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

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

MAIN ROTOR FLIGHT CONTROLS

DESCRIPTION AND OPERATION

1. Main Rotor Flight Controls

provides inboard support for the collective

torque tube.

Main rotor flight controls consist of scissors,

rotating swashplate, stationary swashplate,

C. Collective Controls

mixer controls (lateral bellcrank, longitudinal

idler, collective pitch mixer bellcrank, longitu

Pilot's compartment collective controls consist

dinal bellcrank, longitudinal control-mixer

of collective pitch stick, collective bungee, and

link, longitudinal link, and two mixer links)

the interconnecting shaft and linkage. All

and five pitch control rods.

components, except the stick and tunnel-

routed collective mixer control rod, are located

within the pilot's seat structure. Dual control

Movement of collective pitch cyclic control

provisions are incorporated into the pilot's

sticks is transferred to mixer controls through

compartment collective controls installation.

control rods routed up through the controls

tunnel at the center of Sta. 78.50 bulkhead.

D. Pilot’s Collective Pitch Stick

Mixer controls transfer required combination

of collective, longitudinal and lateral travel

The pilot's collective pitch stick consists

through swashplates to main rotor blades. The

primarily of a switch housing, throttle grip and

helicopter may be equipped with either

friction mechanism, collective stick tube and

right-hand or left-hand control configurations

friction mechanism and gas producer control

consisting of cyclic, collective and anti-torque

shaft with right angle (pinion and bevel gear)

controls. The main rotor hub and blades,

drive. Collective pitch stick controls include:

swashplate and control linkage to the crew

the N₁ throttle and idle stop release ring, N₂

compartment controls are identical on either

governor trim switch, landing light switch,

basic configuration.

stick friction adjustment grip throttle friction

nut and a starter-ignition switch.

NOTE: This section contains information for

both L/H command and R/H command heli

E. Copilot’s Collective Pitch Stick

copters. Unless otherwise denoted, the in

formation in this section pertains to both

The copilot's collective stick consists primarily

type helicopters.

of a switch housing, N₁ throttle grip, stick

tube, and internal gas producer control shafts

A. Collective Mixer, Lateral and Longitudinal

having right angle (pinion and bevel) gear

Mixer (Tunnel−Routed) Control Rods

drive. The gear drive linkage is essentially the

same as in pilot's collective stick housing.

Tunnel-routed control rods mechanically

Copilot's collective controls include an N₂

transfer displacement of flight controls to

governor trim switch.

associated bellcranks and the idler at the front

of main rotor mast base. All tunnel-routed

F. Collective Pitch Stick Friction

control rods are removed, inspected, repaired

and installed in same manner.

Pilot's collective pitch stick friction allows the

pilot to vary amount of effort required to raise

B. Controls Support Bracket and Bellcranks

and lower the collective pitch stick as well as

increasing stick resistance to position change

The controls support bracket is below the

resulting from sudden changes in main rotor

pilot's seat cover, between right and left

collective forces. The grip is marked with

inboard sides of the seat structure. The

arrows indicating direction of rotation for

bracket provides the hingeline for longitudinal

increasing or decreasing friction. Friction can

and lateral idler bellcrank, tail rotor bellcrank,

be applied or released with one hand by

and the engine droop control bellcrank. It also

rotating the friction adjustment grip.

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MAINTENANCE MANUAL

Collective stick friction mecha

bracket attachment is to counteract these

CAUTION

nism is designed so that stick

forces so that collective stick loads are

cannot be locked in maximum friction point.

relatively constant throughout full range of

Safety of flight considerations require that

travel. There are two adjustments provided to

pilot be able to instantly change any estab

establish or correct collective flight loads. The

lished collective pitch stick position, without

collective bungee spring corrects variation in

changing friction adjustment in event of a

collective load from low pitch (level flight) to

power failure. There is no suitable check

high pitch (climb). Setting of overcenter bolt to

that pilot can make, with helicopter on the

raise or lower bungee fitting reduces or

ground, to determine if maintenance adjust

increases overall collective forces in both low

ment of collective friction is correct. This is

pitch (level flight) and high pitch (climb).

due to large force application necessary to

I. Inboard Collective Stick Socket Assembly

override collective bungee and blades rest

ing on droop stops. If stick friction is inade

Inboard collective stick socket assembly is a

quate during flight, a maintenance check

cast magnesium housing that contains gas

should be performed. Once friction adjust

producer linkage and provisions for attach

ment is determined to be correct at low fric

ment of dual collective controls. Internal gas

tion point, any further mechanical adjust

producer drive gear linkage is essentially the

ment to alter (increase) friction at low point

same as that in the pilot's collective stick

can cause stripping of mechanism when grip

housing with the addition of a splined N₁

is fully rotated for maximum friction.

pinion gear for simplified installation or

removal of a copilot's collective stick. The lower

G. Collective Control Interconnecting

end of the collective mixer (tunnel-routed)

Torque Tube

control rod is attached to the socket housing

The collective interconnecting torque tube

and the exterior bellcrank, idler and link

consists of the tube, bungee bracket, bungee

transfer movement of the pilot's collective stick

fitting and a tube support bearing. The torque

throttle to the gas producer controls routed

tube interconnects the pilot's collective pitch

through the fuselage to the engine.

stick and the inboard collective stick socket

J. Cyclic Controls

assembly. The torque tube is supported at the

left end by a bearing installed in seat struc

The cyclic pitch control system is a fully

ture, and at the right end by the controls

mechanical control system. Any combination of

support bracket.

lateral and longitudinal cyclic pitch stick

movement is mixed by cyclic lateral and

H. Collective Bungee

longitudinal control mixers and transferred to

the main rotor swashplate, which applies the

The collective bungee installation consists of a

combined motion through pitch control rods to

male bearing assembly, female bearing

the main rotor blades. Forward and rearward

assembly, spring and retainer. This unit

movement of the cyclic pitch stick causes

attaches between the bungee over-center

helicopter motion in a longitudinal direction,

fitting and bungee bracket of collective

while side-to-side movement provides motion

interconnecting torque tube. The collective

in a lateral direction. This action varies lift

bungee helps maintain selected collective pitch

developed by main rotor blades and serves as

stick position in flight by counteracting forces

primary control by horizontal flight. Pilot's

that are fed back in collective pitch stick(s)

compartment cyclic controls include the control

(blade pitching moments, rotor head strap

stick, a lateral interconnecting rod, lateral

pack torsion when collective pitch stick is

cyclic bellcrank, longitudinal cyclic control

raised or lowered from mid-position, and

interconnecting torque tube and lateral and

combined imbalance of forces in the controls

longitudinal friction mechanism.

system). Flight characteristics of the helicopter

are such that collective forces are relatively

K. Pilot’s Cyclic Control Stick

low during most stick travel from low to high

blade pitch. At a point near full pitch, stick

The pilot's cyclic control stick consists of a grip

forces reverse and become heavy. The purpose

and a tube riveted in a socket. The cyclic grip

of the adjustable bungee and the overcenter

contains a toggle switch for cyclic trim control

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MAINTENANCE MANUAL

and a trigger switch for radio/interphone

should the check valve spring fail, the one-

communication. A blank switch socket is

way lock does not function to shunt longitudi

provided at the left of the trim switch for

nal feedback forces to structure. The unit is

optional equipment. Coiled, insulated and

mounted in two pivoting supports attached to

open-ended wiring is provided in the grip for

seat structure, and has a transparent, vented

connection to an optional switch.

reservoir with a capacity of approximately 0.67

fluid ounce (20 cc). The one-way lock control

L. Copilot’s Cyclic Control Stick

system is serviced through the filler with

hydraulic oil (6, Table 203).

The copilot's cyclic control stick is similar to

the pilot's except electrical wiring exits above

O. Cyclic Trim Actuators

the stick socket. The copilot's cyclic stick is

detachable and may be removed or installed by

Each of the two cyclic trim actuators consists

use of two quick-release pins.

of an actuator, housing support, trim tube and

spring assembly. The actuator is essentially a

M. Pilot’s Compartment Lateral and

motor-driven, variable length shaft that

Longitudinal Cyclic Control Linkage

compresses a spring assembly, counteracting

feedback forces from the main rotor and

Pilot's compartment lateral and longitudinal

compensating for imbalance conditions such as

cyclic control linkage consists of two control

those imposed by crosswinds or unevenly

rods and a bellcrank that interconnect lateral

distributed cargo. Cyclic trim is controlled by

control movement, and the cyclic torque tube

the cyclic trim switch on top of cyclic stick grip.

and one-way lock control system that inter

The cyclic trim switch has five positions:

connect longitudinal control movement of

normally OFF at the center, and momentary

pilot's cyclic stick to tunnel-routed mixer

FORWARD, AFT, LEFT, and RIGHT. When

control rods. R/H command configuration is

the trim switch is moved off center to any of

identical to L/H command except for an

the four trim positions, one of the trim motors

additional lateral control rod that attaches

operates to provide trim spring force in the

lower end of copilot's cyclic control stick to

desired direction. By momentarily activation of

lateral cyclic bellcrank.

the switch, very small trim increments are

obtained. Trim forces cannot be applied in two

N. One−Way Lock Control System

directions simultaneously; when both lateral

and longitudinal trim corrections are required,

The one-way lock of the cyclic control system

it is necessary to apply first one, then the

is located in longitudinal control linkage

other. Travel of the cyclic pitch control stick is

within the pilot's seat structure. The one-way

not limited by the cyclic trim mechanism; trim

lock control system is essentially a self-con

spring tension can be overridden at any time.

tained, closed-loop hydraulic unit - consisting

of a check valve, relief valve and pushrod

P. Roof−Mounted Control Rods (600N)

mechanism. The check valve is seated when

longitudinal control force (feed-back) origi

The roof-mounted control rods transmit cyclic

nated by main rotor tends to move the

and collective flight control input from the

one-way lock (and cyclic stick) in an aft

tunnel-routed control rods, via the forward

direction. Seating the check valve prevents

roof-mounted bellcranks, to the link assem

unwanted aft movement of cyclic stick and

blies, via the aft roof-mounted bellcranks, at

shunts feed-back force to helicopter structure.

the mixer assembly.

Normally, only very slight aft movement of the

cyclic stick is required to unseat the check

Q. Roof−Mounted Bellcranks (600N)

valve. Should the check valve (or pushrod

shaft that unseats the valve) gall and freeze in

The forward roof-mounted bellcrank transfer

the valve-closed position, a force of approxi

controls input from the tunnel-routed control

mately 30 pounds is necessary to open the

rods to the roof-mounted control rods. The aft

relief valve and bypass the check valve. This

roof-mounted control rods transfer controls

force is then required for each subsequent aft

input from the roof-routed control rods to the

movement of the cyclic stick. Conversely,

link assemblies.

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MAINTENANCE MANUAL

MAIN ROTOR DRIVE SHAFT

DAMPER

BLADE ATTACH PIN

MAIN ROTOR BLADE

ROTOR MAST SUPPORT

ROTATING SWASHPLATE

MAIN ROTOR CONTROLS (MIXER, IDLER

BELLCRANKS AND LINKS)

LATERAL MIXER CONTROL ROD (CYCLIC)

LONGITUDINAL MIXER CONTROL ROD (CYCLIC)

10. COLLECTIVE MIXER CONTROL ROD

11. STATIONARY SWASHPLATE

12. COLLECTIVE CONTROL TORQUE TUBE

13. COPILOT'S COLLECTIVE PITCH STICK

14. DROOP CONTROL OVERRIDE LINK

15. COPILOT'S CYCLIC STICK

16. LATERAL CYCLIC FRICTION KNOB

17. CYCLIC LATERAL CONTROL ROD

18. LATERAL CYCLIC TRIM ACTUATOR

19. LONGITUDINAL CYCLIC TRIM ACTUATOR

20. LONGITUDINAL CYCLIC FRICTION KNOB

21. ONE-WAY LOCK

22. CYCLIC CONTROL TORQUE TUBE

23. GAS PRODUCER CONTROL ROD

24. COLLECTIVE CONTROL BUNGEE

25. ANTI-TORQUE CONTROL ROD (REF)

26. PILOT'S COLLECTIVE PITCH STICK

27. PILOT'S CYCLIC STICK

G67-0000A

Figure 1. Main Rotor and Control System (369D/E/FF − 500N)

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MAINTENANCE MANUAL

MAIN ROTOR DRIVE SHAFT

DAMPER

BLADE ATTACH PIN

MAIN ROTOR BLADE

ROTATING SWASHPLATE

MAIN ROTOR CONTROLS (MIXER, IDLER

BELLCRANKS AND LINKS)

LATERAL MIXER CONTROL ROD (CYCLIC)

LONGITUDINAL MIXER CONTROL ROD (CYCLIC)

COLLECTIVE MIXER CONTROL ROD

10.

