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

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

COUNTERWEIGHT

NOTE 2

BEARING

ASSEMBLY

INTERRUPTER

DOUBLE

(NOTE 3)

INTERRUPTER

COUNTERWEIGHT

(NOTE 4)

ROTATING

SWASHPLATE

NOTE 2

INTERRUPTER

SPACER

INTERRUPTER

(NOTE 3)

(NOTE 4)

INTERRUPTER

(NOTE 4)

STATIONARY

SWASHPLATE

DRAIN HOLES

(HIDDEN)

INDEX

PROTRUSIONS

STATIONARY

SWASHPLATE

GROOVE

DRAIN HOLES

(2 PLCS)

BOOT

NYLON STRAP

NOTES:

COLOR CODED TO MATCH BLADES.

MAST

IF COUNTERWEIGHTS ARE USED, COAT BOLT WITH

GREASE (CM116) BEFORE INSTALLATION.

BOOT INSTALLATION

TORQUE NUT TO 30-60 IN-LBS.

TORQUE NUT TO 15-20 IN-LBS.

G62-3001B

Figure 403. Main Rotor Swashplate

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

SWASHPLATE AND MIXER

INSPECTION/CHECK

1. Swashplate Inspection

(a). Maximum radial play between

sliding surface liner and stationary

mast is 0.020 inch (0.508 mm).

Consumable Materials

(Ref. Section 91−00−00)

(b). Maximum axial play between spheri

Item

Nomenclature

cal ball and teflon liner is 0.010 inch

(0.254 mm).

CM217

Isopropyl alcohol

(c). If play is suspected in double row ball

bearing, turn rotating swashplate

When cleaning swashplate for

until arms line up with those of

CAUTION

inspection, prevent solvent from

stationary swashplate and check

entering either spherical ball bearing or

motion between arms at control bolt

double row ball bearing. Use cloth moist

in stationary swashplate.

ened in alcohol (CM217) to wipe clean

(d). Maximum total vertical movement of

spherical ball, ball bore liner and exterior of

0.015 inch (0.381 mm) is allowable.

double row ball bearing.

(e). If movement limit is exceeded replace

NOTE:

double row ball bearing (Ref. COM).

D Stationary swashplate may be con

(5). Inspect swashplate spherical and

structed of either magnesium or alumi

double row ball bearings for condition.

num alloy. For corrosion control and iden

(a). Nicks and dents that do not deform

tification of magnesium and aluminum

ID chamfered edge of hard anodized

alloys (Ref. Sec. 20-40-00).

ball, and not more than 0.10 inch

D In the following inspection, the rotating

(0.254 mm) deep along spherical ball

and stationary swashplates must be dis

surface from edge are allowed.

connected (Ref. Swashplate and Mixer

(b). Scratches, any length, on OD of

Removal/Installation).

spherical ball are allowed if they are

no deeper than 0.010 inch (0.254

(1). Inspect swashplate bearing assembly

mm) or wider than 0.060 inch (1.524

(Ref. Figure 403 for evidence of binding

mm).

in either radial or axial movement.

(c). Not more than two scratches are

(2). Inspect teflon liners for condition.

permitted in a one inch wide area.

(6). Check existing preload on spherical

(3). Ensure that all flexible rubber seals

bearing.

enclosing ball bearing races are in

place; inspect for deterioration and

(a). Hook spring scale over one of the

indication of grease leakage. (For

bolts securing stationary swashplate

bearing maintenance information

to the bearing flange.

(including lubrication), Ref. COM).

(b). With stationary swashplate in

motion, drag should be no more than

NOTE: New swashplate bearing assembly nor

30 pounds (13.61 kg). (Use average

mally shows some signs of grease leakage

of four readings taken 90 degrees

for first 10-15 hours of operation after in

apart).

stallation.

(c). If readings are more than 30 pounds

(4). Inspect swashplate spherical ball and

(13.61 kg), clean spherical bearing

double row ball bearing for radial or

with isopropyl alcohol and recheck

axial play.

drag.

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(d). Repair damage or replace bearings

mixer link for binding, play in link bore

(Ref. COM).

and wear. Wear limit is 0.008 inch

(0.203 mm) radially and 0.040 inch

(7). Check double row ball bearing for

(1.016 mm) axially. Replace complete

serviceability, with seals in place and

mixer link if bearings are faulty.

unbroken.

Inspect bearings in other linkage for

binding and looseness in mating bores.

(a). Check for correct operation and

lubrication.

3. Scissors Inspection

(b). Bearing must rotate smoothly,

(Ref. Figure 401)

without roughness. Binding or

catching should not exist when

Any evidence of failure,

bearings are rotated 360°.

WARNING

damage, or deformation of

crank or link is justification for re

(c). Replace defective double row ball

placement of either crank, link, or com

bearings (Ref. COM).

plete scissors assembly. Failure of any

(8). Perform careful visual inspection of

of these components in flight can result

stationary and rotating swashplate for

in failure of movable flight controls,

cracks, wear in bolt and bushing bores,

loss of helicopter, and possible injury

and fork inner surfaces; and for

or loss of life.

corrosion, nicks and dents.

(1). Inspect crank and link for evidence of

(9). Perform dye penetrant check on

impact damage and deformation. If

questionable areas.

condition is questionable, perform

fluorescent dye penetrant inspection.

(10). Check that counterweights are securely

bonded in rotating swashplate.

(2). Inspect bearings for binding, looseness

in bore and wear. Maximum wear limits

2. Mixer Controls Inspection

are 0.010 inch (0.254 mm) radial and

0.020 inch (0.508 mm) axial.

(Ref. Figure 402)

4. Pitch Control Rod Inspection

(1). Inspect all bushings for security of fit.

(Ref. Figure 401)

(2). Inspect longitudinal link, support

bracket, longitudinal control mixer link,

Ensure that rod end bearings

mixer links, longitudinal pitch idler,

CAUTION

are centered and do not contact

longitudinal pitch mixer bellcrank,

attach clevis.

lateral bellcrank and collective pitch

mixer bellcrank for scratches, cracks,

(1). Visually inspect upper and lower rod

corrosion and similar surface defects.

end bearings for evidence of excessive

For components that are questionable,

axial play, 0.040 inch (1.016 mm)

perform fluorescent dye penetrant

maximum; and for any extrusion,

inspection.

displacement or damage to the bearing

teflon liner.

(3). Inspect spherical, teflon (or equivalent)

lined, bearings in longitudinal link,

(2). Replace rod end bearing if discrepan

mixer link, and longitudinal control

cies are noted.

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CSP-HMI-2

MAINTENANCE MANUAL

SWASHPLATE AND MIXER

REPAIRS

1. Swashplate Repairs

be restored on magnesium and alumi

num parts.

(Ref. Figure 403) Disassembly other than as

illustrated is considered a part of swashplate

(7). Replace defective bearings and bush

overhaul (Ref. COM). If tracking interrupters

ings, except swaged spherical bearings

are to be removed, mark them for reinstalla

in mixer links which require link

tion at original locations.

replacement. Remove bearings or

bushings by pressing them out. Install

2. Mixer Controls Repair

new bearing with surface primer and

grade A locking compound (CM321 and

(Ref. Figure 402)

CM431).

NOTE: Left-hand bearing in support bracket is

Consumable Materials

not supplied as part of bracket. This bearing

(Ref. Section 91−00−00)

is installed at time support bracket and lon

Item

Nomenclature

gitudinal pitch idler are assembled. Install

CM321

Surface primer locking compound

new bearing by seating flush with inner face

CM431

Sealing, locking and retaining compound

of support bracket flange.

CM802

Abrasive cloth, aluminum oxide

3. Scissors Bushing and Bearing

Replacement

NOTE: Following depth limits are total limits,

(Ref. Figure 401)

including effects of all previous repairs to

any given area.

Consumable Materials

(1).

Repair minor surface defects such as

(Ref. Section 91−00−00)

scratches, nicks and corrosion using

Item

Nomenclature

abrasive cloth, grade 400 - 600

CM103

Solid film lubricant

(CM802) to smooth out and blend in

CM222

1,1,1-Trichloroethane

such defects.

CM318

Primer

(2).

Cast and forged surfaces may be

CM321

Surface primer locking compound

reworked to depth of 0.020 inch (0.508

CM431

Sealing, locking and retaining compound

mm).

(3).

Flat machined surfaces, except clevis

(1). Remove cotter pin, nut, washer, and

inner ears, may be reworked to depth of

bolt that join link and crank.

0.015 inch (0.381 mm). Clevis inner ear

(2). Remove two bushings from link only if

surfaces may be reworked to depth of

replacement is necessary.

0.020 inch (0.508 mm).

(3). Do not remove bearing from link.

(4).

Machined holes may have 0.003 inch

Replace complete link if bearing is

(0.076 mm) removed from bore wall in

defective.

an area no greater than 15 percent of

circumference and 50 percent of depth.

(4). Remove slotted bushings and bearings

from crank, only if replacement is

(5).

All edges may have 0.030 inch (0.762

necessary.

mm) removed except around machined

holes which are limited to 0.010 inch

During cleaning, do not allow

CAUTION

(0.254 mm) chamfer.

solvent to enter bearings.

(6).

All rework must be smoothly blended

(5). Install new bushings using solid film

into adjacent surfaces and finish must

lubricant (CM103); do not use zinc

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

chromate. Press in bushing until end

scissors to 369D21002-21 configuration to

is flush with inside surface of crank

preclude shimming problems experienced with

inboard ears.

the early crank configuration. Field rework

consists primarily of relocating existing

(6). If bearings were removed from crank at

bushings in the crank outboard attach lugs to

disassembly, reinstall using the

the inboard lugs, and installing new flange

following procedure:

type bushings in the outboard lugs. The wall

thickness of the crank outboard attach lugs

NOTE: Do not allow sealant to enter bearing

must be reduced to accommodate installation

race.

of the flange bushings.

(a).

Clean bearing outer face, counterbore

and faying surfaces with trichloroe

Instructions are also provided for replacement

thane (CM222). Do not allow trichlo

of existing hardware for the crank assembly.

roethane to enter bearing.

Existing attach bolts may have insufficient

thread length which, in some cases, can cause

(b).

Coat the faying surfaces with surface

loosening of the bolt in service.

primer (CM321) as per manufactur

er's instructions.

It is to be noted that the field modification and

(c).

Apply locking compound (CM431) to

installation of the PN 369D21002-21 crank

faying surfaces.

assembly with new attach hardware also

upgrades the PN 369D21001 scissors assembly

(d).

Press bearing until outer face is

to PN 369D2101-501 configuration.

seated firmly against shoulder of

counterbore.

Consumable Materials

(e).

Remove excess sealant. Do not allow

(Ref. Section 91−00−00)

sealant to enter bearing race.

Item

Nomenclature

(f).

Apply a small fillet of sealant to the

CM206

Chemical coating

faying edges of bearing housing. Use

CM318

Primer

cellophane or masking tape to

exclude air and allow sealant to cure

for 24 hours at ambient temperature

or force cure by heating to

(1). Disconnect scissors crank from hub

140°-160°F (60°-72°C for one hour

lower shoe and scissors link.

prior to use of assembly.

(7). If bushings were removed from link at

(2). Remove existing HS626-S-4-500

disassembly, install new bushings.

bushings from outboard lugs of scissors

After installation, dimension between

crank.

outside faces of bushings should be

1.579-1.586 inches (4.0107-4.0284 cm).

(3). Using grinder or file, remove minimum

(8). Align bore of link with bore of crank;

0.063 inch (1.6002 mm) material from

install bolt, washer and nut. Torque nut

inner side of both outboard attach lugs,

to 30 - 40 inch-pounds (3.39 - 4.52

to obtain distance of 9.735 inches

Nm).

(24.7295 cm) between lugs. After

removal of material, wall thickness of

Scissors Modification

lugs should not be less than 0.230 inch

(5.842 mm). Coat reworked area of lug

(Ref. Figure 801) The following procedure is for

with iridite (CM206) or equivalent

modification of 369D21002 main rotor hub

corrosion protective chemical film.

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

9.736 IN.

(24.7295 CM)

MINIMUM WALL 0.230 IN. (5.8420 MM) TYP.

NOTE 5

MAXIMUM WALL 0.249 IN. (6.3246 MM) TYP.

HS626-S-4-500

BUSHING (2 REQ'D)

NAS77-4-23 BUSHING

(TYP. 2 PLCS)

369D21002-21 CRANK

0.020 IN. (0.508 MM) X 45°

ASSEMBLY

CHAMFER (4 PLCS)

0.3750 IN. (9.5250 MM)

DIA.

0.3755 IN. (9.5377 MM)

(NOTE 3)

6.421 IN.

16.3093 CM)

NAS6204-38D BOLT

AN960C416 WASHER

PLAT

2 REQ'D (NOTE 2)

MS17826-4 NUT (NOTE 1)

INSTALL THIS SIDE

TOWARD BLADES

NOTE 4

NOTES:

TORQUE NUT 30 - 40 INCH-POUNDS (3.39 - 4.52 NM).

SCISSORS LINK

ONE WASHER EACH UNDER BOLT HEAD AND NUT.

ASSEMBLY

TWO HOLES IN LINE (TYP. 2 PLACES)

FILL GAP WITH HS5079-2646 WASHERS. SHIM WASHERS

SHOULD BE EQUALLY SPACED.

REMOVE MATERIAL EVENLY FROM INNER SIDE OF OUTBOARD

G62-3004B

Figure 801. Field Modification − 369D21002−11 Crank Assembly to 369D21002−21 Configuration

NOTE: Remove material only from inner side of

(a). Install scissors crank to hub lower

existing crank outboard attach lugs.

shoe with NAS6204-18D bolts,

AN960PD416L washers, MS17826-4

(4).

