HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369D/E/FF-500/600N HELICOPTERS (ISSUED: 1990)

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

4. Overtorque

water, snow, thick vegetation, or other object of

sufficient mass to cause deceleration. Use the

Overtorque is an incident in which the main

schedule of inspections in Table 1, Conditional

transmission torque loads are more than the

Inspections, After Tail Rotor Blade Strike

permitted limits. Use the schedule of inspec

when sudden stoppage of the tail rotor has

tions in Table 1, Conditional Inspections, After

occurred.

Main Transmission Overtorque Beyond

Transient Limits when an overtorque has

6. Lightning Strike

occurred.

When you think there has been a lightening

5. Sudden Stoppage

strike on the helicopter, use the schedule of

inspections in Table 1, Conditional Inspec

Sudden stoppage is a rapid deceleration of the

tions, After Lightening Strike inspection

main rotor, rotor drive system, tail rotor, or

procedures.

anti-torque fan.

Sudden stoppage of the main rotor and rotor

7. Conditional Inspection Table

drive system is caused when the main rotor

blades hit the ground, water, snow, thick

D Inspections in this table are for MDHI

vegetation, or other object of sufficient mass to

369D/E/FF and 500/60N helicopters only.

cause deceleration. Sudden stoppage of the

The first column of the table denotes which

main rotor and rotor drive system can also

model helicopter the inspections are

occur during a hard landing if the blades hit

applicable to.

the fuselage or the tailboom. Use the schedule

of inspections in Table 1, Conditional Inspec

D The second column of the table has a short

tions, After Main Rotor Blade/Drive System

description of the necessary inspection or

Sudden Stoppage when sudden stoppage of the

procedure.

main rotor has occurred.

D The third column of the table shows, if

Sudden stoppage of the tail rotor is caused

applicable, the manual or section that has

when the tail rotor blades hit the ground,

the specific inspection or procedure.

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Revision 44

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

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.

ALL

Main rotor blade droop stops for damage.

ALL

Main rotor hub assembly and strap pack assembly for evidence of damage.

ALL

Accessible areas of main rotor mast assembly and transmission attachment area for

damage.

ALL

Perform Landing Gear Inspection. Forward and aft rub plates for condition.

32−10−00

ALL

Perform Tailboom Inspection; retorque mount bolts.

53−40−00

53−40−30

ALL

Inspect tailboom attachment area for damage.

500/600N

Inspect stationary thruster attachment flange for damage; retorque mount bolts.

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.

500/600N

Main transmission−to−fan 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.

ALL

Perform Engine Mounts and Fittings Inspection. Inspect mounting pads and firewall for

damage and distortion. Inspect all suspected parts by magnetic particle or

dye−penetrant methods, as applicable (Ref. CSP−SRM−6).

ALL

All flight and engine control system push−pull tubes, links, bellcranks and bearings for

bends, cracks, security and free movement.

ALL

Tunnel area A−frame for distortion, buckling or any other damage.

ALL

Fuselage fittings for bends and cracks.

ALL

Main transmission chip detectors for metal particles.

Main transmission mounting flanges for cracks.

ALL

Perform Main Transmission Drive Shaft Inspection.

63−10−00

ALL

All engine accessories for cracked flanges, loose bolts and nuts, connections and

general condition.

ALL

Engine accessory drive housing for cracks.

ALL

Engine chip detectors for metal particles.

ALL

Engine oil tank, supports, tubing and hoses for leaks, cracks and security.

ALL

Fuel cells, supports, tubing and hoses for leaks, cracks and security.

ALL

Armor for security of attachment, buckling and distortion.

CSP−014

ALL

Rotor brake installation for security of attachment and disc alignment.

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Revision 42

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

Table 1. Conditional Inspections (Cont.)

Model

Requirement

Chap/Sect

AFTER MAIN ROTOR OVERSPEED

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 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.

Main rotor blade dampers for security.

369D/E/FF

Tail rotor blades and hub for visible damage, free movement and security.

500/600N

NOTAR fan blades and hub for visible damage, free movement and security.

ALL

Main rotor hub and strap pack assembly for evidence of damage.

If overspeed is over 549 (369D/E) or 533 (369FF, 500N) rpm, or 112 percent (600N):

ALL

Remove main rotor hub assembly for overhaul inspection.

MDHI

ALL

Remove and scrap main rotor blades.

500/600N

Inspect anti−torque fan assembly.

369D/E/FF

Remove tail rotor hub assembly for overhaul inspection.

AFTER MAIN TRANSMISSION OVERTORQUE BEYOND TRANSIENT LIMITS

ALL

Main transmission for freedom of movement.

ALL

Main transmission chip detectors for metal particles. Re−inspect after 8 hours of

operation.

AFTER AIRSPEED 10% BEYOND V^NE LIMIT

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 scrapped.

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.

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.

369D/E/FF

Horizontal stabilizer for skin damage and loose rivets.

Tip plates and vertical stabilizer for damage to leading and trailing edges and

damaged stressed side panels (no repair of side panels permitted).

Mounting fittings for cracks and security.

Retorque stabilizer attach bolts.

500/600N

Horizontal stabilizer for skin damage and loose rivets.

600N − Damage to gurney flap.

Vertical stabilizers for damage to leading and trailing edges and damaged side panels.

Mounting fittings for cracks and security.

Retorque stabilizer attach bolts.

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CSP-HMI-2

MAINTENANCE MANUAL

Table 1. Conditional Inspections (Cont.)

Model

Requirement

Chap/Sect

ALL

Tailboom for visible deformation, loose or missing rivets, cracks and security; attaching

points to fuselage for cracks and security.

ALL

Canopy glass for security

AFTER MAIN ROTOR BLADE/DRIVE SYSTEM SUDDEN STOPPAGE

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 scrapped.

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.

ALL

Perform inspection of the main rotor hub and lead−lag link attach lugs. If the lead−lag

lug is broken or the pitch housing striker strip shows evidence of contact with the main

rotor hub and damage occurred the the engine running, perform the additional

inspection in After Main Rotor Drive System Sudden Stoppage − Level 2.

ALL

Perform Main Rotor Strap Pack Lamination Inspection.

62−20−00

62−20−60

ALL

Perform Main Rotor Blade and Damper Attach Pin Disassembly and Special

62−10−00

Inspection. If a pin is found cracked or bent and damage occurred with the engine

running, perform the additional inspection in After Main Rotor Drive System Sudden

Stoppage − Level 2.

ALL

Perform Main rotor Damper and Attachments Inspection. If damage to a damper is

62−20−00

suspected, perform Main Rotor Damper Weight Loading and Extension Check.

62−20−60

ALL

Perform Main Rotor Drive Shaft Inspection. If main rotor drive shaft is rejected for

63−10−00

broken shaft splines, straightness or sheared shaft, perform the additional inspection

in After Main Rotor Drive System Sudden Stoppage − Level 2.

ALL

Inspect overrunning clutch sprag assembly (Ref. Detailed Inspection after Cleaning).

COM

CAUTION:

Kamatic couplings are a balanced unit and cannot be disassembled.

ALL

Perform a visual inspection of all power train drive shafts and couplings for distortion,

breaks, cracks, contact with bulkheads and other damage.

ALL

Perform a visual inspection of the oil cooler blower assembly.

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

Table 1. Conditional Inspections (Cont.)

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.

ALL

Perform visual inspection of main rotor flight controls.

ALL

Perform visual inspection of the anti−torque system.

ALL

Perform visual inspection of engine mounts for security, cracks or misalignment.

ALL

Perform visual inspection of the engine control linkage for bends, breaks and proper

alignment.

ALL

Inspect engine per the special inspection requirements in the appropriate Allison

Operation and Maintenance Manual.

