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

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

NOTE: Determine cement adhesive tack with a

Plates must be larger than cemented

test specimen. Apply cement to a piece of

repair area.

buffed, scrap patch material each time ce

ment is spread on cell and repair patch.

Excessive clamp pressure may

CAUTION

deform cell and, or squeeze ce

(12). Coat patch, test specimen, and fuel cell,

ment out of joint.

including edges of damage, with EC678

cement (CM607). Allow cement to dry

(a). Cover both sides of repair with sheet

15 minutes before application of a

polyethylene plastic or oiled paper

second coat. Allow second coat to dry 15

large enough to cover entire cem

minutes.

ented area.

NOTE: Do not include opposite cell wall in

(13). Press a bare knuckle into cement on

clamp up. Work through cell access opening

test specimen. Cement that tears away

and arrange cell as necessary to clamp only

from skin leaving a rough, finely

the wall with the patch installation.

peaked imprint without transferring to

knuckle, is ready for patch installation.

(b). Sandwich repair area and barrier

material between pressure plates.

NOTE: Wipe cement with cheesecloth moist

Install at least two C-clamps over

ened with solvent to reactivate adhesive

pressure plates. Equalize clamp

when required.

pressure.

(14). A brayer or similar tool is required to

(16). Do not disturb cell. Maintain pressure

systematically roll patch into contact

for six hours, minimum, after which cell

with cell. Apply patch as follows:

is ready for internal patch installation.

(a). Center patch on repair area. Stick

(17). Remove clamps and plates.

one edge down and double check

patch alignment. If required, release

(18). Clean patch and cell internal repair

adhesive by flooding joint with

area with MEK saturated cheesecloth

solvent. Check adhesive tack again

swabs.

before proceeding with patch installa

tion.

(a). Apply two coats of cement, allowing

15 minutes drying time between

NOTE: The object of the next step is to get the

coats. Allow 15 minutes for second

patch down without trapping any air under

coat to set.

it.

(b). Install and roll out patch.

(b). Hold free edge of patch off cell.

Follow one line and roll tool back-

(19). Position a barrier sheet under each

and-forth over patch. Advance

pressure plate. Clamp and cure instal

toward loose end, 1/4 inch (6.35 mm)

lation for a minimum of 24 hours at 60

per pass until patch is down and free

- 80°F (16 - 27°C) before leak testing

of trapped air.

and returning cell to service.

(c). An alternate technique is to lay

7. Loose Edge and Lap Seam Repairs

prepared patch on a perfectly clean

sheet of polyethylene plastic about

Loose lap seams should be re

CAUTION

twice the size of the patch. Locate

paired as soon as possible after

plastic sheet and patch over cell

discovery.

repair area; then, slip sheet from

under patch as patch is rolled down,

NOTE: Loose lap seam edges not more than two

1/4 inch (6.35 mm) at a time.

inches long on cell interior or exterior sur

faces may be repaired. Seam separation re

(15). Fabricate two smooth, flat, rigid, metal

pairs require buffing, cementing and a

plates with no sharp edges or corners.

patch installation.

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MAINTENANCE MANUAL

(1). Lift seam separation and buff flap and

(f). Cover repair with a sheet of polyeth

cell faying surfaces with emery cloth

ylene plastic or oiled paper large

(CM804).

enough to cover entire cemented

area.

(a). Buff an area on exterior surface

extending 2 inches (5.08 cm) in all

(2). Fabricate two smooth, flat, rigid, metal

directions from seam separation.

plates with no sharp edges or corners.

Plates must be larger than cemented

repair area.

CAUTION

Excessive clamp pressure may

D Fuel cell and patch contact surfaces must

CAUTION

deform cell and, or squeeze ce

be perfectly clean and dry prior to adhe

ment out of joint.

sive and patch application. Rubber and

fabric particles, moisture, and fuel or oil

(a). Cover both sides of repair with

from fingers will prevent proper patch/

polyethylene plastic or oiled paper

cell adhesive seal and may subsequently

sheets large enough to cover entire

provide a leak path. Wear clean, lint free

cemented area.

gloves to handle patch and cell after pre

NOTE: Do not include opposite cell wall in

paring surfaces for cement and patch

clamp up. Work through cell access opening

application.

and arrange cell as necessary to clamp only

D Careless application of compressed air be

the wall containing the seam repair.

tween lap joints may separate seam fur

ther.

(3). Sandwich cell wall repair area and

barrier material between pressure

(b). Either air-vacuum or blow buffing

plates. Install at least two C-clamps

dust out of separation with dry, low

over pressure plates. Equalize clamp

pressure, compressed air.

pressure.

(c). Wipe inside and outside of repair

(4). Do not disturb cell. Maintain pressure

area clean with cheesecloth (CM820)

for six hours, minimum, after which cell

moistened with MEK (CM219).

is ready for patch installation.

Continue wiping with fresh solvent

(a). Remove clamps and plates.

dampened cheesecloth as required

until no stain or particle appears on

(5). Use #5200/5187/5194 sandwich patch

the swab after the last wipe. Allow

material on cell interiors.

area to dry.

(6). Use #5218 patch material on cell

Use cement sparingly. Two thin,

exterior surfaces.

CAUTION

even coats provide better adhe

(7). Prepare cell wall and patch for installa

sion than one thick coat.

tion per (Ref. Patch Installation):

NOTE: Determine cement adhesive tack with a

Install patch.

test specimen. Apply cement to a piece of

8. Blister Repair

buffed, scrap patch material each time ce

ment is spread on cell and repair patch.

Blisters can occur on cell interior and exterior

surfaces. blisters are caused by a separation of

(d). Apply two coats of EC678 cement

the cell laminates and may contain air or a

(CM607) allowing 15 minutes be

combination of air and fuel.

tween applications. Allow second coat

to dry 15 minutes.

NOTE: Exterior blisters that contain fuel indi

cate that the barrier has been penetrated.

(e). Roll separation together starting

Blisters inside cell measuring under one

from the bottom of the pocket toward

inch diameter are acceptable and need not

the open end, 1/4 inch (6.35 mm) per

be disturbed.

pass. Ensure no air is trapped

underneath.

(1). Repair blisters as follows:

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CSP-HMI-2

MAINTENANCE MANUAL

(a). Buff surface of blister and area

(2). Fabricate two smooth, flat, rigid, metal

extending two inches (5.08 cm) in all

plates with no sharp edges or corners.

directions from its edge.

Plates must be larger than cemented

repair area.

Avoid damaging nylon barrier

CAUTION

membrane. Do not probe, cut, or

Excessive clamp pressure may

CAUTION

puncture blisters with tool perpendicular to

deform cell and, or squeeze ce

cell wall.

ment out of joint.

(a). Cover both sides of repair with

(b). Slit blister open with an X cut to

polyethylene plastic or oiled paper

expose all of the delaminated surface.

sheets large enough to cover entire

Lift flaps and mop interior with clean

cemented area.

cheesecloth (CM820) and MEK

(CM219). Buff underlying cell surface

NOTE: Do not include opposite cell wall in

and blister flaps with emery cloth

clamp up. Work through cell access opening

(CM804). Air-vacuum or blow away

and arrange cell as necessary to clamp only

all traces of buffing dust.

the wall containing the blister repair.

(c). Wipe inside and outside of repair

(3).

Sandwich cell wall repair area and

area clean with cheesecloth moist

barrier material between pressure

ened with solvent or MEK. Continue

plates. Install at least two C-clamps

wiping with fresh solvent dampened

over pressure plates. Equalize clamp

cheesecloth as required until no stain

pressure.

or particle appears on the swab after

(4).

Do not disturb cell. Maintain pressure

the last wipe. Allow area to dry.

for six hours, minimum, after which cell

Use cement sparingly. Two,

is ready for patch installation; remove

CAUTION

thin, even coats provide better

clamps and plates.

adhesion than one thick coat.

(5).

Use #5200/5187/5194 sandwich patch

material on cell interiors.

NOTE: Determine cement adhesive tack with a

test specimen. Apply cement to a piece of

(6).

Use #5218 patch material on non-self-

buffed, scrap patch material each time ce

sealing cell exterior surfaces.

ment is spread on cell and repair patch.

(7).

Prepare cell wall and patch for installa

(d). Apply two coats of EC678 cement

tion per instructions for Patch Installa

allowing 15 minutes between applica

tion. Install patch.

tions. Allow second coat to dry 15

minutes.

(8).

Heat soak transmitter assembly in an

oven set at 100°F (38°C), maximum for

(e). Roll blister together starting from the

one hour to vaporize trapped volatiles.

bottom of each flap pocket toward the

A heat gun may be used as an alternate

open end, 1/4 inch (6.35 mm) per

drying method. Pot transmitter electri

pass. Ensure no air is trapped

cal connections with sealing compound

underneath.

MIL-S-8802 (CM425).

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CSP-HMI-2

MAINTENANCE MANUAL

ANTI−ICE/AIRFRAME FUEL FILTER

DESCRIPTION AND OPERATION

Table 1. Anti−Ice/Airframe Fuel Filter Effectivity

Installation

Model & Production Number

Features

369H90022−BSC

369D, 003 and subsequent

Helicopters equipped with slimline instrument panel.

369H90022−503

369E, 001 and subsequent

Helicopters equipped with T−instrument panel.

369H90022−503

500N, 001 and subsequent

Helicopters equipped with T−instrument panel.

600N98110−501

600N, 003 and subsequent

Helicopters equipped with T−instrument panel.

NOTE: Anti−ice / airframe fuel filter is not certified for installation on C30 engine installation.

NOTE: On the 600N helicopter, the airframe

pilot of an impending or total fuel filter

fuel filter is not certified as an anti-ice fuel

blockage by lighting the AIRFRAME

filter. Throughout this section, the airframe

FILTER caution lamp in the caution/

fuel filter will be refered to as an anti-ice

warning panel. The pilot must manual

fuel filter.

ly set the START PUMP switch ON to

pressurize the fuel system.

Description

(4).

On all installations, total filter blockage

(1). The airframe mounted anti-ice fuel

forces a filter bypass valve in the filter

filter is installed on the aft face of the

body open to second supply unfiltered

firewall upstream of the engine fuel

fuel to the engine.

pump filter. The 10 micron, 500 square

inch disposable filter element strips ice

(5).

Pressing the FUEL FILTER caution

and other solids from the fuel before it

light/switch supplied with

enters the engine fuel system.

369H90022-BSC installations resets

relay K254 and the time delay relay,

Operation

shuts down the start pump and START

PUMP ON light and switches off the

(1). A flow pressure sensing switch in the

FUEL FILTER caution light.

filter body furnished with all installa

tions closes when flow differential

(6).

The caution light dimmer switch on the

pressure across the filter drops to a

lower left control panel of -BSC

preset level.

installations controls only FUEL

FILTER caution light intensity with

(2). On the 369H90022-BSC installation,

DIM or BRT positions. FUEL FILTER

pressure switch contact closure directs

caution lamp test is executed with the

28Vdc current across the S2 contacts of

PRESS TO TST WARN LT switch on

the FUEL FILTER relay K254 to

the caution/warning light panel.

activate the RT170-277 time delay

relay (TDR). The TDR energizes relay

(7).

On -503, -505 and -501 installations,

K254 after a two to five second delay,

caution light intensities, including the

closing switches S1, S2, and S3;

AIRFRAME FILTER light are

energizing the FUEL FILTER caution

controlled through the WARN LT DIM

light, start pump and START PUMP

potentiometer on the pedestal switch

ON light.

panel.

(3). On 369H90022-503, -505 and

(8).

Circuit protection is provided by the 7.5

600N98110-501 fuel filter installations,

ampere anti-ice FUEL FILTER circuit

pressure switch closure only advises the

breaker on the anti-ice fuel filter panel.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

Determine why a circuit break

Air in the fuel system will

CAUTION

WARNING

er popped before pushing the re

cause a power reduction or

set button (Ref. Table 101).

flameout. Do a fuel system vacuum leak

check and system air bleed after open

(9). A press-to-test button located on top of

ing fuel system to atmosphere and

the filter body is featured in all installa

prior to releasing helicopter for flight.

tions. Pressing the button simulates a

Ensure start/boost pump is operating

blocked filter condition for power-on

before taking fuel samples from system

ground test.

drain valves.