Using existing hole in outboard lug as

nuts and cotter pins (Ref.

guide, drill and ream 0.252 inch (6.4008

Figure 802).

mm) dia. hole in outboard lugs to

0.3750-0.3755 inch (9.5250-9.5377

(b). Install scissors link to scissors crank

mm) dia. for press fit of

assembly with NAS6204-38D bolt,

HS626-S-4-500 bushings.

AN960C416 washers, MS17826-4

nut and cotter pins (Ref. Figure 801).

(5).

Install HS626-S-4-500 bushings in

Torque nut to 30 - 40 inch-pounds

inboard lugs of scissors crank with

(3.39 - 4.52 Nm).

primer (CM318).

(10). Record upgrade of PN 369D21002 main

(6).

Install new NAS77-4-23 flanged

rotor hub scissors crank assembly to

bushings with primer (CM318) in

PN 369D21002-21 configuration per

outboard lugs.

DN-46.1 in Component Record of

Helicopter Log Book.

(7).

Re-identify crank assembly as PN

369D21002-21 on ID plate.

(11). Record upgrade of PN 369D21001 main

(8).

zinc chromate

rotor hub scissors assembly to PN

369D21001-501 configuration per

(9).

Reinstall scissors crank assembly using

DN-46.1 in Component Record of

new attach hardware as follows:

Helicopter Log Book.

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

369D21204 LOWER SHOES

369H1001 BOOT

NAS6204-18D BOLT (2 REQD)

AN960PD416L WASHER (4 REQD)

MS17826-4 NUT (2 REQD) (NOTE)

MS24665-153 COTTER PIN (2 REQD)

369D21002-21 CRANK ASSEMBLY

NOTE:

TORQUE NUT 30 - 60 INCH-POUNDS (3.39 - 6.78 NM).

G63-3005A

Figure 802. Installation of 369D21002−21 Crank to Hub Lower Shoes

5. Mixer Controls Rework

(a). Chamfer 369D21002-3 scissors crank

and 369A1003 link assembly per

dimensions shown (Ref. Figure 803).

(Ref. Figure 803) The following lists

instructions and criteria for rework of the

(b). Touch up reworked area with chemi

mixer controls to preclude interference

cal film (CM206) and refinish with

between mixer components. Rework is

primer (CM318) and black paint

applicable to 369D helicopter, Serial No.

(CM305).

0001D thru 0129D only, unless already

(c). Using permanent ink stamp

accomplished, and is to be performed prior to

(CM312), reidentify scissors link part

rigging the main rotor controls.

number as 369A1003-501.

(d). Apply a coat of varnish (CM314) over

Consumable Materials

ink stamp.

(Ref. Section 91−00−00)

(2). Rework installed 369D27611 rotating

Item

Nomenclature

swashplate as follows:

CM206

Chemical coating

(a). Chamfer 369D27611 swashplate per

CM305

Lacquer, acrylic

dimensions shown (Ref. Figure 803).

CM312

Ink stamp, permanent

(b). Touch up reworked area with chemi

CM314

Varnish, moisture resistant

cal film and refinish with primer and

black paint.

CM318

Primer

(c). Using permanent ink stamp, reiden

tify rotating swashplate assembly

part number as 369A27611-501.

(1). Remove and rework the 369D21002-3

scissors crank assembly and scissors

(d). Apply a coat of varnish over ink

link assembly as follows:

stamp.

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CSP-HMI-2

MAINTENANCE MANUAL

(3). Remove and rework 369N2664 collec

(d). Apply a coat of varnish over ink

tive mixer bellcrank and 369N2670

stamp.

lateral mixer bellcrank as follows:

(a). Chamfer collective and lateral

NOTE: The 369N2666-503 longitudinal mixer

bellcrank assemblies per dimensions

idler is compatible installed with the

shown (Ref. Figure 803).

369N2668 basic longitudinal mixer bell

crank only. If the 369N2666-505 idler is in

(b). Touch up reworked area with chemi

stalled, the 369N2668-503 bellcrank must

cal film and refinish with primer and

be used.

black paint.

(c). Using permanent ink stamp, re-iden

(4). Reinstall removed components.

tify collective bellcrank part number

as 369N2664-501; reidentify lateral

bellcrank part number as

(5). Perform rigging of main rotor controls

369N2670-501.

(Ref. Sec. 67-10-00).

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

0.38 IN.

0.080 IN. (2.032 MM) X 45°

(9.652 MM)

ROTOR

CHAMFER AND BLEND

CHAMFERED ZONE

BOTH ENDS SMOOTHLY

HUB

(TYP 4 PLACES)

LOWER

369D21002

0.38 IN. (9.652 MM)

SHOE

SCISSORS

CRANK

SECTION A - A

0.20 IN. (5.08 MM)

0.25 IN. (6.35 MM)

(TYP 4 PLACES)

(TYP BOTH SIDES)

0.25 IN.

0.040 IN. (1.016 MM)

CHAMFER

(6.35 MM)

0.060 IN. (1.524 MM)

BLEND BOTH ENDS

369A1003

AT 0.25 IN. (6.35 MM)

SCISSORS

WIDTH SMOOTHLY

LINK

0.25 IN.

(6.35 MM)

SECTION B - B

(TYP BOTH SIDES)

LOF 0.625 IN.

0.040 IN. (1.016 MM)

X 45° CHAMFER

(15.875 MM)

0.060 IN. (1.524 MM)

SLOT

BLEND BOTH ENDS

SMOOTHLY

LONGITUDINAL

CONTROL

MIXER LINK

LONGITUDINAL

PITCH IDLER

COLLECTIVE PITCH

369D27611 ROTATING

MIXER BELLCRANK

SWASHPLATE

COLLECTIVE PITCH

CONTROL ROD

0.10 IN. (2.54 MM) X 30°

CHAMFER, BLEND

2.25 IN. (5.715 CM)

BOTH ENDS WITH

(TYP)

SMOOTH RADIUS TO

LONGITUDINAL PITCH

2.25 IN. (5.715 CM) DIM.

CONTROL ROD

LATERAL MIXER

0.10 IN. (2.54 MM)

BELLCRANK

(TYP BOTH SIDES

1.50 IN. (3.81 CM)

(TYP FAR SIDE)

SECTION C - C

G62-3006-1A

Figure 803. Rework of Main Rotor and Mixer Controls (Sheet 1 of 2)

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CSP-HMI-2

MAINTENANCE MANUAL

369N2666 LONGITUDINAL

PITCH IDLER

369A7607 LONGITUDINAL

CONTROL MIXER

MIXER BELLCRANK

369N2670

STATIONARY

LATERAL MIXER

SWASHPLATE

BELLCRANK

CHAMFER

0.15 IN. (3.81 MM)

0.040 IN. (1.016 MM) X

0.20 IN. (5.08 MM)

BLEND BOTH ENDS

SMOOTHLY

MIXER LINK

1.50 IN. (3.81 CM)

1.68 IN. (4.2672 CM)

MIXER

SUPPORT

BRACKET

369N2664 COLLECTIVE

PITCH MIXER BELLCRANK

CHAMFER 0.080 IN. (2.032 MM)

MAX X 0.180 IN. (4.57 MM)

BLEND BOTH ENDS SMOOTHLY

0.25 IN. (6.35 MM)

(TYP)

1.62 IN. (4.1148 CM)

1.50 IN. (3.81 CM)

1.75 IN. (4.445 CM)

MAST BASE

1.75 IN. (4.445 CM)

0.180 IN.

(4.57 MM)

0.425 IN. (10.795 MM)

32°

0.440 IN. (11.176 MM)

6°

0.45 IN. (11.43 MM) (TYP 4

PLACES)

4.375 IN.

(11.1125 CM)

0.48 IN. (12.19 MM) R

0.48 IN. (12.19 MM) R (TYP 4

(TYP)

PLACES)

30°

(TYP 4 PLACES)

0.50 IN. (12.70 MM) R

G62-3006-2A

Figure 803. Rework of Main Rotor and Mixer Controls (Sheet 2 of 2)

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

SWASHPLATE AND MIXER

REMOVAL/INSTALLATION

1. Main Rotor Swashplate

Do not strike rotating swash

CAUTION

plate or bearing assembly (Ref.

Figure 403) with tools or in any way deface

(Ref. Figure 403) The main rotor swashplate

these components, the rotating swashplate

includes a rotating swashplate, stationary

is a stressed part. Use particular care to pro

swashplate, bearing and retainer and one

tect teflon liner in bearing bore. A damaged

counterweight. The rotating swashplate

swashplate bearing must not be retained in

converts movement from the stationary

service.

swashplate into rotating motion and transfers

it to the main rotor hub assembly for lift, and

(8). Lift swashplate carefully up and off of

longitudinal and lateral control of the helicop

mast.

ter.

(9). To remove boot from mast, remove

self-clinching nylon strap.

2. Swashplate Replacement

B. Swashplate Installation

A. Swashplate Removal

(1).

If swashplate lower boot was removed,

install boot on mast (Ref. Figure 403).

(1). Tag or color-identify six pitch control

(2).

Position swashplate over main rotor

rods (Ref. Figure 401) to simplify

mast and carefully lower into place.

replacement at same locations.

(3).

Engage upper end of boot in groove at

lower side of stationary swashplate.

Failure to reinstall pitch control

CAUTION

Secure boot with self-clinching nylon

rods at correct locations may re

strap (Ref. Figure 403).

sult in main rotor blades excessively out of

track.

(4).

Align longitudinal link with stationary

swashplate (Ref. Figure 402).

(2).

Disconnect pitch control rods from

(5).

Install flanged bushing, if removed,

rotating swashplate.

bolt, two washers, nut and cotter pin to

secure upper end of longitudinal link.

(3).

Remove scissors.

(6).

Align upper ends of mixer links with

stationary swashplate. Install slotted

(4).

Remove main rotor hub.

bushing (if removed), bolt, two washers,

nut and cotter pin to secure each link to

swashplate.

(5).

Disconnect longitudinal link (Ref.

Figure 402) from stationary swash

(7).

Install scissors.

plate.

(8).

Using color code, reinstall pitch control

rods at same locations from which

(6).

Disconnect right and left side mixer

removed.

links (Ref. Figure 402) from stationary

swashplate.

(9).

Check track of main rotor blades (Ref.

Sec. 18-10-60) following any mainte

(7).

Remove protective boot from groove in

nance activity that could result in a

lower side of stationary swashplate

dimensional variation affecting rigging

(Ref. Figure 403).

or tracking.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

ROTOR HUB

LOWER SHOE

WASHERS

(NOTE 4)

BEARING

SLOTTED BUSHING

SCISSORS CRANK

WASHERS

(NOTE 1)

(NOTE 4)

BUSHING

CLOSE TOLERANCE

SCISSORS LINK

BOLT (NOTE 5)

BEARING

PITCH CONTROL

ROD (NOTE 2)

SLOTTED BUSHING

ELASTOMER RING

(NOTE 1)

ROTATING

ELASTOMER RING

SWASHPLATE

INTERRUPTER

SLOTTED BUSHING

(NOTE 1)

COLLECTIVE LINK

ASSEMBLY

LONGITUDINAL

LINK ASSEMBLY

6.25 IN.

(15.875 CM)

(NOTE 3)

0.040 IN. (1.016 MM) MAX

ALLOWABLE LOOSENESS

AT INSTALLATION, ROD

SLOTTED BUSHING

ENDS TO BE PARALLEL

(NOTE 1)

WITH MATING CLEVIS

LATERAL CONTROL

1.30 IN. (3.302 CM)

LINK ASSEMBLY

(TYP UPPER BEARING ONLY)

NOTES:

END OF SLOTTED BUSHING MUST PROTRUDE MINIMUM OF

0.010 IN. (0.254 MM) TO MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE

OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.

COLOR CODED TO MATCH BLADE.

OPTIMUM INITIAL SETTING (SIX PLACES).

AS REQUIRED TO FILL GAP.

6G62-031B

Figure 401. Pitch Control Rods and Swashplate Scissors − Installation

Page 402

Revision 27

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CSP-HMI-2

MAINTENANCE MANUAL

3. Controls Mixer

(1). Position support bracket over forward

lug on mast base.

Controls mixer includes links, bellcranks,

idlers, support bracket and fasteners to secure

(2). Install two aft bolts and washers in

these components in place and to the control

support bracket and mast base. Install

rods and main rotor swashplate.

two thin washers and nuts; torque nuts

to 80 - 100 inch-pounds (9.04 - 11.30

4. Controls Mixer Replacement

Nm) plus drag torque.

A. Controls Mixer Removal

(3). Using ball hole gage and standard

micrometer, check that misalignment

(Ref. Figure 402)

between forward bolt hole bore in

(1). Remove air intake forward fairing for

support bracket and bore in mast base

access.

lug is 0.015 inch (0.381 mm) or less.

(2). Disconnect upper ends of collective,

NOTE: If necessary, loosen aft two bracket-to-

lateral and longitudinal control links

fitting nuts, position support bracket to

(Ref. Figure 401).

minimize misalignment and retighten nuts.

NOTE: Control links are attached by slightly

(4).

Install mixer support attaching bushing

different length bolts. Reinstall each bolt in

in bracket and mast base lug.

its bellcrank following control rod removal

to simplify reinstallation at correct loca

(5).

Check that sleeve bushing is in place;

tions.

then install bolt, two washers and nut.

Torque nut to 80 - 100 inch-pounds

(3). Remove mixer links. (Mixer link

(9.04 - 11.30 Nm).

bearings are not replaceable.)

