
cable;
(a). Lay the cable straight.
(b). Grasp one end and shake.
(c). This procedure aligns races and
removes any twisting.
NOTE: When straightened, the cable will have

a natural bend or curve.
(d). Put marks on the cable housing to
show the natural bend plane of the
cable.
(2). Push engine control cable through
control cable conduit from engine
compartment forward into the cockpit.
(3). Keep the cable natural bend plane
aligned with the bends required to
route the cable.
(4). Install bottom jam nut on engine
control cable.
(5). Cable with Cable Bulkhead Swivel Install cable bulkhead swivel on engine
control cable.
(6). Cable with Cable Bulkhead Swivel Install cable bulkhead swivel in bracket
with screws, washers and nuts. Torque
nuts to 12 - 15 inch pounds (1.35 1.69 Nm).
CSP-HMI-2
NOTE: When installing a 600N7714-3 throttle

cable, the 600N7718-1 control cable bracket
must be installed for proper control cable
alignment.
(7). Cable without Cable Bulkhead
Swivel - Install engine control cable in
bracket.
(8). Install flat washer and jam nut on
cable. Do not tighten jam nut.
(9). Install jam nut and rod end bearing on
engine control cable. Torque jam nut to
40 inch pounds (4.51 Nm)
(10). Connect rod end bearing to engine
throttle bellcrank with bolt, washers,
nut and cotter pin. Torque nut to 30 40 inch pounds (3.38 - 4.51 Nm).
NOTE: Ensure there are no sharp bends in

cable when clamping into position.
(11). Install clamp, screw, washers, spacer
and nut attaching control cable to
bracket in engine compartment. Torque
nut to 12 - 15 inch pounds (1.35 1.69 Nm).
(12). Run cable through full range of travel
to ensure smooth operation.
Do not lubricate cable if cable
action is not smooth. Lubricant
attracts dirt which will damage the cable.
CAUTION
(13). Install control cable end into engine

control box coupling and connect cable
nut. Torque nut to 50 inch pounds
(5.64 Nm).
(14). Rig engine control cable.
76-47-00
Page 207
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
DRIVE BELT
PULLEY
PEDAL
PULLEY
BOLT
ELECTRICAL
HARNESS
MOUNTING
BRACKET
DIRECTIONAL
PEDAL ASSY.
DIRECTIONAL
POTENTIOMETER
ASSEMBLY
COLLECTIVE
POTENTIOMETER
ASSEMBLY
SCREW
WASHER
WASHER
ELECTRICAL HARNESS
SCREW
MOUNTING BRACKET
ELECTRONIC
CONTROL UNIT
PILOT'S
COLLECTIVE
STICK
PULLEY
DRIVE BELT
MOUNTING
BRACKET
WASHER
EXISTING
NUTPLATE
PULLEY TO
BRACKET BOLT
BUSHING
WASHER
WASHER
BOLT
FS
126.675
LBL
7.52
SCREW
WASHER
LOCK WASHER
BOLT
WASHER
ELECTRICAL
HARNESS
WL
46.75
INLET PLENUM
BONDING
JUMPER
CIT
SENSOR
6G76-006-1
Figure 202. Engine Controls Installation (Sheet 1 of 2)

Page 208
Revision 44
76-47-00
MAINTENANCE MANUAL
NUT
CSP-HMI-2
ENGINE THROTTLE
BELLCRANK
WASHER
COTTER PIN
WASHER
JAM NUT
BOLT
ROD END
BEARING
MOUNTING
BRACKET
(NOTE 1)
SCREW
FLAT WASHER
JAM NUT
ELECTRICAL
CONDUIT
JAM NUT
FLAT WASHER
CABLE BULKHEAD
SWIVEL
FLAT WASHER
FLAT WASHER
JAM NUT
CONTROL CABLE
CONDUIT
NUT
RBL
10.1
ENGINE CONTROL CABLE
ROD END
BEARING
SCREW
JAM NUT
JAM NUT
BOLT
WASHER
SHIM
FLAT WASHER
FLAT
WASHER
DOUBLER
600N7720-1
(NOTE 2)
DOUBLER
600N7720-3
JAM NUT
RIG PIN HOLE
FLAT WASHER
ENGINE
CONTROL BOX
NUT
ENGINE CONTROL
CABLE
INSTALL CABLE END

INTO ENGINE CONTROL
BOX COUPLING
NOTE:
1.
600N7718-1 MOUNTING BRACKET MUST BE
INSTALLED WHEN INSTALLING THE 600N7714-3
ENGINE CONTROL CABLE.
2.
DOUBLERS USED WITH 600N7714-7 ENGINE
CONTROL CABLE.
ENGINE HYDROMECHANICAL
CONTROL UNIT
ENGINE CONTROL CABLE
VIEW ROTATED-LOOKING INBOARD AT RIGHT SIDE

6G76-006-2E
Figure 202. Engine Controls Installation (Sheet 2 of 2)
76-47-00
Page 209
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
9. Engine Throttle Control Cable Mounting

Bracket Replacement
(Ref. Figure 202)
A. Engine Throttle Control Cable Mounting
Bracket Removal
(2). Set lever on engine hydromechanical

control unit to idle and insert
0.1535-0.1545 inch (3.8989-3.9243
mm) rig pin (or #23 drill blank) in rig
pin hole (ensure that rig pin engages
the fuel control gearbox, gear, pointer
arm and casting.
(1). Disconnect throttle cable at collective

stick (Ref. Engine Control Cable
Replacement).
(3). Set collective twist grip at idle detent

position.
(2). Disconnect throttle cable from bracket

(Ref. Engine Control Cable Replace
ment).
(4). Position the cable in the cable bulkhead

swivel or bracket so that the cable is
not binding and tighten the jam nuts.
Torque jam nuts to 40 inch-pounds
(4.51 Nm).
(3). Remove two nuts, four washers, two

spacers and two bolts securing bracket
to socket assembly.
(4). Slide bracket over end of throttle cable.
(5). Bracket with Doublers - Remove
nuts, washers and screws that attach
doublers to bracket and remove dou
blers.
B. Engine Throttle Control Cable Mounting
Bracket Installation
(1). Bracket with Doublers - Attach
doublers to bracket with screws,
washers and nuts. Torque nuts to 12 15 inch pounds (1.35 - 1.69 Nm).
(2). Slide bracket over end of throttle cable
and align with bolts holes in socket
assembly.
(3). Install bolts with washers through
bracket and socket assembly.
(4). Install spacers, washers and nuts on
bolts (spacers are installed before
washers).
(6). Connect throttle cable (Ref. Engine
Control Cable Replacement).
10. Engine Control Cable Rigging
(Ref. Figure 203)
(1). Loosen engine control cable jam nuts at
cable bulkhead swivel or bracket.
Page 210
Revision 44
76-47-00
(5). Remove rig pin (or drill blank).

(6). Rotate the throttle twist grip to full and
shutoff positions and verify that the
hydromechanical control unit lever
contacts the stops at both settings.
(7). Rotate the throttle twist grip from full
to idle positions and verify that the
pointer on the hydromechanical control
unit is between 30-40 degrees.
11. Engine Controls Inspection
(1). Visually inspect ECU for damage and
security of installation.
(a). Inspect ECU for security of hard
ware. Torque or replace loose or
missing hardware.
(b). Inspect electrical connectors, wire
harnesses and bonding jumper for
chafing or cuts. None allowed.
Ensure connectors are securely
attached.
(2). Visually inspect collective and direc
tional potentiometers for damage and
security of installation.
(a). Inspect potentiometers for security of
hardware. Torque or replace loose or
missing hardware.
(b). Inspect drive belts for cuts and
excessive tension. None allowed.
(c). Inspect electrical connectors and wire
harnesses for chafing or cuts. None
allowed. Ensure connectors are
securely attached.
MAINTENANCE MANUAL
CSP-HMI-2
BOLT
WASHER
RIG PIN HOLE
ENGINE THROTTLE
BELLCRANK
ENGINE
CONTROL BOX
ENGINE
HYDROMECHANICAL
CONTROL UNIT
JAM NUT
REF. ENGINE
CONTROL CABLE
JAM NUT
6G76-050C
Figure 203. Engine Control Cable Rigging

(3). Visually inspect CIT sensor for damage
and security of installation.
(a). Inspect CIT sensor for security of
hardware. Torque or replace loose or
missing hardware.
(b). Inspect electrical connector and wire
harness for chafing or cuts. None
allowed. Ensure connector is securely
attached.
(4). Visually inspect engine control box and
control cable for damage and security of
installation.
(a). Inspect engine control cable for sharp
bends, chafing, binding (smooth
operation through full range of
travel), corrosion and dents. None
allowed.
Do not lubricate cable if cable

action is not smooth. Lubricant
attracts dirt which will damage the cable.
CAUTION
(b). Inspect engine control box and

control cable for security of hard
ware. Torque or replace loose or
missing hardware.
(c). Inspect control cable to control box
connection for security. Torque
control cable nut.
12. Engine Control Cable Shipping and
Handling
(Ref. Figure 204) The following procedures
should always be used when handling the
engine control cable. This cable can be
damaged if handled incorrectly.
A. Control Cable Removal From Shipping
Box
The control cable is shipped in a lazy figure 8
configuration.
(1). Lift control cable from box.
76-47-00
Page 211
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
(2). Hold the cable upright in both hands.

(3). Remove the shipping wire.
(4). Starting with the nearest end fitting,
pay out the loops of the cable, one at a
time.
(5). Lay the cable straight.
(6). Grasp one end fitting and shake the
cable to align the races.
B. Control Cable Installation into Shipping

Box
(Ref. Figure 204) The cable is to be folded into
a lazy figure 8 position whenever it is
shipped.
Never allow cable to be bent
more than 180 degrees effective
bend angle, this will damage cable.
CAUTION
NOTE: The following procedure may require

more than one person to perform.
(1). Lay cable flat.
(2). Grasp both ends of cable and gently

bend in opposite directions.
180
(3). Continue bending until you have a

figure 8.
(4). To fit the cable into a shipping box, the

cable may have to be bent into a double
figure 8.
0
90
0
76-006-3
Figure 204. Effective Bend Angle
Page 212
Revision 44
76-47-00
(5). Gently wire the cable together in the

center of the figure 8 to prevent
damage in shipping or storage.
MAINTENANCE MANUAL
Chapter
78
Engine Exhaust
System
CSP-HMI-2
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
78-20-00 Engine Exhaust System (250-C20B and 250-C20R/2) . . . . . . . . . . . . . . . . . . A

1.
2.
Exhaust System Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

A. Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3.
Exhaust System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

A. Tailpipe Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Supports and Fasteners Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
C. Clamp Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Exhaust System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.
Exhaust System Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

A. Tailpipe Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Hanger Cushion Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
C. Tailpipe Clamp Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 203. Exhaust System Repairs (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 204. Engine Exhaust Extension (500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
78-30-00 Engine Exhaust System (250-C30 and 250-C47) . . . . . . . . . . . . . . . . . . . . . . . A

1.
2.
Exhaust System Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

A. Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.
Exhaust System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4.
Exhaust System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Figure 201. Engine Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
78 Contents
Page i
Revision 35
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page ii
Revision 35
78 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
782000
Engine Exhaust
System (250C20B
and 250C20R/2)
MAINTENANCE MANUAL
CSP-HMI-2
EXHAUST SYSTEM
The engine exhaust system consists of left and
right tailpipes attached to the engine by two
clamps and a flexible suspension system.
Suspension hardware allows exhaust system
thermal expansion and contraction. Movement
is absorbed by a spring, upper and lower
cushioned hanger assemblies and a pivoted
link. The link suspends the tailpipes from an
airframe fitting above the exhaust outlet.
2. Exhaust System Replacement
clamps. Locate clamp T-bolts at 6

o'clock position. Install washers and
nuts. Finger tighten clamp nuts.
NOTE: Use only corrosion resistant fasteners.

(3). Install lower hanger between tailpipe
aft flanges. Attach tailpipe support link
to airframe fitting. Install bolt, washers
and nut. Finger tighten nut.
(4). Install upper hanger between tailpipe
flanges.
(Ref. Figure 201)

A. Exhaust System Removal
(1). Remove right side thermocouple
hardware (Ref. View A).
(2). (500N) Remove clamp from around
tailpipes.
(3). Remove tailpipe clamps.
(4). Remove airframe link attaching
hardware.
(5). Remove two tailpipes as an assembly.
CAUTION
Cover engine exhaust ducts to

keep FOD out of turbine section.
(6). Install covers on engine exhaust

outlets.
(7). Remove spring and hangers. Separate
tailpipes.
B. Exhaust System Installation
Item
CM423
Nomenclature
Sealant
(1). Remove exhaust duct covers.

Support tailpipes during instal
lation. Unsupported tailpipes
could damage mounting flanges or result in
clamp joint misalignment and subsequent
exhaust gas leakage.
CAUTION
(2). Butt tailpipe flanges up to engine

exhaust duct flanges and install
(5). Attach spring hook to upper clip

bushing with two captive washers on
each side (Ref. View C).
(6). Attach lower spring hook to clip
bushing between support link and thin
washer (Ref. View D).
(7). Inject sealant (CM423) into cavity
around spring attach points. Allow
sealant to cure per manufacturers
instructions.
(8). Torque engine/tailpipe clamp nuts to 15
- 18 inch-pounds (1.69 - 2.03 Nm).
(9). Tap around both clamps with a rawhide
mallet to seat clamps on flanges.
Retorque clamp nuts 15 - 18 inchpounds (1.69 - 2.03 Nm).
(10). Continue tapping around clamp and
applied.
(11). Install thermocouple wire support on
right tailpipe clamp T-bolt with one
washer on each side of support. Install
nut (Ref. View A). Install thermocouple
wire, clamp, screw, washers and nut on
support.
(12). Torque tailpipe support link nut to 12 15 inch-pounds (1.36 - 1.69 Nm).
Install cotter pin.
(13). (500N) Install clamp around tailpipe.
78-20-00
Page 201
Revision 38
MAINTENANCE MANUAL
CSP-HMI-2
WIRE
SCREW
UPPER HANGER
CLAMP
SUPPORT
NUT
WASHER
RH CLAMP T-BOLT
WASHER
WIREMESH
REPLACEMENT
CUSHION
NUT
WASHER
THERMOCOUPLE WIRE
SUPPORT INSTALLATION
WIRE MESH OR
SILICONE RUBBER
CUSHION
HANGER INSTALLATION
(NOTE 1)
SILICONE RUBBER
REPLACEMENT CUSHION
SPRING HOOK
(NOTE 3)
UPPER HANGER
ASSEMBLY
LINK
ONE THIN
WASHER
WASHERS (2)
WASHERS (2)
WASHERS (2)
LOWER HANGER ASSEMBLY
UPPER HANGER SPRING

