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

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

MISCELLANEOUS FURNISHINGS

MAINTENANCE PRACTICES

1. Crew Compartment Miscellaneous

between foot rest and bulkhead for correct

Furnishings Replacement

four-point contact.

Methods for removal and installation are

D. Ash Receiver and Cigarette Lighter Panel

obvious for most miscellaneous furnishing

(1). The cigarette lighter panel may be

items. Some maintenance instructions are

removed by releasing four turnlock

provided in the following procedures.

fasteners.

Crew compartment furnishings for the 600N

(2). Disassembly of the cigarette lighter and

Helicopter are the same as for the 369D/E/FF

panel for maintenance purposes is

- 500N Helicopters.

shown in the figure.

A. Stowage Box

2. Passenger Compartment Miscellaneous

Furnishings Replacement

Access to stowage box is thru crew compart

ment right side floor access door (Ref. Sec.

Methods for removal and installation are

52-50-00).

obvious for most miscellaneous furnishing

items. Some maintenance instructions are

Consumable Materials

provided in the following procedures.

(Ref. Section 91−00−00)

Passenger compartment furnishings for the

Item

Nomenclature

600N Helicopter are the same as for the

CM117

Grease

369D/E/FF - 500N Helicopters except, where

applicable, panels and ducting is 30 inches

longer.

NOTE: Helicopters equipped with certain op

tional communications and avionics instal

A. Convenience Panel Replacement (R/H

lations do not have stowage box installed.

Command)

When installing replacement stowage box,

(1). Remove attachment screws. Lower

cover screwheads with tape (CM717).

panel and disconnect any wiring and

heat valve connectors before removing

B. Heat Duct

panel.

The heat duct consists of an upper and lower

(2). Reinstall using reverse procedure.

section with a magnetic compass mounted on

the lower section just above the instrument

3. Passenger Step Assembly Description

panel. The anti-icing control (Ref. Sec.

75-10-00) and cabin heat control (Ref. Sec.

(Ref. Figure 203) Due to the extended fuselage

21-40-00) mount on the upper section of the

of the 600N Helicopter, the addition of an

heat duct. Removal of magnetic compass is not

elongated passenger step is unique to this

required for removal of heat duct. However,

aircraft. The step is secured at two positions

wiring to the light must be disconnected at the

on each side of the fuselage, as compared to

splices.

one position on the 369D/E/FF - 500N

Helicopters. The step is available in either a

C. Foot Rest (L/H Command)

high or low step configuration depending on

the landing gear option installed.

For access to foot rest attaching hardware,

remove stowage box. Position replacement foot

4. Passenger Step Assembly Inspection

rest on floor support bulkhead and install

attaching hardware. When necessary, use

(1). Inspect step attach point(s) for security

additional thin aluminum washers to shim

of installation and general condition.

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MAINTENANCE MANUAL

(2). Inspect ”no skid” surface of step for

(1). To replace worn or lost safety-walk

general condition. Replace or reattach if

tape, carefully scrape away damaged

worn excessively.

tape. Remove all residual adhesive by

wiping with naphtha (CM220) wetted

5. Passenger Step Assembly Replacement

cloth.

A. Passenger Step Assembly Removal

(2). Install new tape (CM724) and press

(1). Gain access to passenger step assembly

firmly into place. Expel air bubbles by

attaching hardware under floor cover

pressing down tape from center out to

ing of passenger/cargo compartment.

the edges.

(2). Remove quick release pin(s) that secure

step assembly in mounting hole(s).

7. Miscellaneous Furnishings Inspection

(3). Remove step assembly.

(1). Inspect for cracks, breaks or other

B. Passenger Step Assembly Installation

unserviceable condition.

(1). Align and insert passenger step

assembly into mounting hole(s) in

(2). Inspect helicopter checklist and

fuselage.

magnetic compass card for condition

(2). Insert quick release pin(s) to secure

and legibility.

step assembly.

(3). Inspect for loose, damaged or missing

(3). Secure floor covering in passenger/cargo

rivnuts and other attaching hardware

compartment.

as applicable.

6. Passenger Step Assembly Repair

The passenger step has black, non-slip,

8. Miscellaneous Furnishings Repair

pressure-sensitive, safety-walk tape applied

to the upper surface of the step plate.

(1). Repair cracks or breaks in thermoplas

tic material (Ref. Sec. 20-30-00,

Consumable Materials

Boltaron Trim Panels Repair).

(Ref. Section 91−00−00)

Item

Nomenclature

(2). Perform minor weld and rivet repairs

CM220

Naphtha aliphatic

according to FAA AC 43.13-1B Inspec

CM724

Tape, non-slip

tion and Repair for Standard Sheet

Metal Repair.

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CSP-HMI-2

MAINTENANCE MANUAL

CARGO HOOK

FAULT ISOLATION

1. Cargo Hook Description

located on the left side of the hook body.

Regardless of the method used to release the

The cargo hook provides a means of transport

hook, the hook will return to the closed

ing external cargo. The cargo hook installation

(retracted) position.

consists of a cargo hook assembly, electrical

hook release equipment and backup emergen

3. Cargo Hook Fault Isolation

cy manual release equipment. The cargo hook

(Ref. Table 101) Cargo hook system malfunc

assembly is externally attached to the center

tions might be caused by any one of several

beam of the helicopter at Station 99.325. The

general conditions which are easily corrected.

cargo hook operational rating (external load

Before starting specific troubleshooting

limit) is 2000 pounds.

procedures, make the following checks and

The cargo hook and swivel assembly are

take indicated action for troubleshooting

mounted on the helicopter center beam by four

procedures.

bolts at Station 99.325. The swivel assembly

(1). Refer to applicable wiring diagram and

allows the cargo hook to swing in any direction

check for loose or damaged wires and/or

through a 30-degree arc.

terminals and connectors; reconnect or

replace as required.

2. Cargo Hook Operation

(2). Check for damaged interconnect wires

The cargo hook is normally operated electrical

and/or equipment (Ref. Chap. 96).

ly by pressing the CARGO HOOK switch on

the pilot's cyclic stick grip (Ref. Figure 403).

(3). Check for loose or defective terminal

Actuation of the CARGO HOOK switch

board connections; repair or replace as

energizes a solenoid in the cargo hook. The

required.

maximum electrical current required to

operate the cargo hook solenoid is 14 amperes

(4). Check for loose ground wires.

at 28 Vdc. however, the solenoid is designed to

(5). Make certain circuit breaker is pushed

operate with voltage as low as 23 Vdc. Actua

to full in (closed) position.

tion of the cargo hook solenoid releases the

hook (load beam).

(6). Check system power source.

In the event of an electrical malfunction, the

4. Wiring Diagrams

hook can be released (opened) by pulling a

manual release cable lever attached to the

(Ref. Figure 101) Wiring diagrams of the

pilot's cyclic stick (Ref. Figure 401). The

various cargo hook electrical system circuits

manual release cable releases (opens) the

have been illustrated. Wire charts are provided

cargo hook in the same manner as the electri

in Table 102 and Table 103. For helicopter

cally operated solenoid. The hook can be

electrical system interface information refer to

released for testing or by cargo personnel by

DC Electrical Load Distribution (Ref. Chap.

turning (clockwise) a cargo hook release knob

96).

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MAINTENANCE MANUAL

Table 101. Troubleshooting − Cargo Hook Installation

Symptom

Probable Cause

Corrective Action

NOTE: Following procedures are to be performed with electrical system power on and CARGO HOOK circuit

breaker (CB603) closed.

Hook release operates manually (by

Defective hook ground

Replace hook assembly.

lever) but fails to operate electrically

Defective ground

Secure ground wire.

(by HOOK RELEASE switch).

Defective HOOK RELEASE switch Replace switch.

Defective CARGO HOOK circuit

Replace circuit breaker (CB603).

breaker (CB603)

Hook release operates electrically

Manual release cable housing

Reset adjustment nut at lever−end

(by HOOK RELEASE switch) but

adjusted incorrectly at lever.

of cable housing.

fails to operate manually (by lever).

Defective hook assembly

Replace hook assembly.

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

From

Wire No.*

Terminal

Termination

Terminal

Termination

M532A20

TB1−18D

MPCM20M−H2**

K104−X1

Solder

TB1−19B

MPCM20M−H2**

K104−X1

Solder

M531A16

TB3−1D

AYH11−H1**

K104−D2

Solder

M523A20N

J104−X2***

Solder

E24

MS25036−103

M522C16

K104−D1***

Solder

TB3−4A

AYH14−H1**

M520AA16

SP92−B

32447

TB3−1C

AYH14−H1**

J616−q

Crimp

TB3−1C

AYH14−H1**

M520A16

CB603−2

MS25036−106

SP92−A

32447

CB603−2

MS25036−106

P616−q

− −

M520B20

TB1−18C

MPCM20M−H2**

TB3−1D

AYH14−H1**

TB1−18A

MPCM20M−H2**

TB3−1D

AYH14−H1**

TB1−19A

MPCM20M−H2**

TB3−1D

AYH14−H1**

*(Ref. Figure 101 sheets 1 & 2) for applicable wiring diagrams.

**Burndy Corp., Norwalk, Conn.

***K312−X2, _D1 for helicopters equipped with 369D24153 ‘‘Tee’’ console.

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CSP-HMI-2

MAINTENANCE MANUAL

Table 103. Wire Chart, 369E/FF T−Panel with Center Electrical Console, R/H Command.

From

Wire No.*

Terminal

Termination

Terminal

Termination

M520AA16

K104−X2

Solder

E24

MS25036−103

M532A20

K104−X1

Solder

TB1−8F

M39029/22−192

M531A16

K104−D2

Solder

TB3−1C

M39029/22−193

M531B16

K104−D1

Solder

TB3−8B

M39029/22−193

M520B20

TB3−1E

M39029/22−193

TB1−8E

M39029/22−192

M523C20N

J605−C

MS3193A16−16A

E20

M7928/1−24

M520A16

CB118−2

M7928/1−41

P616− Q

M39029/31−228

M520AA16

J616− Q

M39029/32−247

TB3−1

M39029/22−193

*(Ref. Figure 101 sheet 3) for applicable wiring diagram.

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MAINTENANCE MANUAL

P605J

TB3-4

TB1-18

M522D16

M522C16

M523A20

TB3-1

M523B16N

E20

M531A16

M520B20

K104

SP92

M523BB20

M520AA16

B A

CARGO HOOK

CB603

CR3

369D STANDARD CYCLIC STICK GRIP

M520A16

HOOK RELEASE

15A

3-1149, 1151-1184

SWITCH (S114)

P130J

10-20

M522A20

E24

M523A20N

9-20

M521E20

P605J

TB3-4

TB1-18

M522D16

M522C16

M523A20

TB3-1

M523B16N E20

K104

M531A16

M520B20

SP92

C M520AA16

B A

CARGO HOOK

CB603

CR3

M520A16

369D OPTIONAL CYCLIC STICK GRIP

HOOK RELEASE

15A

RIGHT OF LEFT HAND COMMAND

SWITCH (S4)

P130J

10-20

M520C20

E24

M523A20N

9-20

M522A20

P605J

NOTE 1

TB3-4

TB1-19

M522D16

M522C16

M523A20

TB3-1

M523B16N

E20

M531A16

M520B20

K104

J616P

M523BB20

C M520AA16

CARGO HOOK

CB603

CR3

369D RIGHT HAND COMMAND

M520A16

HOOK RELEASE

15A

CYCLIC STICK GRIP

SWITCH

3-1149, 1151-1184

P109J

WHT/VIO

OR BLUE

M521F20

E24

M523A20N

WHT/GRAY

M520F20

NOTES:

OR GRAY

369D294402 CENTER ELECTRICAL CONSOLE:

P109J

TB1-19

-703 WITH ARMAMENT PANEL

-701 WITHOUT ARMAMENT PANEL

M521F20

NOTE 2

369D294500 CENTER ELECTRICAL CONSOLE

M520F20

WITH VHF-FM RADIO SET AND ASW EQUIPPED

HELICOPTERS.

