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

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

PINION GEAR MOUNTING DISTANCE

0.699-0.709 IN. (17.7546-18.0086 MM)

PINION GEAR

PINION BEARING

SPLIT SHIMS

GAS PRODUCER TORQUE TUBE

(NOTES 1, 3)

BEARING

DRIVEN GEAR

BEARING

BACKLASH SHIM(S)

TOP VIEW

HOUSING CAP

(NOTES 2, 3)

GENERAL NOTE:

IDLE STOP

SHIM SELECTED AS REQUIRED.

6°

STEEL SHIMS PROVIDED IN 0.001, 0.002,

GRIP MID-TRAVEL

0.005, 0.012 AND 0.032 IN.≥≥.025, 0.051,

0.127, 0.305, 0.813 MM) THICKNESS.

N1 CLOSED

N1 OPEN

15°

70° 40'

15°

73° 30'

2° 50'

(NOTE 5)

CENTERLINE OF GAS

PRODUCER TORQUE TUBE

(NOTE 4)

CUTOUT IN

DRIVEN GEAR

LEFT SIDE VIEW

NOTES:

DETERMINES GEAR MOUNTING DISTANCE.

DETERMINES GEAR BACKLASH MAXIMUM 0.003 IN. (0.0762 MM).

SELECTED AS REQUIRED; STEEL SHIMS AVAILABLE IN 0.001, 0.002, 0.005,

0.0012 AND 0.032 IN. (0.025, 0.051, 0.127, 0.305, 0.813 MM) THICKNESSES.

ALSO CENTERLINE OF PINION GEAR AND CUTOUT IN DRIVEN GEAR.

CENTERLINE OF CENTER TOOTH ON DRIVEN GEAR.

G67-1014B

Figure 504. Gas Producer Drive Backlash Adjustment (Outboard Collective Stick)

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MAINTENANCE MANUAL

(8). Install backlash shims and gear shaft

(6). Reinstall bolt to secure bellcrank to

in pilot's collective stick socket housing.

inboard gearshaft.

Ensure that gearshaft and pinion are

aligned and mated when pilot's throttle

(7). Reinstall snap plug in exterior skin.

grip is at mid-travel.

(8). Reinstall pilot seat cover.

NOTE: Make sure that shims are installed in

original locations.

NOTE: If optional dual controls are installed,

perform following rigging and deceleration

(9). Reinstall outboard bearing and cap on

checks using copilot throttle.

pilot's stick housing.

(9). Check engine gas producer controls

(10). Check that both pilot's throttle grip and

rigging (Ref. Chap. 76).

inboard collective pitch stick socket N₁

pinion gear wide toothspace are correct

(10). Perform deceleration check (Ref. Pilot's

at mid-travel.

Flight Manual).

(11). Remove snap plug from skin, rotate

12. Gas Producer Interconnecting Torque

pilot's throttle grip and visually check

Tube Assembly Shimming (0003D thru

for evidence of backlash between gas

0929D)

producer interconnect torque tube and

hexagonal interior surfaces of gear

(Ref. Figure 506)

shaft. If necessary, remove cover and

gearshaft from torque tube and elimi

(1).

Remove pilot's seat cover and access

nate any backlash by tightening pipe

door.

plug in end of torque tube. Zero back

lash is required at both ends of tube.

(2).

Make an index mark on end of collec

Reinstall snap plug.

tive torque tube fitting flush with

inboard end of pilot's collective stick

11. Pipe Plug Adjustment

assembly housing using a felt pen or

pencil. Do not scribe index mark on

(Ref. Figure 407)

fitting.

(1). Remove pilot seat cover for access to

(3).

Remove four bolts securing pilot's

under seat controls.

collective stick assembly to end of

collective torque tube fitting.

(2). Remove snap plug from exterior skin.

(4).

Loosen pipe plug in end of gas producer

(3). Remove bolt securing bellcrank to

interconnecting torque tube which

inboard gearshaft.

secures it to gas producer gearshaft in

(4). Position throttle midway between idle

pilot's collective stick assembly.

stop and full open.

(5).

Remove pilot's collective stick assembly.

(5). With assistant, tighten pipe plugs at

each end of torque tube simultaneously;

(6).

Using rubber mallet or equivalent soft

maintain throttle as set in step (4).

tool, tap gas producer interconnecting

Initial torque required to turn pipe

torque tube assembly toward copilot's

plugs may be high because of dried zinc

collective socket assembly. Avoid

chromate primer used at installation.

damage to gas producer interconnecting

torque tube hex end or pipe plug

NOTE: If the normally installed plug does not

threads.

sufficiently expand tube, a 1/8-27 internal-

wrenching pipe plug 0.380 inch (9.652 mm)

(7).

Measure distance between index mark

long may be substituted. Whichever plug is

on collective torque tube fitting and hex

used, it must not protrude more than 0.030

end of gas producer interconnecting

inch (0.762 mm) when tightened.

torque tube.

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MAINTENANCE MANUAL

MEASUREMENT BETWEEN INBOARD END OF PILOT'S

COLLECTIVE STICK HOUSING AND END OF GEAR

SHAFT IN PILOT'S COLLECTIVE STICK ASSEMBLY

PILOT'S COLLECTIVE STICK

HOUSING ASSEMBLY

GEAR SHAFT IN PILOT'S

COLLECTIVE STICK ASSEMBLY

GEAR SHAFT RECESSION MEASUREMENT

TOTAL THICKNESS OF AN960C816 WASHERS AND SNAP RING.

EQUAL TO 0.750 IN. (19.05 MM) MINUS ENGAGEMENT LENGTH OF

GAS PRODUCER INTERCONNECTING TORQUE TUBE INTO GEAR

SHAFT IN PILOT'S COLLECTIVE STICK ASSEMBLY ADDED TO

END OF GAS PRODUCER INTERCONNECTING TORQUE TUBE.

ENGAGEMENT LENGTH OF GAS PRODUCER

INTERCONNECTING TORQUE TUBE INTO GEARSHAFT

OF PILOT'S COLLECTIVE STICK ASSEMBLY.

0.750 IN. (19.05 MM) LENGTH OF HEX END ON

THE GAS PRODUCER INTERCONNECTING

TORQUE TUBE.

TORQUE TUBE SHIMMING

G67-1015-2

Figure 506 Gas Producer Interconnecting Torque Tube Shimming Procedure

(0003D thru 0929D) (Sheet 2 of 2)

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MAINTENANCE MANUAL

(8).

Measure distance between inboard end

al rotation of drive gear grip and cause ny

of pilot's collective stick assembly

lon gears to be stripped.

housing and inboard face of gas produc

er gearshaft in pilot's collective stick

(1). Remove friction mechanism guard.

assembly.

(2). Rotate friction drive gear counterclock

(9).

Subtract measurement taken in step

wise to maximum friction position.

(8). from measurement taken in step

(7). Remainder is engagement of gas

(3). Remove cotter pin, nut, retainer

producer interconnecting torque tube

assembly, teflon washer and one

with gearshaft in pilot's collective stick

phenolic washer.

assembly.

(4). Slide gear assembly out far enough to

disengage it from idler gear. Use care to

(10).

Subtract engagement (remainder) from

keep other washers and spacer from

0.750 inch (19.05 mm). In addition to

thickness of external snap ring, add PN

dropping.

AN960C816 washers to end of gas

producer interconnecting torque tube to

(5). Remesh gear assembly with idler gear

a total thickness equal to the remainder

to position pin on peak of cam. Check

from 0.750 inch (19.05 mm) less

that drive gear is still at maximum

engagement. Equivalent washers in

friction stop position.

varying thicknesses may be in combina

tion with PN AN960C816 washers.

(6). If gear assembly does not correctly

position pin, reposition idler gear on

drive gear.

(11).

Reinstall pilot's collective stick assem

bly.

NOTE:

Ratio of idler gear to gear assembly is

3:1, which permits fine adjustment. When

(12).

Tighten pipe plug of gas producer

repositioning idler gear, be sure to reinstall

interconnecting torque tube to obtain

same number of washers that were removed

zero backlash between torque tube and

from between cotter pin and idler. These

gearshaft in pilot's collective stick

washers limit gear end play to maximum of

assembly.

0.010 inch (0.254 mm). When reassembled,

gear train must rotate freely.

(13).

Reinstall pilot's seat cover and access

door.

(7). Reinstall phenolic washer, teflon

washer, retainer assembly and nut.

13. Collective Stick Friction Mechanism

Adjustment

(8). With drive gear still at maximum

friction position, tighten retainer nut

(Ref. Figure 507)

until it just bottoms on retainer stop.

For collective friction mecha

(9). Rotate friction drive gear clockwise to

CAUTION

nism to be correctly adjusted for

minimum friction stop position, release

maximum friction, three actions must occur

grip and perform checks in steps (10).

at same time: Drive gear must contact stick

and (11). below.

fitting fixed stop; spring retainer housing

washer must contact retainer internal stop;

(10). If pin has overridden low point of cam

and gear assembly pin must be at approxi

(desired minimum friction position),

mate peak of cam. Do not overtighten re

and grip-to-stick friction prevents

tainer nut so that retainer washer contacts

springback of pin to cam low point, turn

retainer stop before friction drive gear

grip and move pin to low point.

reaches stick fitting stop. Adjustment that

does not produce approximately simulta

NOTE: A drive gear that does not rotate freely

neous contact will allow excessive addition

on collective stick tube should be replaced.

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MAINTENANCE MANUAL

GUARD

WASHER(S)

STICK FITTING

(NOTE 1)

COTTER

FRICTION

DRIVE GEAR

PHENOLIC WASHERS

(ROTATING

TEFLON

STOP)

WASHER

RETAINER HOUSING

COTTER PIN

MAXIMUM

IDLER

FRICTION

GEAR

NUT

STICK FITTING

(FIXED STOP)

FRICTION CONTROL

WASHER

DRIVEN

GEAR

STOP SPRING

SPACER

GEAR

ASSEMBLY

CAM

GUIDE

(NOTE 2)

ALUMINUM

WASHER

GUARD

FRICTION MECHANISM

ATTACHMENT

NYLON STRAP

GEAR ASSEMBLY PIN

(NOTE 4)

NOTE 3

NOTE 5

NOTE 6

NOTES:

CAM ACTION

SHIMMED AS REQUIRED FOR 0.010 IN. (0.254 MM) MAXIMUM

END PLAY. GEAR TRAIN MUST ROTATE FREELY.

GEAR ASSEMBLY MUST SLIDE AND ROTATE FREELY IN FITTING.

GREASE APPLIED TO SHAFT.

ACCEPTABLE MINIMUM FRICTION POSITION.

DESIRED MINIMUM FRICTION POSITION (CAM LOW POINT).

G67-1016B

CORRECT MAXIMUM FRICTION POSITION (CAM HIGH POINT).

Figure 507. Collective Stick Friction Adjustment

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MAINTENANCE MANUAL

(11). With pin on cam low point, rotate

(2). Prior to test flight, establish half-way

retainer assembly. It should turn freely

point of collective friction adjustment

on shaft of gear assembly with only

grip (drive gear) as follows.

light finger pressure. Adjust retainer

nut to nearest castellation that pro

(a). Using soft, colored pencil; index

duces zero friction (no drag on retainer

collective friction adjustment grip at

assembly during rotation). Install cotter

zero friction.

pin.

(b). Roll on maximum friction (approxi

NOTE: If undesirable collective forces (”light”,

mately 275 degrees rotation). Note

”heavy” or ”creeping”) are reported to exist

travel and reset friction grip half-

in collective stick during flight, do not at

way; hold in this position.

tempt to compensate by an increase in col

lective friction. Condition should be cor

(c). Using dot of white paint or similar

rected elsewhere in control system (Ref.

method, temporarily mark top of

Collective Controls Rigging (L/H Command)

friction grip and adjacent exposed

and Collective Bungee Adjustment).

area of collective stick. Friction

half-way index mark should be

visible to pilot.