(10). On all installations, a filter bowl drain

valve plumbed into the drain manifold

provides for filter draining and fuel

(11). Refer to Table 101 for anti-ice fuel filter

sampling.

fault isolation information.

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CSP-HMI-2

MAINTENANCE MANUAL

ANTI−ICE/AIRFRAME FUEL FILTER

FAULT ISOLATION

NOTE: On the 600N helicopter, the airframe

fuel filter is not certified as an anti-ice fuel

filter. Throughout this section, the airframe

fuel filter will be refered to as an anti-ice

fuel filter.

1. Anti−Ice Fuel Filter System Fault Isolation

Table 101. Anti−Ice Fuel Filter System Fault Isolation

Symptom

Probable Trouble

Corrective Action

FUEL FILTER caution lamp

No power. Battery switch OFF.

Supply power. Set battery switch to BATT or

does not light.

EXT PWR position.

Circuit breaker reset button

Press circuit breaker reset button.

pulled out. (369D/E − 500N)

Defective wiring or connection. Locate circuit defect and repair as required.

FUEL FILTER caution light on. System not reset.

Press FUEL FILTER caution light to reset.

Clogged fuel filter.

Drain filter bowl into a suitable container.

Inspect sample for foreign substances.

Remove and replace filter element.

Defective wiring.

Locate circuit defect and repair as required.

START PUMP ON lamp fails

No power. Battery switch OFF.

Supply power. Set battery switch to BATT or

to light.

EXT PWR.

Circuit breaker reset button

Press circuit breaker reset button.

pulled out. (369D/E − 500N)

Defective lamp.

Replace lamp.

Defective wiring.

Locate circuit defect and repair as required.

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MAINTENANCE MANUAL

ANTI−ICE/AIRFRAME FUEL FILTER

MAINTENANCE PRACTICES

NOTE: On the 600N helicopter, the airframe

B. Anti−Ice Fuel Filter Installation

fuel filter is not certified as an anti-ice fuel

filter. Throughout this section, the airframe

Consumable Materials

fuel filter will be refered to as an anti-ice

(Ref. Section 91−00−00)

fuel filter.

Item

Nomenclature

CM113

Anti-seize compound low temperature

1. Anti−Ice Fuel Filter Replacement

(Ref. Figure 201)

(1). Attach assembled filter to bracket with

bolts, washers and spacers. Torque

A. Anti−Ice Fuel Filter Removal

bolts 50 - 70 inch-pounds (5.65 - 7.91

Nm). Install lockwire.

Prevent fuel vapor ignition.

WARNING

(a). Apply a thin coat of anti-seize

Turn OFF and disconnect all

compound (CM113) to all male fuel

electrical power. Electrically ground

line fittings.

helicopter before opening fuel system.

Do not twist hoses while torqu

(1). Disconnect battery and external power

CAUTION

ing hose nuts. Use a backup

(Ref. Sec. 96-05-10).

wrench to stabilize hose.

(a).

Pull FUEL VALVE knob to close fuel

(b). Install hose between filter and

shut off valve.

engine. Install hose between filter

and firewall fitting. Torque hose nuts

(b).

Open engine access doors.

230 - 260 inch-pounds (25.99 -

29.38 Nm).

(c).

Drain fuel from filter bowl and

(c). Connect wire harness connector to

supply line drain valves.

fuel filter plug.

(d).

Unclamp and disconnect filter drain

(d). Connect drain tube to filter drain

tube.

valve. Clamp tube to valve with

lockwire.

(e).

Remove fuel supply hose between

engine driven fuel pump and anti-ice

Air in the fuel system will

WARNING

filter. Cap hose ends and fittings.

cause a power reduction or

flameout. Do a fuel system vacuum leak

check and system air bleed after open

(f).

Remove hose assembly between

ing fuel system to atmosphere and

anti-ice filter and firewall fitting.

prior to releasing helicopter for flight.

Cap hose ends and fittings.

Ensure start pump is operating before

taking fuel samples from system drain

(g).

Remove anti-ice filter electrical

valves.

connector.

(e). Perform a fuel system vacuum leak

(h).

Unbolt and remove filter body

check (Ref. Fuel System Vacuum

assembly.

Leak Check).

(i).

Unscrew filter bowl from body, as

(f). Bleed fuel system (Ref. Fuel System

required.

Air Bleed).

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MAINTENANCE MANUAL

2. Fuel System Air Bleed

(d). Set helicopter master switch to

BATT.

Prevent fuel vapor accumu

WARNING

lation, ignition and fire. Per

(e). Set START PUMP switch ON to

form work in an open, well ventilated

pressurize fuel system. Check start

area away from all potential ignition

pump for operation.

sources. Attach helicopter to an ap

(f). Loosen engine filter bowl plug. Let

proved electrical ground. Wear ap

fuel flow until a steady, bubble free,

proved eye protection.

uninterrupted fuel stream emerges

without any evidence of trapped air.

Do not operate start pump in an

CAUTION

Tighten plug.

empty fuel tank.

(2). Refer to applicable Allison Engine

NOTE: The object of fuel system bleeding is to

Operation and Maintenance Manual for

remove all air trapped in the fuel supply

specific engine fuel system air bleed

system.

information.

(1). Refuel helicopter as required.

(a). Purge air from engine fuel system

per Allison Engine Operation and

(a). Connect battery.

Maintenance Manual.

(b). Open engine access doors.

(3). Set START PUMP and battery

switches OFF.

(c). In crew compartment; push FUEL

shutoff valve knob in to open shutoff

(4). Reassemble drain system as required

valve.

and install lockwire.

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MAINTENANCE MANUAL

ANTI−ICE/AIRFRAME FUEL FILTER

INSPECTION/CHECK

NOTE: On the 600N helicopter, the airframe

(g). Do an anti-ice fuel filter functional

fuel filter is not certified as an anti-ice fuel

check (Ref. Anti-Ice Fuel Filter

filter. Throughout this section, the airframe

Installation Operational Check:

fuel filter will be refered to as an anti-ice

369H90022-BSC).

fuel filter.

(2). Inspect wiring for damage and security.

Repair or replace damaged components.

1. Anti−Ice Fuel Filter System Inspection

Air in the fuel system will

A one time diode inspection and

WARNING

CAUTION

cause a power reduction or

polarity check is mandatory for

flameout. Do a fuel system vacuum leak

helicopters

equipped

with

check and system air bleed after open

369H90022-BSC anti-ice fuel filter instal

ing fuel system to atmosphere and

lation and, or 369H90118 auto-reignition

prior to releasing helicopter for flight.

installation on helicopters delivered in

Ensure start pump is operating before

1979. The following procedures address only

taking fuel samples from system drain

the anti-ice fuel filter installation.

valves.

(3). Inspect fuel system as follows:

Special Tools

(Ref. Section 91−00−00)

(a). Apply external power to the helicop

Item

Nomenclature

ter.

N/A

Ohmmeter

(b). Open the engine compartment doors.

N/A

Voltmeter

(c). Set battery switch to EXT PWR.

(d). Push FUEL VALVE knob in to open

(1). Determine ohmmeter lead polarity with

fuel shutoff valve.

voltmeter.

(e). Set START PUMP switch; ON.

(a). In crew compartment; remove cover

Check start pump operation.

from anti-ice caution/warning light

panel.

NOTE: Failure to drain in freezing tempera

tures may be due to ice buildup.

(b). Find part number stamped on diode

C26 (Ref. Figure 201).

(f). Drain several ounces of fuel from

filter bowl into a suitable container.

(c). Diodes, part numbers 1N3210 do not

Inspect sample for solids and water

require a polarity check.

contamination. Dismantle and clean

filter bowl as required. Replace filter

(d). Replace diodes, part number

element.

1N3210R with a new part number

1N3210 diode.

(g). Inspect hose assemblies for evidence

of leakage, swelling or dampness,

(e). If the diode is unidentifiable, test

kinks, cuts, twists, tears and fraying.

diode to determine polarity.

Check hose nut threads for damage.

Replace damaged parts.

1). Check for low forward resistance

with ohmmeter positive lead

(h). Disconnect drain tubes from drain

attached to terminal end and

valves. Check each drain valve for

negative lead attached to stud end.

leakage. Replace damaged drain

Reverse leads and check for very

valves.

high resistance.

(i). Inspect filter fuel line fittings for

(f). Replace diode with a new 1N3210

leakage. Repair or replace parts as

unit if polarity is reversed.

required.

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MAINTENANCE MANUAL

(j). Connect drain tubes to drain valves.

(c). Start pump stops running.

Inspect drain tubes for security and

(5). Inspect fuel system for leakage.

correct routing without fluid traps or

kinks.

3. Anti−Ice Fuel Filter Installation

Operational Check: 369H90022−503, −505

(k). Inspect fuel filter press-to-test

and 600N98110−501

button for security.

(1). Apply external power to the helicopter.

2. Anti−Ice Fuel Filter Installation

Set battery switch to EXT PWR.

Operational Check: 369H90022−BSC

(a). Reset PNL LT circuit breaker.

NOTE: The system may be operated with a ful

(b). Press PRESS TO TST WRN LT on

ly charged battery that can provide more

the caution/warning light panel.

than the 23.8 Vdc required to actuate sys

Check entire caution/warning light

tem solenoids. If battery state is an un

array. Replace lamps as required.

known, use external power.

(c). Push FUEL VALVE knob in to open

fuel shutoff valve.

(1). Apply external power to the helicopter.

Set battery switch to EXT PWR.

(2). Set START PUMP switch ON.

(a). Reset PNL LT and FUEL ANTI-

(a). START PUMP ON indicator light

ICE circuit breakers.

comes on and start pump pressurizes

fuel system.

(b). Press PRESS TO TST WRN LT on

(3). Open the engine compartment doors.

the caution/warning light panel.

Check entire caution/warning light

(4). Press the red press-to-test button on

array. Replace lamps as required.

top of airframe filter body. Result shall

be:

(c). Push FUEL VALVE knob in to open

(a). AIRFRAME FILTER caution light

fuel shutoff valve.

comes on.

(d). Open the engine compartment doors.

(5). Release the press-to-test button.

(2). Press the red press-to-test button on

(a). AIRFRAME FILTER caution light

top of the filter body for five or more

goes out.

seconds. Test results shall be as follows:

(6). Set START PUMP switch OFF.

(a). FUEL FILTER caution light comes

(7). Inspect fuel system for leaks.

on.

4. Fuel System Vacuum Leak Check

(b). START PUMP ON indicator light

(1). Fuel is drawn out of the tank by the

comes on and start pump pressurizes

engine driven fuel pump when the start

fuel system.

pump is switched off. Water, ice, dirt,

fungus, trapped air or a few pinhole

(3). Release the press-to-test button.

leaks in the supply system between the

(a). FUEL FILTER and START PUMP

fuel tank sump pickup and engine

ON lights remain on and start pump

combustion chamber nozzles may cause

continues to operate.

power surges, deceleration and, or

flameout. A vacuum leak inspection will

(4). Press FUEL FILTER caution light to

determine whether or not air can be

reset system. Result shall be:

drawn into the fuel system by the

engine driven fuel pump.

(a). FUEL FILTER caution light goes

out.

(2). An automotive vacuum test pump and

hardware that will provide 8 Hg

(b). START PUMP ON indicator light

vacuum or better is required to do the

goes out.

vacuum leak check.

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MAINTENANCE MANUAL

(3). Assemble vacuum pump, hoses, filter

(b). Fuel system shall hold vacuum

port adapter, shutoff valve and vacuum

between 8 and 7.5 Hg for two min

gage as follows:

utes.

(a).

Insert a vacuum gage in the vacuum

(c). If test is satisfactory, remove test

hose between the engine fuel filter

apparatus. Inspect and replace filter

port adapter and vacuum shutoff

plug O-ring as required. Install filter

valve. Attach the vacuum pump to

plug.

the vacuum hose above the shutoff

valve.

(6). Vacuum loss exceeding 0.5 Hg in two

minutes indicates a leak somewhere in

(b).