(6).

Position longitudinal pitch idler and

(4). Disconnect longitudinal link from

collective pitch mixer bellcrank on

stationary swashplate.

support bracket. Position washer

between right side of longitudinal pitch

(5). Remove longitudinal control mixer link.

idler bearing and center bearing of

(6). Disconnect lateral mixer bellcrank from

mixer support bracket. Install left-

collective pitch mixer bellcrank.

hand bearing, with attaching hardware.

(7). Remove connecting hardware (includ

(7).

Position lateral bellcrank between

ing flanged bushing) from each side of

collective pitch mixer bellcrank bear

longitudinal pitch mixer bellcrank.

ings and install attaching hardware.

Carefully remove bellcrank. Retain any

shims that may be installed.

(8).

Position longitudinal pitch mixer

bellcrank with collective pitch mixer

(8). Remove bolt from hingeline of support

bellcrank; insert two flanged bushings.

bracket, longitudinal pitch idler and

Install two bolts.

collective pitch mixer bellcrank.

Separate the three parts.

(9).

Push longitudinal bellcrank to one side

and measure gap between bellcrank

(9). Remove mixer support bracket from

and bearings in collective pitch bell

mast base.

crank.

To prevent washing dirt into

CAUTION

(10).

Using HS5079-2646 laminated wash

bearings, or washing grease out

er(s), shim evenly to take up gap.

of bearings, do not permit solvent to enter

bearings when cleaning mixer control com

(11).

Insert flanged bushings, bolts, six

ponents.

washers (two under each nut) shims

and nuts. Torque nut to 30 - 40 inch-

B. Mixer Controls Installation

pounds (3.39 - 4.52 Nm) and install

(Ref. Figure 402)

cotter pin.

Page 403

62-30-60

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

BUSHING LONGITUDINAL CONTROL

(NOTE 2)

MIXER LINK

STATIONARY

BUSHING

LONGITUDINAL

SWASHPLATE

STATIONARY

MIXER LINK

(NOTE 2)

PITCH IDLER

SWASHPLATE

LONGITUDINAL

FLANGED

LINK

BUSHING

(NOTE 3)

LATERAL MIXER

BEARING

BELLCRANK

(NOTE 5)

NOTE 1

MIXER

LINK

WASHER

BEARING

NOTE 1

BUSHING

(NOTE 2)

BEARING

FLANGED

BUSHING

(NOTE 4)

BEARING

MIXER

BEARING

SUPPORT

ATTACHING

BUSHING

(NOTE 6)

MIXER

SUPPORT

NOTE 7

BRACKET

BEARING

LONGITUDINAL

COLLECTIVE PITCH

PITCH MIXER

SLEEVE

MIXER BELLCRANK

BELLCRANK

BEARING

BUSHING

FLANGED BUSHING

(NOTE 4)

MAST BASE

TWO IDENTIFYING LOCATORS

ONE IDENTIFYING LOCATOR

(FACING UP AND OUT)

(FACING OUT) L/H SIDE ONLY

R/H SIDE ONLY

LEFT-HAND

RIGHT-HAND

NOTES:

DIRECTION OF BOLT OPTIONAL.

MIXER LINK

(600N7636-1/-9)

(600N7636-3/-11)

EDGE OF BUSHING MUST PROTRUDE MINIMUM OF 0.010 IN.

(0.254 MM) TO MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE

OUTSIDE OF PART AFTER NUT IS TIGHTENED.

LONGITUDINAL LINK DETAILS ROTATED FOR CLARITY.

LONGITUDINAL LINK

MUST BE PULLED OUT FIRST TO REMOVE BELLCRANK.

PART MAY BE EITHER MAGNESIUM OR ALUMINUM ALLOY.

MAST CL

(FOR ALLOY IDENTIFICATION AND CORROSION CONTROL,

REFER TO SECTION 20-40-00).

MIXER LINK IDENTIFICATION

INSTALL BUSHING AFTER THE TWO AFT ATTACHING BOLTS

FOR PROPER INSTALLATION

6G62-032C

Figure 402. Controls Mixer − Assembly

Page 404

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CSP-HMI-2

MAINTENANCE MANUAL

(12). Position longitudinal control mixer link

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

between longitudinal pitch idler and

bolt from each leg of scissors crank.

longitudinal pitch mixer bellcrank;

Disconnect crank from hub lower shoe.

check that two slotted bushings are in

(3). Remove cotter pin, nut, washer, and

place. Install bolt, three washers (two

bolt connecting scissors link to swash

under each nut), nut and cotter pin at

plate; remove scissors.

each end of link.

B. Scissors Installation

(13). Position longitudinal link between

longitudinal pitch mixer bellcrank

(Ref. Figure 401)

bearings. Install attaching hardware.

(1). Place scissors link in mounting posi

tion, chamfered edge of link must face

NOTE: In the following step, ensure mixer

outboard.

links are not installed inverted and are

installed in the correct position (Ref.

(2). Check that slotted bushing is in

Figure 402, View A).

swashplate web and install attaching

hardware. Torque nut to 15 - 20

(14). Position mixer links in stationary

inch-pounds (1.69 - 2.26 Nm).

swashplate and lateral mixer bellcrank;

check that slotted bushings are in

Scissors crank must be posi

CAUTION

place. Install attaching hardware.

tioned (Ref. Figure 401) with de

cal up and proper direction towards lower

(15). Place collective, lateral longitudinal

side lugs.

control links (Ref. Figure 401) in

mounting position; check that slotted

NOTE: Ensure crank-to-hub lower shoe lugs

bushing is in place. Install attaching

are not preloaded.

hardware.

(3). Position scissors crank on hub lower

shoe lugs; install connecting hardware.

(16). Install air intake forward fairing.

Install bolts with bolt heads facing

inward and a washer under head of bolt

(17). Check rigging of collective and cyclic

(Ref. Figure 401). Torque nuts to 30 -

controls.

60 inch-pounds (3.39 - 6.78 Nm).

5. Scissors

NOTE: Shim washers may be required on

shouldered bushing side of clevis.

The scissors provide a movable connection

between the rotating swashplate and main

(4). Position elastomer rings and lower end

rotor hub.

of pitch control rod in swashplate lug

and install attaching hardware. (Nut is

6. Scissors Replacement

to be adjacent to bushing in swash

plate.) Torque nut to 30 - 60 inch-

A. Scissors Removal

pounds (3.39 - 6.78 Nm).

(Ref. Figure 401)

7. Scissors Link Replacement

Removal of all pitch control rods

CAUTION

Consumable Materials

is recommended prior to scissors

(Ref. Section 91−00−00)

removal. Failure to observe this precaution

Item

Nomenclature

could result in damage to pitch control rods,

CM103

Solid film lubricant

swashplate and/or hub. Ensure all rods are

color-coded or marked so they will be rein

stalled in the correct location.

(1). Remove cotter pin, nut, washer and bolt

that join link and crank.

(1). Disconnect lower end of pitch control

rod that is in line with scissors link in

(2). Remove two bushings from link only if

rotating swashplate.

replacement is necessary.

Page 405

62-30-60

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(3). Do not remove bearing from link,

(2). Remove pitch control rod and O-ring.

replace complete link if bearing is

B. Pitch Control Rod Installation

defective.

NOTE: Install new bushings using solid film lu

(Ref. Figure 401)

bricant (CM103); do not use zinc chro

At installation, install rod at

mate.

CAUTION

correct color code location. Cen

(4). If bushings were removed at disassem

ter bearing rodends between attach clevis. If

bly, install new bushings. After installa

rod length is changed, blades must be

tion, dimension between outer faces of

tracked.

bushings should be 1.579-1.586 inches

(1). If actual rod length is incorrect or

(4.011-4.028 cm).

either actual or required rod length is

(5). Align bore of link with bore of crank;

unknown, preset link length to opti

install bolt, washer and nut. Torque nut

mum length of 6.25 inches (15.88 cm).

to 30 - 40 inch-pounds (3.39 - 4.52

NOTE: Install both pitch change rod bolts in

Nm); install cotter pin.

direction of rotation.

8. Pitch Control Rods

(2). Install rod with elastomeric rings on

Six pitch control rods transfer pitch control

both sides of lower bearing.

from the rotating swashplate to the main rotor

blades.

NOTE: Add washers as required to align nut

with cotter pin hole.

9. Pitch Control Rod Replacement

(3). Torque upper nut to 100 - 130 inch-

A. Pitch Control Rod Removal

pounds (11.30 - 14.69 Nm).

(Ref. Figure 401)

NOTE: Bushing must project 0.010-0.060 inch

(0.254-1.524 mm) after nut is torqued.

NOTE:

D If rod is not to be reinstalled, but is to be

(4). Torque lower nut to 30 - 60 inch-

replaced, measure and record length of

pounds (3.39 - 6.78 Nm).

removed link. Optimum length may have

(5). Secure nuts with cotter pins.

been changed at previous rigging; pre-ad

just replacement link to length of link re

(6). Rotate pitch control rod assembly fore

moved.

and aft to ensure clearance exists

D Rods are color coded for reinstallation at

between rod end bearing and pitch

correct locations. If more than one rod is

housing clevis at both ends.

being removed and color coding is not vis

ible, identify each by color or similar

(7). If installation is final and tracking is

means to points of connection to simplify

not required, safetywire rod ends to rod;

reinstallation.

ensure rod ends are centered.

(1). Remove cotter pin, nut, washer and bolt

(8). As necessary, repeat above procedures

from each end of pitch control rod.

for remaining pitch control rods.

Page 406

Revision 35

62-30-60

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

SWASHPLATE AND MIXER

INSPECTION/CHECK

1. Swashplate Inspection

(a). Maximum radial play between

sliding surface liner and stationary

mast is 0.020 inch (0.508 mm).

Consumable Materials

(Ref. Section 91−00−00)

(b). Maximum axial play between spheri

Item

Nomenclature

cal ball and teflon liner is 0.010 inch

(0.254 mm).

CM217

Isopropyl alcohol

(c). If play is suspected in double row ball

bearing, turn rotating swashplate

When cleaning swashplate for

until arms line up with those of

CAUTION

inspection, prevent solvent from

stationary swashplate and check

entering either spherical ball bearing or

motion between arms at control bolt

double row ball bearing. Use cloth moist

in stationary swashplate.

ened in alcohol (CM217) to wipe clean

(d). Maximum total vertical movement of

spherical ball, ball bore liner and exterior of

0.015 inch (0.381 mm) is allowable.

double row ball bearing.

(e). If movement limit is exceeded replace

NOTE:

double row ball bearing (Ref. COM).

D Stationary swashplate may be con

(5). Inspect swashplate spherical and

structed of either magnesium or alumi

double row ball bearings for condition.

num alloy. For corrosion control and iden

(a). Nicks and dents that do not deform

tification of magnesium and aluminum

ID chamfered edge of hard anodized

alloys (Ref. Sec. 20-40-00).

ball, and not more than 0.10 inch

D In the following inspection, the rotating

(0.254 mm) deep along spherical ball

and stationary swashplates must be dis

surface from edge are allowed.

connected (Ref. Swashplate and Mixer

(b). Scratches, any length, on OD of

Removal/Installation).

spherical ball are allowed if they are

no deeper than 0.010 inch (0.254

(1). Inspect swashplate bearing assembly

mm) or wider than 0.060 inch (1.524

(Ref. Figure 403 for evidence of binding

mm).

in either radial or axial movement.

(c). Not more than two scratches are

(2). Inspect teflon liners for condition.

permitted in a one inch wide area.

(6). Check existing preload on spherical

(3). Ensure that all flexible rubber seals

bearing.

enclosing ball bearing races are in

place; inspect for deterioration and

(a). Hook spring scale over one of the

indication of grease leakage. (For

bolts securing stationary swashplate

bearing maintenance information

to the bearing flange.

(including lubrication), Ref. COM).

(b). With stationary swashplate in

motion, drag should be no more than

NOTE: New swashplate bearing assembly nor

30 pounds (13.61 kg). (Use average

mally shows some signs of grease leakage

of four readings taken 90 degrees

for first 10-15 hours of operation after in

apart).

stallation.

(c). If readings are more than 30 pounds

(4). Inspect swashplate spherical ball and

(13.61 kg), clean spherical bearing

double row ball bearing for radial or

with isopropyl alcohol and recheck

axial play.

drag.

Page 601

62-30-60

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(d). Repair damage or replace bearings

mixer link for binding, play in link bore

(Ref. COM).

and wear. Wear limit is 0.008 inch

(0.203 mm) radially and 0.040 inch

(7). Check double row ball bearing for

(1.016 mm) axially. Replace complete

serviceability, with seals in place and

mixer link if bearings are faulty.

unbroken.

Inspect bearings in other linkage for

binding and looseness in mating bores.

(a). Check for correct operation and

lubrication.

3. Scissors Inspection

(b). Bearing must rotate smoothly,

(Ref. Figure 401)

without roughness. Binding or

catching should not exist when

Any evidence of failure,

bearings are rotated 360°.

WARNING

damage, or deformation of

crank or link is justification for re

(c). Replace defective double row ball

placement of either crank, link, or com

bearings (Ref. COM).

plete scissors assembly. Failure of any

(8). Perform careful visual inspection of

of these components in flight can result

stationary and rotating swashplate for

in failure of movable flight controls,

cracks, wear in bolt and bushing bores,

loss of helicopter, and possible injury

and fork inner surfaces; and for

or loss of life.

corrosion, nicks and dents.

(1). Inspect crank and link for evidence of

(9). Perform dye penetrant check on

impact damage and deformation. If

questionable areas.

condition is questionable, perform

fluorescent dye penetrant inspection.