14. Collective Bungee Adjustment

(3). While helicopter is on ground, adjust

(Ref. Figure 404) Adjustment of bungee system

bungee to extent necessary to avoid any

is only permissible when helicopter is on

upload in flat pitch at normal rpm. This

ground.

adjustment must also provide absence

of an excessive download or upload

WARNING

while in hover and at 120 knots level

cruise. Helicopter must be landed after

D Do not attempt bungee adjustment in

each flight check, before making

flight, control jamming can result.

corrective adjustment.

D Use all necessary precautions to pre

vent possible entry of any foreign ob

CAUTION

jects into controls linkage exposed

by removal of pilot's seat cover to

D After each bungee adjustment is made,

make adjustment of bungee system.

collective stick must be slowly moved

Do not attempt bungee adjustment in

through its full travel range to assure

flight, control jamming could result.

that there is no binding or restriction of

stick motion, and that spring does not bot

(1). Collective load forces are affected by

tom at overcenter position.

any adjustment made in main rotor

D Do not turn female bearing assembly

system. Comply with the following.

spring retainer while bungee installation

tool is spring loaded.

(a). Bungee adjustment should be made

only when main rotor blades are in

D When making adjustments to the bungee

track and autorotation rpm is

over-center fitting, ensure nut turns

established.

when bolt adjustment is made. Cotter pin

can be sheared if nut does not turn with

(b). Ensure that collective stick friction is

bolt.

correctly adjusted.

(a). If an upload exists on ground at flat

(c). Perform flight evaluation of collective

pitch and normal rpm but a down

forces with helicopter takeoff weight

load prevails during hover and at 120

at 2350 pounds (1066 kg), N₂ at 103

knot level cruise, turn bungee

percent and zero collective stick

adjustment retainer nut clockwise to

friction.

increase preload in bungee system.

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MAINTENANCE MANUAL

(b). To correct a download on ground

During following tests, do not

CAUTION

during flat pitch at normal rpm and

retract spring assembly (ram) so

an upload condition during hover and

that actuator length is less than 13.50 in

120 knot level cruise, turn bungee

ches (34.29 cm) between attach bolt centers.

adjustment retainer nut counter

clockwise to decrease preload in

(4). With actuator spring assembly (ram)

bungee system.

approximately halfway between travel

limits (actuator length at 14.46 inches

(c). When a relatively constant upload

(36.7284 cm) between attach bolt

condition prevails during flat pitch at

centers), set up test dial indicator and

normal rpm on the ground, at hover,

measure ram end play. End play must

and at 120 knot level cruise, decrease

be within 0.010-0.050 inch (0.254-1.27

upload by turning bungee over-cent

mm). While adjusting screw, check that

er adjustment bolt clockwise.

there is thread-locking friction from

self-locking threaded insert. If end play

(d). When a relatively constant download

is excessive, replace actuator.

condition prevails during flat pitch at

normal rpm on the ground, at hover,

NOTE:

and at 120 knot level cruise, decrease

download by turning bungee over-

D When power is applied to the 8222M6

center adjustment bolt counterclock

(369A7014) actuator, it will move in the

wise.

commanded direction until it reaches the

end of the stroke. If, during mid-travel,

NOTE: Rotation of adjustment bolt head is the

an opposite power is applied simulta

only mechanical operation required to ad

neously, it will stop and remain stopped

just over-center position of bungee fitting.

until one or the other input is removed.

(e). After minimum and balanced collec

D When power is applied to the 8222M7

tive forces are obtained, not more

(369D27001) actuator, it will move, as

than one-half of available collective

commanded, and like the M6, if power is

stick friction (friction grip at half-

applied simultaneously in the opposite di

way index) must cancel collective

rection, it will stop. Unlike the M6, when

forces during flight test at 140 knots

one of the inputs is removed, the M7 ac

level flight.

tuator may or may not start. If it does not

restart, it has been latched into the off

(f). If friction applied in step (e). above is

state by the current surge generated upon

insufficient to cancel collective forces,

applying the second input. The M7 has a

repeat adjustment procedure.

built-in current limit circuit that latches

it off if the actuator current exceeds 2.7

15. Cyclic Trim Actuator Bench Testing

amp. All power must be removed in order

(369D/E/FF − 500N)

to unlatch it.

(Ref. Figure 508)

(5). Position test switch to RETRACT and

(1). Connect cyclic trim actuator to test

allow actuator ram to retract to a

harness and equipment.

length of 13.50 inches (34.29 cm)

between attach bolt centers.

(2). Mount actuator in suitable fixture that

allows vertical extension and retrac

(6). Using stopwatch, check actuator ram

tion.

travel time from fully retracted to fully

(3). Turn on direct-current power and

extended. Check time interval for

adjust output to 25.75 - 26.25 volts.

actuator motor tested.

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MAINTENANCE MANUAL

NOTE: The times in the following charts are

(0.508 mm) maximum with an overrid

maximum times. Some actuators will travel

ing (aiding) load; otherwise there must

at a greater speed than others. Intervals of

be no overtravel.

less time are acceptable.

(12). Remove 163 pound (74 kg) load and

repeat step (4). above.

Actuator Motor

Time Interval

Part number

(Seconds)

(13). Run actuator until arm is extended 1.75

inches (4.445 cm). Turn power off and

369A7001

58.4

disconnect cyclic trim actuator.

369A7014 (High Speed)

38.0

16. Cyclic Trim Actuator Bench Testing (600N)

369D27001 (Super Fast)

17.5

(Ref. Figure 508)

(1). Connect cyclic trim actuator to test

(7). Measure length of extended ram.

harness and equipment.

Subtract measured result of step (5).

above from this value. Result must be

(2). Mount actuator in suitable fixture that

1.92 inches (4.8768 cm) minimum.

allows vertical extension and retrac

tion.

Do not run actuator against ex

CAUTION

tend limit stop with the

(3). Turn on direct-current power and

163-pound weight aiding actuation. Actua

adjust output to 25.75 - 26.25 volts.

tor thrust bearing may be damaged.

During following tests, do not

CAUTION

retract spring assembly (ram) so

(8). Connect a 163 pound (74 kg) load to

that actuator length is less than 13.50 in

actuator. Set switch at RETRACT.

ches between attach bolt centers.

Check time it takes ram to travel

1.72-1.78 inches (4.3688-4.5212 cm) to

(4). With actuator spring assembly (ram)

retract stop. Check retraction time for

approximately halfway between travel

actuator motor tested.

limits (actuator length at 14.46 inches

(36.7284 cm) between attach bolt

Actuator Motor

Time Interval

centers), set up test dial indicator and

Part number

(Seconds)

measure ram end play. End play must

be within 0.010-0.050 inch (0.254-1.27

369A7001

30−50

mm). While adjusting screw, check that

369A7014 (High Speed)

15−25

there is thread-locking friction from

self-locking threaded insert. If end play

369D27001 (Super Fast)

7−12

is excessive, replace actuator.

NOTE: When power is applied to the 8222M21

(9). Operating current under load condi

(600N7001) actuator, it will move, as com

tions must not exceed 1.2 amperes

manded, and if power is applied simulta

running and 2.0 amperes stalled.

neously in the opposite direction, it will

(10). Reduce voltage input to 21 volts.

stop. When one of the inputs is removed, the

Actuator ram must retract and extend.

actuator may or may not start. If it does not

Overtravel is limited to 0.020 inch

restart, it has been latched into the off state

(0.508 mm) with an overriding (aiding)

by the current surge generated upon apply

load; otherwise there must be no

ing the second input. The actuator has a

overtravel.

built-in current limit circuit that latches it

off if the actuator current exceeds 3.1 amp.

NOTE: It is not necessary to extend or retract

All power must be removed in order to un

actuator ram more than 1/4 inch (6.35 mm)

latch it.

for test in steps (10). above or (11). below.

(5). Position test switch to RETRACT and

(11). Increase input voltage to 28 volts.

allow actuator ram to retract to a

Actuator arm must retract and extend.

length of 13.50 inches (34.29 cm)

Overtravel is limited to 0.020 inch

between attach bolt centers.

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MAINTENANCE MANUAL

(6). Using stopwatch, check actuator ram

Actuator Motor

Time Interval

travel time from fully retracted to fully

Part number

(Seconds)

extended. Check time interval for

actuator motor tested.

600N7001−1 (longitudinal)

7−12

NOTE: The time in the following chart is maxi

369D27001−3 (lateral)

7−12

mum time. Some actuators will travel at a

600N7014−1 (lateral, with

7−12

greater speed than others. Intervals of less

YSAS)

time are acceptable.

(9). Operating current under load condi

Actuator Motor

Time Interval

tions must not exceed 1.2 amperes

Part number

(Seconds)

running and 2.0 amperes stalled.

600N7001−1 (longitudinal)

6.6

(10). Reduce voltage input to 21 volts.

Actuator ram must retract and extend.

369D27001−3 (lateral)

11.0

Overtravel is limited to 0.020 inch

(0.508 mm) with an overriding (aiding)

600N7014−1 (lateral, with

11.0

load; otherwise there must be no

YSAS)

overtravel.

(7). Measure length of extended ram.

NOTE: It is not necessary to extend or retract

Subtract measured result of step (5).

actuator ram more than 1/4 inch (6.35 mm)

above from this value. Result must be

for test in steps (10). above or (11). below.

1.92 inches (4.8768 cm).

(11). Increase input voltage to 28 volts.

Actuator arm must retract and extend.

Do not run actuator against ex

CAUTION

Overtravel is limited to 0.020 inch

tend limit stop with the

(0.508 mm) maximum with an overrid

163-pound weight aiding actuation. Actua

ing (aiding) load; otherwise there must

tor thrust bearing may be damaged.

be no overtravel.

(8). Connect a 163 pound (74 kg) load to

(12). Remove 163 pound (74 kg) load and

actuator. Set switch at RETRACT.

repeat step (4). above.

Check time it takes ram to travel

1.72-1.78 inches (4.3688-4.5212 cm) to

(13). Run actuator until arm is extended 1.75

retract stop. Check retraction time for

inches (4.445 cm). Turn power off and

actuator motor tested.

disconnect cyclic trim actuator.

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MAINTENANCE MANUAL

SPRING

ADAPTER

SPRING GUIDE

SPRING ADAPTER SCREW

TEST LOAD

CONNECTION

ADAPTER

TRIM TUBE

ACTUATOR

TRIM DECAL

SELF-LOCKING THREAD INSERT

SPRING

NOTE

WASHER

ACTUATOR

RIVET

(4 PLCS)

SPRING PIN

ACTUATOR HOUSING

TRIM TUBE

ADAPTER

ACTUATOR

PIN INSTALLATION

TUBE

1.00 IN.

HOUSING

HOLE

(2.54 CM)

NOTE:

REPLACEMENT PARTS HAVE NUTPLATE

RIVETED IN PLACE. WASHER, NUT AND COTTER PIN NOT

REQUIRED.

TRIM TUBE - INSTALLATION

ITEM

TEST EQUIPMENT

SPDT SWITCH

NO.

STOPWATCH, MARKED IN

EXTEND

1/10-SECOND

INCREMENTS (MINERVA OR

26 VDC

OFF

EQUIVALENT).

ELECTRICAL

V M2

POWER

RETRACT

6 IN. (15.25 CM) SCALE.

SOURCE

DC VOLTMETER, 0-50 VOLTS

TEST HOOKUP

CONNECTOR

(WESTON

MODEL 931 OR EQUIVALENT).

DC MILLIAMMETER, 0-5 AMPERES

(WESTON

MODEL 931 OR EQUIVALENT).

VARIABLE DC POWER SUPPLY,

G67-1017B

Figure 508. Cyclic Trim Actuator Assembly

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MAINTENANCE MANUAL

MAIN ROTOR FLIGHT CONTROLS

INSPECTION/CHECK

1. Tunnel−Routed Control Rod Inspection

(c). Lightly deflect tube laterally from

one extreme to other (maintain

(Ref. Figure 601)

preload).