COLLECTIVE CONTROL TORQUE TUBE

11.

COPILOT'S COLLECTIVE PITCH STICK

12.

COPILOT'S CYCLIC STICK

13.

LATERAL CYCLIC FRICTION KNOB

14.

CYCLIC LATERAL CONTROL ROD

15.

LATERAL CYCLIC TRIM ACTUATOR

16.

LONGITUDINAL CYCLIC TRIM ACTUATOR

17.

LONGITUDINAL CYCLIC FRICTION KNOB

18.

ONE-WAY LOCK

19.

CYCLIC CONTROL TORQUE TUBE

20.

GAS PRODUCER CONTROL ROD

21.

COLLECTIVE CONTROL BUNGEE

22.

ANTI-TORQUE CONTROL ROD (REF)

23.

PILOT'S COLLECTIVE PITCH STICK

24.

PILOT'S CYCLIC STICK

6G67-035A

Figure 2. Main Rotor and Control System (600N)

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MAINTENANCE MANUAL

MAIN ROTOR FLIGHT CONTROLS

REMOVAL/INSTALLATION

1. Tunnel−Routed Control Rod Replacement

tube to angle up through the double

hole.

(Ref. Figure 401)

(9). Remove bolt from bottom of 7012 tube

A. Tunnel−Routed Control Rod Removal

and lower to belly of aircraft and angle

up through the double hole.

Special Tools

(10). Remove bolts from bottom of 7007 tube

(Ref. Section 91−00−00)

and lower to the belly of aircraft, then

Item

Nomenclature

angle up through the double hole.

ST508

Collective bungee installation tool

(11). Move 7009 tube to the other side of

center beam and angle up through the

Before disconnecting collec

double hole.

WARNING

tive pitch control rod, install

B. Tunnel−Routed Control Rod Installation

collective bungee installation tool to

prevent spring reaction due to droop

To reinstall tunnel-routed control rods,

stop load on control rod.

reverse the sequence of Tunnel-Routed

Control Rod Removal.

(1). Install collective bungee installation

tool (ST508) and remove collective

2. Roof−Mounted Control Rod Replacement

bungee.

(600N)

(2). For access to lower rod ends, remove

(Ref. Figure 402)

controls access door at base of canted

bulkhead in cargo compartment.

A. Roof−Mounted Control Rod Removal

(600N)

(3). Hand turn main rotor blades to align

blue blade to right side of aircraft.

Special Tools

(4). Disconnect upper end of control rod.

(Ref. Section 91−00−00)

Item

Nomenclature

(5). Remove double boot from control tunnel

ST508

Collective bungee installation tool

cover. All tubes will be removed

through the double hole.

(1). Install collective bungee installation

Use care during removal of con

tool (ST508) and remove collective

CAUTION

trol rods. Any surface damage

bungee.

caused by hasty removal may result in un

serviceable control rods.

(2). For access to roof-mounted control

rods, remove upper fuselage controls

(6). Move blue blade pitch housing down as

fairing.

far as it will go. This will allow the

tubes to go past the housing.

NOTE: If same rods are to be reinstalled, mark

rods for proper positioning upon reinstalla

(7). Remove bolts from bottom of 369A7009

tion. If new rods are installed, main rotor

and 7011 tubes.

flight controls must be re-rigged.

(8). Move cyclic controls so that the 7012

(3). Mark control rod for proper reinstalla

tube moves to its highest point. Place

tion.

7009 tube to the far right and lower out

of way. Lower 7011 tube to the left side

(4). Remove hardware from control rods

of center beam. This will allow 7011

and remove rods from aircraft.

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MAINTENANCE MANUAL

LINK ASSEMBLY

AFT ROOF-MOUNTED

BELLCRANKS

ROOF-MOUNTED

CONTROL RODS

FORWARD

ROOF-MOUNTED

BELLCRANKS

ROTATING

SWASHPLATE

MAIN ROTOR CONTROLS

COLLECTIVE MIXER

(MIXER, IDLER BELLCRANKS

CONTROL ROD

AND LINKS)

DIRECTIONAL

LONGITUDINAL MIXER

CONTROL ROD

(CYCLIC)

LATERAL MIXER

CONTROL ROD

(CYCLIC)

6G67-039

Figure 402. Roof−Mounted Controls Installation

B. Roof−Mounted Control Rod Installation

3. Roof−Mounted Bellcrank Replacement

(600N)

(Ref. Figure 402) Replacement of the roof-

(1). Install control rods in bellcranks

mounted bellcranks is the same procedure for

ensuring RH threaded rod end is

the forward and aft bellcranks.

forward.

A. Roof−Mounted Bellcrank Removal (600N)

(2). Install hardware connecting control

rods. Torque nuts to 30 - 40 inch-

Special Tools

pounds (3.39 - 4.52 Nm) and install

(Ref. Section 91−00−00)

cotter pin.

Item

Nomenclature

ST508

Collective bungee installation tool

(3). Remove collective bungee installation

tool.

(1). Install collective bungee installation

tool (ST508) and remove collective

(4). Reinstall upper fuselage controls

bungee.

fairing.

(2). For access to roof-mounted control rods

and bellcranks, remove upper fuselage

(5). Perform flight controls rigging check.

controls fairing.

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MAINTENANCE MANUAL

(3). Remove hardware connecting rod from

(2). Ensure bushing protrudes a minimum

bellcrank.

of 0.010 inch (0.254 mm) to a maximum

of 0.060 inch (1.524 mm) beyond the

(4). Remove hardware from bellcrank pivot

surface of mixer.

point and remove bellcrank.

(3). Torque nuts to 30 - 40 inch-pounds

B. Roof−Mounted Bellcrank Installation

(3.39 - 4.52 Nm) and install cotter pin.

(600N)

NOTE: Ensure bellcranks are installed in prop

(4). Remove collective bungee installation

er position. If bellcranks are install in the

tool.

wrong position, rigging will be impossible

(Ref. Illustrated Parts Catalog).

(5). Reinstall upper fuselage controls

fairing.

(1). Install bellcrank in mount with word

FORWARD facing up and arrow

5. Controls Support Bracket and Bellcrank

pointing towards front of aircraft.

Replacement

(2). Install hardware connecting bellcrank

(Ref. Figure 403)

to mount. Torque nuts to 30 - 40

inch-pounds (3.39 - 4.52 Nm) and

A. Controls Support Bracket and Bellcrank

install cotter pin.

Removal

(3). Reinstall disconnected control rods.

Special Tools

(4). Remove collective bungee installation

(Ref. Section 91−00−00)

tool.

Item

Nomenclature

(5). Reinstall upper fuselage controls

ST508

Collective bungee installation tool

fairing.

4. Link Assembly Replacement (600N)

(1). Remove foot fairings and controls

(Ref. Figure 402)

access door (Sta. 78.50) and pilot's seat

cover.

A. Link Assembly Removal (600N)

Before disconnecting collec

WARNING

tive pitch control rod, install

Special Tools

collective bungee installation tool to

(Ref. Section 91−00−00)

prevent spring reaction due to droop

Item

Nomenclature

stop load on control rod.

ST508

Collective bungee installation tool

(2). Install collective bungee installation

tool (ST508) and remove collective

(1). Install collective bungee installation

bungee.

tool (ST508) and remove collective

bungee.

(3). Disconnect tunnel-routed control rods.

(2). Remove upper fuselage controls fairing.

(4). Disconnect upper end of each cyclic

NOTE: Upper link bolt has a bushing in the

trim actuator.

mixer bellcrank.

(5). Disconnect floor-routed tail rotor

(3). Remove hardware from link and

control rod from tail rotor bellcrank.

remove link from aircraft.

(6). Disconnect Sta. 70 lateral control rod

B. Link Assembly Installation (600N)

from lateral idler bellcrank.

(1). Install link between lower bellcrank

and mixer bellcrank with hardware

(7). Disconnect one-way lock from longitu

previously removed.

dinal idler bellcrank.

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MAINTENANCE MANUAL

COLLECTIVE TORQUE

BUNGEE SUPPORT BRACKET

TUBE

WASHER (SPECIAL)

* * CONTROLS SUPPORT

BRACKET

DROOP CONTROL

OVERRIDE LINK

(COUNTERSUNK)

* * TAIL ROTOR BELLCRANK

BEARING

BUSHING

BEARING

NOTE 2

(NOTE 3)

LATERAL IDLER

BELLCRANK

FLOOR-ROUTED TAIL

BEARING

3/16 IN.

ROTOR CONTROL ROD

AND SPACER

(4.7625 MM)

DIAMETER

BUSHING

(NOTE 3)

1/4 IN.

(6.35 MM)

BEARING

STA 70 LATERAL

DIA

CONTROL ROD

(COUNTERSUNK)

BEARING

SPACER

* * LONGITUDINAL

NOTE 6

IDLER BELLCRANK

LATERAL CYCLIC

STA. 72 DROOP

TRIM ACTUATOR

CONTROL BELLCRANK

ONE-WAY

LOCK

LONGITUDINAL CYCLIC

TRIM ACTUATOR

NOTE 4

NOTE 6

BOLT INSTALLATION

HOLE

SHIM WASHERS USED AS REQUIRED TO OBTAIN NO SIDELOAD

ON ONE-WAY LOCK.

BUSHING AND BOLT MUST NOT ROTATE WITH TRIM UNIT

AFTER INSTALLATION.

BOND JUMPER ATTACHMENT TYPICAL FOR BOTH ACTUATORS.

NOTES:

DOUBLE ASTERISK (**) INDICATES PARTS THAT MAY BE EITHER

ASTERISK (*) IDENTIFIES SLOTTED BUSHINGS. EDGE OF BUSHINGS

MAGNESIUM OR ALUMINUM ALLOY.

MUST PROTRUDE A MINIMUM OF 0.010 IN. (0.254 MM) TO A MAXIMUM

REPLACEMENT PARTS HAVE NUTPLATE RIVETED IN PLACE.

OF 0.080 IN. (2.032 MM) ABOVE OUTSIDE SURFACE OF PART AFTER

WASHER, NUT AND COTTER PIN NOT REQUIRED.

G67-1002A

NUT IS TIGHTENED

Figure 403. Controls Support Bracket, Idler Bellcranks and Cyclic Trim Actuators Installation

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(8). Remove pilot's collective pitch stick.

(8). Connect floor-routed tail rotor control

rod to tail rotor bellcrank.

(9). Provide support for collective torque

tube. Remove bolts, washers and nuts

(9). Connect upper end of each cyclic trim

securing bungee support bracket and

actuator.

collective torque tube to controls

support bracket.

NOTE: Lateral actuator uses 3/16 inch (4.7625

mm) diameter bolt. The longitudinal actua

(10). Disconnect aft end of droop control

tor requires 1/4 inch (6.035 mm) diameter

override link from collective torque tube

bolt.

bracket.

(10). Connect lower ends of tunnel-routed

(11). Remove Sta. 72 droop control bellcrank

control rods.

from support bracket.

(11). Install collective bungee and remove

(12). Disconnect and remove support bracket

collective bungee installation tool.

from seat structure. Avoid striking any

bellcranks and pushrods.

6. Pilot’s Collective Pitch Stick Replacement

B. Controls Support Bracket and Bellcrank

(L/H Command)

Installation

(Ref. Figure 404)

(1). Carefully position assembled support

bracket and bellcranks between seat

A. Pilot’s Collective Pitch Stick Removal

structure bulkheads and secure with

(L/H Command)

attaching hardware.

Special Tools

(2). Position Sta. 72 droop control bellcrank

(Ref. Section 91−00−00)

in support bracket and install.

Item

Nomenclature

NOTE: Cap is matched to cradle of each control

ST508

Collective bungee installation tool

support bracket. Check that numbers on

each part are identical before accomplishing

step (3). below.

(1). Remove outboard collective stick cover.

