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

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(b). Probes - Must be correct for the part

(4). Standardization

shape, depth of penetration, and

(a). Standardization must be done in

frequency range for material ex

accordance with the manufacture

amined, and sensitivity to sense the

recommendations.

defect. Test probes must not give

interference during movement.

(b). Calibration scan must be done

Probes must be identified with the

before, during and after the inspec

manufacturer's part number and

tion. If the after calibration shows

frequency range.

test equipment is not accurate, do a

calibration of the equipment and do

(c). Standards - Reference calibration

another inspection on all components

standards can be actual parts (with

examined since last acceptable

natural defects) or from test blocks.

calibration.

All calibration standards must be

calibrated and certified.

1). Reference standards must be of an

(5). Regulatory Requirements

alloy of the same base material

The Eddy Current Inspection of

and temper or approximately the

components must be done with the

same electrical conductivity,

test facilities local aviation regulato

surface texture, shape, and defect

ry authority and approved proce

location as the part to be in

dures.

spected.

(6). Test Facilities

2). Only the reference standards

calibrated and certified must be

(a). Approved facilities must use the

used for the specific component

same or equivalent equipment.

examined. All calibration stan

(b). Analysis of all indications must be

dards must be kept to a national

made in accordance with the test

standard. Records must be kept

facilities approved procedures and

and made available when reques

with defects.

ted.

(c). Parts with defects must be removed

(3).

Surface preparation - All surface

from service in accordance with the

contamination that could cause an

facilities approved procedures.

interference with the inspection must

be removed. Methods of cleaning must

(d). Records must be completed in

not damage surface finish or damage to

accordance with the facilities ap

the part.

proved procedures.

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CSP-HMI-2

MAINTENANCE MANUAL

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

21-10-00 Ventilation Systems

Maintenance Practices

201

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

Description and Operation

201

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

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MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

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

904

Table 901. Weight and Balance Data

904

Figure 902. Engine Air Bleed Line Installation (250-C20B)

905

Figure 903. Engine Air Bleed Line Installation (250-C20R/2)

906

Figure 904. Engine Air Bleed Line Installation (250-C30)

907

Figure 905. Heating Valve Installation

908

Figure 906. Duct, Hose and Convenience Panel Installation (Sheet 1 of 2)

909

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21 Contents

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

VENTILATION SYSTEMS

MAINTENANCE PRACTICES

1. Environmental Systems

(4). Remove control cable nut from plunger

housing and pull entire control cable

The cabin ventilation system consists of a

out aft through instrument panel

ventilation valve, control cable and snapvents

mounting hole.

installed in the door windows. The ventilation

B. Cabin Vent Control Cable Installation

valve contains a moveable vane operated by a

push-pull cable mounted in the right center of

(1).

Route replacement control cable

the instrument panel. The control cable locks

through instrument panel and secure in

the vane in any selected position, controlling

place using lockwasher and control

airflow. Fresh air forced through an opening in

cable nut.

the lower front canopy passes through the

valve and is directed into the cabin.

(2).

Secure control cable sleeve to valve

bracket with clip.

Adjustable snapvents are installed in each

(3).

Position shaft arm so that vane assem

door window. The snapvents can be opened

bly is fully closed.

and rotated to face the airstream to supple

ment fresh air intake, or in the trail position,

(4).

Insert control cable wire through hole

provide a vent-air exhaust outlet.

in swivel and move control knob to fully

closed position.

Before high speed flight; ensure

CAUTION

that all snapvents are posi

(5).

Tighten swivel on control cable wire

tioned up, aft or down with outs in the trail

and install cotter pin.

position. Door damage and vibrations could

(6).

Check swivel for free rotation by

occur if vent cutouts face the airstream.

actuating control knob through full

stroke. Inspect valve assembly for

NOTE:

complete closure of inlet opening when

D The following maintenance procedures

control knob is pushed forward against

cover round or pointed nose helicopters.

cable panel fitting stop. Check valve

Whenever reference is given to diffuser

door for looseness on shaft and defor

type valve this is for round nose military

mation; valve door must be flat; a firm,

D model, and likewise the “Y” type is for

snug fit is required in the inlet.

civil models.

(7).

Reinstall right side fairing on instru

D For round nose model with diffuser or “Y”

ment panel.

type valve, refer to Figure 202. For

pointed nose “Y” type valve, refer to

3. Cabin Ventilating Valve Replacement

Figure 201.

A. Cabin Ventilating Valve Removal

2. Cabin Vent Control Cable Replacement

(1). Remove left and right side fairing from

instrument panel; then remove ducts

A. Cabin Vent Control Cable Removal

from rear of ventilating valve.

(2). Actuate control cable to full open

(1). Ensure that electrical power is OFF.

position.

(2). Remove right side fairing from instru

(3). Remove control cable clip and discon

ment panel.

nect control cable from swivel on valve

shaft.

(3). Disconnect control cable from swivel in

valve shaft. Remove clip and separate

(4). Drill out rivets and remove valve

control cable from support bracket.

assembly from helicopter canopy panel.

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MAINTENANCE MANUAL

B. Cabin Ventilation Valve Installation

(3). Position vane assembly on shaft and

secure with screws using loctite

(1). Position ventilating valve on canopy

(CM431).

panel and align rivet holes. Attach

valve to canopy panel with rivets

(4). Install washer on end of shaft and

spaced at 90 degrees.

insert cotter pin.

NOTE: If rivet holes are elongated or oversize,

(5). Operate valve several times to assure

install next larger rivets.

freedom of operation and positive

closing.

(2). Secure control cable sleeve to valve

bracket with clip.

6. Cabin Ventilating Valve Inspection

(3). Install swivel assembly loosely in arm

(1). Inspect for cracks, secure attachment to

of shaft.

canopy panel and separation of bonded

joints.

(4). Position shaft arm so that vane assem

bly is fully closed.

NOTE: Very small, widely separated spots or

voids in plastic joints are not separation but

(5). Insert control cable wire into swivel

air pockets produced during solvent bonding

assembly and move control knob to

at manufacture.

fully closed position.

(2). Inspect for bent shaft or vane assembly

(6). Tighten swivel assembly on control

and excessive shaft wear in pivot areas.

cable wire; install cotter pin.

(3). Inspect seal on vane assembly for wear.

(7). Operate valve through several open-

close cycles to assure ease of operation

7. Cabin Ventilating Valve Repair

and to determine that valve locks in

any position when control knob is

released.

Consumable Materials

(Ref. Section 91−00−00)

(8). Install ducts on rear of valve; then

Item

Nomenclature

install instrument panel left and right

CM418

Cement, epoxy

side fairings.

Cabin Ventilation Valve Disassembly

(1). Patch polycarbonate valve body cracks

and repair seam separations according

(1). Remove screws and separate vane

to repair methods specified for polycar

assembly from shaft.

bonate plastic (Ref. Sec. 20-30-00).

(2). Remove cotter pins and slide shaft from

(2). Replace unserviceable seal if installed,

valve body.

using cement (CM418) according to

container instructions.

Cabin Ventilating Valve Reassembly

8. Snap−Vent Replacement

Consumable Materials

A. Snap−Vent Removal

(Ref. Section 91−00−00)

Item

Nomenclature

(1). Push snapvent outward in window

CM431

Sealing, locking and retaining compound

(open position).