Plug vacuum hose and pull 5 - 10 Hg

the system between the fuel shutoff

vacuum. Apparatus should hold the

valve and engine.

selected pressure indefinitely. Repair

leaky equipment before proceeding

(a). Torque fuel line connections (Ref.

with fuel system test.

Table 601). Repeat vacuum test.

(c).

Open engine access doors.

(b). If system continues to leak, discon

(d).

Remove left fuel cell floor access

nect and install airtight caps or plugs

panel.

in tubes, hoses and fitting ports in a

progressive sequence from fuel

(e).

In crew compartment; pull FUEL

shutoff valve toward engine. The fuel

shutoff valve knob out to stop. Verify

shutoff and drain valve installations

that fuel shutoff valve lever on left

should be especially suspect. Apply

fuel cell access cover is hard against

vacuum at each stage until leak has

its OFF stop. Rig control cable as

been isolated. Replace parts as

required.

(f).

In engine compartment; remove the

upper drain plug from the fuel pump

(c). Apply a torque stripe to all effected

filter bowl.

fuel line fittings and nuts.

(4). Disconnect the fuel bleed return line at

(d). If the airframe system vacuum held

Sta. 124.00 (if equipped) and cap off.

at 7.5 Hg or better, system seal is

satisfactory and malfunction is

(5). Attach vacuum test apparatus to

probably due to an engine system

engine fuel filter upper drain port.

leak. Refer to the applicable Allison

(a). Apply 8 Hg vacuum. Close vacuum

and Bendix manuals for additional

line shutoff valve.

information.

Table 601. Fuel Supply System Torque Values

Torque Range

Item & Location

Inch−Pounds (Nm)

Tube end−nuts; fuel shutoff valve; Sta. 124.00 Blkhd elbow

230 − 260 (25.99 − 29.38)

Blkhd elbow jamnut; Sta. 124.00

145 − 155 (16.38 − 17.51)

Three−port elbow jamnuts

145 − 155 (16.38 − 17.51)

Anti−ice filter drain fitting bolt

185 − 200 (20.90 − 22.60)

Anti−ice filter in/out reducers

550 − 600 (62.14 − 67.79)

Hose end−nuts; firewall/filter

230 − 260 (25.99 − 29.38)

Hose end−nuts; filter/engine

230 − 260 (25.99 − 29.38)

Drain valves (all)

95 − 105 (10.73 − 11.86)

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CSP-HMI-2

MAINTENANCE MANUAL

ANTI−ICE/AIRFRAME FUEL FILTER

INITIAL INSTALLATION

NOTE: On the 600N helicopter, the airframe

tal and drill three 0.219 inch (5.56 mm)

fuel filter is not certified as an anti-ice fuel

diameter holes in pedestal.

filter. Throughout this section, the airframe

(3). Make cutout shown in instrument

fuel filter will be refered to as an anti-ice

pedestal fairing.

fuel filter.

(4). Deburr holes and cutout edges. Remove

1. Anti−Ice Fuel Filter Initial Installation

debris.

A. Preparations for Installation

(5). Install rivnut and attach anti-ice fuel

filter panel to instrument pedestal with

Prevent fuel vapor ignition.

screws, washers and spacers.

WARNING

Turn OFF and disconnect all

electrical power. Attach helicopter to

(6). Connect wires (Ref. Figure 903).

approved grounding points before

(7). Install cover and screws.

opening fuel system.

(8). Install ANTI-ICE FUEL FILTER

(1). Disconnect external power and battery.

INSTALLATION placard decal on

heater duct three inches (7.62 cm)

(2). Remove aft compartment seats.

above standby compass bracket. Roll

(3). Remove aft upper left bulkhead panel.

placard edges to follow duct contour.

(9). Seal both ends of electrical conduit with

(4). Remove lower aft bulkhead panel.

silicone adhesive/sealant (CM430).

(5). Remove pilot compartment left floor

C. Anti−Ice Fuel Filter Control Panel

access door.

Installation: 369H90022−503, and −505

(6). Remove instrument panel hood and left

fairing.

Consumable Materials

(Ref. Section 91-00-00)

(7). Pull FUEL VALVE knob to close fuel

Item

Nomenclature

shut off valve.

CM430

Sealant, solvent resistant

B. Anti−Ice Fuel Filter Control Panel

Installation: 369H90022−BSC

(1). Pull fuel filter wire harness forward

through conduit and along an existing

wire bundle to instrument pedestal.

Consumable Materials

(Ref. Section 91−00−00)

(2). Secure wire to engine compartment

Item

Nomenclature

airframe with clamps, screws, washers

CM430

Sealant, solvent resistant

and nuts and to wire bundle with

ty-raps (Ref. Figure 901).

(1). Pull filter wire harness forward

(3). Install 20 gage bus wire and insulating

through conduit and along an existing

sleeve on back side of caution light

wire bundle to instrument pedestal.

DS31 (Ref. Figure 904).

Secure to engine compartment airframe

(4). Remove fourth plug from the right on

with clamps, screws, washers and nuts

caution/warning light panel.

and to wire bundle with ty-raps (Ref.

Figure 901).

(5). Wire and connect electrical system (Ref.

Figure 904).

(2). Use anti-ice fuel filter subpanel as a

template on left side of slimline pedes

(6). Install caution light in panel.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

(7). Install ANTI-ICE FUEL FILTER

E. Firewall Modifications and Bracket

INSTALLATION placard decal on

Installation

heater duct three inches (7.62 cm)

(Ref. Figure 901 for 369H90022-BSC, -503

above standby compass bracket. Roll

and -505)

placard edges to follow duct contour.

(Ref. Figure 902 for 600N96110-501)

(8). Seal both ends of electrical conduit with

silicone adhesive/sealant (CM430).

Consumable Materials

D. Anti−Ice Fuel Filter Control Panel

(Ref. Section 91−00−00)

Installation: 600N98110−501

Item

Nomenclature

CM318

Primer

(Ref. Figure 601)

(1). To install caution/warning light:

(1). Open engine access doors.

(a). Remove third plug from the right on

(2). Drain fuel from supply lines into a

caution/warning light panel.

suitable container.

(b). Install caution light in panel.

(3). Remove fuel supply hose between

engine driven fuel pump and firewall

(c). Install 22 gage jumper wire on back

fitting elbow. Cap hose ends, firewall

side of caution lights between DS21C

elbow and fuel pump port.

and DS22C.

(4). Reposition firewall elbow 18 - 22°

(d). Run O506D22 wire from DS21-2 to

clockwise (Ref. view A).

P12-14 and secure to existing wires.

Do not score, scratch or gouge

(2). To install fuel pump switch and light:

CAUTION

firewall surface when trimming

insulation blanket.

(a). Remove edge-lighted switch panel.

(5).

Lay out and remove insulation strips

(b). Remove tape from start pump switch

from firewall to eliminate interference

and light holes in instrument panel.

with filter support bracket installation.

(c). Install CB118 in panel.

(6).

Position doubler on Sta. 124.00 firewall.

Identify, mark and drill-out existing

(d). Run 22 gage jumper wire from

rivets used in doubler installation. Do

CB115-1 to CB118-1.

not enlarge rivet holes.

(e). Run Q1169A22 wire from CB118-2 to

(7).

Locate doubler on firewall forward

TB503-2-2.

surface. Drill doubler through existing

rivet holes.

(f). Install light (XDS7) from back side of

panel.

(8).

Deburr holes and remove debris.

(g). Run E1181A22 wire from P13-46 to

(9).

Cleco doubler to firewall.

XDS7.

(10).

Apply primer (CM318) to rivet holes

(h). Run E1181B22N wire from XDS7 to

and rivets.

E31-E.

(11).

Install rivets while primer is wet.

(i). Reinstall edge-lighted switch panel.

(12).

Use filter support bracket as a tem

plate. Mark and drill filter bracket rivet

(3). Install ANTI-ICE FUEL FILTER

holes.

INSTALLATION placard decal on

heater duct three inches (7.62 cm)

(13).

Deburr holes and remove debris.

above standby compass bracket. Roll

placard edges to follow duct contour.

(14).

Cleco bracket in position.

Page 902

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CSP-HMI-2

MAINTENANCE MANUAL

(15). Apply primer to rivet holes and rivets.

(4). Apply a thin coat of anti-seize com

pound (CM113) to fitting-bolt threads.

(16). Rivet bracket in place while primer is

Stack fitting and gaskets on bottom of

wet.

filter. Install and torque bolt 185 - 200

inch-pounds (20.90 - 22.60 Nm).

(17). Install electrical bonding jumper

between bracket and airframe.

(5). Lubricate drain valve O-ring packing

with clean jet fuel and install on drain

(18). Position double aft of Sta. 124.00

valve. Apply a thin coat of anti-seize

between LBL 4.250 and LBL 8.450.

compound to drain valve threads.

Drill rivet holes and cleco in place.

(6). Install drain valve with O-ring packing

(19). Drill hole for drain hose.

on fuel filter drain fitting. Torque drain

valve 95 - 105 inch-pounds (10.73 -

(20). Remove doubler , deburr and remove

11.86 Nm).

debris.

(7). Install and clamp drain tube to drain

(21). Apply primer (CM318) to rivet and

valve with lockwire.

drain holes.

NOTE: Provide enough slack in drain tubes to

(22). Install doubler while rivets are still

allow unrestrained drain valve operation.

wet.

(8). On 600N96110-501 installation, install

F. Fuel Filter Installation

mount to firewall using adhesive

(CM438).

Air in the fuel system will

WARNING

(9). Clamp tube to bulkhead frame or

cause a power reduction or

mount at LBL 8.45 with TY-25M

flameout. Do a fuel system vacuum leak

TYRAP.

check and system air bleed after open

ing fuel system to atmosphere and

(10). Lubricate the two reducer O-rings with

prior to releasing helicopter for flight.

clean jet fuel. Install O-rings on large

Ensure start pump is operating before

ends of reducers. Apply a thin coat of

taking fuel samples from system drain

anti-seize compound to reducer

valves.

threads.

(Ref. Figure 901 for 369H90022-BSC, -503

(11). Install reducers with O-rings in filter

and -505)

inlet and outlet ports. Torque reducers

to 550 - 600 inch-pounds (62.14 -

(Ref. Figure 902 for 600N96110-501)

67.79 Nm).

Do not allow hose to twist when

Consumable Materials

CAUTION

torquing hose nuts. Use a back

(Ref. Section 91−00−00)

up wrench to stabilize hose.

Item

Nomenclature

(12). Connect hose between filter outlet port

CM113

Anti-seize compound low temperature

and engine fuel pump filter inlet port.

CM438

Adhesive, epoxy

Torque hose nuts 230 - 260 inch-

pounds (25.99 - 29.38 Nm).

(1). Remove engine gearcase cooling duct

(13). Install hose between filter inlet port

clip and attaching hardware.

and firewall fitting elbow. Torque hose

nuts 230 - 260 inch-pounds (25.99 -

(2). Drill a 0.250 inch (6.35 mm) diameter

29.38 Nm).

hole and relocate clip.

(14). Secure hoses with clamps, screws,

(3). Install filter assembly on bracket with

washers and nuts.

bolts, washers and spacers. Torque

bolts 50 - 70 inch-pounds (5.65 - 7.91

(15). Install wire connector plug on filter

Nm). Install lockwire.

receptacle.