(3). Check that two slotted bushings are in

(2). Disconnect pilot's collective stick

place in bungee support bracket.

electrical plug.

Position collective torque tube and

bungee bracket on support bracket

(3). Remove attaching hardware that

cradle and install cradle bolts, washers

secures guide to seat structure bracket.

and nuts. Ensure index groove, in edge

of cap that clamps torque tube to

Before disconnecting collec

WARNING

tive stick, install collective

support bracket cradle, mates with

matching index at bracket cradle

bungee installation tool to prevent

parting surface.

spring reaction due to droop stop load

on controls.

(4). Install pilot's collective pitch stick.

(4). Install collective bungee installation

(5). Connect aft end of droop control

tool (ST508).

override link to collective torque tube

droop control bracket.

(5). Remove collective bungee and inboard

collective socket. Disconnect droop

(6). Connect one-way lock to longitudinal

control override link (369D/E/FF -

idler bellcrank.

500N only), slide bungee bracket to

NOTE: For following steps, ensure that slotted

side, remove cradle cap and slide

bushing is in bellcrank ear.

collective torque tube inboard.

(7). Connect Sta. 70 lateral control rod to

(6). Remove attaching hardware that

lateral idler bellcrank.

connects stick housing to torque tube.

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COLLECTIVE MIXER

TUNNEL-ROUTED

CONTROL ROD

NOTE 3

INBOARD COLLECTIVE

STICK SOCKET

BUNGEE OVER-CENTER

ADJUSTMENT BOLT

GAS PRODUCER

(NOTE 1)

CONTROL ROD

BUNGEE

GAS PRODUCER

INTERCONNECTING

TORQUE TUBE

COLLECTIVE CONTROL

INTERCONNECTING

TORQUE TUBE

BUNGEE SPRING

N₂ DROOP CONTROL OVERRIDE

ADJUSTMENT NUT

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

(NOTE 2 - SEE CAUTION)

COLLECTIVE STICK FRICTION

MECHANISM AND GUARD

THROTTLE

PILOT'S COLLECTIVE

PITCH STICK

NOTE 4

NOTE 5

THROTTLE

FRICTION

SLEEVE

GUIDE

FUSELAGE

BUSHING

SKIN

NOTE 5

NOTES:

ROTATED CLOCKWISE TO INCREASE, COUNTERCLOCKWISE TO

DECREASE OVERALL COLLECTIVE DOWNLOADS.

ROTATED CLOCKWISE TO INCREASE COUNTERCLOCKWISE TO

DECREASE, BUNGEE PRELOAD.

CAUTION: DO NOT ADJUST BUNGEE SPRING TENSION WHILE BUNGEE

INSTALLATION TOOL IS INSTALLED. USE OVER-CENTER ACTION OF STICK

TO COMPRESS SPRING TO REMOVE TOOL.

BUSHINGS MUST PROTRUDE A MINIMUM OF 0.010 IN. (0.254 MM) TO

A MAXIMUM OF 0.060 IN. (1.524 MM) AFTER BOLT IS TIGHTENED.

FOUR NUTS TORQUED EQUALLY AND BY SMALL INCREMENTS.

G67-1003B

Figure 404. Dual Collective Controls (L/H Command)

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MAINTENANCE MANUAL

(7). Remove stick by sliding it outboard off

(1). Remove stick cover from seat structure.

torque tube.

(2). Disconnect pilot's collective stick

B. Pilot’s Collective Pitch Stick Installation

electrical plug.

(L/H Command)

(3). Remove attaching hardware that

Consumable Materials

secures guide to seat structure bracket.

(Ref. Section 91−00−00)

Item

Nomenclature

CM116

Grease, aircraft and instrument

Before disconnecting collec

WARNING

tive stick, install collective

bungee installation tool to prevent

(1).

Lubricate stick housing socket with

spring reaction due to droop stop load

grease (CM116).

on controls.

(2).

Install stick by sliding housing on

collective control interconnecting torque

(4). Install collective bungee installation

tube. Install bolts, washers and nuts.

tool (ST508).

Tighten nuts equally and by small

increments until correct torque is

(5). Remove collective bungee and inboard

applied.

collective socket. Disconnect droop

control override link (369D/E/FF -

(3).

Connect electrical plug.

500N only), slide bungee bracket to

(4).

Install outboard collective stick cover.

side, remove cradle cap and slide

Raise and lower stick; verify that

collective torque tube inboard.

wiring does not foul.

(6). Disconnect gas producer control rod.

(5).

Remove snap plug from exterior skin,

rotate throttle and visually check for

zero backlash between gas producer

(7). Remove attaching hardware that

interconnect torque tube and hexagonal

connects stick housing to torque tube.

interior surfaces of drive gearshaft in

stick housing. Eliminate any backlash

B. Pilot’s Collective Pitch Stick Installation

by tightening pipe plug in end of torque

(R/H Command)

tube; zero backlash is required at both

ends of tube.

Consumable Materials

(6).

Check that inboard stick socket gears

(Ref. Section 91−00−00)

are at mid-travel when pilot's stick

Item

Nomenclature

throttle grip is set to mid-travel. If not,

adjust collective stick gas producer

CM116

Grease, aircraft and instrument

control linkage.

Pilot’s Collective Pitch Stick Replacement

(1). Lubricate surfaces that are in contact

(R/H Command)

during rotation with grease (CM116).

(Ref. Figure 405)

(2). Ensure that pilot's and copilot's throttle

A. Pilot’s Collective Pitch Stick Removal

grips are in same relative positions.

(R/H Command)

Slide pilot's stick housing on collective

interconnecting torque tube, align

Special Tools

matching holes and secure stick to

(Ref. Section 91−00−00)

torque tube. Connect gas producer

Item

Nomenclature

control rod. Align and/or match bell

ST508

Collective bungee installation tool

crank centerline, gearshaft assembly

gear cutout and pilot's throttle.

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MAINTENANCE MANUAL

PILOT'S COLLECTIVE

COLLECTIVE

PITCH STICK COVER

FRICTION GUIDE

FLEXIBLE

CLOSURE

PILOT'S

THROTTLE

FRICTION

NUT

GAS PRODUCER INTERCONNECTING

GRIP

TORQUE TUBE

COLLECTIVE CONTROL

INTERCONNECTING

TORQUE TUBE

IDLE STOP

COLLECTIVE

RELEASE RING

STICK FRICTION

CONTROL

N₂ DROOP CONTROL

OVERRIDE LINK

PILOT'S COLLECTIVE

(369D/E/FF - 500N)

PITCH CONTROL STICK

COPILOT'S

NOTE 3

THROTTLE

COLLECTIVE PITCH

GRIP

CONTROL STICK

PLAIN

BUSHING

NOTE 1

SLOTTED

BUSHING

(NOTE 2)

BUSHING INSTALLATION

NOTES:

ARRANGE WASHERS TO LINE UP GUIDE WITH STICK; SPACE LOOSELY WITH

THREE WASHERS.

SLOTTED BUSHING MUST PROTRUDE A MINIMUM OF 0.010 INCH (0.254 MM) TO A

MAXIMUM OF 0.060 INCH (1.524 MM) AFTER BOLT IS TIGHTENED.

FOUR NUTS TORQUED; EQUALLY AND BY SMALL INCREMENTS.

ALLOWABLE FREE PLAY IN CO-PILOT'S TWIST GRIP IS ±5°.

G67-1004A

Figure 405. Dual Collective Controls (R/H Command)

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MAINTENANCE MANUAL

(3). Position friction guide in seat structure

(3). Remove hardware from stick tube

bracket with plain bushing, slotted

socket adapter and remove pitch stick

bushing, and three washers loosely

assembly by sliding it forward and off

spaced between bracket ears so guide is

the inboard stick housing.

in line (parallel) with stick. Install bolt,

B. Copilot’s Collective Pitch Stick

two washers, nut and new cotter pin.

Installation (L/H Command)

(4). Connect electrical plug.

Consumable Materials

(5). Perform operational check of collective

(Ref. Section 91−00−00)

stick friction and adjust friction

Item

Nomenclature

mechanism as necessary.

CM116

Grease, aircraft and instrument

(6). Install collective stick cover on seat

structure. Check that wiring is not

(1). Lubricate stick housing socket with

fouled when stick is raised and lowered.

grease (CM116).

8. Copilot’s Collective Pitch Stick

(2). Rotate pilot's or copilot's throttle grips

Replacement (L/H Command)

so that the grip attach bolts are down.

(Ref. Figure 406)

(3). Install copilot's stick socket adapter on

the inboard housing socket extension

A. Copilot’s Collective Pitch Stick Removal

and, while moving copilot's throttle

(L/H Command)

back and forth slightly to get engage

ment of the socket pinion and adapter

(1). Remove collective stick cover from seat

splines, slide the adapter into place.

structure.

(4). Install attaching hardware to secure

(2). Disconnect electrical plug.

socket adapter.

STICK ASSEMBLY

COLLECTIVE PITCH STICK ASSEMBLY

NOTE 2

0.030-0.150 IN.

NOTES:

(0.762-3.81 MM)

0.030-0.150 IN. (0.762-3.81 MM) MUST BE MAINTAINED BETWEEN

(NOTE 1)

STOP AND BRACKET WHEN PILOT COLLECTIVE CONTROL IS IN

FULL DOWN POSITION.

DOWNSTOP CLEARANCE

G67-1005A

LUBE SOCKET WITH GREASE BEFORE STICK INSTALLATION

Figure 406. CoPilot’s Collective Stick Assembly Installation (L/H Command)

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MAINTENANCE MANUAL

(5). Connect electrical plug.

backlash is required at both ends of

tube.

(6). Position downstop assembly. Check that

0.030-0.150 inch (0.762-3.302 mm)

NOTE: The R/H command configuration collec

clearance exists between downstop and

tive friction mechanism is the same as L/H

seat structure with collective pitch stick

command except no separate friction guard

in full down position.

is provided, since the pilot's collective pitch

cover also functions as a guard for the fric

(7). Install collective cover on seat struc

tion mechanism.

ture. Check that wiring is not fouled

when stick is raised and lowered.

10. Collective Control Interconnecting Torque

Tube Replacement

9. Copilot’s Collective Pitch Stick

(Ref. Figure 407)

Replacement (R/H Command)

A. Collective Control Interconnecting

(Ref. Figure 404)

Torque Tube Removal

A. Copilot’s Collective Pitch Stick Removal

(R/H Command)

Special Tools

(Ref. Section 91−00−00)

Remove copilot's collective stick according to

Item

Nomenclature

instructions in Pilot's Collective Pitch Stick

ST508

Collective bungee installation tool

Removal (L/H Command) except disregard

information on friction guide.

Before disconnecting collec

B. Copilot’s Collective Pitch Stick

WARNING

tive pitch control rod, install

Installation (R/H Command)

collective bungee installation tool to

prevent spring reaction due to droop

stop load on control rod.

Consumable Materials

(Ref. Section 91−00−00)

(1).

Install collective bungee installation

Item

Nomenclature

tool (ST508) and remove collective

CM116

Grease, aircraft and instrument

bungee.

(2).

Remove inboard collective socket

(1).

Lubricate stick housing socket with

assembly.

grease (CM116).

(3).

Disconnect aft end of droop control

(2).

Slide stick housing on collective control

override link (369D/E/FF - 500N only)

interconnecting torque tube. Align

from torque tube droop control bracket.

matching holes and install bushings,

(4).

Remove hardware securing bungee

bolts, washers and nuts. Tighten

support bracket reinforcement strap

equally and by small increments until

and torque tube to controls support

proper torque is applied.

bracket. Slide bungee bracket aside and

remove controls bracket cradle cap and

(3).

Install outboard collective stick cover.

reinforcement strap.

Secure electrical plug and check that

wiring will not foul when stick is raised

(5).

Slide collective control torque tube

and lowered.

sufficiently toward right side of seat

structure to remove pilot's collective

(4).

Remove snap plug from exterior skin,

pitch stick housing from end of tube.

rotate throttle and visually check for

zero backlash between gas producer

(6).

Remove hardware that connects stick

interconnect tube and hexagonal ID of

housing to torque tube.

drive gearshaft in stick housing.

Eliminate any backlash by tightening

(7).

Remove stick by sliding it outboard and

pipe plug in end of torque tube; zero

off torque tube.