(1). Inspect rod end bearings for binding

(d). With dial indicator or 6 inch (15.25

and excessive wear, 0.040 inch (1.016

cm) rule, measure total horizontal

mm) maximum axial play.

movement at top of tube where rod

end enters.

(2). Inspect control rod for surface damage

and evidence of bending.

(e). If total movement exceeds 1/16 inch

(1.5875 mm) rod assembly must be

(3). Inspect upper two inches (5.08 cm) of

replaced with serviceable parts.

each tunnel routed control rod for wear.

Replace rods with wear depth exceeding

(f). Movement less than 3/64 inch

0.020 inch (0.508 mm), or having outer

(1.190625 mm) is considered negligi

diameter (OD) less than minimum

ble.

which follow.

(g). If movement is between 3/64 and 1/16

inch (1.5875 and 1.190625 mm),

Minimum OD

inspect rod threads, step (6)., or rod

Control Rod

Inches (mm)

insert, step (7).

Collective mixer

0.470

(11.938)

(6). For early control tubes without swaged

Longitudinal mixer

0.520

(13.208)

inserts:

Lateral mixer

0.530

(13.462)

(a). If total lateral movement of upper

end of tube is found to be between

Tail rotor

0.470

(11.938))

3/64 and 1/16 inch (1.5875 and

1.190625 mm), check rod threads.

(4). Inspect for loose rivet at fixed rod end

(lower end).

(b). Disconnect rod end from control

system.

CAUTION

(c). Screw rod end completely out of

control rod.

D When tightening loosened jam nuts on

rod ends as in steps (5). and (6). or (7). be

(d). Use 0.339 inch (8.6106 mm) diameter

low, always hold rod end with wrench.

drill (size R), free of burrs, to check

rod threads.

D Do not disconnect rod ends from mixer as

sembly to perform this inspection except

1). If drill can be inserted, rod assem

as instructed.

bly is unserviceable and must be

replaced.

(5). Inspect upper end of tunnel-routed

control rod assemblies for excessive rod

2). If drill cannot be inserted, rod is

end play.

serviceable.

(a). Loosen jam nut minimum of two

(e). Reinstall rod end, reconnect rod to

threads.

control system and tighten jam nut.

(b). Preload rod end against either side of

(7). For current control rods with swaged

attaching clevis with light finger

inserts:

pressure to eliminate play other than

in area being inspected and effect of

(a). Disconnect rod end from control

bearing play.

system.

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

LONGITUDINAL PITCH IDLER

COLLECTIVE PITCH MIXER BELLCRANK

LONGITUDINAL MIXER

CONTROL ROD

COLLECTIVE MIXER

CONTROL ROD

LATERAL BELLCRANK

TAIL ROTOR CONTROL ROD

LATERAL MIXER CONTROL ROD

INITIAL ROD LENGTH (BEFORE RIG)

DIM L

CONTROL ROD

INCH (CM)

56.67

(

LONGITUDINAL MIXER

143.9418)

56.51

(

COLLECTIVE PITCH FITTING

LATERAL MIXER

143.5354)

COLLECTIVE MIXER

55.67

(

141.4018)

2.00 IN. (5.08 CM)

RIVET

(NOTE)

53.14

(

134.9756)

MAXIMUM ALLOWABLE AXIAL

PLAY 0.040 IN. (1.016 MM)

CONTROLS

SUPPORT BRACKET

LONGITUDINAL IDLER

BELLCRANK

LATERAL IDLER BELLCRANK

NOTE:

INSPECT FOR WEAR. REPLACE RODS WITH WEAR

DEPTH EXCEEDING 0.020 IN. (0.508 MM) OR HAVING

OD LESS THAN ALLOWABLE MINIMUM.

G67-1020A

Figure 601. Tunnel−Routed Control Rod Inspection

Page 602

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CSP-HMI-2

MAINTENANCE MANUAL

(b). Back off jam nut sufficiently enough

NOTE: Pitch stick housing and cap may be ei

to inspect insert.

ther magnesium or alloy casting. (For corro

sion control and identification of magne

(c). Inspect insert for proper installation,

sium or aluminum alloys, Ref. Sec.

flush to a maximum of 0.010 inch

20-40-00.)

(0.254 mm) below the surface of the

rod.

4. Copilot’s Collective Pitch Stick Inspection

(d). Check that insert is tight inside of

(Ref. Figure 603)

rod.

(1). Inspect bearings for binding or play.

1). If insert is loose or protrudes above

surface of rod, rod assembly is

(2). Inspect all gears for cracks, and

unserviceable and must be repla

chipped or broken teeth.

ced.

(3). Inspect stick tube and gas producer

2). If insert is tight and swaged flush

control tube for corrosion, deformation

to 0.010 inch (0.254 mm) below the

and loose rivets.

surface of the rod, rod is servi

ceable.

5. Collective Stick Friction Mechanism

Operational Check

(e). Reconnect rod to control system and

tighten jam nut.

(Ref. Figure 602)

(8). Check rigging of re-connected control

(1).

Remove guard from collective stick.

system.

(2).

Check that teeth of friction drive gear,

Controls Support Bracket and Bellcrank

idler gear, and driven gear are not

Inspection

stripped or otherwise damaged.

(Ref. Figure 403)

(3).

Rotate friction drive gear grip counter

clockwise to maximum friction stop;

(1). Inspect bearings in bellcranks for

gear train must rotate freely. Check

binding.

position of shaft assembly pin. Pin

should be at highest point of cam.

(2). Perform fluorescent dye penetrant

inspection on any suspected part.

(4).

If pin is not at approximate peak of cam

NOTE: Parts identified with double asterisk

or has overridden peak, friction mecha

(**) (Ref. Figure 403) may be either magne

nism must be readjusted. If pin is in

correct position, continue with step (5).

sium or aluminum alloy. (For corrosion con

trol and identification of magnesium and

below.

aluminum alloys, Ref. Sec. 20-40-00.)

(5).

Rotate drive gear grip clockwise to

minimum friction position and release

3. Pilot’s Collective Pitch Stick Inspection

grip; gear train must rotate freely. Pin

should be at approximate low point of

(Ref. Figure 602)

cam.

(1). Inspect bearings for binding or play.

(6).

With pin on low point of cam, hand

(2). Inspect all gears for cracks, and

rotate spring release housing. If there is

chipped or broken teeth.

drag on retainer, there is friction on

guide and collective friction must be

(3). Inspect stick tube and gas producer

readjusted. If retainer rotates freely,

control tube for corrosion, deformation

without obvious play, low point friction

and loose rivets.

setting is correct.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

FRICTION WASHER

(FELT)

BACKUP DISC

THROTTLE GRIP

(METAL)

(NOTE 1)

THROTTLE FRICTION

MOUNTING DISTANCE

NUT (NOTE 1)

SWITCH HOUSING

SHIM (CUT)

FRICTION DISC (NYLON)

COVER

BEARING

SPRING

BACKUP DISC (METAL)

(NOTE 3)

GRIP ATTACH BOLTS

GAS PRODUCER

CONTROL TUBE

IDLE STOP RELEASE RING

PINION

HOUSING SOCKET

NYLON STRAP

(NOTE 1)

SETSCREW

(NOTE 1)

FITTING

(NOTE 5)

SHIM WASHER

SETSCREW

IDLER GEAR

BEARING

BACKLASH

NYLON

STICK

(NOTE 3) SHIM GEARSHAFT

GUARD

STRAP

FITTING

BACKLASH SHIM

BEARING

(NOTE 3)

NYLON STRAP

GEAR

CAP

(NOTE 1)

PHENOLIC WASHERS

CAM

(NOTE 2)

(NOTE 1)

FRICTION ADJUSTMENT

TEFLON WASHER

STICK TUBE

WIRE GUIDE

SPACER

NOTE 1

FRICTION

(NOTE 1)

RETAINER

DRIVE GEAR

GUIDE

(NOTE 4)

SETSCREW

NOTES:

SURFACES IN CONTACT DURING ROTATION, OR OTHERWISE

NOTED, TO BE LUBRICATED WITH GREASE.

NEW PHENOLIC WASHERS ABRADED TO REMOVE GLAZE.

BEARINGS INSTALLED WITH GRADE A LOCKING COMPOUND

AFTER SHIMMING.

DRIVE GEAR END PLAY 0.002-0.010 IN. (0.0508-0.254 MM).

USED ONLY WITH OPTIONAL EQUIPMENT.

G67 1021B

Figure 602. Outboard Collective Stick Inspection (L/H Command)

Page 604

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CSP-HMI-2

MAINTENANCE MANUAL

MOUNTING DISTANCE SHIM

(CUT)

BEARING

(NOTE 2)

GAS PRODUCER CONTROL TUBE

COVER

PINION

HOUSING SOCKET

(NOTE 1)

BEARING

(NOTE 2)

BACKLASH SHIM

GEARSHAFT

NYLON STRAP

BACKLASH SHIM

ELECTRICAL

WIRING

STICK TUBE

BEARING

(NOTE 2)

NOTE 1

CONNECTOR

CAP

SETSCREW

WIRE GUIDE

ADJUSTMENT NUT

SETSCREW

THROTTLE GRIP

GRIP ATTACH BOLT

NOTES:

SURFACES IN CONTACT DURING ROTATION

TO BE LUBRICATED OR OTHERWISE NOTED,

WITH GREASE (CM116).

SETSCREW

INSTALL BEARINGS WITH GRADE A LOCKING

COMPOUND (CM431) AFTER SHIMMING FOR

SWITCH HOUSING

MOUNTING DISTANCE AND BACKLASH.

44-162B

Figure 603. Outboard Collective Stick Inspection (R/H Command)

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

6. Collective Control Interconnecting Torque

NOTE: Bungee support bracket may be either

Tube Inspection

an aluminum or magnesium casting. (For

corrosion control and identification of mag

nesium and aluminum alloys, Ref. Sec.

(Ref. Figure 404)

20-40-00.)

(1). Remove pilot's seat cover, control access

8. Inboard Collective Stick Socket Assembly

door, and left side foot support fairing.

Inspection

(Ref. Figure 408)

(2). Inspect collective interconnecting

(1). Inspect all bearings for binding or play.

torque tube for cracks, bends or

distortions.

(2). Inspect gears for cracks, and chipped or

broken teeth.

(3). Inspect bungee bracket and bungee

(3). Inspect all components for cracks,

fitting for security and condition.

corrosion and deformation.

Ensure cotter pin in over-center

adjustment bolt is not sheared.

NOTE: Bellcrank and idler may be either an

aluminum or magnesium casting. (For cor

(4). Inspect all accessible rivets for play.

rosion control and identification of magne

inspect support bearings for security

sium and aluminum alloy parts, Ref. Sec.

and evidence of binding.

20-40-00.)

(5). Reinstall pilot's seat cover, controls

9. Pilot’s Cyclic Control Stick Inspection

access door and foot support fairing.

(Ref. Figure 604)

NOTE:

7. Collective Bungee Inspection

D For this inspection, friction stop nut must

be loosened.

(Ref. Figure 407)

D Socket may be either an aluminum or

magnesium casting. (For corrosion con

NOTE: Replace any bungee parts in question

trol and identification of magnesium and

able condition.

aluminum alloys, Ref. Sec. 20-40-00.)

(1). Inspect bearings in male and female

(1). Inspect stick tube attachment to socket

bearing assemblies for evidence of

for evidence of loose rivets, distortion

binding, corrosion and galling.

and corrosion.

(2). Inspect parts of friction mechanism for

(2). Inspect female bearing assembly

physical damage. Free length of friction

threads for damage.

spring should be approximately 0.580

inch (14.732 mm).

(3). Inspect spring for evidence of deforma

tion. Free length of spring must be;

(3). To check installation, loosen lateral and

longitudinal friction knobs, move cyclic

(a). Effectivity: 369D/E/FF-500N, 3.64 ±

control stick and check for binding or

0.06 inches (92.456 ±1.524 mm)

unusual noises. Check that rod end

bearings of pilot's lateral control rod do

not jam when stick is full forward and

(b). Effectivity: 600N, 4.50 ±0.025 inches

full aft.