ATTACHMENT
LOWER HANGER SPRING
ATTACHMENT
AIRFRAME TAILPIPE
SUPPORT FITTING
TORQUE TAILPIPE CLAMP
15-18 IN. LBS. (1.69-2.03 NM)
(NOTE 2)
RIGHT TAILPIPE
HANGER
SPRING HOOK
(NOTE 3)
EXTENDED TAILPIPE
(500N ONLY)
TORQUE NUT
12-15 IN. LBS.
(1.36-1.69 NM)
SUPPORT LINK
WASHER
WASHE
R
BOL
T
SPRING
ENGINE
EXHAUST
DUCT
CLAMP
(500N ONLY)
HANGER
LEFT TAILPIPE
NOTES:
1. TYPICAL FOR UPPER AND LOWER HANGERS.
2. LOCATE T-BOLTS AT 6 O'CLOCK POSITION.
3. FILL CAVITY BETWEEN SPRING AND WASHERS
WITH SEALANT (CM423).
Figure 201. Exhaust System Installation

Page 202
Revision 38
78-20-00
G78-0002B
MAINTENANCE MANUAL
CSP-HMI-2
3. Exhaust System Inspection
(2). Replace damaged hanger cushions.
(Ref. Figure 202)
(3). Check spring for cracks, pits, nicks,

kinks, gouges, evidence of overheating,
wear and corrosion. Replace a spring
showing such damage.
A. Tailpipe Inspection
(1). Inspect tailpipe flanges and duct
interior/exterior surfaces for cracks and
broken weld seams.
(a). No cracks allowed across flange.
Replace tailpipe.
(b). Weld seams may be repaired pro
vided cracks meet limits in the
following steps.
(c). Fluorescent penetrant inspect
suspected cracks to determine crack
ends and length.
(d). Nonintersecting single line cracks up
to 2.00 inches (5.08 cm) long may be
repaired if they do not affect the
forward flange.
(e). Intersecting cracks of any length
forming an acute angle and an
unsupported section may not be
repaired.
(2). Repair cracks or separations.
(3). Replace an unrepairable tail pipe.
(4). Inspect engine and tailpipe flanges for
evidence of gas leakage.
(a). Gas leakage may be caused by flange
misalignment, loose or improperly
installed flange clamp, cracked,
warped, nicked, dented, gouged or
distorted flange areas or a combina
tion of causes.
(5). Straighten flange distortions.
(6). Replace a tailpipe having a cracked
forward flange.
(7). Inspect entire duct for dents, crimps,
creases, wrinkles, sags and bulges.
(8). Repair distortions.
B. Supports and Fasteners Inspection
(1). Inspect hanger cushions for wear, tears
and security.
(a). Inspect braided metal cushions for
spotweld security.
(a). Measure spring free length from hook

center to hook center. Spring free
length shall be 6.28 inches (15.951
cm). Replace a stretched spring.
(b). Anchor one end of spring. Attach an
accurate weight scale to the other
end. Stretch spring to 7.10 inches
(18.034 cm), hook center to center.
Spring tension at specified length
must be 8-12 pounds (35.6-53.4 N).
Replace a spring failing tension
requirement.
(4). Inspect hanger/clip rivets and washers
for security. Inspect spring hook
bushings, washers and rivets for wear
and security. Replace worn parts.
Repair loose rivets.
(5). Inspect support link for cracks, corro
sion and hole wear exceeding specifica
tions (Ref. Figure 202).
(6). (500N) Inspect clamp around tailpipes
for security and condition. Fiberglass
wrap for fraying and condition of
sealant at ends.
C. Clamp Inspection
A failed exhaust duct clamp
may present a serious inflight
problem. Replace any clamp you think is in
marginal condition.
CAUTION
(1). Inspect T-bolt threads for condition.

Repair damaged threads.
(2). Check self locking nut for run-on
torque resistance. Replace a worn nut.
(3). Inspect strap/channel spotwelds for
security.
(4). Check strap for cracks, creases, bends,
joggles and other evidence of fatigue.
Replace clamps showing metal crystalli
zation or cracks anywhere on the strap.
(5). Inspect clamp channels for cracks,
spread or crimp (Ref. Figure 202).
78-20-00
Page 203
Revision 38
MAINTENANCE MANUAL
CSP-HMI-2
STOP DRILL HOLE

0.040 IN. (1.016 MM)
(TYP)
SMALL SIMPLE CRACKS

WITH OBTUSE ANGLES
ARE REPAIRABLE
COMPLEX CRACKS AT ACUTE

INTERSECTING ANGLES ARE
NOT REPAIRABLE
0.190-0.194 IN.
(4.826-4.9276 MM)
DIA. HOLE
9.80 IN.
(24.892 CM)
REPAIRABLE CRACK LENGTH

2.00 IN. (5.08 CM) MAXIMUM
CRACK REPAIR LIMITS
BUSHING
0.4360 0.4365 IN.
(11.0744-11.0871 MM)
DIA. HOLE
SUPPORT LINK
DIMENSIONAL LIM
0.625 IN.
(15.875 MM)
0.156 IN. (3.9624 MM)
CLAMP STRAP
A
0.022 0.052 IN.

(0.5588-1.3208 MM)
R (TYP)
0.218 IN. (5.5372 MM)
CHANNEL
40 5
0.50 IN.
(12.70 MM)
ENGINE FLANGE
A - A
CLAMP CROSS-SECTION
CLAMP DIMENSIONAL LIMITS
G78-0003A
Figure 202. Exhaust System Inspection

Page 204
Revision 22
78-20-00
MAINTENANCE MANUAL
4. Exhaust System Repairs
(Ref. Figure 203)
A. Tailpipe Repair
Item
CM824
Nomenclature
Welding rod
(1). Remove dents and distortions with a

suitably shaped form-block and mallet.
(2). Repair cracks meeting repair limits as
follows:
(a). Stop-drill crack ends with a 0.040
inch (1.016 mm) diameter drill.
(b). Remove all carbon and debris from a
one inch area bordering crack with a
stainless steel brush. Clean inside
and outside surfaces.
(c). Route out crack a minimum width
from end to end to expose bare metal.
(d). Flood back side of weld area with
inert gas or shield with a suitable
stainless steel flux.
(e). Tungsten inert gas weld crack with
21-6-9 CRES rod or wire (CM824).
(f). Fluorescent penetrant inspect repairs
for cracks. Weld cracks as required.
B. Hanger Cushion Repair
Item
CM423
Nomenclature
Sealant
CSP-HMI-2
NOTE: Either bonded silicone rubber or welded

all metal original equipment cushions may
be installed. Replacement parts may be tab
attached metal or bonded silicone rubber
cushions.
(1). Replace original equipment metal
cushions with tabbed metal cushions as
follows:
(a). Cut away cushion debris.
(b). Grind spot welds smooth and level
with hanger surfaces.
NOTE: Avoid weakening replacement cushion

tabs. Ensure cushions are correctly located
prior to bending tabs.
(c). Position cushion assembly on hanger.
Bend cushion tabs to grip hanger
(Ref. View B).
(2). Replace original equipment metal
cushions with silicone rubber cushions
as follows:
(a). Cut away cushion debris.
(b). Grind spot welds smooth and level
with hanger surfaces.
(c). Clean hanger components and
cushion bond joint-surfaces per
sealant manufacturers instructions.
(d). Bond cushion to hanger with RTV
106 sealant (CM423). Inject sealant
into cavity around spring attach
points. Allow sealant to cure per
manufacturers instructions.
C. Tailpipe Clamp Repair
(1). Chase clamp T-bolt threads with a
10-32NF-38 die or replace clamp, as
required.
78-20-00
Page 205
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
0.06 IN. (1.524 MM) R

(TYP)
0.50 IN. (12.7 MM)
(TYP)
0.85 IN.
(21.59 MM)
0.25-0.31 IN.
(6.35-7.874 MM)
LAP
DETAIL
NOTE 1
NOTE 1
1.00 IN.
(2.54 CM)
5.00 IN.
(12.7 CM) R
0.25-0.31 IN.
(6.35-7.874 MM)
LAP
0.13 IN. (3.302 MM)
(2 PLCS) (TYP)
(NOTE 3)
CL
0.18 IN.
(4.572 MM)
NOTE 1
FAIR FROM ELLIPSE TO SEMI
CIRCLE IN THIS AREA
7.75 IN.
ELLIPSE ROTATED
(19.685 CM)
IN THIS AREA
0.25-0.31 IN.
(6.35-7.874 MM)
LAP
91
41
8.00 IN.
(20.32 CM)
A
B
0.12 IN.
(3.048 MM
15.78 IN.
(40.082
CM)
STA.
7.75
45
NOTE 2 (TYP)
DUCT AREA TO BE
CONSTANT TO HERE
C
6.12 IN.
(15.545 CM)
50
26.33 IN.
(66.878 CM)
C
NOTES:
1. FILLET WELD ALL AROUND, NEAR SIDE.
2. BUTTWELD.
3. STITCHWELD. X X X X
Figure 203. Exhaust System Repairs (Sheet 1 of 3)

Page 206
Revision 22
78-20-00
G78-0004-1A
MAINTENANCE MANUAL
E
E
0.16 IN.
(4.064 MM)
(TYP)
CSP-HMI-2
0.68 IN. (17.272 MM)

(TYP)
10.13-10.38 IN.
(25.7302-26.3652 CM)
0.46 IN. (11.684 MM)

0.92 IN. (23.368 MM)
0.68 IN. (17.272 MM) R
(TYP)
T. E. STA
1.00 IN.
(2.54 CM)
R (TYP)
1.75 IN. (4.445 CM)

(TYP)
STA. 7.75
0.50 IN. (12.7 MM)

(TYP)
4.25 IN. (10.795 CM) R

(TYP)
0.12 IN. (3.048 MM)
(TYP)
0.12 IN. (3.048 MM)

(TYP)
0.65-0.97 IN. (16.51-24.638 MM)

MINIMUM PREFERRED (TYP)
5.00-5.25 IN. (12.7-13.335 CM)

(TYP)
D
BB
2.415 IN.
(6.1341 CM)
1.768 IN.
(4.4907 CM)
0.647 IN.
(16.4338 MM)
0.922 IN. (23.4188 MM)

1.781 IN. (4.5237 CM)
2.519 IN. (6.3983 CM)
3.085 IN. (7.8359 CM)
3.441 IN. (8.7401 CM)
3.562 IN. (9.0475 CM)
1.250 IN.
(3.175 CM)
CC
2.165 IN.
(5.4991 CM)
2.500 IN.
(6.3500 CM)
ROTATED 40 C-CLOCKWISE
0.63 IN. (16.002 MM)
2.00 IN. (5.08 CM)
16.25 IN.
(41.275 CM)
13.76 IN.
(34.9504 CM)
2.00 IN. (5.08 CM)
G
G
SEAMWELD
1.25 IN. (3.175 CM)
DD
1.25 IN. (3.175 CM)
G78-0004-2B
78-20-00
Page 207
Revision 22
MAINTENANCE MANUAL
CSP-HMI-2
0.06 IN. (1.524 MM) R

(TYP)
0.63 IN. (16.002 MM) R
0.85 IN. (21.59 MM)

(TYP)
1.50 IN. (3.81 CM)

(TYP)
0.19 IN. (4.826 MM)

(TYP)
20
0.294 IN. (7.4676 MM) CONSTANT
0.289 IN. (7.3406 MM) CONSTANT
0.25 IN. (6.35 MM) R
EE
FF
CONTINUOUS SEAMWELD (REF)

SPOTWELD WHERE REQUIRED
0.190 IN. (4.826 MM)

FREE DIMENSION
1.00 IN. (2.54 CM)

0.19 IN. (4.826 MM)
0.31 IN. (7.874 MM) R
1.50 IN. (3.81 CM) (TYP)

0.06 IN. (1.524 MM) R
(TYP)
0.18 IN. (4.572 MM)
(TYP)
45 ANGLE FROM
FLAT PATTERN
0.18 IN. (4.572 MM)
(TYP)
0.442-0.562 IN.
(11.2268-14.2748 MM) R
GG
HH
G78-0004-3
Page 208
Revision 22
78-20-00
MAINTENANCE MANUAL
CSP-HMI-2
451.0
A
0.92-1.02 IN.
(2.337-2.591 MM)
6.00-6.25 IN.
(15.24-15.875 CM)
STIFFENER
A
STIFFENER
C
0.50 IN. (12.7 MM)
0.06 IN. (1.524 MM) R
B-B
0.25 IN. (6.35 MM)
SECTION A - A
SECTION D - D
45 (TYP)
0.12 IN. (3.048 MM)

R (TYP)
0.25 IN.
(6.35 MM)
R (TYP)
0.74 IN. (18.796 MM)

(TYP)
0.71-0.97 IN.
(18.034-24.638
MM) (TYP)
1.45-1.55 IN. (3.683-3.937 CM)

0.35 IN. (8.89 MM)
SECTION B - B
D
SECTION C - C
G78-0005
Figure 204. Engine Exhaust Extension (500N)
78-20-00
Page 209
Revision 22
CSP-HMI-2
MAINTENANCE MANUAL
Page 210
Revision 44
78-20-00
MAINTENANCE MANUAL
CSP-HMI-2
Section
783000
Engine Exhaust
System (250C30
and 250C47)
MAINTENANCE MANUAL
CSP-HMI-2
EXHAUST SYSTEM
Engine exhaust is ducted through a tailpipe
bolted to the engine exhaust duct flange and
supported by a flexible link mounting attached
to the aft fuselage. Figure 201 shows the
exhaust system and mounting details.
2. Exhaust System Replacement
(Ref. Figure 201)
A. Exhaust System Removal
(1). Detach tailpipe from engine exhaust
duct by removing:
(a). Six nuts, bolts, and 12 washers from
exhaust pipe side flanges.
(b). Two nutplate strips, 14 bolts and
washers from exhaust pipe fore and
aft flanges.
(2). Loosen the tensioning bolt passing
through the hanger torsion spring
mandrel.
(3). Disengage the adjuster from the spring
pin.
Whenever tailpipes are re
moved, cover engine exhaust
ducts with clean covers to prevent entry of
foreign materials into turbine section of en
gine.
CAUTION
(4). Remove tailpipe and gasket.