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MAINTENANCE MANUAL

(8). Remove torque tube by sliding it

Position torque tube, controls bracket

approximately three inches toward

cradle cap, reinforcement strap and

right side of seat structure to disengage

bungee bracket on controls support

left end from support bearing inside left

bracket. Check that cap-to-cradle

torque tube support. Provide support at

index grooves are matched. Install with

seat structure lightening hole and care,

hardware removed. Apply thin layer of

fully withdraw torque tube from

grease (CM116) to sliding surfaces of

structure.

bungee overcenter fitting.

(9). Remove gas producer interconnect

(7). Install droop control override link

torque tube by carefully sliding it out of

(369D/E/FF - 500N only) to torque tube

collective torque tube.

droop control bracket.

B. Collective Control Interconnecting

(8). Install inboard collective socket

Torque Tube Installation

assembly.

(9). Complete installation of pilot's collec

Consumable Materials

tive stick.

(Ref. Section 91−00−00)

Item

Nomenclature

(10). Install collective bungee.

CM116

Grease, aircraft and instrument

11. Collective Bungee Replacement

(1). Install gas producer interconnect

(Ref. Figure 407)

torque tube by sliding it carefully into

place in collective control interconnect

A. Collective Bungee and Over−Center

ing torque tube.

Fitting − Removal

(2). Insert torque tube into lightening hole

in seat structure. Use care when

Special Tools

inserting tube into place to prevent

(Ref. Section 91−00−00)

scraping on edge of hole. Insert tube

Item

Nomenclature

only to a position that provides suffi

cient space between tube end and

ST508

Collective bungee installation tool

fuselage skin for installation of pilot's

stick housing on end of tube.

Before disconnecting collec

WARNING

(3). Lubricate pilot's stick housing with

tive pitch control rod, install

grease (CM116).

collective bungee installation tool to

prevent spring reaction due to droop

stop load on control rod.

(4). Slide pilot's stick housing on collective

control interconnecting torque tube.

(1). Remove pilot's seat cover from seat

NOTE: Stick housing must be placed on torque

structure.

tube before installing torque tube attaching

hardware.

(2). Raise collective stick and use torque

tube over-center action to compress

(5). Complete insertion of tube and position

bungee spring until bungee installation

left end of tube in fixed bearing bore.

tool (ST508) fits over spring retainers.

Rotate torque tube slowly back and

Secure tool halves in place with clamp.

forth until right end bearing rests in

cradle of controls support bracket.

(3). With stick in over-center position,

remove cotter pin, nut, washer and bolt

(6). Check that two slotted bushings are in

that secure male bearing to bungee

place in upper lugs of bungee bracket.

over-center fitting.

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CSP-HMI-2

MAINTENANCE MANUAL

FUSELAGE SKIN SNAP PLUG

COLLECTIVE CONTROL INTERCONNECTING

TORQUE TUBE

GAS PRODUCER INTERCONNECT

TORQUE TUBE

DROOP CONTROL

OVERRIDE LINK

BUSHING

BRACKET (NOTE 4)

(NOTE 1)

CLIP

N_R DISABLE SWITCH

(3 PLACES)

TORQUE TUBE

AND BRACKET (NOTE 4)

SUPPORT BEARING

0.30 IN. (7.62 MM)

ACTUATING CAM

(NOTE 3)

CONTROLS BRACKET CRADLE

(NOTE 4)

INDEX GROOVE

PIPE PLUG

NOTE 5

THREADED

TORQUE TUBE SUPPORT

CONTROLS

INSERT

BEARING

SUPPORT

INBOARD

BRACKET

COLLECTIVE

BUNGEE OVER-CENTER

GAS PRODUCER

STICK SOCKET

ADJUSTMENT BOLT

CONTROL ROD

ASSEMBLY

BUNGEE OVER-CENTER

FITTING

MALE BEARING

NOTE 2

SLOTTED

BUSHING

RETAINER

(NOTE 1)

SPRING

FEMALE

BEARING

ASSEMBLY

BUNGEE

(NOTE 2)

INSTALLATION TOOL

RETAINER

(NOTE 2)

NOTES:

EDGE OF BUSHING MUST PROTRUDE A MINIMUM

OF 0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.080 IN.

(2.032 MM) ABOVE OUTSIDE SURFACE OF PART

AFTER NUT IS TIGHTENED.

LUBRICATION POINTS FOR GREASE.

PRELIMINARY ADJUSTMENTS ONLY.

COMPRESSION TOOL

BUNGEE ASSEMBLY-EXPLODED VIEW

USED ON 369D/E/FF - 500N HELICOPTERS ONLY.

ROD AND CHANNEL

WITH COLLECTIVE STICK AT FULL DOWN POSITION,

PRELIMINARY ADJUSTMENT OF BUNGEE

INSTALLATION IS:

G67-1006B

369D/E/FF

500N; 2 20 ±0 05 IN (5 588 ±0 127 CM)

Figure 407. Collective Torque Tube, Gas Producer Torque Tube and Collective Bungee

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MAINTENANCE MANUAL

SNAP RING

GAS PRODUCER INTERCONNECT

N₁ PINION GEAR

TORQUE TUBE

AFT BEARING

(NOTE 4)

PIPE PLUG

SNAP RING

SLOTTED

BUSHING

CLIP

(3 PLCS)

SOCKET HOUSING

SPACER

(NOTE 1)

BEARING (NOTE 4)

BACKLASH SHIM

FORWARD BEARING

(NOTES 2, 4)

SHAFT ASSEMBLY

BACKLASH SHIM

BEARING

(NOTE 4)

LINK

N_R DISABLE SWITCH

(NOTE 3)

AND BRACKET

(NOTE 5)

ACTUATING CAM

(NOTE 5)

HOUSING CAP

IDLER

BELLCRANK

IDLER BEARING

(NOTE 4)

NOTES:

FOUR SPACERS USED ONLY ON REMOVED SOCKET ASSEMBLY TO KEEP ASSEMBLY INTACT.

N₁ PINION FORWARD BEARING IS LIGHT PRESS FIT IN HOUSING BORE.

LINK MUST BE BOLTED TO BELLCRANK BEFORE BELLCRANK AND SHAFT ASSEMBLY ARE INSTALLED.

BEARINGS INSTALLED WITH LOCKING COMPOUND. THE TWO SHAFT ASSEMBLY BEARINGS BONDED

ONLY AFTER SHIMMING FOR BACKLASH.

G67-1007B

Figure 408. Inboard Collective Stick Socket Assembly (L/H Command)

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CSP-HMI-2

MAINTENANCE MANUAL

(4). Remove cotter pin, nut, two washers

Do not turn female bearing as

CAUTION

and bolt that attach female bearing end

sembly spring retainer while

of bungee to the bungee bracket.

bungee installation tool is spring loaded.

(5). Remove collective bungee and installa

(6). Raise collective stick so that torque

tion tool as a unit.

tube over-center action compresses

spring until bungee installation tool can

(6). Remove cotter pin, nut and washer

be removed; remove tool.

from over-center fitting.

(7). With collective stick at full down

(7). Remove bolt that secure over-center

position, preliminary adjustment of

fitting to collective torque tube and

bungee installation is:

remove fitting.

369D/E/FF - 500N; 2.2 ±0.05 inch

(5.588 ±0.127 cm)

B. Collective Over−Center Fitting and

600N; 2.70 ±0.05 inch (6.86 ±0.127 cm).

Bungee − Installation and Preliminary

Adjustment

(8). Flight test helicopter and complete

adjustment of collective bungee.

Consumable Materials

12. Inboard Collective Stick Socket Assembly

(Ref. Section 91−00−00)

Replacement

Item

Nomenclature

(Ref. Figure 408)

CM116

Grease, aircraft and instrument

A. Inboard Collective Stick Socket Assembly

Special Tools

Removal

(Ref. Section 91−00−00)

(1). Remove pilot's seat cover and controls

Item

Nomenclature

access door.

ST508

Collective bungee installation tool

(2). Disconnect collective mixer tunnel-

routed control rod.

(1).

Lubricate sliding surfaces of over-cen

ter fitting with grease (CM116) and

(3). Disconnect gas producer control rod

position on collective torque tube.

from idler.

(2).

Install bolt and washer though fitting

(4). Remove N_R disable switch (369D/E/FF

and torque tube, and adjust to obtain

- 500N only) (Ref. Chap. 95).

0.30 in. (7.62 mm) preliminary adjust

(5). Remove four nuts and washers that

ment between upper surface of fitting

attach socket assembly to collective

and tips on torque tube fitting.

torque tube and remove assembly.

(3).

Install washer and nut on bolt and

NOTE: If disassembly is not intended, install

torque to 30 - 40 inch-pounds (3.39 -

four spacers and reinstall washers and nuts

4.52 Nm); install cotter pin.

on protruding bolts to keep assembly intact.

(4).

Position collective bungee, compressed

B. Inboard Collective Stick Socket Assembly

in installation tool (ST508), so that

Installation

female bearing assembly is forward and

aligns with mating hole in bungee

bracket. Check that slotted bushing for

Consumable Materials

bracket lug is in place, install bolt, two

(Ref. Section 91−00−00)

washers, nut and cotter pin.

Item

Nomenclature

CM318

Primer

(5).

Position male bearing to align with

mating hole in bungee over-center

fitting. Install bolt, washers, nut and

(1). Remove four nuts washers and spacers

install cotter pin.

from socket assembly mounting bolts.

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MAINTENANCE MANUAL

(2). With throttle grip on pilot's collective

(10). Connect gas producer control rod to

stick at midtravel, rotate bellcrank

idler.

back and forth slightly to engage socket

(11). Connect collective mixer tunnel-routed

assembly to gearshaft on hexagonal end

control rod.

of gas producer interconnect torque

tube. Bellcrank centerline, N₁ pinion

(12). Remove bungee installation tool.

gear centerline toothspace and pilot's

throttle must be as shown.

(13). Reinstall pilot's seat cover and the

controls access door.

NOTE:

(14). Check that inboard collective pitch stick

D With pilot's throttle grip at midtravel, two

socket gears are at midtravel when

grip attach bolts should be approximately

pilot's collective pitch stick throttle grip

straight down. Simultaneously, idler-to-

is set to midtravel. If not, adjust

gas producer control rod bolt holes should

collective pitch stick(s) gas producer

be in line with centerline of inboard stick

control linkage.

assembly housing cap.

D At midtravel, inboard N₁ pinion gear

(15). Adjust N_R disable switch (369D/E/FF -

spline wide toothspace should be at ap

500N only) (Ref. Chap. 95).

proximately one o'clock as viewed looking

aft into open end of socket.

13. Cyclic Control Stick Replacement

(Inboard)

(3).

Install N_R disable switch (369D/E/FF -

500N only) (Ref. Sec. 95) and secure

(Ref. Figure 409)

socket assembly housing to collective

A. Cyclic Control Stick Removal (Inboard)

torque tube.

(1). Disconnect control stick electrical plug.

(4).

Rotate pilot's throttle and check for zero

backlash between gas producer inter

(2). Remove hardware that secures pilot's

connect torque tube and hexagonal

lateral control rod to stick socket.

interior of drive gearshaft in socket

assembly housing.

(3). Remove hardware that attaches lateral

friction mechanism link to cyclic torque

(5).

Eliminate backlash by removing

tube.

housing cap and gearshaft, and then

removing pipe plug in end of torque

(4). Remove hardware that attaches stick

tube.

socket to end of cyclic torque tube;

remove stick with lateral friction

(6).

Coat pipe plug with wet zinc chromate

mechanism attached.

primer (CM318), reinstall and tighten it

B. Cyclic Control Stick Installation (Inboard)

so there is no backlash between torque

tube and control gearshaft at each end

(1). Position pilot's cyclic control stick to

of the tube.

align with mating holes in torque tube.

(7).

If the normally installed plug does not

(2). Install attaching hardware.

sufficiently expand tube, a 1/8-27

internal-wrenching pipe plug 0.38 inch

(3). Check that slotted bushing is in place;

(9.65 mm) long may be substituted.

then align pilot's lateral control rod

Whichever plug is used, it must not

with stick socket. Install attaching

protrude more than 0.030 inch (0.762

hardware.

mm) when tightened.

(4). Position guide link to align with mating

(8).

Zero degree backlash is required at

hole in torque tube. Install bolt, sleeve

both ends of tube.

bushing three washers, nut and cotter

pin.

(9).