(114.30 +0.635 mm)

NOTE: Set minimum friction so that phenolic

(4). Inspect male bearing rod for cracks,

washers can be slightly turned by hand. If

evidence of binding, corrosion and

minimum friction is set too low, stick shake

deformation.

will occur.

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CSP-HMI-2

MAINTENANCE MANUAL

10. Copilot’s Cyclic Control Stick Inspection

(5). Replace one-way lock if exposed portion

of piston has nicks, scratches or wear

(Ref. Figure 604)

penetrates chrome plating.

(6). Replace external mounting bushing if

Consumable Materials

outside diameter is less than 0.4979

(Ref. Section 91−00−00)

inch (12.64666 mm).

Item

Nomenclature

CM114

Petrolatum

(7). One-way lock must be replaced if nicks,

dents and scratches to body exceed

0.040 inch (1.016 mm) depth after

(1). Inspect quick-release pins for secure

repair.

fit, also stick tube and socket for

security, distortion and corrosion.

(8). One-way lock must be replaced if end

Check for presence of a light coating of

play between rod ends exceeds 0.010

grease in socket and on stick tube end.

inch (0.254 mm) measured at input

Apply thin coating of petrolatum

(forward) end.

(CM114), on contact surfaces.

(2). To check controls installation, loosen

(9). One-way lock must be replaced if

lateral and longitudinal friction knobs,

leaking, except as noted for reservoir in

move stick and check for binding or

step (1). above.

unusual noises. Check that rod end

bearings of copilot's lateral control rod

12. Cyclic Trim Actuator Inspection

do not jam throughout full range of

stick travel.

(Ref. Figure 508)

NOTE: Set minimum friction so that phenolic

(1). Inspect electrical connector for evidence

washers can be slightly turned by hand. If

of damage, and broken or missing

minimum friction is set too low, stick shake

contacts.

will occur.

(2). Inspect exterior of trim actuator for

11. One−Way Lock Inspection

evidence of damage and deformation.

(1). Replace reservoir if cracked, leaking or

(3). When actuator speed (response and/or

has loose or damaged filler cap (Ref.

travel time) is questionable, perform

COM).

bench test (Ref. Cyclic Trim Actuator

NOTE: It is normal for a thin hydraulic oil film

Bench Test).

to remain on piston as a result of wiping

contact with the piston seal. This should not

13. Cyclic Control System Operational Check

be considered leakage or cause for rejection.

Excessive slack or free play in the cyclic

(2). Replace forward input rod end bearing

control system may result in premature

if bearing binds.

control stop contact or roughness of the

helicopter and fanning out (out of track) of the

Do not attempt to adjust larger

CAUTION

main rotor tip path plane (Ref. Sec.

(aft) of two rod ends and do not

18-10-00/60). Areas to be checked include

remove cotter pin; malfunction of lock will

mixer linkages (Ref. Sec. 62-30-00/60) at the

likely result. (For overhaul and replacement

base of the main rotor mast, rotating controls

instructions, Ref. COM).

above the swashplate, trim actuators, and

(3). Replace one-way lock if aft (output) end

cyclic control stick in the pilot's compartment.

bearing binds.

If total free play at the top of the cyclic grip

exceeds 3/8 inch (9.525 mm) in either longitu

(4). Replace protective boot if it is cracked,

dinal or lateral direction, perform the follow

torn or deteriorated.

ing:

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

SLEEVE BUSHING

NOTE 2

NOTES:

LINK

FRICTION

EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF

MECHANISM STUD

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

ABOVE OUTSIDE SURFACE OF PART AFTER BOLT IS

TIGHTENED.

WASHERS ARRANGED TO ALIGN LINK WITH TORQUE

TUBE; LOOSELY SPACED WITH THREE WASHERS.

CAP NUT ADJUSTED TO STOP KNOB WITH SPRING AT

KNOB

FREE LENGTH ±1/32 IN (0.79375 MM).

(NOTE 4)

CYCLIC STICK LATERAL FRICTION MECHANISM IS SIMILAR

(SEE MAIN VIEW).

IF NUT CAN BE TURNED WITH FINGER PRESSURE, NUT

SPRING

CAP NUT

MUST BE REPLACED.

RETAINER

(NOTE 3, 5)

DISC

TORQUE TUBE

CYCLIC STICK LONGITUDINAL

FRICTION MECHANISM

(NOTE 4)

SCREW

PILOT'S LATERAL

CONTROL ROD

SLOTTED BUSHING

(NOTE 1)

NYLON STRAP AND

MOUNTING PLATE

STA. 67 LATERAL

DIM L

CYCLIC BELLCRANK

CONTROL ROD

ANGLE A

INCH (CM)

PILOT'S LATERAL

12.63

(32.0802

42°

STA 70 LATERAL

) 6.65

(16.891)

90°

MAXIMUM ALLOWABLE AXIAL

PLAY 0.040 IN. (1.016 MM)

LATERAL CONTROL ROD

(INBOARD END) RIVET

INBOARD END ATTACHMENT

G67−1022

Figure 604. Cyclic Stick and Friction Inspection

Page 608

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CSP-HMI-2

MAINTENANCE MANUAL

When replacing control rod

(c). Check lower end of cyclic stick and

CAUTION

ends, measure length accurate

play at attachment of cyclic intercon

ly to ensure that replacement rod is exactly

necting torque tube. Replace bearings

the same length as the original. Control rods

and bushings as required.

are factory adjusted at installation to pro

(4). Check for axial play in cyclic trim

vide necessary clearances.

actuators.

(1). With the rotor stopped, check for free

(a). Disconnect lower end of cyclic control

play at the cyclic stick grip. While

rods from aft ends of trim actuators

moving cyclic stick through free play

and check for free play. Remove free

range, have assistant check controls

play by adjusting spring adjustment

mixer area for any free play motion.

screw located in center recess at aft

end of actuator. If end play exceeds

0.0075 inch (0.1905 mm), replace

(a). Check pivot bolt areas where mixer

actuator. Reconnect control rod.

bellcranks attach to control rod

bellcranks. If free play is noted,

(b). Check for free play in attachments

remove pivot bolts and inspect for

and linkages between trim actuators

wear and/or play between bolts,

and cyclic pitch interconnecting

bushings, and bellcranks. Replace

torque tube. Replace parts as re

parts as required.

quired; Install controls tunnel access

door.

(b). Check control rod assemblies by

14. Main Rotor Flight Control System

Pressing sidewards near the rod end

600−Hour Inspection

bearing. Replace rod end as required.

(Ref. Figure 508)

(2). Check for free play in blade pitch links

(1). With the rotor stopped, check for free

which connect rotating swashplate to

play at the cyclic stick grip.

blade pitch housings. Replace rod ends

NOTE: If total free play at the top of the cyclic

having free play in excess of 0.040 inch

grip is 3/8 inch (9.525 mm) or less in either

(1.016 mm) side motion.

longitudinal or lateral direction inspection

is not required. If total free play at the top of

NOTE: Rod ends on pitch links should be

the cyclic grip exceeds 3/8 inch (9.525 mm)

checked under a no-load condition which is

in either longitudinal or lateral direction,

best achieved by removing blades.

perform the following:

(2). While moving cyclic stick through free

(3). While moving cyclic stick through free

play range, have assistant check

play range, check lower controls for free

controls mixer area for any free play

play motion; Remove controls tunnel

motion.

access door.

(a). Check each pivot bolt area where

lateral mixer bellcranks attach to

(a). Check control rod assemblies by

collective bellcranks. If free play is

pressing sidewards near the rod end

noted at the lateral bellcranks,

bearings. Looseness indicates axial

remove pivot bolts and inspect for

play in rod end bearing. Replace rod

wear and/or looseness between bolt,

end as required.

bushings and bellcrank. Replace

parts as required.

(b). Check pivot bolt areas of lateral and

longitudinal bellcranks. If free play is

(b). Check control rod assemblies by

noted, remove pivot bolts and inspect

pressing sidewards near the rod end

for wear and/or play between bolts,

bearings; motion here indicates axial

bushings, and bellcranks. Replace

play in rod end bearing. Replace rod

parts as required.

end as required.

Page 609

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CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(3). Check for free play in blade pitch links

(a). Disconnect lower end of longitudinal

which connect rotating swashplate to

cyclic control rod from aft end of trim

blade pitch housings.

actuator and check for axial play.

Remove free play by adjusting spring

adapter screw located in center

NOTE: Both rod ends on each pitch link should

recess at aft end of actuator assem

be checked under a no load condition which

bly.

is best achieved by removing blades. Re

(b). Check for looseness in longitudinal

place rod ends having free play in excess of

and lateral cyclic control rod ends,

0.040 inch (1.016 mm) side motion.

located in tunnel. Replace rod ends

as required.

(4).

Inspect lower controls for slack between

(c). Check for free play in attachments

cyclic stick and attachment of the

and linkages between trim actuators

longitudinal and lateral control rods to

and cyclic pitch interconnecting

the mixer mechanisms, located just

torque tube. Replace parts as re

forward of the main rotor mast.

quired. Reinstall access door.

When replacing adjustable rod

CAUTION

(5).

Check lower end of cyclic stick for

ends, measure length accurate

ly to ensure that replacement rod is exactly

looseness at the attachment point to

same length as original. Mixer control rods

cyclic pitch interconnecting torque tube.

are factory adjusted at original installation

Replace bearings and/or bushings as

to provide necessary clearances.

required.

(8). Recheck for free play at the top of the

cyclic stick grip; as required, repeat

(6).

Check interconnecting torque tube

steps (1). thru (3). until total free play

bearings for free play; replace bearings

at top of grip is 3/8 inch (9.525 mm) or

if excessive free play is noted.

less in either longitudinal or lateral

direction.

(7).

Check for axial play in cyclic trim

(9). If replacement of parts is required

actuators (remove access door at lower

perform rigging of main rotor controls

end of pilot's bulkhead center tunnel in

(Ref. Collective Controls Rigging and

the cargo compartment).

Cyclic Controls Rigging).

Page 610

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CSP-HMI-2

MAINTENANCE MANUAL

MAIN ROTOR FLIGHT CONTROLS

REPAIRS

1. Tunnel−Routed Control Rod Repair

A. Control Tube End Sleeve Installation

Consumable Materials

(Ref. Figure 401)

(Ref. Section 91−00−00)

Item

Nomenclature

(1). Perform straightness check on control

CM219

Methyl-ethyl-ketone

rod that appears bent or bowed. Total

CM229

Paint remover

length of any tunnel-routed rod

CM230

Paint remover

(excluding rod ends) must be straight

within 0.050 inch (1.270 mm), with

CM231

Plastic bead, spherical 20 - 30 mesh

straightness variation limited to

CM318

Primer

maximum of 0.010 inch (0.254 mm) in

CM409

Adhesive, epoxy

each foot of length.

(1). Remove all four control rods (Ref.

Dye-check for cracking

Tunnel-Routed Control Rod Replace

WARNING

must always be performed

ment).

after cold-straightening. Replace

cracked rod, or cracked or bent rod

(2). Using paint remover (CM229, CM230

end.

or CM231) remove paint approximately

six inches back from end of each tube,

tape and cover-rap remaining area of

(2). Cold-straighten bent rod that is not

tube.

within tolerance (step (1). above)

provided there are no nicks or sharp

NOTE: Control tubes that are cracked must be

dents in bent length. Do not use rod

removed from service.

ends to support rod during straighten

ing.

(3). Dye penetrant inspect external surface

of stripped area for cracks.

Use care when drilling to re

CAUTION

(a). Cracked are indicated by heavy bleed

move or install riveted rod end;

out. It may be necessary to wipe off

rod end is steel and rod is aluminum.

and reapply the developer to distin

guish between surface defects caused

during swaging operation.