(2). Grasp open side of snapvent and gently

(1). Install cotter pin in hole at control arm

squeeze it into an elliptical shape.

end of shaft. Install washer on shaft to

(3). Slip snapvent out of window hole at

bear on cotter pin.

about a 30 degree angle to surface of

(2). Insert shaft in body of valve.

window.

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CSP-HMI-2

MAINTENANCE MANUAL

HEATING SYSTEM

DESCRIPTION AND OPERATION

Heating System Description and

enclosed behind the heating system

Operation

access cover. Air is Ducted overhead

from the muffler into the cargo/pas

(1).

The heating system mixes cold air

senger and crew compartments. Six

supplied by the oil cooler blower and

fan-shaped diffusers distribute air

hot air extracted from the engine

throughout the cabin.

compressor scroll. Cabin air tempera

ture is mechanically controlled with a

(4). The muffler consists of a laminated

handle in the crew compartment that

fiberglass housing, perforated alumi

positions a cable operated mixing valve.

num core, and a one inch layer of

The system distributes temperature

fiberglass wool around the core.

controlled air via a muffler and ducts to

(5). Air outlets are also provided for the

strategically located cabin outlets.

cargo/passenger compartment through

an overhead duct diffuser valve

(2).

The heat control valve is mounted on

mounted in the passenger convenience

the forward left side of the firewall

panel. Diffuser valve airflow can be

bulkhead. The valve consists of a

adjusted as required.

housing that contains air control ports

for mixing hot and cold air. A 90° inlet

(a). The -519 heating system adds

elbow attaches the valve to the com

ducting to provide two floor-heated

pressor bleed air tube through the

air outlets.

firewall bulkhead. The valve housing

inlet contains a stainless steel bleed air

(b). The -521 heating system provides

flow control ball valve that is rotated by

ducting for one floor-heated air

an attached drive pulley. A nozzle on

outlet.

the inlet body injects hot air down

(6). The control handle, control cable and

stream of cold air. A fitting supports the

conduit assembly are incorporated in

cold air control vane and drive pulley

the left side of the duct attached to the

that is rotated by a drive belt. Hot air is

overhead canopy structure. Moving the

mixed with cold air at a variable ratio.

Because engine bleed air temperature

control handle forward opens the heat

is approximately 500°F (260°C), cold air

control valve. Control handle travel is

is never completely shut off while the

approximately 2-3/4 inches (6.985 cm)

system is in use.

from open to closed. Cable routing is

along the left side of the main rotor

(3).

The duct system and the direct air flow

mast support structure and down to the

muffler are forward of the firewall and

firewall mounted control valve.

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MAINTENANCE MANUAL

2. Heating System Fault Isolation

(Ref. Table 201)

Table 201. Troubleshooting Heating System

Symptom

Probable Trouble

Corrective Action

Actuation of heat valve control

Control valve pulley drive belt

Replace faulty parts and adjust

lever produces no heated air at

broken

valve.

outlets

Pulley shaft retaining pin sheared

Replace faulty parts and adjust

or control cable spring pin sheared

valve.

Heat valve ball binding in housing

Shim between valve housing and

elbow fitting.

Heat control valve internally

Replace valve.

defective

Heat control clevis improperly

Adjust control cable clevis.

adjusted for length

Cracked, broken or disconnected

Replace defective ducts.

ducting in system

Movement of heat valve does not

Same troubles as above

Replace faulty parts and adjust

shut off hot air

valve.

Movement of heat valve control

Control cable crushed or one or

Check cable operation with clevis

lever very difficult

more routing bend radii less than 3

detached from pulley arm.

inch (7.62 cm) minimum

Heat valve control lever does not

Cable sleeve (sheath) damage

Replace defective parts.

remain in selected position

causing preload spring−back

Air excessively hot at diffusers (*)

Improper cold air mixing

Adjust valve.

(*) CAUTION: Do not operate engine until this condition is corrected. Canopy plastic or ducting may be badly

damaged if operation is continued.

3. Heat Control Valve Replacement

(4). In left side of engine compartment,

disconnect the hot bleed air line at the

heat control valve elbow fitting.

(Ref. Figure 201)

(5). Loosen the elbow tube nut and remove

A. Heat Control Valve Removal

elbow fitting and gasket.

(1). Remove interior trim and left aft

(6). Remove hardware attaching the upper

bulkhead access cover.

and lower end of control valve assembly

to the canted firewall.

(2). Remove cotter pin, washer, and pin

attaching clevis to heat control valve.

(7). Remove clamp securing cool air duct to

valve.

(3). If particle separator is installed, loosen

and back off tube coupling nut of

(8). Remove attaching hardware connecting

369H90149-51 tube assembly at end

the muffler and valve. Remove heat

connected to elbow assembly.

control valve and gasket.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

B. Heat Control Valve Installation

4. Heat Control Valve Cable Replacement

(Ref. Figure 202)

Consumable Materials

(Ref. Section 91−00−00)

A. Heat Control Valve Cable Removal

Item

Nomenclature

(1). Remove left half of engine air inlet

CM113

Anti-seize compound low temperature

forward fairing, interior trim and left

aft bulkhead access cover.

(1). Install control valve assembly on

(2). Remove seven screws attaching heat

forward left side of firewall with bolts,

duct outer box to heat duct and canopy

washers and nuts, but do not tighten.

frame.

NOTE: Use anti-seize compound (CM113) on

(3). Remove clamps, straps, and grommets

threaded fittings.

that attach cable to structure along its

full length. Remove cotter pin and

(2).

For helicopters equipped with particle

clevis pin from clevis at heater control

separator kit, re-engage tube coupling

valve arm.

nut of the 369H90149-51 tube assem

B. Heat Control Valve Cable − Installation

bly with elbow assembly, and tighten

fasteners.

Consumable Materials

(3).

In left side of engine compartment,

(Ref. Section 91−00−00)

install elbow, nut and new gasket.

Item

Nomenclature

Tighten retaining hardware on heating

CM430

Sealant, solvent resistant

valve.

(4).

Connect control valve flange to muffler,

(1). Route the cable assembly into position.

using new gasket and four nuts,

Check that grommet is in place on

washers, and bolts.

cable.

(5).

Install cool air connector hose on

(2). Install clamps and straps that attach

control valve inlet and secure with

cable to structure. Install grommet at

clamps.

structure fairing that cable passes

through using adhesive (CM430).

(6).

Position control handle fully forward.

Position lever on control valve to open,

NOTE: The clamp nearest to the valve should

and insert a 1/8 inch (3.175 mm)

not be tightened until after travel is

rigging pin through lever and into valve

checked.

boss.

(3). Attach heat duct outer box to heat duct

and canopy frame with seven screws.

(7).

Loosen jam nut on control cable and

adjust clevis so attach holes align with

(4). For adjustment of clevis refer to initial

hole in valve lever. Install pin through

installation.

clevis and valve lever, and safety with

cotter pin.

(5). When assured that cable will operate

the valve freely through full range of

(8).

Tighten clevis jam nut. Remove rigging

travel, tighten the clamp nearest the

pin from valve lever.

valve.

(9).

Move control handle full aft and

(6). Reinstall aft bulkhead access cover,

forward several times to check ease of

interior trim, and left half of engine

heat control operation.

inlet fairing.

(10).

Reinstall left aft bulkhead cover and

(7). After installation, adjust handle to be

interior trim.

parallel to windshield glass.