After plug is tightened, reinstall

gearshaft and housing cap.

(5). Connect electrical plug.

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MAINTENANCE MANUAL

LATERAL CYCLIC

CYCLIC STICK

BELLCRANK

ASSEMBLY

STRAP

LATERAL CONTROL ROD

(NOTE 2)

QUICK RELEASE

NOTES:

EDGE OF BUSHING MUST PROTRUDE A MINIMUM

OF 0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.060 IN.

QUICK

(1.524 MM) ABOVE OUTSIDE SURFACES OF PART

RELEASE

AFTER NUT IS TIGHTENED.

SLOTTED BUSHING

CONTROL ROD END BEARINGS MUST NOT JAM

(NOTE 1)

THROUGHOUT FULL RANGE OF LONGITUDINAL

TRAVEL (34°).

G67-1008A

Figure 409. Cyclic Stick Assembly Installation (Inboard)

14. Cyclic Control Stick Replacement

(5). Remove stick tube from socket.

(Outboard)

B. Cyclic Control Stick Installation

(Ref. Figure 410)

(Outboard)

(1). Insert stick tube into stick socket and

A. Cyclic Control Stick Removal (Outboard)

install two quick-release pins.

(1). Disconnect control stick electrical plug.

NOTE: Omit steps (2). thru (4). when installing

stick without socket.

NOTE: Omit steps (2). and (3). below to remove

stick without removing stick socket.

(2). Position cyclic stick to align holes in

socket with mating holes in torque

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

tube.

bolt securing copilot's lateral control rod

to stick socket.

(3). Install bolt, two washers, nut and new

cotter pin.

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

bolt attaching stick socket to end of

(4). Check that slotted bushing is in place;

cyclic torque tube. Remove stick tube

then align copilot' s lateral control rod

with stick socket attached.

with stick socket. Install bolt, two

washers, nut and new cotter pin.

(4). Remove two quick-release pins attach

ing stick tube to stick socket.

(5). Connect electrical plug.

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MAINTENANCE MANUAL

CYCLIC PITCH

INTERCONNECTING

TORQUE TUBE

CYCLIC STICK

ASSEMBLY

ONE-WAY LOCK

ASSEMBLY

WASHER

LINK

STA. 67 LATERAL

CYCLIC BELLCRANK

LONGITUDINAL CONTROL

FRICTION MECHANISM

SLOTTED

BUSHING

(NOTE 1)

NOTES:

LATERAL CONTROL

EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF

ROD (NOTE 2)

FRICTION MECHANISM

SLEEVE

0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.080 IN. (2.032 MM)

ABOVE OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.

BUSHING

CONTROL ROD END BEARINGS MUST NOT JAM THROUGHOUT

G67-1009B

FULL RANGE OF LONGITUDINAL TRAVEL (34°)

Figure 410. Cyclic Stick Assembly Installation (Outboard)

15. Lateral Control Rods and Sta. 67 Lateral

between rod end bearing centers for use

Cyclic Bellcrank Replacement (L/H

at replacement.

Command)

B. Lateral Control Rods and Sta. 67 Lateral

(Ref. Figure 411)

Cyclic Bellcrank Installation (L/H

Command)

A. Lateral Control Rods and Sta. 67 Lateral

Cyclic Bellcrank Removal (L/H Command)

(1). Check that slotted bushing is in upper

(1). Remove large (central) cyclic stick

web of seat structure fitting. Align Sta.

guard.

67 lateral cyclic bellcrank and install

attaching hardware.

(2). Remove pilot's seat cover, and controls

access door from Sta. 78.50 canted

(2). Check that slotted bushings are in

bulkhead.

place and install Sta. 70 lateral control

rod and pilot's lateral control rod.

(3). Remove pilot's lateral control rod, or

Sta. 70 lateral control rod, as applica

(3). Move cyclic stick full forward, then full

ble.

aft and set pilot's lateral control rod end

bearing angularity so that bearings do

(4). Remove Sta. 67 lateral cyclic bellcrank

not jam at full travel positions.

from seat structure fitting.

(5). If rod or rod ends require replacement,

(4). If control rod or rod ends are replaced,

accurately measure and record distance

perform a cyclic control rigging check.

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MAINTENANCE MANUAL

NOTES:

ASTERISK (*) IDENTIFIES SLOTTED BUSHING. EDGE OF BUSHING

ELECTRICAL

MUST PROTRUDE A MINIMUM OF 0.010 IN. (0.254 MM) TO A

PLUG

MAXIMUM OF 0.060 IN. (1.524 MM) ABOVE OUTSIDE SURFACE

TUBE

CYCLIC STICK SOCKET

OF PART AFTER NUT IS TIGHTENED.

AND LATERAL FRICTION

WASHERS ARRANGED TO ALIGN LINK WITH TORQUE TUBE,

RIVET

INSTALLATION

LOOSELY SPACED WITH FOUR WASHERS.

CLAMP

SOCKET

CONTROL RODS MUST NOT JAM THROUGHOUT FULL

RANGE OF LONGITUDINAL TRAVEL (34°).

FRICTION STUD

INSTALLED WITH LOCKING COMPOUND.

FRICTION DISC

LATERAL GUIDE

RETAINER

NOTE 2

NUT

FRICTION

SPRING

FRICTION

KNOB

PILOT'S CYCLIC

STICK ASSEMBLY

PILOT'S CYCLIC

STICK GUARD

BUSHING

LONGITUDINAL

CONTROL FRICTION

MECHANISM

CYCLIC STICK GRIP

LATERAL

COPILOT'S CYCLIC

CONTROL

STICK ASSY

FRICTION

MECHANISM

ELECTRICAL PLUG

PILOT'S LATERAL

CONTROL ROD

(NOTE 3)

CYCLIC CONTROLS

CENTER GUARD

COPILOT'S CYCLIC

STICK GUARD

QUICK RELEASE PIN

FRICTION SPRING

FRICTION

KNOB

QUICK RELEASE

RETAINER

COUNTERSUNK

BOLT

FRICTION DISC

NUT

COUNTERSUNK

LATERAL

NOTE 2

WASHER

IDLER

BELLCRANK

FRICTION STUD

BEARING

LONGITUDINAL GUIDE

(NOTE 4)

SPRING

BUSHING

RIVET

STA 70 LATERAL

CONTROL ROD

LONGITUDINAL FRICTION INSTALLATION

PILOT'S LATERAL

STA 67 LATERAL CYCLIC

CONTROL ROD

BELLCRANK

LATERAL BELLCRANK CONNECTIONS

G67-1010A

Figure 411. Cyclic Controls (R/H Command)

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MAINTENANCE MANUAL

16. Lateral Control Rods and Sta. 67 Lateral

each end with a bolt, two washers, nut

Cyclic Bellcrank Replacement (R/H

and new cotter pin.

Command)

(3). Move both cyclic sticks full forward,

then full aft and set both lateral control

(Ref. Figure 411)

rods so that rod end bearings do not

jam at full throw positions; hold rod

A. Lateral Control Rods and Sta. 67 Lateral

ends and tighten jam nuts.

Cyclic Bellcrank Removal (R/H

Command)

(4). If control rod or rod ends were replaced,

perform cyclic control rigging check.

(1).

Remove cyclic stick guards.

(5). Install cyclic stick guards, pilot's

collective pitch stick cover, controls

(2).

Install large (central) cyclic stick guard

access door, and foot fairing.

pilot's seat cover and controls access

door.

17. Cyclic Pitch Interconnecting Torque Tube

Replacement (L/H Command)

(3).

Remove pilot's collective pitch stick

cover, and controls access door and left

(Ref. Figure 412)

foot support fairing from Sta. 78.50

canted bulkhead.

A. Cyclic Pitch Interconnecting Torque Tube

Removal (L/H Command)

(4).

Remove cotter pin, two washers and

bolt from each end of pilot's lateral

(1).

Remove pilot's seat cover.

control rod, copilot's lateral control rod,

or Sta. 70 lateral control rod, as

(2).

Position pilot's cyclic stick to align holes

applicable; remove rod assembly.

in one-way lock support links with bolt

that attaches forward end of one-way

(5).

Remove cotter pin, nut, two washers

lock to torque tube; tighten longitudinal

and bolt securing Sta. 67 lateral cyclic

friction. Disconnect rod end from torque

bellcrank to seat structure fitting;

tube arm.

remove bellcrank.

(3).

Remove pilot's cyclic stick.

(6).

If rod or rod ends require replacement,

accurately measure and record distance

(4).

Remove all of cyclic stick guard instal

between rod end bearing centers for

lation except small guard next to pilot's

future reference; use trammel method,

cyclic stick.

or equivalent.

(5).

Remove longitudinal control friction

mechanism.

B. Lateral Control Rods and Sta. 67 Lateral

Cyclic Bellcrank Installation (R/H

(6).

Remove pilot's lateral control rod from

Command)

Sta. 67 lateral cyclic bellcrank.

(1). Check that slotted bushing is in upper

(7).

Cut lockwire and remove support nuts,

web of seat structure fitting. Align Sta.

support bolts and two wide (L/H)

67 lateral cyclic bellcrank and install

support spacers from seat structure

bolt, two washers, nut and new cotter

fitting lugs and torque tube. Prevent

pin.

torque tube from dropping as bolts are

removed.

(2). Check that slotted bushings are in

place and install Sta. 70 lateral control

(8).

Remove torque tube and two narrow

rod. Install both lateral control rods at

(R/H) support spacers.

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MAINTENANCE MANUAL

NOTES:

CONTROLS

EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF

SUPPORT

0.010 IN. (0.254 MM) TO A MAXIMUM OF 0.080 IN. (2.032 MM)

BRACKET

ABOVE OUTSIDE SURFACE OF PART AFTER NUT IS TIGHTENED.

MAY BE INSTALLED IN EITHER DIRECTION.

MAY BE INTERCHANGED TO ALIGN ONE-WAY LOCK.

INSTALLED WITH GREASE ON OUTSIDE CIRCUMFERENCE.

INSTALLED WITH LOCKING COMPOUND.

SHIM WASHERS AS REQUIRED TO ALIGN ONE-WAY LOCK (REMOVE

SIDELOAD).

CAUTION:

DO NOT HAMMER RIVETS: SQUEEZE ONLY.

LONGITUDINAL IDLER

BELLCRANK

SHIM WASHER

(NOTE 6)

ONE-WAY

LOCK

SLOTTED BUSHING

(NOTE 1)

INPUT END

CYCLIC STICK

PIVOT BEARING

OUTPUT

END

SHIM WASHER

(NOTE 6)

SLOTTED BUSHING

CYCLIC PITCH

(NOTE 1)

SLEEVE

PIVOT BUSHING

INTERCONNECTING

BUSHING

SUPPORT LINK

TORQUE TUBE

SUPPORT BEARING

(NOTE 5)

FLANGE

RETAINER

BUSHING

SUPPORT BOLT

(NOTE 2)

SUPPORT SPACER,

0.20 IN. (5.08 MM) WIDE

CYCLIC STICK

(NOTE 3)

PIVOT BEARING

SUPPORT SPACER, 0.430 IN.

SUPPORT BEARING

(10.29 MM) WIDE

(NOTE 4)

SUPPORT NUT

SUPPORT

RIVET

NUT

RIVET

STUD

(SEE CAUTION)

SUPPORT SPACER,

0.260 IN. (6.60 MM) WIDE

SUPPORT BOLT

SPRING PIN

(NOTE 3)

(NOTE 2)

SUPPORT SPACER, 0.520 IN.

STUD (FRICTION

(13.21 MM) WIDE

MECHANISM) (TYPICAL)

G67-1011A

Figure 412. Cyclic Torque Tube and One−Way Lock Installation

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MAINTENANCE MANUAL

B. Cyclic Pitch Interconnecting Torque Tube

one-way lock support links; install

Installation (L/H Command)

attaching hardware.

(9). Install pilot's seat cover.

Consumable Materials

(Ref. Section 91−00−00)

18. Cyclic Pitch Interconnecting Torque Tube

Item

Nomenclature

Replacement (R/H Command)

CM702

Lockwire CRES

(Ref. Figure 411)

A. Cyclic Pitch Interconnecting Torque Tube

(1). Align cyclic torque tube support

Removal (R/H Command)

bearings with holes in structure fitting

Removal of torque tube is essentially the same

lugs. Place narrow support spacer on

as L/H command except note the following:

right side of each support bearing, and

install two wide support spacers and

(1). Remove pilot's collective pitch stick

support bolts.

cover.