(3). Replace control rod end if bearing axial

play is more than 0.040 inch (1.016

(b). Light penetrant indications are not

mm). Set initial control rod length (Ref.

cause for rejection.

Figure 601).

(4). If no cracks are found; inspected control

tube can be reworked for sleeve instal

2. Tunnel−Routed Control Tube Inspection

lation. All four control tubes are to be

and Sleeve Installation

reworked as follows:

(a). Measure and record length of control

(Ref. Figure 801) The following procedures are

tubes for reinstalling rod ends and to

for inspection and installation of reinforcing

prevent rerigging after tube rein

sleeves to the tunnel-routed control tubes.

stallation.

Page 801

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MD Helicopters, Inc.

MAINTENANCE MANUAL

0.097-0.102 IN.

DIA

0.340 IN.

(2.4638-2.5908 MM)

(8.635 CM)

SLEEVE

CONTROL TUBE

0.750 IN.

DIA.

A DIA

(19.05 MM)

7° ±0.5°

0.000-0.080 IN.

(0.000-2.032 MM)

0.720 IN.

(18.288 MM)

0.910 IN.

(23.114 MM)

G67-1035A

Dimensional Table

Sleeve No.

Dim A

Tube O.D.

Rod No.

369D27013

inch (mm)

−1

0.540−0.545

(13.716−13.843)

0.501−0.530

(12.7254−13.462)

369A7007

369A7009

−2

0.510−0.515

(12.954−13.081)

0.470−0.500

(11.938−12.70)

−3

0.590−0.595

(14.986−15.113)

0.551−0.580

(13.9954−14.732)

369A7011

−4

0.560−0.565

(14.224−14.351)

0.520−0.550

(13.208−13.970)

369A7012

−5

0.570−0.575

(14.478−14.605)

0.530−0.560

(13.462−14.224)

NOTES:

(1) Material; 2024−T351 or T4 (QQA 225/6) bar or round stock

(2) Break sharp edges 0.005−0.015 inch (0.127−0.381 mm).

(3) Surface finish 125 RMS.

(4) Chemical film per MIL−C−5541.

(5) Tolerance * ±0.010 inch (±0.254 mm).

Figure 801. Sleeve Fabrication and Installation

Page 802

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CSP-HMI-2

MAINTENANCE MANUAL

Drilled out rivets may damage

Do not use heat gun. Use of heat

CAUTION

threads upon removal. Visually

lamp is acceptable.

inspect control tube threads for damage

from rivet and rod end removal. Replace

(i).

Allow to cure for 24 hours at mini

damaged control tubes. Drilled rod ends are

mum ambient temperature of 68°F

matched drilled to each control tube and

(20°C) (alternate cure 4 hours at

must be reinstalled into control tube end

115°-140°F (47°-60°C)).

from which removed.

(j).

Repeat procedure for ends of each

control tube.

(b). Remove rod ends, MS20470AD3

rivets must be removed from fixed

(k).

Using primer (CM318), touch-up

end.

repaired area(s) of control tube.

(c). Measure outside diameter of control

(l).

Install rod ends into ends in which it

tube end and select proper sleeve.

was removed. On fixed rod end, align

witness/rivet hole in sleeve and tube

with rivet hole in rod end. Drill (#40)

thru opposite end of sleeve. Rivet

(d). Temporarily install sleeve onto

fixed end with MS20470AD3-15

control tubes. Align sleeve and

rivet.

control tube witness hole. If sleeve

protrudes past end of control tube,

trim end of sleeve flush to 0.000 inch

(m).

Adjust each control tube to its

(0.000 mm) or back 0.080 inch (2.032

previously measured length and

mm) from end of tube.

paint the control tube ends with

primer. Paint adjustable ends of

control tube flat black.

NOTE: Bond integrity is dependent on clean

surfaces.

(n).

Reidentifiy, with permanent ink, the

control tubes that have been re

worked (Ref. Table 801).

(e).

Thoroughly clean end of control tube

and interior surface of sleeve with

lint free cloth and MEK (CM219) or

Table 801. Control Tube Re−Identification

equivalent.

Old Part Number

New Reworked Part Number

369A7007

369A7007−5

(f).

Mix epoxy adhesive (CM409) per

369A7009

369A7009−5

manufacturer's instructions.

369A7011

369A7011−5

369A7012

369A7012−5

(g).

Remove excessive adhesive with lint

free cloth moistened with MEK or

(o). Rework control tube boot (Ref.

equivalent. Do not saturate the

Figure 802).

cleaning cloth. Remove adhesive from

witness holes.

If control rod is not accurately

CAUTION

measured, flight controls will

(h).

Plug end of control tube to prevent

require rerigging.

adhesive from entering threads. Bond

sleeve to control tube. Apply adhesive

(p). Reinstall control tubes. Reinstall

to both surfaces and install sleeve.

trimmed boot with vertical seam

Align witness/rivet hole in sleeve and

facing aft. Check flight controls for

tube.

interference or binding.

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MAINTENANCE MANUAL

B. Control Tube Straight Area Sleeve

(2). Tape around area to be repaired.

Installation

(3). Using paint remover (CM229, CM230

This repair is permissible on the straight area

or CM231), strip paint 1.0 inch (2.54

of the tube only and increases the outside

cm) beyond area of repair.

diameter.

(4). Polish out burrs and sharp edges.

Consumable Materials

Ensure defects do not exceed allowable

(Ref. Section 91−00−00)

limits (Ref. Table 801). Dye penetrant

Item

Nomenclature

inspect area per MIL-I-25135; no

cracks allowed.

CM219

Methyl-ethyl-ketone

CM229

Paint remover

NOTE: Bond integrity is dependent on clean

CM230

Paint remover

surfaces.

CM231

Plastic bead, spherical 20 - 30 mesh

CM318

Primer

(a). Thoroughly clean repair area of

CM409

Adhesive, epoxy

control tube and interior surface of

sleeve with lint free cloth and MEK

(CM219) or equivalent.

NOTE:

D Ensure adequate clearance exists prior to

(b). Mix epoxy adhesive (CM409) per

performing the repair. Determine and re

manufacturer's instructions.

pair condition that caused damage.

(c). Apply adhesive to both surfaces and

D Maximum length of repair sleeve is 6 in

install sleeve.

ches (15.24 cm). Two sleeve repairs per

mitted per control tube.

(d). Remove excessive adhesive with lint

(1). Remove damaged control rod(s) (Ref.

free cloth moistened with MEK or

Tunnel-Routed Control Rod Replace

equivalent. Do not saturate the

ment).

cleaning cloth.

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MAINTENANCE MANUAL

Table 802. Control Tube Straight Area Repair Limits

Nicks and Gouges (2)

Dents and Depressions (2)

Repair Sleeve (3)

Tube

Max. Depth

Wall

O.D.

369A

W/O Repair (4)

With Repair (1)

W/O Repair (4)

With Repair (1)

Thickness

inch (cm)

Inch (mm)

inch (mm)

7007

0.006

(0.152)

0.015

(0.381)

0.010

(0.254)

0.025

(0.635)

1.375

(3.4925)

0.049

(1.2446)

7009

0.008

(0.203)

0.020

(0.508)

0.010

(0.254)

0.025

(0.635)

1.50

(3.81)

0.049

(1.2446)

7011

0.010

(0.254)

0.025

(0.635)

0.010

(0.254)

0.025

(0.635)

1.625

4.1275)

0.049

(1.2446)

7012

NOTES:

(1) Sleeve repair not permitted in tapered area. Two sleeve repairs per control tube. Maximum defect area

0.375 in² (2.41935 cm²) per sleeve.

(2) Must be free of burrs and sharp areas.

(3) Aluminum tube 6061−T6 WW−T−700/6 or 2024−T3 WW−T−700/3. Alternate: field fabricate from

2024−T351 or 2024−T4 (QQ−A−225/6 or QQ−A−200/3). Inside diameter to be 0.010−0.025 inch

(0.254−0.635 mm) larger than outside diameter of tube to be repaired. Outside diameter as listed in table,

±0.010 inch (±0.254 mm) and concentric to inside diameter 0.005 inch (0.127 mm). Maximum length of

repair sleeve 6 inches (15.24 cm). Break sharp edges 0.005−0.015 inch (0.127−0.381 mm).

(4) Maximum defect area without repair 0.10 in² (0.64516 cm²) total. For threaded area, last 2 inches (5.08

cm) of both ends, maximum depth of defect 0.020 inch (0.508 mm).

Do not use heat gun. Use of heat

4. Controls Support Bracket and Bellcrank

CAUTION

lamp is acceptable.

Repair

(Ref. Figure 403)

(e). Allow to cure for 24 hours at mini

mum ambient temperature of 68°F

(20°C) (alternate cure 4 hours at

Consumable Materials

115°-140°F (47°-60°C)).

(Ref. Section 91−00−00)

Item

Nomenclature

(f). Using primer (CM318), touch-up

CM321

Surface primer locking compound

repaired area(s) of control tube.

CM431

Sealing, locking and retaining compound

3. Controls Support Bracket and Bellcrank

Disassembly

(1). Replace unserviceable bearings. Install

new bearing with surface primer

(Ref. Figure 403)

(CM321) and grade A locking compound

(CM431).

NOTE: In following steps, do not remove

slotted bushings unless replacement is nec

NOTE: When idler bellcrank bearings are re

essary.

placed, make sure that idler bellcrank

spacers are reinstalled between bearings.

(1). Remove lateral idler bellcrank.

(2). Replace bellcranks or controls support

(2). Remove tail rotor bellcrank.

bracket that has distortion, cracks or

elongated holes.

(3). Remove longitudinal idler bellcrank.

5. Controls Support Bracket and Bellcrank

NOTE: Shim washers between longitudinal

Reassembly

idler bellcrank and support brackets align

(Ref. Figure 403)

one-way lock for no sideload. Keep shim

washers with bracket for use during reas

(1). Install longitudinal idler bellcrank.

sembly.

Check that slotted bushing is in place

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MAINTENANCE MANUAL

in support bracket lug, and reinstall

NOTE: Removal of additional setscrew is also

shim washers between bellcrank and

required on helicopters equipped with cargo

bracket for no sideload of one-way lock.

release mechanism.

(3). Cut nylon strap or twine that secures

NOTE: When performing following steps, en

electrical wiring to stick tube. Push

sure that slotted bushing is in support

wire slack into stick, carefully pull

bracket lug.

housing and wiring from end of stick

tube and disconnect wiring from

(2). Install lateral idler bellcrank.

switches.

(3). Install tail rotor bellcrank.

(4). Remove setscrew and wire guide from

forward end of stick. Tie string on each

wire bundle to aid reassembly and

6. Pilot’s Collective Pitch Stick Disassembly

remove wiring.

(L/H Command)

(5). Remove spring and idle stop release

(Ref. Figure 602)

ring.

(6). Remove grip attach bolts. Slide throttle

(1). Cut two nylon straps, and remove stick

grip friction washer and discs, and

friction mechanism guard.

friction nut from stick tube.

(2). Remove setscrews that secure switch

(7). Remove friction mechanism and guide

housing.

from stick fitting.

SEWN SEAMS

2 PLACES

0.40-0.50 IN.

(10.16-12.70 MM)

(NOTE 1)

DOUBLE BOOT

SINGLE BOOT

NOTES:

TRIM BOOTS BELOW HORIZONTAL SEAM.

CAUTION: DO NOT USE SOLVENTS OR PETROLEUM BASED CLEANING

FLUIDS ON VINYL BOOTS.

CLEAN INSIDE AND OUTSIDE OF VERTICAL SEAM AND TOP OF

BOOT WITH CLEAN CLOTH DAMPENED WITH ISOPROPYL ALCOHOL.

COAT BOTH SIDES OF VERTICAL SEAM WITH CONTACT CEMENT.

APPLY THIN COAT OF CONTACT CEMENT ALONG TRIMMED EDGE

AND 0.125-0.250 INCH (3.175-6.350 MM) DOWN INSIDE AND OUTSIDE

SURFACES OF BOOTS TO PREVENT FRAYING.