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Revision 28

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

BOLT, WASHER,

LOCKWIRE

RIVET

HOSE

(7 PLCS)

(NOTE 1)

BRACKET

(NOTE 2)

HOSE

(TANK TO FILTER)

LOOKING DOWN

CLAMP, SCREW,

0.75 INCH

WASHER, NUT

(17.05 MM)

CLAMP, SCREW

(NOTE 10)

WASHER, (2 REQD)

0.260 INCH (6060 MM)

RIVET

NUT

DIA HOLE

RIVET

(NOTE 9)

(NOTE 8)

CLAMP

(NOTE 8)

ENGINE FUEL

(2 PLCS)

DUCT (REF)

PUMP (REF)

WL 22.85

WIRE HARNESS

RIVET

(NOTE 8)

CLIP (NOTE 3)

RIVET

(NOTE 1)

(NOTES 8, 9)

INSULATION

FILTER ASSY

(REF)

RIVET

ELBOW

(NOTE 8)

(NOTE 4)

WL 13.10

LANDING GEAR DAMPER

(REF)

FITTING, BOLT

TORQUE TO 185-200 IN-LBS

(20.90-22.60 NM)

18°

GASKET (2 REQD) (NOTE 7)

20°

TUBE

TY-25N TY-RAP

(NOTE 5)

CONDUIT

(REF)

WL 5.14

STA 124.0

CONDUIT (REF)

CLAMP, SCREW,

(NOTE 6)

WASHER, NUT

LBL 13.23

(NOTE 10)

WIRE HARNESS ASSY

0.00-0.12 INCH

LBL 8.45

(0.00-3.05 MM)

(NOTE 15)

LOOKING FORWARD

SCREW, CLAMP,

WASHER, NUT

(NOTE 10)

STA 137.50

VIEW A-A

EFFECTIVITY: 369D/E - 500N

G28-2003-1D

Figure 901. Anti−Ice Fuel Filter Modifications and Installation (369D/E − 500N) (Sheet 1 of 2)

Page 904

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

0.25 INCH

(6.35 MM)

STIFFENER

1.00 INCH

(2.54 CM)

1.00 INCH

PANEL

(2.54 CM)

1.75 INCH

(4.445 CM)

NOTE 13

INSULATION

PANEL

REDUCER (2 REQD)

5.00 INCH

STA 124.0

PACKING (2 REQD)

(12.70 CM)

(NOTE 12)

BRACKET

DOUBLER

(NOTE 14)

HOSE ASSY

PANEL

STIFFENER PANEL

STIFFENER

SPACER

(3 REQD)

HOSE ASSY

DUCT

PLACARD

(NOTE 11)

WL 13.10

3.00 INCH

(7.62 CM)

VALVE PACKING

(NOTE 12)

TUBE

COMPASS BRACKET

(REF)

7.25 INCH

0.12 R

(18.415 CM)

(TYP)

5.50 INCH

(13.97 CM)

DOUBLER

EFFECTIVITY: 369D/E - 500N

G28-2003-2D

Figure 901. Anti−Ice Fuel Filter Modifications and Installation (369D/E − 500N) (Sheet 2 of 2)

Page 905

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Revision 19

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

NOTE:

(1)

Pick up existing rivet locations, seven places. Install MS29615−4M rivets or NAS1738 M4 alternates. Install

rivets in wet MIL−P−23377 Type 1, Class 1, epoxy primer or, MIL−P−8585 primer.

(2)

Electrically bond bracket to firewall with an approved bonding jumper installed per requirements of FAA

publication EA−AC43.13−1A and 2A.

(3)

Reposition clip 0.75 inch (19.05 mm) inboard.

(4)

Shim elbow to 18−22 degrees clockwise.

(5)

Route filter drain tube to clear landing gear damper while allowing unrestrained drain valve operation.

(6)

Seal both ends of conduit with RTV 732 sealant/adhesive after wire harness installation.

(7)

Apply low temperature anti−seize compound, MIL−T−5544B Thread Lube or equivalent to assembly

threads prior to installation. Torque bolt 185 − 200 inch−pounds (20.90 − 22.60 Nm).

(8)

Install MS20615−3M rivets in wet MIL−P−23377, Type 1, Class 1, epoxy primer or, MIL−P−8585 primer.

(9)

Install MS20615−4M or alternate NAS−1738M4 rivets in wet MIL−P−23377, Type 1, Class, 1 epoxy primer

or, MIL−P−8585 primer.

(10)

Clamp wire harness in place as shown using existing tool holes.

(11)

Roll placard edges to follow heater duct contour.

(12)

Apply MIL−T−5544B low temperature anti−seize compound to threads prior to assembly.

(13)

Cut away insulation blanket per dimensions shown for bracket installation. Remove blanket debris. Do not

scratch firewall surface.

(14)

Install doubler on forward firewall surface as shown. Pick up all existing rivet holes in doubler installation.

(15)

Trim drain tube protrusion flush to 0.12 inch (3.048 mm) below grommet surface.

Page 906

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28-25-00

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

ENGINE INSTALLATION

CLAMP, SCREW

WASHER (2 REQD)

LBL

RIVET

NUT

8.450

(NOTE 6)

(NOTE 8)

CONNECTOR

22.850

REDUCER

O-RING

(NOTE 9)

HOSE

FILTER

MOUNT

(NOTE 4)

BOLT

NUT

WASHER

HOSE

0.00-0.12 INCH

O-RING

LBL

(NOTE 3)

(0.00-3.05 CM)

RIVET (7 PL)

BUSHING

8.450

(NOTE 12)

(NOTE 1)

O-RING

BULKHEAD ELBOW

124.000

LOOKING FORWARD

CLAMPS,

HOSE

SCREW

(TANK-TO-FILTER)

WASHERS,

NUT

137.500

BRACKET

(NOTE 2)

LOOKING DOWN

EFFECTIVITY: 600N

G28-2009-1

Figure 902. Anti−Ice Fuel Filter Modifications and Installation (600N) (Sheet 1 of 2)

Page 907

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Revision 19

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

1.00 INCH

STIFFENER

(2.54 CM)

1.75 INCH

(4.45 CM)

STIFFENER

PANEL

NOTE 10

STIFFENER

0.25 INCH

(6.35 MM)

1.00 INCH

(2.54 CM)

INSULATION

5.00 INCH

(12.70 CM)

PANEL

SPACER

(3 REQD)

PANEL

LOOKING FORWARD

13.100

FITTING, BOLT

TORQUE TO 185 - 200 INCH-POUNDS

(20.90 - 22.60 NM)

GASKET (2 REQD) (NOTE 5)

DRAIN VALVE O-RING

(NOTE 9)

DOUBLER

LBL

RIVET

(NOTE 11)

8.450

(NOTE 1)

137.000

RIVET

(NOTE 7)

LOOKING INBOARD

LEFT SIDE

124.000

22.850

RIVET

(NOTE 6)

(NOTE 1)

LBL

8.450

4.250

RIVET

(NOTE 6, 7)

RIVET

(NOTE 1)

124.000

(NOTE 6)

LOOKING AFT

DOUBLER

RIVET

GROMMET

LOOKING DOWN

EFFECTIVITY: 600N

G28-2009-2

Figure 902. Anti−Ice Fuel Filter Modifications and Installation (600N) (Sheet 2 of 2)

Page 908

Revision 19

28-25-00

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

NOTE:

(1) Pick up existing rivet locations, seven places. Install MS29615−4M rivets or NAS1738 M4 alternates. Install

rivets in wet MIL−P−23377 Type 1, Class 1, epoxy primer or, MIL−P−8585 primer.

(2) Electrically bond bracket to firewall with an approved bonding jumper installed per requirements of FAA

publication EA−AC43.13−1A and 2A.

(3) Route filter drain tube to clear landing gear damper while allowing unrestrained drain valve operation.

(4) Install with adhesive CM438.

(5) Apply low temperature anti−seize compound, MIL−T−5544B Thread Lube or equivalent to assembly

threads prior to installation. Torque bolt 185 − 200 inch−pounds (20.90 − 22.60 Nm).

(6) Install MS20615−3M rivets in wet MIL−P−23377, Type 1, Class 1, epoxy primer or, MIL−P−8585 primer.

(7) Install MS20615−4M or alternate NAS−1738M4 rivets in wet MIL−P−23377, Type 1, Class, 1 epoxy primer

or, MIL−P−8585 primer.

(8) Clamp wire harness in place as shown using existing tool holes.

(9) Apply MIL−T−5544B low temperature anti−seize compound to threads prior to assembly.

(10) Cut away insulation blanket per dimensions shown for bracket installation. Remove blanket debris. Do not

scratch firewall surface.

(11) Install doubler on forward firewall surface as shown. Pick up all existing rivet holes in doubler installation.

(12) Trim drain tube protrusion flush to 0.12 inch (3.048 mm) below grommet surface.

Page 909

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(16). Measure electrical resistance between

Prevent fuel system contamina

CAUTION

filter bowl and firewall. Resistance

tion. Install caps on the ends of

shall not be more than 0.003 ohms.

hoses, tubes and fittings as the parts are re

moved. Bag and identify small parts to pre

G. Post−Installation Inspection

vent loss or damage.

(1). Ensure that all installation debris has

(1). Defuel helicopter (Ref. Sec. 12-00-00).

been removed.

Drain remaining fuel from tank sump

drain valve into a suitable container.

(2). Check all electrical connections for

(2). Disconnect electrical power.

correct routing and security.

A. Fuel Cell Cover Removal

(3). Ensure that all hardware, tubes, and

(1). To remove left aft fuel cell access cover:

hoses are properly secured.

(a).

Remove left aft fuel cell access panel

(4). Ensure that no fuel can be trapped by

from passenger/cargo compartment

the drain system.

floor.

H. Furnishings, Panels and Equipment

(b).

Unclamp and disconnect control

Installation

cable from fuel shutoff valve.

(c).

Disconnect engine feed fuel supply

(1). Install instrument panel hood and

hose assembly between fuel shutoff

instrument panel left side fairing.

valve and Sta. 124.00 bulkhead. Use

(2). Install pilot's compartment left floor

backup wrench on fuel shutoff valve

access panel.

so it will not rotate.

(d).

Disconnect motive flow fuel hose

(3). Install upper left aft bulkhead panel

assembly between Sta 124.00 bulk

and lower aft bulkhead panel.

head and fuel cell access cover.

(4). Install aft compartment seats.

(e).

Disconnect fuel quantity probe wire

harness connector from fuel cell cover

(5). Close engine access doors.

receptacle.

(6). Connect battery.

(f).

Unfasten and remove Sta. 91.00 and

102.00 left aft fuel cell cover support

2. Anti−Ice Fuel Pump Initial Installation

brackets.

(600N98110−501 Installation)

(g).

Remove cover bolts and washers.

(Ref. Figure 907)

Prop cover open with suitably padded

blocks.

Consumable Materials

(h).

Using a backup wrench on valve,

(Ref. Section 91−00−00)

separate engine feed fuel cell supply

Item

Nomenclature

hose from fuel shutoff valve and fuel

CM114

Petrolatum

inlet from fuel cell access cover.

CM124

Kerosene

(i).

Disconnect submerged motive flow

CM702

Lockwire CRES

fuel hose assembly between fuel

check valve and ejector pump from

fuel cell access cover.

Avoid fuel vapor ignition

WARNING

(j).

Disconnect fuel cell scavenge hose

and fire. Use only nonspark

assembly from bottom of fuel cell

ing tools and explosion proof work

access cover bracket assembly to

lights. Attach helicopter to an ap

ejector pump.

proved electrical ground. Switch OFF

all electrical power. Disconnect exter

(k).

Cut safety wire from fuel probe

nal power and battery before opening

electrical connector base nut and

fuel system. Ensure work area is ade

remove connector from fuel cell

quately ventilated.

access cover.

Page 916

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CSP-HMI-2

MAINTENANCE MANUAL

FUEL PROBE

93.15

HOSE

P250 WIRE HARNESS

0.00

FUEL CELL

WIRE HARNESS

COVER

WL 13.10

BOLT

WASHER

LBL 13.00

PUMP

WL 0.00

UNION

O-RING

SPACER

BRACKET

VIEW LOOKING AFT

95.628

VIEW LOOKING DOWN

G28-2007

Figure 907. Fuel Pump Initial Installation (600N)

(l). Remove fuel cell scavenge hose

(5). Attach fuel supply hose to pump

bracket assembly, bulkhead union

pressure port union. Torque hose nut to

and fuel shutoff valve from fuel cell

230 - 260 inch-pounds (25.99 - 29.38

cover.

Nm).

(2). Remove unused bulkhead union from

C. Fuel Cell Cover Installation

cover.

(1). Wipe fuel cell and cover sealing sur

B. Pump Installation

faces clean with kerosene (CM124) on a

(1). Disconnect fuel feed hose from fuel inlet

clean lint free cloth.

plate and remove plate.