NOTE: Support bolts may be installed from ei

(2). Remove pilot's cyclic stick and copilot's

ther direction, and two narrowest (R/H) sup

cyclic stick.

port spacers are to be interchanged for best

(3). Remove cyclic stick guards.

alignment of torque tube with one-way lock.

(4). Remove longitudinal control friction

(2).

Check that slotted bushing is in torque

mechanism.

tube arm, and fit one-way lock rod end

against unbushed lug of arm. If tighten

(5). Remove both lateral control rods from

ing of attachment bolt will apply

Sta. 67 lateral cyclic bellcrank.

sideload on the rod end, interchange

B. Cyclic Pitch Interconnecting Torque Tube

two narrowest (R/H) support spacers,

Installation (R/H Command)

and/or adjust lateral position shimming

of longitudinal idler bellcrank or

Installation of torque tube is essentially the

one-way lock rod ends until there is no

same as L/H command except note the

sideload on one-way lock control

following:

system. Check that no structural

interference results from spacer

(1). Install pilot's and copilot's lateral

interchange.

control rods (riveted rod ends) to Sta.

67 lateral cyclic bellcrank.

(3).

Without sideload on one-way lock,

(2). Install longitudinal control friction

install and tighten support nuts. Using

mechanism.

lockwire (CM702), safetywire each nut

to hole in threaded end of mating bolt.

(3). Install cyclic stick guards.

When installing lockwire do not

damage aluminum nut and bolt.

(4). Install pilot's cyclic stick and copilot's

cyclic stick.

(4).

Install pilot's lateral control rod (riveted

(5). Install pilot's collective pitch stick

rod) end to Sta. 67 lateral cyclic

cover.

bellcrank.

19. One−Way Lock Replacement

(5).

Install longitudinal control friction

mechanism.

(Ref. Figure 412)

(6).

Install cyclic stick guards.

A. One−Way Lock Removal

(7).

Install pilot's cyclic stick.

(1). Remove pilot's seat cover or inboard

collective pitch stick cover and controls

(8).

Position pilot's cyclic stick to align bolt

access door from Sta. 78.50 canted

holes in torque tube arm with holes in

bulkhead.

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MAINTENANCE MANUAL

(2). Remove cyclic stick guard.

NOTE: Two narrowest (R/H) cyclic torque tube

support spacers may also be interchanged to

(3). Position pilot's cyclic stick to align holes

align one-way lock.

in one-way lock support links with bolt

(7). Without sideload on one-way lock,

that attaches forward end of one-way

secure each rod end bearing with

lock to cyclic torque tube; tighten

attaching hardware.

longitudinal friction. Disconnect rod

end from torque tube arm.

(8). Check reservoir fluid level (Ref. Sec.

12-00-00).

(4). Disconnect one-way lock lower rod end

from longitudinal idler bellcrank.

(9). Install cyclic stick guard.

(5). Disconnect upper end of each support

(10). Install pilot's seat cover or inboard

link from seat structure and remove

collective pitch stick cover and control

one-way lock with links attached.

access door.

(6). Remove two cotter pins, washers and

20. Cyclic Trim Actuator Replacement

links. Do not remove pivot bushings

(Ref. Figure 403)

from links unless replacement is

necessary.

A. Cyclic Trim Actuator Removal

B. One−Way Lock Installation

(1). Jack helicopter (Ref. Sec. 07-00-00)

until landing gear is fully extended and

(1).

Check that rod end bearing center-to-

clears ground.

center distance is correct.

(2). Remove foot fairing, controls access

(2).

Attach lower ends of links to one-way

door from Sta. 78.50 canted bulkhead

lock with bushings, washers and cotter

and open pilot's compartment floor

pins.

access door.

(3). Disconnect bonding jumper and

(3).

Align upper ends of links with mating

electrical connector from actuator

holes in seat structure fitting and

housing.

attach each link with bolt, sleeve

bushing, washer, nut and cotter pin.

(4). Disconnect upper end of trim actuator.

Keep pivot bushing with actuator

(4).

Check that slotted bushing is in place

unless actuator is being replaced.

in longitudinal idler bellcrank; then fit

lower rod end bearing against un

(5). Disconnect lower end of trim actuator.

bushed lug of bellcrank to check if

Access to attaching nut is through hole

sideloading occurs when attachment

in under-floor compartment aft

bolt is tightened. There must be no

bulkhead, near centerline beam.

sideloading of one-way lock mecha

(6). Remove trim actuator. Reinstall

nism. Arrange shim washers, as

original lower end attaching hardware

necessary, to position longitudinal idler

if actuator is being replaced; new

bellcrank and/or lower rod end for

actuator includes this hardware.

alignment without sideload.

B. Cyclic Trim Actuator Installation

(5).

Position pilot's cyclic stick to align holes

in support links with hingeline for

(1). Check trim actuator spring assembly

upper end of one-way lock and cyclic

for free play between spring and spring

torque tube arm; tighten longitudinal

adapters. Adjust spring adapter screw

friction.

until 0.010-0.050 inch (0.254-1.27 mm)

is felt while pushing or pulling on

(6).

Repeat check for sideload on one-way

spring assembly.

lock, step (4)., and arrange shim

washers, if necessary, to position upper

(2). Remove hardware supplied in housing

rod end for alignment without sideload.

end of new trim actuator.

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MAINTENANCE MANUAL

(3). Check that slotted bushings are in

NOTE: Lateral actuator upper hingeline has

place in actuator housing. Place one

3/16 inch (4.7625 mm) bolt hole; longitudi

washer around each side of pivot

nal has 1/4 inch (6.35 mm) bolt hole.

bearing in center beam support lug and

align actuator housing with bearing.

(5). Connect bonding jumper. Connect

Install bolt, two washers and nut (and

electrical plug to actuator.

cotter pin if old style).

(6). With main rotor blades lifted off droop

(4). Align actuator with idler bellcrank.

stops, perform power-on operational

Check that slotted bushing is in

check of cyclic trim actuator. Actuator

bellcrank lug; install actuator pivot

must not bind throughout travel range

bushing if actuator is a replacement.

in either direction, and must maintain

Pivot bushing must rotate freely in

at least 0.015 inch (0.381 mm)minimum

actuator. Install bolt, two washers, nut

clearance with center beam structure.

and cotter pin. After bolt is tightened,

pivot bushing must not rotate in idler

bellcrank.

(7). Lower helicopter and remove jacks.

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MAINTENANCE MANUAL

MAIN ROTOR FLIGHT CONTROLS

ADJUSTMENT/TEST

1. Cyclic and Collective Control System

(2). Release friction and raise pilot's

Rigging

collective stick. Position collective

rigging fixture (ST501) in outboard

Rigging of the main rotor control system must

lower end of slot in collective friction

be accomplished immediately after replace

guide link (view C).

ment of linkage that cannot be accurately

measured (by trameling, etc.) before it is

(3). Lower collective stick on rigging fixture

installed in the main rotor control system, or if

and tighten friction grip (drive gear).

helicopter operation reveals rigging deficiency.

(4). Position mixer rigging plate (ST503) on

NOTE:

mast support fitting.

D Cyclic and collective controls must be

rigged in sequence, starting with collec

NOTE: When installing the mixer rigging plate

tive controls. Control rod end bearing ad

on the 500N helicopter, removal of the split

justments are to be made to nearest half

ter bungee and bracket is required. (Ref. Sec

turn that produces correct rigging. When

67-20-30).

tightening jam nut at adjustable end of

control rods, always hold rod end with

wrench to prevent jamming of bearing.

(5).

Measure and record distance from

horizontal centerline of mast support

D On the 600N helicopter, make all rigging

bracket hingeline bolt (attaching

adjustments using the roof-mounted con

longitudinal idler bellcrank and

trol rods.

collective pitch mixer bellcrank to mast

D On the 600N helicopter, tunnel-routed

support bracket) to surface of mixer

control rods should only be adjusted if a

plate (view A). This dimension shall be

flight control component, forward of the

used as the basic dimension in rigging

roof-mounted bellcranks, has been re

the mixer controls.

placed.

(6).

Measure distance from horizontal

2. Collective Controls Rigging (L/H

centerline of bolt that attaches collec

Command) (369D/E/FF − 500N)

tive pitch mixer bellcrank to longitudi

nal pitch mixer bellcrank (view B) to

(Ref. Figure 501)

surface of mixer rigging plate; it should

be same as basic dimension recorded in

step (5). above. If not, loosen checknut,

Special Tools

disconnect upper end of collective

(Ref. Section 91−00−00)

control rod and adjust rod end (to

Item

Nomenclature

nearest half-turn of rod end bearing)

ST501

Collective rigging fixture

until dimensions are equal.

(LH command)

ST503

Mixer rigging plate

(7).

Reconnect control rod, remove collective

stick rigging fixture and check mixer

travel. With stick at down stop, center

(1). Remove main rotor blades, or manually

line of collective pitch mixer bellcrank

raise blades off droop stops by simulta

bolt (view B) should move down so that

neously lifting blade tips. All five blades

dimension recorded in step (5). above

must be off stops during rigging.

decreases not less than 0.74 inch

Padded supports should be used.

(18.796 mm).

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MD Helicopters, Inc.

MAINTENANCE MANUAL

0.75 IN. (19.05 MM)

1.190 IN.

(30.226 MM)

FWD

0.45 IN. (11.43 MM)

0.74 IN.

0.76 IN. (19.304 MM)

1.190 IN.

(18.796 MM)

(30.226 MM)

0.43 IN.

2.25 IN.

(10.922 MM)

0.74 IN. (18.796 MM)

(57.15 MM)

0.43 IN. (10.922 MM)

REF

NOM

0.57 IN.

0.50 IN. (12.70 MM)

0.74 IN. (18.796 MM)

(14.478 MM)

0.50 IN.

0.57 IN.

1.92 IN. (48.564 MM) REF

0.74 IN.

(12.70 MM)

(14.478 MM)

(18.796 MM)

LFT

AFT

SIDE VIEW

0.32 IN.

1.05 IN

FRONT VIEW

(26.67MM)

(8.128 MM)

0.125 IN.

2.25 IN. (57.15 MM)

(3.175 MM)

1.00 IN.

GENERAL NOTES FOR BUILDING FIELD RIGGING AID:

(25.4 MM)

MAKE FROM T-ANGLE STOCK TO DIMENSIONS SHOWN.

SCREWS, NUTS AND WASHERS AS REQUIRED.

HOLES IN VERTICAL T-ANGLE TO BE SLOTTED TO ADJUST

2.25 IN.

TO MIXER SUPPORT BOLT NOMINAL DIMENSION.

(57.15 MM)

SCRIBE MARKING ON VERTICAL T-ANGLE AS SHOWN.

MANUFACTURE FROM 2024-T4 AL ALY PLATE.

IMPRESSION STAMP PART NO. AND INSTRUCTIONS.

SURFACE TO BE FLAT AFTER STAMPING.

TOP VIEW

0.81 IN. (20.57 MM)

.09 R

0.375 IN. (9.525 MM)

NOTE 5

1.75 IN. (44.45 MM)

6.71 IN. (170.43 MM)

1.12 IN. (28.45 MM)

1.75 IN. (44.45 MM)

NOTE 6

2.75 IN. (69.85 MM)

369A9930

THIS SIDE UP

4.18 IN.

(106.17 MM)

2.18 IN. (55.37 MM)

.09 R

8.56 IN. (217.42 MM)

90°

11.38 IN. (289.05 MM)

2.18 IN. (55.37 MM)

0.94 IN. (23.88 MM)

FIELD RIGGING AID

G67-1012-3E

Figure 501. Main Rotor Control System Rigging (369D/E/FF − 500N) (Sheet 3 of 3)

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MAINTENANCE MANUAL

0.75 IN. (19.05 MM)

1.05 IN.

0.75 IN. (19.05 MM)

(26.67 MM)

FWD

0.48 IN. (12.192 MM)

1.05 IN.

0.83 IN.

0.79 IN. (20.066 MM)

(26.67 MM)

(21.082 MM)

0.37 IN

2.25 IN.

(9.398 MM)

(57.15 MM)

0.83 IN. (21.082 MM)

REF

0.37 IN (9.398

NOM

0.65 IN.

0.52 IN. (13.208 MM)

0.71 IN. (18.034 MM)

0.52 IN.

(16.51 MM)

0.65 IN.

(13.208 MM)

0.71 IN.

(16.51 MM)

LFT

(18.034 MM)

AFT

0.50 IN. (12.7 MM)

0.29 IN.

FRONT VIEW

SIDE VIEW

(7.366 MM)

0.125 IN.

2.25 IN. (57.15 MM)

(3.175 MM)

1.00 IN.

(25.4 MM)

GENERAL NOTES FOR BUILDING FIELD RIGGING AID:

2.25 IN.

MAKE FROM T-ANGLE STOCK TO DIMENSIONS SHOWN.