G67-1036A

Figure 802. Control Tube Boot Rework

(8). Remove idler gear from stick fitting.

(10). Remove gear shaft assembly. Keep

backlash shims with gear shaft.

NOTE: In following steps, do not remove bear

(11). Remove cover from back of stick

ings or pinion unless replacement is neces

housing.

sary.

(12). Remove gas producer control tube

(9). Remove cap from stick housing.

through access hole at back of stick

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CSP-HMI-2

MAINTENANCE MANUAL

housing. Remove mounting distance

shim only if necessary to adjust pinion

Consumable Materials

gear mounting distance.

(Ref. Section 91−00−00)

Item

Nomenclature

7. Pilot’s Collective Pitch Stick Repair (L/H

CM116

Grease, aircraft and instrument

Command)

CM431

Sealing, locking and retaining compound

CM807

Twine, nylon

(Ref. Figure 602)

CM815

Solder

Consumable Materials

(1).

Check gearshaft bearings in housing

(Ref. Section 91−00−00)

cap a housing for security of outer

Item

Nomenclature

races. Use grade A locking compound

CM116

Grease, aircraft and instrument

(CM431) to install replacement bear

ings. Use care to prevent compound

from entering bearings, and make sure

(1). Replace bearings if corroded, excessive

that each bearing is seated against its

ly worn, or if outer or inner races of

bore shoulder.

bearings rotate on mating surfaces and

locking compound is inadequate to

(2).

Using grease (CM116), lubricate stick

prevent rotation.

tube interior where gas producer

control tube fitting makes contact.

(2). Replace loose rivets in gas producer

control tube.

(3).

Attach strings routed through stick

tube during disassembly, and thread

(3). Replace friction drive gear or idler gear

electrical wire bundles from plug

with cracked, chipped or broken teeth.

through exit hole, throttle friction nut,

friction washers and discs, throttle grip,

(4). Replace friction drive gear if it does not

idle stop release ring and spring. Pull

rotate freely on stick tube, or if rotating

wiring out through front end of stick

stop is damaged. To remove gear, drill

tube.

out rivets that attach throttle friction

(4).

Install wire guide so that it divides

nut fitting to stick.

switch wiring: three wires in one cutout

NOTE: Before replacing drive gear for binding,

and four in the other. Align guide with

clean and relubricate bore with grease

matching hole in stick tube and install

(CM116). Reinstall gear on stick tube and

setscrew. When tightened, setscrew

recheck for free rotation. If gear still binds it

must be flush or not recessed more than

0.010 inch (0.254 mm) below outer tube

must be replaced.

surface.

(5). Replace phenolic friction washers

NOTE: Ensure gas producer control tube is in

against guide if worn to less than 1/32

stalled into stick housing with elongated

inch thickness.

area of fitting facing down.

(6). Replace friction gear assembly if driven

(5). Install gas producer control tube

gear has cracked, chipped or broken

through access hole in back of stick

teeth or if cam pin is bent.

housing, and through stick tube until

control tube fitting engages wire guide

(7). Replace damaged idle stop release ring.

bore. Reinstall mounting distance

Ring must slide freely on tube and in

shims forward side of pinion bearing if

throttle grip.

removed during disassembly. (One edge

of shim must be cut for installation.)

8. Pilot’s Collective Pitch Stick Reassembly

(L/H Command)

NOTE: Steps (6). thru (8). below are used to de

termine gas producer control tube pinion

(Ref. Figure 602)

mounting distance.

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MAINTENANCE MANUAL

(6).

Install approximate required thickness

(14). Lubricate teeth of pinion gear and shaft

of split shims between pinion bearing

assembly bevel gear with grease

and housing to establish gas producer

(CM116).

control tube pinion mounting distance.

(15). Apply grade A locking compound

(CM431) to secure gearshaft to bear

(7).

Use throttle friction nut to pull gas

ings. Do not allow compound to enter

producer torque tube forward until not

bearings. With throttle grip at mid-tra

less than 10 pounds (44.48 N) of force is

vel, install driven gear. Note that at

applied to compress shims.

throttle-grip mid-travel, cut out

portion of the driven gear is to be

(8).

Add or subtract shims to provide

opposite pinion gear. (Centerline of

0.699-0.709 inch (17.7546-18.0086

center tooth of driven gear is two

mm) dimension (Ref. Figure 504).

degrees and fifty minutes from center of

Repeat step (7). during each measure

driven gear cutout.)

ment.

NOTE: With throttle grip at mid-travel, two

grip attach bolts are positioned approxi

(9).

After mounting distance shimming is

mately straight down.

correct, remove gas producer control

tube and apply grade A locking com

(16).

Install housing cap on shaft assembly

pound (CM431) to outside diameter

and seat with hand pressure while

pinion bearing outer race and stick

slowly rotating grip back and forth.

housing bore. Reinstall control tube,

Secure cap to side of housing and cover

and check that compound does not

to back of housing.

enter bearing and that bearing outer

(17).

Using solder (CM815), connect wiring

race and shims are firmly seated

to stick switches. Pull electrical wiring

against housing bore.

slack out through exit holes in stick

tube, position release ring and. spring

(10).

Install throttle friction nut, friction

and install switch housing with set

discs and washers.

screws. Using nylon strap, or twine

(CM807), secure electrical wiring to

(11).

Using grease (CM116), lubricate

stick tube approximately one inch aft of

interior of throttle grip and install grip

exit holes.

on stick tube. Align grip and gas

producer control tube fitting and install

(18).

Install friction cam and driven gear

grip attach bolts. When tightened, bolts

assembly on stick fitting. Temporarily

must be flush or not more than 0.010

mesh idler gear and driven gear, and

inch (0.254 mm) below outer face of

rotate friction drive gear counterclock

grip.

wise to maximum stop.

(19).

Hold drive gear at stop and remesh

(12).

Establish gas producer control tube

idler gear and driven gear so that gear

pinion and shaft assembly bevel gear

assembly pin is at high point of cam.

backlash by temporarily installing

driven gear, shaft, and two bearings,

(20).

Use shim washers sufficient to limit

plus approximate required thickness of

gear end play to maximum of 0.010 inch

backlash shims in housing. Temporarily

(0.254 mm), and secure idler gear with

install housing cap. Add or subtract

cotter pin.

shims to provide maximum backlash of

(21).

Assemble remainder of friction mecha

0.003 inch (0.076 mm) without bind in

nism.

gears. Make certain that bearings are

completely seated in bores while

(22).

Adjust collective friction mechanism.

establishing this backlash adjustment.

9. Pilot’s Collective Pitch Stick Disassembly

(R/H Command)

(13).

After backlash shimming is correct,

remove housing cap and gear shaft.

(Ref. Figure 603)

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CSP-HMI-2

MAINTENANCE MANUAL

(1).

Disassemble collective stick to extent of

from entering bearings, and make sure

removing friction mechanism idler gear

that each bearing is seated against its

from stick fitting, except also remove

bore shoulder.

screw and nut to disconnect electrical

(2). Completely reassemble pilot's collective

terminals from stick housing.

stick to the extent of assembling

(2).

Detach link and idler.

friction mechanism.

(3). Connect two electrical terminals to

(3).

Remove idler from socket housing. Do

stick housing.

not remove idler bearing unless

replacement is necessary.

(4). Shim and adjust pinion mounting

distance and backlash.

(4).

Remove four bolts and washers that

attach housing cap to socket housing.

(5). After backlash shimming is correct,

Rotate shaft assembly until gear tooth

install bellcrank on shaft assembly and

cutout clears pinion (bellcrank ears at

link to bellcrank; then install, seat and

approximately 195 degrees);, then

secure housing cap on stick housing. Do

separate bellcrank, housing cap and

not adjust collective friction mechanism

shaft assembly from housing.

at this point of assembly.

(5).

Remove bellcrank from shaft assembly

(6). Install idler to the stick housing, and

to separate housing cap from shaft. Do

link to the idler.

not press bearings from cap or housing

(7). Adjust the collective friction mechanism

unless replacement is necessary. Keep

(Ref. Collective Stick Friction Mecha

backlash shims with shaft assembly.

nism Adjustment).

(6).

Remove link from bellcrank.

11. Copilot’s Collective Pitch Stick

(7).

Remove gas producer control tube

Disassembly (L/H and R/H Command)

through access hole at back of pilot's

(1).

Cut nylon strap or twine securing

collective stick housing.

wiring to stick tube.

(8).

Remove mounting distance shim only if

(2).

Remove setscrews that secure the

necessary to adjust pinion gear mount

switch housing.

ing distance.

(3).

Push wire slack into stick and carefully

(9).

Remove pinion and bearing from

pull switch housing from end of stick

control tube only if replacement is

tube; disconnect wiring from N₂ switch

necessary.

(Ref Chap. 96).

10. Pilot’s Collective Pitch Stick Reassembly

(4).

Remove grip attach bolts and grip.

(R/H Command)

(5).

Remove adjusting nut pin and throttle

end play adjusting nut only if stick tube

(Ref. Figure 603)

replacement is necessary, or if end play

must be adjusted.

Consumable Materials

(Ref. Section 91−00−00)

(6).

Remove setscrew and wire guide. Tie a

Item

Nomenclature

``fish'' string on end of wire bundle to

aid reassembly, and then remove the

CM431

Sealing, locking and retaining compound

wiring.

(7).

Remove cap from stick housing. Do not

(1). Check gearshaft bearings in housing

remove bearing from cap unless

cap and housing for security of outer

replacement is necessary.

races. Use grade A locking compound

(CM431) to install replacement bear

(8).

Remove gearshaft assembly. Keep

ings. Use care to prevent compound

backlash shims with gearshaft and do

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MAINTENANCE MANUAL

not remove bearing from stick housing

(4).

Install wire guide in stick tube so it

unless replacement is necessary.

positions wire bundle in right cutout of

guide. Align guide with matching hole

(9). Remove cover from back of stick

in stick tube, and install setscrew.

housing.

When tightened, setscrew must be at

least flush and not recessed more than

(10). Remove gas producer control tube

0.010 inch (0.254 mm) below outer

through access hole in back of stick

surface of tube.

housing. Remove mounting distance

shim only if necessary to adjust pinion

(5).

Install gas producer control tube

gear mounting distance. Remove pinion

through access hole in back of stick

and bearing from control tube only if

housing, and through stick tube until

replacement is necessary.

control tube fitting engages wire guide

bore. Reinstall mounting distance

12. Copilot’s Collective Pitch Stick Repair

shims at forward side of pinion bearing

if removed during disassembly. (One

(1). Replace bearings if locking compound

edge of shims must lie cut for installa

does not prevent outer or inner races

tion.)

from rotating on mating surfaces, if

(6).

Establish gas producer control tube

corroded, or if excessively worn.

pinion mounting distance (Ref. Gas

(2). Replace loose rivets in gas producer

Producer Linkage Adjustment).

control tube, or damaged pinion gear.

(7).

After mounting distance shimming is

correct, remove gas producer control

13. Copilot’s Collective Pitch Stick

tube and apply grade A locking com

Reassembly

pound (CM431) to OD of pinion bearing

outer race, and stick housing bore.

Consumable Materials

Reinstall control tube and check that

(Ref. Section 91−00−00)

compound does not enter bearing and

Item

Nomenclature

that bearing outer race and shims are

firmly seated against housing bore.

CM116

Grease, aircraft and instrument

CM431

Sealing, locking and retaining compound

(8).

Using grease (CM116), lubricate ID of

CM807

Twine, nylon

throttle grip and install grip on stick

tube. Align grip and gas producer

CM815

Solder

control tube fitting and install grip

attach bolts. When tightened, bolts

(1). Check gearshaft bearings in housing

must be at least flush and not recessed

cap and housing for security of outer

more than 0.010 inch (0.254 mm) below

races. Use grade A locking compound

outer surface of grip.

(CM431) to install replacement bearing.

(9).