(5). Visually inspect bottom of upper aft
section firewall for contact marks with
discoloration, holes or tears. Pay
particular attention to firewall blanket
retainer clips at Sta. 155.75 fuselage
ring.
B. Exhaust System Installation
(1). Remove protective cover from engine
exhaust duct.
(2). Install gasket onto engine exhaust
flange.
Support aft ends of tailpipe dur

ing installation. Displacement
from proper mounting position may damage
forward mounting flanges.
CAUTION
(3). Place tailpipe over engine exhaust duct

and secure with nuts, nutplate strips,
bolts and washers; torque bolts to 36 46 inch-pounds (4.07 - 5.20 Nm)
plus drag torque.
(4). Install duct with duct clamp link
standing vertical.
(5). When viewed from left side of helicop
ter. turn torsion spring adjuster 150
15 degrees clockwise and engage
spring pin in nearest hole in adjuster.
(6). Tighten tensioning bolt to adjust
spring.
(7). Inspect for no contact between top of
exhaust and firewall retainer clips at
Sta. 155.75 fuselage ring.
NOTE: If installing a new exhaust gasket, the

exhaust bolts should be retorqued after first
flight. If bolts are found to be loose, retorque
after every flight until bolts retain torque.
3. Exhaust System Inspection
(Ref. Figure 201)
(1). Inspect for cracks and broken weld
seams.
(2). Inspect for dents and bends.
(3). Using flashlight and mirror, look in
engine bay through engine access doors
and look through engine oil filter access
cutout.
(a). Inspect top of engine exhaust duct for
contact marks and bottom of upper
aft section firewall for contact marks
with discoloration, holes or tears. Pay
particular attention to firewall
blanket retainer clips at Sta. 155.75
fuselage ring.
78-30-00
Page 201
Revision 38
MAINTENANCE MANUAL
CSP-HMI-2
4. Exhaust System Repair

(Ref. Figure 201)
Item
Nomenclature
CM824
Welding rod
(1). Repair dents and bends using a form

block and suitable mallet.
(2). Repair cracks and breaks in tailpipes as
follows:
Page 202
Revision 35
78-30-00
(a). Using stainless steel brush, thor

oughly clean at least 1 inch (2.54 cm)
on all sides of cracked area. Cleaning
should remove all carbon from both
inner and outer surfaces and from
crack itself.
(b). Weld, using inert arc method, with
rod (CM824). Shield back side of weld
with inert gas or suitable stainless
steel flux.
(c). Repair single cracks less than 2
inches (5.08 cm) in length by stopdrilling 0.040 inch (1.016 mm)
diameter hole at termination of each
end of crack. This method of repair
does not apply to intersecting cracks
that form an acute angle leaving an
unsupported section.
MAINTENANCE MANUAL
CSP-HMI-2
EXHAUST DUCT SUP

PORT ASSEMBLY INSTAL
LATION
BUSHING
BRACKET
SPRING
LINK ASSY
SPRING PINS
BUSHING
DUCT ASSY
MANDREL
ADJUSTER
CLAMP
CUSHION
EXHAUST FLANGE
BOLT (20 PLCS)
EXHAUST DUCT INSTALLATION
GASKET
NUT
PLATE
(TYP)
G78-3001
Figure 201. Engine Exhaust System Installation
78-30-00
Page 203
Revision 35
CSP-HMI-2
MAINTENANCE MANUAL
Page 204
Revision 35
78-30-00
MAINTENANCE MANUAL
CSP-HMI-2
Chapter
79
Engine Oil Supply
System
CSP-HMI-2
MAINTENANCE MANUAL
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
79-00-00 Engine Oil Supply System (369D/E/FF - 500/600N) . . . . . . . . . . . . . . . . . . . . A

1.
Engine Oil Supply System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . 201

A. Oil Supply System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Oil Supply System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201. Engine Oil Supply System Schematic Diagram . . . . . . . . . . . . . . . . . 202
2.
Engine Oil Supply System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Table 201. Engine Oil Supply System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . 203
3.
Oil Cooler Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Figure 202. Oil Cooler Flush Equipment and Arrangement . . . . . . . . . . . . . . . . . . 205
4.
Oil Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

A. Oil Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Oil Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5.
Oil Tank Sight Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

A. Oil Tank Sight Plug Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Oil Tank Sight Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6.
Oil Temperature Sender Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7.
Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

A. Oil Cooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8.
Oil Tank Return Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

A. Oil Tank Return Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Oil Tank Return Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203. Engine Oil Supply System (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 208
9.
Oil Supply Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
10. Oil Cooler Duct Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

A. Oil Cooler Duct Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
B. Oil Cooler Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
11. Oil Tank Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
12. Oil Cooler Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Table 202. Oil System Hardware Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 204. Engine Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
13. One Time Mandatory Hose Inspection (369D Serial Numbers 0003D thru
0374D, Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
14. Oil Lines and Fittings Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
15. Oil Tank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
16. Oil Cooler Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
79 Contents
Page i
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page
17. Oil Cooler Duct Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

79-10-10 Airframe-Mounted Engine Scavenge Oil Filter
(369D/E/FF - 500N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1.
2.
Scavenge Oil Filter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.
Scavenge Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4.
Scavenge Oil Filter Bypass Indicator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Figure 201. Facet Scavenge Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

1.
Scavenge Oil Filter Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
2.
Post Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902

Figure 901. Scavenge Oil Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Page ii
Revision 23
79 Contents
MAINTENANCE MANUAL
CSP-HMI-2
Section
790000
Engine Oil Supply
System (369D/E/FF
500/600N)
MAINTENANCE MANUAL
CSP-HMI-2
ENGINE OIL SUPPLY SYSTEM

1. Engine Oil Supply System Description
and Operation
A. Oil Supply System Description
(1). MDHI helicopters feature a dry sump,
air cooled, recirculating engine oil
system consisting of an oil tank, oil
temperature sender, oil cooler/heat
exchanger and air duct, thermostat,
drain valve, check valve, hoses, tubes,
fittings and attaching hardware.
B. Oil Supply System Operation
(1). Hot oil scavenged from the engine is
pumped through a one way check valve
into the oil cooler. Oil cooler blower air
at ambient temperature is ducted
through the cooler/heat exchanger. The
oil cooler reduces oil temperature to
approximately 185F (86C). Cooled oil
is returned to the oil tank. Oil drawn
from the tank by the suction side of the
engine driven pump is then distributed
through the engine under pressure to
cool and lubricate moving parts. The
heated oil drains into various engine
sumps, and the cycle is repeated.
(2). An all welded, spherical aluminum
alloy oil tank is fitted with a filler neck,
optional filler neck strainer, locking
cap, vent tube, oil inlet and outlet
fittings, temperature sender, sight plug
and mounting support bosses. A
replaceable sight plug provides oil
quantity information at a glance.
(3). The oil cooler is an all aluminum,

radiator-type heat exchanger. A
thermostat in the oil cooler set at 140 180F (60 - 82C) returns cold oil
directly to the tank, bypassing the
cooler until the oil has reached operat
ing temperature. The oil cooler also
features a pressure-relief bypass valve
that opens at 25-30 psi (172-207 kPa)
and a one way ball type check valve
mounted on the oil cooler inlet fitting
that prevents oil from flowing back into
the engine after shut down.
(4). A fiberglass duct guides cooling air
from the oil cooler blower to the oil
cooler.
(5). The oil supply system drain valve is
mounted on a bracket below the oil
cooler. Tubes from the oil tank, oil
cooler and overboard drain are con
nected to the drain valve which is
spring-loaded closed.
NOTE: DN-72.1 discloses installation proce

dures modifying early 369D helicopter oil
tank and cooler drains for easier access.
(6). All oil supply system hoses and tubes
are lightweight assemblies incorporat
ing permanent fittings. Hoses installed
near the engine are equipped with fire
shields.
(7). Refer to the applicable Allison Engine
specific engine oil system information
(Ref. Sec. 01-00-00).
79-00-00
Page 201
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
TANK DRAIN
TUBE
BULKHEAD
FIREWALL
ELBOW
UNION
DRAIN
PORT
UPPER
CONNECTOR
OIL COOLER BLOWER
INLET
PORT
ENGINE-TO-COOLER
OIL HOSE
CLAMP (2)
OIL TANK
RETURN HOSE
CHECK
VALVE
COOLER DUCT
ELBOW
COOLER
DRAIN
TUBE
LOWER CONNECTOR
ENGINE OIL
TANK DRAIN
COOLER OUTLET
PORT
TIE STRAP (2)
THERMOSTATIC
VALVE
DIFFUSER
ENGINE-TO-FILTER
OIL HOSE
GASKET
SHIELD
ENGINE OIL
COOLER DRAIN
SPACER
SHIELD
DEFLECTOR
ENGINE OIL
COOLER
FIREWALL
TANK DRAIN
TUBE
FILTER-TO-COOLER
OIL HOSE
SCAVENGE OIL FILTER

(NOTE)
GASKET
EARLY CONFIGURATION
STA. 124.00
COOLER INLET AND
DRAIN CONNECTIONS
LOCKWIRE
UNION
DRAIN
PORT
CAUTION:
AT REMOVAL OR INSTALLATION OF CHECK
VALVE OR HOSE, FLATS ON PORT SHOULD
BE HELD TO PREVENT DEFORMATION OF
COOLER FRAME.
NOTE:
APPLICABLE TO ALL ALLISON 250-C20R/2
ENGINES. OPTIONAL EQUIPMENT FOR
ALLISON 250-C20B AND C30 ENGINES.
BRACKET
INLET PORT
(SEE CAUTION)
DRAIN VALVE
FILTER-TOCOOLER OIL
HOSE (NOTE)
O-RING
ENGINE-TO-COOLER
OIL HOSE
DRAIN HOSE
CHECK VALVE
GROMMET
O-RING
COOLER DRAIN VALVE
EARLY CONFIGURATION
G79-0004
Figure 201. Engine Oil Supply System Schematic Diagram

Page 202
Revision 23
79-00-00
MAINTENANCE MANUAL
CSP-HMI-2
2. Engine Oil Supply System Fault Isolation

Table 201. Engine Oil Supply System Fault Isolation
Symptom
Low or zero oil pressure.
Probable Trouble
Corrective Action
Oil tank empty.
Top off oil supply tank (Ref. Sec.

120000).
Oil line restriction.
Inspect, clean or replace plumbing.
Restricted oil filter element.
Clean oil filter per Allison Operation

Replace sensor and, or indicator.
Adjust regulator per Allison
Inspect filter and chip detectors.
Drain and flush oil system. Refill
system (Ref. Sec. 120000).
Defective sensor or indicator.

Oil pressure regulator valve
improperly adjusted.
Contaminated oil.
Sudden oil pressure reduction or

pressure fluctuations.
Low oil quantity.
Check oil level and service system

(Ref. Sec. 120000).
Oil contamination.
Inspect filter and chip detectors.

Drain and flush system. Replace oil
(Ref. Sec. 120000).
Repair or replace hoses, tubes or
engine components as required.
Replace sensor and, or indicator.
Clean oil filter; adjust pressure
regulator valve. Replace valve if oil
pressure can not be adjusted (refer
to applicable Allison Operation and
Replace oil pump per applicable
Manual.
Oil leak.
Defective sensor or indicator.
Oil filter or pressure regulator valve
restriction.
Defective oil pump.
High oil pressure.
Abnormally high oil temperature

indication.
Defective indicator.
Replace indicator.
Pressure regulator valve out of

adjustment.
Adjust pressure regulator valve per

Manual.
Defective temperature sensor or

indicator.
Replace temperature sensor and/or

indicator.
Oil cooler bypass valve stuck closed.

Oil cooler air passages blocked or
damaged.
Oil cooler oil passages blocked or
damaged.
Oil cooler blower intake air blockage.
Oil cooler blower failed or impeller
damaged.
Repair or replace oil cooler.

Inspect oil filter and chip detectors.
Open intake airway.
Repair or replace blower.
79-00-00
Page 203
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
Table 201. Engine Oil Supply System Fault Isolation

Symptom
Probable Trouble
Abnormally low oil temperature

indication.
Oil consumption exceeds 6.5 oz.
(192.21 cc) per hour.
Chip detector warning light on.
Defective temperature sensor or

indicator.
Replace temperature sensor and/or

indicator.
Oil cooler bypass valve stuck open.
Leakage; loose fittings or

connections.
Repair or replace fittings and

connections.
Restricted vent lines.

Defective engine bearing oil seals.
Inspect and clean as necessary.

Repair or replace engine.
Contaminated oil.
Inspect engine chip detectors per

Manual.
3. Oil Cooler Flushing

(Ref. Figure 202)
Item
Nomenclature
CM226
CM234
Cleaning compound, alkaline waterbase

NOTE: Maintain the engine oil cooler per the

following steps. For additional information,
refer to manufacturer's publications (Ref.
Sec. 01-00-00). Where a conflict exists be
tween this manual and manufacturer's pub
lication, information in this manual super
sedes manufactures data.
(1). Remove thermostat, elbows, unions and
O-rings. Plug all openings.
Use only oil cooler manufactur
er's recommended cleaning so
lutions or a substitute that is stated as safe
for use on aluminum. Copper or copper nick
el cleaning compounds or solutions may cor
rode the oil cooler. Cleaning equipment that
has been used with an unknown material, or
a known corrosive cleaning solution must be
thoroughly flushed with the recommended
solution prior to use on the oil cooler.
CAUTION
(2). Steam clean oil cooler exterior surfaces.

(3). Attach oil cooler to flushing setup
shown. Flush oil cooler as follows:
Page 204
Revision 23
Corrective Action
79-00-00
(a). Start with solvent (CM234) to flush

oil cooler interior. Initially reverse
solvent flow through cooler by
Connecting hose from pump dis
charge port to oil cooler outlet port.
(b). Connect hose from storage tank to
inlet port of oil cooler.
(c). Start cleaning equipment pump.
Flush cooler for 30 minutes, or until
solution appears clean after passing
through unit.
(d). Shut down equipment and drain oil
cooler.
NOTE: If metal particles are found, clean

screens with solvent (CM234) and blow dry
with clean, dry, filtered, low pressure com
pressed air.
(4). Examine filter screens for metal or
other foreign particles after flushing
the unit per the following steps.
(a). Flush oil cooler with compound
(CM226) in direction opposite to
normal flow for 30 minutes.
(b). Reverse hoses and flush oil cooler for
10-15 minutes in normal flow
direction.
(c). Rinse oil cooler with solvent (CM234)
for 10 minutes.
(5). Check filter screens. Replace oil cooler
if additional metal particles are found.
MAINTENANCE MANUAL
CSP-HMI-2
HYDRAULIC PRESSURE GAUGE
100 MESH SCREEN

INLET
HYDRAULIC PRESSURE GAUGE
COOLER
PRESSURE RELIEF VALVE
(SET FOR 75 PSI)
TANK
100 MESH SCREEN
OUTLET
CENTRIFUGAL PUMP
(28 - 56 GPM; 75 PSI
DISCHARGE PRESSURE)
FULL-FLOW FILTER
IN
OUT
G79-0002
Figure 202. Oil Cooler Flush Equipment and Arrangement

4. Oil Tank Replacement
(a). Install vent hose on tank.
(Ref. Figure 203)
(b). Install unions and O-rings on oil

return and supply hoses and tank
drain tube fittings.
A. Oil Tank Removal

(1). Drain oil system (Ref. Sec. 12-00-00).
(a). Remove engine oil cooler duct.
(b). Disconnect hose between tank and
vent. Disconnect supply, return and
tank drain lines from oil tank fit
tings. Allow tank to drain dry.
(c). Disconnect oil temperature sender
wires and remove sender.
(d). Remove oil filler seal, oil tank cap
retaining plate and oil tank.
(e). Unfasten and remove oil tank.
B. Oil Tank Installation
(1). Assemble tank as follows:
(c). Install oil temperature sender and

gasket. Torque sender body to 100 150 inch-pounds (11.30 - 16.95
Nm). Install lockwire. Torque wire
terminal nut to 12 - 25 inchpounds (1.36 - 2.82 Nm).
(d). Install sight plug (Ref. Oil Tank
Sight Plug Replacement).
(2). Position engine oil tank on Sta. 124.00
firewall and secure with bolts and
washers.
(a). Install oil tank filler seal and retain
ing plate. Ensure filler seal fits over
oil tank filler neck and is secure with
attaching hardware (Ref. Figure 203,
Detail B).
(b). Install oil tank filler seal clamp.
79-00-00
Page 205
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
(3). Connect the following oil lines and

torque (Ref. Table 202, Oil System
Hardware Torque Values).
(a). Connect return hose between engine
and cooler.
(b). Connect supply hose between tank
and engine.
(c). Connect drain tubes to oil tank
fittings.
(d). Install O-ring and connect vent hose
between tank and engine.
(e). Install oil cooler duct.
5. Oil Tank Sight Plug Replacement
(Ref. Figure 203)
Item
Nomenclature
CM125
CM126
Oil
Oil, turbine
(4). Install oil tank (Ref. Oil Tank Replace

ment).
6. Oil Temperature Sender Replacement
NOTE: 369A4533-BSC sensor is compatible

with the 369D296305-21, -23 and -31
instrument clusters only. 369A4533-3 sen
sor is compatible with the 369D296305-33,
-35 and -37 instrument clusters only.
(1). Switch off and disconnect all electrical
power.
(2). Drain oil tank.
(3). Disconnect electrical wire from oil
temperature sender, break lockwire and
remove sender from oil tank fitting.
(a). Install oil temperature sender and
gasket. Torque sender body to 100 150 inch-pounds (11.30 - 16.95
Nm). Install lockwire. Torque wire
terminal nut to 12 - 25 inchpounds (1.36 - 2.82 Nm).
(4). Fill oil tank (Ref. Sec. 12-00-00).
A. Oil Tank Sight Plug Removal

(1). Drain oil system.
(2). Remove oil tank (Ref. Oil Tank Replace
ment).
(5). Start engine (Ref. Pilot's Flight Manu

al). Check for oil leakage and tempera
ture gauge operation.
(6). Install aft bulkhead access cover.
7. Oil Cooler Replacement
(Ref. Figure 204)
(3). Break lockwire and remove sight plug.