G25-5005-1

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

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CSP-HMI-2

MAINTENANCE MANUAL

CARGO HOOK RE

J130P

TB1-12

LEASE SWITCH

J109-A (REF)

10 OR BLU

M522A20

J109-B (REF)

9 OR GRY

M521E20

M520B20

M532A20

TB3-1

J9P

K104

M520AA16

M531A16

CR3

CB603

E24

M520A16

15A

M523A20N

CARGO HOOK RELEASE

TB3-4

P605J

M522C16

M522D16

BLK

M523BB20N

369D CYCLIC STICK GRIP

LEFT OR RIGHT HAND COMMAND

E20

M523B16N

WHT

1150, 1185-1204

TB1-12

E24

K312

M523A20

M520B20

CR3

J9P

M531A16

D C

M520AA16

TB3-1

CB603

M531B16

15A

J605P

HOOK RELEASE

SWITCH (PILOT'S)

M520A16

M522D16

J130P

TB3-4

M523C20N

M522A20

M521E20

HOOK RELEASE

SWITCH (CO-PILOT'S)

CARGO HOOK

E20

J109P

ASSEMBLY

M522C20

369E/FF CYCLIC STICK GRIP

M521G20

LEFT OR RIGHT HAND COMMAND

G25-5005-2

Figure 101. Cargo Hook − Wiring Diagrams (Sheet 2 of 4)

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MD Helicopters, Inc.

MAINTENANCE MANUAL

TB3-1

PILOT

CB118

P616J

J109P

REF

M520A16

M520AA16

15A

TB1-8

M522C20

M531A16

M521G20

E M520B20

CO-PILOT

J130P

M532A20

M522A20

M J

M521E20

CR3

M523A20N

E24

16 AWG BUS WIRE

TB3-8

J605P

M531B16

B A

M522D16

M523B16N

M523C20N

K104

HOOK

369E/FF RIGHT HAND COM

MAND CONFIGURATION

E20

G25-5005-3

Figure 101. Cargo Hook − Wiring Diagrams (Sheet 3 of 4)

HOOK ASSY

CB603

P/J1202

J/P605

15A

M1015A16

M1015B16

M1015C16

M1105A22

M1107A22

M1020A16N

M1021A20N

K201

HOOK RELAY

E36

M1179A22N

E37

J109

P109

2M1106B22

HOOK

2M1106A22

P130

J130

(RIGHT COLLECTIVE GRIP)

1M1106B22

HOOK

1M1106A22

TB200-4

(LEFT COLLECTIVE GRIP)

EFFECTIVE 369E 384 & SUBS

AND 369FF 076 & SUBS

TB200-4

G25-5005-4

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

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MAINTENANCE MANUAL

CARGO HOOK

REMOVAL/INSTALLATION

1. Cargo Hook Replacement

cable, installation and adjustment of the

manual release lever as follows:

A. Cargo Hook Removal

(1).

Secure base of cargo hook assembly

Remove the cargo hook assembly including the

(Ref. Figure 404) to fuselage underside

cargo hook manual release cable and electri

with bolts and washers.

cal harness as follows:

(2).

Remove protective cap from cargo hook

electrical receptacle (J605); check that

(1).

Remove cotter pin (Ref. Figure 405),

BATTERY switch is in OFF position

washer, and slotted bushing from

and connect plug (P605) to receptacle.

manual release lever on pilot's cyclic

stick.

(3).

Insert free end of hook manual release

cable through elongated hole adjacent

(2).

Loosen locking nut securing adjustment

to electrical receptacle (Ref.

nut shaft to release lever bracket.

Figure 402). Push manual release cable

up into fuselage and insert cable

(3).

Remove screws (Ref. Figure 401), nuts,

through hole in pilot's floor.

washers, and clamps securing manual

release cable to cyclic stick.

(4).

Loosely attach harness and manual

release cable using clamps (Ref.

(4).

Remove adjustment nut shaft (Ref.

Figure 402) screws, washers, and nuts.

Figure 405) from release lever bracket.

Adjust harness and cable to allow

sufficient slack for hook to swing 30

(5).

Loosen dust cover from pilot's cyclic

degrees conically from centerline

stick control trim cover (Ref. Sec.

without creating strain on harness and

25-30-00).

cable. Arrange harness and cable to

(6).

Remove passenger/cargo compartment

form smooth flow to cutouts in fuselage

left foot fairing trim (Ref. Sec.

skin; tighten clamps. Install tie straps

25-30-00).

approximately as shown (Ref.

Figure 402).

(7).

Carefully push manual release cable

NOTE: The 600N helicopters equipped with

(Ref. Figure 401) down through grom

emergency floats require the manual re

mets in pilot's floor and fuselage skin.

lease handle to be mounted on the collective

Do not pull on cable housing.

stick (Ref. Figure 406).

(8).

Remove cargo hook electrical harness

(5). Loosely attach manual release cable to

plug from receptacle in fuselage; install

cyclic stick with clamps, screws,

protective caps on receptacle and plug.

washers, and nuts (Ref. Figure 401).

(9).

Remove clamps (Ref. Figure 402)

(6). Engage approximately half of the

securing cable and harness to clips on

threads on the manual release cable

fuselage underside.

adjustment nut shaft into the bracket

portion of the manual release lever

(10).

Remove four bolts (Ref. Figure 404)

assembly (Ref. Figure 405).

securing cargo hook base to attach

holes in fuselage keel.

(7). Engage swaged ball on release cable in

lever bushing (Ref. Figure 405). Secure

B. Cargo Hook Installation

bushing with washer and cotter pin.

Installation of the cargo hook kit consists of

(8). Attach manual release lever assembly

attaching the hook, and electrical/manual

to cyclic stick with clamp and screws.

release cables on the underside of the helicop

Adjust cable and/or release lever as

ter, routing and securing the manual release

shown (Ref. Figure 405).

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MAINTENANCE MANUAL

(9). Tighten three sets of clamps securing

(12). Install grommet (Ref. Figure 401) in

release cable to cyclic stick.

crew compartment floor cutout.

(10). Perform adjustment/test of cargo hook

(13). Install grommet (Ref. Figure 402) in

installation.

elongated hole in fuselage lower skin

(11). Readjust cable lever (Ref. Figure 405)

and doubler.

as required to obtain smooth consistent

(14). Safetywire manual release lever clamp

release of hook.

screws with lockwire (Ref. Figure 405).

NOTE: The manual release lever clamp may be

loosened and the lever assembly moved on

cyclic stick to simplify adjustment, provid

ing the 2.250 ±0.250 inch (5.715 ±0.635 cm)

dimension limit is maintained

(Ref.

Figure 405).

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MAINTENANCE MANUAL

CARGO HOOK

MANUAL RELEASE CABLE

AND ELECTRICAL HARNESS

STATION

99.325

NOTE 4

BUTT LINE 00

(CENTERLINE)

5.5 ±0.5 INCHES

11.5 ±0.5 INCHES

STRAP (NOTE 3)

CREW COMPARTMENT

ELECTRICAL WIRE HARNESS

FLOOR

STRAP

FUSELAGE

GROMMET

SKIN LINE

STATION

84.79

MANUAL RELEASE CABLE

STRAP

CANTED STATION 78.50

ELECTRICAL

EXTERIOR ATTACHMENT OF MANUAL

WASHER

RECEPTACLE

RELEASE CABLE AND ELECTRICAL

WIRE HARNESS

CLAMP (ELECTRICAL)

CLIP

NOTES:

LEFT HAND COMMAND ILLUSTRATED. RIGHT HAND COMMAND

CLAMP

DIMENSIONS THE SAME EXCEPT ON OPPOSITE SIDE.

NUT

(MANUAL)

EXISTING RIVET LOCATION AT STATION 84.79.

P4 HUCK RIVET MAY BE USED INSTEAD AT STATION 84.79.

SCREW

HARNESS AND CABLE TIED TOGETHER MIDWAY BETWEEN

STATION 84.79 AND HOOK ASSEMBLY.

RIVET (NOTES 1, 2)

MAINTAIN SUFFICIENT SLACK IN NOTED SECTION OF CABLE

AND HARNESS TO ALLOW HOOK TO SWING 30 DEGREES

CONICALLY FROM CENTERLINE WITHOUT CREATING STRAIN

CLAMP ATTACHMENT

ON CABLE AND HARNESS.

(TYPICAL)

G25-5001

Figure 402. Manual Release Cable and Electrical Wire Harness Routing − Exterior

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MAINTENANCE MANUAL

DECAL

FUSELAGE LOWER

SKIN SURFACE

NEOPRENE PAD

0.090 X 1.75 X 4.0 IN.

(0.229 X 4.445 X

10.16 CM) (NOTE)

NEOPRENE PAD

0.090 X 1.75 X 1.75

WASHER (4 PLACES)

IN. (0.229 X 4.445 X

4.445 CM) (NOTE)

BOLT (4 PLACES)

EXTERNAL RELEASE

(TURN CLOCKWISE)

ELECTRICAL WIRE

HARNESS

SWIVEL

STA 99.325

KEEPER

1.62 ±0.12 IN.

(4.1148 ±0.3048 CM)

1.12 ±0.12 IN.

MANUAL RELEASE CABLE

(2.8448 ±0.3048 CM)

HOOK (LOAD BEAM)

1.00 ±0.12 IN.

(2.54 ±0.3048 CM)

LONGITUDINAL

CENTERLINE OF

FWD

4-HOLE LAYOUT

1.88 ±0.12 IN. (4.7752 ±0.3048 CM)

2.00 ±0.12 IN.

(5.08 ±0.3048 CM)

3.75 ±0.12 IN.

(9.525 ±0.3048 CM)

(2 PLCS)

LATERAL CENTERLINE

NOTE:

OF 4-HOLE LAYOUT

PADS PREVENT FUSELAGE SKIN DAM

AGE AT HOOK CONTACT POINTS.

G25-5003A

Figure 404. Hook and Pad − Installation

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CSP-HMI-2

MAINTENANCE MANUAL

20° (NOTE 2)

CARGO HOOK MANUAL RE

LEASE LEVER ASSEMBLY

SLOTTED BUSHING

(NOTE 5)

CARGO HOOK

RELEASE CABLE

2.250 ±0.250

INCHES

POSITIONING LEVER ON STICK

CLAMP

LOCKWIRE

HOOK-ENGAGED LEVER

POSITION (NOTES 3, 6)

LOOKING AFT AND DOWN

CARGO HOOK

RELEASE LEVER

BALL TERMINAL

COTTER PIN

(NOTE 1)

LOCKING NUT

(NOTE 4)

WASHER

NOTES:

CABLE BALL TERMINAL RETAINED IN SLOTTED BUSHING OF RELEASE LEVER.