After Main Rotor Drive System Sudden Stoppage − Level 2

WARNING: Any component, assembly or detailed part that is removed for overhaul must be identified as

being removed due to Main Rotor Sudden Stoppage − Level 2. Components that require replacement

must be scrapped.

ALL

Overhaul main rotor hub.

ALL

Remove and scrap main rotor drive shaft.

ALL

Overhaul main transmission assembly (Ref. COM).

ALL

Remove and scrap engine−to−transmission drive shaft.

ALL

Overhaul overrunning clutch assembly (Ref. COM).

AFTER TAIL ROTOR BLADE STRIKE

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 scrapped.

After tail rotor blade strike, inspect the following:

369D/E/FF

If equipped with Bendix couplings, remove and scrap couplings.

369D/E/FF

Tail rotor blades for dents, nicks, scratches or separation of skin.

369D/E/FF

Tail rotor flapping hinge bolt for damage.

369D/E/FF

Tail rotor transmission for radial play and run−out of output shaft, cracks in mounting

flanges, and chip detector for metal particles.

Remove for overhaul tail rotor transmission if damage is indicated.

369D/E/FF

If equipped with Kamatics couplings:

63−15−10

63−25−10

Perform Tail Rotor Drive Shaft Twist Inspection. Misaligned or missing stripes require

63−25−20

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.

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.

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

Table 1. Conditional Inspections (Cont.)

Model

Requirement

Chap/Sect

369D/E/FF

Upper fuselage and boom tail rotor control linkage.

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.

369D/E/FF

Main transmission chip detectors and transmission lube pump oil filter for metal

particles.

369D/E/FF

Main rotor hub assembly and strap pack assembly for evidence of damage.

AFTER TAILBOOM STRIKE

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 scrapped.

If one or more main rotor blades strike tailboom while blades are rotating, inspect following:

ALL

Perform Main Rotor Blade Inspection.

62−10−00

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.

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.

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).

CAUTION:

Any tailboom damage is significant (Ref. CSP−SRM−6).

ALL

Perform Tailboom Inspection. Dye−check or remove and scrap tailboom attach bolts.

53−40−00

53−40−30

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. CSP−SRM−6).

ALL

Perform Upper Fuselage and Tailboom Control Linkage Inspection.

ALL

Perform Horizontal Stabilizer Inspection.

53−50−10

53−50−30

Perform Vertical Stabilizer Inspection.

Retorque stabilizer attach bolts.

369D/E/FF

Tail rotor assembly.

369D/E/FF

Tail rotor transmission for radial play and run−out of output shaft; cracks in mounted

flanges and chip detector for metal particles.

ALL

Main rotor brake, if installed, for condition and alignment of brake disc, calipers and

security of attachment.

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.

ALL

Main transmission chip detectors and transmission lube system oil filter for metal

particles. Re−inspect chip detectors and oil filter after 8 hours of engine operation.

Visually check transmission mounting flanges for cracks.

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

Table 1. Conditional Inspections (Cont.)

Model

Requirement

Chap/Sect

ALL

Engine air inlet and plenum chamber for foreign objects; motor engine and check for

unusual noise.

Engine mounts for security, cracks or distortion.

Engine control linkage for bends, breaks and proper operation.

500/600N

Inspect stationary thruster attachment flange for damage; retorque mount bolts.

ALL

Inspect tailboom attachment area for damage; retorque mount bolts.

AFTER CHIP DETECTOR LIGHT COMES ON

ALL

Remove chip detector leads, in turn, to determine which chip detector caused indicator

to light.

Remove and inspect applicable chip detector for metal accumulation.

ALL

If an engine chip detector caused indicator to light, refer to applicable Rolls−Royce

Engine Operation and Maintenance Manual.

ALL

If main transmission chip detector caused indicator to light, perform Main

63−21−00

Transmission Filter Replacement.

ALL

If chips measure no longer than 0.125 inch (3.175 mm), drain and refill main

transmission, tail rotor transmission or fan transmission as applicable with new oil.

Recheck applicable chip detectors after 4 hours of flight.

AFTER ENGINE CHANGE BECAUSE OF INTERNAL ENGINE FAILURE

NOTE: Oil coolers are NOT cleanable and must be scrapped if an engine failure produces metal and NO scav-

enge oil filter is installed or if a scavenge oil filter is installed and indicates a by−pass has occurred.

ALL

Remove, flush and reinstall oil tank.

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.

ALL

Remove and install new scavenge oil filter element (if installed).

AFTER ENGINE FLAMEOUT CAUSED BY FUEL EXHAUSTION

ALL

Bleed fuel system to remove any entrapped air.

AFTER ENGINE SHUTDOWN USING EMERGENCY FUEL SHUTOFF VALVE

ALL

Bleed fuel system to remove any entrapped air.

AFTER MAIN TRANSMISSION CHANGE BECAUSE OF INTERNAL TRANSMISSION FAILURE

ALL

Reverse flush or replace transmission oil cooler, all lines, fittings and associated

components.

AFTER FUEL FILTER CAUTION LIGHT COMES ON

ALL

Check FUEL FILTER caution light and circuit for discrepancies.

ALL

Perform Fuel Filter (Bypass) Caution Light Pressure Switch Test.

28−00−00

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CSP-HMI-2

MAINTENANCE MANUAL

Table 1. Conditional Inspections (Cont.)

Model

Requirement

Chap/Sect

ALL

Remove and install new engine−driven fuel pump filter.

Remove and clean gas producer fuel control filter.

Clean and flush all lines and fittings.

Check bypass valve per applicable Allison Engine Operation and Maintenance

Manual.

369D/E

Inspect start pump inlet screen for contamination when large amounts of foreign

500N

material are found in the engine driven fuel pump filter (or optional airframe fuel filter, if

installed).

ALL

Perform Fuel Cell Inspection.

28−00−00

AFTER NEW OR REPLACEMENT MAIN ROTOR HUB IS INSTALLED

ALL

Perform Main Rotor Hub Droop Angle Check.

62−20−00

BEFORE INSTALLATION OF NEW BATTERY

ALL

Perform Battery Charging − Deep Cycling Procedure. Repeat deep cycling procedure

96−05−00

once to ensure complete stabilization of battery.

AFTER MAIN TRANSMISSION DRIVE SHAFT IS REMOVED (ENGINE INSTALLED)

ALL

Check overrunning clutch for correct oil level.

AFTER COOLER BLOWER IS REMOVED

ALL

Perform Cooling Blower Inspection (Disassembled). Check belt tension and clearance

after installation.

WHEN MAIN ROTOR DRIVE SHAFT IS REMOVED

ALL

Perform Main Rotor Drive Shaft Inspection.

63−10−00

AFTER LIGHTNING STRIKE

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 scrapped.

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).

ALL

Inspect all wiring.

ALL

Inspect antenna(s) for burns and pitting.

ALL

Inspect all electrically operated components and lighting systems for damage.

ALL

Inspect communications and navigation equipment for damage.

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.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

Table 1. Conditional Inspections (Cont.)

Model

Requirement

Chap/Sect

ALL

Perform specific inspection/replacements as required.

500/600N

Check fan transmission and interconnecting drive shafts for magnetism and/or burns.

500/600N

If previous drive train items show magnetism, overhaul fan transmission.

COM

500/600N

Inspect anti−torque fan and components for evidence of arcing and magnetism;

replace any part showing evidence of arcing or magnetism.

500/600N

Inspect bellcrank and control rod for any indications of arcing. Scrap parts with

indications of arcing.

500/600N

Inspect thruster cables, bellcranks and control tubes for any indications of arcing.

Scrap parts with indications of arcing.

500/600N

Inspect thruster rollers for any indications of arcing. Scrap parts with indications of

arcing.