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CSP-HMI-2

MAINTENANCE MANUAL

CANOPY FRAME

RIGID TUBING

CANOPY CENTER

FRAME TRIM AND

SPRING PLUNGER

HEAT DUCT - LOWER

CABLE SUPPORT BLOCK

(3 PLCS) (NOTE)

2 PLCS

SET SCREW

WASHER

CONTROL HANDLE

(NOTE)

HANDLE SHAFT

OUTER BOX

HEAT DUCT/TRIM

6 PLCS

CANOPY CLIP

INCREASE HEAT

DIFFUSER

ASSEMBLY

HEAT DUCT MOUNTING

SCREW

CONTROL HANDLE

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

(f). Inspect rubber hose for tears and

evidence of deterioration.

(Ref. Figure 202)

(g). Inspect all ducts and muffler for

(1). With the helicopter on the ground,

security of attachment and coupling

perform the following:

hardware and any duct section or

muffler damage that would allow

(a). Inspect heat valve control lever and

heated air leaks. Inspect diffuser

cable for freedom of operation.

outlets for condition of cemented

joints or distribution ducts.

(b). Remove interior trim and left aft

bulkhead access cover in cargo

(h). In engine compartment, inspect tube

compartment. Inspect cable for

connecting engine air bleed fitting to

condition and security.

control valve for cracks and security

of hex nuts.

(c). Inspect cable clevis for security of

(2). Perform an operational check (Ref.

jam nut and cotter pin.

Heating System Operational Check).

(d). Inspect security of heat control valve

A. Heat Control Valve Inspection

to firewall; check pulley belt for

condition.

(1). Inspect timing belt for deterioration,

stretching, worn teeth, or evidence of

(e). Inspect flexible fiberglass hose for

slipping.

tears and deformation due to failure

of inner supporting wire or short

(2). Inspect valve housing for deep dents

radius bends.

and cracks, mating flanges and connect

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MAINTENANCE MANUAL

ing area for bends or dents which would

(2).

Remove hardware (nut, washer, bolt)

prevent tight connections, bearing

attaching elbow to valve housing and

bosses for galling and excessive wear,

remove elbow and shims if installed.

and interior seat and ball valve for

galling.

(3).

The O-ring, wave washer, retainer, ball

valve and coupling are now free for

(3). Inspect pulley shafts for galling and

removal.

evidence of wear.

(4).

Cut lockwire and remove three screws

(4). Inspect ball valve and retainer for

from valve lever and drive pulley.

cracks, galling and evidence of wear;

Remove timing belt.

cold air vane for flatness and evidence

of excessive edge wear.

(5).

Remove pin from drive pulley. Remove

B. Heat Control Valve Cable Inspection

shaft from valve housing; inner and

outer washers will fall free.

(1). Inspect cables for kinks, crushed sleeve,

and corrosion.

(6).

Remove screws attaching cold air valve

vane to shaft. Remove plate spring and

(2). Clean all corrosion from cable.

spacers. Remove vane.

(3). If cable is kinked or crushed, locate

(7).

Remove pulley, shaft, and washers from

problem and repair or replace cable as

valve housing.

required.

(8).

Remove pin from driven pulley to

Heating System Operational Check

complete disassembly.

(1). Perform an operational check of the

heating system as follows:

8. Heat Control Valve Repair

(2). Move CABIN HEAT control handle full

(1). Repair small dents in valve housing by

forward to open heat valve. Control

bumping out and burnishing. Repair

handle should not creep away from ON

warped flanges by straightening on a

position.

surface plate. No weld repairs are

(3). Remove left aft bulkhead access cover.

permitted.

(4). Check that valve is full open position by

(2). No repairs are permitted on moving

inserting a 1/8 inch (3.175 mm) drill

parts, ball valve, retainer, coupling, or

shank (or rod) into the drive pulley

shafts which are cracked, bent or badly

alignment hole (Ref. Figure 201). The

worn.

drill shank should pass through the

pulley and enter a mating alignment

(3). Place valve housing upside down on a

hole in the valve housing inlet body.

suitable workbench (Ref. Figure 204).

Find the thickness of shims required

(5). Check the cold air vane drive pulley

between valve body and elbow fittings

alignment mark. The mark should align

as follows.

with a similar mark on the cold air

vane housing.

(a). Measure diameter of the ball valve

using an outside micrometer. Record

Heat Control Valve Disassembly

as dimension A.

(Ref. Figure 203)

(b). Place ball valve in housing and use a

(1). Rotate ball valve lever fully counter

depth micrometer to measure dis

clockwise to position the ball valve

tance from housing flange to top of

open.

ball. Record as dimension B.

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MAINTENANCE MANUAL

(c).

Multiply dimension A by 0.933; then

position ball valve in housing to engage

subtract the result from 1.627 in.

coupling (ball valve in open position).

(4.1356 cm). Record as dimension C.

(6). Install new O-ring in elbow flange

Example:

groove.

Ball dia. A = 1.441 in. (3.6601 cm)

(7). Install retainer and washer in housing

1.441 in. (3.6601 cm) x 0.933 = 1.344

on ball valve.

in. (3.4138 cm)

NOTE: A 1/2 inch (12.7 mm) wood dowel may

1.627 - 1.344 in. (3.4138 cm) = 0.283

be inserted through top of assembly to tem

in. (7.1882 mm) (dim. C)

porarily hold these parts in position.

(d).

Compare dimension B with dimen

(8). Install shim(s) of thickness determined

sion C. If B is greater than C, no

in above steps; then install elbow on

shims are required. If C is greater

valve housing flange with four bolts

than B, add shims 369H8007 until B

and nuts. Washers are installed under

is equal to or greater, 0.010 in. (0.254

both the bolt head and the nut. Use

mm) max., than C.

care to avoid nicking or cutting the

Example:

O-ring during mating.

B = 0.270 in. (6.858 mm) and C =

The flanges of the valve housing

CAUTION

0.283 in. (7.1882 mm)

and elbow should mate without

the use of undue force. If flanges do not mate

(e).

Add a 0.015 in. (0.381 mm) shim to

easily, the internal parts of the valve may be

dimension B. B now equals 0.285 in.

misaligned. Investigate before tightening

(7.239 mm), or 0.002 in. (0.0508 mm)

bolts.

more than dimension C, and is a

correct total shim thickness for use.

(9). Install washer and ball valve so that

rigging pin holes in pulley and in valve

(4). Install washer (Ref. Figure 203) on ball

housing boss are aligned (ball valve in

valve shaft; then insert this assembly

open position).

into valve housing boss.

(5). Install coupling on shaft (check that the

(10). Install pin through ball valve pulley

ball drive lug is chamfered); then

and shaft.

DEPTH MICROMETER

DIMENSION B (FLANGE-TO-BALL)

VALVE HOUSING

DIMENSION A (BALL DIAMETER)

NOTE:

FIND DIMENSION C AS FOLLOWS:

C = 1.627 IN. (4.1356 CM) - A X 0.993).

REFER TO TEXT FOR USAGE.

BALL VALVE

BALL VALVE SUPPORT

G21-4004A

Figure 204. Control Valve Shim Thickness Determination

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CSP-HMI-2

MAINTENANCE MANUAL

(11).