(10). Check that counterweights are securely

bonded in rotating swashplate.

(2). Inspect bearings for binding, looseness

in bore and wear. Maximum wear limits

2. Mixer Controls Inspection

are 0.010 inch (0.254 mm) radial and

0.020 inch (0.508 mm) axial.

(Ref. Figure 402)

4. Pitch Control Rod Inspection

(1). Inspect all bushings for security of fit.

(Ref. Figure 401)

(2). Inspect longitudinal link, support

bracket, longitudinal control mixer link,

Ensure that rod end bearings

mixer links, longitudinal pitch idler,

CAUTION

are centered and do not contact

longitudinal pitch mixer bellcrank,

attach clevis.

lateral bellcrank and collective pitch

mixer bellcrank for scratches, cracks,

(1). Visually inspect upper and lower rod

corrosion and similar surface defects.

end bearings for evidence of excessive

For components that are questionable,

axial play, 0.040 inch (1.016 mm)

perform fluorescent dye penetrant

maximum; and for any extrusion,

inspection.

displacement or damage to the bearing

teflon liner.

(3). Inspect spherical, teflon (or equivalent)

lined, bearings in longitudinal link,

(2). Replace rod end bearing if discrepan

mixer link, and longitudinal control

cies are noted.

Page 602

Revision 32

62-30-60

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

SWASHPLATE AND MIXER

REPAIRS

1. Swashplate Repairs

be restored on magnesium and alumi

num parts.

(Ref. Figure 403) Disassembly other than as

illustrated is considered a part of swashplate

(7). Replace defective bearings and bush

overhaul (Ref. COM). If tracking interrupters

ings, except swaged spherical bearings

are to be removed, mark them for reinstalla

in mixer links which require link

tion at original locations.

replacement. Remove bearings or

bushings by pressing them out. Install

2. Mixer Controls Repair

new bearing with surface primer and

grade A locking compound (CM321 and

(Ref. Figure 402)

CM431).

NOTE: Left-hand bearing in support bracket is

Consumable Materials

not supplied as part of bracket. This bearing

(Ref. Section 91−00−00)

is installed at time support bracket and lon

Item

Nomenclature

gitudinal pitch idler are assembled. Install

CM321

Surface primer locking compound

new bearing by seating flush with inner face

CM431

Sealing, locking and retaining compound

of support bracket flange.

CM802

Abrasive cloth, aluminum oxide

3. Scissors Bushing and Bearing

Replacement

NOTE: Following depth limits are total limits,

(Ref. Figure 401)

including effects of all previous repairs to

any given area.

Consumable Materials

(1).

Repair minor surface defects such as

(Ref. Section 91−00−00)

scratches, nicks and corrosion using

Item

Nomenclature

abrasive cloth (CM802), grade 400 -

CM103

Solid film lubricant

600 to smooth out and blend in such

CM222

1,1,1-Trichloroethane

defects.

CM318

Primer

(2).

Cast and forged surfaces may be

CM321

Surface primer locking compound

reworked to depth of 0.020 inch (0.508

CM431

Sealing, locking and retaining compound

mm).

(3).

Flat machined surfaces, except clevis

(1). Remove cotter pin, nut, washer, and

inner ears, may be reworked to depth of

bolt that join link and crank.

0.015 inch (0.381 mm). Clevis inner ear

(2). Remove two bushings from link only if

surfaces may be reworked to depth of

replacement is necessary.

0.020 inch (0.508 mm).

(3). Do not remove bearing from link.

(4).

Machined holes may have 0.003 inch

Replace complete link if bearing is

(0.076 mm) removed from bore wall in

defective.

an area no greater than 15 percent of

circumference and 50 percent of depth.

(4). Remove slotted bushings and bearings

from crank, only if replacement is

(5).

All edges may have 0.030 inch (0.762

necessary.

mm) removed except around machined

holes which are limited to 0.010 inch

During cleaning, do not allow

CAUTION

(0.254 mm) chamfer.

solvent to enter bearings.

(6).

All rework must be smoothly blended

(5). Install new bushings using solid film

into adjacent surfaces and finish must

lubricant (CM103); do not use zinc

Page 801

62-30-60

Revision 20

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

chromate. Press in bushing until end

(e). Remove excess sealant. Do not allow

is flush with inside surface of crank

sealant to enter bearing race.

inboard ears.

(6). If bearings were removed from crank at

(f). Apply a small fillet of sealant to the

disassembly, reinstall using the

faying edges of bearing housing. Use

following procedure:

cellophane or masking tape to

exclude air and allow sealant to cure

NOTE: Do not allow sealant to enter bearing

for 24 hours at ambient temperature

race.

or force cure by heating to

140°-160°F (60°-72°C) for one hour

(a). Clean bearing outer face, counterbore

prior to use of assembly.

and faying surfaces with trichloroe

thane (CM222). Do not allow trichlo

roethane to enter bearing.

(7). If bushings were removed from link at

disassembly, install new bushings.

(b). Coat the faying surfaces with surface

After installation, dimension between

primer (CM321) as per manufactur

outside faces of bushings should be

er's instructions.

1.579-1.586 inches (4.0107-4.0284 cm).

(c). Apply locking compound (CM431) to

faying surfaces.

(8). Align bore of link with bore of crank;

(d). Press bearing until outer face is

install bolt, washer and nut. Torque nut

seated firmly against shoulder of

to 30 - 40 inch-pounds (3.39 - 4.52

counterbore.

Nm).

Page 802

Revision 20

62-30-60

MD Helicopters, Inc.

CSP−HMI−2

MAINTENANCE MANUAL

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

63-00-00 Transmission and Drive System (369D/E/FF - 500/600N)

Fault Isolation

101

1. Power Train System

101

2. Power Train System Troubleshooting

101

Table 101. Troubleshooting Power Train System

101

Figure 101. Power Train System

104

63-10-00 Drive Shafts / Clutches / Couplings (369D/E/FF - 500/600N)

Removal/Installation

401

Main Rotor Drive Shaft

401

Main Rotor drive Shaft Replacement

401

A. Main Rotor Drive Shaft Removal

401

B. Main Rotor Drive Shaft Installation

401

Figure 401. Main Rotor Drive Shaft Installation (Sheet 1 of 2)

402

Main Transmission Drive Shaft

404

Main Transmission Drive Shaft Replacement

404

A. Main Transmission Drive Shaft Removal (Bendix and Kamatic)

404

B. Main Transmission Drive Shaft Installation (Bendix and Kamatic)

404

Figure 402. Main Transmission Drive Shaft Installation

405

Overrunning Clutch

406

Overrunning Clutch Replacement

406

A. Overrunning Clutch Removal

406

B. Overrunning Clutch Installation

406

Figure 403. 369A5350 Overrunning Clutch Installation

407

Figure 404. 369F5450 Overrunning Clutch Installation

408

Overrunning Clutch Subassembly Replacement

409

A. Overrunning Clutch Subassembly Removal

409

B. Overrunning Clutch Subassembly Installation

410

Overrunning Clutch-to-Firewall Seal

410

Overrunning Clutch-to-Firewall Seal Replacement

410

10. Main Transmission Drive Shaft Couplings

411

11. Main Transmission Drive Shaft Coupling Replacement

411

A. Main Transmission Drive Shaft Coupling Removal

411

B. Main Transmission Drive Shaft Coupling Installation

411

Page i

63 Contents

Revision 42

CSP−HMI−2

MD Helicopters, Inc.

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

12. Tail Rotor Drive Shaft Coupling Replacement

412

A. Tail Rotor Drive Shaft Coupling Removal

412

B. Tail Rotor Drive Shaft Coupling Installation

412

Figure 405.

369F5468/5469 Bolt Removal Tool

413

Inspection/Check

601

369D25510 Main Rotor Drive Shaft Inspection

601

600N5510 and 369F5510 Main Rotor Drive Shaft Inspection

601

Figure 601. Main Rotor Drive Shaft Inspection

602

Figure 602. Main Rotor Drive Shaft Overtorque Verification Stripe

603

3. Main Transmission Drive Shaft Inspection (Bendix)

603

4. Main Transmission Drive Shaft Inspection (Kamatic)

604

5. Overrunning Clutch Inspection

605

6. Overrunning Clutch-to-Firewall Seal Inspection

605

7. Bendix Tail Rotor Drive Shaft Coupling Inspection

605

8. Kamatic Coupling Inspection

605

9. Main Rotor Drive Shaft Inspection (300 Hour)

605

Repairs

801

1. Main Rotor Drive Shaft Exterior Repair

801

2. Main Rotor Drive Shaft Corrosion Removal

802

3. Main Transmission Drive Shaft Repair (Bendix)

802

4. Main Transmission Drive Shaft Repair (Kamatic)

803

5. Overrunning Clutch Repair/Overhaul

803

6. Overrunning Clutch-to-Firewall Seal Repair

803

7. Main Transmission Drive Shaft Coupling Corrosion Removal

803

8. Bendix Coupling Repair

804

9. Kamatic Coupling Repair

804

Page ii

Revision 42

63 Contents

MD Helicopters, Inc.

CSP−HMI−2

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

63-15-10 Tail Rotor Drive Shaft (369D/E/FF)

Removal/Installation

401

1. Tail Rotor Drive Shaft

401

2. Tail Rotor Drive Shaft Replacement

401

A. Tail Rotor Drive Shaft Removal

401

B. Tail Rotor Drive Shaft Installation with Bendix Couplings

401

Figure 401. Tail Rotor Drive Shaft Installation (369D/E/FF) (Sheet 1 of 3)

402

Figure 402. Tail Rotor Drive Shaft Installation (369FF)

407

C. Tail Rotor Drive Shaft Installation with Kamatic Couplings

408

3. Tail Rotor Drive Shaft Damper

409

4. Tail Rotor Drive Shaft Damper Replacement

409

Inspection/Check

601

1. Tail Rotor Drive Shaft Inspection

601

2. Tail Rotor Drive Shaft Twist Inspection

601

Figure 601. Tail Rotor Drive Shaft - Inspection Markings

602

Figure 602. Tail Rotor Drive Shaft - Inspection Markings (Extended Tailboom)

603

3. Tail Rotor Drive Shaft Damper Inspection

604

Figure 603. Tail Rotor Drive Shaft Damper - Inspection

605

Repairs

801

1. Tail Rotor Drive Shaft Repair Procedure

801

2. Tail Rotor Drive Shaft Index Stripe Application

801

63-15-30 NOTAR) Anti-Torque System Drive Shafts (500/600N)

Maintenance Practices

201

1. Anti-Torque System Drive Shafts

201

2. Fan Gearbox Drive Shaft Replacement

201

A. Fan Gearbox Drive Shaft Removal

201

B. Fan Gearbox Drive Shaft Installation

201

3. Fan Gearbox Drive Shaft Inspection

203

4. Fan Gearbox Drive Shaft Repair Procedure

203

Figure 201. Fan Gearbox and Inter-Connecting Drive Shafts

204

5. Fan Inter-Connect Drive Shaft Replacement

205

A. Fan Inter-Connect Drive Shaft Removal

205

B. Fan Inter-Connect Drive Shaft Installation

205

6. Inter-Connect Drive Shaft Inspection

205

7. Inter-Connect Drive Shaft Repair

206

8. Transmission and Fan Coupling Inspection

206

Page iii

63 Contents

Revision 42

CSP−HMI−2

MD Helicopters, Inc.

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

9. Gearbox and Fan Coupling Repair

206

10. Transmission Coupling / Fan Coupling Replacement

207

A. Transmission Coupling / Fan Coupling Removal

207

B. Transmission Coupling / Fan Coupling Installation

207

Figure 202. Fan Interconnect Drive Shaft Coupling Installation

207

63-20-00 369D25100 Main Transmission (369D/E/FF - 500N)

Maintenance Practices

201

1. Main Transmission

201

2. Main Transmission Buildup and Replacement

201

A. Main Transmission Removal

201

Figure 201. 369D25100 Main Transmission Installation

202

B. Main Transmission Installation

203

3. Main Transmission Inspection Procedure

204

4. Main Transmission Repair Procedure

204

5. Input Drive Assembly - Oil Leakage Repair Procedure

204

Figure 202. Input Drive Assembly O-Ring Replacement

206

Figure 203. Assembly Aid Tool for Input Drive

207

63-20-25 369F5100 Main Transmission (369D/E/FF - 500/600N)

Maintenance Practices

201

1. Main Transmission

201

2. Main Transmission Replacement

201

A. Main Transmission Removal

201

B. Main Transmission Installation

201

Figure 201. 369F5100 Main Transmission Installation

202

3. Main Transmission Stripping

203

Figure 202. 369F5100 Main Transmission Build-Up

204

4. Main Transmission Build-Up

205

5. Main Transmission Inspection Procedure

205

6. Main Transmission Repair Procedure

205

7. Input Drive Assembly - Oil Leakage Repair Procedure

206

A. Input Pinion O-Ring Replacement

206

Figure 203. Drive Assembly O-Ring Replacement

207

B. Input Pinion Seal Replacement

208

8. Main Transmission Filter Replacement

209

9. Main Transmission Run-In Procedure

209

Page iv

Revision 42

63 Contents

MD Helicopters, Inc.