ALL

Check oil cooler blower assembly and overrunning clutch for residual magnetism;

replace as necessary.

ALL

Inspect oil cooler assembly for damage; replace as necessary.

ALL

If previous drive train items show magnetism, overhaul transmission.

ALL

If overrunning clutch assembly shows magnetism, remove engine and overrunning

clutch and overhaul.

ALL

Perform a ground run operational check on the aircraft. Functionally check the flight

control system, and all avionics, electrical, lighting, communication, and navigation

systems.

ALL

Repair any damage and replace damaged components as required.

If lightning strike is evident on main rotor system:

ALL

Inspect blades for damage such as burns, pitting, skin separation, etc. If damage is

evident, scrap damaged blade(s).

ALL

Remove hub assembly and return for overhaul.

ALL

Inspect all bearings in the fixed and rotating control system located on the main rotor

mast.

ALL

Remove transmission assembly and overhaul.

ALL

Inspect main rotor mast and drive shaft for evidence of burns.

ALL

Check drive shafts for residual magnetism. If magnetized or damaged, scrap drive

shafts and remove engine for overhaul.

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.

COM

369D/E/FF

Scrap pitch change links and pitch change assembly.

369D/E/FF

Inspect bellcrank and control rod for any indications of arcing. Scrap parts with

indications of arcing.

369D/E/FF

Overhaul tail rotor gearbox.

COM

369D/E/FF

Inspect tail rotor drive shaft and drive shaft damper for magnetism and/or burns.

Page 10

Revision 42

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

Table 1. Conditional Inspections (Cont.)

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.

369D/E/FF

Inspect oil cooler assembly for damage; replace as necessary.

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.

COM

369D/E/FF

Inspect engine mounts and fitting for damage. Replace as necessary.

AFTER 369F5100 MAIN TRANSMISSION LUBRICATION PUMP IMPENDING BYPASS INDICATOR POPS

ALL

Refer to Troubleshooting Power Train System

63−00−00

WHENEVER ENGINE IS REMOVED

ALL

Remove fire blanket from above engine and inspect airframe above engine for

evidence of cracks.

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CSP-HMI-2

MAINTENANCE MANUAL

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

06-00-00 Dimensions and Areas

Maintenance Practices

201

1. Principal Dimensions

201

2. Airframe Stations Locations

201

Figure 201. Principal Dimensions - Model 369D

202

Figure 202. Principal Dimensions- Models 369E

203

Figure 203. Principal Dimensions Model 369FF

204

Figure 204. Principal Dimensions - Model 500N

205

Figure 205. Principal Dimensions - Model 600N (Sheet 1 of 2)

206

Figure 206. Station Diagram - Model 369D

208

Figure 207. Station Diagram - Models 369E/FF

209

Figure 208. Station Diagram - Model 500N

210

Figure 209. Fuselage Station Diagram - Model 600N

211

Figure 210. Aft Empenage Access Plugs - Model 600N

212

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

DIMENSIONS AND AREAS

MAINTENANCE PRACTICES

1. Principal Dimensions

cm) forward of the fuselage nose for

Models 369E/FF. WL 0.00 is tangential

(Ref. Figure 201 for Model 369D,

to bottom of fuselage at STA 90.61.

Figure 202 for Model 369E,

Canted stations start at WL 0.00 unless

Figure 203 369FF,

otherwise specified. The canted station

Figure 204 for 500N and

is not the same distance from STA 0.00

Figure 205 for 600N)

over its length, and should be referred

to in association with a waterline

Airframe Stations Locations

reference.

(1).

Reference is occasionally made to

(3).

For the 600 Series Helicopter, all

Fuselage Station (STA or FS), Fuselage

dimensions are from three reference

Station Plug (P. STA or FSP) and

points designated as STA 0.00, P. STA

Waterline (WL) throughout the manual.

0.00 and WL 0.00 for the fuselage/engi

P. STA or FSP refers to the stretched

neering station references. STA 0.00 is

area or longer fuselage section of the

15.00 inches (38.1 cm) forward of the

600N as compared to the 500 Series

fuselage nose. P. STA 0.00 is located at

Helicopter. Fuselage Station and

the forward lower edge of the mid door

Waterline are the same as those

(also designated as canted STA 78.50).

referred to in the other 500 Series

All references outside of the designated

publications. To assist in locating

P. STA areas are labeled STA or FS.

components being discussed, station

Waterline 0.00 is tangential to bottom

diagrams are provided (Ref. Figure 206

of fuselage at fuselage station STA

for Model 369D, Figure 207 for Models

90.61. Canted stations start at water

369E/FF, Figure 208 for 500N and

line 0.00 unless otherwise specified.

Figure 209 for 600N). Station and

The canted station is not the same

Waterline references are also necessary

distance from WL 0.00 over its length,

for weight and balance procedures (Ref.

and should be referred to in association

Sec. 08-10-00).

with a waterline reference.

(2).

For the 500 Series Helicopters, all

(4).

Measurements from a station repre

dimensions are from two reference

sented by a rib, frame, or bulkhead that

points designated as STA 0.00 and WL

is not accessible may be taken by noting

0.00. STA 0.00 is 28.00 inches (71.12

flange bend direction and compensating

cm) forward of the fuselage nose for

on the correct side of visible external

Model 369D, and 15.00 inches (38.10

skin attachment rivet line.

Page 201

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MD Helicopters, Inc.

MAINTENANCE MANUAL

GENERAL NOTES:

HELICOPTER ON GROUND, MAX.

COMPRESSED DIMENSION: 6.8 IN.

(17.272 CM).

IF OPTIONAL EXTENDED LANDING

GEAR IS INSTALLED, ADD 0.63 FT.

8.2 FT.

7.2 FT

(10.19 M) TO ALL VERTICAL DIMENSIONS.

(2.5 M)

(2.2M)

0.76 FT

(0.23 M)

26.41 FT (8.06 M)

5.46 FT.

6.45 FT.

4.57 FT.

(1.97 M)

(1.67 M)

(1.39 M)

13.205 FT. (4.028 M)

31.31 FT. (9.55 M)

30.84 FT. (9.41 M)

22.53 FT. (6.72 M)

6.002 FT. (1.831 M)

15.208 FT. (4.64 M)

8.9 FT.

(2.7 M)

4.58 FT.

7.67 FT.

(1.40 M)

(2.34 M)

6.3 FT.

(1.9 M)

1.58 FT. (0.48 M)

21.21 FT. (6.50 M)

2.29 FT. (0.70 M)

23.5 FT. (7.2 M)

G06-0001B

Figure 201. Principal Dimensions − Model 369D

Page 202

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MD Helicopters, Inc.

MAINTENANCE MANUAL

CANT STA

STA

78.50

146.62

164.87

185.89

CANT STA

STA

CANT STA

124.00

137.50

155.75

174.00

MAST

197.78

STA

28.00

WL 45.36

49.37

CORNER

PILOT'S

38.64

SEAT

JACKING

32.00

WL 21.50

POINT

34.50

STA 96.89

WL 11.98

22.75

14.19

13.10

0.00

STA

44.65

56.85

84.79

96.42

108.04

119.67

137.50

0.00

STA

STA CANT STA STA STA

STA STA

50.50

64.37

78.50

90.61

102.23

113.85

124.00

96.91

55.34

54.17

CANT STA

209.78

CANT STA

CANT STA CANT STA

197.78

219.96

242.14

264.32

CANT STA

26.67

273.00

CANT STA

281.12

NOTE:

FRAME BASE

WHEN MEASURING EXTERNALLY FROM RIVET LINES,

NOTE THE SIDE AT BULKHEAD OR FRAME INDICATED AS

THE STATION AND COMPENSATE FOR RIVET POSITION

IN THE ATTACHMENT FLANGE.