(2). Inspect fuel cell cover seals for debond

(2). Clean pump and sump plate mount

ing, nicks or cuts and any other damage

contact surfaces to establish an electri

having a leak producing potential.

cal bond.

Replace covers or left aft cover as

required.

Do not mark torque alignment

CAUTION

stripes on fuel cell internal

(3). Install left aft fuel cell access cover as

hardware.

follows:

(3). Install pump on sump plate with bolts,

washers and spacers. Torque bolts to 36

(a). Apply a coating of petrolatum

- 46 inch-pounds (4.07 - 5.20 Nm).

(CM114) to a new fuel shutoff valve/

cover sealwasher. Install valve on cell

(4). Apply a thin coat of petrolatum

cover with sealwasher next to valve

(CM114) to a new O-ring and pump

body and valve properly aligned to

pressure port union threads. Install

make connection with valve control

O-ring on union. Install union in pump

cable. Torque valve jamnut to 240 -

pressure port and torque to 280 - 305

280 inch-pounds (27.12 - 31.64

inch-pounds (31.64 - 34.46 Nm).

Nm).

Page 917

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MD Helicopters, Inc.

MAINTENANCE MANUAL

(b). Apply a coating of petrolatum to

(9).

Install three support brackets on Sta.

sealwasher. Install check valve and

91.00 and 102.00 floor cross-members

sealwasher to inside cover and a

with washers and screws. Torque

plain washer outside. Torque jamnut

screws to 20 - 25 inch-pounds (2.26 -

to 85 - 105 inch-pounds (9.6 -

2.82 Nm).

11.86 Nm).

(10).

Install cover bolts and washers. In a

(c). Install bulkhead elbow to support

cross pattern, progressively torque

bracket. with washer and nut. Torque

cover bolts to 70 - 90 inch-pounds

jamnut to 240 - 280 inch-pounds

(7.91 - 10.17 Nm).

(27.12 - 31.64 Nm).

(11).

Connect engine feed fuel supply hose to

(d). Install support bracket to cover with

fuel shutoff valve. Torque hose nut to

bolts, washer, and sealwashers.

230 - 260 inch-pounds (25.99 - 29.38

Apply a coating of petrolatum to

Nm).

sealwasher. Torque bolts to 36 - 46

inch-pounds (4.06 - 5.19 Nm).

(12).

Connect fuel motive flow hose to access

cover/check valve. Torque hose nut (50

(4). Place left aft fuel cell access cover into

- 65 inch-pounds (5.65 - 7.34 Nm).

position on fuel cell.

(13).

Connect fuel quantity probe and pump

NOTE: Install new seal washer, AS3578-024,

connectors to wire harness receptacles.

on wire harness connector.

(14).

Slip control cable through hole in fuel

(5). Connect fuel quantity probe and pump

shutoff valve lever swivel.

wire harness connectors to cell cover.

Torque connector jamnuts and safety

(15).

Rig cable control system. (Ref. Sec.

wire to bulkhead union with lockwire

28-00-60, Fuel Shutoff Valve Control

(CM702).

Cable Installation).

(6). Install fuel cell inlet hose assembly to

(16).

Apply a torque alignment stripe to fuel

access cover fuel shutoff valve. Torque

line tube, hose and fitting fasteners.

hose assembly 230 - 260 inch-pounds

(25.99 - 29.38 Nm).

(17).

Install access panels on passenger

cargo compartment floor.

(7). Install submerged motive flow hose

assembly to access cover check valve.

Torque hose assembly 50 - 65 inch-

3. Anti−Ice Fuel Filter Installation Weight

pounds (5.65 - 7.34 Nm).

and Balance

(8). Install scavenge fuel cell hose assembly

(1). After installation of the anti-ice fuel

to access cover bulkhead elbow. Torque

filter, incorporate changes to helicopter

hose assembly 230 - 260 inch-pounds

weight and balance record (Ref. Sec.

(25.99 - 29.38 Nm).

Section 08-10-00).

Table 901. Weight and Balance Data

Configuration

Weight

Arm

Moment

Pounds (kg)

inches (cm)

in.−lb

(kg cm)

369H90022−BSC

+6.6

(+2.996)

107.8

(273.81)

+711.48

(+819.710)

369H90022−503

+5.3

(+2.406)

122.7

(311.66)

+650.31

(+749.235)

369H90022−505

+5.3

(+2.406)

122.7

(311.66)

+650.31

(+749.235)

600N98110−501

+7.3

(+3.311)

112.7

(286.26)

+822.7

(+947.807)

Page 918

Revision 19

28-25-00

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

32-10-00 Landing Gear System (369D/E/FF - 500N)

Description and Operation

1. Landing Gear

A. Skid

B. Strut

C. Damper

D. Entry Step

E. Fairing

Servicing

301

1. Landing Gear Damper Nitrogen Servicing

301

Figure 301. Landing Gear Damper Nitrogen Servicing - On Helicopter

302

Table 301. Nitrogen Service Schrader Valve Equipped 369D26301 Extended

Landing Gear Dampers - on Helicopter

303

Table 302. Nitrogen Service Schrader Valve Equipped 369D26300 Standard

Landing Gear Dampers - on Helicopter

306

Removal/Installation

401

1. Landing Gear Replacement

401

A. Landing Gear Removal

401

B. Landing Gear Installation

401

Figure 401. Landing Gear and Damper Installation

402

2. Landing Gear Damper Replacement

403

A. Landing Gear Damper Removal

403

B. Landing Gear Damper Installation

403

3. Landing Gear Skid Replacement

403

A. Landing Gear Skid Removal

403

B. Landing Gear Skid Installation

403

4. Landing Gear Fairing Replacement

404

A. Landing Gear Fairing Removal

404

B. Landing Gear Fairing Installation

404

Figure 402. Fairing Installation

405

5. Cabin Entry Step Replacement

407

A. Cabin Entry Step Removal

407

B. Cabin Entry Step Installation

407

Inspection/Check

601

1. Landing Gear Inspection

601

2. Landing Gear Skid Inspection

601

3. Landing Gear Strut Inspection

602

Page i

32 Contents

Revision 19

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

Figure 601. Landing Gear Strut Inspection

603

4. Landing Gear Damper Inspection

604

5. Cabin Entry Step Inspection

605

6. Landing Gear Fairing Inspection

605

Table 601. Minimum Damper Extension

605

Table 602. Landing Gear Damper Bench Test Requirements

605

Repairs

801

1. Landing Gear System Repairs

801

2. Skid Adapter Sleeve Replacement

801

3. Abrasion Strip Replacement

801

Table 801. Maximum Damage Limits - Landing Gear Components

802

Figure 801. Landing Gear Repairs (Sheet 1 of 2)

803

4. Ground Handling Fitting Replacement

805

5. Safety Walk Tape Replacement

805

6. Landing Gear Fairing Repair

805

7. Landing Gear Fairing Fillet Modification

805

8. Landing Gear Strut Drag Brace Hole Repair

806

A. Landing Gear Strut with Bushing Installed

806

B. Landing Gear Strut with No Bushing Installed

806

Figure 802. Landing Gear Fairing Repairs

807

Initial Installation

901

1. Extended Landing Gear Initial Installation

901

A. Standard Landing Gear Removal

901

B. Standard Landing Gear Disassembly

901

C. Extended Landing Gear Assembly

901

Figure 901. Extended Landing Gear Assembly (Early Configuration)

902

Figure 902. Extended Landing Gear Assembly (Current Configuration)

904

D. Early Configuration Extended Landing Gear Assembly Buildup

906

E. Current Configuration Extended Landing Gear Skid Tube Assembly

Buildup

906

F. Extended Landing Gear Installation

907

G. Weight and Balance

907

Table 901. Weight and Balance Data

907

Figure 903. Extended Landing Gear

908

32-10-60 Landing Gear System (600N)

Description and Operation

1. Landing Gear System

Page ii

Revision 26

32 Contents

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

A. Skid

B. Strut

C. Damper

D. Entry Step

E. Fairing

Servicing

301

1. Landing Gear Damper Nitrogen Servicing

301

Figure 301. Landing Gear Damper Nitrogen Servicing - On Helicopter

302

Table 301. Nitrogen Recharge Pressure

303

Removal/Installation

401

1. Landing Gear Strut Replacement

401

A. Landing Gear Strut Removal

401

B. Landing Gear Strut Installation

401

2. Landing Gear Damper Replacement

402

A. Landing Gear Damper Removal

402

B. Landing Gear Damper Installation

402

Figure 401. Landing Gear and Damper Installation

403

3. Landing Gear Skid Replacement

404

A. Landing Gear Skid Removal

404

B. Landing Gear Skid Installation

404

4. Landing Gear Fairing Replacement

404

A. Landing Gear Fairing Removal

404

B. Landing Gear Fairing Installation

404

Figure 402. Fairing Installation

406

Figure 403. Landing Gear Rubber Washer Locations

407

Inspection/Check

601

1. Landing Gear Inspection

601

2. Landing Gear Skid Inspection

601

3. Landing Gear Strut Inspection

601

4. Landing Gear Damper Inspection

602

5. Forward Cabin Entry Step Inspection

602

6. Landing Gear Fairing Inspection

602

Table 601. Minimum Damper Extension

603

Repairs

801

1. Landing Gear System Repairs

801

2. Abrasion Strip Replacement

801

Page iii

32 Contents

Revision 26

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

3. Ground Handling Bolt Replacement

801

4. Safety Walk Tape Replacement

801

5. Landing Gear Fairing Repair

802

Table 801. Maximum Damage Limits - Landing Gear Components

802

32-40-00 Ground Handling Wheels (369D/E/FF - 500N)

Maintenance Practices

201

1. Ground Handling Wheel Assembly

201

A. Ground Handling Wheel Description and Operation

201

2. Standard Ground Handling Wheel Installation and Use

201

3. Special Ground Handling Wheel Installation and Use

201

Figure 201. Ground Handling Wheel Assembly (Standard)

202

4. Standard Ground Handling Wheel Disassembly (Early Configuration)

202

5. Standard Ground Handling Wheel Re-assembly (Early Configuration)

202

Figure 202. Ground Handling Wheel Assembly/Disassembly

203

6. Standard Ground Handling Wheel Disassembly (Current Configuration)

204

7. Standard Ground Handling Wheel Re-assembly (Current Configuration)

204

8. Standard Ground Handling Wheel Servicing

204

9. Special Ground Handling Wheel Disassembly

204

10. Special Ground Handling Wheel Re-assembly

204

11. Special Ground Handling Wheel Servicing

205

Figure 203. Special Ground Handling Wheel Assembly (Float Type)

205

Figure 204. Special Ground Handling Wheel Assembly/Disassembly

206

32-40-60 Ground Handling Wheels (600N)

Maintenance Practices

201

1. Ground Handling Wheel Assembly

201

A. Ground Handling Wheel Assembly Description and Operation

201

2. Ground Handling Wheel Assembly Maintenance

201

Figure 201. Ground Handling Wheel Assembly

202

32-81-00 Utility Float System (369D/E)

Maintenance Practices

201

1. Utility Float Description and Operation

201

A. Utility Float Operational Check

201

2. Utility Float Inspection

201

A. Skid Tube and Extension Assembly Inspection

201

B. Utility Float Repair

201

3. Utility Float Troubleshooting

201

Page iv

Revision 26

32 Contents

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

Table 201. Troubleshooting Utility Floats

202

4. Utility Float Replacement

202

A. Utility Float Removal

202

B. Utility Float Installation

202

5. Skid Tube Extension Replacement

203

A. Skid Tube Extension Removal

203

B. Skid Tube Extension Installation

203

Figure 201. Utility Float Installation

204

Initial Installation

901

1. Utility Float Initial Installation

901

A. Preparation for Installation

901

B. Disassembly of Extended Landing Gear

901

Figure 901. Extended Landing Gear - Disassembly

902

C. Landing Gear Strut Modification

903

D. Landing Gear Skid Extension Assembly

903

Figure 902. Extended Landing Gear Modification

904

Figure 903. Skid Tube Extension Installation

905

E. Utility Float to Landing Gear Assembly

906

F. Utility Floats/Landing Gear Installation

907

G. Weight and Balance

907

Table 901. Weight and Balance Data

907

Figure 904. Utility Float Buildup (Sheet 1 of 2)