Establish gas producer control tube

Use care to prevent compound from

pinion and gearshaft bevel gear

entering bearings, and make sure each

backlash.

bearing is seated against its bore

shoulder.

(10).

After backlash shimming is correct,

remove housing cap and gearshaft.

(2). Using grease (CM116), lubricate stick

tube interior where gas producer

(11).

Lubricate teeth of pinion gear and

control tube fitting makes contact.

gearshaft bevel gear with grease

(CM116).

(3). Attach ``fish'' string (routed through

stick during disassembly) and thread

(12).

Apply grade A locking compound

electrical wire bundle from electrical

(CM431) to gearshaft and ID of bear

plug through exit hole in stick tube and

ings. With throttle grip at mid-travel,

out front end of tube.

install shaft assembly gear.

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MAINTENANCE MANUAL

(13).

Install housing cap on gearshaft and

right end fitting to torque tube to

seat with hand pressure while slowly

replace right support bearing. Install

rotating grip back and forth. Secure cap

new bearings and rivets at existing

on side of housing and cover on back of

holes.

housing.

(2). Replace torque tube if it is cracked or

(14).

Check throttle grip for zero end play on

has elongated holes.

stick tube and that not more than 1

NOTE: Torque tube droop control bracket may

pound torque is required to rotate the

be either an aluminum or magnesium cast

grip. If these conditions exist, proceed

ing. (For corrosion control and identification

with step (18). below. If there is end

of magnesium and aluminum alloy parts,

play, or too much torque is required to

Ref. Sec. 20-40-00.)

rotate the grip, perform steps (15)., (16).

and (17).

(3). Replace bent or stripped bungee

adjusting bolt. Torque nut to 30 - 40

(15).

Remove grip attach bolts and grip.

inch-pounds (3.39 - 4.52 Nm).

(16).

Insert 3/64 inch (1.190625 mm) diame

(4). Replace scratched, nicked or otherwise

ter drift punch into access hole on

damaged reinforcement strap.

forward face of adjusting nut and drive

grooved taper pin from adjusting nut

15. Collective Bungee Disassembly

and threaded fitting of stick tube.

(Ref. Figure 407)

(17).

Reinstall grip with grip attach bolts

and establish zero end play and correct

rotational friction, 1 pound (4.448 N)

Special Tools

maximum, between nut and grip. The

(Ref. Section 91−00−00)

match-drill 3/64 inch (1.190625 mm)

Item

Nomenclature

maximum diameter stick tube fitting

ST510

Bungee spring compression tool rod and

threads to existing pin groove in nut,

channel

and install pin.

(18).

Using solder (CM815), connect wiring

(1). Remove male bearing from bungee

to N₂ switch. Pull electrical wiring

clamped in compression by installation

slack out through exit hole in stick tube

tool.

and install switch housing with set

screws. Using nylon strap or twine

(2). Install bungee compression tool rod and

(CM807), secure electrical wiring to

channel (ST510) on compressed bungee.

stick tube, approximately one inch (2.54

Insert 1/4 inch (6.35 mm) bolt through

cm) aft of exit hole.

channel and female bearing rod end.

14. Collective Control Interconnecting Torque

(3). Place compression tool and bungee in

Tube Repair

vise so that vise jaws make contact with

tool rod and channel. Compress vise

(Ref. Figure 407)

and remove bungee clamp.

(1). Replace loose or binding torque tube

(4). Slowly open vise and remove bungee

sup- port bearings. Drill out rivets

components.

securing retainer and doubler to seat

structure to replace left support

NOTE: Do not disassemble female bearing as

bearing. Drill out three rivets securing

sembly; if defective, replace as a unit.

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MAINTENANCE MANUAL

16. Collective Bungee Reassembly

Rotate shaft assembly until gear tooth

cutout clears pinion (bellcrank ears at

(Ref. Figure 407)

approximately 195 degrees); then

separate bellcrank, housing cap and

shaft assembly from housing.

Consumable Materials

(Ref. Section 91−00−00)

(4). Remove bellcrank from shaft assembly

Item

Nomenclature

to separate housing cap from shaft. Do

CM116

Grease, aircraft and instrument

not press bearings from cap or housing

unless replacement is necessary. Keep

backlash shims with shaft assembly.

Special Tools

(Ref. Section 91−00−00)

(5). Remove link from bellcrank.

Item

Nomenclature

ST508

Collective bungee installation tool

(6). Remove snap ring that retains N₁

ST509

Not used at this time

pinion gear aft bearing in housing.

ST510

Bungee spring compression tool rod and

Press pinion gear and aft bearing, as an

channel

assembly, out through access hole at the

back of housing. Disassemble pinion

bearings from pinion and housing only

(1).

Lubricate cups of spring retainers and

if replacement is necessary.

threads and bore of female bearing

assembly with grease (CM116).

18. Inboard Collective Stick Socket Assembly

Repair

(2).

Assemble retainer, spring and female

bearing assembly. Install compression

(Ref. Figure 408)

tool rod and channel (ST510). Insert a

1/4 inch (6.35 mm) bolt through channel

and female bearing rod end.

Consumable Materials

(Ref. Section 91−00−00)

(3).

Position assembly in bench vise.

Item

Nomenclature

Compress bungee spring until bungee

CM116

Grease, aircraft and instrument

installation tool (ST508 or ST509) fits

over retainers. Secure tool halves in

place with clamp.

(1). Replace bearings if corroded, excessive

ly worn, or if outer or inner races of

(4).

Open vise slowly and remove bungee

bearings rotate on mating surfaces and

compression tool rod and channel.

locking compound does not prevent

(5).

Install male bearing in compressed

rotation. Install new bearings with

bungee.

grade A locking compound (CM116).

Check that replacement bearing is

properly seated in mounting bore.

17. Inboard Collective Stick Socket Assembly

Disassembly

(2). Replace any cracked part.

(Ref. Figure 408)

(3). Replace entire link if bearings are

(1). Disconnect link from idler.

defective; link bearings are not replace

able.

(2). Remove idler from socket housing. Do

not remove idler bearing unless

(4). Replace pinion gear or shaft assembly

replacement is necessary.

bevel gear when correct backlash

cannot be maintained because of tooth

(3). Remove four bolts and washers that

irregularities caused by wear or

attach housing cap to socket housing.

deformation.

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MAINTENANCE MANUAL

19. Inboard Collective Stick Socket Assembly

NOTE: Bellcrank attachment bolt must be in

Reassembly

stalled with head slightly down and for

ward.

(Ref. Figure 408)

(7). Lubricate teeth of pinion gear and shaft

assembly bevel gear with grease

(CM116).

Consumable Materials

(Ref. Section 91−00−00)

(8). Apply grade A locking compound

Item

Nomenclature

(CM431) to bond bevel gearshaft and

CM116

Grease, aircraft and instrument

bearings. With centerline of wide

toothspace of N₁ pinion gear spline up

CM431

Sealing, locking and retaining compound

(on top), install shaft assembly gear at

midtravel position.

(1).

Check gearshaft bearings in housing

NOTE: N₁ pinion shaft spline wide toothspace

cap and housing for security of outer

should be positioned up at approximately

races. Use grade A locking compound

one o'clock position, as viewed looking aft

(CM431) to install replacement bear

into open end of socket.

ings. Use care to prevent compound

from entering bearings, and make sure

(9). Install four bolts, eight washers, four

that each bearing is seated against bore

spacers and nuts to secure cap to

shoulder.

housing.

(10). Install idler to housing, and link to

(2).

Apply grade A locking compound

idler.

(CM431) to pinion gear aft bearing

outer circumference and matching bore

NOTE: When installed, idler to gas producer

in socket housing. Install assembled N₁

control rod bolt holes should be in line with

pinion gear and aft bearing; seat

centerline of stick assembly housing cap

bearing firmly against bore shoulder.

when gearshaft and pinion gears are posi

tioned as outlined in step (8). above.

(3).

Install snap ring that retains aft-bear

ing in housing bore. Apply locking

20. Cyclic Control Stick Repair

compound to bond pinion shaft to

(Ref. Figure 411) Disassemble cyclic control

forward bearing and to bond forward

stick only as necessary to replace damaged or

bearing to housing bore. Press bearing

faulty parts. Pilot's stick tube should not be

firmly against housing shoulder.

removed from stick socket; the assembly

(Housing is machined to provide a light

should only be replaced as a unit.

press-fit.)

21. Cyclic Friction Mechanism Repair

(4).

Establish N₁ pinion and shaft assembly

bevel gear backlash by rotating N₁

(Ref. Figure 603)

pinion gear assembly so that wide

toothspace on spline is at about one

(1). Remove cap nut from friction stud and

o'clock when viewed from socket

disassemble friction mechanism from

(looking aft). Install backlash shims to

stick socket or torque tube.

obtain maximum backlash of 0.003 inch

(2). Replace bent or stripped friction stud.

(0.076 mm) with bearings firmly seated

Drill out rivet and press stud from

in bores.

socket; install new stud and rivet in

place. Press replacement spring pin

(5).

After backlash shimming is correct,

into friction stud until one end of pin is

remove housing cap and gearshaft.

flush with surface of stud.

(6).

Install bellcrank on shaft assembly, and

(3). Assemble friction mechanism to stick

link to bellcrank.

socket or torque tube.

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MAINTENANCE MANUAL

(4). Adjust friction knob cap nut to stop

Use care when drilling to re

CAUTION

knob when spring extends to free

move or install riveted rod end;

length, no compression ±1/32 inch

rod end is steel and rod is aluminum. Do not

(±0.79375 mm).

tighten adjustable rod end jam nut on pilot's

lateral control rod until rod is installed and

cyclic stick longitudinal travel is checked.

22. Lateral Control Rods and Sta. 67

(3). Replace control rod end if bearing axial

Bellcrank Repair

play is more than 0.040 inch (1.016

mm). Set initial control rod length and

(Ref. Figure 411)

bearing angularity.

23. Cyclic Pitch Interconnecting Torque Tube

Repair

Consumable Materials

(Ref. Section 91−00−00)

(Ref. Figure 412)

Item

Nomenclature

CM431

Sealing, locking and retaining compound

Consumable Materials

(Ref. Section 91−00−00)

Item

Nomenclature

(1). Replace Sta. 67 lateral bellcrank if it

CM116

Grease, aircraft and instrument

has elongated holes or is cracked.

CM431

Sealing, locking and retaining compound

Replace pivot bearing if it binds or is

excessively worn; install with grade A

NOTE: Cyclic torque tube may be either a ma

locking compound (CM431). Check free

chined magnesium or aluminum casting.

play of bellcrank with newly installed

(For corrosion control and identification of

pivot bearing by applying light up and

magnesium and aluminum alloys, Ref. Sec.

down pressure at forward end of

20-40-00.)

bellcrank with bearing secured. For

bearing to be acceptable, bellcrank total

(1). Replace torque tube if it is cracked, has

play measured at centerline of bolt that

elongated holes or deformed bearing

attaches pilot's lateral control rod end

supports.

must not exceed ±0.024 inch (±0.6096

mm).

(2). Replace main support bearings or cyclic

stick pivot bearings if they bind or are

excessively worn. Drill out four rivets

NOTE: Sta. 67 lateral bellcrank may be either

and remove bearing retainer to replace

an aluminum or magnesium machined forg

right support bearing. Install cyclic

ing. (For corrosion control and identification

stick pivot bearing and right support

of magnesium and aluminum alloys, Ref.

bearing with grade A locking compound

Sec. 20-40-00.)

(CM431).

NOTE: Left support bearing is a slip-fit in

(2). Perform straightness check on control

torque tube lug; coat outer circumference of

rod(s) that appear bent or bowed. Total

bearing with grease (CM116) prior to inser

length of rod (excluding rod ends) must

tion in lug.

be straight within 0.010 inch (0.254

mm). Cold-straightening of rod is

(3). Replace bent or stripped friction stud.

permissible if no nicks or sharp dents

Drill out rivet; install and rivet new

exist in bend length, and rod ends are

stud in place. Insert spring pin with one

not used to support rod during straight

end flush with stud.

ening process. Dye-check for cracking

is to be performed after cold-straigh

24. One−Way Lock Repair

tening. Replace cracked rod, or cracked

or bent rod end.