G06-0004B

Figure 206. Station Diagram − Model 369D

Page 208

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CSP-HMI-2

MAINTENANCE MANUAL

CANT STA

78.50

STA

108.50

STA

146.62

164.87

185.89

CANT STA

STA

124.00

137.50

MAST

155.75

174.00

CANT STA

197.78

WL 76.70

WL 66.00

STA

15.00

WL 45.36

49.37

CORNER

PILOT'S

SEAT

WL 34.50

WL 21.50

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

STA

44.65

56.85

84.79

96.42

108.04

119.67

137.50

STA

0.00

STA

50.50

64.37

102.23

90.61

124.00

CANT STA

STA

78.50

113.85

WL 102.17

WL 96.91

STA 289.12 (369FF)

WL 55.34

WL 54.17

CANT STA

369FF ONLY

209.78

CANT STA

264.32

197.78

219.96

242.14

WL 26.67

CANT STA

WL 25.46 (369E)

273.00

WL 22.36 (369FF)

CANT STA

281.12

NOTE:

FRAME BASE

WHEN MEASURING EXTERNALLY FROM RIVET LINES,

NOTE THE SIDE AT BULKHEAD OR FRAME INDICATED AS

THE STATION AND COMPENSATE FOR RIVET POSITION

IN THE ATTACHMENT FLANGE.

G06-0005B

Figure 207. Station Diagram − Models 369E/FF

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MAINTENANCE MANUAL

STA

129.00

STA

132.90

STA

155.75

STA

124.75

146.62

168.20

STA

137.50

CANT

174.00

MAST

STA

159.97

WL 66.00

STA

WL 60.00

15.00

WL 34.50

WL 22.75

WL 14.19

WL 13.10

JACKING POINT

STA 96.89, BL ±25.60

WL 0.00

STA

96.42

STA

44.65

84.79

STA

108.04

119.67

137.50

STA

56.85

STA

STA CANT STA

STA

102.23

STA

0.00

50.50

64.37

78.50

90.61

113.85

124.00

STA

AFT JACKING

315.00

POINT STA 275.40,

NOTE:

BL 0.00, WL 41.00

WHEN MEASURING EXTERNALLY FROM RIVET LINES,

NOTE THE SIDE AT BULKHEAD OR FRAME INDICATED AS

THE STATION AND COMPENSATE FOR RIVET POSITION

IN THE ATTACHMENT FLANGE.

G06-0007B

Figure 208. Station Diagram − Model 500N

Page 210

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MAINTENANCE MANUAL

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

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CSP-HMI-2

MAINTENANCE MANUAL

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

07-00-00 Lifting and Jacking

Maintenance Practices

201

1. Component Weights for Hoisting

201

Table 201. Approximate Maximum Hoisting Weights of Components -

369D/E

201

Table 202. Approximate Maximum Hoisting Weights of Components -

369FF

201

Table 203. Approximate Maximum Hoisting Weights of Components -

500N

201

Table 204. Approximate Maximum Hoisting Weights of Components -

600N

201

2. Helicopter Hoisting

201

3. Helicopter Sling Lifting

202

A. Helicopter Preparations

202

B. Helicopter Lifting

202

C. Helicopter Landing

202

4. Helicopter Jacking

203

Figure 201. Hoisting and Jacking Helicopter (Sheet 1 of 3)

204

Page i

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CSP-HMI-2

MAINTENANCE MANUAL

LIFTING AND JACKING

MAINTENANCE PRACTICES

1. Component Weights for Hoisting

Table 203. Approximate Maximum Hoisting

Weights of Components − 500N

(Ref. Table 201 thru Table 204) The maximum

weights for large components that may require

Wgt

hoisting are listed.

Item

Lb/kg

Use hoist with minimum 3500

Tailboom (w/o empennage, thruster)

35/16

CAUTION

pound (1589 kg) capacity when

Main rotor hub

92/42

hoisting complete helicopter. Use hoisting

equipment with minimum 20% overrate to

Main transmission (wet) (369D25100)

105/48

hoist heavier components of helicopter (Ref.

Main transmission (wet) (369F5100)

140/64

Table 201 thru Table 204 for approximate

weights).

Engine (built−up)

207/94

Table 201. Approximate Maximum Hoisting

Helicopter (less main rotor hub,

1314/597

Weights of Components − 369D/E

swashplate, scissors and rotor blades)

Wgt

Helicopter (complete)

1542/700

Item

Lb/kg

Table 204. Approximate Maximum Hoisting

Tailboom

18/8

Weights of Components − 600N

Main rotor hub

85/39

Wgt

Main transmission (wet) (369D25100)

105/48

Item

Lb/kg

Main transmission (wet) (369F5100)

140/64

Tailboom (w/o empennage, thruster)

55/25

Engine (built−up) C20B

192/87

Main rotor hub (with dampers, pins)

107/49

Engine (built−up) C20R/2

207/94

Main transmission (wet)

140/64

Helicopter (less main rotor hub,

1153/523

swashplate, scissors and rotor blades)

Engine (built−up) C47

292/133

Helicopter (complete)

1361/618

Helicopter (less main rotor hub,

1830/830

swashplate, scissors and rotor blades)

Table 202. Approximate Maximum Hoisting

Helicopter (complete)

2100/953

Weights of Components − 369FF

2. Helicopter Hoisting

Wgt

Item

Lb/kg

(Ref. Figure 201)

Tailboom

23/10

Special Tools

Main rotor hub

92/42

(Ref. Section 91−00−00)

Item

Nomenclature

Main transmission (wet) (369D25100)

105/48

ST201

Hoisting adapter

Main transmission (wet) (369F5100)

140/64

N/A

Cable or Rope

Engine (built−up)

271/123

(1). Remove dome fairing (N/A 600N) from

Helicopter (less main rotor hub,

1369/622

main rotor hub and install hoisting

swashplate, scissors and rotor blades)

adapter (ST201) on hub so that hoisting

eyebolts fit into slots on hoisting

Helicopter (complete)

1589/721

adapter.

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MAINTENANCE MANUAL

(2). Install quick release pins.

(7). Secure tail rotor hub to Sta. 284

bellcrank with strap or rope (369D/E/

(3). Attach cable from overhead hoist to

FF only).

adapter eye.

(8). Position one person to support tail of

(4). Secure a line to tailboom. Have assis

helicopter.

tant hold line to keep helicopter from

(9). Position one person to accomplish

swinging.

hookup to recovery helicopter.

(5). Hoist slowly and smoothly to maintain

(10). Position one person in view of recovery

steady lifting force.

helicopter to act as ground guide during

hookup.

3. Helicopter Sling Lifting

B. Helicopter Lifting

Follow below procedures for sling lifting the

helicopter.

Tail of helicopter may come

WARNING

down sharply if helicopter is

lifted abruptly.

Special Tools

(Ref. Section 91−00−00)

Avoid dragging helicopter dur

CAUTION

Item

Nomenclature

ing lift before ground clearance

is obtained. Dragging helicopter may cause

ST201

Hoisting adapter

extensive damage.

(1). Carefully lift helicopter. Ensure that

Sling-lift helicopter only when

CAUTION

person at tail of helicopter is familiar

other means of recovery are not

with above warning.

available. Ensure recovery helicopter has

adequate capabilities, performance and fuel

(2). Transport recovery crew and removed

to accomplish sling-lift recovery. Ensure re

equipment to landing site before

covery crew has experience level to assure

recovery helicopter with lifted helicop

optimum performance at assigned positions.

ter arrives.

Do not attempt lifting or lowering during

C. Helicopter Landing

adverse wind or weather conditions.

(1). Indicate wind direction with smoke

A. Helicopter Preparations

cannister.