B. Oil Tank Sight Plug Installation
NOTE: Liquid level decal is applied after plug

is installed and torqued.
(1). Install a new O-ring on sight plug.
Coat O-ring and sight plug threads
with clean engine oil (CM125) or
(CM126). Torque sight plug to 80 - 90
inch-pounds (9.04 - 10.17 Nm);
lockwire.
(2). Project a pencil line from the oil tank
upper mount through the centers of
nutplate and sight plug (Ref.
Figure 203, view A).
(3). Install sight plug decal on plug face
with decal water line (WL) marks
aligned with pencil line.
Page 206
Revision 23
79-00-00
Item
CM125
CM126
Nomenclature
Oil
Oil, turbine
A. Oil Cooler Removal

Avoid oil cooler damage. Use a
backup wrench to support oil
cooler port bosses when unfastening or
torquing threaded fittings.
CAUTION
(1). Drain oil system (Ref. Sec.

12-00-00).
(a). Remove oil cooler duct.
(b). Disconnect oil return hose from elbow
at cooler outlet fitting. Remove elbow.
MAINTENANCE MANUAL
CSP-HMI-2
(c). Remove cooler drain tube. Remove

drain union and O-ring from cooler
inlet port.
(g). Install tank return hose elbow in

cooler outlet port. Connect oil tank
return hose.
(d). Remove check valve.
(h). Install oil cooler duct (Ref. Oil Cooler

Duct Installation).
(e). Disconnect engine power turbine

cooling air duct from oil cooler
deflector. Remove deflector from
cooler mounting flange.
(f). Remove oil cooler.
(g). Remove lockwire and separate
shields from cooler, if installed.
(i). Service tank with oil (CM125) or

(CM126) (Ref. Sec. 12-00-00).
Manual. Inspect oil system for leaks.
8. Oil Tank Return Hose Replacement
B. Oil Cooler Installation

backup wrench to support oil
cooler port bosses when unfastening or
torquing threaded fittings.
CAUTION
(1). Install oil cooler per the following steps.

Refer to manufacturer's publications for
additional information as required (Ref.
Sec. 01-00-00). This information
supersedes cooler manufacturer's data
wherever conflicting information exists.
(a). On Harrison coolers only, position
shields on sides of oil cooler so that
outboard shield without tab is
adjacent to oil inlet port. Secure
shields with one lockwire wrap
around cooler.
(b). Position oil cooler on firewall and
secure with attaching hardware.
(c). Position deflector on cooler mounting
flange and secure with screws and
washers. Connect engine power
turbine cooling duct to oil cooler
deflector.
(d). Coat check valve threads with oil
(CM125) or (CM126); Install check
valve.
NOTE: Torque all oil cooler hardware per Oil

System Hardware Torque Values (Ref.
Table 202).
(e). Install union and O-ring in cooler
drain port.
(f). Connect cooler drain tube.
Item
Nomenclature
CM125
CM126
Oil
Oil, turbine
A. Oil Tank Return Hose Removal

(1). Remove trim and R/H bulkhead access
panel.
(2). Drain oil supply system.
backup wrench on oil cooler port
boss when removing or installing oil line fit
tings.
CAUTION
(3). Disconnect hose from oil cooler OUT

port elbow.
(4). Remove oil cooler OUT port elbow.
(5). Disconnect hose from oil tank IN port
union. Remove union.
B. Oil Tank Return Hose Installation
(1). Lubricate male threads with clean
engine oil (CM125) or (CM126) prior to
installation. Thread hose straight end
fitting into oil tank. Attach opposite end
to oil cooler.
(2). Torque hose ends per Oil System
Hardware Torque Values (Ref.
Table 202).
(3). Install bulkhead panel and trim.
(4). Enter compliance in helicopter records.
79-00-00
Page 207
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
OIL COOLER
BLOWER
SIGHT PLUG
OIL TANK
O-RING
TANK-TO-ENGINE
VENT HOSE
OIL COOLER
OIL
DRAIN
TANK
DRAIN
TANK-TO-ENGINE
OIL HOSE
TO ENGINE
CHECK VALVE
DRAIN TUBE
ENGINE-TO-COOLER
HOSE
OVERBOARD
DRAIN TUBE
ENGINE-TO-FIL
TER HOSE
FILTER-TO-COOL
ER OIL HOSE
SCAVENGE OIL FILTER INSTALLATION

(NOTE 1)
EARLY CONFIGURATION
SIGHT PLUG
UPPER MOUNT
NUTPLATE
DECAL
WL 48.63
(NOTE 1)
NOTES:
1. WL - WATERLINE.
2. APPLICABLE TO ALL
ALLISON 250-C20R/2 ENGINES.
OPTIONAL EQUIPMENT FOR ALLISON
250-C20B AND 250-C30 ENGINES.
PROJECTED LINE
WL LOCA
TOR MARKS
SIGHT PLUG ALIGNMENT
(LOOKING INBOARD)
G79-0003-1
Figure 203. Engine Oil Supply System (Sheet 1 of 2)

Page 208
Revision 23
79-00-00
MAINTENANCE MANUAL
CSP-HMI-2
OIL TANK
OUTLET FITTING
OIL TANK
UNION
FILLER
OIL TANK
RETURN TUBE
STA.
124.00
FIREWALL
TANK VENT HOSE
OIL TANK SUPPORT

OIL TANK
RETURN HOSE
BUSHING
O-RING
OIL TANK
(ALLISON 250-C20R/2 ENGINE)
OIL TEMPERATURE
SENSOR (NOTE 1)
ENGINE OIL
COOLER DUCT
WASHER
OIL TANK
INLET PORT
TANK DRAIN TUBE
O-RING
UNION
UNION
TANK-TO-ENGINE
VENT HOSE
TANK-TO-ENGIN
E OIL HOSE
OIL TANK INSTALLATION

(ALLISON 250-C20B ENGINE)
CAP RETAINING PLATE
CLAMP
FILLER SEAL
OIL TANK FILLER

SEAL INSTALLATION
G79-0003-2
Figure 203. Engine Oil Supply System (Sheet 2 of 2)
79-00-00
Page 209
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
9. Oil Supply Lines and Fittings

Replacement
(Ref. Figure 203)
(3). Remove attaching hardware from

diffuser. Lift diffuser to separate from
cooler flange. Retain spacers.
B. Oil Cooler Duct Installation
Item
Nomenclature
CM125
CM126
Oil
Oil, turbine
CAUTION
Over tightening bolts can crack

duct flange.
(1). Align diffuser on oil cooler flange with

spacers and gasket. Secure with
attaching hardware.
(1). Drain system before removing oil lines.
NOTE:
D Lubricate all fitting threads with oil
(CM125) or (CM126) prior to installation.
D Torque hardware per Oil System Hard
ware Torque Values (Ref. Table 202).
Avoid oil system damage. Use a
backup wrench to support
bosses, fittings and subassemblies when un
fastening or torquing all threaded compo
nents.
CAUTION
(2). Install oil lines and fittings.

10. Oil Cooler Duct Replacement
(Ref. Figure 203)
A. Oil Cooler Duct Removal
(1). Remove clamps and separate cooler
duct elbow from oil cooler blower.
Remove upper connector.
(2). Remove tie straps and separate cooler
duct elbow from diffuser. Remove lower
connector.
(a). Place lower connector on cooler duct

elbow, then slide connector over
diffuser. Secure lower connector to
cooler duct elbow and diffuser with
tie-straps.
(b). Place upper connector on cooler duct
elbow, then install elbow over oil
cooler blower scroll. Slide upper
connector over scroll; secure with
clamps.
11. Oil Tank Inspection
(1). Check oil tank for obvious damage,
corrosion, evidence of leakage and
security.
(2). Repair or replace oil tank as required.
12. Oil Cooler Inspection
(1). Inspect engine oil cooler for cracks,
corrosion, damaged or bulged plates,
broken welds, clogged airways, oil leaks
and security. Inspect all hoses and
fittings for oil leaks and security.
(2). Repair or replace oil cooler and compo
nents as required.
Table 202. Oil System Hardware Torque Values

Item
Torque
1/4 inch (6.35 mm) OD tube nuts
40 65 inchpounds
(4.52 7.34 Nm)
60 80 inchpounds
(6.78 9.04 Nm)
150 200 inchpounds
(16.95 22.60 Nm)
1/4 inch (6.35 mm) OD hose nuts
70 120 inchpounds
(7.91 13.56 Nm)
85 180 inchpounds
(9.60 20.34 Nm)
210 420 inchpounds
(23.73 47.45 Nm)
Page 210
Revision 23
79-00-00
MAINTENANCE MANUAL
CSP-HMI-2
TANK DRAIN
TUBE
BULKHEAD
FIREWALL
ELBOW
UNION
DRAIN
PORT
UPPER
CONNECTOR
OIL COOLER BLOWER
INLET
PORT
ENGINE-TO-COOLER
OIL HOSE
CLAMP (2)
OIL TANK
RETURN HOSE
CHECK
VALVE
COOLER DUCT
ELBOW
COOLER
DRAIN
TUBE
LOWER CONNECTOR
ENGINE OIL
TANK DRAIN
COOLER OUTLET
PORT
TIE STRAP (2)
THERMOSTATIC
VALVE
DIFFUSER
ENGINE-TO-FILTER
OIL HOSE
GASKET
SHIELD
ENGINE OIL
COOLER DRAIN
SPACER
SHIELD
DEFLECTOR
FILTER-TO-COOLER
OIL HOSE
ENGINE OIL
COOLER
FIREWALL
TANK DRAIN
TUBE
SCAVENGE OIL FILTER

(NOTE)
GASKET
EARLY CONFIGURATION
STA. 124.00
COOLER INLET AND
DRAIN CONNECTIONS
LOCKWIRE
UNION
DRAIN
PORT
CAUTION:
AT REMOVAL OR INSTALLATION OF CHECK
VALVE OR HOSE, FLATS ON PORT SHOULD
BE HELD TO PREVENT DEFORMATION OF
COOLER FRAME.
NOTE:
APPLICABLE TO ALL ALLISON 250-C20R/2
ENGINES. OPTIONAL EQUIPMENT FOR
ALLISON 250-C20B AND C30 ENGINES.
BRACKET
INLET PORT
(SEE CAUTION)
DRAIN VALVE
FILTER-TOCOOLER OIL
HOSE (NOTE)
O-RING
ENGINE-TO-COOLER
OIL HOSE
DRAIN HOSE
CHECK VALVE
GROMMET
O-RING
COOLER DRAIN VALVE
EARLY CONFIGURATION
G79-0004
Figure 204. Engine Oil Cooler Installation
79-00-00
Page 211
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
13. One Time Mandatory Hose Inspection

(369D Serial Numbers 0003D thru 0374D,
Only)
(1). Remove trim and aft R/H bulkhead
access panel.
(2). Locate return hose between oil cooler
and tank. Check part number. Part
number 369D28309 hose must be
replaced with a part number
369D28311-3 hose assembly per
instructions in `Removal and Installa
tion'.
14. Oil Lines and Fittings Inspection
(1). Inspect tubes and hoses for uniform
diameter, interference with adjoining
structure and the following:
(a). Inspect tubes for kinks or dents
which could obstruct oil flow. Dents
may not exceed 0.015 inch (0.381
mm) deep.
(b). Look for cracks. No tubing cracks are
allowed.
(c). Inspect coupling nut threads for
Cross-thread damage. No thread
damage allowed.
(d). Inspect tubing for chafe damage in
excess of 0.010 inch (0.254 mm) deep.
No chafe damage allowed on or near
flared tubing end.
(e). Look for nicks in excess of 0.010 inch
(0.254 mm) depth.
(f). Replace any tubes exceeding damage
limits.
15. Oil Tank Repair
Item
CM206
CM234
CM802
CM825
Nomenclature
Chemical coating
Welding rod
Page 212
Revision 23
79-00-00
(1). Remove sight plug, oil temperature

sender, unions and hoses.
(2). Flush tank with solvent (CM234).
(3). Oxy-acetylene weld all cracks, loose
fittings, open seams, and tubes with
welding rod (CM825).
(4). Blend scratches and nicks with fine grit
aluminum oxide abrasive cloth
(CM802).
(5). Touch up reworked surfaces with
(6). Install sight plug, oil temperature
sender, unions and hoses.
16. Oil Cooler Repair
Item
Nomenclature
CM206
CM802
CM825
Chemical coating
Welding rod
(1). Replace a defective thermostatic valve.