909

32-82-00 Emergency Float System

(369D/E/FF - 500N)

Maintenance Practices

201

1. Emergency Float System Description and Operation

201

A. Emergency Float Description

201

2. Certification and Shelf/Service Life

202

3. Emergency Float Inspection (Stowed Configuration)

202

4. Emergency Float Inspection

202

Table 201. Troubleshooting Emergency Flotation Equipment

203

5. Emergency Float Compartment Pressure Test

203

6. Emergency Float Inspection (After Inflation)

203

7. Emergency Float Test

204

8. Float Compartments Pressure Test

204

9. Emergency Float Repair

204

10. Solenoid-to-Squib Rework Procedure

204

Removal/Installation

401

1. Emergency Float Replacement

401

Page v

32 Contents

Revision 26

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

A. Emergency Float Removal

401

B. Emergency Float Installation

401

Figure 401. Emergency Float Installation

402

2. Emergency Float Pressure Vessel Servicing and Replacement

403

Figure 402. Solenoid Valve Assembly

404

3. Squib and Squib Actuated Valve Replacement

404

Figure 403. Squib Valve Assembly

405

4. Emergency Float Folding

406

Figure 404. Emergency Float Folding

407

Initial Installation

901

Emergency Float System Initial Installation

901

A. General

901

B. Initial Preparation

901

C. Existing Equipment Removal

901

D. Landing Gear Skid Extension Assembly

901

E. Emergency Float System Electrical Equipment Installation

901

Figure 901. Emergency Float Kit - Electrical Installation

902

F. Emergency Float System Electrical Wiring Installation

903

Figure 902. Emergency Float Inflation System Wiring Diagram

(369D290121-501 and -505)

904

Figure 903. Emergency Float Inflation System Wiring Diagram

(369D290121-515, -517 and -519) (Sheet 1 of 2)

905

Figure 904. Emergency Float Inflation System Wiring Diagram

(369D290121-521, -523, -525 and -527) (Sheet 1 of 2)

907

Figure 905. Emergency Float Installation with Generic Wire Harness

909

G. Emergency Float Electrical System Inspection

910

H. Emergency Float System Strut Fairing Installation

910

Figure 906. Emergency Float System Strut Fairing Installation

911

I. Emergency Float Installation

912

Table 901. Weight and Balance Data

912

Page vi

Revision 26

32 Contents

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

LANDING GEAR SYSTEM

DESCRIPTION AND OPERATION

1. Landing Gear

compartment seat structure. Aft damper

assemblies are attached to oleo support fittings

The landing gear consists of two strut-

in the engine compartment.

mounted, shock-dampened skids aligned

longitudinally along the helicopter fuselage.

The damper assemblies are approximately

Both right and left skids pivot as the damper

12.21 inches (31.01 cm) long when extended

assemblies extend and retract. Replaceable

and 8.96 inches (22.76 cm) long when com

abrasion strips are installed on each skid to

pressed. The dampers are poppet-type and

retard wear on hard surfaces.

consist of a barrel, upper and lower mounting

cap, main poppet, rebound poppet and a

A. Skid

piston. Damper exterior surfaces are painted

white for surface protection and as an aid to

Landing gear skids provide helicopter rest

identification.

mounts. Skid tubes are constructed from

seamless, extruded aluminum alloy tubing.

A damper must be replaced if damaged, or if

Abrasion strips attached to undersides of skid

loss of pneumatic pressure (nitrogen gas) or

tubes retard wear and damage. Ground

hydraulic oil occurs.

handling fittings riveted to skid tubes are the

ground handling attach points. Forward end of

D. Entry Step

skid contains provisions for night lighting

Entry steps mounted on the landing gear

equipment. An adapter sleeve at the aft end of

struts allow for easy access into cabin. The

skid tube provides a nonrigid mount for the aft

landing gear step is covered with non-skid

foot bearing and skid extension.

tape and attached to the landing gear strut

B. Strut

with lockbolts.

E. Fairing

The landing gear struts attach to the fuselage

center beam. Landing gear braces between the

Fiberglass/aluminum fairings on each strut

landing gear strut and fuselage center beam

reduce aerodynamic drag during flight. The

prevent shearing of the strut and keep the

fairings extend from the fuselage to the skids

strut in alignment with the landing gear. At

to form streamlined enclosures for the landing

the lower ends of the struts, foot-shaped

gear struts. Each fairing assembly is con

components attach the landing gear skids to

structed of three main parts: a fillet, an upper,

the struts. Feet for the aft strut are bearing-

and lower two-piece fairing. The fillet is

mounted to provide a nonrigid and pivotal

spring-loaded to remain in firm contact with a

mount.

fiberglass rubbing plate that is bonded and

riveted to the fuselage. The fairing is secured

C. Damper

to the landing gear and telescopes up inside

Landing gear assemblies are equipped with

the fillet to allow movement of the strut as the

front and rear damper assemblies. Dampers

landing gear dampers compress or extend. A

absorb vertical shock to landing gear struts

seal on the bottom edge of the fairing forms a

during helicopter landings. Front damper

fillet between the fairing and the skid tube.

assemblies are attached to oleo attachment

Fairings also have openings for cabin entry

fittings on the outboard side of the pilot's

steps.

Page 1

32-10-00

Revision 19

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

LANDING GEAR SYSTEM

SERVICING

1. Landing Gear Damper Nitrogen Servicing

servicing hose-schrader valve connec

tion.

(Ref. Figure 301) Service landing gear damp

ers equipped with schrader valve according to

(6). Tighten servicing hose while nitrogen is

the following steps.

flowing. Allow nitrogen pressure to

build to the valve according to dash

Do not recharge a damper if

number and part number of damper

CAUTION

there is evidence of fluid leak

(Ref. Table 301 or Table 302).

age. Recharging of damper will cause fur

ther leakage of both gas and damper fluid,

To prevent damage to damper or

CAUTION

posing a danger to the helicopter.

loss of damper fluid do not open

schrader valve without pressurizing the

(1). Place helicopter on jacks or hoist.

servicing line. If fluid loss occurs, damper

will require overhaul.

NOTE: A minimum of two dampers shall be re

charged; either the two forward dampers,

(7). Once pressure level is reached open

two aft dampers, or both forward and aft

schrader valve by turning outside nut

dampers.

counter clockwise, allowing system and

damper pressure to equalize for a

(2). For forward damper servicing, remove

minimum of 2 minutes. If slightly over

footwell panel located in passenger

pressurized, bleed off excess very

compartment (Ref. Sec. 25-30-00). For

slowly.

aft damper servicing, open engine

access doors.

(8). Close schrader valve by turning the

outside nut clockwise. Torque nut to 60

(3). Remove cap from schrader valve and

inch pounds (6.78 Nm) and safety

connect servicing hose, but do not

wire.

tighten.

(9). Reduce charge pressure to zero, and

(4). Ensure low side of nitrogen pressure

remove servicing hose. Install cap on

regulator is backed off to the unpres

schrader valve.

surized position. Slowly open the high

(10). Inspect damper for leakage approxi

pressure nitrogen bottle valve.

mately two hours after servicing. Check

(5). Slowly turn regulator control until

damper extension according to

nitrogen begins to flow at the loose

Table 601 of this section.

Page 301

32-10-00

Revision 19

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

Table 301. Nitrogen Service Schrader Valve Equipped 369D26301 Extended Landing Gear

Dampers − on Helicopter

Degrees

Winterized Recharge

Mid−Temp Recharge

Ambient Recharge

Pressure (1)

Pressure (2)

Pressure (3)

°F

°C

psi

kPa

psi

kPa

psi

kPa

−40

1,262

8,702

−38

−39

1,264

8,715

−36

−38

1,266

8,728

−34

−37

1,268

8,740

−32

−36

1,270

8,753

−30

−34

1,271

8,766

−28

−33

1,273

8,778

−26

−32

1,275

8,791

1,051

7,247

−24

−31

1,277

8,804

1,052

7,255

−22

−30

1,279

8,816

1,053

7,262

−20

−29

1,281

8,829

1,054

7,270

−18

−28

1,282

8,842

1,056

7,278

−16

−27

1,284

8,855

1,057

7,286

−14

−26

1,286

8,867

1,058

7,293

−12

−24

1,288

8,880

1,059

7,301

−10

−23

1,290

8,893

1,060

7,309

−8

−22

1,292

8,905

1,061

7,316

−6

−21

1,293

8,918

1,062

7,324

−4

−20

1,295

8,931

1,063

7,332

−2

−19

1,297

8,943

1,065

7,340

−18

1,299

8,956

1,066

7,347

−17

1,301

8,969

1,067

7,355

−16

1,303

8,981

1,068

7,363

−14

1,305

8,994

1,069

7,371

−13

1,306

9,007

1,070

7,378

−12

1,308

9,019

1,071

7,386

1,145

7,891

−11

1,310

9,032

1,072

7,394

1,146

7,900

−10

1,312

9,045

1,074

7,401

1,147

7,908

−9

1,314

9,057

1,075

7,409

1,148

7,917

−8

1,316

9,070

1,076

7,417

1,150

7,925

−7

1,317

9,083

1,077

7,425

1,151

7,934

−6

1,319

9,096

1,078

7,432

1,152

7,943

−4

1,321

9,108

1,079

7,440

1,153

7,951

Page 303

32-10-00

Revision 19

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

Table 301. Nitrogen Service Schrader Valve Equipped 369D26301 Extended Landing Gear

Dampers − on Helicopter

Degrees

Winterized Recharge

Mid−Temp Recharge

Ambient Recharge

Pressure (1)

Pressure (2)

Pressure (3)

°F

°C

psi

kPa

psi

kPa

psi

kPa

−3

1,323

9,121

1,080

7,448

1,154

7,960

−2

1,325

9,134

1,081

7,455

1,156

7,968

−1

1,327

9,146

1,082

7,463

1,157

7,977

1,328

9,159

1,084

7,471

1,158

7,985

1,330

9,172

1,085

7,479

1,159

7,994

1,332

9,184

1,086

7,486

1,161

8,002

1,334

9,197

1,087

7,494

1,162

8,011

1,336

9,210

1,088

7,502

1,163

8,019

1,338

9,222

1,089

7,510

1,164

8,028

1,339

9,235

1,090

7,517

1,166

8,037

1,341

9,248

1,092

7,525

1,167

8,045

1,343

9,260

1,093

7,533

1,168

8,054

1,345

9,273

1,094

7,540

1,169

8,062

1,347

9,286

1,095

7,548

1,171

8,071

1,349

9,299

1,096

7,556

1,172

8,079

1,351

9,311

1,097

7,564

1,173

8,088

1,352

9,324

1,098

7,571

1,174

8,096

1,354

9,337

1,099

7,579

1,176

8,105

1,356

9,349

1,100

7,587

1,177

8,113

1,358

9,362

1,102

7,594

1,178

8,122

1,360

9,375

1,103

7,602

1,179

8,131

1,362

9,387

1,104

7,610

1,181

8,139

1,363

9,400

1,105

7,618

1,182

8,148

1,365

9,413

1,106

7,625

1,183

8,156

1,367

9,425

1,107

7,633

1,184

8,165

1,369

9,438

1,108

7,641

1,185

8,173

1,109

7,649

1,187

8,182

1,110

7,656

1,188

8,190

1,112

7,664

1,189

8,199

1,113

7,672

1,190

8,208

1,114

7,679

1,192

8,216

1,115

7,687

1,193

8,225

1,116

7,695

1,194

8,233

Page 304

Revision 19

32-10-00

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

Table 301. Nitrogen Service Schrader Valve Equipped 369D26301 Extended Landing Gear

Dampers − on Helicopter

Degrees

Winterized Recharge

Mid−Temp Recharge

Ambient Recharge

Pressure (1)

Pressure (2)

Pressure (3)

°F

°C

psi

kPa

psi

kPa

psi

kPa

1,195

8,242

1,197

8,250

1,198

8,259

1,199

8,267

100

1,200

8,276

102

1,202

8,284

104

1,203

8,293

106

1,204

8,302

108

1,205

8,310

110

1,207

8,319

112

1,208

8,327

114

1,209

8,336

116

1,210

8,344

118

1,212

8,353

120

1,213

8,361

122

1,214

8,370

124

1,215

8,379

126

1,216

8,387

NOTES:

(1) For 369D26301−221, and −231 extended landing gear dampers.