Prepare helicopter to be lifted before attempt

(2). Ground guide recovery helicopter to

ing lift to avoid damage or loss of equipment

hover into wind before lowering begins.

during flight.

Do not attempt lowering if heli

(1). Remove dome fairing from main rotor

CAUTION

copter is spinning.

hub (N/A 600N).

(3). Lower helicopter.

(2). Remove main rotor blades (Ref. Sec.

(4). Restrain and support tail of helicopter

62-10-00).

as it contacts ground.

(3). Replace and secure blade damper bolts

Ground guide must signal re

and attaching pins.

CAUTION

covery helicopter to move to one

side before dropping sling or helicopter win

(4). Tape elastomeric damper to pitch

dow damage may occur.

housing.

(5). Signal recovery helicopter to drop sling.

(5). Install hoisting adapter (ST201).

(6). Remove sling and hoist adapter.

(6). Attach lifting straps or swivel-equipped

cable slings that clear lead by 10 feet

(7). Inspect recovered helicopter to deter

(3.048 M) to hoisting adapter.

mine condition.

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MAINTENANCE MANUAL

(8). Inspect main rotor blades prior to

(1). Install jack fittings (ST202) in fuselage

installation for damage caused during

jacking points. Secure jack fittings with

removal and transportation (Ref. Sec.

locking pins located in fuel cell access

62-10-00).

doors.

4. Helicopter Jacking

NOTE: When jacking the 600N helicopter, only

(Ref. Figure 201) Provisions for jacking

use the forward and aft jacking points.

helicopter are provided by two (369D/E/FF -

500N) or four (600N) forward (side) jacking

point fittings and an aft jacking pad. The aft

(2). Place suitable jacks (ST203 or ST204)

jack pad locations differ for the 369D/E/FF and

under jack fittings and AFT jacking

the 500/600N helicopters.

pad.

Special Tools

NOTE: If helicopter is jacked from one side

(Ref. Section 91−00−00)

only, in next step, a cushioned saddle-type

Item

Nomenclature

support should be placed under tailboom at

ST202

Jack fittings

aft jacking pad location for extra stability.

ST203

Hydraulic jack: 1-5 ton (900-4500 kg)

ST204

Hydraulic jack: 80 inch (203 cm) leg

(3). Raise helicopter to desired height.

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MAINTENANCE MANUAL

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

08-00-00 Leveling

Maintenance Practices

201

1. Helicopter Leveling

201

Figure 201. Leveling Helicopter (Sheet 1 of 2)

202

08-10-00 Weight and Balance

Maintenance Practices

201

General Weight and Balance Information

201

A. Approved Center of Gravity Limits

201

B. Terminology

201

Helicopter Weighing

202

A. Helicopter Weighing Preparation

202

B. Preparation for Weighing - Electronic Method

203

C. Helicopter Weighing - Electronic Method

204

D. Preparation for Weighing - Mechanical Scales Method

(369D/E/FF - 500N Only)

204

E. Weighing Procedures - Mechanical Scales Method

(369D/E/FF - 500N Only)

205

F. Longitudinal CG Determination for Unadjusted Net Weight

(369D/E/FF - 500N Only)

205

G. Lateral CG Determination for Unadjusted Net Weight

205

H. Basic Weight and CG Determination

206

Figure 201. Balance Diagram - Model 369D

207

Figure 202. Balance Diagram - Model 369E

208

Figure 203. Balance Diagram - Model 369FF

209

Figure 204. Balance Diagram - Model 500N

210

Figure 205. Balance Diagram - Model 600N

211

Figure 206. Weight and Balance Report Form (Sheet 1 of 2)

212

Figure 207. Surplus and Missing Items Report

214

Figure 208. Basic Weight and Balance Record

215

Figure 209. Example 1 (Sheet 1 of 2)

216

Page i

08 Contents

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CSP-HMI-2

MAINTENANCE MANUAL

LEVELING

MAINTENANCE PRACTICES

1. Helicopter Leveling

(1). Suspend plumb line from bracket on

right side of controls tunnel at Sta.

92.64, BL+ 6.20.

(Ref. Figure 201) Leveling is accomplished by

positioning helicopter to align a plumb bob

(2). Adjust plumb line swing to leveling

with register marks on the target plate on

target plate on floor of passenger/cargo

cargo compartment floor.

compartment.

(3). With weight of helicopter supported by

Special Tools

load cells of electronic weighing kit or

(Ref. Section 91−00−00)

jacks (ST203), as applicable, adjust

Item

Nomenclature

appropriate jack until plumb line is

centered (Ref. Sec. 07-00-00, Helicop

N/A

Plumb bob (commercially available)

ter Jacking).

N/A

Twine

(a). Adjust side jacks to level helicopter

N/A

Electronic weighing kit

laterally.

ST202

Jack fittings

(b). Adjust tailboom jack to level helicop

ST203

Hydraulic jack: 1-5 ton (900-4500 kg)

ter longitudinally.

(c). Recheck lateral and longitudinal

levels until plumb bob exactly aligns

NOTE: Access to plumb line support bracket

with marks on target plate.

and target plate on floor of passenger/cargo

compartment requires removal of trim on

(4). After leveling helicopter, remove plumb

right side of controls tunnel, and floor carpet

bob, reinstall trim and carpet, and close

in aft compartment (Ref. Chap. 25).

compartment door.

Page 201

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CSP-HMI-2

MAINTENANCE MANUAL

WEIGHT AND BALANCE

MAINTENANCE PRACTICES

General Weight and Balance Information

NOTE: Weight and balance information for op

tional equipment is found in the Initial In

(1).

Removal or addition of fuel or equip

stallation section for the optional equip

ment results in changes to weight and

ment.

balance of a helicopter, and the permis

sible useful load is affected accordingly.

These changes must be investigated to

Parameter

lb/kg

eliminate possible adverse effects on

the helicopter's flight characteristics.

Certified Gross Weight (369D/E)

3000/1362

Certified Gross Weight (369FF)

3100/1407

(2).

Basic weight and corresponding center

Certified Gross Weight (500N)

3350/1521

of gravity is determined by weighing

the helicopter without crew and

Certified Gross Weight (600N)

4100/1860

payload; however, basic weight does

Cargo Deck Capacity

1300/590

include trapped and unusable fuel, full

(369D/E/FF − 500N)

operating fluids, lubricants, etc., and

installed equipment.

Cargo Deck Capacity (600N)

1350/613

Cargo Deck Capacity not to exceed 115 pounds per

(3).

369D/E/FF - 500N - The longitudinal

square foot.

reference datum is located 100 inches

(254 cm) forward of the main rotor

Certified Gross Weights are for weight−on−skids.

centerline. The lateral reference datum

is located along the longitudinal

A. Approved Center of Gravity Limits

centerline of the helicopter. The vertical

reference datum is located at a point

(Ref. PFM)

100 inches (254 cm) below the center of

the main rotor blades.

B. Terminology

Following are terms with definitions, used

(4).

600N - The Weight and Balance

when determining helicopter weight and

longitudinal reference datum is located

balance:

100 inches (254 cm) forward of the

main rotor centerline or 15 inches (38.1

(1). Arm: The distance in inches from the

cm) aft of the aircraft nose. The Weight

longitudinal (longitudinal arm) and

and Balance (longitudinal) Reference

lateral (lateral arm) reference datum of

Datum is different from the Fuselage/

a part to the center of gravity (CG) of

Engineering Reference Datum (Ref.

the part.

Section 06-00-00). The lateral refer

ence datum is located along the longitu

NOTE: When viewing helicopter from rear,

dinal centerline of the helicopter. The

items to left of lateral reference datum (cen

vertical reference datum is located at a

ter line of helicopter) will be expressed as

point 83 inches (210.8 cm) below the

having negative (-) lateral arm, and those

center of the main rotor blades.

items to right of reference datum, a positive

(+) lateral arm.