APPROXIMATE ANGULAR POSITION OF LEVER REQUIRED FOR

CONVENIENCE AND RELEASE OF CARGO HOOK.

CABLE BALL TERMINAL AFT TRAVEL SHOULD BE APPROXIMATELY

ADJUSTMENT

1/2 INCH TO RELEASE HOOK.

NUT (NOTE 4)

WITH LOCKING NUT LOOSENED, TURN ADJUSTMENT NUT TO PULL RELEASE

RELEASE

LEVER TO FULL FORWARD (HOOK ENGAGED) POSITION WITH SLIGHT

BRACKET

TENSION ON CABLE; TIGHTEN LOCKING NUT. IF REQUIRED, ADJUST

POSITION OF LEVER ASSEMBLY ON CYCLIC STICK.

LOOKING INBOARD FROM

BUSHING 369H92631 MAY BE USED AS ALTERNATE.

LEFT SIDE OF HELICOPTER

LEVER SHOULD NOT MOVE FROM HOOK-ENGAGED POSITION WHEN

CYCLIC STICK IS MOVED THROUGH FULL TRAVEL IN ALL DIRECTIONS.

G25-5004

Figure 405. Cargo Hook Manual Release Lever − Installation

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CSP-HMI-2

MAINTENANCE MANUAL

CARGO HOOK

INSPECTION/CHECK

1. Cargo Hook Operational Check

Cargo hook must remain

WARNING

closed while moving

Perform the following operational check

through all positions of extreme travel

procedure whenever it is necessary to verify

fore and aft as well as side-to-side.

that the cargo hook system is operating

(8). Grasp load ring and pull downward

properly:

while moving cargo hook manually full

travel side-to-side. Ensure hook (load

(1). Place battery switch in BATTERY

beam) remains in locked position.

position.

2. Adjustment

(2). Check that CARGO HOOK/HOOK

Adjust the manual release cable so that the

circuit breaker is pressed to full in

2.250 ±0.250 inch (5.715 ±0.635 cm) dimension

position (Ref. Figure 402).

shown (Ref. Figure 405) is maintained.

NOTE: Cargo load rings (or equivalent check

3. Exterior Components Inspection

tool) with a maximum cross-section thick

On cargo hooks, manufac

ness of 3/4 inch can be used for testing or for

WARNING

tured by Breeze-Eastern,

cargo transport operations.

Model 2A20B, P/N 17149-1 thru -5, en

sure Warning Plate P/N 13830-1 is at

(3).

Push cargo load ring forward into hook

tached to the manual release side of the

throat (Ref. Figure 404); keeper should

cargo hook. If Warning Plate is not

permit easy entrance to hook throat.

installed, contact Breeze-Eastern for

Warning Plate and installation instruc

(4).

Pull aft and downward on load ring;

tions.

hook must remain in locked position.

(1).

Make certain that neoprene pads (Ref.

Figure 404) are securely bonded to skin.

(5).

Rotate external release knob located on

Check pads for excessive wear.

left side of cargo hook body, while

pulling downward on load ring; hook

(2).

Verify security of four bolts attaching

(load beam) bar should drop and release

hook assembly to fuselage (Ref.

load ring.

Figure 404); examine hook assembly for

damage or excessive wear. Check that

(6).

Reinsert load ring in hook throat. Pull

hook body swivels freely in all direc

CARGO HOOK EMERGENCY RE

tions.

LEASE (manual release) lever on pilot's

(3).

Verify security of clips and clamps

cyclic stick while load ring is being

attaching electrical wire harness and

pulled downward; hook (load beam)

manual release cable housing to

should release load ring. Reinsert load

fuselage (Ref. Figure 402).

ring and move pilot's cyclic stick to all

extreme positions; CARGO HOOK

(4).

Verify presence and security of grom

EMERGENCY RELEASE lever must

met (Ref. Figure 401) through which

not move from hook-engaged position

manual release cable passes at fuselage

and hook load beam must remain in

skin.

locked position.

(5).

Check electrical wire harness for cuts,

wear, and skinned insulation.

(7).

Press CARGO HOOK switch on pilot's

cyclic stick grip (Ref. Figure 403) while

(6).

Examine manual release cable housing

load ring is being pulled downward;

for nicks, cuts, kinks, dents, or general

hook load beam should release load

damage that would restrict movement

ring.

of cable within housing.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

Interior Components Inspection

NOTE: The 600N helicopters equipped with

emergency floats require the manual re

lease handle to be mounted on the collective

(1). Verify security of electrical receptacle

stick (Ref. Figure 406)

(J605) at fuselage connection (Ref.

Figure 401).

(6). Verify security of clamps attaching

manual release cable housing to pilot's

cyclic stick (Ref. Figure 401); check for

(2). Examine electrical wire harness for

damage to manual release cable

cuts, wear, or skinned insulation.

housing that might restrict movement

of cable.

(3). Check manual release cable housing for

nicks, cuts, kinks, dents, or general

(7). Check security of manual release lever

damage that would restrict movement

attachment to pilot's cyclic stick (Ref.

of cable within housing.

Figure 405).

(8). Examine decals (Ref. Figure 403) for

(4). Verify presence and security of grom

secure attachment and legibility.

met where manual release cable passes

through pilot's floor (Ref. Figure 401).

(9). Examine cargo hook circuit wiring for

damage and/or loose connections.

(5). Check security of manual release cable

(10). Verify secure installation of CARGO

housing adjustment nut; verify that

HOOK circuit breaker and HOOK

release lever freely returns to hook-en

RELEASE push-button switch (Ref.

gaged position (Ref. Figure 405).

Figure 403).

Page 602

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CSP-HMI-2

MAINTENANCE MANUAL

CARGO HOOK

INITIAL INSTALLATION

1. Cargo Hook Initial Installation

NOTE: Fuselage cutouts for left and right hand

command are as illustrated

(Ref.

Procedures in this section may be performed at

Figure 901). Use applicable dimensions ac

the operator's discretion and are applicable to

cording to the model helicopter being modi

369D/E/FF - 500N helicopters. These instruc

fied.

tions provide for the installation of the cargo

hook assembly.

(1). Make cutouts in three places as

illustrated (Ref. Figure 901).

A. Preparation for Installation

Consumable Materials

Preparation for installation of the cargo hook

(Ref. Section 91−00−00)

assembly includes the following:

Item

Nomenclature

(1). Identify all components, including

CM318

Primer

attaching hardware, or components to

be removed for access to work areas.

(2). Deburr cutouts and apply thin coat of

Protect components from damage and

primer (CM318) to exposed bare metal.

contamination until installed.

D. Cargo Hook Provisions Installation

(2). Check that all electrical switches are in

OFF position.

(Ref. Figure 404) The following procedure

involves installation of the cargo hook provi

(3). Make certain BATT-OFF-EXT switch

sions exclusive of the cargo hook assembly kit.

is in OFF position.

To complete installation of the cargo hook

system, both cargo hook provisions, and the

B. Helicopter Equipment Removal

cargo hook assembly kit installations must be

(Ref. Figure 404) Prior to installing the cargo

accomplished. Hook provision equipment

hook, a limited number of items must be

omitted in the following procedure is included

removed from the helicopter to accommodate

in the cargo hook installation procedure.

cargo hook installation.

Install cargo hook provisions as follows:

(1). Remove plug button from cargo switch

Consumable Materials

hole in stick grip; discard plug button.

(Ref. Section 91−00−00)

Item

Nomenclature

(2). Remove passenger/cargo compartment

left support fairing.

CM206

Chemical coating

CM228

Surface cleaner

(3). Remove passenger/cargo compartment

CM230

Paint remover

seat.

CM318

Primer

(4). Remove cyclic stick control cover.

CM418

Cement, epoxy

(5). Remove pilot's floor left covering.

NOTE: The cargo hook and provision kits are

(6). Remove pilot's floor left access door.

supplied with as many parts assembled as

practical, however, some parts might re

C. Modification of Helicopter

quire assembly at installation. The operator

should omit those steps which may have al

Modification of the helicopter consists of

ready been accomplished.

cutouts in the pilot's floor and fuselage lower

skin to accommodate routing of the cargo hook

(1). Install cargo hook neoprene pads as

manual control cable and electrical harness.

follows:

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MAINTENANCE MANUAL

(a). Remove paint from fuselage skin in

E. Electrical Components and Wiring

pad installation areas as shown; use

Installation (Left and Right Hand

paint remover (CM230).

Command)

(b). Clean metal in areas where paint as

Consumable Materials

removed; use surface cleaner

(Ref. Section 91−00−00)

(CM228).

Item

Nomenclature

CM404

Adhesive, epoxy

(c). Bond neoprene pads to skin at

CM614

Sleeving, heat-shrink

locations shown; use adhesive

CM704

Tie strap, nylon

(CM418).

NOTE: The order and manner of installation

(2). Prime and touch-up border areas

for left or right hand command is the same.

around pads as follows:

Refer to dimensions given in applicable fig

ures, for model of helicopter being modified.

(a). Wash affected area with solution of

(1). Make certain BATTERY switch is in

mild soap and fresh water. Rinse

OFF position.

area with clean water and wipe dry

with clean lint-free cloth.

(2). Disconnect battery connector.

(3). Connect cargo hook switch to existing

(b). Using swab, liberally apply chemical

wires according to stick grip and model

film (CM206).

helicopter being modified. Insulate

wires and contacts on switch with

(c). Allow solution to remain on surface

sleeving (CM614). Ref. Table 901 and

for 1 to 3 minutes, or until surface

applicable wiring diagrams (Ref.

becomes amber to brown in color.

Figure 101).

(4). Install switch guard on switch. Apply

NOTE: Avoid letting chemical mixture dry on

small amount of adhesive (CM404) to

surface. If it has dried, re-wet surface with

O.D. of switch.

solution.

(5). Install switch in grip. Allow minimum

(d). Rinse treated surface with clean

cure time of 24 hours ±30 minutes.

water. After rinsing, wipe off excess

(6). Install relay on bracket with screws,

moisture with clean lint-free cloth.

washers, and nuts (Ref. Figure 902).

Allow area to dry completely at room

temperature for 1 hour.

Table 901. Cargo Hook Relay Installation

Relay Model Location

Remarks

(e). Wipe surface clean with thinner and

dry off immediately.

K104

369A2519

Slim console

Bulkhead

(f). Apply primer (CM318) and allow to

K312

E/FF

369H2500

T−Panel

dry for 30 minutes.

Bulkhead

(g). Apply lacquer to match original

(7). Locate existing mounting holes accord

factory finish color.

ing to model of helicopter being modi

fied. (Ref. Table 902 and Figure 902).

NOTE: Installation of the cargo hook manual

Using relay bracket as a template,

release lever assembly and clamp assem

mark and drill attachment hole(s)

blies is accomplished during installation of

0.165-0.177 inch (4.191-4.4958 mm) in

the cargo hook kit.

bulkhead as required.