Remove wood dowel if used to align

(20). Reinstall and actuator belt pulley on

internal parts; then rotate pulley

ball valve using three screws (Ref.

through full travel several times to

Figure 201). Note that the screw

assure ease of operation and positive

located 180 degrees from the rigging

closing of ball valve. A valve torque

pinhole is 1/8 inch (3.175 mm) longer

check, step (18). below, is made after

than the others. Remove rigging pin

the timing belt is installed.

installed in step (10). above. Safety

screws to each other with lockwire.

(12).

Install cold air pulley and washer on

shaft.

9. Heating System Muffler and Ducts Repair

(13).

Install cold air pulley and shaft assem

Consumable Materials

bly into valve housing.

(Ref. Section 91−00−00)

(14).

Attach cold air vane to shaft using two

Item

Nomenclature

screws.

CM432

Dichloromethane

CM433

Ethylene chloride

(15).

Rotate ball valve pulley fully counter

clockwise to full stop.

Repair of heat system ducting will depend

(16).

Rotate cold air pulley so that the vane

upon the type of material used in the section

is 45 degrees from fully closed, or align

that requires repair. Rubber hose or flexible

yellow rigging marks, if present.

fiberglass hose that is torn, flattened, or

deteriorated must be replaced. When removing

(17).

Install a serviceable timing belt

ducting for repair or replacement, use illustra

between pulleys while maintaining

tion as a guide (Ref. Figure 205).

valve position located in steps (15).and

(16). above.

(1). Repair rigid fiberglass or muffler

according to the fiberglass repair

(18).

Check valve operation by applying 6 -

procedures outlined in the SRM, except

11 inch-ounces (0.0423 - 0.0777 Nm)

use fire-retardant resin.

of torque on the ball valve shaft. If the

ball valve does not operate within this

(2). Repair rigid polycarbonate plastic

range, change thickness of shims

sections by bonding a patch according

between the valve elbow and housing as

to the criteria and methods specified for

required. Shims are provided inch 0.015

acrylic plastic in FAA AC 43.13-1B,

inch (0.381 mm), 0.010 in. (0.254 mm),

Aircraft Inspection and Repair for

and 0.005 inch (0.127 mm) thicknesses.

Standard Sheet Metal Repair. Use

dichloromethane (CM432) or ethylene

NOTE: Final total shim thickness should not

dichloride (CM433) as the bonding

exceed dimension C (step (c).) by more than

agent.

0.10 inch (2.54 mm).

(3). Repair small areas of rib or seam

(19). If rigging marks have not been applied,

separation in plastic sections by

paint a yellow index mark, 1/16 inch

injecting ethylene dichloride (CM433)

(1.59 mm) wide, on pulley and housing

into the void area and clamping

(Ref. Figure 201).

together under light pressure.

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CSP-HMI-2

MAINTENANCE MANUAL

HEATING SYSTEM

INITIAL INSTALLATION

1. Heating System Initial Installation

assembly (Sta. 31.50); retain washers

for use when installing diffuser assem

Procedures in this section may be performed at

blies.

the operator's discretion and are applicable to

369D/E/FF model helicopters.

(4). Remove attaching hardware and outer

box from heat duct and canopy frame.

A. Preparation for Installation

(5). Remove rubber plug from left side of

convenience panel.

Consumable Materials

(Ref. Section 91−00−00)

(6). Remove cap from cool air manifold duct.

Item

Nomenclature

B. Heating Valve Initial Installation

CM702

Lockwire CRES

(1). Using hardware, install heating valve,

but do not tighten.

(1). Remove engine (Ref. Chap. 71).

(2). On aircraft equipped with engine air

(a).

250-C20B - 250-C20R/2: (Ref.

particle separator only, engage tube

Figure 902 or Figure 903)

coupling nut of 369H90149-51 tube

assembly and tighten fasteners.

1). Remove existing plugs and install

tee and elbow.

(3). Install elbow, nut and gasket from aft

side of firewall. Tighten heating valve

Tee and elbow must be installed

CAUTION

attaching hardware.

so that no interference will exist

between hose assembly and existing bleed

(4). Reinstall engine (Ref. Chap. 71).

air tube.

(a).

250-C20B - 250-C20R/2: (Ref.

2). Install hose assembly and tube

Figure 902 or Figure 903)

assembly. Do not reinstall engine

at this time.

1). Connect tube assembly to elbow

using nut and gasket. Torque both

(b).

250-C30: (Ref. Figure 904)

connecting nuts onto tube assem

bly to 350 inch-pounds (39.54

1). Remove existing plate and install

Nm).

fitting, using engine supplied

washers and bolts. Safety with

(b).

250-C30: (Ref. Figure 904)

lockwire (CM702).

1). Connect engine bleed assembly to

2). Install engine bleed assembly to

elbow. Torque connecting nut to

fitting, and secure tube assembly

350 inch-pounds (39.54 Nm).

by connecting one end of the strap

to the inlet bell with bolt, nut and

C. Ducting Installation (−517)

washers, but do not tighten. Attach

(Ref. Figure 906)

clamp to bleed assembly. Secure to

strap with attaching hardware.

Tighten nut.

Consumable Materials

(Ref. Section 91−00−00)

(2). Remove interior trim panels and aft

Item

Nomenclature

bulkhead access.

CM411

Adhesive, epoxy

(3). Remove left and right hand guide

CM821

Gasket material

assemblies from forward end of duct

Page 901

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(1).

Using clamps, install air hose between

NOTE: Ensure that heater hose does not con

heating valve and cold air manifold

tact transmission oil lines or structure.

duct (Ref. Figure 905).

(8). Install aft valve assembly (23) in

(2).

Install muffler assembly with gasket

convenience panel (24) and connect

and hardware; attach hose to muffler

valve to duct (3) with hose (25) and

with clamp.

clamps (26).

(3).

Remove protective cap from existing

(9). Install diffuser assemblies (Ref.

duct assembly (1). Install grommets (2)

Figure 202); add washers as necessary

with cement (CM411) to prevent

to obtain diffuser to duct fit.

chafing.

D. Ducting Installation (−519)

(4).

Route heater hose (9) and secure to oil

flex line (10) with clamps (11, 12),

(Ref. Figure 906)

bracket (13), and attaching hardware

(14, 15, and 16).

Consumable Materials

(5).

Position standoff (17) on inboard side of

(Ref. Section 91−00−00)

channel (18) as shown. Drill two #40

Item

Nomenclature

holes and deburr. Attach standoff to

CM318

Primer

channel using two rivets (19).

CM702

Lockwire CRES

(6).

Install clamp (20) around hose and

secure to standoff, using attaching

hardware (21 and 22). Install Scotch

(1). Perform installation as described (Ref.

Foam (CM821) as required to prevent

Ducting Installation (-517), steps (1).

chafing.

thru (4). and (6).) except that duct (27),

replaces duct (3) and that hose (5) is not

(7).

Connect duct (3) to duct assembly (1),

secured to duct (27) at this time.

and hose (5). Attach duct (3) to bulk

head using attaching hardware (6, 7,

(2). Install splitter duct (28) with attaching

and 8). Attach hose (5) to duct with

hardware (29, 30) and valve (23) into

clamp (4).

convenience panel (24).