CSP−HMI−2

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

63-21-00 Main Transmission Lubrication and Cooling System

(369D/E/FF - 500/600N)

Removal/Installation

401

Main Transmission Lubrication System

401

Main Transmission Lubrication Pump Replacement

(369D25100 Transmission)

401

A. Main Transmission Lubrication Pump Removal

(369D25100 Transmission)

401

B. Main Transmission Lubrication Pump Installation

(369D25100 Transmission)

401

Main Transmission Lubrication Pump Replacement

(369F5100 Transmission)

401

A. Main Transmission Lubrication Pump Removal

(369F5100 Transmission)

401

B. Main Transmission Lubrication Pump Installation

(369F5100 Transmission)

401

Figure 401. Main Transmission Lubrication Pump

(369D25100 Transmission)

402

Figure 402. Main Transmission Lubrication Pump

(369F5100 Transmission)

403

Main Transmission Filter Replacement (369D25100 Transmission)

404

Main Transmission Filter Replacement (369F5100 Transmission)

404

Main Transmission Scavenge Pump Replacement (369F5100 Transmission)

404

A. Main Transmission Scavenge Pump Removal (369F5100 Transmission)

404

B. Main Transmission Scavenge Pump Installation (369F5100 Transmission)

404

Main Transmission Oil Cooler Bypass Valve Replacement

405

Main Transmission Oil Cooler Replacement

405

A. Main Transmission Oil Cooler Removal

405

B. Main Transmission Oil Cooler Installation

405

Figure 403. Main Transmission Oil Cooler Installation

406

Main Transmission Oil Temperature Sender Replacement

407

10. Main Transmission Oil Pressure Sender Replacement

407

11. Liquid Level Plug Replacement

407

Figure 404. Main Transmission - Cross-Section View

408

12. Chip Detector Replacement

408

Page v

63 Contents

Revision 42

CSP−HMI−2

MD Helicopters, Inc.

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

13. Cooling Blower Replacement

408

A. Cooling Blower

408

B. Cooling Blower Removal

408

C. Cooling Blower Installation (369D25100 Transmission)

409

Figure 405. Cooling Blower Installation (369D25100 Transmission)

410

D. Cooling Blower Installation (369F5100 Transmission)

411

Figure 406. Oil Cooler Blower Installation (369F5100 Transmission)

412

E. 369D, E, F, and 500N - Cooling Blower Belt Tracking

413

Figure 407. Cooling Blower Belt Tracking

413

Inspection/Check

601

1. Lubrication System Inspection

601

2. Cooling Blower Inspection

601

3. Cooling Blower Inspection (Disassembled)

601

Figure 601. Main Transmission Cooling Blower and Duct

602

4. Cooling Blower Belt Tension Check and Adjustment

603

Repairs

801

369D25630 Cooling Blower Disassembly

801

Figure 801. 369D25630 Cooling Blower - Cross-Section View

802

369D25630 Cooling Blower Reassembly

803

600N5630 Cooling Blower Disassembly

804

Figure 802. 600N5630 Cooling Blower - Cross-Section View

805

600N5630 Cooling Blower Reassembly

806

5. Cooling Blower Cleaning (Disassembled)

808

6. Transmission and Cooling Blower Drain Tube Repair and Replacement

808

7. Installation of Heating System and Oil Cooling Line Standoff Clamps

(0003D - 0539D)

808

Figure 803. Installation of Standoff Clamps - Heating and Oil Cooling Lines

810

Page vi

Revision 42

63 Contents

MD Helicopters, Inc.

CSP−HMI−2

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

63-22-00 Rotor Brake (369D/E/FF - 500/600N)

Maintenance Practices

201

1. Rotor Brake

201

2. Rotor Brake Operation

201

3. Rotor Brake Troubleshooting Procedure

201

4. Master Cylinder Servicing

201

5. Rotor Brake Hydraulic System Bleeding

202

6. Rotor Brake Component Repair

203

7. Master Cylinder Assembly Overhaul

203

8. Caliper Assembly Overhaul

203

Table 201. Troubleshooting Rotor Brake Installation

204

Removal/Installation

401

Rotor Brake Component Access

401

Master Cylinder Assembly Replacement

401

A. Master Cylinder Assembly Removal

401

Figure 401. Airframe-Mounted Rotor Brake Components

402

B. Master Cylinder Assembly Installation

403

Master Cylinder Linkage Assembly Replacement

403

A. Master Cylinder Linkage Assembly Removal

403

Figure 402. Master Cylinder Linkage Assembly

404

B. Master Cylinder Linkage Assembly Installation

404

Caliper Assembly, Brake Disc, and Drive Coupling Replacement

(369D25100 Transmission)

405

A. Caliper Assembly, Brake Disc, and Drive Coupling Removal

(369D25100 Transmission)

405

Figure 403. Transmission-Mounted Rotor Brake Components

406

B. Caliper Assembly, Brake Disc and Drive Coupling Installation

(369D25100 Transmission)

407

Figure 404. Caliper Assembly and Brake Disc Interface

(369D25100 Transmission)

408

Figure 405. Lockwire Installation (369D25100 Transmission)

408

Caliper Mounting Bracket Replacement (369D25100 Transmission)

409

A. Caliper Mounting Bracket Removal (369D25100 Transmission)

409

B. Caliper Mounting Bracket Installation (369D25100 Transmission)

409

Page vii

63 Contents

Revision 42

CSP−HMI−2

MD Helicopters, Inc.

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

6. Caliper Assembly, Brake Disc, and Drive Coupling Replacement

(369F5100 Transmission)

409

A. Caliper Assembly, Brake Disc, and Drive Coupling Removal

(369F5100 Transmission)

409

B. Caliper Assembly, Brake Disc and Drive Coupling Installation

(369F5100 Transmission)

410

Figure 406. Rotor Brake Caliper Installation (369F5100 Transmission)

411

7. Hydraulic Relief Valve Replacement

412

A. Hydraulic Relief Valve Removal

412

B. Hydraulic Relief Valve Installation

412

8. Hydraulic Tube Assembly Replacement

413

A. Hydraulic Tube Assembly Removal

413

B. Hydraulic Tube Assembly Installation

413

9. Rotor Brake Forward Cover Assembly Installation

413

Inspection/Check

601

1. Rotor Brake Assembly Inspection

601

2. Rotor Brake Operational Check

602

Initial Installation

901

1. Rotor Brake Initial Installation

901

A. Aircraft Preparation

901

B. Installation Access

901

C. Removing Components to be Replaced

901

D. Angle Assembly Installation (500D)

902

E. Master Cylinder Linkage Assembly and Mount Bracket Installation

902

Figure 901. Locating Permanently Installed Components (Sheet 1 of 2)

903

F. Handle Retainer Assembly Installation

905

G. Rivnut Installation

905

Figure 902. Rotor Brake Installation (Sheet 1 of 2)

906

H. Window Support Channel Modification

908

I. Caliper Mounting Bracket Initial Installation

908

J. Caliper Assembly, Brake Disc and Drive Coupling Installation

908

Figure 903. Modifying Window Support Channel

909

Figure 904. Hydraulic Tube Installation

910

Page viii

Revision 42

63 Contents

MD Helicopters, Inc.

CSP−HMI−2

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

K. Master Cylinder Assembly Initial Installation

911

Figure 905. Positioning Master Cylinder

911

L. Hydraulic Relief Valve Initial Installation

912

M. Hydraulic Tube Assemblies Initial Installation

912

N. Rotor Brake Installation Servicing

912

Figure 906. Reworking Master Cylinder Gasket

912

O. Installing Interior Furnishings

913

P. Map Case Assembly Modification and Installation

913

Q. Convenience Panel Cover Assembly Modification and Installation

913

R. Rotor Brake Forward Cover Assembly Installation

913

Figure 907. Modifying Map Case Panel

914

Figure 908. Modifying Rotor Brake Cover Panel Assemblies (Sheet 1 of 2)

915

S. Weight and Balance

917

Table 901. Weight and Balance Data

917

63-25-10 Tail Rotor Transmission (Two and Four Blade) (369D/E/FF)

Maintenance Practices

201

1. Tail Rotor Transmission

201

2. Tail Rotor Transmission Replacement

201

A. Tail Rotor Transmission Removal

201

B. Tail Rotor Transmission Installation

201

Figure 201. Tail Rotor Transmission - Stripping/Buildup

202

3. Tail Rotor Transmission Inspection

203

Figure 202. Replacement of Liquid Level Plug and Breather-Filler

204

4. Tail Rotor Transmission Stripping

205

5. Tail Rotor Transmission Buildup

205

6. Tail Rotor Transmission Parts Replacement

205

7. Input and Output Gearshaft Cover Oil Leak Repair

206

8. Tail Rotor Transmission Housing Assembly Rework (PN 369D25401)

206

Figure 203. Tail Rotor Transmission Mount Stud Limits

206

Figure 204. Rework of Tail Rotor Transmission Housing Assembly

207

Page ix

63 Contents

Revision 42

CSP−HMI−2

MD Helicopters, Inc.

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

63-25-30 NOTAR) Anti-Torque System Fan Transmission (500/600N)

Maintenance practices

201

1. Fan Transmission

201

2. Fan Transmission Replacement

201

A. Fan Transmission Removal

201

B. Fan Transmission Installation

201

Figure 201. Fan Transmission Removal/Installation

202

3. Fan Transmission Inspection

203

4. Tube Support Inspection

203

5. Fan Transmission Parts Replacement

203

Figure 202. Fan Transmission Parts Replacement

204

63-30-00 Main Rotor Static Mast (369D/E/FF - 500/600N)

Maintenance Practices

201

1. Main Rotor Static Mast

201

2. Main Rotor Static Mast Replacement (369D25100 Transmission Installation) . . .

201

A. Main Rotor Static Mast Removal (369D25100 Transmission Installation)

201

B. Main Rotor Static Mast Installation (369D25100 Transmission Installation) . .

201

Figure 201. Main Rotor Mast and Support Structure

(369D25100 Transmission Installation)

202

3. Main Rotor Static Mast Replacement (369F5100 Transmission Installation)

203

A. Main Rotor Static Mast Removal (369F5100 Transmission Installation)

203

B. Main Rotor Static Mast Installation (369F5100 Transmission Installation) . . .

203

4. Main Rotor Static Mast Inspection and Repair

203

Figure 202. Main Rotor Mast and Support Structure

(369F5100 Transmission Installation)

205

Figure 203. Main Rotor Mast - Inspection and Repair

206

Page x

Revision 42

63 Contents

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

TRANSMISSION AND DRIVE SYSTEM

FAULT ISOLATION

1. Power Train System

2. Power Train System Troubleshooting

(Ref. Figure 101) The power train system,

starting at the engine power takeoff pad,

(Ref. Table 101) Diagnose and repair power

consists primarily of the overrunning clutch,

train system malfunctions using procedures as

drive shafts, and transmissions.

follows.

Table 101. Troubleshooting Power Train System

Symptom

Probable Trouble

Corrective Action

Main drive shaft vibrates

Coupling flange bolts on main drive

Retorque bolts to 50 − 70

excessively. (For serviceability

shaft are loose.

inch−pounds (5.65 − 7.91 Nm).

limits, refer to Section 63−10−00).

Excessive noise or vibration in

Defective impeller or damaged

Replace impeller or scroll (Ref. Sec.

cooling blower.

scroll.

63−21−00).

Main drive shaft turns erratically or

Defective overrunning clutch.

Replace overrunning clutch (Ref.

not at all.

Sec. 63−10−00).

Main transmission requires

Leakage at main transmission input

If leakage is found at input shaft or

frequent addition of oil.

or output seals.

tail rotor shaft, replace seal

according to instructions (Ref. COM).

If leakage is at main rotor drive shaft,

replace transmission (Ref. Sec.

63−20−00).

Oil leak around accessory drive

Tighten cover or replace

cover.

transmission (Ref. Sec. 63−20−00).

Oil temperature warning light

Defective oil temperature sender.

Replace oil temperature sender (Ref.

comes on when oil temperature is

Sec. 63−21−00).

normal.

Oil temperature warning light

Defective cooling blower.

Repair or replace cooling blower

comes on when oil temperature is

(Ref. Sec. 63−21−00).

abnormally high.

Low or high oil level in

Establish correct oil level (Ref. Sec.

transmission.

12−00−00).

Defective lubrication pump.

Replace pump (Ref. COM).

Defective oil cooler bypass valve.

Replace valve. (Ref. Sec.

63−21−00).

Defective bearings or gears.

Replace transmission (Ref. Sec.

63−20−00).

Page 101

63-00-00

Revision 28

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

Table 101. Troubleshooting Power Train System (Cont.)

Symptom

Probable Trouble

Corrective Action

NOTE: Noise that indicates a defective transmission should not be confused with normal gear backlash noise at

rundown or low rpm and power conditions.

Excessive noise in main

Inadequate oil supply.

Service main transmission (Ref. Sec.

transmission.

12−00−00).

Defective bearings or gears.

Replace transmission (Ref. Sec.

63−20−00).

Oil pressure warning light (low oil

Low oil in main transmission.

Service main transmission (Ref. Sec.

pressure) remains lighted at above

12−00−00).

55% N₂.

Defective oil pressure switch.

Replace oil pressure switch (Ref.

Sec. 63−21−00).

Defective lube pump.

Replace lube pump (Sec.

63−20−00).

Filter clogged.

Replace filter (Ref. Sec. 63−21−00).

369F5100 Transmission impending

Filter clogged.

Reset indicator. On second pop−up,

bypass indicator popped.

replace filter (Ref. Sec. 63−21−00).

Defective differential pressure

Replace differential pressure

indicator.

indicator (Ref. COM).

369F5100 Transmission impending

Defective differential pressure

Replace differential pressure

bypass indicator popped in less

indicator.

indicator (Ref. COM).

than 100 hours since filter change.

Tail rotor drive shaft damper

Damper out of adjustment.

Adjust damper (Ref. Sec. 63−15−00).

vibrates.

Damper defective.

Replace damper (Ref. Sec.