(2). Straighten bent cooling fins with a pair
of duckbill pliers ground to fit between
cooling tubes.
(3). Weld all small holes, cracked seams or
loose fittings with welding rod (CM825).
(4). Smooth scratches and nicks with fine
grit aluminum oxide abrasive cloth
(CM802). Touch up surface with
17. Oil Cooler Duct Repair
NOTE: Repairs must not restrict airflow, pre

vent proper mating or interfere with instal
lation.
(1). Repair cooler duct per standard
fiberglass repair procedures in the
structural repair manual (CSPSRM-6).
MAINTENANCE MANUAL
CSP-HMI-2
Section
791010
AirframeMounted
Engine Scavenge Oil
Filter (369D/E/FF
500N)
MAINTENANCE MANUAL
CSP-HMI-2
AIRFRAMEMOUNTED ENGINE SCAVENGE OIL FILTER

(1). The optional scavenge oil filter is
installed in the return line between the
engine and oil cooler. The scavenge
filter supplements the engine oil filter
and provides the capacity to keep the
oil clean enough to operate extended
hours (Ref. applicable Rolls-Royce
Maintenance Manual, Sec. 72-00-00,
Table 602) between changes.
(7). Install a new oil filter element.

3. Scavenge Oil Filter Element Replacement
(Ref. Figure 201)
Item
CM701
Nomenclature
Lockwire CRES
(2). The 10 micron filter element keeps

otherwise recirculated microscopic
carbon and metal particles from
accumulating in the cooler, supply tank,
engine or on magnetic plugs.
(3). The filter body is equipped with a

bypass valve and red impending bypass
warning indicator that extends when
differential pressure across the filter
element reaches 6-8psid (41-55 kPa).
The indicator is inoperative until the oil
temperature exceeds 85-115F
(30-46C). The filter bypass valve opens
at 9-11 psid (62-76 kPa).
(3). Install a new filter element.
2. Scavenge Oil Filter Check

(Ref. Figure 201)
(2). Inspect red bypass indicator button on
bottom of filter bowl. Button extension
indicates a filter element impending
bypass condition.
(3). Press and turn indicator button 90 to
reset.
(2). Break lockwire and remove bowl and

filter element. Inspect element, bowl
seal and inside of bowl. Clean bowl as
required. Replace seal as required.
(4). Hand tighten bowl snug into filter body.

Lockwire (CM701) bowl.
(5). Motor engine until oil pressure is
indicated. Check oil quantity and top off
oil tank as required.
(6). Start and operate engine at idle for five
minutes per Pilot's Flight Manual. Shut
down engine and check for oil leaks.
(7). Enter filter element change in helicop
ter records.
4. Scavenge Oil Filter Bypass Indicator Test
(Ref. Figure 201)
Item
CM701
Nomenclature
Lockwire CRES
Item
ST408
Special Tools
Nomenclature
Test tool

Manual until engine oil reaches normal
operating temperature.
(5). Shut down engine. Check indicator
button.
(6). If button has reappeared, investigate
cause of filter bypass condition per the
applicable Rolls-Royce Operation and
Maintenance Manual.

(2). Break lockwire and remove filter bowl
and element. Inspect element and
79-10-10
Page 201
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2
inside of bowl per the applicable

Rolls-Royce Operation and Mainte
nance Manual.
(3). Install Facet test tool (ST408) and
reinstall bowl without lockwire.
will not reset, contact Facet Enter

prises, Inc., or your authorized Facet
distributor (Ref. Sec. 01-00-00).
NOTE: The bypass indicator is functioning

properly if it extends.
NOTE: Bypass indicator remains inoperative

until oil temperature exceeds 85-115F
(30-46C).
Manual until engine oil reaches normal
operating temperature and filter bypass
indicator extends (about 10 minutes).
Bypass indicator and bowl are
matched assemblies and factory
set. Do not attempt to adjust or replace by
pass indicator assembly.
CAUTION
(5). If bypass indicator fails to extend or

HEAD ASSY

Manual. Remove filter bowl and test
tool. Clean filter bowl as required.
(7). Install a new seal kit and filter ele
ment. Hand tighten bowl snug into
filter body. Lockwire (CM701) bowl.
(8). Press and turn indicator button 90 to
reset.
(9). Drain and service engine oil system.
SCREEN
REDUCER
REDUCER
SEAL
BOWL ASSY
FILTER ELEMENT
BYPASS INDICATOR
Figure 201. Facet Scavenge Oil Filter Assembly

Page 202
Revision 44
79-10-10
G79-1001
MAINTENANCE MANUAL
CSP-HMI-2
AIRFRAMEMOUNTED ENGINE SCAVENGE OIL FILTER

1. Scavenge Oil Filter Initial Installation
(Ref. Figure 901)
Item
Nomenclature
CM219
CM318
CM721
Methyl-ethyl-ketone
Primer
Tape, aluminum foil
Prevent installation errors and

equipment damage. Study in
stallation instructions before beginning
work. Contact Facet Enterprises, Inc. for ad
ditional information (Ref. Sec. 01-00-00).
CAUTION
(1). Disconnect external electric power. Set

all switches OFF. Disconnect battery.
(3). Drain engine oil tank, lines and cooler
(Ref. Sec. 12-00-00).
(4). Disconnect electrical plug from engine
gear case chip detector. Remove chip
detector from gear case. Bag parts for
reinstallation.
(5). Disconnect scavenge oil line from gear
case OUT port union (Ref. Sec.
79-00-00). Remove and discard union.
backup wrench on oil cooler port
boss when removing or installing oil line fit
tings.
CAUTION
(6). Disconnect scavenge oil hose from oil

cooler IN port check valve union.
Remove union from oil cooler check
valve. Discard union and hose.
(7). Unclamp wire bundle on BL 15.250
vertical stiffener. Bag clamp hardware
for reuse.
(8). Locate airframe centerline on firewall
bulkhead in engine compartment.
(9). Locate two vertical stiffeners located on

RBL 8.500 and RBL 15.250.
(10). Locate flanged horizontal stiffener on
WL 24.750. Stiffener is installed across
helicopter centerline between left and
right BL 8.500 vertical stiffeners.
Avoid fatigue concentrations.
Do not scratch, score or gouge
firewall when removing insulation.
CAUTION
(11). Remove insulation between RBL 8.500

and RBL 15.250 vertical stiffeners
beginning at WL 24.750 and down
about 6 inches (15.24 cm). Retain
insulation.
Do not position mounting brack
ets and filter lower than the
hoses will reach. Install filter so that line
connections can be made without straining
hoses.
CAUTION
(12). Locate and clamp LH mounting bracket

within 0.1250-0.3125 inch
(3.1750-7.9375 mm) of WL 24.75
horizontal stiffener with bracket flange
facing inboard.
(13). Locate and clamp RH mounting bracket
level with LH bracket and flange facing
inboard.
(14). Locate and clamp filter mounting plate
to brackets with plate flanges facing aft
and triangular hole pattern pointing
up.
(15). Position filter on its mounting plate and
loosely install spacers, bolts, washers
and nuts.
(16). Install O-ring on engine oil OUT port
reducer. Install and torque reducer per
requirements of the applicable Allison
Prevent oil cooler damage. Use a
backup wrench on oil cooler
check valve while torquing reducer.
CAUTION
(17). Install O-ring on oil cooler IN port

reducer. Relieve lightening hole for
additional clearance as required. Install
79-10-10
Page 901
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
reducer in oil cooler check valve and

torque to 280 - 305 inch-pounds
(31.64 - 34.46 Nm).
(18). Loosely install hose between engine
gear case OUT port and filter IN port
with 90 hose fitting attached to filter.
(19). Loosely install hose between filter OUT
port and oil cooler IN check valve with
90 fitting attached to filter.
NOTE: Reposition brackets and filter as re

quired to relieve any strain on hoses before
drilling mounting bracket holes through
stiffeners. Relocate and drill three new filter
mounting bracket bolt holes when addition
al hose strain relief is required.
(20). Unclamp and move filter and mounting
plate assembly out of the way.
Avoid fatigue concentrations.
Do not scratch, score or gouge
firewall while drilling stiffeners.
CAUTION
(28). Install chip detector and torque to 60 80 inch-pounds (6.78 - 9.04 Nm).
(29). Attach chip detector electrical connector
to chip detector.
(30). Select a location for filter bypass
indicator reset label in plain view on
upper LH corner of RH engine access
door. Activate label adhesive with MEK
(CM219).
2. Post Installation Inspection
It is possible to install the fil
WARNING ter with its IN and OUT

ports reversed. This condition renders
both the impending bypass indicator
and filter bypass valve inoperative.
Subsequent clogging of the outlet port
screen will not provide any visual indi
cation. If allowed to continue, the oil
flow reduction could have a disastrous
effect on the engine and oil system
components.
(21). Ensure bracket upper edges are lined

up and level. Drill three 0.189 inch
(4.8006 mm) diameter bolt holes
through left and right brackets and
airframe stiffeners.
(1). Ensure that the engine gear case oil

OUT port hose is connected to the
scavenge oil filter IN port. Ensure that
the filter OUT port hose is connected to
the oil cooler IN port.
(22). Unclamp brackets and deburr holes.

Coat holes with primer (CM318).
(2). Check for adequate hose clearances

near structure and engine.
(23). Install brackets with bolts, washers and

nuts. Install wire harness clamp under
upper right bolt.
(24). Attach insulation to firewall with
aluminum foil tape (CM721).
(25). Torque three filter mounting nuts to 50
- 55 inch-pounds (5.65 - 6.21 Nm).
(26). Attach filter mounting plate to airframe
brackets with bolts, washers and nuts.
(27). Torque hose nuts to 280 - 305 inchpounds (31.64 - 34.46 Nm).
Page 902
Revision 23
79-10-10
(3). Inspect attaching hardware for security

and line connections for correct torque
values.
(4). Service engine oil system (Ref. Sec.
12-00-00).
(5). Connect battery.
(6). Pick up tools and debris before closing
Manual and inspect installation for oil
leaks prior to releasing helicopter for
flight.
MAINTENANCE MANUAL
INDICATOR
RESET LABEL
CSP-HMI-2
REDUCER
REDUCER
HOSE
HOSE ASSY
RBL
8.50
STA. 124.00
RBL
15.25
LIGHTENING
HOLE
STIFFENER
STIFFENER
STIFFENER
WASHER
WL 24.75
NUT
WASHER
FILTER ASSY
NUT
BRACKET
WASHER
WASHER
BOLT
NUT
WASHER
BOLT
0.125-0.3125 IN.
(3.1750-7.9375 MM)
GAP
WASHER
WL 24.75
BRACKET
STIFFENER
SPACER
BOLT
BRACKET
STIFFENER
FILTER ASSY
RBL
8.50
G79-1000A
Figure 901. Scavenge Oil Filter Installation
79-10-10
Page 903
Revision 23
CSP-HMI-2
MAINTENANCE MANUAL
Page 904
Revision 44
79-10-10
MAINTENANCE MANUAL
Chapter
91
Charts
CSP-HMI-2
MAINTENANCE MANUAL
CSPHMI2
TABLE OF CONTENTS
Para/Figure/Table
Title
Page
91-00-00 Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Consumable Materials and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.
Manufacturer/Supplier Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 1. Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2. Manufacturer/Supplier Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3. Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4. Tool Manufacturer/Supplier Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91 Contents
1
2
11
15
21
Page i
Revision 43
CSPHMI2
MAINTENANCE MANUAL

Para/Figure/Table
Title
Page ii
Revision 43
91 Contents
Page
MAINTENANCE MANUAL
CSP-HMI-2
Section
910000
Charts
CSP-HMI-2
MAINTENANCE MANUAL
MAINTENANCE MANUAL
CSP-HMI-2
CHARTS
CONSUMABLE MATERIALS AND SPECIAL TOOLS
1. General
D CM601 - Rubber Material
This chapter provides a table of Consumable

Materials and a table of Special Tools used on
the 500/600N Series Helicopter.
D CM701 - Lockwire, Fasteners and Tape
The information in each table is divided into

groups. Within each group, materials or tools
are identified by a number. Numbers have a
prefix of CM identifying a consumable
material, or a ST identifying a special tool. CM
and ST numbers are used throughout the
maintenance manual, allowing quick reference
for Consumable Materials and Special Tools.
3. Special Tools
2. Consumable Materials
4. Manufacturer/Supplier Number
Table 1 lists Consumable Materials, such as

fuels and oils used to support repair or
servicing procedures.
Table 2 lists Manufacturer/Supplier (Vendor)

Number with address. Table 2 is used with
Table 1, Consumable Materials.
Consumable materials are assigned a CM

number, with associated material name,
specification number and commercial name.
Table 4 lists Tool Manufacturer/Supplier

(Vendor) Number with address. Table 4 is used
with Table 3, Special Tools.
The following consumable materials are

approved for use on the 500/600N Series. Do
not use replacement materials unless equal in
quality and grade. Refer to notes at the end of
Table 1.
For additional servicing information, such as
capacities Refer to Section 12-00-00.
D CM801 - Miscellaneous Materials
Table 3 identifies special tools, necessary for

maintenance operations.
Each tool is assigned an ST number, with an
associated part number, descriptive title and
function.
D ST101 - Ground Handling

D ST201 - Jacking and Leveling
D ST301 - Main Transmission
D ST401 - Engine
D ST501 - Flight Controls
D CM101 - Lubricants
D ST601 - Anti-Torque
D CM201 - Solvents, Cleaners and Corrosion

Preventative Compounds
D ST701 - Main Rotor
D CM301 - Paints, Primers and Coating

Compounds
D ST901 - Track and Balance
D ST801 - Fuel
D CM401 - Adhesives, Cements and Sealants
D ST1001 - Electrical/Instrument/Avionic
D CM501 - Composite Materials
D ST2001 - Miscellaneous
91-00-00
Page 1
Revision 23
MAINTENANCE MANUAL
CSP-HMI-2
Table 1. Consumable Materials

Item
No.
Material
Specification No. (1)

Type Class Grade
Commercial Name/No. (2)
Vendor
(Table 2)
Lubricants
CM101
MIL-L-46010
(3)
CM102
MIL-L-46010A
Ecoalube No. 642
MS27
CM103
MIL-L-8937
MIL-L-23398
HMS 4-1078 1
Lubribond A
Molyspray Type PT-101
MS25
MS63
CM104
Lubricant, spray
Tri-Flow
Break-Free
MS37
MS43
CM105
Lubricant, spray
Moly-Dee
MS9
CM106
S-122
MS53
CM107
Fluorocarbon release agent (dry

film lubricant)
6611N
MS24
CM108
Graphite, powdered
CM109
Molybdenum disulfide powder

lubricant
CM110
Grease
CM111
Grease, aircraft
CM112
(3)
MIL-L-7866
(3)
GD568-S
MS35
MIL-G-81322
Mobil Grease 28
Aero Shell 22
Braycote 622
MS54
MS73
MS13
Anti-seize compound high tem

perature
MIL-PRF-907E
(3)
CM113
Anti-seize compound low tem

perature
MIL-T-5544
Thread Lube
CM114
Petrolatum (petrolatum jelly)
MIL-G-6032
VV-P-236
CM115
MIL-G-25537
MIL-A-8623
Aero Shell 14
A-1177-B
MS73
MS12
CM116
MIL-G-23827
Braycoat 627
Exxon 5114EP
Aero Shell 7
MS13
MS28
MS73
CM117
Grease
MIL-G-23872
CM118
Grease
930A
MS47
CM119
Grease
130A
MS47
CM120
Steelgard 1301
MS36
CM121
Preservation oil (general pur

pose)
VV-L-800
MS13
CM122
Preservative oil, hydraulic
MIL-H-6083
(3)
CM123
Hydraulic fluid
MIL-H-5606
(3)
CM124
Kerosene
VV-K-211
(3)
CM125
Oil (4) (7)
Page 2
Revision 34
MS22
MS70
MS81
(3)
Mobil SHC 626 (6)
91-00-00
MS59
MS54
MAINTENANCE MANUAL
CSP-HMI-2
Table 1. Consumable Materials (Cont.)