369D292479-1 OUTLET

INSTALLATION SAME

FOR 369D292479-2

0.188 IN. (4.7752 MM)

HOLE IN PANEL

REIDENTIFY AS 369H90020-5

369A2544-3

NAS1402-2 SCREW

CONVENIENCE PANEL, TO BE

NAS1329A08-75 RIVNUT

FITTING

AN960-8 WASHER

MADE FROM 369D26553-21 PANEL

NAS1402-2 SCREW

AN960-8 WASHER

(OPPOSITE SIDE)

PICK UP EXISTING RIVET

0.40 IN. (10.16 MM)

1.00 IN.

LOCATION

TRUE HOLE LOCATION

(2.54 CM)

0.30 IN.

1.38 IN. (3.5052 CM)

(7.62 MM)

2.75 IN. (6.985 CM)

369D292480

DRILL 0.020-0.023 IN.

SPLITTER DUCT

(0.508-0.584 MM) HOLE

NAS1303-4 BOLT

MS21042-3 NUT

AN960KD10 WASHER

PICK UP EXISTING

RIVET LOCATION

G21-4006A

Figure 901. Outlet Installation and Convenience Panel Modification

Page 902

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

(3).

Attach hose (25) to valve (23) with

F. Ducting Installation (−521)

clamp (26), and hose (31) to splitter

(Ref. Figure 906)

duct (28) with lockwire (CM702).

(4).

Attach hose (25) to lower outlet on duct

Consumable Materials

(27) with clamp (26), and second hose

(Ref. Section 91−00−00)

(31) to upper outlet on duct (27) with

Item

Nomenclature

lockwire.

CM318

Primer

(5).

Mount convenience panel (24) with

attached duct, valve, and hose to

(1). Perform installation as described (Ref.

bulkhead with with attaching hardware

Ducting Installation (-519), steps (1).

(32, 33).

thru (5). except replace splitter duct

(28) with duct (43) (Ref. Figure 905).

(6).

Measure distance between splitter duct

(2). Position duct (35) and outlet duct (36)

outlets. Using this dimension, position

on bulkhead. Match drill three

ducts (34, 35) and outlet ducts (36)

0.221-0.226 inch (5.6134-5.7404 mm)

parallel to each other on bulkhead.

holes common to clips into bulkhead.

Match drill six 0.221-0.226 inch

Remove outlet duct (36) and duct (35).

(5.6134-5.7404 mm) holes common to

Deburr and apply primer (CM318) to

duct clips to bulkhead. Remove ducts.

bare metal surfaces. Install rivnuts

Deburr and apply primer (CM318) to

(37).

bare metal surfaces. Install rivnuts

(37). Reconnect ducts (34, 35) to splitter

(3). Connect duct (43) to duct (35) and

duct (28) and attach ducts to bulkhead

secure to bulkhead and convenience

with screws (38) and washers (39).

panel with attaching hardware (29, 30,

38, 39, 40, 41, and 42).

(7).

Install outlets (36) on ducts (34, 35).

Match drill holes through outlet duct

(4). Attach hose (5) to duct (27) with clamp

clips into bulkhead (Ref. Figure 901).

(4).

Remove outlets. Deburr and apply

G. Cabin Heat Control Cable Initial

primer to bare metal. Install rivnuts

Installation

(37) were applicable. Install outlets

with attaching hardware (38, 39, 40, 41,

(Ref. Figure 201)

and 42).

(8).

Attach hose (5) to duct (27) with clamp

Consumable Materials

(4).

(Ref. Section 91−00−00)

Item

Nomenclature

E. Modification of Existing −517 to −519

CM425

Sealing compound

Configuration

(1). Remove clevis and jam nut assembly;

(Ref. Figure 906)

install grommet on cable, remove

existing plug button in canted frame

(1). The -517 heating system may be

structure, and route cable through hole

modified by replacing duct (3) with duct

in structure and hole in structure

(27), modifying the convenience panel,

fairing.

as illustrated, and by installing addi

tional hose (31), splitter duct (28), ducts

(2). Remove clamps from duct assembly and

(34 and 35), outlets (36), and associated

secure control handle and rigid portion

hardware.

of control cable assembly with clamps.

(2). Follow installation instructions (Ref.

(3). Tie control cable to existing tubing and

Ducting Installation (-519).

cables with straps.

Page 903

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(4). Secure grommet in structure and seal

(c). Tighten clevis jam nut. Remove

hole at structure fairing that cable

rigging pin from valve lever.

passes through, using adhesive

(CM425).

(d). Move pilot's heat control handle full

aft and forward several times to

(5). Secure lower end of cable assembly to

check ease of heat control operation.

structure with clamp and attaching

hardware.

(e). Tighten clamp nearest clevis end of

NOTE: Do not tighten clamp until after travel

control cable.

is checked.

(f). Reinstall aft bulkhead access cover,

(6). Install heat duct outer box to heat duct

interior trim, and left half of engine

and canopy frame with seven screws.

inlet fairing.

(7). Install jam nut and clevis as follows;

(g). After installation, adjust control

(a). Position heat control handle full

handle to be parallel with windshield

forward. Position lever on heat

glass.

control valve to open and insert a 1/8

inch (0.125 mm) rigging pin through

H. Weight and Balance

lever and valve boss.

(b). Loosen jam nut on control cable and

Weight and balance changes resulting from

adjust clevis so attach holes align

installation of heating system equipment are

with hole in valve lever. Install pin

listed in Table 901. After installation of

through clevis and valve lever. Install

heating system equipment, incorporate

washer and secure pin with cotter

changes in helicopter weight and balance

pin.

record (Ref. Sec. 08-10-00).

Table 901. Weight and Balance Data

Weight

Arm

Moment

Configuration

Pounds (kg)

Inches (cm)

in−lb (kg cm)

369H90020−517

Added

+8.2

(+3.719)

106.7

(271.02)

+874.9

(+1007.990)

Removed

0.0

−

Change

+8.2

(+3.719)

106.7

(271.02)

+874.9

(+1007.990)

369H90020−519

Added

+8.6

(+3.901)

110.1

(279−65)

+946.9

(+1090.942)

Removed

0.0

−

Change

+8.6

(+3.901)

110.1

(279−65)

+946.9

(+1090.942)

Page 904

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CSP-HMI-2

MAINTENANCE MANUAL

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

25-00-00 Equipment/ Furnishings

Description and Operation

1. Interior Furnishings Description

A. Upholstered Seat Furnishings Configuration

B. Mesh Seat Furnishings Configuration

C. Crew Upholstered Seating

D. Crew Mesh Seating

E. Passenger Upholstered Bench Seating

F. Mid Bench Seat (600N)

G. Upholstered Passenger Individual Seat

H. Passenger Mesh Seating

I. Seat Belts and Shoulder Harnesses (369D/E/FF - 500N)

J. Seat Belts and Shoulder Harness (600N)

K. Interior Trim

L. Floor Trim and Covering

M. Miscellaneous Furnishings

25-10-00 Upholstered Seats

Maintenance Practices

201

Upholstered Crew Seat Replacement

201

Upholstered Passenger Aft Bench Seat Replacement

201

Mid Bench Seat Assembly Replacement (600N)

201

A. Mid Bench Seat Removal

201

B. Mid Bench Seat Installation

201

Upholstered Passenger Individual Seat Replacement

201

Upholstered Seat Inspection

201

A. Upholstered Seat Cleaning

201

Upholstered Seat Repair

202

Optional Mid Business Seat Replacement (600N)

202

A. Business Seat Removal

202

B. Business Seat Installation

202

Figure 201. Upholstered Seat Installation (369D)