Page 902

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CSP-HMI-2

MAINTENANCE MANUAL

STA. 64.365

CREW COMPARTMENT

DOOR

10.00 LBL

CHANNEL

PILOT'S FLOOR

GROMMET

4.25 IN.

5.00 ±0.25 IN.

(10.795 CM)

PILOT'S FLOOR

(12.7 ±0.635 CM)

0.555-0.562 IN.

3.00 ±0.25 IN.

(14.0970-14.2748 MM)

(7.62 ±0.625 CM)

HOLE

GROMMET

10.00 RBL

CLIP

0.555-0.562 IN.

CHANNEL

(14.0970-14.2748 MM)

0.88 IN.

(22.352 MM)

HOLE

CREW COMPARTMENT FLOOR CUTOUT

(LEFT-HAND COMMAND)

(RIGHT-HAND COMMAND)

LONGERON

GROMMET

12.05 LBL

0.68 X 1.18 IN.

(17.272 X

STIFFENER

29.972 MM)

0.68 X 1.18 IN.

(NOTE 1)

(17.272 X

29.972 MM)

0.890-0.901 IN.

(NOTE 1)

(22.606-

12.05 RBL

22.8854 MM)

(NOTE 2)

0.890-0.901 IN.

(22.606-

22.8854 MM)

(NOTE 2)

LONGERON

STIFFENER

0.38 IN.

DOUBLER

0.38 IN.

DOUBLER

(9.652 MM)

DOUBLER INSTALLATION

(LEFT-HAND COMMAND)

(RIGHT-HAND COMMAND)

NOTES:

SLOT IN SKIN TO MATCH SLOT IN DOUBLER.

HOLE IN SKIN TO MATCH HOLE IN DOUBLER.

G25-5006A

Figure 901. Fuselage Skin Cutouts

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MD Helicopters, Inc.

MAINTENANCE MANUAL

(8).

Attach relay bracket to bulkhead with

manual release cables on the underside of the

screws, washers and nuts. Identify

helicopter, routing and securing the manual

relay as indicated (Ref. Table 902),

release cable, and installation and adjustment

using a suitable contrasting permanent

of the manual release lever.

ink.

(1).

Secure base of cargo hook assembly to

(9).

On left hand command helicopters,

fuselage underside with bolts and

remove edgelighted panel from lower

washers (Ref. Figure 404).

switch and circuit breaker panel: loosen

lower circuit breaker panel. Remove

(2).

If installed, remove protective cap from

hole cover button; install circuit

cargo hook electrical receptacle (J605);

breaker (CB603) (Ref. Figure 402).

check that BATTERY switch is in OFF

position and connect plug (P605) to

(10).

On right hand command helicopters

receptacle.

with center electrical console, remove

edgelighted panel from circuit breaker

(3).

Insert free end of hook manual release

panel located on the pilot's collective

cable through elongated hole adjacent

pitch stick cover; loosen circuit breaker

to electrical receptacle; push manual

panel remove hole cover button; install

release cable up into fuselage and

circuit breaker (Ref. Figure 402).

insert cable through hole in pilot's floor

(Ref. Figure 401).

(11).

On right or left hand command helicop

ters with standard cyclic stick grip,

(4).

Install electrical harness and manual

install module and cover on TB3.

release cable clamp (provision) clips

with rivets (Ref. Figure 402).

(12).

Install cargo hook circuit wiring; see

applicable wiring diagram (Ref.

(5).

Loosely attach harness and cable

Figure 101). For wire termination and

clamps with screws, washers and nuts;

terminal hardware, refer to Table 102.

adjust harness and cable to allow

(13).

Install cargo hook electrical connector

sufficient slack for hook to swing 30

with washer and connector nut. Install

degrees conically from centerline

protective cap on receptacle if cargo

without creating strain on harness and

hook kit is not being installed concur

cable. Arrange harness and cable to

rent with provisions.

form smooth flow to cutouts in fuselage

skin; tighten clamps. Install tie straps

(14).

Secure cargo hook circuit wiring with

(CM704) approximately as shown (Ref.

tie-straps (CM704) as required. Check

Figure 402).

that wires and terminals are not

stressed.

(6).

Loosely attach manual release cable to

cyclic stick with clamps, screws,

(15).

Check all wiring for correct installation

washers, and nuts (Ref. Figure 401).

and security of attachment.

(7).

Engage swaged ball on release cable in

(16).

Connect battery connector.

lever bushing; secure bushing with

F. Cargo Hook Installation

washer and cotter pin (Ref. Figure 405).

(8).

Attach manual release lever assembly

Consumable Materials

to cyclic stick with clamp and screws;

(Ref. Section 91−00−00)

adjust cable and/or release lever as

Item

Nomenclature

shown (Ref. Figure 401).

CM429

Sealing compound, silicone

CM702

Lockwire CRES

(9).

Tighten three sets of clamps securing

release cable to cyclic stick.

CM704

Tie strap, nylon

(10).

Check that hook does not release when

The cargo hook installation consists of

cyclic stick is moved to extremes in all

attaching the hook and emergency electrical/

directions.

Page 904

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(11). Pull manual release lever; check that

(16). Install HOOK RELEASE decal on left

hook load beam opens. Repeat opera

or right hand cyclic stick grip (Ref.

tion several times to ensure proper

Figure 403).

release of hook.

(17). Install CARGO HOOK EMERGENCY

RELEASE decal on cyclic stick (Ref.

(12). Re-adjust cable/lever as required to

Figure 405).

obtain smooth consistent release of

hook.

(18). Install EXTERNAL LOAD LIMIT 2000

POUNDS decal (Ref. Figure 404).

NOTE: The manual release lever clamp may be

loosened and the lever assembly moved on

Table 902. VNE Card Installation

cyclic stick to simplify adjustment, provid

Part Number

Model

Effectivity

ing the 2.250 ±0.250 inch (5.715 ±0.635 cm)

dimension limit is maintained

(Ref.

369D29571

003 − 523

Figure 405).

−17, −19

−21, −23

D/E

D 524 & Subs

(13). Install grommet in crew compartment

E 001 & Subs

floor cutout (Ref. Figure 401). Fill any

voids between grommet and cable. Use

369D292588

001 & Subs

sealant (CM429).

(19). Replace V_NE

card on instrument panel

(14). Install grommet in elongated hole in

as applicable (Ref. to Table 903).

fuselage lower skin and doubler (Ref.

Figure 402). Fill any voids between

G. Helicopter Equipment Installation

grommet and manual release cable. Use

Reinstall equipment initially removed in

sealant (CM429).

reverse order of removal.

(15). Safety manual release lever clamp

NOTE: At completion of installation, perform

screws with lockwire (CM702), (Ref.

an operational check of cargo hook installa

Figure 405).

tion.

Table 903. Cargo Hook Switch Installations − Stick Grip

Part Number

Model

Remarks

369H90153−BSC

D/E/FF

For models equipped with emergency floats, left or right hand

command (Ref. Figure 403).

−3

D/E/FF

For models equipped with hoist, left or right hand command

(Ref. Figure 403).

369D27133

D/E/FF

Standard grip, left hand command (Ref. Figure 403).

369D297846−BSC

Center electrical console, ‘‘T’’ grip right hand command (Ref.

Figure 403).

−3

Center electrical console, ‘‘T’’ grip right hand command (Ref.

Figure 403).

369H92805

Center electrical console, ‘‘T’’ grip right hand command (Ref.

Figure 403).

Page 906

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

EMERGENCY FIRST AID KIT

MAINTENANCE PRACTICES

1. Emergency First Aid Kit

(3). Kit contents include a direction sheet

and the following eight packaged items:

(Ref. Figure 201)

adhesive and plain bandage compres

ses, iodine, swabs, ammonia inhalants,

(1). The Emergency First Aid Kit uses a

burn ointment, tourniquet, forceps, and

plastic case that meets Federal Aviation

scissors. The contents of the kit meet or

Regulation (FAR) 27.8530 requirements

exceed the requirements of Federal

for fire protection. The kit is installed

Aviation Authority (FAA) Specification

on the lower right front of the seat

121, Appendix A for aircraft with a

structure in the crew compartment and

passenger capacity of five persons or

centered at right buttline 20.75 just

less.

above the pilot's floor mold line. It

attaches to the station bulkhead with

two parallel velcro pile strips, 1 x 8

2. Emergency First Aid Kit Contents Check

inches (2.54 x 20.32 cm), bonded two

Periodically check kit contents to ensure an

inches (5.08 cm) apart in the horizontal

adequate supply of medical items. Purchase

position. Two matching velcro hook

individual items locally. To purchase a

strips are bonded across the width of

replacement kit, contact:

the case back.

(2). The kit is easily detached from its

MD Helicopters Inc.,

velcro tape mount by a firm pull on the

5000 East McDowell Road,

handle. The case is opened by off-set

Mesa, AZ 85205,

ting the snap fastener.

Att: New Parts Sales.

Page 201

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

HOIST PASSENGER/CARGO

MAINTENANCE PRACTICES

1. Hoist Passenger/Cargo

mounted on a support tube attached

with quick-release pins to three fittings

located on the exterior of the fuselage

(Ref. Figure 201)

on either side and above the passenger/

cargo door. The support tube positions

(1).

The hoist configuration is installed on

the winch to allow raising and lowering

the right side of L/H command helicop

the cable between the side of the

ters. The configuration for R/H com

fuselage and landing gear skid. Two

mand is identical except that the hoist

modified mounting brackets are used to

is installed on the opposite (left) side of

accommodate installation of the winch

the helicopter. The passenger/cargo

on the support tube. The winch incorpo

hoist assembly consists of an electrical

rates a disc-type brake, housed on the

ly-operated winch mounted on a

end of the hoist drum, which consists of

support tube, a hoist operator's safety

spring-loaded friction plates and an

harness, a passenger door (hold open)

actuating solenoid. The solenoid is

retainer assembly, a passenger door sill

energized to release the brake at the

antichafing bar assembly, a control

same time the motor is energized. Once

pendant, and associated electrical

the control pendant switch is released

equipment. The hoist provides a means

to the off position, the brake solenoid is

for lifting and lowering personnel or

deenergized and the brake sets,

objects weighing up to 300 pounds (136

preventing any possibility of uncon

kg). The hoist system employs light

trolled cable payout. Cable up (full-in)

weight, readily-attachable and -de

and down (full out) limit switches are

tachable exterior-mounted equipment

incorporated in the winch brake

without using passenger or cargo space

system. When either limit switch is in

in the helicopter. For safety purposes, a

the closed position, the brake solenoid

guillotine-type cable cutting device is

is energized, releasing the brake discs

incorporated in the hoist winch assem

and allowing the winch drum to rotate.

bly. The hoist function is identical when

Conversely, when either limit switch is

operated from either side of the helicop

in the open position the brake solenoid

ter.

is deenergized and the winch brake

automatically sets and stops the winch.

NOTE: When the hoist is installed on L/H com

mand helicopters equipped with emergency

floats, the floats must be in a stowed condi

(3).

(Ref. Figure 203) The passenger/cargo

tion during hoisting operations. Emergency

door retainer assembly consists of a

floats must be removed from R/H command

tubular housing attached with four

before conducting hoisting operations.

clamps securing the housing horizontal

ly across the canted bulkhead in the

(2).