(57.15 MM)

SCREWS, NUTS AND WASHERS AS REQUIRED.

HOLES IN VERTICAL T-ANGLE TO BE SLOTTED TO ADJUST

TO MIXER SUPPORT BOLT NOMINAL DIMENSION.

SCRIBE MARKING ON VERTICAL T-ANGLE AS SHOWN.

MANUFACTURE FROM 2024-T4 AL ALY PLATE.

IMPRESSION STAMP PART NO. AND INSTRUCTIONS.

SURFACE TO BE FLAT AFTER STAMPING.

TOP VIEW

0.375 IN. (9.525 MM)

0.81 IN. (20.57 MM)

.09 R

NOTE 5

1.75 IN. (44.45 MM)

6.71 IN. (170.43 MM)

1.12 IN. (28.45 MM)

1.75 IN. (44.45 MM)

NOTE 6

2.75 IN. (69.85 MM)

369A9930

THIS SIDE UP

4.18 IN.

(106.17 MM)

2.18 IN. (55.37 MM)

.09 R

8.56 IN. (217.42 MM)

90°

11.38 IN. (289.05 MM)

2.18 IN. (55.37 MM)

0.94 IN. (23.88 MM)

FIELD RIGGING AID

6G67-037-3B

Figure 502. Rigging Main Rotor Control System (600N) (Sheet 3 of 3)

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MAINTENANCE MANUAL

NOTE: To facilitate field rigging of the collec

used in inboard lower end of collective friction

tive control (up and down) and the cyclic

guide slot.

control (both forward and aft, and right and

left) a field rigging aid may be fabricated as

4. Collective Control System Rigging (L/H

illustrated (Ref. Figure 501, Sheet 3). If the

Command) (600N)

mixer bellcranks are in dimension with ref

(Ref. Figure 502)

erence to the mixer rigging plate (ST503)

the collective and cyclic controls are proper

ly rigged. The dimension attained in steps

Special Tools

(7). and (8). shall correspond to the dimen

(Ref. Section 91−00−00)

sions marked on the field rigging aid. If the

Item

Nomenclature

dimensions attained do not correspond, full

ST501

Collective rigging fixture

rigging procedures must be performed.

(LH command)

ST503

Mixer rigging plate

(8). With stick at up stop, centerline of

ST504

Longitudinal rigging fixture

collective pitch mixer bellcrank bolt

(LH command)

should move up so that dimension

ST506

Lateral rigging fixture

recorded in step (5). above increases

(LH command)

minimum of 0.74 inch (18.796 mm).

ST511

Test fixture

Do not adjust control rod end be

CAUTION

(1). Remove main rotor blades, or manually

yond witness hole. Tighten jam

raise blades off droop stops by simulta

nut after final adjustment. Failure to ob

neously lifting blade tips. All six blades

serve this precaution can result in parts

must be off stops during rigging.

damage and/or equipment failure.

Padded supports should be used.

(9). If necessary, adjust rod end of collective

(2). Release friction and raise pilot's

pitch control rod to meet limits speci

collective stick. Position collective

fied in steps (7). and (8). above. When

rigging fixture (ST501) in outboard

adjustment is complete, tighten jamnut

lower end of slot in collective friction

and make certain that length of control

guide link (view C).

rod does not change.

NOTE: The collective bungee has very high

(10). Remove mixer rigging plate. On the

over-center spring pressure. Ensure collec

500N helicopter reinstall the spitter

tive stick is fully seated on rigging fixture or

bungee and bracket. (Ref. Sec

rigging may not be correct.

67-20-30).

(3). Lower collective stick on rigging fixture

(11). Reconnect collective pitch control rod.

and tighten friction lock.

3. Collective Controls Rigging (R/H

(4). Adjust longitudinal cyclic trim for

Command) (369D/E/FF − 500N)

no-load and install longitudinal cyclic

rigging fixture (ST504) (Ref. View D).

(Ref. Figure 501 and Figure 503)

(5). Adjust lateral cyclic trim for no-load

and install lateral cyclic rigging fixture

Special Tools

(ST506) (Ref. View E).

(Ref. Section 91−00−00)

Item

Nomenclature

NOTE: For both longitudinal and lateral cyclic

ST502

Collective rigging fixture

rigging fixtures, ensure that the bolt of the

(RH command)

friction lock is engaged in the slot of the rig

ging fixture and that the hook of the fixture

is properly engaged with the checknut tight

Collective control rigging for the R/H command

ened.

helicopter is accomplished according to

instructions for L/H command helicopters,

(6). Position mixer rigging plate (ST503) on

except collective rigging fixture (ST502) is

mast support fitting.

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NOTE: To facilitate field rigging of the collec

(a). With collective stick at down-stop,

tive control (up and down) and the cyclic

centerline of bolt in collective bell

control (both forward and aft and right and

crank (369N2664) shall move down a

left) a field rigging aid may be fabricated as

minimum of 0.71 inch (18.0 mm)

illustrated (Ref. Figure 502, Sheet 3). If the

below nominal setting.

mixer bellcranks are in dimension with ref

(b). With collective stick at up-stop,

erence to the mixer rigging plate (ST503)

centerline of bolt in collective bell

the collective and cyclic controls are proper

crank (369N2664) shall move up a

ly rigged. The dimension attained in the fol

minimum of 0.83 inch (21.0 mm)

lowing paragraphs shall correspond to the

above nominal setting.

dimensions marked on the field rigging aid.

If the dimensions attained do not corre

5. Collective Controls Rigging (R/H

spond, full rigging procedures must be per

Command) (600N)

formed.

(Ref. Figure 502 and Figure 503) Collective

control rigging for the R/H command helicopter

(7). Using a six inch (16 cm) scale, measure

is accomplished according to instructions for

and record distance from rigging

L/H command helicopters, except the following

plate-to-collective hinge bolt center,

rigging fixtures must be substituted.

this is your nominal setting, or, position

test fixture (ST511) on rigging plate

Special Tools

and adjust NOM indicator to centerline

(Ref. Section 91−00−00)

of collective hinge bolt.

Item

Nomenclature

ST502

Collective rigging fixture

Do not allow test fixture points

CAUTION

(RH command)

to scribe or mark the bolts.

ST503

Mixer rigging plate

ST505

Longitudinal rigging fixture

NOTE: Do not change the setting of the test fix

(RH command)

ture. This setting will be the basic NOMI

ST507

Lateral rigging fixture

NAL for locating, to the nearest half turn of

(RH command)

the respective control rod end fitting, the

ST511

Test fixture

height of the bolts.

(a). Adjust collective control rod so

6. Cyclic Controls Rigging (L/H Command)

centerline of bolt of the collective

(369D/E/FF − 500N)

bellcrank (369N2664) is at NOM, to

(Ref. Figure 501)

nearest half-turn on rod end bearing.

Special Tools

(b). Adjust longitudinal control rod so

(Ref. Section 91−00−00)

centerline of bolt of the longitudinal

Item

Nomenclature

bellcrank (369N2666) is at NOM, to

ST501

Collective rigging fixture

nearest half-turn on rod end bearing.

(LH command)

ST503

Mixer rigging plate

(c). Adjust lateral control rod so center

ST504

Longitudinal rigging fixture

line of bolt of the lateral bellcrank

(LH command)

(369N2670) is at NOM, to nearest

ST506

Lateral rigging fixture

half-turn on rod end bearing.

(LH command)

(8). Remove collective rigging fixture and

check travel as follows:

NOTE: All cyclic control rigging is done with

collective controls at mid-position.

NOTE: Adjust rod end, as required, to obtain

(1). Remove main rotor blades, or manually

the following limits.

raise blades off droop stops by simulta

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neously lifting blade tips. All five blades

NOTE: Field rigging aid (Ref. Figure 501,

must be off stops during rigging.

Sheet 3) may be used to check dimensions

Padded supports should be used.

attained in steps (4). and (5).. If dimensions

attained do not correspond with dimensions

(2).

Release friction and raise pilot's

shown on rigging aid, full rigging proce

collective stick. Position collective

dures must be performed.

rigging fixture (ST501) in outboard

(9). Reposition mixer rigging plate to clear

lower end of slot in collective friction

longitudinal pitch mixer bellcrank.

guide link (view C).

With stick at aft stop, centerline of

(3).

Lower collective stick on rigging fixture

longitudinal pitch mixer bellcrank bolt

and tighten friction grip (drive gear).

(view B) should move down so that

basic dimension recorded in step (3).

(4).

Position mixer rigging plate (ST503) on

above decreases minimum of 0.570 inch

mast support fitting.

(14.478 mm).

(5).

Loosen longitudinal friction knob and

Do not adjust control rod beyond

CAUTION

set longitudinal cyclic trim for no load

witness hole. Tighten jamnut af

by neutralizing cyclic stick. Position

ter final adjustment. Failure to observe this

cyclic stick so that longitudinal rigging

precaution can result in parts damage and/

fixture (ST504) fits in outboard side of

or equipment failure.

slot in longitudinal friction guide link.

(10).

If necessary, adjust rod end of longitudi

(Index pin of fixture butts against

nal pitch control rod to meet limits

forward end of slot, and friction knob

specified in steps (4). and (5). above.

stud fits in fixture detent - view F.)

Adjust carefully; tolerance is only 1/2

turn. When adjustment is complete,

(6).

Secure fixture hook in aft end of slot.

tighten jamnut and ensure that length

Tighten knurled thumbnut to seat

of control rod does not change.

bushing at forward end and tighten

friction knob.

(11).

Reconnect control rod to longitudinal

pitch idler.

(7).

Measure and record distance from

horizontal centerline of bolt at aft end

(12).

Reinstall longitudinal rigging fixture;

of longitudinal pitch mixer bellcrank

reposition and secure mixer rigging

(view H) to surface of mixer rigging

plate.

plate. It should be same as distance

(13).

Loosen friction knob and set lateral

from horizontal centerline of mast

cyclic trim for no load by neutralizing

support bracket hingeline bolt to

cyclic stick. Position cyclic stick so that

surface of mixer plate (Ref. Collective

lateral rigging fixture (ST506) fits in

Controls Rigging (L/H Command), step

forward side of slot in lateral friction

(5).). If not, loosen jamnut, disconnect

guide link. (Index pin of fixture butts

longitudinal pitch control rod and

against outboard end of slot, and

adjust rod end, to nearest half turn of

friction knob stud fits in fixture detent

rod end bearing, until dimensions are

- view E.)

equal. This will be basic dimension for

cyclic control rigging.

(14).

Secure fixture hook in inboard end of

slot, tighten knurled thumbnut to seat

(8).

Reconnect control rod, remove longitu

bushing at outboard end, and tighten

dinal stick rigging fixture and check

friction knob.

mixer travel. With stick at forward

stop, centerline of longitudinal pitch

(15).

Measure distance from horizontal

mixer bellcrank bolt (view B) should

centerline of bolt connecting lateral

move up so that basic dimension

bellcrank to stationary swashplate

recorded in step (7). above is increased

mixer link to (view D) surface of mixer

minimum of 1.19 inches (3.0226 cm), or

rigging plate; it should be same as basic

a maximum of 1.22 inches (3.0988 cm).

dimension recorded in step (3).. If not,

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loosen checknut, disconnect lateral

Check for interference between

CAUTION

pitch control rod and adjust rod end (to

rod end bearings and lugs of

nearest half-turn on rod end bearing)

pitch control housing. Adjust bearings as re

until dimensions are equal.

quired to provide clearance.