(5).

Refer to the following for balance

diagrams

(2). Center of gravity (CG): A point on a

Figure 201 for Model 369D

part where the part will be perfectly

Figure 202 for Model 369E

balanced. Center of gravity is measured

Figure 203 for Model 369FF

in inches from a known reference. It

Figure 204 for Model 500N

can be determined using the following

Figure 205 for Model 600N.

formula:

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MAINTENANCE MANUAL

CG(in)

= Moment (in−lb)

CAUTION

Weight (lb)

D The controls access panel (aft side of Sta.

78.5 bulkhead) and the fuel cell access

panels must be installed before jacking

(3). Moment: Product of weight of a part

helicopter.

and its arm, either longitudinal or

lateral, and is expressed in inch-

D 369D/E/FF - 500N: There are two meth

pounds (in-lb).

ods approved for weighing the helicopter.

Longitudinal moment = weight x

The preferred method is by using elec

longitudinal arm;

tronic weighing equipment. If equipment

Lateral moment = weight x lateral arm.

for electronic weighing is unavailable, the

second approved method, mechanical

scales, may be used.

(4). Reaction point: A fixed point on helicop

D 600N: There is one method approved for

ter where weight of helicopter counter

weighing the helicopter. The method is by

acts on a weighing device. The main

using electronic weighing equipment.

reaction points are;

A. Helicopter Weighing Preparation

The following items are required and should be

(a). ALL: Long. Sta. 96.9.

readily available prior to preparing and

weighing the helicopter, using the electronic

weighing method.

(b).

369D/E/FF - 500N: Lat. Sta. ±25.6.

Special Tools

(c).

600N: Lat. Sta. ±26.0.

(Ref. Section 91−00−00)

Item

Nomenclature

ST202

Jack fittings

(d).

369D/E/FF: Tail reaction point is at

Long. Sta. 197.2, Lat. Sta. 0.0.

NOTE:

D Weigh helicopter without fuel if possible.

(e).

500N: Tail reaction point is at Long.

Sta. 275.4, Lat. Sta. 0.0.

D 369D/E/FF - 500N: If fuel is drained from

low point in cell, 1.4 pounds (0.64 kg) of

trapped fuel at 93.5 inch (237.5 cm) arm

(f).

600N: Tail reaction point is at Long.

will remain. If fuel is pumped out using

Sta. 303.3, Lat. Sta. 0.0.

start pump, 3.7 pounds (1.68 kg) of

trapped (unusable) fuel at 93.5 inch

(237.5 cm) arm will remain.

Helicopter Weighing

D 600N: If fuel is drained from low point in

cell, 1.6 pounds (0.73 kg) of trapped (un

usable) fuel at 93.5 inch (237.5 cm) arm

will remain. If fuel is pumped out using

start pump, 9.5 pounds (4.31 kg) of

Forms

trapped (unusable) fuel at 93.5 inch

Form Figure

(237.5 cm) arm will remain.

Nomenclature

No.

(1). If defueling is not possible, ensure that

Weight and Balance Report

765B

206

fuel cell is full.

Surplus and Missing Items

1702

207

(a). Fluid weights at 70° ambient are:

Basic Weight and Balance

885

208

Fuel (Jet A)

Record

6.75 Lb (3.06 kg) per U.S. gallon

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MAINTENANCE MANUAL

Fuel (JP-4)

B. Preparation for Weighing − Electronic

6.50 Lb (2.95 kg) per U.S. gallon

Method

Fuel (JP-5)

Special Tools

6.80 Lb (3.09 kg) per U.S. gallon

(Ref. Section 91−00−00)

Item

Nomenclature

Fuel (JP-8)

N/A

Electronic weighing kit/Platform Scales

6.75 Lb (3.06 kg) per U.S. gallon

N/A

Roll-away table (with weighing platform)

PRC Fuel (No 3)

N/A

Plumb Bob

6.75 Lb (3.06 kg) per U.S. gallon

ST203

Hydraulic jack: 1-5 ton (900-4500 kg)

ST204

Hydraulic jack: 80 inch (203 cm) leg

Lubricating Oil

7.70 Lb (3.50 kg) per U.S. gallon

(1).

Position hydraulic jack (ST203) under

(2).

De-fuel helicopter (Ref. Sec. 12-00-00).

each of main jacking points at Sta. 96.9,

left and right sides of helicopter.

(3).

Select weighing area that is enclosed

(2).

Position third hydraulic jack (ST203 or

and draft-free, with hard-surfaced

ST204), on roll-away table if needed,

floor.

and attached load cell at aft jacking

point of helicopter.

(4).

Ensure that helicopter and weighing

area is cleared of all tools and debris.

(3).

Attach electronic weighing kit load cell

to each jack, and to weighing kit control

(5).

369D/E/FF - 500N: Verify that five

unit.

main rotor blades are uniformly spaced

(72 degrees apart).

(4).

Turn electronic weighing kit power ON

600N: Verify that six main rotor blades

and allow warm up time as specified in

are uniformly spaced (60 degrees

electronic weighing kit operation

apart).

manual.

(6).

Check lubricant level at engine oil tank,

(5).

Calibrate and zero-in each load cell

main rotor gear box and tail rotor or fan

prior to applying aircraft load (Ref.

gearbox sight gages. Add lubricant as

Electronic Weighing Kit operation

necessary where less than full indica

manual).

tion is noted (Ref. Sec. 12-00-00).

On the 600N helicopter, never

CAUTION

exceed aft (tailboom) jack load of

(7).

Record weight, arm and moment of

500 Lbs (227 kg).

surplus equipment on board helicopter

at time of weighing, which will not be

(6). Exercise load cells by jacking all three

part of basic helicopter weight (Ref.

jacks simultaneously until load is

Figure 206).

supported by load cells at all jack point

stations. Do not check helicopter level

(8).

Record weight, arm and moment of

at this time.

missing equipment, to be installed after

weighing and prior to flight, that will

(7). Lower helicopter to floor so that no load

become part of basic helicopter weight

is supported by load cells.

(Ref. Figure 206).

(8). Repeat above steps (exercise load cells

(9).

Install two fuselage jack fittings

and lower helicopter) twice.

(ST202) for main weighing points at

Longitudinal Sta. 96.9 and Lateral Sta.

(9). Recheck calibration and zero of each

±25.6. Secure fittings with pip pins.

load cell.

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MAINTENANCE MANUAL

C. Helicopter Weighing − Electronic Method

(Ref. Figure 209, example 1(b)). This

reading represents calibration correc

When preparations have been made (Ref.

tion for each load cell. Depending on

Helicopter Weighing Preparation and Prepara

sign shown on control unit (+ or -),

tion for Weighing - Electronic Method), weigh

reading will have to be added to or

helicopter as follows:

subtracted from reading in step (3).

above to obtain corrected weight for

Special Tools

each cell (Ref. Figure 209, example

(Ref. Section 91−00−00)

1(c)).

Item

Nomenclature

(6). Add corrected readings for all three

N/A

Spirit level

cells to determine total unadjusted net

N/A

Plumb Bob

weight of helicopter (Ref. Figure 209,

ST203

Hydraulic jack: 1-5 ton (900-4500 kg)

example 1(c).

ST204

Hydraulic jack: 80 inch (203 cm) leg

D. Preparation for Weighing − Mechanical

ST205

Inclinometer

Scales Method (369D/E/FF − 500N Only)

When preparing to weigh helicopter using

(1). Operate three hydraulic jacks (ST203

mechanical scales, complete preliminary

and/or ST204) simultaneously until

procedure (Ref. Helicopter Weighing Prepara

entire load is supported by load cells.

tion), then perform the following:

NOTE: If conditions permit, helicopter may be

leveled using plumb bob instead of spirit

Special Tools

level (Ref. Sec. 08-00-00).