(Ref. Figure 202) The weatherproof

passenger/cargo compartment. With the

winch consists of a 28 Vdc motor that

passenger/cargo door in full open

drives a cable drum to which a 110 foot

position, a smaller tube stowed inside

(33.5 M) stainless steel cable with a

the tubular housing extends in a

swivel hook is attached. The winch is

telescoping effect and engages a bracket

equipped with an automatic brake

located on the outboard frame of the

system; up (full-in) and down (full out)

door, thus retaining the door in an open

limit stop switches; and an explosive,

position. The telescoping tube can be

electrically-activated guillotine-type

used in either end of the tubular

cable cutter for cutting the cable in an

housing to hold the left or right passen

emergency. The hoist assembly is

ger/cargo door open as required.

Page 201

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

(4).

(Ref. Figure 201) An antichafing bar,

2. Preparation for Hoisting Operations

installed just below the passenger/cargo

To avoid inadvertent firing of

door sill, prevents the hoist cable from

CAUTION

cable cutter, ensure cable cutter

cutting the door frame during hoisting

electrical circuits are not energized.

operations. A hoist operator's safety

harness. provided with the hoist, is

(1).

Connect external electrical power to

connected to the seat belt anchor fitting

helicopter.

on the side of the passenger/cargo

compartment opposite the side where

(2).

Place BATTERY switch in EXT posi

the hoist is installed.

tion.

(3).

Open passenger/cargo door; extend and

(5).

The hoist system electrical equipment

secure door (hold-open) retainer tube.

consists of a hand held electrical

pendant control for use in the passen

(4).

Using hoist system control pendant,

exercise winch by paying out 3 or 4 feet

ger/cargo or crew compartments to

of cable under approximately 15 pounds

operate the winch, an emergency cable

(6.8 kg) tension, pulling cable straight

cutter switch on the pilot's cyclic stick,

down to avoid rubbing cable on cable

circuit breaker equipment, and asso

bellmouth. Reverse control and reel

ciated electrical wiring. The pendant

cable in. Check that cable winds on

control contains a three position switch,

winch drum evenly and that winch

spring loaded to the off position, for

operation is smooth and consistent.

raising and lowering the swivel hook,

Make certain winch stops automatically

and a guarded switch for cutting the

when top of swivel hook pushes against

cable at the winch in an emergency. The

winch bumper pad.

pilot's cyclic stick cable cutter switch

allows the pilot to cut the hoist cable

(5).

If installed, remove cable cutter jumper

independent of the pendant control. The

wire (Ref. Figure 202).

circuit breakers are mounted on the

Cable cutter jumper wire

lower switch and circuit breaker panel

WARNING

must be removed to allow

in L/H command, and on the circuit

cable cutter electrical circuit to be

breaker panel located aft of the pilot's

completed by switch control, providing

collective stick on R/H command. The

instantaneous in-flight cable cutting

cable cutter circuits are independently

capability should such emergency ac

protected by a separate lower-amper

tion be required.

age circuit breaker located adjacent to

the hoist power circuit breaker. Electri

(6). If winch has not been used for an

cal wiring, plugs, receptacles, and

extended period of time, or if cable has

terminals interconnect the various

been replaced, perform an operational

electrical components.

check (Ref. Hoist System Operational

Check).

(7). Check that winch support tube attach

(6).

Differences in hoist installations and

safety pins are secure and fully seated.

electrical circuitry for L/H and R/H

command is described in subsequent

(8). Check that winch electrical connector

text and illustrations. Refer to man

plug is secure on receptacle on side of

ufacturer's publications (Ref. Table 201,

fuselage.

Sec. 01-00-00, BL-16600 Series 300 Lb

Capacity Hoist Operating lnstructions -

(9). Connect hoist system operator's safety

Hoist Winch Assembly, Breeze Corpora

harness to seat belt fitting on opposite

tion, Inc)) for additional hoist, hook,

side of passenger/cargo compartment

cable, and parts information.

from where winch is installed.

Page 205

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

WINCH

HOIST SUPPORT

TUBE

DOUBLE HELICAL

SCREW SHAFT

CABLE GUIDE

ASSEMBLY

IDLER GUIDE

ROLLER

TORQUE NUT TO

TRACTION ROLLER

70 - 100 INCH-POUNDS

(7.91 - 11.30 NM)

PRESSURE ROLLER

ALLEN HEAD SET SCREW

INDENT

FILL-IN (UP)

LIMIT SWITCH

CABLE CUTTER

BELLMOUTH

(GUILLOTINE)

BUMPER RING

PROTECTIVE

ELECTRICAL

RUBBER BUMPER

JUMPER

PAD

(REF. WARN

ING)

WARNING: REMOVE JUMPER WIRE AFTER

1/8 IN. (3.175 MM)

DIA. CABLE

SYSTEM INSTALLATION OR MAINTENANCE

ELECTRICAL

(REFER TO TEXT)

GROUND WIRE

WIRING

(WHITE, BLUE

POSITIVE WIRE (BLACK,

CABLE CUTTER

CAUTION: CONNECT POSITIVE WIRE ONLY

OR WHITE/BLUE)

REPLACEMENT

GREEN, OR WHITE/GREEN)

(BLACK, GREEN, OR WHITE/GREEN) TO POS

(REF. CAUTION)

ITIVE (+) POST OF CABLE CUTTER.

G25-6002-1A

Figure 202. Winch Cable, Cable Cutter, and Swivel Hook Replacement (Sheet 1 of 2)

Page 206

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MD Helicopters, Inc.

MAINTENANCE MANUAL

(10). Place BATTERY switch in OFF posi

NOTE: If support tube fittings are to be re

tion.

moved from fuselage, make certain nylon

screws are installed in attachment holes.

(11). Remove external electrical power from

helicopter.

(8). Remove bolts securing winch to support

tube brackets.

3. Hoist System Troubleshooting

B. Hoist Assembly Installation

(Ref. Table 201) Wiring diagrams are provided

for the hoist systems used on L/H command

Consumable Materials

(Ref. Figure 204) and R/H command helicop

(Ref. Section 91−00−00)

ters (Ref. Figure 205). A schematic diagram of

Item

Nomenclature

the winch is also provided (Ref. Figure 206).

CM703

Tie strap

(Ref. Chap. 96 for interfacing schematics and

wiring diagrams)

NOTE: If support tube fittings

(Ref.

Figure 201) were removed from fuselage, re

4. Cyclic Stick Grip and Cyclic Stick Cable

move nylon screws installed in support fit

Cutter Switch (S600) Replacement

ting attachment holes on fuselage.

(Ref. Sec. 67-10-20)

(1). If required, install winch support tube

attach fittings on fuselage using screws

5. Hoist Assembly Replacement

and washers.

A. Hoist Assembly Removal

(2). Attach winch to support tube using

bolts, washers, and nuts. Torque bolts

(1). Check that cable is fully retracted on

to 70 - 100 inch-pounds (7.91 - 11.30

winch drum.

Nm).

(2). Check that BATTERY switch is in OFF

(3). Attach link assembly to support tube

position.

using bearing pin, washer, and cotter

pin.

(3). Install safety jumper wire on cable

cutter electrical terminals (Ref.

(4). Attach winch support tube to fuselage

Figure 202).

fittings using quick-disconnect pins.

Protective jumper wire should

NOTE: Install pins in positions shown.

CAUTION

remain on cable cutter electrical

terminals until winch is reinstalled for use.

Check that all electrical power

CAUTION

is OFF to eliminate possibility

(4). Disconnect winch electrical plug (Ref.

of inadvertent firing of cable cutter.

Figure 201) from receptacle on fuselage;

install protective cap on receptacle.

(5). Remove protective cap from electrical

receptacle on side of fuselage. Connect

(5). Support winch; remove three quick-dis

winch electrical plug to fuselage

connect safety pins securing winch

receptacle. Secure wire harness to

support tube to fittings on fuselage.

support tube using tie-straps (CM703).

(6). Remove winch and support tube from

Remove protective electri

WARNING

fuselage.

cal jumper wire

(Ref.

Figure 202) from cable cutter whenev

(7). Remove cotter pin, washer, and bearing

er winch is installed on helicopter.

pin securing link assembly to winch

Jumper wire will prevent operation of

support tube.

cable cutter in an in-flight emergency.

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MAINTENANCE MANUAL

6. Winch Components Replacement

(c). Continue unwinding cable until down

(full-out) limit switch (Ref.

A. Winch Cable Replacement

Figure 202) activates (opens) and

allows brake to engage, thus stopping

(Ref. Replacement of the winch cable (Ref.

cable payout.

Figure 202) is required if cable is damaged,

NOTE: Three turns of cable will remain on

worn excessively, or cable cutter has been fired

winch drum when down limit switch opens.

(Ref. Hoist Equipment Inspection for inspec

(d). Remove winch cable drum cover.

tion requirements and for cable replacement

criteria).

(e). Manually raise roller wheel, at top

right rear of winch drum, to close the

(1). Install hoist and support on helicopter

down limit switch (release brake) and

(Ref. Hoist Assembly Installation).

allow remaining cable to be reeled off

cable drum.

When electrical power is pres

(f). Using control pendant, finish un

CAUTION

ent, make certain cable cutter

winding cable. Stop winch when

electrical circuits remain deenergized to

cable is fully unwound from drum.

eliminate the possibility of inadvertent ac

(5). Remove winch cable from drum as

tuation of cable cutter. To avoid possibility of

follows:

cutting cable, install jumper wire between

cable cutter electrical terminals.

(a). Loosen Allen head setscrew securing

cable end in drum anchor hole.

NOTE: An external power source should be

Remove cable end from winch by

connected to the helicopter to prevent exces

pulling cable down through cable

sive battery discharge. Hoist uses up to 40

guide, cable cutter, and bumper

amperes electrical current during operation.

guide.

Anchor hole setscrew should be

(2). Connect external electrical power

CAUTION

temporarily tightened to pre

source to helicopter.

vent fouling winch mechanism if winch is

inadvertently operated.

(3). Place BATTERY switch in EXT posi

(b). Retighten setscrew in anchor hole.

tion.

(6). Remove swivel hook from cable (Ref.

(4). Using hoist pendant control (Ref.

Swivel Hook Replacement).

Figure 201), reel off all cable from

NOTE: Replacement cable must be 0.125 inch

winch drum as follows:

(3.175 mm) diameter stainless steel, 19 by 7

cable strand, extra strength, antispin cable

NOTE: Two persons can facilitate cable remov

with a minimum breaking strength of 1800

al; one person to operate winch and a second

pounds. Make certain any replacement

person to handle and coil cable.

cable, other than cable supplied by winch

manufacturer, is approximately 113 feet

(a). Operate winch and start reeling cable

(34.442 M) long, is equipped with a swaged

off winch drum.

ball fitting, and is proof-tested to a mini

mum load of 1850 pounds (840 kg).

To prevent bellmouth wear,

(7). Install swivel hook on replacement

CAUTION

cable should not be pulled

cable (Ref. Swivel Hook Replacement).

against side of bellmouth on cable guide.