(2) For 369D26301−241, and −251 extended landing gear dampers.

(3) For 369D26301−211 extended landing gear dampers.

Page 305

32-10-00

Revision 19

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

Table 302. Nitrogen Service Schrader Valve Equipped 369D26300 Standard Landing Gear

Dampers − on Helicopter

Degrees

Winterized Recharge

Mid−Temp Recharge

Ambient Recharge

Pressure (1)

Pressure (2)

Pressure (3)

°F

°C

psi

kPa

psi

kPa

psi

kPa

−40

704

4,854

−38

−39

705

4,864

−36

−38

707

4,873

−34

−37

708

4,882

−32

−36

709

4,891

−30

−34

711

4,901

−28

−33

712

4,910

−26

−32

714

4,919

704

4,855

−24

−31

715

4,929

705

4,862

−22

−30

716

4,938

706

4,869

−20

−29

718

4,947

707

4,876

−18

−28

719

4,956

708

4,883

−16

−27

720

4,966

709

4,889

−14

−26

722

4,975

710

4,896

−12

−24

723

4,984

711

4,903

−10

−23

724

4,994

712

4,910

−8

−22

726

5,003

713

4,916

−6

−21

727

5,012

714

4,923

−4

−20

728

5,021

715

4,929

−2

−19

730

5,031

715

4,936

−18

731

5,040

716

4,942

−17

732

5,049

717

4,949

−16

734

5,058

718

4,955

−14

735

5,068

719

4,962

−13

736

5,077

720

4,968

−12

738

5,086

721

4,974

637

4,392

−11

739

5,096

722

4,980

638

4,397

−10

740

5,005

723

4,987

639

4,403

−9

742

5,114

724

4,993

639

4,409

−8

743

5,123

725

4,999

640

4,415

−7

744

5,133

725

5,005

641

4,420

−6

746

5,142

726

5,011

642

4,426

−4

747

5,151

727

5,017

643

4,432

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MAINTENANCE MANUAL

Table 302. Nitrogen Service Schrader Valve Equipped 369D26300 Standard Landing Gear

Dampers − on Helicopter

Degrees

Winterized Recharge

Mid−Temp Recharge

Ambient Recharge

Pressure (1)

Pressure (2)

Pressure (3)

°F

°C

psi

kPa

psi

kPa

psi

kPa

−3

748

5,160

728

5,023

644

4,438

−2

750

5,170

729

5,029

645

4,444

−1

751

5,179

730

5,035

645

4,449

753

5,188

731

5,041

646

4,455

754

5,198

732

5,047

647

4,461

755

5,207

732

5,052

648

4,467

757

5,216

733

5,058

649

4,473

758

5,225

734

5,064

650

4,478

759

5,235

735

5,070

650

4,484

761

5,244

736

5,075

651

4,490

762

5,253

737

5,081

652

4,496

763

5,263

737

5,087

653

4,502

765

5,272

738

5,092

654

4,507

766

5,281

739

5,098

655

4,513

767

5,290

740

5,103

655

4,519

769

5,300

741

5,109

656

4,525

770

5,309

741

5,114

657

4,531

771

5,318

742

5,120

658

4,536

773

5,327

743

5,125

659

4,542

774

5,337

744

5,130

660

4,548

775

5,346

744

5,136

660

4,554

777

5,355

745

5,141

661

4,559

778

5,365

746

5,146

662

4,565

779

5,374

747

5,152

663

4,571

781

5,383

747

5,157

664

4,577

782

5,392

748

5,162

665

4,583

749

5,167

666

4,588

750

5,172

666

4,594

750

5,177

667

4,600

751

5,182

668

4,606

752

5,188

669

4,612

753

5,193

670

4,617

753

5,198

671

4,623

Page 307

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MAINTENANCE MANUAL

Table 302. Nitrogen Service Schrader Valve Equipped 369D26300 Standard Landing Gear

Dampers − on Helicopter

Degrees

Winterized Recharge

Mid−Temp Recharge

Ambient Recharge

Pressure (1)

Pressure (2)

Pressure (3)

°F

°C

psi

kPa

psi

kPa

psi

kPa

671

4,629

672

4,635

673

4,641

674

4,646

100

675

4,652

102

676

4,658

104

676

4,664

106

677

4,670

108

678

4,675

110

679

4,681

112

680

4,687

114

681

4,693

116

681

4,698

118

682

4,704

120

683

4,710

122

684

4,716

124

685

4,722

126

686

4,727

NOTES:

(1) For 369D26300−221, and −231 standard landing gear dampers.

(2) For 369D26300−241, and −251 standard landing gear dampers.

(3) For 369D26300−211 standard landing gear dampers.

Page 308

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CSP-HMI-2

MAINTENANCE MANUAL

LANDING GEAR SYSTEM

REMOVAL/INSTALLATION

1. Landing Gear Replacement

doors, engine access doors and foot

supporting fairings.

(Ref. Figure 401)

(2). With helicopter supported by jacks,

A. Landing Gear Removal

position landing gear to align struts

with openings in fuselage structure.

Consumable Materials

NOTE: Check that fairing fillet guide pins en

(Ref. Section 91−00−00)

gage fairing guide holes before positioning

Item

Nomenclature

struts for attachment to structure.

CM729

Tape, masking, pressure sensitive

(3). Lift and carefully position landing gear;

then place supports beneath landing

NOTE: Following procedures apply to removal

gear to hold it in place.

of entire right or left landing gear assembly.

NOTE: Install left forward damper upper bolt

For component disassembly, refer to appli

with bolt head aft. Bolt direction on right

cable section. For removal, two persons are

side is optional.

needed.

(4). Be sure that slotted bushing (view C) is

(1).

Jack up helicopter until landing gear

in place. Align lower bearing of damper

dampers are fully extended (Ref. Sec.

with mating holes in strut and install

07-00-00). Place support beneath skid

attaching hardware.

tubes at strut locations.

(5). Align struts with mating bearings in

(2).

Pull strut fairing fillet downward

fuselage support fittings. Install bolt,

against spring tension and secure with

slotted bushing, two washers, nut and

tape (CM729).

cotter pin.

(3).

Open compartment access doors for

(6). Align inboard end of each brace with

access to forward brace, strut and

mating bearing in fuselage supporting

damper. Disconnect brace, strut and

fitting. Install slotted bushing and

damper from attachment points.

attaching hardware.

(4).

For access to aft landing gear attach

(7). Secure electrical bonding jumper with

ment points, open engine access doors.

clamp and attaching hardware to aft

Disconnect aft brace, strut and damper

strut.

from attachment points.

Do not over-tighten brace-to-

CAUTION

(5).

Remove clamp attaching electrical

strut hardware. Maximum per

bonding jumper to aft strut.

missible nut torque is finger-tight; then

backed off to nearest cancellation for instal

(6).

Disconnect electrical wiring connections

lation of cotter pin.

at upper area forward strut.

(8). If brace is detached from strut, align

(7).

Remove supports from below skid and

outboard end of each brace with mating

carefully remove struts, skid and

holes in strut. Attach brace to strut

fairings as an assembled unit.

with attaching hardware. Torque nut to

5 inch-pounds (0.56 Nm) maximum.

B. Landing Gear Installation

(9). Connect wiring at forward strut.

NOTE: Following procedures apply to installa

tion of right or left landing gear assemblies.

(10). Remove skid supports, lower helicopter,

and remove jacks.

(1). For access to landing gear attachment

points, open or remove fuselage access

(11). Close or replace all access doors.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

FILLET

FAIRING

SKID

EXTENSION

CABIN ENTRY STEP

KNIFE SPLICE

GROUND HANDLING

FITTINGS

SAFETY

WALK TAPE

ABC BOLTS

ABRASION STRIP

SEALING COMPOUND

LANDING GEAR SKID

POSITION LIGHT

ELECTRICAL HARNESS

TORQUE STRIPE

SERVICE LOOP

DAMPER

(NOTE 3)

0.37-0.62 INCH

CENTER BEAM

(9.398-15.748 MM)

DIMENSION

SLOTTED

BUSHING

(NOTE 1)

CLAMP

BARREL

BONDING

JUMPER

0.37-0.62 INCH

(9.398-15.748 MM)

STRUT

5 IN.-LB.

(0.56 NM)

TORQUE

MAXIMUM

BRACE

STRIPE

(NOTE 3)

NOTE 2

STRUT AND BRACE ATTACHMENT

BUSHING

(NOTE 1)

NOTES:

EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF 0.010 INCH

0.030 INCH (0.762 MM)

(0.254 MM) TO A MAXIMUM OF 0.060 INCH (1.524 MM) ABOVE

MAXIMUM DEFECT

OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.

DEPTH (TYPICAL)

LEFT FORWARD DAMPER ATTACHING BOLT HEAD AFT FOR

REMOVAL CLEARANCE.

DAMPER UPPER ATTACHMENT

TORQUE STRIPES PAINTED CONTRASTING BLACK OR WHITE,

AS APPLICABLE.

G32-1000B

Figure 401. Landing Gear and Damper Installation

Page 402

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CSP-HMI-2

MAINTENANCE MANUAL

2. Landing Gear Damper Replacement

3. Landing Gear Skid Replacement

(Ref. Figure 401)

A. Landing Gear Skid Removal

A. Landing Gear Damper Removal

(1). If landing gear assembly is attached to

(1). Jack up or hoist helicopter on level

helicopter, jack up helicopter until

surface until landing gear skids just

dampers are fully extended (Ref. Sec.

clear resting surface.

07-00-00). Place supports beneath skid

tubes at strut locations.

(2). For forward damper removal, remove

foot well fairings located in passenger

(2). Remove lower fairing from two-piece

compartment. For access for aft damper

fairing assembly.

removal, open engine access doors.

(3). Remove bolts attaching forward

(3). Remove hardware (except bushings)

skid-to-foot assembly.

attaching forward damper assemblies

to fuselage attachment fittings and

(4). Disconnect electrical connections at

landing gear struts.

forward strut.

(5). Remove bolts attaching extension to

(4). Remove hardware from damper

skid adapter sleeve. Remove extension,

attachment points.

index plug and bearing from skid.

B. Landing Gear Damper Installation

B. Landing Gear Skid Installation

(1). Jack up helicopter on level surface until

landing gear skids (Ref. Sec. 07-00-00)

Consumable Materials

just clear resting surface.

(Ref. Section 91−00−00)

Item

Nomenclature

NOTE:

CM318

Primer

D Always be sure that replacement damper

CM420

Sealant

is correct for the helicopter. Ensure that

CM425

Sealing compound

cap torque stripes will be visible for in

spection after installation.

NOTE: Left or right replacement skids are in

D If installing schrader valve equipped

terchangeable by using or removing nylon

dampers, ensure fwd damper is installed

screws from side of skid at forward strut.

with schrader valve facing forward and

aft damper with schrader valve facing aft.

(1). Position skid in place with aft foot

bearing installed over skid adapter

(2). Install replacement damper in upper

sleeve. Connect electrical connections

and lower mounting position with

for skid position light at forward strut.

attaching hardware. Ensure bushings

are in place.

(2). Apply thin coating of primer (CM318) to

forward strut and skid tube mating

NOTE: Left forward damper upper bolt must be

surfaces.

installed with bolt head aft. Bolt direction

on right side is optional.

(3). Align mating parts and install bolts

with wet coating of zinc chromate

(3). Torque nuts to 48 - 55 inch-pounds

primer. Torque bolts 40 - 60 inch-

(5.42 - 6.21 Nm) and cotter pin.

pounds (4.52 - 6.78 Nm). Apply

sealant (CM420) to head of bolt and to

(4). Check installation for proper alignment

nuts.

of torque stripes.

(4). Align skid extension with skid tube

(5). Install foot support fairings and close

adapter sleeve. Coat attaching bolts

engine access doors.

with primer and install while wet.