63−15−00).

Tail rotor drive shaft bent or dented.

Replace defective drive shaft (Ref.

Sec. 63−15−00).

Tail rotor out of balance.

Adjust tail rotor balance (Ref. Sec.

18−10−00).

Tail rotor transmission output shaft

Worn or damaged bearing or gear

Replace tail rotor transmission (Ref.

vibrates.

in tail rotor transmission.

Sec. 63−25−10).

Excessive shaft wobble or end play

Replace tail rotor transmission (Ref.

(Ref. Sec. 63−15−10).

Sec. 63−25−10).

Excessive noise in tail rotor

Inadequate oil supply.

Service tail rotor transmission (Ref.

transmission.

Sec. 12−00−00).

Defective bearings or gears in tail

Replace tail rotor transmission (Ref.

rotor transmission.

Sec. 63−25−10).

Page 102

Revision 29

63-00-00

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

Table 101. Troubleshooting Power Train System (Cont.)

Symptom

Probable Trouble

Corrective Action

Chip detector caution light on.

Metallic chips in either main

Inspect and clean chip detector

transmission, fan transmission or

magnetic plugs. If there are heavy

tail rotor transmission.

chip deposits (chips larger than 1/8

inch in any direction), replace

transmission. If chips are smaller,

drain and refill transmission with new

oil. Reinstall chip detector and check

after four hours of flight. If more

chips are found, replace

transmission (main − Sec. 63−20−00

or 63−20−25; tail rotor − Sec.

63−25−10; fan − 63−25−30).

Chip detector caution light is on,

Defective chip detector circuit

Troubleshoot chip detector circuit

but no chips are on detector.

components.

(Ref. CSP−HMI−3).

NOTE: High frequency vibrations in helicopter can also be caused by components in other systems.

High frequency vibrations.

Loose tail rotor drive shaft

Tighten coupling bolts (Ref. Sec.

coupling(s).

63−15−00).

Tail rotor drive shaft coupling

Shim correctly (Ref. Sec. 63−15−00).

shimmed improperly.

Loose, mismatched or bottomed

Tighten or install correct hardware

hardware retaining tail rotor drive

and be sure hardware is installed

shaft coupling to main

correctly (Ref. Sec. 63−15−00).

transmission.

Cooling blower impeller has cracks,

Replace impeller (Ref. Sec.

loose rivets, defective blades or

63−21−00).

other damage.

Tail rotor drive shaft damper out of

Adjust damper friction (Ref. Sec.

adjustment.

63−15−00).

Defective overrunning clutch.

Replace overrunning clutch (Ref.

Sec. 63−10−00).

Tail rotor drive shaft damaged.

Replace shaft (Ref. Sec. 63−15−00).

Abnormal drag in drive system.

Excessive drag in main

Replace transmission (Ref. Sec.

transmission.

63−20−00).

NOTE: Drag is excessive when force required to rotate transmission input shaft exceeds 25 inch−pounds (2.82

Nm) with all shafting disconnected and transmission temperature between 50°F (10°C) and 100°F (38°C).

Page 103

63-00-00

Revision 30

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

DRIVE SHAFTS / CLUTCHES / COUPLINGS

REMOVAL/INSTALLATION

1. Main Rotor Drive Shaft

B. Main Rotor Drive Shaft Installation

The main rotor drive shaft is a shot-peened,

Special Tools

steel alloy forging having a nitrided spline at

(Ref. Section 91−00−00)

one end that mates with the transmission

Item

Nomenclature

output shaft, and a flanged opposite end that

attaches to the rotor hub with seven bolts and

ST704

Adapter, torque wrench

three eyebolts.

Damage to main rotor drive

2. Main Rotor drive Shaft Replacement

CAUTION

shaft or transmission splines

can occur during installation. Care should

(Ref. Figure 401)

be taken while meshing driveshaft splines

into transmission output splines to prevent

When removing or installing the

CAUTION

damage.

main rotor drive shaft external-

wrenching bolts or eyebolts, always hold

(1).

Slowly and carefully lower drive shaft

bolts stationary while installing or remov

through main rotor hub and mast until

ing nuts. Never turn external-wrenching

rotor shaft splines and transmission

bolts or eyebolts while inserting or removing

shaft splines engage.

from drive shaft holes.

(2).

Rotate hub to align holes in flange with

A. Main Rotor Drive Shaft Removal

holes in drive shaft.

Main rotor drive shaft is a high

(3).

Install three eyebolts, washers, and

CAUTION

ly stressed part. Do not allow

nuts. Using torque wrench adapter

tools to strike shaft, or shaft to strike any

(ST704), torque nuts to 120 - 140

object. Any impact damage may require re

inch-pounds (13.56 - 15.82 Nm).

placement of drive shaft.

(4).

With fairing support spacers and

(1). Remove main rotor fairing.

special washers in place, position main

rotor fairing support so that eyebolt

(2). Remove seven external-wrenching

shoulders are inserted in large holes in

bolts; and associated hardware. Lift off

fairing support. Make certain that

main rotor fairing support and remove

support extensions are between pitch

seven spacers.

housings.

Any time drive shaft is removed,

(5).

Install seven external-wrench bolts,

CAUTION

cover opening in top of main ro

seven washers and nuts as in step (3).

tor hub to prevent possible entry of foreign

above.

matter into hub, mast and transmission.

NOTE: Phillips screws, used to attach main ro

NOTE: If special washers between fairing sup

tor hub fairing, may be replaced with hex

port and drive shaft dome are not bonded to

head Phillips screws (PN NAS1096-3-10)

the underside of fairing support, remove

and washers (PN HS306-223). The hex

washers before proceeding.

head will make torquing the screws easier.

(3). Remove three eyebolts and associated

(6). Install main rotor fairing with five

hardware and lift drive shaft clear of

screws. Torque screws to 20 - 25

main rotor hub.

inch-pounds (2.26 - 2.82 Nm).

Page 401

63-10-00

Revision 20

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

HUB FAIRING

EYEBOLT (3 PLCS AS SHOWN)

SCREW

(NOTE 4)

(5 PLCS)

NOTE 1

WASHER

(5 PLCS)

EXTERNAL

WRENCHING BOLT

(7 PLCS)

NOTE 1

FAIRING SUPPORT

(NOTE 5)

NOTE 3

SPACER

(7 PLCS)

CORK

(NOTE 2)

DRIVE SHAFT

HUB

THIN WASHERS

(TYP, 10 PLACES)

TORQUE WRENCH

ADAPTER

369D/E/FF - 500N INSTALLATION

NOTES:

INSTALLED WITH COUNTERSINK NEXT TO BOLT HEAD, WASHERS UNDER NUT ARE FLAT.

INSTALLED WITH SEALING COMPOUND.

MAY BE BONDED TO FAIRING SUPPORT.

WHEN INSTALLING EYEBOLTS, ENSURE FAIRING SUPPORT ARMS ARE NOT POSITIONED OVER

PITCH HOUSINGS.

THREE HOLES IN FAIRING SUPPORT ARE LARGER TO GO OVER EYEBOLTS AND TO AID IN FAIRING

G63-1001B

SUPPORT ALIGNMENT.

Figure 401. Main Rotor Drive Shaft Installation (Sheet 1 of 2)

Page 402

Revision 20

63-10-00

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

3. Main Transmission Drive Shaft

less than 25 inch-pounds (2.82

Nm) before torquing bolt.

The main transmission drive shaft is equipped

with a flexible diaphragm-type joint and

(b). For 36F5450 clutch, actual drag

mounting flange (coupling) at each end. The

torque plus 315 - 365 inch-

shaft connects the overrunning clutch and the

pounds (35.59 - 41.24 Nm). If bolt

transmission input shaft.

is not seated and/or existing torque is

found to be less than 315 - 365

inch-pounds (35.59 - 41.24 Nm),

4. Main Transmission Drive Shaft

ensure self-locking drag torque is not

Replacement

less than 25 inch-pounds (2.82

Nm) before torquing bolt.

(Ref. Figure 402)

Compression of drive shaft dia

A. Main Transmission Drive Shaft Removal

CAUTION

phragms (static state) is limited

(Bendix and Kamatic)

to 0.020 inch (0.508 mm). Do not stress dia

phragms by forcing drive shaft into position

(1). Remove sound insulation and main

for installation in step (2). below.

transmission access cover over main

transmission drive shaft in cargo

NOTE: If original shaft and couplings are being

compartment.

reinstalled, a check of shimming as de

scribed below is not necessary. Install drive

(2). Remove eight bolts and washers that

shaft to clutch and transmission couplings

secure shaft to couplings.

as described in steps (1). above and (4). be

low.

(3). Remove drive shaft; use care to keep it

from striking any object.

(2). Position drive shaft alongside transmis

sion input and clutch couplings. If

NOTE: Clutch oil level should be checked any

compression is required to fit shaft

time engine or main drive shaft is removed

between couplings, continue with step

(Ref. Sec. 12-00-00).

(3). below. If there is a gap between

drive shaft flanges and coupling

B. Main Transmission Drive Shaft

flanges, continue with step (6). below.

Installation (Bendix and Kamatic)

NOTE: Removal or addition of shims should be

accomplished at transmission input cou

Consumable Materials

pling only. Shims at overrunning clutch cou

(Ref. Section 91−00−00)

pling are of predetermined thickness to pre

Item

Nomenclature

vent O-ring damage and oil leakage.

CM111

Grease, aircraft

(3). Remove coupling bolt that secures

CM112

Anti-seize compound high temperature

transmission input coupling; remove

coupling and shims.

(1). Check overrunning clutch for correct oil

level, indications of oil seepage, drive

CAUTION

shaft couplings for corrosion and that

coupling bolt securing clutch coupling is

D The 0.010 inch (0.254 mm) minimum

torqued to:

measurement between the bolt seating

surface and the input shaft must be ob

(a). For 369A5350 clutch, actual drag

tained to ensure proper clamp up. Warped

torque plus 250 - 300 inch-

shims or foreign material could provide a

pounds (28.25 - 33.90 Nm). If bolt

false 0.010 inch (0.254 mm) minimum

is not seated and/or existing torque is

measurement and improper clamp up

found to be less than 250 - 300

could result during normal operation

inch-pounds (28.25 - 33.90 Nm),

which may damage the main transmis

ensure self-locking drag torque is not

sion input shaft.

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MAINTENANCE MANUAL

D Do not use clutch coupling shims under

bolts to 50 - 70 inch-pounds (5.65 -

transmission input coupling. Inside diam

7.91 Nm).

eter of clutch coupling shims, 1.260-1.270

(7). Manually align drive shaft and trans

inches (3.2004-3.2258 cm), is approxi

mission input coupling flanges:

mately 0.070 inch (1.778 mm) larger than

inside diameter of shims used at trans

(8). Using feeler gage, measure gap be

mission coupling. Incorrect diameters can

tween flanges. Gap should be 0.010

cause an improperly seated shim, mis

inch (0.254 mm) gap to 0.020 inch

alignment and cocked coupling.

(0.508 mm) compression.

NOTE: Transmission input coupling shims are

(a). If gap is 0.010 inch (0.254 mm) or

laminated stock. Each lamination is 0.002

less, attach upper end of drive shaft

inch (0.051 mm) thick. Peel to thickness re

to transmission input coupling with

quired.

four bolts and washers. Torque bolts

to 50 - 70 inch-pounds (5.65 - 7.91

(4).

Add sufficient shims to get a measure

Nm).

ment of 0.010 inch (0.254 mm) mini

(b). If gap exceeds 0.010 inch (0.254 mm),

mum between bolt seating surface on

repeat step (3). thru (5). above,

coupling and transmission input shaft.

except install thickness of shims

equal to measured gap, plus thick

(5).

Lubricate input shaft splines with

ness that results in not more than

grease (CM111). Coat bolt threads with

0.010 inch (0.254 mm) gap between

anti-seize compound (CM112). Rein

coupling and drive shaft nor more

stall coupling and bolt. Check coupling

than 0.020 inch (0.508 mm) compres

bolt for minimum drag of 25 inch-

sion of flexible couplings. Install four

pounds (2.82 Nm). Torque bolt to 250

bolts and washers and torque bolts to

- 300 inch-pounds (28.25 - 33.90

50 - 70 inch-pounds (5.65 - 7.91

Nm) plus drag torque.

Nm).

(6).

Attach drive shaft to clutch coupling

(9). Install access door and sound insulation

with four bolts and washers. Torque

over main transmission drive shaft.

TRANSMISSION INPUT COUPLING

INTERNAL-WRENCHING BOLT

MAIN TRANSMISSION DRIVE SHAFT

(EARLY CONFIGURATION) (BENDIX)

DIAGRAM

0.010 IN. (0.254 MM)

MAXIMUM GAP

0.020 IN. (0.508 MM)

MAXIMUM COMPRESSION

MAIN TRANSMISSION DRIVE SHAFT

DRIVE

(CURRENT CONFIGURATION) (KAMATIC)

PULLEY

TRANSMISSION INPUT

COUPLING-TO-DRIVE SHAFT ATTACHMENT

G63-1002B

Figure 402. Main Transmission Drive Shaft Installation

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MD Helicopters, Inc.

MAINTENANCE MANUAL

5. Overrunning Clutch

(b). Insert a long 3/8 inch (9.525 mm) hex

wrench, approximately 10 inches

The overrunning clutch transmits power from

(25.4 cm) long, through tool and into

the engine to the main transmission drive

back of clutch assembly.

shaft. The clutch disengages the engine from

(c). While holding internal hex wrench

the remainder of the drive system in case of

[3/8 inch (9.525 mm)], turn external

engine failure and during autorotations.

hex wrench [1.00 inch (2.54 cm)]

The clutch contains a sprag unit that disen

counter-clockwise to remove bolt

gages automatically when N₂ rpm is less than

from back of clutch.

corresponding main rotor rpm.