(8). Attach new replacement cable to winch

as follows:

(b). As cable unwinds, maintain straight

downward tension, approximately 15

(a). Insert free end of replacement cable

pounds (6.8 kg); lay or coil cable in a

up through bumper pad guide center,

clean clear area. Position cable so

bellmouth, switch, cable cutter, and

that cable will not kink or tangle, to

between cable rollers in the cable

facilitate rewinding.

guide assembly (Ref. Figure 202).

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MAINTENANCE MANUAL

(b). Ensure cable guide assembly is

NOTE: The up limit switch should actuate be

centered and aligned with first

fore excessive cable pressure is applied to

groove on double helical screw shaft.

vertically compress bumper pad. Permanent

damage can result if rubber bumper pad is

Facing cable guide mechanism, check

stowed in a compressed state over an ex

that guide will travel from right to

tended period of time; rubber bumper will

left when winding cable on drum.

remain in a compressed (set) state.

(d). Install cover on winch.

(c). Secure cable to drum by loosening set

screw and inserting cable end into

(10). Perform an operational check of hoist

drum cable anchor hole until cable

system (Ref. Hoist System Operational

end bottoms, approximately 3/8 inch

Check).

(9.525 mm); tighten setscrew.

B. Swivel Hook Replacement

(d). Check that replacement cable is

(Ref. Figure 202)

positioned in first drum groove at

right when facing cable guide mecha

Consumable Materials

nism.

(Ref. Section 91−00−00)

Item

Nomenclature

(9). Operate hoist and wind replacement

CM114

Petrolatum

cable on winch as follows:

(1). Remove swivel hook assembly from

cable as follows:

(a).

Deactivate down limit switch by

manually raising teflon roller wheel

(a). Remove rubber bumper covering

at top right rear of winch drum; use

swivel hook housing by pulling

control pendant to wind replacement

bumper upward off top of hook

cable on winch. Release the down

housing.

limit switch after three turns of cable

are on drum.

(b). Remove cable swaged ball end fitting

from hook housing socket: pull cable

swaged ball fitting through rubber

(b).

Maintain sufficient tension, approxi

bumper.

mately 15 pounds (6.8 kg) on cable

while winding cable on drum; check

(2). Install swivel hook on cable as follows:

that cable winds straight, smooth,

and snug, without kinking against

(a). Lubricate cable swaged ball end

cable windings on drum. Avoid cable

fitting with petrolatum (CM114).

rubbing on side of bellmouth during

(b). Insert cable through top of rubber

cable winding.

bumper.

(c). Insert cable ball fitting in hook

(c).

Continue winding operation until

housing keyway and socket.

entire cable is wound on drum: check

that winch stops automatically when

Ensure hook rubber bumper

top of swivel hook pushes against

CAUTION

completely covers hook housing.

winch rubber bumper pad. (Bumper

pad upward movement actuates

(d). Secure cable ball fitting in housing

(opens) full-in (up) limit switch at

socket by sliding rubber bumper

cable guide base.

down over hook housing.

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MAINTENANCE MANUAL

NOTE: Hook rubber bumper should completely

Setscrew mates with indent on cable

cover housing, and bumper base will overlap

cutter.

inward around housing base by approxi

(6). Connect one electrical terminal lug to

mately 1/16 inch when fully seated on hous

cable cutter terminal, leaving protective

ing.

short-circuiting jumper installed on

C. Cable Cutter Replacement

cable cutter. Then connect second wire

(Guillotine−Type)

to remaining cable cutter terminal in

the same way.

(Ref. Figure 202)

Protective jumper wire should

CAUTION

remain connected to cable cutter

Consumable Materials

electrical terminals until hoist is to be used.

(Ref. Section 91−00−00)

Item

Nomenclature

(7). Cover exposed electrical terminal areas

CM425

Sealing compound

with sealing compound (CM425).

7. Hoist System Operational Check

Cable must be removed from winch (Ref.

The following procedure is used to verify the

Winch Cable Replacement) before guillotine-

capability of the hoist system to function

type cable cutter can be replaced. Replace a

correctly. The procedure should be performed

spent cable cutter guillotine on winch as

any time a malfunction is suspected, and prior

follows:

to normal use after repair.

The cable cutter contains an

WARNING

Remove protective electri

explosive squib that is elec

WARNING

cal jumper wire

(Ref.

trically fired. A protective short-cir

Figure 202) from cable cutter whenev

cuiting electrical jumper should re

er winch is installed on helicopter.

main connected to cable cutter, not

Jumper wire will prevent operation of

installed on the winch, to eliminate

cable cutter in an in-flight emergency.

possibility of inadvertent accidental

firing.

(1). Open applicable passenger/cargo door;

extend door retainer tube to hold door

(1). Disconnect two electrical wire terminal

in full open position.

lugs from spent cable cutter.

Avoid inadvertent operation of

(2). Loosen two Allen head setscrews at side

CAUTION

cable cutter. Make certain cable

of movable cable guide and remove

cutter switches are not actuated when hoist

spent cable cutter from guide.

system circuits are energized.

(3). Check that all electrical power is OFF.

(2). Energize helicopter electrical system;

check that both HOIST PWR (power)

Do not use an ohmmeter or

WARNING

and CBL CTR (cable cutter) circuit

any other device containing

breakers are in closed position (Ref.

an internal voltage source which could

Figure 201).

fire cable cutter.

(3). Using hoist system control pendant,

(4). Using a voltmeter, check for zero

exercise hoist winch by paying out 3 to

voltage between electrical wiring

4 feet (1.2 M) of cable under approxi

terminal lugs; also check for zero

mately 15 pounds (6.8 kg) tension; pull

current between lugs with a milliamme

cable straight down to avoid cable

ter.

rubbing on cable bellmouth. Reverse

(5). Insert cylindrical end of new cable

control and reel cable in. Check that

cutter into winch movable cable guide,

cable winds on winch drum evenly and

with shorting jumper positioned

that winch operation is smooth and

downward, and secure cable cutter to

consistent. Check that winch stops

guide with two Allen head setscrews.

automatically when top of swivel hook

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MAINTENANCE MANUAL

rubber bumper pushes against winch

(6). Stow door retainer tube; close passen

bumper pad.

ger/cargo door.

(4). Test hoist lifting capability with 300

8. Hoist Equipment Inspection

pound weight. Check that hoist oper

ates smoothly throughout hoisting and

General inspection procedure for the hoist

lowering operations.

system is as follows:

NOTE: Cable retraction rate should be approxi

(1). Inspect components for security of

mately 55-60 feet (16.8-18.3 M) per minute.

attachment, damage, deformation,

The full usable cable length should unwind

cracks, and excessive wear.

in approximately 95 seconds and rewind in

approximately 103 seconds.

WARNING

(a).

With helicopter hovering approxi

mately 100 feet (45.4 M) above test

D Human life might depend on cable

weight, lower hoist hook between

condition. Inspect full length of cable

fuselage and landing gear skid.

carefully and thoroughly.

Continue lowering hook until hook

D Use heavy leather gloves to protect

can be connected to test weight.

hands from injury due to broken

cable strands.

(b).

Gradually maneuver helicopter to

remove cable slack and to center

Keep cable clean. Provide a

hoist over test weight.

CAUTION

clean area to coil cable during

inspection. Dirt and oil grime will create an

(c).

Slowly elevate helicopter to raise test

abrasive wear on cable and winch compo

weight approximately 20 feet (6.1 M)

nents.

from ground.

(2). Inspect cable for fraying, corrosion,

(d).

Using pendant control, payout full

broken strands, and security of attach

usable length of cable. Check that

ment to winch drum and cable ball

hoist down limit switch stops winch

swivel hook attachment. General

with three turns of cable on winch

criteria for cable replacement are as

drum. If required, adjust position at

follows:

which down limit switch activates.

(a). Any single broken strand (cluster of 7

(e).

Reverse pendant control. Lift test

individual wires) requires cable

weight to within approximately 10

replacement.

feet (3.0 M) of helicopter skid.

(b). Both ends of individual broken wires

(f).

Lower helicopter and remove hoist

should be tucked into cable to

hook from test weight; raise hoist

prevent fouling when cable travels

hook and check that hoist winch

through cable guides and nonfouling

automatically stops when top of

mechanisms. Breaks of individual

swivel hook rubber bumper pushes

wires are allowable, unless the

up against hoist bumper pad.

number is excessive as defined in

NOTE: Up limit switch should actuate before

next criterion.

excessive cable pressure is applied to verti

cally compress bumper pad

(Ref.

(c). Generally, one individual broken wire

Figure 202).

(two ends) for each foot of cable is

permissible, up to a total of 20

(g). Land helicopter; deenergize electrical

individual wire breaks for each 100

system.

foot (30.5 M) length of cable. A

greater number of breaks requires

(5). Stow pendant control.

cable replacement.

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MAINTENANCE MANUAL

Table 201. Troubleshooting Hoist System

Symptom

Probable Trouble

Corrective Action

Winch will not raise or lower cable.

Tripped circuit breaker.

Reset circuit breaker.

Defective pendant control.

Repair pendant control.

Defective winch assembly.

Repair winch assembly.

Improper lower cable travel limit.

Down (full−out) limit switch out of

Reset lower limit adjustment.

adjustment.

W3 BUS

A526A12

A527G12N

E19

A527H20N

P107C14-8S

RECEPTACLE

A527J20N

(MATES WITH

CYCLIC STICK

PT06P14-8P

CABLE CUTTER

WINCH PLUG)

CB600

TB10

SWITCH S600

(NOTE 4)

P506AH12

M535A12

40A

JUMPER

AWG 20

CB601

TB1-16

P130

M503B20

M503F20

13-20

7.5A

14-20

SPARE

M504H20

CC8A20

CC9A20

E24

PENDENT CONTROL

CC10A20

XJ2

CC2AA20

HOIST

CC1AA20

NOTES:

DOWN

THIS DIAGRAM IS TO BE USED WITH ELECTRICAL SYSTEM WIRING

CUTTER

DIAGRAMS IN CHAP. 96 FOR COMPLETE CIRCUIT IDENTIFICATION.

DASHED LINE ( - - ) ITEMS ARE PART OF HELICOPTER BASIC

MS3101E16S-1S

ELECTRICAL SYSTEM.

RECEPTACLE

COMPONENT TERMINAL NUMBERS ARE FOR REFERENCE AND MAY

NOT BE SHOWN ON COMPONENT.

REFER TO WINCH SCHEMATIC DIAGRAM FOR INTERNAL CONNECTIONS.

G25-6009

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

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MAINTENANCE MANUAL

CB600

J28

A526A12

40A

SPLICING PERMISSIBLE

A527G12N

HOIST (PWR) OR (ORD)

A527H20N

CB133

A527J20N

PT07C14-8S

A526A12

40A

RECEPTACLE

(MATES WITH

HOIST CUT (CTR)

CYCLIC STICK

PT06P14-8P

CB134

CABLE CUTTER

WINCH PLUG)

SWITCH S600

(NOTE 4)

M503A20

7.5A

SLAE ONLY

CB601

P616

TB1-40

TB1-19

P109

M503A20

M503AA20

M504K20

M521F20

7.5A

(NOTE 5)

NOTE 6

M520F20

K504M20

SPARE

E24

CC10A20

CC8A20

CC9A20

CABLE CUTTER

0.040 IN. (1.016 MM)

SWITCH BUTTON

PENDANT CONTROL

369H90070-67 DECAL

GRIP

HOIST

CABLE CUTTER SWITCH

DOWN

GRIP

CC2AA20

CUTTER

CC1AA20

CYCLIC GRIP REWORK

MS3101E16S-1S

RECEPTACLE

NOTES:

THIS DIAGRAM IS TO BE USED WITH ELECTRICAL SYSTEM WIRING DIAGRAM

IN CHAP. 96 FOR COMPLETE CIRCUIT IDENTIFICATION.