Item
No.
Material
CM126
Oil, turbine (4) (5)
CM127
Grease, YSAS Actuator

Type Class Grade
MIL-L (PRF)-23699
Vendor
(Table 2)
(3)
168043
MS90
Solvents, Cleaners and Corrosion Preventative Compounds

CM201
Protective coating
MIL-C (PRF)-6799
1
(3)
CM202
CM203
Potting compound
MIL-S (PRF)-8516G
MS77
CM204
Compound, corrosion preventa

tive
MIL-C (PRF)-16173E Braycote

.............. 3
.............. 4
MS10
MS13
MS88
CM205
Dielectric compound
CM206
Chemical coating
CM207
Chromic acid solution (pH 2.6 to

3.4, magnesium touchup)
CM208
Barrier material (grease-proof)
MIL-B (PRF)-121G
1 ..... 2 ..... A
MIL-B (PRF)-131L
....... 1
CM209
Putty, general purpose
MIL-P (PRF)-8116
CM210
Corrosive preventive (aircraft

gas turbine, synthetic base)
MIL-C (PRF)-8188
CM211
Solvent
3339
MS82
CM212
Releasing agent
TC7-527
MS26
CM213
Releasing agent
225
MS64
CM214
Releasing agent
CM215
Parting agent
Slip-Spray
Fre-Kote 33
MS24
MS31
CM216
Loctite remover (for disas

sembled parts)
Oakite 156
MS17
MS57
MS74
CM217
Isopropyl alcohol
TT-I-735
(3)
CM218
Alcohol, denatured
O-E-760
1
(3)
CM219
Methyl-ethyl-ketone
TT-M-261
(3)
CM220
Naphtha aliphatic
TT-N-95
2
(3)
CM221
Xylene
CM222
O-T-620
(3)
CM223
Acetone
O-A-51
(3)
Molykote
MIL-C-5541
MS22
DC-4
MS22
Iridite 14-2
Al-Coat
Alodine 1201
MS67
MS85
Dow #19 or equivalent
MS22
(3)
Compound 3998
MS32
(3)
MIL-P (PRF)-23377
HMS 20-1245
MS14
MS17
(3)
91-00-00
Page 3
Revision 36
MAINTENANCE MANUAL
CSP-HMI-2

Item
No.

Type Class Grade
Material
Vendor
(Table 2)
CM224
Soap paste
P-S-560
(3)
CM225
Detergent, general purpose
MIL-O-16791
(3)
CM226
Cleaning compound, alkaline

waterbase
MIL-C-25769
(3)
CM227
CM228
Surface cleaner (pre-paint solu

tion with phosphoric acid base)
TT-C-490
MIL-C-10578
2
CM229
Paint remover (acid-type for

epoxy)
TT-R-25134
MS79
CM230
Paint remover (solvent-type)
MIL-R-25314
(3)
CM231
Plastic bead, spherical 20 - 30

mesh
Poly Plus 20/30 (8)
MS1
MS2
MS61
CM232
WD-40
MS68
CM233
LPS3
MS46
CM234
P-D-680
(3)
CM235
Cleaner
Desoclean 45
MS17
Turtle Zip Wax
(3)
WO#1
MS79
Paints (9), Primers and Coating Compounds

CM301
Pre-treatment
CM302
Epoxy primer /
Catalyst reducer
CM303
Wash primer
MIL-C-8514
CM304
Enamel, epoxy
(FedStd595)
MDM 15-1100
2
Black #37038
White #37769
Tan #20318
Parchment #20371
Red #11958
Green #34151
Gray #36231
Yellow #13655
(3)
CM305
Lacquer, acrylic
(FedStd595)
MDM 15-1083
Black #17038
Black #37038
Parchment #20371
Green #34151
Blue #15102
Blue #35044
Brown #30140
(3)
CM306
Lacquer, clear (aluminum clad

alloy surfaces)
MIL-L-6066
(3)
CM307
Lacquer, acrylic semi-gloss
HMS 15-1083
(3)
CM308
Lacquer, blue
FED-STD-15102
(3)
CM309
Lacquer, green
TT-L-32
(3)
Page 4
Revision 41
MIL-P-15328
(3)
1-1G-69 /
1-1H-75
91-00-00
MS3
(3)
MAINTENANCE MANUAL
CSP-HMI-2

Item
No.

Type Class Grade
Material
TT-E-527
Vendor
(Table 2)
CM310
Enamel, lusterless
(3)
CM311
Coating, logo white /

Thinner
CM312
MIL-M-43719
TT-I-558
(3)
Ink, marking, stencil
A-A-208 Type 1, color

number 37038
(3)
Q-881 (Color No. 484) /

T-80695
(3)
Fine tip permanent marker
Sharpie
(3)
CM313
Insulation varnish
Glyptal 1201
MS33
CM314
MIL-V-173
2
(3)
CM315
Adhesive primer (liquid primer)
HMS 16-1069
....... 1
MS50
CM316
Epoxy coating /
Thinner
Poly-EP
MS19
CM317
Resin primer /
Thinner (paint base for polycar
bonate plastic)
Q-881 /
T-80679
MS11
CM318
Primer
MIL-P-85582
1 . . . . . C2
(3)
CM319
Barrier material, grease-proof
MIL-B-121
1 ..... 2 ..... A
MIL-B-131
....... 1
(3)
CM320
Thinner, lacquer (acrylin-nitro

cellulose)
MIL-T-19544
Prepsol
(DuPont 3919)
MS24
CM321
Surface primer locking com

pound (single component, grade
as noted)
MIL-S-22473
Locquic
MS45
CM322
Primer, Silicone, Red
Dow Corning 1200
MS43
CM323
Primer
MIL-P-23377
1 ..... C
(3)
Adhesives, Cements and Sealants

CM401
Adhesive
Stabond G-304
MS75
CM402
Adhesive
EA9323
EA956
MS21
CM403
Adhesive
Epon 919
MS72
CM404
Adhesive, epoxy (non-structural) HMS 16-1147

....... 2
EC2216B/A
Scotch Weld
MS86
CM405
Adhesive
C-111
MS75
CM406
Adhesive
U-136
(AC-AAAA)
MS75
MDM 16-1068
. . . . . . . 11
HMS 16-1149
91-00-00
Page 5
Revision 41
MAINTENANCE MANUAL
CSP-HMI-2

Item
No.
Material

Type Class Grade
Vendor
(Table 2)
CM407
Adhesive /
Primer /
Catalyst
A-4000 /
A-4004 /
xy22
MS22
CM408
Adhesive, silicone rubber
Silastic 140
MS22
CM409
Adhesive, epoxy
MDM 16-1068
....... 1
EA9330.3
MS21
CM410
Adhesive, epoxy
MDM 16-1068
....... 7
EA9309.3
MS21
CM411
Adhesive, epoxy (non-structural) MIL-A-52194

MDM 16-1068
....... 2
Scotch-Weld EC1838
A1177B
MS86
MS12
CM412
Adhesive, bonding, vulcanized

(synthetic rubber-to-steel)
CM413
CM414
Adhesive, cyanoacrylic /
Accelerator
MIL-A-46050
3CI-1000 /
Super Drop Accelerator
MS21
CM415
Cement
MIL-A-8576B
PS-18
S147
MS69
CM416
Cement
#2210
MS86
CM417
Cement
HMS 16-1149
2 ..... 1
Grip
MS38
CM418
Cement, epoxy
HMS 16-1149
2 ..... 2
EC1300L
MS86
CM419
Sealer
MDM 16-1068
....... 2
A1177B
MS12
CM420
Sealant
MIL-S-81733
PR-1431 Type IV
PR1436G Type II
PR1436GB-2
MS62
CM421
Sealant
Anchor Weld #220
MS58
CM422
Sealant
#5220
MS30
CM423
Sealant
RTV106 (2)
MS34
CM424
Sealing compound
HT-4
MS75
CM425
Sealing compound
(fuel resistant)
HMS 16-1097
1 . . . . . B2
MIL-S-8802
Pro-Seal 890
MS62
CM426
Sealing compound
MIL-S-8516
....... 2
3C-3007
MS14
CM427
Sealing compound
MIL-S-8516
1 . . . . . 2 . . . . . A1/2
PR1422
MS62
CM428
Sealing compound
MIL-S-8516
1 ..... 2
RTV730
Silastic 730
MS22
MS34
CM429
Sealing compound, silicone
RTV11
MS34
Page 6
Revision 41
MIL-A-1154
91-00-00
MS86
MAINTENANCE MANUAL
CSP-HMI-2

Item
No.
Material

Type Class Grade
Vendor
(Table 2)
CM430
MIL-S-8660B
RTV732
Silastic 732
RTV 157
MS22
MS34
CM431
Sealing, locking and retaining

compound (single component,
grade as noted)
MIL-S-22473
MIL-R-46082
Loctite #85 or
RC/609
MS45
MS60
CM432
Dichloromethane (methylene
chloride)
MIL-D-6998
CM433
Ethylene chloride (ethylene dich MIL-E-10662

loride, EDC)
CM434
Thread sealant
CM435
Tetrahydrofuran (THF)
CM436
Plastic steel
CM437
Sealing compound
(3)
(3)
P412
MS60
MS51
Devcon A
MS20
Permabond 102
MS43
MS60
Loctite 414
MS45
MS87
CM438
Adhesive, Epoxy
HMS16-1068
. . . . . . . 12
EA9321
CM439
Adhesive
HMS16-1149
5
CM440
Sealant, electrically conductive
MDM16-1261
CM441
Sealing Compound, Corrosion

Inhibiting
HMS-16-1097
MIL-PRF-81733
T3 . . . . CB . . . 1/2
MS21
MS75
Cho-bond 2165
MS91
(3)
Composite Materials
CM501
Fiberglass cloth (0.022, 2 ply)
SAE-AMS-C-9084
No. 181
(3)
CM502
Sleeving, fiberglass (No. 4, 0.214

in. ID x 4.0 in.)
MIL-I-3190
. . . . . . . HA-1
(3)
CM503
Fiberglass repair kit
CM504
Epoxy resin with catalyst (low

pressure laminating)
MIL-R-9300
1
(3)
CM505
MIL-R-7575
(3)
CM506
Resin, fiberglass
Epon 828
MS72
CM507
Resin, filler
Epon 960F
MS72
CM508
Resin, filler
#RP1257-3
MS66
Cordokit RK-10
MS29
Rubber Material
CM601
Insulation sleeving, electrical

(vinyl tubing; size as notes)
MIL-I-631
F ..... 1 ..... A
Form U, Category 1
91-00-00
(3)
Page 7
Revision 44
MAINTENANCE MANUAL
CSP-HMI-2

Item
No.

Type Class Grade
Material
MIL-I-3190
Vendor
(Table 2)
CM602
Insulation sleeving, electrical, fi

berglass (size as notes)
(3)
CM603
Patching material (inside/out

side)
#5200/5187/5194
MS82
CM604
Patching material (outside only)
#5218 or #5241/5241
MS82
CM605
RK3CL
MS82
CM606
Rubber cement
MIL-A-5092
CM607
Cement
MIL-S-9117
CM608
(3)
EC-678
MS82
Cement
Uniroyal #3230
MS80
CM609
Repair kit (non-self- sealing

cell)
Uniroyal #RK-10-34
MS80
CM610
Patch material (self- sealing cell,

exterior)
Uniroyal #5241/5241 sand

wich
MS80
CM611
Tubing, vinyl clear
PVC tubing, 2 GA, clear

105C
MS71
CM612
Tube, silicone
No. 4 (H.A.I.)
MS83
CM613
Sleeve, vinyl
No. 2 Resinite
MS13
CM614
Sleeving, heat-shrink (class,

type or diameter as noted)
RNF100X3/8
RNF100X1/2
RNF100 .125 ID
MS65
MIL-I-23053
Lockwire, Fasteners and Tape

CM701
Lockwire CRES
MS20995C20
(3)
CM702
Lockwire CRES
MS20995C32
(3)
CM703
Tie strap (size as noted)
MS3367-*-*
MS78
CM704
Tie strap, nylon
MS17821-1-9
CM705
TY-RAP
(3)
Tie, cable
SST2
MS18
CM706
Tie strap base
TC112
MS78
CM707
Tape, fastener (nylon hook and

pile)
Velcro
(3)
CM708
Tape
#850
MS86
CM709
Tape
CT93C
MS42
CM710
Tape, high temperature (thick

ness as noted)
Temp-R
MS16
MS39
CM711
Tape, pressure sensitive (water

proof for packaging and sealing,
width and thickness as noted)
CM712
Tape, pressure sensitive (width

as noted)
#41
MS86
CM713
#471
MS86
CM714

as noted)
#4104
MS86
Page 8
Revision 41
PPP-T-60
1 ..... 1
91-00-00
MS60
MS86
MAINTENANCE MANUAL
CSP-HMI-2

Item
No.