Page 403

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(5). Seal edges of all rigid parts on skid

(e). Carefully spread fillet at trailing

with an approximate 0.060 inch (1.524

edge and remove in forward direc

mm) fillet of sealing compound

tion.

(CM425).

(3). Remove upper part of fairing as follows.

(6). Install lower fairing.

(a). Remove rivets that secure trailing

edge of fairing.

4. Landing Gear Fairing Replacement

(b). Remove rivets that secure fairing to

(Ref. Figure 402)

strut bracket.

A. Landing Gear Fairing Removal

(c). Use putty knife or similar thin-

bladed tool to carefully pry apart

The following instructions are typical for and

bonding and separate upper 5 inches

apply to all four fairing assemblies.

of trailing edge; then separate fairing

from flange of lower guide.

(1). Remove lower fairing from fairing

assembly as follows.

(d). Carefully spread trailing edge of

fairing and remove in forward

(a). Remove attaching hardware that

direction.

secures lower fairing to two strut

brackets, and that secures trailing

B. Landing Gear Fairing Installation

edge of lower fairing.

The following instructions apply to all four

(b). Carefully spread trailing edge of

fairing assemblies. Where riveting is required,

lower fairing and remove in forward

use rivets of type shown in Figure 802.

direction.

NOTE: Ensure that doublers between lamina

Consumable Materials

tions at trailing edge are retained for reuse.

(Ref. Section 91−00−00)

Item

Nomenclature

(2). Remove fillet from upper part of fairing

CM318

Primer

assembly as follows.

CM411

Adhesive, epoxy

(a). Remove rivets from trailing edge of

fillet.

(1). Install upper part of the fairing as

follows.

(b). Drill out one of the rivets securing

fillet to upper guide. Replace rivet

(a). Assemble upper guide, pin assembly,

with sheet metal hole fastener (Cleco,

inner guide half, outer guide half,

or equivalent). Repeat this step on

springs and lower guide on landing

other rivets.

gear strut. Install rivets with wet

primer (CM318) to secure lower

(c). Open underfloor compartment or

guide to strut.

engine compartment doors for access

to strut cutout in fuselage skin. Have

(b). Push guide pins into matching holes

an assistant push down on upper

of lower guide. Wedge temporary

guide with suitable tool (wood dowel

holding device between upper guide

or equivalent), to relieve spring

and strut to keep pins engaged.

tension.

NOTE: Use two small wood blocks or any simi

(d). With spring tension off guide, remove

lar suitable means to keep springs com

fasteners. Slowly relax dowel pres

pressed. Device used must be small enough

sure on guide until springs fully

to be removed through strut cutout in skin

expand.

after fillet is assembled.

Page 404

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MD Helicopters, Inc.

MAINTENANCE MANUAL

(c).

Install blind hole transfer punches

(b).

Carefully spread trailing edge of fillet

(two or four places, as applicable) or

and position about upper guide.

fabricate suitable tools as shown

Clamp lower end of fillet trailing

(Ref. Figure 802). Install tool(s)

edge to upper end of fairing trailing

edge. Clamping prevents fillet

between opposing holes in strut

movement when fillet rivets are

bracket(s).

installed. Have an assistant remove

temporary holding device and push

down on upper guide with suitable

(d).

Carefully spread trailing edge of

tool (wood dowel, etc). Have guide

fairing and position fairing on strut

pushed down where a pencil line

bracket(s) and lower guide. Have an

drawn on guide flange is visible

assistant hold fairing in this position.

through one #40 hole in fillet. Match-

drill guide and secure fillet and guide

with hole fastener (Cleco, or equiva

(e).

Back up fairing with a fiber block at

lent). Repeat procedure for all rivet

transfer punch location. Using plastic

locations. Remove pushing tool from

hammer, carefully strike opposite

strut opening.

side of fairing to transfer hole

centers.

(c).

Remove one fastener at a time, and

install screws and washers (Ref.

Landing Gear Fairing Fillet Modifi

(f).

Remove fairing and check that all

cation).

transfer marks appear within outline

(d).

Install screws, washers and nuts to

of small laminated doublers. Drill out

secure fillet trailing edge together.

located holes.

(e).

Check for smooth telescoping action

of fairing into fillet by manually

(g).

Carefully bond fairing to lower guide

sliding fillet up and down several

(Ref. Figure 802). Use adhesive

times.

(CM411) according to container

instructions.

(f).

Close access doors.

(3). Install lower part of two-piece fairing

(h).

Install rivets to secure fairing to

as follows.

strut bracket(s).

(a). Carefully spread trailing edge of

fairing and position on upper fairing

(i).

Install rivets to secure trailing edge

and lower strut bracket; at correct

position there should be 0.020 -

of fairing.

0.080 inch (0.508 - 2.032 mm)

compression of fairing seal against

skid tube. Have an assistant hold

(j).

Using soft lead pencil, draw a

fairing at this position.

continuous line along horizontal

center of upper guide flange.

(b). Back up fairing with fiber block at

transfer punch location. Using plastic

hammer, carefully strike opposite

(2). Install fillet as follows.

side of fairing to transfer hole

centers.

(a). Drill a #40 hole in center of each 3/8

(c). Remove fairing and check that all

inch (9.525 mm) square doubler in

transfer marks appear within outline

fillet. (There are six doublers in the

of small laminated doublers. Drill out

fiberglass fairings.)

located holes.

Page 406

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CSP-HMI-2

MAINTENANCE MANUAL

(d). Reinstall fairing in mounting position

B. Cabin Entry Step Installation

and secure to upper and lower strut

brackets with screws and washers.

Consumable Materials

(Ref. Section 91−00−00)

(e). Secure fairing trailing edge with

Item

Nomenclature

attaching hardware.

CM318

Primer

NOTE: Be sure doublers are installed between

(1). Install replacement step on forward

laminations at trailing edge.

landing gear strut, using four lockbolts

with wet primer (CM318). Four holes in

step collar must be drilled out to 0.164

5. Cabin Entry Step Replacement

- 0.167 inch (4.166 - 4.242 mm) for

installation of lockbolts. If holes are

elongated, use next size larger lock

(Ref. Figure 801)

bolts.

A. Cabin Entry Step Removal

NOTE: At strut replacement, locate step by us

ing skid centerline-to-step centerline mea

surement of 11.78 inches (29.92 cm).

(1). Remove landing gear fairing.

(2). Install step on aft landing gear strut,

using two bolts, washers and nuts with

(2). Remove four lockbolts and step from

wet primer. Torque nuts to 60 - 85

forward landing gear strut, or two bolts,

inch-pounds 6.78 - 9.60 Nm).

washers and nuts from aft landing gear

strut (extended gear only).

(3). Install lower fairing on strut.

Page 407

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Revision 26

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

LANDING GEAR SYSTEM

INSPECTION/CHECK

1. Landing Gear Inspection

(1).

Jack helicopter until landing gear

dampers are fully extended.

(Ref. Figure 801)

(2).

Remove lower fairing from two-piece

NOTE: Inspection should be performed with

fairing assembly.

helicopter skids clear of ground.

(3).

Inspect for dents. If dents exceed a

(1). Inspect skids, skid abrasion strips,

depth of 0.20 inch (5.08 mm), they will

struts, feet, braces and fairings for

require repair.

dents, cracks, loose components or

(4).

Inspect for punctures and cracks.

rivets, loose nuts and for missing

hardware.

(5).

Perform fluorescent-penetrant inspec

tion of all crack areas, and of those

(2). Inspect skid-to-foot and foot-to-strut

areas adjacent to all punctures. These

attachments for loose bolts. Check aft

areas will require repair.

foot-to-bearing rivet installation for

security.

(6).

Inspect from aft end of tube to a point

10 inches (25.40 cm) forward of aft strut

NOTE: Loose or defective bolts at forward foot-

for scratches and nicks. If scratches and

to-skid locations requires replacement of

nicks exceed a length of 0.25 inch (6.35

nutplates.

mm) and a depth of 0.015 inch (0.381

mm), they will require repair.

(3). Using 10X glass and bright light,

visually inspect area at, around and

(7).

Inspect from forward end of tube to 10

between foot-to-strut attach bolts not

inches (25.40 cm) forward of aft strut

covered by sealant for cracks and

for scratches and nicks. If scratches and

corrosion.

nicks exceed a length of 0.25 inch (6.35

mm) and a depth of 0.020 inch (0.508

NOTE: If cracks or corrosion other than light

mm), they will require repair.

surface corrosion is found, replace affected

(8).

Inspect ground handling fittings for

part.

cracks, loose rivets, corrosion and other

(4). Inspect keel beam areas where the

damage.

strut assemblies attach for loose

(9).

Inspect abrasion strips for damage,

bearings, condition of hardware and

excessive wear, and for loose bolts and

strut adapters.

screws.

(5). Check condition of beaded seal around

(10).

Check skid adapter sleeve rivet attach

edges of all rigid-mounted skid tube

ment for security. On early configura

components.

tions, check sleeve slots for wear and

damage.

2. Landing Gear Skid Inspection

(11).

Check condition of plug installed in

(Ref. Figure 801)

skid adapter sleeve.

NOTE: If landing gear assembly has not been

(12).

Check aft foot bearing and extension for

removed from helicopter, perform following

wear, damage and corrosion. On early

steps (1). and (2). before proceeding with in

configurations, check condition of

spection.

extension packing.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

3. Landing Gear Strut Inspection

a). Diameter of top hole (DIM. A)

should be 0.5313 inch (13.495

(Ref. Table 801 and Figure 601)

mm) maximum in any direction.

b). Diameter of bottom hole (DIM.

Consumable Materials

B) should be 0.50 inch (12.70

(Ref. Section 91−00−00)

mm) maximum in any direction.

Item

Nomenclature

CM318

Primer

4). If no cracks are found around drag

brace attach hole in strut and hole

is not elongated, install new

(1).

Check landing gear dampers for correct

bushing in hole with wet primer

servicing by observing stance of

(CM318).

helicopter. Check rear dampers for

correct extension and signs of leakage.

5). If either hole is oversized or

cracking is noted, rework strut

(2).

Remove foot support fairings in passen

(Ref. Landing Gear Strut Drag

ger/cargo compartment and open engine

Brace Hole Repair).

access doors.

(b). If no bushing is installed in drag

(3).

Visually inspect strut attachment

brace attach hole in strut, proceed as

points and pivot bearing for signs of

follows:

fretting, wear and damage. Fretting

will be evident by gray or black materi

1). Using 10X glass and bright light,

al around bearing, rivets or seams.

inspect strut around drag brace

attach holes (top and bottom

(4).

Jack helicopter until landing gear

surfaces) for cracks. If any cracks

dampers are fully extended.

longer than 0.030 inch (0.762 mm)

in length are noted, strut must be

(5).

Shake landing gear assemblies and

scrapped and serviceable strut

note any play or looseness at pivot

installed.

bearings, inboard strut assembly

fittings and drag brace holes.

2). Check drag brace attach holes in

strut for elongation.

(6).

If any play or looseness is noted,

remove landing gear (Ref. Landing

3). If any cracks, 0.030 inch (0.762

Gear Removal) and inspect drag brace

mm) in length or less, are noted or

and strut.

hole is elongated, rework strut

(Ref. Landing Gear Strut Drag

(7).

Inspect strut bolt hole where drag brace

Brace Hole Repair).

attaches as follows:

(8). Reinstall landing gear (Ref. Landing

(a). If bushing is installed in drag brace

Gear Installation).

attach hole in strut, proceed as

follows:

(9). Inspect strut for cracks or dents.

1). Check bushing for looseness then

(a). If strut is cracked, scrap strut and

remove bushing.

replace with serviceable strut.

2). Using 10X glass and bright light,

(b). If dents in strut exceed 0.060 inch

inspect strut around drag brace

(1.524 mm) depth; or, if scratches and

attach holes (top and bottom

repair area depth would exceed 0.010

surfaces) for cracks.

inch (0.254 mm) when measured to

surrounding unrepaired surface strut

3). Check drag brace attach holes in

must be scrapped and serviceable

strut for elongation.

strut installed.

Page 602

Revision 26

32-10-00

HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369D/E/FF-500/600N HELICOPTERS (ISSUED: 1990) - page 12