DASHED LINE ( - - ) ITEMS ARE PART OF HELICOPTER BASIC ELECTRICAL

SYSTEM.

COMPONENT TERMINAL NUMBERS ARE FOR REFERENCE AND MAY NOT BE

SHOWN ON COMPONENT.

REFER TO WINCH DIAGRAM FOR INTERNAL CONNECTIONS.

EXISTING WIRE, RELOCATED TO TB1-40A.

REMOVE EXISTING WIRE M520B20.

G25-6004A

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

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MAINTENANCE MANUAL

HOIST PASSENGER/CARGO

INITIAL INSTALLATION

1. Hoist Passenger/Cargo Initial Installation

(2). Remove left and right foot support

fairings in passenger/cargo compart

The passenger/cargo hoist can be installed on

ment.

any L/H command or R/H command Model

(3). Remove passenger/cargo compartment

369D helicopter. On L/H command, the hoist

forward bulkhead trim panel (L/H

winch is installed on the right side of the

command) and controls access door.

fuselage. On R/H command, the hoist winch is

installed on the left side of the fuselage.

(4). Remove fuel cell forward vent from

Subsequent procedures provide separate

control tunnel (Ref. Sec. 28-00-00).

instructions for electrical installations in L/H

command and R/H command to accommodate

NOTE: Fuel vent must be removed to avoid

differences in component location and wire

damage during structural modification hole

routing.

drilling operations.

(5). Remove crew compartment seat and

Installation instructions include procedures for

back cushions.

installing a passenger/cargo door retainer

assembly, a door sill antichafing bar assembly,

(6). Remove left (outboard) collective stick

a winch and winch support tube assembly, and

cover.

the electrical wiring and components required

for operation of the hoist system.

(7). Remove crew compartment lower aft

trim panels (left and right).

The hoist passenger/cargo installations may be

(8). Remove crew compartment left or right

performed at the discretion of the operator, or

bulkhead panel and lower portion of

the helicopter may be returned to the factory

right upper side panel.

for modification. The instructions which follow

are for the 369H90070-521 and -522 installa

(9). Remove edgelighted panel face from

tions only.

lower switch and circuit breaker panel

(Ref. Chap. 96). Loosen lower switch

A. Preparation for Installation

and circuit breaker panel to accommo

date installation of additional circuit

Instructions in the following paragraphs are

breakers.

applicable to both left and right hoist installa

tions, except as noted.

C. Helicopter Modification

(1). Identify all components that are to be

(Ref. Figure 901) Modification of the helicopter

installed, along with those removed to

involves cutting a hole in the fuselage skin to

gain access to work areas. Protect

facilitate installation of an electrical receptacle

components from damage and contami

(J28) to receive a winch electrical plug, and a

nation.

hole in the lower left area of the canted

bulkhead and forward bulkhead trim panel to

(2). Check that all electrical switches are in

facilitate installation of an electrical receptacle

OFF position.

(XJ2) to receive a control pendant plug.

Ensure BATTERY switch is in

CAUTION

Consumable Materials

OFF position.

(Ref. Section 91−00−00)

B. Helicopter Equipment Removal

Item

Nomenclature

CM318

Primer

Remove following panels, access doors, and

equipment as applicable to accommodate

installation of the hoist system components:

(1). Cut and deburr holes, remove chips,

and apply a thin coat of primer

(1). Remove battery (Ref. Chap. 96).

(CM318) to exposed metal surfaces.

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(2). Fit forward bulkhead trim panel to

(Ref. Figure 201) and receptacle nut

canted bulkhead; locate and cut hole in

externally to retain J28 receptacle in

trim panel to match XJ2 receptacle hole

place.

in bulkhead. Remove trim panel to

accommodate installation of door

NOTE: The J28 receptacle is temporarily in

retainer assembly.

stalled to provide a means of determining

wire length to receptacle.

NOTE: Hoist electrical connector (J28) doubler

is located in the crew compartment, below

(3).

Install circuit breakers in positions

the aft lower corner of the upper canopy

CB60l and CB600 respectively, on lower

windshield, and immediately forward of the

switch and circuit breaker panel (Ref.

canted frame (Sta. 78.50) for either right

View A).

side (L/H command) or left side (R/H com

mand) hoist winch installation.

(4).

(Ref. Figure 204) Install terminal on

circuit breaker jumper wire; install

D. Electrical Equipment Installation (L/H

jumper wire on contact 1 of CB60l.

Command)

(5).

Install terminal on wire P506AH12 and

Install hoist kit electrical wire harness

install on contact 1 of CB600 together

assembly, general wiring, and components on

with jumper wire fabricated in previous

L/H command as follows:

step. Route wire P506AH12 to contact 7

of BUSS W3; cut wire to length and

install terminal. Connect wire

Consumable Materials

P506AH12 to contact 7 of BUSS W3.

(Ref. Section 91−00−00)

Item

Nomenclature

(6).

Install terminal on wire M535A12 and

CM614

Sleeving, heat-shrink

connect wire to contact 1 of TB10.

CM703

Tie strap

Route wire M535A12 to contact 2 of

CM807

Twine, nylon

CB600 and install terminal. Connect

wire M535A12 to contact 2 of CB600.

CM815

Solder

(7).

Install terminal on wire M503B20 and

connect to contact 2 of CB601. Route

Ensure wires and/or wire

CAUTION

opposite end of wire M503B20 to

bundles do not chafe or bind

TB1-16, install pin and insert pin in

control mechanisms.

TB1-16, contact A.

NOTE: When providing ground contact for elec

trical components, clean the contacting sur

(8).

Connect terminal of wire A526A12 to

faces to bare metal (Ref. Chap. 96). Route

TB10, contact 1, and route wire below

wire and wire bundles with existing wires

floor through center beam, below crew

and bundles. Temporarily tie wires in place

compartment right seat and up right

with existing bundles until installation is

side aft of door frame to J28 receptacle.

complete, then secure wires with nylon

twine (CM807), tie-straps (CM703), or

NOTE: Temporarily tie wires in place. Do not

clamps as required.

cut wires until all wires are adjusted and

tied in place.

(1). Install cyclic stick grip (Ref. Figure 201

and Sec. 67-10-20).

(9). Insert pin of wire CC10A20 in TB1-16,

contact C. Connect terminal on shield

(2). From inside crew compartment,

ing of wire CC10A20 to ground stud

temporarily install J28 receptacle

E24. Do not tighten ground stud nut.

through hole provided in right side of

Route wire CC10A20 to J28 receptacle

ship (Ref. Figure 901). Install washer

and tie in place.

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CUT HOLE IN SKIN TO

MATCH HOLE IN DOUBLER

HOIST ELECTRICAL CON

NECTOR DOUBLER

UPPER CANOPY

WINDSHIELD

E19

CREW COMPARTMENT

RIGHT DOOR FRAME

NOTE: LH COMMAND VERSION SHOWN. RH

COMMAND VERSION IS INSTALLED AT SAME

LOCATION OR LEFT SIDE OF HELICOPTER.

LH COMMAND HELICOPTER

CONFIGURATION, CUT

1.00 IN. (2.54 CM) HOLE IN SKIN

WINCH ELECTRICAL RECEPTACLE

(J28) CUTOUT LOCATION

(NOTE)

WL 21.50

2.00 IN.

XJ2

(5.08 CM)

0.970 IN.

(24.638 MM)

(TYP)

2.00 IN.

(5.08 CM)

2.00 IN.

(5.08 CM)

1.50 IN.

XJ2

(3.81 CM)

0.970 IN.

(24.638 MM)

(TYP)

RH COMMAND HELICOPTER CON

FIGURATION, CUT

VIEW LOOKING FORWARD, LOWER LEFT

1.00 IN. (2.54 CM) HOLE IN SKIN

CORNER OF CANTED BULKHEAD STA. 78.50

0.121-0.135 IN.

PENDANT CONTROL ELECTRICAL

(3.0734-3.429 MM)

RECEPTACLE - CUTOUT LOCATION

HOLE (4 PLCS)

G25-6006A

Figure 901. Helicopter Modification

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MAINTENANCE MANUAL

(10). Install XJ2 receptacle.

connect wires A526A12, A527G12N,

A527H20N, A527J20N, CCl0A20,

(a). Insert XJ2 receptacle (Ref.

CC8A20, and CC9A20 to J28 receptacle

Figure 201) in hole provided in lower

contacts as indicated (Ref. Figure 203).

left corner of canted bulkhead (Ref.

Figure 901). Using XJ2 receptacle

(15). Install J28 receptacle and secure with

bracket as a template, mark and drill

washer and nut. Install protective cap

four 0.121-0.133 inch (3.0734-3.3782

(Ref. Figure 201).

mm) attach holes. Protect attached

(16). Install ground stud on forward side of

wires during drilling operation.

canted bulkhead frame (Ref.

(b). Install XJ2 receptacle (Ref.

Figure 901). Identify ground stud as

Figure 201) from forward side of

E19.

canted bulkhead, with screws,

(17). Install wires A527G12N, A527H20N,

washers, and nuts.

and A527J20N, from J28 receptacle, on

(11). Route wires CC1AA20 and CC2AA20

ground stud E19. Adjust and trim

(Ref. Figure 203) from XJ2 receptacle to

insulation tubing (CM614) to accommo

TB1-16; install pin of wire CC1AA20 in

date ground wire connection as re

contact B and pin of wire CC2AA20 in

quired; heat shrink tubing.

contact D. Connect terminal on shield

(18). Replace existing cyclic stick grip with

ing of wire CC2AA20 to ground stud

part number 369H90129-505 (Ref. Sec.

E24; tighten ground stud nut.

67-10-20). Wire cyclic stick cable cutter

(12). Route wires CC8A20 and CC9A20 to

switch S600 as shown (Ref. Figure 204).

J28 receptacle and tie in place.

E. Electrical Equipment Installation (R/H

(13). Wire J28 receptacle.

Command)

(a). Cut and strip wires at J28 receptacle.

Install hoist kit electrical wire harness

Ensure sufficient wire length to

assembly, general wiring, and components on

provide a smooth right angle wire

R/H command helicopters, as follows:

flow to J28 receptacle.

Consumable Materials

(b). Install approximately 6 inches (15.24

(Ref. Section 91−00−00)

cm) of 0.50 inch (12.7 mm) insulation

Item

Nomenclature

tubing (CM614) on wire bundle to

cover all wires extending from J28

CM614

Sleeving, heat-shrink

receptacle.

CM703

Tie strap

CM725

Tape, electrical, plastic

(c). Ensure that all electrical contact

CM807

Twine, nylon

installations are correct and secure.