203

Figure 202. Upholstered Seat Installation (369E/FF - 500/600N)

204

Figure 203. Mid and Aft Seating Configuration (600N)

205

Figure 204. Mid and Aft Bench Seat Assembly Installation (600N)

206

Figure 205. Upholstered Passenger Individual Seat Installation (369D)

207

Figure 206. Mid-Cabin Business Seat Installation (600N)

208

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MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

25-15-00 Mesh Seats

Maintenance Practices

201

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

Initial Installation

901

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

Maintenance Practices

201

1. Seat Belts/Inertia Reel Description and Operation (369D/E/FF - 500N)

201

2. Seat Belts/Inertia Reel Description and Operation (600N)

201

3. Crew Seat Belt/Harness Cleaning

201

4. Seat Belt/Inertia Reel Replacement (369D/E/FF - 500N)

201

Figure 201. Seat Belt/Inertia Reel Installation (Sam Browne Style)

(369D)

202

Figure 202. Seat Belt/Inertia Reel Installation (Yoke Style) (369D)

203

Figure 203. Seat Belt/Inertia Reel Installation (Yoke Style)

(369E/FF - 500N)

204

5. Crew Seat Belt/Harness Replacement With Manual Lock Option

(369D/E/FF - 500N)

205

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TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

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

A. Seat Belt/Restraint Harness Removal

208

B. Seat Belt/Restraint Harness Installation

208

11. Seat Belt/Restraint Harness, Aft Passenger Seat, Replacement (600N)

208

A. Seat Belt/Restraint Harness Removal

208

B. Seat Belt/Restraint Harness Installation

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)

Maintenance Practices

201

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

Initial Installation

901

1. Seating/Belts (Four on the Floor) Initial Installation

901

A. Preparation for Installation

901

B. Removal of Existing Equipment

901

C. Seating and Belts Installation - General

901

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MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

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

906

Table 901. Weight and Balance Data

906

Figure 903. Seat Belt and Seat Assemblies Installation

(369D/E/FF - 500N)

907

Figure 904. Shoulder Straps and Fittings Installation

(369D/E/FF - 500N)

908

25-30-00 Interior Trim

Maintenance Practices

201

Interior Trim

201

A. Cyclic Stick Control Cover

201

B. Copilot's Inboard Collective Pitch Stick Cover

201

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

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

Interior Trim and Carpeting General Repair

209

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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MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

Figure 205. Boltaron Panel Repair

212

D. Bond and Rivet Patch Method

213

25-40-00 Miscellaneous Furnishings

Maintenance Practices

201

1. Crew Compartment Miscellaneous Furnishings Replacement

201

A. Stowage Box

201

B. Heat Duct

201

C. Foot Rest (L/H Command)

201

D. Ash Receiver and Cigarette Lighter Panel

201

2. Passenger Compartment Miscellaneous Furnishings Replacement

201

A. Convenience Panel Replacement (R/H Command)

201

3. Passenger Step Assembly Description

201

4. Passenger Step Assembly Inspection

201

5. Passenger Step Assembly Replacement

202

A. Passenger Step Assembly Removal

202

B. Passenger Step Assembly Installation

202

6. Passenger Step Assembly Repair

202

7. Miscellaneous Furnishings Inspection

202

8. Miscellaneous Furnishings Repair

202

Figure 201. Miscellaneous Furnishings (369D) (Sheet 1 of 2)

203

Figure 202. Miscellaneous Furnishings (369E/FF - 500/600N)

(Sheet 1 of 2)

205

Figure 203. Passenger Step Assembly (600N)

207

25-50-00 Cargo Hook

Fault Isolation

101

1. Cargo Hook Description

101

2. Cargo Hook Operation

101

3. Cargo Hook Fault Isolation

101

4. Wiring Diagrams

101

Table 101. Troubleshooting - Cargo Hook Installation

102

Table 102. Wire Chart, 369D/E/FF Right or Left Hand Command

102

Table 103. Wire Chart, 369E/FF T-Panel with Center Electrical Console,

R/H Command

103

Figure 101. Cargo Hook - Wiring Diagrams (Sheet 1 of 4)

104

Removal/Installation

401

1. Cargo Hook Replacement

401

A. Cargo Hook Removal

401

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MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

B. Cargo Hook Installation

401

Figure 401. Manual Release Cable Routing - Interior

403

Figure 402. Manual Release Cable and Electrical Wire Harness Routing -

Exterior

404

Figure 403. Cargo Hook Electrical Equipment Installation

405

Figure 404. Hook and Pad - Installation

406

Figure 405. Cargo Hook Manual Release Lever - Installation

407

Figure 406. Cargo Hook Release for 600N Helicopters

408

Inspection/Check

601

1. Cargo Hook Operational Check

601

2. Adjustment

601

3. Exterior Components Inspection

601

4. Interior Components Inspection

602

Initial Installation

901

1. Cargo Hook Initial Installation

901

A. Preparation for Installation

901

B. Helicopter Equipment Removal

901

C. Modification of Helicopter

901

D. Cargo Hook Provisions Installation

901

E. Electrical Components and Wiring Installation (Left and Right Hand

Command)

902

Table 901. Cargo Hook Relay Installation

902

Figure 901. Fuselage Skin Cutouts

903

F. Cargo Hook Installation

904

Figure 902. Relay and Bracket Installation Pilots Floor (369D/E/FF)

905

Table 902. VNE Card Installation

906

G. Helicopter Equipment Installation

906

Table 903. Cargo Hook Switch Installations - Stick Grip

906

H. Weight and Balance Data

907

Table 904. Weight and Balance Data

907

25-60-00 Emergency First Aid Kit

Maintenance Practices

201

1. Emergency First Aid Kit

201

2. Emergency First Aid Kit Contents Check

201

Figure 201. Emergency First Aid Kit

202

25-63-00 Hoist Passenger/Cargo

Maintenance Practices

201

1. Hoist Passenger/Cargo

201

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MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

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

202

Preparation for Hoisting Operations

205

Figure 202. Winch Cable, Cable Cutter, and Swivel Hook Replacement

(Sheet 1 of 2)

206

Hoist System Troubleshooting

208

Cyclic Stick Grip and Cyclic Stick Cable Cutter Switch (S600) Replacement

208

Hoist Assembly Replacement

208

A. Hoist Assembly Removal

208

B. Hoist Assembly Installation

208

Figure 203. Passenger/Cargo Door Retainer Installation

209

Winch Components Replacement

210

A. Winch Cable Replacement

210

B. Swivel Hook Replacement

211

C. Cable Cutter Replacement (Guillotine-Type)

212

Hoist System Operational Check

212

Hoist Equipment Inspection

213

Table 201. Troubleshooting Hoist System

214

Figure 204. Wiring Diagram - Hoist System (L/H Command)

214

Figure 205. Wiring Diagram - Hoist System (R/H Command)

215

Figure 206. Schematic Diagram - Hoist System Winch

216

Initial Installation

901

1. Hoist Passenger/Cargo Initial Installation

901

A. Preparation for 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

Table 901. Weight and Balance Data

909

Figure 903. Cable Antichafing Bar Installation

910

Page vii

25 Contents

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

EQUIPMENT/FURNISHINGS

DESCRIPTION AND OPERATION

1. Interior Furnishings Description

D. Crew Mesh Seating

The crew compartment is equipped with

Standard furnishings on the 369D/E/FF -

two-part seats. Each two-part seat consists of

500/600N Helicopters include seats in the crew

a seat back and a seat bottom constructed of

and passenger compartments, seat belts,

aluminum tubing frames with a nylon mesh

interior trim, floor trim and covering, and

covering and rubber pads cemented to the

other miscellaneous furnishing items.

frame mounting plates. The seat backs are

mounted on the Station 78.50 canted frame.