Type Class Grade
Material

#4508
Vendor
(Table 2)
CM715

as noted)
CM716
Tape, pressure sensitive (adhe

sive, filament reinforced)
CM717
Tape, pressure sensitive, (poly

urethane, width as noted)
#Y8560
MS86
CM718
Tape, double-faced
E-706
MS8
CM719
Tape, vinyl plastic
#330
MS76
CM720
Tape and activator, vinyl
Scotch Cal #45

Scotch Tite A-2
MS86
CM721
Tape, aluminum foil
#425
MS86
CM722
Tape, polyethylene
#483
MS86
CM723
Tape, nitrile rubber
NE-71-A
MS7
CM724
Tape, non-slip (pressure sensi

tive, medium grade, black)
P-D-00455
CM725
MIL-I-7798
CM726
PPP-T-97
MS86
(3)
(3)
#33
MS86
Tape teflon
#520
#48
MS60
MS86
CM727
Tape, foam (adhesive backing)
4104Y
92772
MS86
CM728
Tape, pressure sensitive (sponge

rubber)
4504
Scotchfoam tape
MS86
CM729
Tape, masking, pressure sensi

tive
#216
(High Temp)
MS86
CM730
Tape, duct
CM731
Lockwire CRES
UU-T-106
(3)
MS20995C15
(3)
Miscellaneous Materials
CM801

(grade as noted)
P-P-101
(3)
CM802

(grade as noted)
P-C-451
(3)
CM803
Crocus cloth
P-C-458
(3)
CM804
Emery cloth, fine
CM805
Dye penetrant kit
MIL-I-25135
CM806
Micro-Mesh plastic restoration

kit
5350-01-290-4002
CM807
Twine, nylon
MIL-T-713
(3)
CM808
Lacing cord (high temperature)
Type T-3333
MS84
CM809
Nylon cord (lacing)
MIL-C-5040
(3)
CM810
MIL-L-25567C
CM811
(3)
MS6
MS48
Micro-Mesh Kit KR-70
MS52
Leak-Tec
MS4
Snoop
MS56
91-00-00
Page 9
Revision 41
MAINTENANCE MANUAL
CSP-HMI-2

Item
No.
Material

Type Class Grade
Vendor
(Table 2)
CM812
Splice, knife
32445
CM813
Wire
CM814
Dykem, red or blue
CM815
Solder (tin alloy, rosin core)
QQ-S-571
SN60WRP2
(3)
CM816
Solder (tin alloy, acid core)
QQ-S-571
(3)
CM817
Brazing flux (paste)
O-F-499
(3)
CM818
Brazing alloy (silver base)
MS86
CM819
Kimwipe
(3)
CM820
Cheesecloth
(3)
CM821
Gasket material (adhesive one

side only)
CM822
Acetylene, technical grade
BB-A-106
(3)
CM823
Oxygen, industrial grade
BB-O-925
1 ............ B
(3)
CM824
Welding rod (corrosion and heat

resistant alloys, class or type as
noted)
AMS 5656, AWS A5.9, 21-6-9 (Nitronic 40)

ER219
(3)
CM825
Welding rod
QQ-R-566
CLFS RA12 or
RA143 (04043)
5% silicon
(3)
CM826
Desiccant
MIL-D-3464 Type I
or II
MS22759/34-22-9
MS5
(3)
DX-296
Scotchfoam #4304
Desiccant
MS23
MS40
MS49
MS86
(3)
NOTES:
(1) Numbers are U.S. Specifications and Standards. Prefix symbols are specified as follows:
AMS American Materials Standards;
MS Military Standards;
MIL Military Specification; Single, Double or Triple alpha prefix of the same letter Federal Specification;
AN Air Force/Navy Aeronautical Standard;
NAS National Aerospace Standard.
(2) Primary selection. All equivalent material can be used as a different selection. Time increments on
manufacturers instructions must be adhered to, unless given differently in a specific task.
(3) Use the best comparable grade material when conformity of available materials of same type with given
Specification Number cannot be found.
(4) Oils approved for use in 500/600N Series Helicopter main and fan transmission are synthetic compounds
having Ryder Gear Value in excess of 2500 pounds.
(5) For Model 250 Series engine oil change requirements and restrictions on mixing oils, refer to Allison
CAUTION: Mixing of oils within an oil series not in the same group is permitted only in an emergency. Use
of mixed oils (oils not in the same group) in an engine is limited to five hours total running time. Adequate
maintenance records must be maintained to ensure that the five hour limit is not exceeded. Mixing of oils
from different series is not permitted.
Page 10
Revision 41
91-00-00
MAINTENANCE MANUAL
CSP-HMI-2
(6) Mobil oil SHC 626 can be formulated such that it may have two different colors. The oil can still be mixed
with no adverse affects.
(7) Use only Mobil SHC 626 oil in the 369F5450 overrunning clutch and 369F5100 main transmission.
(8) Do not use over 50 psig air pressure for abrasive cleaning method. Mask or shield threaded areas or
critical surfaces where damage may result from abrasive blasting.
(9) When ordering paint, give each paint by type (i.e. acrylic, epoxy, polyurethane); by color and AC part
number. Also include compatible HS or federal standard (FEDSTD) number to make sure correct type and
color paint is supplied. The color code numbers for finish paints used on 500/600N Series Helicopters are
entered in helicopter log books before delivery of aircraft. When ordering paints, ensure AC Number and
SA Number are compatible.
Table 2. Manufacturer/Supplier Number

Number
Name
MS1
Abrasive Cleaning Equipment

20122 State Rd.
Cerritos, CA 92701
MS2
Abrasives Unlimited
4653 S. 33rd St.
Phoenix, AZ 85040
(602) 2760077
MS3
Advanced Coating and Chemicals

2213 N. Tyler
S. El Monte, CA 91733
MS4
American Gas and Chemical Co.

220A Pegasus Ave.
Northvale, NJ 07647 1904
(201) 7677300
(800) 5261008
MS5
MS6
MS7
AMP Co.
P.O. Box 55
Winston Salem, NC 27102
(336) 7259222
(800) 5226752
Ardrox Inc.
19 Woodburn Ave.
P.O. Box 814
St. Catherines, Ontario
Canada L2R 6Y3
(416) 6841800
Armstrong Cork Co.
Lancaster, PA 17604
MS8
Arno Adhesive Tapes Inc.

Los Angeles, CA
MS9
Arthur Withrow
5511 District Blvd.
Number
Name
MS10
Tectyl Industrial Products A Div. Of

Ashland Inc.
3499 Dabney Dr.
Lexington, KY 40509
(859) 3577534
MS11
Bee Chemical Co.

2700T E. 170th St.
Lansing, IL 60438
(708) 4747000
MS12
B.F. Goodrich Co.

500 S. Main St.
Akron, OH 44318
MS13
Castrol Industrial North America Inc.

1001 W. 31st St.
Downers Grove, IL 60515
(630) 2414000
(800) 6212661
MS14
Churchill Chemical Corp.

Los Angeles, CA
MS15
PRCDesoto International, Inc.

5454 San Fernando Rd.
Glendale, CA 91203
(818) 240 2060
MS16
Connecticut Hard Rubber Co.

New Haven, CT
MS17
Crown Metro Inc

P.O. Box 5857
Greenville, SC 29606
(864) 2991331
MS18
Danquit Corp.
Tinley Park, IL
91-00-00
Page 11
Revision 41
MAINTENANCE MANUAL
CSP-HMI-2
Number
Name
Number
Name
MS19
Detroit Graphite Co.

Detroit, MI
MS32
Fuller OBrien Co.

S. San Francisco, CA
MS20
Devcon
30 Endicott St.
Danvers, MA 01923
(978) 7771100
MS33
General Electric
Insulation Dept.
Schenectady, NY
MS21
Dexter Adhesive & Coating Systems

2850 Willow Pass Rd.,
P.O. Box 312
Bay Point, CA 945650031
(925) 4588000
(800) 4249300
MS34
General Electric Company

Silicone Products Business Division
260 Hudson River Rd.
Waterford, NY 12188
(518) 2333330
MS35
GC Electronics
Los Angeles, CA
MS36
Harry Miller Corp.

4th & Bristol Sts.
( 215) 3244000
MS37
IKS American Corp.

Szumoto Seiko Division
1555 W. Rosecrans Ave.
Gardena, CA 90249
(800) 4212761
MS22
Dow Corning Corporation

P.O. Box 0994, South Saginaw Road
Midland, MI 48686
(800) 6349660
MS23
ITW/Dykem
805 E. Old 56 Hwy.
Olathe, KS 6606
(800) 4439536
MS24
Du Pont
Wilmington, DE 19898
(302) 7741000
(800) 4417515
MS38
E/M Corp.
100T Cooper Circle
Peachtree City, GA 30269
(770) 2614800
Columbia Aluminum Products

7020 E. Slauson Ave.
Commerce, California 90040
(323) 7287361
MS39
MS26
EPD Industries
2055 E. 223 St.
Long Beach, CA 90810
Insulectro Co.
1410 W. Olympic Blvd.
Los Angeles, CA
MS40
MS27
Everlube Corp.
North Hollywood, CA
IrwinHobson Co.
Ninth and S.E. Woodward
Portland, OR 97202
MS41
Deleted Not used at this time.
MS28
Exxon Co.
P.O. Box 2380
Houston, TX 77001
MS42
Jones Industrial Supply

Culver City, CA
MS43
MS29
Ferro Corp.
Composites Division
34 Smith St.
Norwalk, CT 06852
K.R. Anderson
4316 E. University Dr.
Phoenix, AZ 85034
(602) 4370030
MS30
FiberResin Corp
170 W Providencia Ave
Burbank, CA 91502
(800) 6249487
MS44
MS45
MS31
FreKote Inc.
Loctite Inc.
1001 Trout Brook Crossing
Rocky Hill, CT 060673910
Phone: (860) 5715100
FAX: (860) 5715465
MS25
Page 12
Revision 41
91-00-00
MAINTENANCE MANUAL
Number
Name
Chemetall Oakite Products, Inc.

50 Valley Rd.
Berkeley Heights, NJ 07922 2712
(908) 4646900
MS58
Pacific Upholstery
Gardena, CA
MS59
Magna Flux
11898T Burnside Lane
Roscoe, IL 61073
( 815) 6237634
ParkerHannifin
711 Taylor Street
P.O. Box 4032 Elyria, OH 44036
(440) 2846300
MS60
Markall Products Co.

4772T W. 139 St.
Cleveland, OH 44135
(216) 2673235
Permabond International Corp.

480 S. Dean St.
Englewood, NJ 07631
(201) 5679494
MS61
Polyrock Co.
4763 Murrita Ave.
Chino, CA 91710
MS62
Product Research and Chemical Co.

5426 San Fernando Rd.
Glendale, CA 91209
MS63
Product Techniques, Inc.

511 East 8th Pl.
Los Angeles, CA
MS64
Ram Chemical Co.

Gardena, CA
MS65
Raychem Corp.
305 Constitution Dr., Mailstop 103/2A
Menlo Park, CA 940251164
(800) 9262425
(650) 3613860
MS66
Ren Plastics Inc.

Lansing, MI 48910
MS67
Richardson Company
AlliedKelite Products Division
2400 E. Devon Ave.
Des Plains, IL
MS68
Rocket Chemical Co. Inc.

San Diego, CA
LPS Laboratories Inc.

4647 Hugh Howell Rd., Dept. M
Tucker, GA 30084
( 800) 2418334
MS47
Lubriplate Div., Fiske Bros. Refining Co.

129T Lockwood St.
Newark, NJ 07105
( 973) 5899150
MS49
MS50
MD Helicopters Inc.
4555 E. McDowell
Mesa, AZ 852159734
(480) 3466377
(800) 3883378
MS51
McKesson and Robbins

Chemical Dept.
Los Angeles, CA
MS52
MicroSurface Finishing Products Inc.

1217 W. Third Street
P.O. Box 818
Wilton, IA 52778
(319) 7323240
MS53
MillerStevenson Chemical Co.

1001 E. first St.
Los Angeles, CA
MS54
Name
MS57
MS46
MS48
Number
CSP-HMI-2
Mobil Oil Corp.

International Aviation Division
150 E. 42nd St.
New York, NY 10017
MS55
Rohm and Haas Company

100 Independence Mall West
(215) 5923000
(215) 5923377
MS69
Rohm and Haas Company

100 Independence Mall West
(215) 5923000
(215) 5923377
MS56
Nupro Company
4800 East 345th Street
Willoughby, OH 44094 4460
(440) 9517100
MS70
Royal Lubricants, Inc.

215 Merry Lane, P.O. Box 518
East Hanover, NJ 07936 0518
(800) 9897692
91-00-00
Page 13
Revision 41
MAINTENANCE MANUAL
CSP-HMI-2
Number
Name
Number
Name
MS71
Sea Wire and Cable Inc.

P.O. Box 647
Madison, AL 35758
18006337210
MS83
Varflex Corp.
512 W. Court St.
Rome, NY 13440
(315) 3364400
MS72
Shell Chemical Co.

910 Louisiana St.
Houston, TX 77002
7132416161
MS84
Warren Wire Co.
MS85
Witco
AlliedKelite Division
29111 Milford Rd.
New Hudson, MI 48165
(313) 4378161
MS86
3M Co.
Bldg. 223N
3M Center
St. Paul, MN 551441000
(612) 7331110
(800) 3623550
MS87
R.S, Hughes
2107 E. Magnolia
Phoenix, AZ 85034
(602) 2755565
(602) 2755025
MS88
Esgard Corrosion Coatings, PO Drawer

2698, Lafayette, LA 70502
(800) 8882511
MS73
Shell Oil Company

50 W. 50th. St.
New York, NY 10020
MS74
Sherwin Williams
MS75
Stabond Corp.
14010T S. Western Ave.
Gardena, CA 90249
(310) 3806168
MS76
Technical Tape Co.

363 Woodycrest Ave.
Nashville, TN 37210
(800) 7148806
MS77
Thiokol
MS78
Thomas and Betts Co.

Elizabeth, NJ
MS79
Turco Products, Inc

Division of Atochem North America
2700 Temple Ave Suite B
Long Beach, CA 90806
(562) 9818307
MS89
Hernon Mfg., Inc.

121T Tech Dr.
Sanford, FL 32771 USA
(800) 5270004
(407) 3224000
MS80
Uniroyal Inc.
Engineered Systems Dept.
Mishawaka, IN 46544
MS90
MS81
UnitedErie Incorporated
438 Huron St.
Erie, PA 16502
(800) 3777561
Astronautics Corporation of America

4115 N. Teutonia Ave.
Milwaukee, WI, 53209
www.astronautics.com
Tel: (414) 4494000
Fax: (414) 4478231
MS91
MS82
U.S. Rubber Co.

Fuel Container Dept.
Mishawaka, IN
Chomerics, Inc.
77 Dragon Court
Woburn, MA 01801
(781) 9354850
Page 14
Revision 41
91-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Table 3. Special Tools

Item
No.
Part No.
Nomenclature
Vendor
(Table 4)
Function
Ground Handling
ST101
369A9905

(369D/E/FF can be used on
500N)
Ground handling of helicopter.
TS21
BDW-500M
Mechanical Ground Handling

Wheels (500N)
BDW-500H
Hydraulic Ground Handling

Wheels (500N)
BDW-600M
Mechanical Ground Handling

Wheels (600N)
BDW-MDH
Hydraulic Ground Handling

Wheels (600N)
ST102
369H9801
Handle-jack assembly,
ground handling (straight)
(369D/E/FF - 500N)
Raising or lowering helicopter

with ground handling wheels.
ST103
369A9906
Handle-jack assembly,
ground handling (offset)
(369D/E/FF - 500N)
Raising or lowering helicopter

with ground handling wheels
when additional clearance is re
quired.
ST104
369H90126

(one side)
Ground handling of helicopter

equipped with utility or emer
gency floats.
ST105
HT-500
Tow bar (369D/E/FF, can be

used on 500N)
Towing of helicopter.
HT-500P
Tow bar (500N/600N)
TS21
Jacking and Leveling

ST201
369D29904
600N9904
Hoisting adapter (5-bladed)

(6-bladed)
Hoisting entire helicopter or re

moving main rotor.
ST202
369A2010-5
Jack fittings
Jacking, leveling or tiedown of

helicopter.
ST203
02-0520-0100
Hydraulic jack: 1-5 ton

(900-4500 kg)
Jacking and leveling at Sta.

90.61.
ST204
02-0234-0100
Hydraulic jack: 80-inch

(203 cm) leg
Jacking and leveling at Sta.