CM815

Solder

(d). Adjust wires at J28 receptacle and

make certain sufficient wire slack

Ensure wires and/or wire

remains to avoid stress on terminals

CAUTION

bundles do not chafe or bind

and contacts below floor and seat

control mechanisms.

areas. Use twine (CM807) and

tie-straps (CM703) to secure wires in

NOTE: When providing ground contact for elec

place.

trical components, clean the contacting sur

faces to bare metal (Ref. Chap. 96). Route

Ensure wires do not chafe or

CAUTION

wire and wire bundles with existing wires

bind throughout full travel of

and bundles. Temporarily tie wires in place

any control mechanism.

with existing bundles until installation is

(14). Remove J28 receptacle from side of

complete, then secure wires with nylon

ship. Install insulation sleeving

twine (CM807), tie-straps (CM703), or

(CM614) and, using solder (CM815),

clamps as required.

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CSP-HMI-2

MAINTENANCE MANUAL

(1). From inside crew compartment,

Install pin and insert pin in contact A of

temporarily install J28 electrical

TB1-40.

receptacle (Ref. Figure 201) through

(8). Remove existing wire M520B20 from

hole provided in left side of ship (Ref.

TB1-19A. Wire end is left open insu

Figure 901). Install washer (Ref.

lated with tape (CM725), and secured to

Figure 201) and receptacle nut exter

basic electrical system tie-strap

nally to retain J28 receptacle in place.

(CM703). Install pin on wire K504M20

NOTE: The J28 receptacle is temporarily in

and insert in contact A of TB1-19.

stalled to provide a means of determining

Route wire K504M20 to TB1-40, install

proper length of wires to be connected to re

pin, and insert pin in contact C of

ceptacle.

TB1-40.

(9). Insert pin of wire CC10A20 in contact C

(2).

On standard R/H command equipped

of TB1-40, route wire to J28 receptacle,

with 369H92143 circuit breaker panel,

and temporarily tie in place. Connect

install circuit breaker CB600 (Ref. View

terminal on shielding of wire CC10A20

B), and a circuit breaker CB601 in

to ground stud E24. Do not tighten

circuit breaker panel located on the

ground stud nut.

pilot's collective pitch stick cover. Make

certain circuit breaker connections to

(10). Install XJ2 receptacle.

buss bar are secure.

(a). Insert XJ2 receptacle in hole pro

(3).

On SLAE-equipped R/H command with

vided in lower left corner of canted

369D294566 circuit breaker panel,

bulkhead (Ref. Figure 901). Using

install circuit breaker CB133 and

XJ2 receptacle bracket as a template,

circuit breaker CB134 in circuit breaker

mark and drill four 0.121-0.133 inch

panel located on the pilot's collective

(3.0734-3.3782 mm) attach holes.

pitch stick cover. Make certain circuit

breaker connections to buss bar are

(b). Install XJ2 receptacle (Ref.

secure.

Figure 201) from forward side of

canted bulkhead, using screws,

(4).

(Ref. Figure 205) Install terminal on

washers, and nuts.

wire A526A12 and connect to contact 2

of CB600 on standard R/H command, or

(11). Route wires CC1AA20 and CC2AA20

to contact 2 of CB133 on SLAE-

(Ref. Figure 205) from XJ2 receptacle to

equipped R/H command. Route opposite

TB1-40, install pin of wire CC1AA20 in

end of wire A526A12 with existing wire

contact B, and pin of wire CC2AA20 in

contact D. Contact terminal on shield

bundles to J28 receptacle and tempo

ing of wire CC2AA20 to ground stud

rarily tie in place.

E24; tighten ground stud nut.

(5).

On standard R/H command, locate

(12). Route wires CC8A20 and CC9A20 to

existing wire M503A20, install terminal

J28 receptacle and temporarily tie in

on wire M503A20, and connect to

place.

contact 2 of CB601. Locate existing wire

M503AA20, remove from TB16 contact

(13). Wire J28 receptacle.

A, and relocate to TB1-40, contact A.

(a). Cut and strip wires at J28 receptacle.

(6).

On SLAE-equipped R/H command,

Ensure sufficient wire length to form

install pin on wire M503A20, insert pin

a smooth right angle wire flow to J28

in contact A of TB1-40. Route wire

receptacle.

M503A20 to CB134; install terminal

and connect to contact 2 of CB134.

(b). Install approximately 6 inches (15.24

cm) of 0.50 inch (12.7 mm) insulation

(7).

Install pin on wire M504K20, insert in

tubing (CM614) on wire bundle to

contact B of TB1-19, and route opposite

cover all wires extending from J28

end of wire M504K20 to TB1-40.

receptacle.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

(c). Ensure that all hoist system electri

F. Passenger/Cargo Door Retainer

cal installations are correct and

Installation

secure.

The passenger/cargo door retainer installation

(d). Adjust wires at J28 receptacle and

consists of a tubular assembly attached to the

make certain sufficient wire slack

aft side of Sta. 78.50 canted bulkhead with

remains to avoid stress on terminals

four clamps. With the passenger/cargo doors in

and contacts below floor seat areas.

the open position, a telescoping tube slides out

Use twine (CM807) and tie straps

of the tubular assembly to engage a bracket

(CM703) to secure wires in place.

attached to the door frame, and thus retains

the door in an open position. Install the

Ensure wires do not chafe or

passenger/cargo door retainer as follows:

CAUTION

bind throughout full travel of

any control mechanism.

(1). Install doubler angles.

(14).

Remove J28 receptacle from side of

(a). Locate doubler angles (Ref.

ship. Install insulation sleeving

Figure 203) on forward side of Sta.

(CM614) and, using solder (CM815),

78.50 canted bulkhead, using two

connect wires A526A12, A527G12N,

existing 0.070 inch (1.778 mm)

A527H20N, A527J20N, CC10A20,

tooling holes (Ref. Figure 902). Use

CC8A20, CC9A20 to J28 receptacle

angles (Ref. Figure 203) as templates

contacts as indicated (Ref. Figure 205).

and determine rivet hole locations on

Sta. 78.50 bulkhead.

(15).

Install J28 receptacle and secure with

washer (Ref. Figure 201) and nut.

(b). Drill rivet attach holes, 0.069-0.074

Install protective cap.

inch (1.7526-1.8796 mm).

(16).

Install ground stud on forward side of

(c). Attach angles to Sta. 78.50 bulkhead

canted bulkhead frame (Ref.

using rivets.

Figure 901). Identify stud as E19.

(17).

Install wires A527G12N, A527H20N,

(2). Install structural reinforcement

and A527J20N from J28 receptacle on

brackets.

ground stud E19. Adjust and trim

insulation tubing (CM614) to accommo

(a). Position structural reinforcement

date ground wire connection as re

brackets on forward side of Sta. 78.50

quired; heat shrink tubing.

canted bulkhead as shown (Ref.

Figure 902). Locate nine existing

(18).

(Ref. Figure 205) Check switch

rivets which must be removed prior

MS25089-4AR (S600) on cyclic stick

to installation of reinforcement

grip to verify that button is flush with

brackets. Remove rivets using drill

guard. If it is not, the switch must be

motor and appropriate drill bit.

reworked, as follows:

(b). Use brackets as templates and

(a). Remove switch from grip (unsolder

determine rivet hole locations on Sta.

wiring).

78.50 bulkhead. Drill rivet attach

holes, 0.069-0.074 inch

(b). Grind off end of switch button as

(1.7526-1.8796 mm).

shown.

(c). Attach brackets to Sta. 78.50 canted

Do not allow file chips to get into

CAUTION

bulkhead using rivets.

switch base.

(3). Drill eight 0.190-0.199 inch

(c). Install modified switch in grip and

(4.826-5.0546 mm) holes through Sta.

resolder wiring as shown.

78.50 canted bulkhead and structural

(d). Install decal 369H90070-67 to grip

reinforcement angles and brackets at

as shown.

locations shown (Ref. Figure 902).

Page 906

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MD Helicopters, Inc.

MAINTENANCE MANUAL

NOTE: Drill retainer tube outboard clamp

(1). Remove nylon screws installed in

holes first; install retainer tube and out

support fitting attachment holes on

board clamps to ensure proper alignment for

fuselage.

marking and drilling inboard clamp holes.

(2). Install support tube attachment fittings

(Ref. Figure 201) on fuselage using

(4). Install the retainer assembly (Ref.

screws and washers.

Figure 203) on Sta. 78.50 canted

bulkhead, using clamps, washers,

(3). Attach winch to support tube, using

spacers, screws, and nuts.

bolts, washers, and nuts. Torque bolts

to 70 - 100 inch-pounds (7.91 - 11.30

(5). Locate bracket on applicable passenger/

Nm).

cargo door in such a manner as to allow

(4). Attach link assembly to support tube

tube to engage bracket when door is in

using bearing pin, washer, and cotter

open position. Install bracket on

pin.

passenger/cargo door frame using

rivnuts, washers, and screws.

(5). Attach winch support tube to fuselage

fittings, using quick-disconnect pins.

G. Hoist Assembly

NOTE:

Install pins in position shown (Ref.

Figure 201).

(Ref. Figure 201) The hoist assembly consists

of a winch assembly, pendant control assembly,

Ensure all electrical power is

hook, hanger, and two attach brackets. To

CAUTION

off, eliminating possibility of in

assemble the hoist, proceed as follows:

advertent firing of cable cutter.

NOTE: Pendant assembly is shipped as

(6). Remove protective cap from electrical

sembled with no additional assembly re

receptacle on side of fuselage. Connect

quired.

winch electrical plug to fuselage

receptacle. Secure wire harness to

(1). Install hanger on winch, using screws,

support tube, using tie-straps (CM703).

lockwashers, and washers.

Remove protective electri

WARNING

cal jumper wire

(Ref.

(2). Remove existing attach brackets from

Figure 202) from cable cutter whenev

winch. Install replacement brackets on

er winch is installed on helicopter.

winch frame, using existing hardware.

Jumper wire will prevent operation of

cable cutter in an emergency.

H. Hoist Installation

(7). Install the hoist operator's body

The hoist system winch is mounted on a

harness (Ref. Figure 201).

support tube and attached with quick-release

(8). Install flush rivets in wheel fittings

safety pins to three fittings installed on either

after removing existing rivets from

side and above the passenger/cargo compart

locations shown (Ref. Figure 903).

ment door. The support tube positions the

winch to raise and lower the cable between the

NOTE: Do not install rivets if wheel fittings

side of the fuselage and the landing gear skid.

have been previously equipped with flush

The winch and support can be installed for use

rivets.

on either the left or right side of the helicopter

(9). Install rivnuts at locations shown (Ref.

as applicable. Install the hoist system as

Figure 903). Secure clips (Ref.

follows:

Figure 201) to fuselage, using screws

and washers. Install bar assembly,

Consumable Materials

using screws, washers, and nuts.

(Ref. Section 91−00−00)

(10). On R/H command, install landing gear

Item

Nomenclature

skid chafing bar assembly

CM703

Tie strap

(369D292556) as follows (Ref.

Figure 903):

Page 908

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HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369D/E/FF-500/600N HELICOPTERS (ISSUED: 1990) - page 9