NOTE: Next step establishes initial adjust

ment of main rotor pitch controls links. Fi

(16). Reconnect control rod, remove lateral

nal adjustment is to be made by tracking

stick rigging fixture and check mixer

and autorotation rpm setting (Ref. Sec.

travel. With stick at left stop, centerline

18-10-00).

of lateral bellcrank bolt (view D) should

move down so that basic dimension

(21).

Remove and adjust length of each pitch

recorded in step (3). decreases a

control link (view G) so that centerline-

minimum of 0.50 inch (12.70 mm) or a

to-centerline distance between rod-end

maximum of 0.53 inch (13.462 mm).

bearings is 6.25 inches (15.875 cm).

Then install the pitch control links.

NOTE: The field rigging aid (Ref. Figure 501,

(22).

With collective stick full down and

sheet 3) may be used to check dimensions

cyclic stick full forward and full left,

attained in steps (12). and (13).. If the di

check clearance between the rotating

mensions attained do not correspond with

swashplate and the longitudinal pitch

dimensions shown on the rigging aid, full

idler bellcrank. Minimum clearance is

rigging procedures must be performed.

0.125 inch (3.175 mm). Adjust the

collective control rod as required.

(17). With stick at right stop, centerline of

(23).

With collective stick full up and cyclic

lateral bellcrank bolt should move up so

stick full left (any position fore or aft),

that basic dimension recorded in step

check clearance between lateral

(3). increases minimum of 0.43 inch

bellcrank and, collective pitch mixer

(10.922 mm).

bellcrank of the mixer controls. Mini

mum clearance is 0.030 inch (0.762

mm). Adjust lateral control rod as

Do not adjust control rod beyond

required.

CAUTION

witness hole. Tighten jamnut af

(24).

With collective stick full down and

ter final adjustment. Failure to observe this

cyclic stick full aft, check clearance

precaution can result in parts damage and/

between the aft longitudinal bellcrank

or equipment failure.

and the mast base. Minimum clearance

is 0.030 inch (0.762 mm). Adjust

longitudinal control rod (preferably) or

(18). If necessary, adjust rod end of lateral

collective control rod as required.

pitch control rod to meet limits speci

fied in steps (12). and (13). above. When

(25).

With collective stick full up and cyclic

adjustment is complete, tighten jamnut

stick full forward and full left, check

and make certain that length of control

clearance between rotating swashplate

rod does not change.

and scissors fitting. Also check clear

ance between scissors rotating link and

lower hub shoe. Minimum clearance in

(19). Reconnect control rod to lateral bell

both cases is 0.030 inch (0.762 mm).

crank.

Rotate hub 360 degrees to determine

location of minimum clearance. Adjust

collective control rod as required.

(20). Loosen friction control, friction knob,

knurled thumbnuts and hooks of

(26).

Repeat step (21). above with collective

rigging fixture and remove all three

stick full up and cyclic stick full forward

fixtures.

and full right.

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(27).

With collective stick full up and cyclic

(2). Use lateral rigging fixture (ST507) on

stick full aft and full left, check clear

forward side of lateral friction guide,

ance between scissors link and edge of

with fixture cutout positioned over

pocket in rotating swashplate. Mini

friction knob stud (view C). Secure

mum clearance is 0.006 inch (0.1524

fixture hook in lower inboard end of

mm). Rotate hub 360 degrees to

slot, tighten knurled thumbnut to seat

determine location of minimum clear

bushing at upper outboard end and

ance. Repeat clearance check with

tighten lateral friction knob.

cyclic stick full aft and full right.

8. Cyclic Controls Rigging (L/H Command)

(28).

Repeat steps (17). thru (22). above to

(600N)

recheck all clearances.

(Ref. Figure 502)

(29).

Repeat steps (7). of Collective Controls

Rigging, step (4)., and steps (9). thru

Special Tools

(15). of Cyclic Controls Rigging, to

(Ref. Section 91−00−00)

recheck mixer control motion travels

Item

Nomenclature

and see that minimums are met.

ST501

Collective rigging fixture

(LH command)

(30).

Install main rotor blades or remove

supports and simultaneously lower all

ST503

Mixer rigging plate

five blades to normal position.

ST504

Longitudinal rigging fixture

(LH command)

(31).

Track main rotor blades and adjust

ST506

Lateral rigging fixture

autorotation rpm (Ref. Sec. 18-10-00).

(LH command)

7. Cyclic Controls Rigging (R/H Command)

NOTE: All cyclic control rigging is done with

(369D/E/FF − 500N)

collective stick on rigging fixture.

(Ref. Figure 501 and Figure 503) Rigging of

(1). Remove main rotor blades, or manually

cyclic controls for the R/H command helicopter

raise blades off droop stops by simulta

is accomplished according to instructions for

neously lifting blade tips. All six blades

L/H command helicopters except as follows:

must be off stops during rigging.

Padded supports should be used.

Special Tools

(2). Release friction and raise pilot's

(Ref. Section 91−00−00)

collective stick. Position collective

Item

Nomenclature

rigging fixture (ST501) in outboard

ST505

Longitudinal rigging fixture

lower end of slot in collective friction

(RH command)

guide link (view C).

ST507

Lateral rigging fixture

(3). Lower collective stick on rigging fixture

(RH command)

and tighten friction grip (drive gear).

(4). Adjust lateral cyclic trim for no-load

(1). Use longitudinal rigging fixture

and install lateral cyclic rigging fixture

(ST505) on outboard side of longitudi

(ST506).

nal friction guide, with fixture cutout

positioned over friction knob stud.

(5). Position mixer rigging plate (ST503) on

Bushing end of fixture butts against

mast support fitting.

upper end of slot in guide (Ref.

Figure 503, view B). Secure fixture

(6). Check longitudinal travel as follows:

hook in lower end of slot, tighten

knurled thumbnut to seat bushing at

NOTE: Adjust rod end, as required, to obtain

upper end, and tighten friction knob.

the following limits.

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(a). With cyclic stick at forward stop,

(369N2670). The minimum allowable

centerline of bolt in longitudinal

clearance shall be 0.125 inch (3.175

bellcrank (369N2666) shall move up

mm). Adjust collective control rod as

a minimum of 1.05 inches (26.67 mm)

required.

above centerline of collective hinge

(13).

With collective stick full up and cyclic

bolt. Reposition mixer plate to clear

stick full left (any position fore and aft),

longitudinal bellcrank.

check for interference between lateral

(b). With cyclic stick at aft stop, center

bellcrank (369N2670) and collective

line of bolt in bellcrank (369N2666)

bellcrank (369N2664) of mixer controls.

shall move down a minimum of 0.65

When there is interference, lengthen

inch (16.51 mm) below centerline of

lateral mixer control rod (369A7012) to

collective hinge bolt.

maintain a minimum allowable clear

ance of 0.030 inch (0.762 mm).

(7). Adjust longitudinal cyclic trim for

(14).

With collective stick full down and

no-load and install longitudinal cyclic

cyclic stick full aft, check clearance

rigging fixture (ST504).

between aft longitudinal bellcrank

(8). Remove lateral cyclic rigging fixture.

(369N2668) and mast base. The

minimum allowable clearance shall be

(9). Check lateral travel as follows:

0.030 inch (0.762 mm). When clearance

is less than 0.030 inch (0.762 mm),

NOTE: Adjust rod end, as required, to obtain

adjust longitudinal control rod (prefera

the following limits.

ble) or collective control rod.

(a). With cyclic stick at left stop, center

(15).

With collective stick full up and cyclic

line of bolt head (fwd end) of bolt in

stick full forward and full left, check

lateral bellcrank (369N2670) shall

clearance between rotating swashplate

move down a minimum of 0.52 inch

and scissors fitting. Also check clear

(13.208 mm) below centerline of

ance between scissors fitting and lower

collective hinge bolt.

hub shoe. The minimum allowable

clearance in both cases is 0.030 inch

(b). With cyclic stick at right stop,

(0.762 mm). Rotate hub 360 degrees to

centerline of bolthead in lateral

determine location of minimum clear

bellcrank (369N2670) shall move up

ance. Adjust collective mixer control rod

a minimum of 0.37 inch (9.398 mm)

as required.

above centerline of collective hinge

bolt.

(16).

Repeat above step with collective stick

full up and cyclic stick full forward and

Do not adjust control rod beyond

CAUTION

full right.

witness hole. Tighten jamnut af

ter final adjustment. Failure to observe this

(17).

With collective stick full up and cyclic

precaution can result in parts damage and/

stick full aft and full left, check clear

or equipment failure.

ance between scissors link and edge of

pocket in rotating swashplate. Rotate

(10). Set pitch change links at nominal 6.25

hub 360 degrees to determine location

inch (158.75 mm).

of minimum clearance. Minimum

clearance is 0.006 inch (0.152 mm).

NOTE: Final adjustment of pitch change links

will be accomplished during tracking and

(18).

Repeat clearance check with cyclic stick

autorotation rpm settings.

full aft and full right.

(11). Remove all rigging fixtures.

(19).

Recheck all clearances from previous

steps.

(12). With collective stick full down and

cyclic stick forward and full left, check

(20).

Recheck control motion travels and

clearance between rotating swashplate

check that minimum clearances are

and longitudinal pitch idler bellcrank

met.

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(21). Install main rotor blades or remove

(2). Remove backlash shims and gear shaft

supports and simultaneously lower all

assembly from socket housing.

six blades to normal position.

NOTE:

Note locations, mark and measure re

(22). Track main rotor blades and adjust

moved shim thicknesses to ensure reas

autorotation rpm (Ref. Sec. 18-10-00).

sembly at same places.

(3). Ensure that inboard collective pitch

9. Cyclic Controls Rigging (R/H Command)

stick socket internal gears are aligned

(600N)

and mated. If gears are correctly

(Ref. Figure 502 and Figure 503) Rigging of

aligned and mated, do not perform

cyclic controls for the R/H command helicopter

steps (4). thru (6). and continue with

is accomplished according to instructions for

step (7). If gears are misaligned,

L/H command helicopters except as follows:

perform steps (4). thru (6).

(4). Disconnect link from idler and remove

Special Tools

link and bellcrank as an assembly from

(Ref. Section 91−00−00)

gearshaft of inboard collective pitch

Item

Nomenclature

stick socket by removing bolt, two

ST501

Collective rigging fixture

washers and nut.

(LH command)

NOTE: During gear shaft rotation to establish

ST503

Mixer rigging plate

correct mid-position for gearshaft and pin

ST505

Longitudinal rigging fixture

ion in next step, gearshaft cutout is seen

(RH command)

through hole in rear of socket assembly

ST507

Lateral rigging fixture

housing.

(RH command)

(5). Rotate end of gas producer interconnect

torque tube in pilot's stick socket

(1).

Use longitudinal rigging fixture

housing until gear shaft-to-N₁ pinion

(ST505) on outboard side of longitudi

gearmesh is at mid-travel and N₁

nal friction guide, with fixture cutout

pinion gear wide toothspace is posi

positioned over friction knob stud.

tioned at approximately one o'clock.

Bushing end of fixture butts against

View pinion by looking aft into open

upper end of slot in guide). Secure

end of collective stick socket.

fixture hook in lower end of slot, tighten

knurled thumbnut to seat bushing at

(6). Attach inboard collective pitch stick

upper end, and tighten friction knob.

socket bellcrank to gearshaft and link

to idler. Bellcrank attachment bolt

(2).

Use lateral rigging fixture (ST507) on

must be installed with head slightly

forward side of lateral friction guide,

down and forward.

with fixture cutout positioned over

friction knob stud. Secure fixture hook

NOTE: Inboard collective N₁ pinion gear must

in lower inboard end of slot, tighten

be held in correct position while steps (7).

thru (9). below are performed. If available,

knurled thumbnut to seat bushing at

optional copilot's collective pitch stick can be

upper outboard end and tighten lateral

used to hold gear in position by setting copi

friction knob.

lot's throttle grip attachment bolts at ap

proximately seven o'clock (looking aft) be

10. Gas Producer Linkage Adjustment

fore engaging stick and socket.

(Ref. Figure 504 and Figure 505) Adjust gas

(7). With inboard collective pitch stick

producer linkage in installed collective pitch

socket N₁ pinion gear held at position

stick(s) and/or inboard socket assembly as

described in step (5)., rotate pilot's

follows:

collective pitch stick throttle grip to

(1). Remove cap and outboard bearing from

mid-travel position (grip attaching

pilot's collective pitch stick housing.

bolts approximately straight down).

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