A. Upholstered Seat Furnishings

Seat bottoms are secured on top of the pilot's

Configuration

seat structure.

The helicopters are equipped with the basic

E. Passenger Upholstered Bench Seating

interior furnishings configuration. This

Passenger compartment seating is provided by

includes upholstered seats with a bench type

a bench type tubular steel structure furnished

in the passenger compartment and three

with upholstered cushions. The bench seat is

individual seats in the crew compartment. The

adjustable fore and aft as well as up and down,

center crew seat is removed for the dual

and may be folded or quickly removed when

controls option. Seat belts are provided at all

cargo space is required. All seat cushions are

seat locations. Interior trim finish is provided

either upholstered and trimmed with vinyl, or

throughout interior cabin enclosure.

may be all vinyl. Velcro strip fasteners secure

seat cushions in place.

The 600N helicopter comes equipped with a

mid position bench seat. At this position in the

F. Mid Bench Seat (600N)

passenger compartment, the mid seat can be

The mid bench seat provides additional three

positioned in either the forward or aft facing

abreast seating in the passenger area. This

configuration.

seat can be positioned in either the forward or

aft facing configuration. The seat belt/harness

B. Mesh Seat Furnishings Configuration

system is completely attached to the seat

structure for quick removal and installation of

The helicopters are equipped with a basic

the entire bench seat assembly.

interior furnishings configuration. This

includes two mesh seats and seat backs in the

G. Upholstered Passenger Individual Seat

crew compartment and two stowable mesh

seats in the passenger/cargo compartment.

Individual seat installations are also available

Seat belts are provided at all seat locations.

for the passenger compartment. The seat

Interior trim is provided for the passenger

frames are secured to the bulkhead attach

convenience panel, transmission, passenger aft

fittings with ball-lock pins. When each seat is

bulkhead, inboard collective pitch stick, and

folded, the flat surface of the seat back serves

cyclic controls.

as a barrier for cargo. Ref. P/N 369D290037 in

the optional equipment list for a further

C. Crew Upholstered Seating

description of individual passenger seat

installations (Ref. Table 202, Sec. 01-00).

The crew compartment on all models with

H. Passenger Mesh Seating

single controls has a three-place seating

arrangement. A two-place seating arrange

Two passenger seats are installed in the aft

ment is provided for optional dual controls.

compartment of the helicopter. The seats are of

Crew compartment seats consist of left and

welded tubular aluminum structure with

right side seat cushions and, if applicable, a

nylon mesh covers. The seats may be folded for

center seat cushion. Each seat has a seat back

clear cargo space and, if desired, are easily

cushion. Crew compartment seat structure is

removed by means of quick disconnect

an integral part of the helicopter fuselage.

attachments.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

I. Seat Belts and Shoulder Harnesses

K. Interior Trim

(369D/E/FF − 500N)

Interior trim used in the crew compartment

In the standard installation, Sam Browne type

and the passenger compartment is of thermo

seat belts with shoulder harness straps are

plastic material contoured to cover interior

installed at each seat position. Seat belts and

structure. Trim panels and covers provide

shoulder straps are fabricated from nylon

interior finish, compartment insulation and

webbing with sewn-in buckles and attach

mounting surfaces for convenience items, and

fittings. Lengths of seat belts and shoulder

certain optional equipment. Trim panels and

straps are not adjustable. Inertia reels are

covers are attached with Velcro fasteners and

provided to take up slack and allow free

with upholstery screws with rivnuts or isolator

movement of the seat occupant.

nut mounts on the fuselage structure.

Comfort clips are available for helicopters

L. Floor Trim and Covering

equipped with Sam Browne type seat belt

assemblies. The comfort clip is designed to

maintain proper strap tension and relieve

Interior floor trim and covering consists of

excessive pressure of the inertia reel shoulder

fire-resistant carpeting and two foot fairing

harness on the crew or passengers during

trim assemblies. The lower part of Sta. 78.50

flight.

bulkhead and access doors are also covered

with fire-resistant carpeting.

After each seat belt and shoulder harness

assembly is fastened and adjusted for individu

M. Miscellaneous Furnishings

al comfort and safety, the comfort clip is moved

from its original position next to the buckle

Miscellaneous furnishings include a stowage

and relocated by sliding up on the harness

compartment, heat duct, V_NE card holder, foot

strap as close as possible to the inertia reel.

rest assembly, helicopter checklist, operational

The clip prevents any further retraction of the

record holder, ashtrays, and LH/RH passenger

strap into the inertia reel, thus keeping a

step assemblies. The stowage compartment is

constant yet comfortable tension of the

under the right floor access door (Ref. Sec.

harness strap against the user. After each

52-50). The compartment has a uniformly-dis

flight, the comfort clip is to be returned to its

tributed load capacity of 50 pounds maximum

original location.

when optional avionics equipment is not

installed in the crew area underfloor compart

J. Seat Belts and Shoulder Harness (600N)

ment. The heat duct provides interior trim for

The crew seats in the helicopter utilize a

the canopy frame and mounting surface for the

four-point restraint harness that combines the

magnetic compass (Ref. Sec. 95-20). The V_NE

lap seat belts with double shoulder straps for

card holder is located on the left side of the

greater occupant security and comfort. Both

instrument panel. The helicopter checklist is

mid and aft passenger seats are equipped with

stored with the magnetic compass card in the

a three-point restraint system. The lap seat

map case. The operational record holder is

belt and shoulder strap are joined at the end

attached to the outboard side of the right

into a single unit for ease of attachment and

instrument panel fairing. Ashtrays and

convenience. In one motion, the lap and

cigarette lighters are provided in the lower

shoulder belts together can be attached to the

portion of the instrument panel and on the

seat buckle. All seat belt/harness systems are

back side of the station 78.50 canted bulkhead.

equipped with an automatic locking inertia

The removable passenger steps are attached to

reel mechanism.

the helicopter side jacking points.

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

UPHOLSTERED SEATS

MAINTENANCE PRACTICES

1. Upholstered Crew Seat Replacement

A. Mid Bench Seat Removal

(1). Remove quick release pins that attach

(Ref. Figure 201, Figure 202 and Figure 204)

seat support fittings to floor rails.

Upholstered Seats for the 369D/E/FF -

500/600N Helicopters are the same. The

(2). Remove seat assembly.

addition of the mid position bench seat is

unique to the Model 600N.

B. Mid Bench Seat Installation

(1). Clear seats of seat belts and shoulder

(1). Install seat assembly in aircraft.

straps.

(2). Align seat support fittings with floor

rails.

(2). Lift seat cushions away from fuselage

seat structure to release Velcro strip

(3). Install quick release pins to secure seat

and fasteners.

assembly to floor.

(3). To replace, position seat cushions so

4. Upholstered Passenger Individual Seat

that Velcro fastener strips mate. Apply

Replacement

slight pressure to secure seat cushions

in place.

(Ref. Figure 205)

(1). Clear seat of seat belts and shoulder

2. Upholstered Passenger Aft Bench Seat

straps.