(Ref. Section 91−00−00)

Item

Nomenclature

(2). After landing gear skids are clear of

N/A

Roll-away table (with weighing platform)

floor, level helicopter as follows:

N/A

Beam platform scales (two), 1000 lb. (450

(a). Remove main rotor hub fairing (Ref.

kg) capacity with current calibration

Sec. 62-20-00) (N/A 600N).

N/A

Platform scale, 300 lb. (135 kg) capacity

with current calibration

(b). Check lateral level by placing spirit

ST202

Jack fittings

level on main rotor mast, with axis of

spirit level 90 degrees to longitudinal

ST203

Hydraulic jack: 1-5 ton (900-4500 kg)

axis of helicopter. Adjust left or right

ST204

Hydraulic jack: 80 inch (203 cm) leg

jack at main jack points, as required,

to center bubble in spirit level.

(1).

Check 1,000 lb. (450 kg) capacity scales

(c). Place protractor or inclinometer

for zero.

(ST205) on main rotor mast so that

(2).

Place 300 lb. (135 kg) capacity scale on

its axis is parallel to longitudinal axis

roll-away table with weighing platform,

of helicopter. Adjust jack at aft

and check zero on scale.

jacking point until protractor or

inclinometer shows 3 degrees forward

(3).

Hoist helicopter so that main landing

tilt.

gear skids are sufficiently clear of floor

to enable 1,000 lb. (450 kg) capacity

(d). Reinstall hub fairing (N/A 600N).

beam platform scales to be rolled under

(3). Record reading shown on weighing kit

main skids on left and right sides.

control unit for each load cell (Ref.

(4).

Roll 1,000 lb. (450 kg) capacity beam

Figure 209, example 1(a)).

platform scales under main skids and

(4). Lower helicopter to floor by bleeding off

position so main jack fittings (ST202) at

jacks, and clear load cells.

Sta. 96.9 are on centerline of scale.

(5). Record reading on control unit for each

(5).

Place jack (ST203) on 300 lb. (135 kg)

load cell under NO LOAD condition

capacity platform scale (67). Position

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CSP-HMI-2

MAINTENANCE MANUAL

roll-away table so that jack and 300

weight at each reaction point (Ref.

pound capacity scale are directly below

Figure 209, example 1(b)).

AFT jacking point.

(9). Subtract total tare weight for the three

(6). Lower helicopter so its weight is

reaction points obtained in step h above

supported by scales.

from weight recorded in step c above to

obtain total unadjusted net weight of

(7). Place jack on each 1,000 lb. (450 kg)

helicopter (Ref. Figure 209, example

capacity platform scale, inboard of main

1(c)).

skids and directly below main jacking

F. Longitudinal CG Determination for

points at Sta. 96.9.

Unadjusted Net Weight (369D/E/FF − 500N

E. Weighing Procedures − Mechanical

Only)

Scales Method (369D/E/FF − 500N Only)

(1). Multiply net weight obtained at each

jacking point by its longitudinal arm, to

Once preparations have been completed (Ref.

obtain a moment (Ref. Figure 209,

Helicopter Weighing Preparation and Prepara

example 1(d)).

tion for Weighing - Mechanical Scales Meth

od), weigh helicopter as follows:

(2). Add three moments determined in step

(1). to calculate total moment (Ref.

(1). Operate jacks (ST203 and/or ST204)

Figure 209, example 1(e)).

simultaneously until helicopter is

supported only by jacks at right and left

(3). Divide total moment obtained in step

Sta. 96.9 and AFT reaction points.

(2). by total unadjusted net weight, to

determine longitudinal CG (Ref.

NOTE: If conditions permit, helicopter may be

Figure 209, example 1(f)).

leveled using plumb bob instead of spirit

level (Ref. Sec. 08-00-00).

G. Lateral CG Determination for Unadjusted

Net Weight

(2).

With main skids clear of 1,000 lb. (450

kg) capacity platform scales, level

NOTE: Lateral CG is not critical with normal

helicopter (Ref. Helicopter Weighting -

internal loading. Certain optional equip

Electronic Method).

ment, such as an external cargo hook, may

induce lateral CG outside lateral CG limits,

(3).

Record weight shown on scale at each

if weight and CG control is not provided.

reaction point (Ref. Figure 209, exam

However, the Initial Installation section for

ple 1(a)).

each optional equipment installation pro

vides complete instructions on lateral CG

(4).

Simultaneously bleed off hydraulic

control, to ensure operation within ap

jacks until helicopter skids contact

proved limits.

1,000 lb. (450 kg) platform scales, and

total weight of helicopter is supported

(1). Multiply net weight for each jacking

by scales and AFT jack point.

point by its lateral reaction point

(369D/E/FF - 500N: left main, -25.6;

(5).

Remove jacks from 1,000 lb. (450 kg)

right main, +25.6; and aft, zero)

capacity platform scales.

(600N: left main, -26.0; right main,

+26.0; and aft, zero) to obtain moment

(6).

Hoist helicopter until scales at right

for each jacking point (Ref. Figure 209,

and left sides and jack at aft reaction

example 1(g)).

point can be rolled clear of helicopter

(Ref. Sec. 07-00-00).

(2). Add three moments determined in step

(1). above to calculate total moment

(7).

Lower helicopter to floor.

(Ref. Figure 209, example 1(h)).

(8).

Weigh each jack on same scale jack

(3). Divide total moment by total unad

occupied during helicopter weighing to

justed net weight to determine lateral

get the tare weight. Record the tare

CG (Ref. Figure 209, example 1(i)).

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MAINTENANCE MANUAL

H. Basic Weight and CG Determination

moment of helicopter determined in

step (1). above.

Using unadjusted net weight and longitudinal

(3). Enter total basic weight, CG and

moment, determine basic weight and CG of

moment in Basic Weight and Balance

helicopter (Ref. Figure 209, example 1).

Record (Ref. Figure 208).

NOTE: Any changes that will affect basic

(1). Add total weight and moment of

weight and CG of helicopter must be re

missing equipment to unadjusted net

corded on Basic Weight and Balance Record

weight and moment of helicopter.

(Ref. Figure 208), and revised basic weight

and CG of helicopter must be calculated

(2). Subtract total weight and moment of

(Ref. PFM for preflight weight and balance

surplus equipment from weight and

requirements).

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MAINTENANCE MANUAL

STA.

78.5

ROTOR C

124.0

CG OF COPILOT/PASSENGER

STA.

CARGO COMPARTMENT

STA.

100.0

28.0

STA.

174.0

+13

+12.1

REFERENCE DATUM

-13

-12.1

TWO-PLACE COCKPIT

CG OF PILOT

(OPTIONAL)

STA.

73.3

105.0

STA.

78.5

ROTOR C

124.0

CG OF RIGHT SIDE

STA.

CARGO COMPARTMENT

FWD PASSENGER

100.0

STA.

28.0

STA.

174.0

+18.1

+12.1

+2.6

REFERENCE DATUM

-12.1

-13.0

CG OF AFT PASSENGERS

CG OF FWD PASSENGER

CG OF PILOT

STA.

THREE-PLACE COCKPIT

28.0

STA. 71.50

STA.

(STANDARD)

73.5

105.0

PERMISSIBLE CG LIMITS

100

120

140

160

180

200

220

240

260

280

300

SLING POINT

OIL TANK (RH SIDE)

LEVELING PLUMB

FIREWALL

STA. 92.6

JIG POINT

3°

AFT JACKING POINT

STA. 197.2 BL 0.00

STA. 174.0

STA.