197.78.
TS15
ST205
KS 5490 old
KS 5549 new
Inclinometer
Angle of incidence tool, flight

control rigging.
TS9
ST206
36-D-2844
Prop protractor
Measure angle of incident.
Main Transmission
ST301
369H9807
Main transmission drain hose Drain main transmission oil.
91-00-00
Page 15
Revision 41
MAINTENANCE MANUAL
CSP-HMI-2
Table 3. Special Tools (Cont.)

Item
No.
Part No.
Nomenclature
Function
Vendor
(Table 4)
Engine
ST401
Engine stand
(250-C20B / 250-C20R/2)
(250-C30 / 250-C47)
Engine support and transport

dolly.
369A8009
369D29905
369DSK410
Engine hoist (250-C20B)

(250-C20R/2)
(250-C30 / 250-C47)
Engine removal and installation.
Engine compressor wash kit

(369D/E - 500N)
(369FF - 600N)
Clean engine compressor.
369H92537
369H92537-501
369A9948
369D28602-80903
-1
ST402
ST403
ST404
6798292
Wrench, ground idle adjust

ing
Bendix fuel control idle speed ad

justment.
ST405
369H9925
Rigging fixture, collective

stick
Gas producer rigging.
ST406
369A7368-80901
Alignment fixture
ST407
MS17990-315
Rigging pin
ST408
#1741145
Test tool
Oil filter bypass indicator test.

Flight Controls
ST501
369H9925
369H9925-3

(LH command)
(369D/E/FF - 500N)
(600N)
Rigging of main rotor collective

controls.
ST502
369A9927

(RH command)

controls.
ST503
369A9930
Mixer rigging plate

and cyclic controls.
Rigging of main rotor cyclic con
trols.
369D29929-9
600N9929-5

(LH command)
(369D/E/FF - 500N)
(600N)

trols.
369A9929-5
369D29929-5

(RH command)
(369D/E/FF - 500N)
(600N)

trols.
369A9928-9
369A9928-19

(LH command)
(369D/E/FF - 500N)
(600N)
(RH command)

trols.
ST504
ST505
ST506
ST507
369A9928-5
Page 16
Revision 41
91-00-00
TS6
MAINTENANCE MANUAL
CSP-HMI-2

Item
No.
Vendor
(Table 4)
Part No.
Nomenclature
Function
Remove bungee installation tool.
Dismantle bungee assembly.
369D29936
369A7300-ATP-1
Collective bungee installation

tool
(369D/E/FF - 500N)
(600N)
ST508
ST509
Not used at this

time
ST510
369D29985
Bungee spring compression

tool rod and channel
(369D/E/FF - 500N)
Compress collective bungee.
ST511
369D29910-32501
Test fixture
Shop aid for rigging main rotor

controls.
AntiTorque
ST601
500N9901-3
ST602
830006-809-00653 Spring tension removal tool
Removal of anti-torque bungee

spring & splitter spring.
ST603
ATP1-500N5365-1 Tip seal cutting fixture

-TD
Anti-torque tip seal felt metal

cutting tool.
ST604
500N9505-1
Coupling socket
Fan & gearbox coupling socket.
ST605
500N9506-1
Fan nut socket
Anti-torque fan removal.

(2-bladed tail rotor)
Rig tail rotor controls.
369D29931
369D29907

Install tail rotor nut.
369D29823
369D29826
ST606
ST607
Rigging pin
Rigging of NOTARR anti-torque

flight controls.
ST608
369D29822-3
Pitch control assembly hold

ing block
Secure tail rotor swashplate

block to remove/install nut.
ST609
369D29822-5
Remove/install tail rotor swash

plate housing bearing nut.
ST610
369A1600-80902
Bushing wrench
Install and torque tail rotor hub

threaded bushing.
ST611
83006-809-00090
-1
Arbor press fixture,

369A7951-5 bearing
Install tail rotor pitch control

link bearings.
ST612
83006-809-00090
-15
Staking tool, 369A7951-5

bearing
Stake tail rotor pitch control link

bearings.
ST613
269A9232
Plug, bearing removal
Remove tail rotor pitch control

housing bearings.
ST614
500N5364-ATP1
Regreasing tool, fan bearing
Regreasing of the 500N5364 and

500N7120 fan bearings.
91-00-00
Page 17
Revision 42
MAINTENANCE MANUAL
CSP-HMI-2

Item
No.
Part No.
Nomenclature
Function
Vendor
(Table 4)
Main Rotor
ST701
369A9829
Loosening/torquing of main rotor

mast nut.
369D29932
600N9932
Hub puller
(369D/E/FF - 500N)
(600N)
Separate main rotor hub from

mast.
ST702
ST703
369A9933
*369A9933-5
Seat main rotor hub.
ST704
369D29957 old
FRDH101 new
Install main rotor drive shaft

fasteners.
ST705
369A9825
Pitch bearing stud wrench
Remove main rotor hub pitch

bearing pivot pin.
ST706
83006-809-00090
-1
Arbor press fixture

(369A7951-5 bearing)
Install main rotor pitch housing

bearings.
ST707
83006-809-00090
-15
Staking tool
(369A7951-5 bearing)
Staking main rotor pitch housing

bearings.
ST708
83006-809-00088
Staking tool (pilot and punch) Install pitch control housing

(369A7951-45 bearing)
bearings and swage rings.
ST709
3006-809-00090
-1/-8
Arbor press fixture

(369A7951-15 bearing)
Install main rotor blade bear

ings.
ST710
3006-809-00090
-15/-20
Staking tool (369A7951-15

bearing)
Stake main rotor blade bearings.
Fuel
ST801
MITYVACR #4000
Hand operated vacuum pump

kit
Pump down airframe and engine

fuel systems for vacuum leak
check.
ST801-1 AN840-D
Nipple, hose
Vacuum pump adaptive hard

ware.
ST801-2 AN910-1D
Coupling
ST801-3 AN816-4D
Nipple
ST801-4 AS3084-04
O-ring
ST802
369A8100-80902
Spanner wrench
Fuel cross-over fitting torquing.
ST803
PTE1-600N8100TD
Fuel Transfer System

Functional Tester
Perform fuel transfer system

functional check.
Page 18
Revision 43
91-00-00
TS13
TS10
MAINTENANCE MANUAL
CSP-HMI-2

Item
No.
Part No.
Nomenclature
Vendor
(Table 4)
Function
Track and Balance

ST901
369D29942
Tip cap assembly
Tracking main rotor blades.
ST902
369H9928
Main rotor blade fixture and

tab bending tool
Adjusting main rotor blade tab

angle/blade track.
ST903
Balancer/analyzer instrument Track and balance of dynamic

kit
components.
TS5
Electrical / Instruments / Avionics

ST1001
RXT20-5 (extract)
RTM20-9 (insert)
HYTIP insertion/extraction
tool.
Install/remove HYTIP electrical

contacts in terminal block mod
ules.
TS4
ST1002
M8ND
N14HCT2
HYTOOL M8ND and

N14HCT
Crimp MINILOK and MODU

LOK terminal block contact tips
on electrical wire.
TS4
ST1003
107-0970
Hand operated crimping tool

(with positioners 107-0976
and 107-0977)
Crimp removable contacts in

rectangular connectors.
TS18
ST1004
107R1001
107-1015
Contact removal tool /

Contact insertion tool
Remove and insert removable

contacts in rectangular connec
tors.
TS18
ST1005
CEIT 20
Insertion/extraction tool (20

Wire Mate connector)
Connect/disconnect No. 20 Wire

Mate electrical connectors.
TS8
ST1006
CEIT 16
Insertion/extraction tool (16

Wire Mate connector)
Connect/disconnect No. 16 Wire

Mate electrical connectors.
TS8
ST1007
CTJ-RO6
Deutsche module removal

tool
Remove terminal block modules

from instrument panel terminal
block frames.
ST1008
46673
Crimping tool
Thermocouple harness terminal

lugs.
TS1
ST1009
^931
Voltmeter
Measure voltage.
TS17
ST1010
^260-7
Volt-ohmmeter
Measure resistance and voltage.
TS14
ST1011
**2312-G-8
Turbine temperature indicat

ing system test set
Test and calibrate TOT indicat

ing system.
TS2
ST1012
**BH112JA-36
Jetcal tester
Test and calibrate TOT indicat

ing system.
TS7
ST1013
500N9701
Yaw S.A.S. test box
Anti-Torque stability augmenta

tion system control rigging.
TS10
ST1014
DPI 603
Pressure calibrator
Test and calibrate torque indicat TS20

ing system (600N).
91-00-00
Page 19
Revision 43
MAINTENANCE MANUAL
CSP-HMI-2

Item
No.
Part No.
Nomenclature
Function
Vendor
(Table 4)
Miscellaneous
ST2001
369H4009
Pitot tube cover
Pitot Tube protection.
ST2002
369H6661-1
Blade socks
Main rotor blade tiedown.
ST2003
369D29913-37

(369D/E/FF - 500N)
Store main rotor blades. Blade

folding pole included.
ST2004
369H9803-503
Air inlet cover.
ST2005
369H9804-101
Engine exhaust duct cover.
ST2006
51-C-887
Sleeve swage, oval C-type
Particle separator installation.
TS12
ST2007
C-6000
Rivnut installation speed

header
TS3
ST2008
C-3576
Rivnut keyway cutter
TS3
ST2009
HG85-10
Inspection gauge
Lockbolt installation inspection.
ST2010
369D29983

(369D/E/FF)
Torque tailboom attachment

bolts.
ST2011
369A6001-50506
-1
Left landing gear foot drill jig
Enlarge holes in lockbolt fas

tened landing gear strut to
install machine-bolt-attached
skids.
ST2012
369A6001-50506
-2
Right landing gear foot drill

jig
Enlarge holes in lockbolt fas

tened landing gear strut to
install machine-bolt-attached
skids.
ST2013
WSI-HT-12AS
Bushing installation tool

(WSI-B-12AS grommet)
Install tail rotor control rod

grommets.
ST2014
369D23601-80910
Angle measuring tool
Check horizontal stabilizer angle

of incidence.
TS16
^ Primary selection. Any equivalent meter with an accuracy capable of measuring voltage within 0.25% full
scale range may be used.
* Hammer and handle same as 369A9933; 7 driver replaces 3 driver.
** Either tester may be used.
Page 20
Revision 43
91-00-00
MAINTENANCE MANUAL
CSP-HMI-2
Table 4. Tool Manufacturer/Supplier Number

Number
TS1
Name
AMP Inc.
441 Friendship Rd.
Harrisgurg, PA 17111
Phone: (717) 5640100
FAX: (717) 9867575
Number
Name
TS11
MD Helicopters Inc.
Field Fabricated
TS12
National Telegraph Supply Co.

Cleveland, OH
TS13
Neward Enterprises Inc.

P.O. Box 725
Cucamonge, CA 91730
7149878975
TS14
Simpson
TS15
Tronair
South 1740 Eber Road
Holland, OH 43528
TS2
Barfield Instrument Corporation

4101 NW 29th Street
P.O. Box 02567
Miami, FL 33102
TS3
B.F. Goodrich Co.

Aerospace Products
Akron, OH
TS4
Burndy Corp.
Norwalk, CT
TS16
TS5
ChadwichHelmuth
4601 N. Arden Drive
El Monte, CA 917311299
Western Sky Industries

21300 Cloud Way
Hayward, CA 94545
TS17
Weston
TS18
Winchester Electronics,
Division of Litton Industries
Main St. and Hillside Ave.
Oakville, CT 06779
TS19
Daniels Manufacturing Corp.

526 Thorpe Road
Orlando, FL 32824
Phone: (407) 8556161
FAX: (407) 8556884
TS20
Druck Incorporated
4 Dunham Drive
New Fairfield CT 06812
Phone: (203) 7460400
FAX: (203) 7462494
Email: druck.inc@druck.com
TS21
Brackett Aricraft Co., Inc.

7045 Flightline Dr. Kingman, AZ 86401
Phone: 9287574005
Fax: 9287571948
Sales inquiries: kfessenden@citlink.net
Technical inquiries: brackett@ctaz.com
TS6
Facet Enterprises Inc.

8439 Traid Dr.
Greensboro, NC 27409
TS7
Howell Instrument Inc.
TS8
I.T.T. Cannon Electric

3208 Humboldt St.
TS9
KellStrom Tool Company

214 Church Street
Wethersfield, CT
TS10
MD Helicopters Inc.
5000 E. McDowell Road
Mesa, AZ 852159797
91-00-00
Page 21
Revision 41
CSP-HMI-2
MAINTENANCE MANUAL
Page 22
Revision 41
91-00-00

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MD Helicopters, Inc.

MDHI 369D/E/FF - 500/600N HELICOPTERS

PRINT DATE: 6 July 2011

MDHI MODEL HELICOPTERS

Copyright E 1999-2011 by MD Helicopters, Inc.

Issued: 31 October 1990

PROPRIETARY RIGHTS NOTICE

FAX: (480) 3466821

FAX: (480) 3466809

ATA Section Number:

This Page Intentionally Left Blank

RECORD OF TEMPORARY REVISIONS

LIST OF EFFECTIVE PAGES

207 thru 210 . . . . . . . . . . . . . . . . . . . . . Revision 23

201 thru 204 . . . . . . . . . . . . . . . . . . . . . Revision 23

511 and 512 . . . . . . . . . . . . . . . . . . . . . Revision 23

201 and 202 . . . . . . . . . . . . . . . . . . . . . Revision 23

203 thru 206 . . . . . . . . . . . . . . . . . . . . . Revision 34

406 and 407 . . . . . . . . . . . . . . . . . . . . .

806 and 807 . . . . . . . . . . . . . . . . . . . . . Revision 37

401 thru 404 . . . . . . . . . . . . . . . . . . . . .

This Page Intentionally Left Blank

Continued Airworthiness Checks / Inspections

Dimensions and Areas

Lifting and Jacking

Leveling / Weight and Balance

Parking and Mooring

Placards and Markings

Vibration and Noise Analysis

Environmental Control System

Transmission and Drive System

Engine AntiIce System

Engine Power Controls

Engine Exhaust System

Engine Oil Supply System

369D 369E 369FF 500N 600N

120000 Helicopter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

PLACARDS AND MARKINGS

110000 Placards and Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

PARKING AND MOORING

101000 Parking and Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

LEVELING / WEIGHT AND BALANCE

LIFTING AND JACKING

070000 Lifting and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

DIMENSIONS AND AREAS

060000 Dimensions and Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

040000 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

VIBRATION AND NOISE ANALYSIS

Main Rotor Track and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

369D 369E 369FF 500N 600N

204000 Corrosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

209000 Nondestructive Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

211000 Ventilation Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

214000 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

251000 Upholstered Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

251500 Mesh Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

252000 Seat Belts/Inertia Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

252100 Seating/Belts (Four on the Floor) . . . . . . . . . . . . . . . . . . . . . . . . . . . X

253000 Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

254000 Miscellaneous Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

255000 Cargo Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

256000 Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X