(5). Remove nuts and washers that secure

overrunning clutch; remove clutch.

Repair and overhaul information for the

overrunning clutch can be found in COM.

(6). If clutch is being replaced, install spare

coupling bolt and O-ring or suitable

6. Overrunning Clutch Replacement

plug in output shaft (clutch inner race

bore) to prevent contamination during

(Ref. Figure 403 or Figure 404)

clutch handling, shipping or storage.

A. Overrunning Clutch Removal

NOTE: Operating lubricant is an approved pre

servative for shipping or storage.

Consumable Materials

(7). Wrap clutch in barrier material

(Ref. Section 91−00−00)

(CM208) to protect splined areas of

Item

Nomenclature

shafts.

CM208

Barrier material

B. Overrunning Clutch Installation

Consumable Materials

NOTE: For removal of only the internal clutch

(Ref. Section 91−00−00)

subassembly as an alternative to complete

Item

Nomenclature

clutch removal, refer to Overrunning Clutch

Subassembly Removal.

CM111

Grease, aircraft

CM112

Anti-seize compound high temperature

(1). Remove engine.

CM125

Oil

CM126

Oil, turbine

(2). Remove bolts, washers, nuts and engine

shaft firewall seal from clutch.

(1). If clutch is new, (369A5350 clutch only)

NOTE: Removal of clutch coupling from clutch

drain preservative oil. Trapped oil can

is unnecessary unless clutch is being re

be removed by inverting clutch a

placed.

minimum of three times. Add lubricat

ing oil (CM125 or CM126) (Ref. Sec.

(3). Remove coupling bolt, packing, clutch

12-00-00). Temporarily install coupling

coupling and coupling shim(s). Keep

bolt and packing.

shim(s) with coupling for reuse.

Reinstall bolt and packing to prevent

NOTE: Relubricate splines on clutch input

spillage of lubricating oil from clutch

shaft and splines inside engine power and

housing during final steps of removal.

accessory gearbox with grease (CM111)

prior to reinstalling overrunning clutch.

(4). On 369F5450 clutch, remove output

shaft cover plate from back of engine

(2). Coat clutch splines and internal splines

accessory drive to gain access to clutch

of engine power accessory gearbox with

bolt.

lubricant (CM111). Insert overrunning

clutch outer-race spline into engine and

(a). Insert tool (Ref. Figure 405) to

install six washers and nuts.

engage bolt in back of clutch.

Deleted.

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MAINTENANCE MANUAL

(3). For 369F5450 clutch installation:

(b). Shim coupling to achieve 0.035-0.055

inch (0.889-1.397 mm) step above

(a). Remove power output shaft cover

clutch output shaft.

plate from back of engine (Ref. Sec.

01-00-00, Allison Engine Operation

When installing clutch coupling

CAUTION

and Maintenance Manual).

bolt, installation torque on the

bolt must be 250 - 300 inch-pounds (28.25

(b). Install O-rings on 369F5469

- 33.90 Nm) for the 369A5350 clutch or 315

(C30/C47 engine) or 369F5468 (C20

- 365 inch-pounds (35.59 - 41.24 Nm) for

series engines) bolt (Ref. Figure 404).

the 369F5450 clutch. Torquing to lower val

ue reduces clutch bearing clamp-up and can

NOTE: Fill all voids and gaps between the out

result in bearing race spinning.

side of bolt and inside of engine shaft with

(6). Coat clutch-to-coupling splines with

grease.

grease (CM111); install shim(s) and

(c).

Lubricate internal spline area of

clutch coupling. Coat coupling bolt

engine output shaft with grease

threads with anti-seize compound

(CM111).

(CM112); install bolt with new O-ring.

Check for bolt self-locking drag torque

(d).

Lubricate bolt threads with anti-

of 25 inch-pounds (2.82 Nm) mini

seize compound (CM112) and insert

mum to 200 inch-pounds (22.60

through engine into overrunning

Nm) maximum. Replace bolt if torque

clutch assembly.

values are exceeded.

(a). For 369A5350 clutch, torque coupling

(e).

Using bolt removal tool (Ref.

bolt to actual drag torque plus 250

Figure 405) either hold output

- 300 inch-pounds (28.25 - 33.90

coupling to prevent overrunning

Nm).

clutch from turning or insert hex

wrench through bolt to engage and

(b). For 36F5450 clutch, torque coupling

hold clutch.

bolt to actual drag torque plus 315

- 365 inch-pounds (35.59 - 41.24

(f).

Torque bolt to 250 - 300 inch-

Nm).

pounds (28.25 - 33.90 Nm) plus

drag torque.

(7). Install engine shaft firewall seal, bolts,

washers, and nuts.

(g).

Using existing hardware, reinstall

power output shaft cover plate on

(8). Reinstall engine.

back of engine (Ref. Sec. 01-00-00,

Allison Engine Operation and

7. Overrunning Clutch Subassembly

Maintenance Manual).

Replacement

(4). Shim coupling on 369F5450 clutch

(Ref. Figure 403 or Figure 404)

assembly as follows:

A. Overrunning Clutch Subassembly

Removal

(a). Remove output coupling bolt and

coupling.

(1). Remove main transmission drive shaft.

(b). Shim coupling to achieve 0.010-0.030

(2). For 369F5450 clutch installation:

inch (0.254-0.762 mm) step above

clutch output shaft.

(a). Remove power output shaft cover

plate from back of engine (Ref. Sec.

(5). Shim coupling on 369A5350 clutch

01-00-00, Allison Engine Operation

assembly as follows:

and Maintenance Manual).

(a). Remove output coupling bolt and

(b). Insert tool (Ref. Figure 405) to

coupling.

engage bolt in back of clutch.

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(c). Insert a long 3/8 inch (9.525 mm) hex

(b). Install O-rings on 369F5469

wrench, approximately 10 inches

(C30/C47 engine) or 369F5468 (C20

(25.4 cm) long, through tool and into

series engines) bolt (Ref. Figure 404).

back of clutch assembly.

NOTE: Fill all voids and gaps between the out

(d). While holding internal hex wrench

side of bolt and inside of engine shaft with

[3/8 inch (9.525 mm)], turn external

grease.

hex wrench [1.00 inch (2.54 cm)]

(c).

Lubricate internal spline area of

counter-clockwise to remove bolt

engine output shaft with grease

from back of clutch.

(CM111).

(3). Remove coupling bolt, clutch coupling

(d).

Lubricate bolt threads with anti-

and shims.

seize compound (CM112) and insert

through engine into overrunning

(4). Remove retaining ring from clutch

clutch assembly.

housing. Then pull complete clutch

subassembly out of housing.

(e).

Using bolt removal tool (Ref.

Figure 405) either hold output

B. Overrunning Clutch Subassembly

coupling to prevent overrunning

Installation

clutch from turning or insert hex

wrench through bolt to engage and

hold clutch.

Consumable Materials

(Ref. Section 91−00−00)

(f).

Torque bolt to 250 - 300 inch-

Item

Nomenclature

pounds (28.25 - 33.90 Nm) plus

CM111

Grease, aircraft

drag torque.

CM125

Oil

(g).

Using existing hardware, reinstall

CM126

Oil, turbine

power output shaft cover plate on

back of engine (Ref. Sec. 01-00-00,

Allison Engine Operation and

(1). Remove shipping plug and O-ring from

Maintenance Manual).

end of shaft in replacement clutch

subassembly.

(h).

Lubricate coupling bolt threads with

anti-seize compound (CM112).

(2). Drain preservative oil from clutch

subassembly by inverting it several

(7). Install clutch coupling, shims and

times. Add lubricating oil (CM125 or

coupling bolt.

CM126) (Ref. Sec. 12-00-00).

(8). Install main transmission drive shaft.

(3). Coat clutch splines with grease

8. Overrunning Clutch−to−Firewall Seal

(CM111).

The overrunning clutch-to-firewall seal

(4). Using care to avoid oil spillage, insert

consists of a stamped steel backing and a seal

clutch subassembly into clutch housing

bonded to the cupped diameter of the backing.

and install retaining ring with beveled

side outward.

9. Overrunning Clutch−to−Firewall Seal

Replacement

(5). Check fluid level of clutch assembly

before installing clutch coupling (Ref.

(Ref. Figure 403)

Sec. 12-00-00).

(1). Remove engine.

(6). For 369F5450 clutch installation:

(2). Remove three bolts, six washers and

three nuts that attach firewall seal to

(a). Remove power output shaft cover

overrunning clutch.

plate from back of engine (Ref. Sec.

01-00-00, Allison Engine Operation

(3). Position replacement clutch-to-firewall

and Maintenance Manual).

seal assembly on flange of clutch with

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

seam orientated at the 6 o'clock position

D Do not use clutch coupling shims under

and secure with attaching hardware.

transmission input coupling. Inside diam

eter of clutch coupling shims, 1.260-1.270

10. Main Transmission Drive Shaft Couplings

inches (3.2004-3.2258 cm), is approxi

mately 0.070 inch (1.778 mm) larger than

The main transmission drive shaft couplings

inside diameter of shims used at trans

connect the overrunning clutch to the drive

mission coupling. Incorrect diameters can

shaft and the drive shaft to the main transmis

cause an improperly seated shim, mis

sion.

alignment and cocked coupling.

11. Main Transmission Drive Shaft Coupling

NOTE: Transmission input coupling shims are

Replacement

laminated stock. Each lamination is 0.002

inch (0.051 mm) thick. Peel to thickness re

(Ref. Figure 402)

quired.

A. Main Transmission Drive Shaft Coupling

(1). Install previously removed shims or

Removal

refer to Main Transmission Drive Shaft

Installation for shim thickness calcula

(1). Remove drive shaft; use care to keep it

tion.

from striking any object.

(2). Lubricate drive shaft splines with

(2). Remove coupling bolt from main

grease (CM111) and install in place.

transmission and overrunning clutch.

Coat bolt threads with anti-seize

Retain shim(s) with couplings for

compound (CM112) and install.

reinstallation.

(a). For 369D25100 transmission instal

B. Main Transmission Drive Shaft Coupling

lation, torque coupling bolt to actual

Installation

drag torque plus 250 - 300 inch-

pounds (28.25 - 33.90 Nm). If bolt

is not seated and/or existing torque is

Consumable Materials

found to be less than 250 - 300

(Ref. Section 91−00−00)

inch-pounds (28.25 - 33.90 Nm),

Item

Nomenclature

ensure self-locking drag torque is not

CM111

Grease, aircraft

less than 25 inch-pounds (2.82

CM112

Anti-seize compound high temperature

Nm) before torquing bolt.

(b). For 369F5100 transmission installa

tion, torque coupling bolt to actual

CAUTION

drag torque plus 315 - 365 inch-

pounds (35.59 - 41.24 Nm). If bolt

D The 0.010 inch (0.254 mm) minimum

is not seated and/or existing torque is

measurement between the bolt seating

found to be less than 315 - 365

surface and the input shaft must be ob

inch-pounds (35.59 - 41.24 Nm),

tained to ensure proper clamp up. Warped

ensure self-locking drag torque is not

shims or foreign material could provide a

less than 25 inch-pounds (2.82

false 0.010 inch (0.254 mm) minimum

Nm) before torquing bolt.

measurement and improper clamp up

could result during normal operation

(3). Reinstall main transmission drive

which may damage the main transmis

shaft, main transmission access cover

sion input shaft.

and sound insulation.

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

12. Tail Rotor Drive Shaft Coupling

Do not immerse Bendix flexible

CAUTION

Replacement

couplings in fluid or cleansers

such as magnetic particle, fluorescent pene

trant, visible dye etc. Do not apply corrosion

A. Tail Rotor Drive Shaft Coupling Removal

protection fluids unless coupling has been

cleaned with solvent or detergent. Apply

(1). Remove tail rotor drive shaft (Ref. Sec.

any corrosion protection very sparingly to

63-15-10).

outside only.

B. Tail Rotor Drive Shaft Coupling

NOTE: With Bendix coupling installed, remove

Installation

socket from main transmission coupling

only if visual inspection reveals signs of con

According to type of coupling installed, instal

tact between coupling bolt and socket.

lation of tail rotor shaft requires shimming of

couplings, and in some instances, tail rotor

(2). Remove couplings from main and tail

gearbox-to-tailboom shimming (Ref. Sec.

rotor transmissions. Retain shims with

63-15-10, Tail Rotor Drive Shaft Installa

couplings for reinstallation.

tion).

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CSP-HMI-2

MAINTENANCE MANUAL

0.375 IN. (9.53 MM) HEX BAR TO PICK UP 0.375 IN.

(9.53 MM) HEX SOCKET IN CLUTCH OUTER RACE

(NOTE 1)

OUTER RACE ENGINE BOLT TORQUED TO

250 - 300 INCH-POUNDS (28.25 - 33.90 NM)

1.00 IN. (2.54 CM) HEX BAR TO PICK UP

1.00 IN. (2.54 CM) HEX SOCKET IN

ENGINE BOLT (THRU HOLE IN CENTER)

0.72 IN.

(18.29 MM)

ÇÇÇÇÇÇ

ÇÇÇÇ

ÇÇÇÇÇÇ

ÇÇÇÇ

1.23 IN.

(3.124 CM)

TOOL REQUIRED

(NOTE 3)

FOR BOLT REMOVAL

0.68 IN.

(17.27 MM)

2.50 IN.

ENGINE PTO SHAFT

(6.35 CM)

(NOTE 3)

9.00 IN.

(22.86 CM)

(NOTE 3)

369F5450 CLUTCH ASSEMBLY

0.375 IN. (9.53 MM) SQUARE

0.375 IN. (9.53 MM) HEX

DRIVE EXTENSION

ÇÇÇÇÇÇÇ

STANDARD 3/8” SOCKET

1.00 IN. (2.54 CM) HEX

(NOTES 2, 3)

369F5468/5469 BOLT REMOVAL TOOL

NOTES:

HOLD HEX BAR STEADY WHEN TORQUING BOLT.