BDH

284.0

ENGINE SECTION

FUEL CELL COMPARTMENT

REFERENCE

BATTERY

STA.

DATUM

78.5

124.0

JIG POINT

MAIN JACKING POINT

STA. 96.9 BL ±25.6

G08-1001

Figure 201. Balance Diagram − Model 369D

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MAINTENANCE MANUAL

STA.

78.5

ROTOR C

124.0

CG OF COPILOT/PASSENGER

STA.

CARGO COMPARTMENT

100.0

STA.

15.00

STA.

174.0

+15.5

+12.2

0.0

REFERENCE DATUM

-12.2

-13.0

TWO-PLACE COCKPIT

(WITH DUAL CONTROLS)

CG OF PILOT

STA.

73.3

105.0

STA.

78.5

124.0

CG OF RIGHT SIDE

ROTOR C

FWD PASSENGER

STA.

CARGO COMPARTMENT

100.0

STA.

15.00

STA.

174.0

+15.5

+12.2

0.0

REFERENCE DATUM

-12.2

-13.0

THREE-PLACE COCKPIT

(WITH SINGLE CONTROLS)

CG OF FWD PASSENGER

CG OF AFT PASSENGERS

CG OF PILOT

STA.

STA. 71.5

73.5

105.0

STA.

15.00

STA. 99.0

107.4

PERMISSIBLE CG LIMITS

100

120

140

160

180

200

220

240

260

280

300

SLING POINT

OIL TANK (RH SIDE)

LEVELING PLUMB

STA. 92.6

FIREWALL

3°

JIG POINT

AFT JACKING POINT

STA. 197.2 BL 0.00

STA. 174.0

STA.

BDH

284.0

ENGINE SECTION

STA.

FUEL CELL

REFERENCE

STA.

JIG POINT

BATTERY

78.5

COMPARTMENT

DATUM

124.0

MAIN JACKING POINT

STA. 96.9 BL ±25.6

G08-1002

Figure 202. Balance Diagram − Model 369E

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MAINTENANCE MANUAL

STA.

78.5

ROTOR C

124.0

CG OF COPILOT/PASSENGER

STA.

CARGO COMPARTMENT

100.0

STA.

15.00

STA.

174.0

+15.5

+12.2

0.0

REFERENCE DATUM

-12.2

-13.0

TWO-PLACE COCKPIT

(WITH DUAL CONTROLS)

CG OF PILOT

STA.

73.3

105.0

STA.

CG OF RIGHT SIDE

78.5

124.0

FWD PASSENGER

ROTOR C

STA.

CARGO COMPARTMENT

100.0

STA.

15.00

STA.

174.0

+15.5

+12.2

0.0

REFERENCE DATUM

-12.2

-13.0

THREE-PLACE COCKPIT

(WITH SINGLE CONTROLS)

CG OF FWD PASSENGER

CG OF AFT PASSENGERS

CG OF PILOT

STA. 71.5

STA.

73.5

105.0

STA.

107.4

15.00

STA. 99.0

PERMISSIBLE CG LIMITS

100 120

140

160

OIL TANK (RH SIDE)

SLING POINT

180 200

220

240

260 280

300

LEVELING PLUMB

FIREWALL

STA. 92.6

3°

JIG POINT

AFT JACKING POINT

STA. 197.2 BL 0.00

STA. 174.0

STA.

BDH

284.0

ENGINE SECTION

REFERENCE

STA.

BATTERY

FUEL CELL

DATUM

78.5

124.0

COMPARTMENT

JIG POINT

MAIN JACKING POINT

STA. 96.9 BL ±25.6

G08-1003

Figure 203. Balance Diagram − Model 369FF

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MAINTENANCE MANUAL

ROTOR

STA

STA CL

78.5

124.0

CARGO COMPARTMENT

CG OF COPILOT/

STA

PASSENGER

100.0

STA

15.0

168.8

+ 15.5

+ 12.2

REFERENCE

0.0

DATUM

- 12.2

- 13.0

TWO-PLACE COCKPIT

CG OF PILOT

WITH DUAL CONTROLS

STA

105.0

73.5

ROTOR

STA

78.5

124.0

STA

CARGO COMPARTMENT

CG OF COPILOT/

100.0

PASSENGER

STA

15.0

168.8

+ 15.5

+ 12.2

+ 0.8

REFERENCE

0.0

DATUM

CG OF CENTER

PASSENGER

- 12.2

- 13.0

THREE-PLACE COCKPIT

CG OF PILOT

STA

WITH SINGLE CONTROLS

73.5

STA

105.0

15.0

STA

71.5

28.0

100.0

100

120

140

3 °

160 180

200

220

240 260

290

300

320LEVELING PLUMB

OIL TANK - RH SIDE

STA 92.6

FIREWALL

JIG POINT

ENGINE SECTION

AFT JACKING POINT

STA 275.4

FUEL CELL

COMPARTMENT

STA

78.5

124.0

JIG POINT

FWD JACKING POINT

STA 96.9

G08-1007

Figure 204. Balance Diagram − Model 500N

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CSP-HMI-2

MAINTENANCE MANUAL

CG OF PILOT OR

COPILOT/PASSENGER

7-PLACE SEATING,

TWO-PLACE COCKPIT WITH DUAL CONTROLS,

AFT-FACING MID-CABIN SEAT

+ 15.0

+ 12.2

0.00

0.00 REFERENCE DATUM

- 13.0

- 12.2

- 15.0

STA

70.4

41.50

8-PLACE SEATING,

THREE-PLACE COCKPIT WITH SINGLE CONTROLS,

FWD-FACING MID-CABIN SEAT

0.00

0.00 REFERENCE DATUM

STA

43.50

77.1

105.0

PASSENGER/CARGO

COMPARTMENT

THIS DIMENSION 15 INCHES

(381 MM) AFT OF NOSE OF

STA

THESE DIMENSIONS

AIRCRAFT

100

IN INCHES

120

140

160

180 200

220

240

3 °

260 280

300

320

LEVELING PLUMB

340

STA 81.54

BL 4.00

FIREWALL

ENGINE SECTION

AFT JACKING

FUEL CELL

COMPARTMENT

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

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MAINTENANCE MANUAL

WEIGHT AND BALANCE REPORT

MODEL ___________

WEIGHED BY

CONFIGURATION

MODEL

SERIAL NO.

REGISTRATION NO.

DATE

TARE OR

NET

LONGITU-

LATERAL

LONGITU-

LATERAL

WEIGHING

SCALE READING

CALIBRATION

WEIGHT

DINAL

ARM

DINAL

MOMENT

POINTS

(LBS)

CORRECTION

(LBS)

ARM

(INCHES)

MOMENT

(INCH−LBS)

(LBS)

(INCHES)

(INCH−LBS)

LEFT MAIN

96.9

−26.0

RIGHT MAIN

96.9

+26.0

TAIL

303.3

0.0

TOTAL UNADJUSTED NET WEIGHT

TOTAL WEIGHT OF SURPLUS EQUIPMENT (SEE TABLE 1)

−

TOTAL WEIGHT OF MISSING EQUIPMENT (SEE TABLE 1)

TOTAL BASIC WEIGHT

FUEL/OIL ABOARD AT TIME OF WEIGHING:

EMPTY

FULL

FUEL

ENGINE OIL

MAIN GEAR BOX

TAIL GEAR BOX

McDonnell Douglas

FORM 765B (REV 4−83)

Page 1

Helicopter Company

Figure 206. Weight and Balance Report Form (Sheet 1 of 2)

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HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369D/E/FF-500/600N HELICOPTERS (ISSUED: 1990) - page 3