Replacement

(2). Remove ball-lock pins from bulkhead

(Ref. Figure 201 or Figure 202)

attach fittings.

(1). Clear seats of seat belts and shoulder

(3). To replace, position seats so that

straps.

quick-disconnect pins align with

bulkhead attach points and lock seats

(2). Release seat quick-disconnect fittings

in place.

at bulkhead, then at floor points.

5. Upholstered Seat Inspection

NOTE: For height adjustment, install ball-lock

(Ref. Figure 201, Figure 202 and Figure 204)

pins in desired position at support legs and

bulkhead fittings. For fore and aft adjust

(1). Inspect upholstery material for cuts,

ment, move and secure seat back at desired

loose stitching or other unserviceable

position on lower frame.

condition.

(3). To replace, position bench seat so that

(2). Inspect Velcro fastener strips for

quick-disconnect fittings align with

security of attachment and condition.

floor and bulkhead attach points.

(3). On passenger seat structure, inspect

quick-disconnect mechanisms for

(4). Lock seat in place, first at floor fittings

proper operation or damage that may

then at bulkhead fittings.

prevent positive locking.

3. Mid Bench Seat Assembly Replacement

A. Upholstered Seat Cleaning

(600N)

(Ref. Sec. 20-20-00, Fuselage Interior Trim

(Ref. Figure 204)

and Upholstery Cleaning)

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MD Helicopters, Inc.

MAINTENANCE MANUAL

6. Upholstered Seat Repair

adjustable seats attached through four seat

tracks that allow seat location adjustment over

a 10 inch span when seats are facing forward.

Consumable Materials

(Ref. Section 91−00−00)

NOTE:

Item

Nomenclature

D With the seats in the full aft position and

CM219

Methyl-ethyl-ketone

facing forward, the rear passenger seats

CM405

Adhesive

become unusable for passenger seating.

D The seats are removable and may be

(1). Lapstitch frayed or worn upholstery.

placed in the aft facing position.

MEK solvent is flammable.

D In the aft facing position, only two seat

WARNING

Use only in well-ventilated

locations are available.

area and away from heat and flame.

A. Business Seat Removal

NOTE: Loosened Velcro strips may be reacti

vated for adhesion by wiping original adhe

(1). Remove quick release pins that attach

sive film with MEK (CM219).

seat support fittings to floor rails.

(2). Replace unserviceable Velcro fastener

(2). Remove seat assembly.

strips. Install new Velcro strips to mate.

Bond in place with adhesive (CM405).

B. Business Seat Installation

(3). Make minor welded or riveted sleeve-

(1). Install seat on tracks with forward

type repairs on tubular structure

guide pin in track cutout first.

according to FAA AC 43.13-1B Inspec

tion and Repair for Standard Sheet

(2). Once seat guide pin is in track, slide

Metal Repair.

seat forward until 2 rear guide pins are

in the track cutouts.

7. Optional Mid Business Seat Replacement

(600N)

(3). When installing seat facing aft, tilt

(Ref. Figure 206) This option replaces the

seat-back full forward during

standard mid bench seat with two fore and aft

installation.

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CSP-HMI-2

MAINTENANCE MANUAL

MESH SEATS

MAINTENANCE PRACTICES

1. Crew/Passenger Mesh Seats

(5). Insert vertical legs into floor structure

and secure.

(Ref. Figure 201 thru Figure 203) The typical

mesh seat installation consists of lightweight

(6). If removed, reinstall seat belts and

nylon mesh-covered seats installed in the crew

shoulder harness.

and passenger compartments. For description

4. Passenger Mesh Seat Adjustment

of the various installations, consult the

Optional Equipment List (Ref. Table 202,

(1).

(Ref. Figure 203) The height of the

01-00-00). Some installations have a bench-

bench seat may be adjusted by install

type passenger seat, some have individual

ing the ball lock pins in any of the three

passenger seats, and others have no passenger

holes in the vertical support legs, and

seats at all. Installations differ depending on

by installing the ball lock pins that

whether the helicopter has a high shoulder

support the horizontal legs in any of the

beam or a low shoulder beam, and various seat

three holes in each aft support fitting.

colors.

(2).

For the fore and aft adjustment of the

2. Crew Mesh Seat Replacement

bench seat, insert the seat back legs

into either pair of holes in the seat

(Ref. Figure 201)

frame.

NOTE: Identify and retain all components and

(3).

(Ref. Figure 202) The height of the

hardware removed from the helicopter.

individual seats may be adjusted by

inserting lock pins into any of three

(1). Remove or clear area of seat belts and

pairs of holes in the aft support fittings

shoulder straps.

to secure the horizontal legs of the seat.

(2). Remove installing hardware and lift

(4).

The individual seats may be folded up

seat bottoms and seat backs from the

out of the way to permit cargo storage

helicopter.

by first releasing the quick-disconnects

at the forward legs and folding the legs

(3). To replace, install seat backs and seat

aft. The seat back is then folded

bottoms with attaching hardware.

forward at the upper hinge point. As

the seat is swung up at the aft fitting,

(4). When removed, reinstall seat belt and

the seat back and the seat bottom are

shoulder harness.

rotated forward and down at the lower

hinge point.

3. Passenger Mesh Seat Replacement

5. Crew Mesh Seat Inspection

(Ref. Figure 202 or Figure 203)

(1). Inspect upholstery material for cuts or

NOTE: Identify and retain all components and

other unserviceable conditions.

hardware removed from helicopter.

(2). Check rubber pads cemented to each

(1). Remove or clear area of seat belts and

mounting plate.

shoulder straps.

6. Passenger Mesh Seat Inspection

(2). Release seat quick-disconnects at aft

fittings, then at floor points.

(1). Inspect upholstery material for cuts or

other unserviceable conditions.

(3). Lift seats from helicopter.

(2). Inspect quick-disconnect mechanisms

(4). To replace, attach horizontal support

for proper operation and for damage

legs to aft attach fittings with lockpins.

that may prevent positive locking.

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MAINTENANCE MANUAL

7. Mesh Seats Cleaning

(1). Lap stitch frayed or torn nylon web

bing, or replace if damaged beyond

(Ref. Sec. 20-20-00, Fuselage Interior Trim

repair.

and Upholstery Cleaning)

(2). Install new rubber pads.

8. Mesh Seats Repair

(3). Clean seat mounting plate with clean

cloth dampened with solvent (CM234).

Consumable Materials

(4). Apply cement (CM405) and attach pad

(Ref. Section 91−00−00)

to seat mounting plate.

Item

Nomenclature

(5). Replace damaged nutplates.

CM234

Solvent, dry-cleaning

CM405

Adhesive

(6). Minor weld repairs may be performed

according to FAA AC 43.13-1B Inspec

tion and Repair for Standard Sheet

Repair of seats is limited to the following:

Metal Repair.

SEAT BACK

AFT SUPPORT FITTING AND

HEIGHT ADJUSTMENT

FRAME

FLOOR STRUCTURE

NYLON MESH

BALL-LOCK PIN

SUPPORT LEG AND

FORE AND AFT

HEIGHT ADJUSTMENT

ADJUSTMENT HOLES

RELEASE PIN

G25-1005

Figure 203. Passenger Bench Mesh Seat Adjustment

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HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369D/E/FF-500/600N HELICOPTERS (ISSUED: 1990) - page 7