TOOL TO BE A MINIMUM OF 2.5 INCHES IN LENGTH

TO CLEAR STUDS ON ENGINE.

THIS IS MINIMUM LENGTH, TOOL MAY BE MADE

LONGER FOR EASE OF MAINTENANCE.

G63-1024A

Figure 405. 369F5468/5469 Bolt Removal Tool

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

DRIVE SHAFTS / CLUTCHES / COUPLINGS

INSPECTION/CHECK

369D25510 Main Rotor Drive Shaft

(a). Thoroughly clean shaft spline with

Inspection

dry cleaning solvent (CM234) to

remove oil, dirt and grease.

(Ref. Figure 601)

(b). Using magnifying glass and light,

inspect spline for cracks. Pay particu

Consumable Materials

lar attention to side of each tooth

(Ref. Section 91−00−00)

with large wear pattern (hairline

Item

Nomenclature

cracks appear crescent-shaped

usually at center bottom of tooth in

CM234

Solvent, dry-cleaning

root area).

CM425

Sealing compound

(c). Inspect neck of spline (area where

spline and shaft meet) for cracks.

(1).

Inspect all surfaces of drive shaft for

dents, nicks, scratches and evidence of

(7). Check shaft straightness. When rotated

deformation. No damage of any kind is

between centers, run-out must not

permissible in the area within two

exceed 0.040 inch (1.016 mm) TIR

inches of the spline. Dents less than

(allowable dents excluded).

0.050 inch (1.270 mm) deep and 0.050

inch (1.270 mm) diameter are permissi

600N5510 and 369F5510 Main Rotor Drive

ble in other areas. A dent is defined as

Shaft Inspection

a smooth depression of surface with no

(Ref. Figure 601 and Figure 602)

sharp edges or abrupt changes in

contour. No nicks or scratches are

permitted.

Consumable Materials

(Ref. Section 91−00−00)

(2).

If shaft condition is questionable,

Item

Nomenclature

perform magnetic particle inspection

CM234

Solvent, dry-cleaning

according to Specification MIL-I-6868.

No surface or subsurface defects are

permissible.

Anytime main rotor drive shaft

CAUTION

is removed, cover opening at top

(3).

Inspect all external surfaces of shaft for

of main rotor hub to prevent entry of any

corrosion.

foreign material into hub, mast and trans

mission.

(4).

Remove cork plug and inspect shaft

interior for corrosion. Remove light

(1). Inspect overtorque verification stripe

surface corrosion and pitting which can

for straightness.

be removed without causing shaft ID to

exceed 1.655 inches (4.2037 cm).

(2). Inspect all surfaces of drive shaft for

dents, nicks, scratches and evidence of

(5).

Inspect splines on end of drive shaft for

deformation. No damage of any kind is

excessive wear by measuring distance

permissible in the area within two

across two 0.108 inch (2.7432 mm)

inches of the spline. Dents less than

diameter pins placed in opposite spline

0.050 inch (1.270 mm) deep and 0.050

grooves. Dimension should be 2.2625

inch (1.270 mm) diameter are permissi

inches (5.74675 cm) minimum.

ble in other areas. A dent is defined as

a smooth depression of surface with no

(6).

Inspect shaft spline for cracks-using

sharp edges or abrupt changes in

bright light and 5X to 10X magnifying

contour. No nicks or scratches are

glass.

permitted.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

1.70 IN.

(4.318 CM)

8.0 IN.

(20.32 CM)

AREA 1: MAX. PIT DEPTH 0.0012 IN. (0.03048 MM)

AREA 2: MAX. PIT DEPTH 0.0008 IN. (0.02032 MM)

AREA 3: MAX. PIT DEPTH 0.0020 IN. (0.0508 MM)

AREA 4: CHECK TEETH BY MEASURING ACROSS

TWO 0.108 IN. (2.7432 MM)-DIAMETER PINS

PLACED IN OPPOSITE INTER-TOOTH

GROOVES. MEASURED DIMENSION

SHOULD BE 2.2625 IN. (5.74675 CM) MIN.

TOOTH

0.010 IN.

0.050 IN. (1.270 MM)

CONTACT

(0.254 MM)

MAX

AREA

MAX. DEPTH

5.40 IN.

13.716 CM)

0.050 IN.

(1.270 MM)

MAX

AREA 4

ROOT AREA

(TYP)

SPLINE

NECK

LARGER WEAR

SIMULATED CRACKS

NOTE:

PATTERN (TYP)

SHOWN

PAY PARTICULAR ATTENTION TO ROOT AREA AT EACH

SPLINE TOOTH. SIMULATED CRACKS SHOWN. ALSO

CHECK SPLINE NECK (SHADED AREA) FOR CRACKS.

G63−1011A

Figure 601. Main Rotor Drive Shaft Inspection

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CSP-HMI-2

MAINTENANCE MANUAL

(3).

If shaft condition is questionable,

perform magnetic particle inspection

according to Specification MIL-I-6868.

No surface or subsurface defects are

permissible.

(4).

Inspect all external surfaces of shaft for

corrosion.

OVERTORQUE

VERIFICATION STRIPE

(5).

Remove cork plug and inspect shaft

interior for corrosion. Remove light

surface corrosion and pitting which can

be removed without causing shaft ID to

exceed 1.655 inches (4.2037 cm).

(6).

Inspect splines on end of drive shaft for

excessive wear by measuring distance

across two 0.108 inch (2.7432 mm)

diameter pins placed in opposite spline

grooves. Dimension should be 2.2625

inches (5.74675 cm) minimum.

(7).

Inspect shaft spline for cracks-using

bright light and 5X to 10X magnifying

glass.

(a). Thoroughly clean shaft spline with

6G63-003

dry cleaning solvent (CM234) to

remove oil, dirt and grease.

Figure 602. Main Rotor Drive Shaft

Overtorque Verification Stripe

(b). Using magnifying glass and light,

inspect spline for cracks. Pay particu

lar attention to side of each tooth

Main Transmission Drive Shaft Inspection

with large wear pattern (hairline

(Bendix)

cracks appear crescent-shaped

usually at center bottom of tooth in

(Ref. Figure 402)

root area).

(c). Inspect neck of spline (area where

Consumable Materials

spline and shaft meet) for cracks.

(Ref. Section 91−00−00)

Item

Nomenclature

(8). Check shaft straightness. When rotated

CM318

Primer

between centers, run-out must not

exceed 0.040 inch (1.016 mm) TIR

(allowable dents excluded).

(1). Inspect drive shaft diaphragms for

dents, cracks, scratches, nicks, rust

(9). Apply thin coat of sealing compound

spots and evidence of joint separation

(CM425), mixed according to container

from shaft or outside edges. Evidence of

instructions, to all cork plug surfaces;

any such defects on either diaphragm

press cork into drive shaft until top of

requires removal of shaft from service.

cork is flush with top of drive shaft.

Allow sealing compound to cure

according to container instructions.

(2). Inspect drive shaft tube between

Apply second coat of sealing compound

diaphragms for dents, scratches, cracks

to exposed surfaces of cork; allow to dry.

or corrosion pits.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

(a). Measure depth and diameter of

4. Main Transmission Drive Shaft Inspection

dents. Dents that blend smoothly into

(Kamatic)

surrounding surface area with no

(Ref. Figure 402)

sharp change in contour and do not

exceed 0.015 inch (0.381 mm) depth

are acceptable. Dents not within

Consumable Materials

these limits require removal of shaft

(Ref. Section 91−00−00)

Item

Nomenclature

from service.

CM318

Primer

(b). Measure depth of cracks, nicks,

(1). Inspect drive shaft for dents, cracks,

corrosion pits, or scratches; length

scratches, nicks, rust spots and evi

and direction are not limited. Maxi

dence of joint separation from shaft or

mum depth allowed before rework is

outside edges.

0.003 inch (0.076 mm).

(2). Inspect drive shaft tube between

couplings for dents, scratches, cracks or

(c). Check suspected cracks using dye

corrosion pits.

penetrant. If crack indication ap

pears, remove black (phenolic com

(a).

Measure depth and diameter of

pound) coating from area.

dents. Dents that blend smoothly into

surrounding surface area with no

sharp change in contour and do not

NOTE: Drive shaft is coated with special phe

exceed 0.010 inch (0.254 mm) in

nolic thermosetting compound. It is a brittle

depth are acceptable. Dents not

coating that may indicate a crack that does

within these limits require removal

not penetrate tube.

of shaft from service.

(b).

Measure depth of cracks, nicks,

(d). Re-inspect suspected area using

corrosion pits or scratches; length

magnetic-particle or dye-penetrant

and direction are not limited. Maxi

methods. If crack does not reappear,

mum depth allowed before rework is

touch up cleaned area with primer

0.005 inch (0.127 mm).

coating (CM318) and return part to

(c).

Check suspected cracks using dye

service.

penetrant. If crack indication ap

pears, remove coating from surface.

NOTE: Perform inspection steps (3). and (4).

(d).

Re-inspect suspected area using

only if shaft damage is suspected.

magnetic particle or dye penetrant

methods. If crack does not reappear,

touch up cleaned area with primer

(3). Inspect shaft tube for out-of-round

coating (CM318) and return part to

condition, which shall not exceed 0.060

service. If shaft is found to be

inch (1.524 mm).

cracked, remove shaft from service.

Kamatic parts cannot be inter

(4). Inspect shaft for straightness. Shaft

CAUTION

changed between drive shafts.

shall be straight within 0.030 inch

(3). Inspect all attaching hardware for

(0.762 mm) at all locations relative to

serviceable condition. Discard and

centerlines of two flange mounting bolt

replace defective hardware.

patterns.

NOTE: Perform the following inspections if

shaft damage is suspected.

(5). Inspect all attaching hardware for

serviceable condition. Check nut plates

(4). Inspect shaft tube for out-of-round

for drag torque. Discard and replace

condition not to exceed 0.060 inch

defective hardware.

(1.524 mm).

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CSP-HMI-2

MAINTENANCE MANUAL

(5). Inspect shaft for straightness. Shaft

(4). Inspect socket and main transmission

shall be straight within 0.030 inch

coupling bolt for signs of contact. If

(0.762 mm) at all locations relative to

signs of contact are noted, remove and

centerlines of two flange mounting bolt

reinstall coupling bolt and socket (Ref.

patterns.

Sec. 63-15-00). Reposition socket and

or bolt so maximum clearance between

5. Overrunning Clutch Inspection

bolt key and socket is obtained.

(Ref. Figure 403 and Figure 404) Perform the

8. Kamatic Coupling Inspection

following inspections any time the helicopter

(1). Inspect coupling springs for dents,

engine or overrunning clutch assembly is

cracks, nicks and rust spots.

removed from the helicopter. For further

inspection requirements, refer to Chapter 05

(2). Inspect coupling splined section and

and Component Overhaul Manual.

flange for scratches, nicks, dents,

cracks and corrosion pits. No cracks are

NOTE: Overrunning clutch subassembly can

allowed. Maximum depth of other

be replaced with engine installed.

defects allowed before rework is 0.005

inch (0.127 mm).

(1). Check clutch oil level (Ref. Sec.

12-00-00).

(3). Measure overall length of coupling at

three different points. If average of

(2). Remove grease and visually check

readings exceed 2.630 inch (6.6802 cm),

clutch input shaft splines for wear (Ref.

coupling must be replaced.

COM).

(4). Inspect drive shaft flange for signs of

NOTE: Component Overhaul Manual contains

contact. If signs of contact are noted,

information relative to inspection of over

remove coupling bolt, re-shim coupling

running clutch on helicopters equipped with

and reinstall coupling bolt (Ref. Sec.

any cargo hook.

63-15-00).

9. Main Rotor Drive Shaft Inspection (300

6. Overrunning Clutch−to−Firewall Seal

Hour)

Inspection

(Ref. Figure 601)

Inspect firewall seal and backing for cracks,

breaks, corrosion or other damage that may

prevent complete sealing of firewall opening.

Consumable Materials

(Ref. Section 91−00−00)

Item

Nomenclature

7. Bendix Tail Rotor Drive Shaft Coupling

Inspection

CM234

Solvent, dry-cleaning

(1). Inspect coupling diaphragms for dents,

Anytime main rotor drive shaft

cracks, nicks, rust spots and joint

CAUTION

is removed, cover opening at top

separation at weld junction.

of main rotor hub to prevent entry of any

(2). Inspect coupling splined section and

foreign material into hub, mast and trans

flange for scratches, nicks, dents,

mission.

cracks and corrosion pits. No cracks are

(1). Remove main rotor drive shaft (Ref.

allowed. Maximum depth of other

Main Rotor Drive Shaft Removal).

defects allowed before rework is 0.005

inch (0.127 mm).

(2). Perform a visual inspection of the shaft

spline as follows:

(3). Measure overall length of couplings at

three different points. If average of

(a). Thoroughly clean with cleaning

readings exceed 2.541 inches (6.45414

solvent (CM234) to remove oil, dirt,

cm), coupling must be replaced.

etc.

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HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369D/E/FF-500/600N HELICOPTERS (ISSUED: 1990) - page 19