For overhaul information, Ref. COM.

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CSP-HMI-2

MAINTENANCE MANUAL

(3). Clean inside of trim tube with solvent

Consumable Materials

(CM234).

(Ref. Section 91−00−00)

(4). Coat outside of replacement spring

Item

Nomenclature

assembly tube lightly with grease

CM206

Chemical coating

(CM116).

CM801

Abrasive paper, silicon carbide

(5). Slide replacement spring assembly into

CM803

Crocus cloth

trim tube.

(6). Install spring adapter screw in open

(1). Remove dents, nicks and scratches by

end of spring assembly and tighten

using grade 400 abrasive paper

screw until 0.010-0.050 inch

(CM801) to remove rough edges. Finish

(0.254-1.27 mm) play is felt while

by polishing with crocus cloth (CM803);

pushing or pulling on spring assembly.

maintain smooth transition into

While tightening screw, check that

surrounding area. After repair treat

friction exists from self-locking

area with chemical film (CM206).

threaded insert.

(2). When replacing input (forward) shaft

(7). Wipe off all excess grease.

rod end bearing, with piston at mid

stroke ensure bearing center-to-center

(8). Perform bench test to check actuator

distance is 8.58 ±0.030 inches (217.932

operation.

±0.762 mm). Adjust as required. After

correct length is set, tighten and safety

26. Cyclic Trim Actuator Housing or Trim

lock nut with lockwire.

Tube Replacement

NOTE: Support links may be either forged alu

(Ref. Figure 508)

minum or magnesium castings. (For corro

sion control and identification of magne

Consumable Materials

sium and aluminum parts, Ref. Sec.

(Ref. Section 91−00−00)

20-40-00.)

Item

Nomenclature

CM318

Primer

25. Cyclic Trim Actuator Spring Assembly

Replacement

(1). Remove actuator spring assembly.

(Ref. Figure 508)

(2). Carefully drill out four rivets attaching

trim tube. Remove trim tube.

Consumable Materials

(Ref. Section 91−00−00)

(3). Remove actuator from actuator hous

Item

Nomenclature

ing. Check housing for condition and

evidence of corrosion.

CM116

Grease, aircraft and instrument

CM234

Solvent, dry-cleaning

NOTE: Housing may be either aluminum or

magnesium casting. (For corrosion control

and identification of magnesium and alumi

(1). Insert screwdriver into open end of

num alloys, Ref. Sec. 20-40-00.)

spring guide and remove screw that

connects two spring adapters.

(4). Use dimensions to assemble replace

ment actuator housing and trim tube. If

NOTE: Identify screw for lateral or longitudi

replacement part is undrilled, drill #40

nal trim; screws are not interchangeable.

- 0.098 inch (2.4892 mm) four attaching

Lateral actuator screw is 2-7/8 inches

rivet holes.

(73.025 mm) long; longitudinal screw is

2-5/8 inches (66.675 mm) long.

(5). Coat mating surfaces of trim tube and

actuator housing with primer (CM318).

(2). Slide spring assembly out of trim tube.

Assemble while primer is still wet.

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MAINTENANCE MANUAL

(6). Install four mechanically expanding

(1). Remove cyclic trim actuator from

rivets.

helicopter.

(7). Reinstall actuator.

(2). If actuator is inoperative, bench test

unit to determine whether mechanical

(8). Reinstall actuator spring assembly.

(stalled), electrical or other mechanical

failures exists.

(9). Perform bench test.

(a). A reading of 0.0 - 0.1 amperes

27. Cyclic Trim Actuator (Motor/Gear Drive

indicates electrical failure; replace

Mechanism) Replacement

actuator.

(Ref. Figure 508)

(b). The motor runs, but the output shaft

(1).

Remove actuator spring assembly.

does not move, indicates a mechani

cal failure; replace actuator.

(2).

Remove trim tube.

(c). A reading of 0.7 amperes (approxi

(3).

Support actuator tube and press out

mately), or actuator extends part way

spring pin.

and stalls, indicates stalled failure;

(4).

Unscrew adapter from actuator and

rework actuator per steps (3). thru

remove actuator from housing.

(9). below.

(5).

Screw adapter into replacement

(3). Remove lockwire and six screws

actuator shaft until it bottoms. If spring

securing actuator cover to housing.

pin hole drilled in adapter does not

align with guide hole in adapter,

When removing housing, note

CAUTION

adapter must be replaced; otherwise

the location and number of

adapter may be reused.

shims on each gear for reassembly in proper

location.

(6).

Use 1/16 inch (0.0625) drill to drill

spring pin hole through adapter and

NOTE: Step (4). not applicable if actuator is op

actuator; deburr hole.

erative. Perform steps (5). thru (9). below.

(7).

Reassemble actuator housing and trim

(4). Using fingers only, check gear drive

tube.

retention (hex) nut for looseness. If nut

is loose, rework per instructions below.

(8).

Install actuator in housing. Screw

If nut is NOT loose, replace actuator

adapter on actuator.

assembly.

(9).

Support actuator shaft; press in spring

(5). Remove nut and clean threads. Rein

pin. Ensure that pin is flush with shaft.

stall nut using Locktight #290 on

threads. Torque nut to 30 - 40 inch-

(10).

Install actuator spring assembly.

pounds (3.39 - 4.52 Nm).

(11).

Bench test actuator.

(6). Reinstall actuator cover with existing

28. Cyclic Trim Actuator Rework (Calco P/N

screws; lockwire screws.

8222M6 and 8222M7)

(7). Add letter ”R” at end of vendor part

The following procedure is for tightening the

number on actuator housing.

trim actuator drive gear retention nut and also

testing stalled actuators.

(8). As applicable, reinstall trim actuator.

NOTE: Rework is NOT applicable to actuators

(9). Record rework of trim actuator in

having letter ”R” following vendor part

Components Record of helicopter Log

number on actuator housing.

Book.

Page 816

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CSP-HMI-2

MAINTENANCE MANUAL

COLLECTIVE AND CYCLIC STICK GRIPS

MAINTENANCE PRACTICES

1. Collective Pitch Stick Switches

provided at the left of the trim switch for

optional equipment. Coiled, insulated and

(Ref. Figure 201) The START, N2 GOV and

open-ended wiring is provided in the grip for

LDG LT switches are on the collective stick

connection to an optional switch.

assembly. Wiring for the switches is routed

down through the collective stick tube and

NOTE: Cyclic stick grip configurations vary

interconnects with electrical system wiring

and may have additional switches. Switch

through a connector at the base of the stick.

functions are described in appropriate sec

tions.

2. Collective Pitch Stick Switches

Replacement

4. Cyclic Control Stick Grip Replacement

(Ref. Figure 201)

A. Cyclic Control Stick Grip Removal

(Ref. Figure 203)

Consumable Materials

(Ref. Section 91−00−00)

(1). Disconnect removable contacts from

Item

Nomenclature

electrical plug.

CM703

Tie strap

CM807

Twine, nylon

(2). Remove nylon strap that secure wiring

to stick socket. Remove strap mounting

plate only if it is unserviceable.

Ensure all electrical power is

CAUTION

OFF.

(3). Remove screw from grip and separate

grip from tube.

(1). Disconnect grounding terminals.

(4). Tie a string to each wire bundle to aid

(2). Remove attaching hardware securing

reassembly. Push wire slack into wiring

stick grip switch housing. Remove

exit holes in stick socket while pulling

housing and switchplate.

grip wiring from stick tube. Remove

grip and wiring; leave strings in tube.

(3). Disconnect wiring and remove affected

switch.

B. Cyclic Control Stick Grip Installation

(4). Install replacement switch in reverse

(Ref. Figure 203)

order of removal. If nylon strap

(CM703) is not available, use twine

(1). Separate grip wiring into approximate

(CM807) to secure wiring to collective

ly equal size color-coded bundles,

pitch stick.

according to wiring diagram.

(5). Perform operational check of switch

(2). Install an eight inch (20.32 cm) length

and associated system or equipment

of AWG Size No. 3 electrical insulation

(Ref. appropriate PFM).

sleeving on each bundle and push

sleeving up into grip.

3. Cyclic Stick Grip Switches

(3). Route wiring through stick tube and

(Ref. Figure 202) The pilot's cyclic stick grip

out wiring exit holes with aid of strings

contains a toggle switch for cyclic trim control

inserted at stick removal. Push wires at

and a trigger switch for radio/interphone

grip end while pulling slack out of

communications. A blank switch socket is

socket.

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MAINTENANCE MANUAL

(4). Install an additional eight inch 20.32

(6). Push slack wiring into wiring exit holes

cm) length of insulation sleeving to

in stick socket while pulling grip wiring

protect each wire bundle where routed

from stick tube.

through exit holes in socket.

(7). Remove trim switch cap by carefully

pulling cap off.

(5). Position grip on stick tube and install

screw.

(8). Remove all attaching hardware secur

ing switches to grip, carefully remove

(6). Push as much wire slack as possible

switches and attached harness from

back into stick. Secure wiring to socket

grip assembly.

with new nylon strap, or equivalent.

(9). Tag, identify and un-solder wires of

(7). Cut wiring to correct length and

switch to be disconnected.

reinstall replaceable contacts and

electrical plug and wiring diagram.

(10). Clean grip, wiring and switches with

alcohol (CM217).

5. Cyclic Stick Grip Switch Replacement

(11). Reconnect all electrical wires using

(Standard Grip)

solder (CM815), remove identification

tags from wires.

(Ref. Figure 203)

(12). Carefully position switches to their

approximate location within the grip.

Consumable Materials

(Ref. Section 91−00−00)

NOTE: Ensure that switches are correctly posi

Item

Nomenclature

tioned with any applicable keyway, pin hole,

CM217

Isopropyl alcohol

etc, for proper alignment of mating parts.

CM425

Sealing compound

(13). Install attaching hardware securing

CM703

Tie strap

switches onto grip.

CM815

Solder

(14). Install trigger and trigger attach pin.

(15). Install cyclic trim switch cap.

Ensure that all electrical

WARNING

power is OFF.

(16). Reinstall grip on stick tube, route grip

wiring through stick tube and attach

(1). Disconnect cyclic grip wiring connector

connector.

from plug at lower end of cyclic stick.

(17). Check switch operation and wiring

(2). Remove strap securing wiring to stick

continuity.

socket; remove strap mounting plate if

(18). Apply sealing compound (CM425) to all

it is unserviceable.

screw holes and insert holes.

(3). Remove exterior sealant from grip

(19). Secure wiring to stick with nylon straps

assembly covering switch mounting

(CM703).

hardware and attaching screws.

Cyclic trim actuators should be

(4). Drive trigger pivot pin from grip to

CAUTION

operated only momentarily to

release trigger. Pin is removed from

prevent damage to equipment.

right to left while holding grip in

normal position. Remove trigger.

(20). Check operation of switch by momen

tarily cycling in all modes ensuring that

(5). Remove screw from grip and separate

the associated system operates correct

grip from stick tube.

ly.

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MAINTENANCE MANUAL

6. Cyclic Stick Grip Disassembly (Optional

cal wires using solder (CM815) and

T−Grip, PN 369D297846 Only)

reinstall switches as applicable.

(Ref. Figure 203)

NOTE: Ensure that switch is correctly posi

tioned with any applicable keyway, pin hole,

Ensure that all electrical

etc, for proper alignment of matching parts.

WARNING

power is OFF.

(2). Insert replacement switch at the

(1). Remove the grip cap by removing six

approximate mounting position on the

screws.

grip subassembly.

NOTE: The grip is to be disassembled only to

(3). Using solder (CM815), connect wiring

the extent required for replacement of the

to terminals of the replacement switch.

switches. The wiring through the grip as

Remove identification tags from wires.

sembly is tied with nylon twine and covered

NOTE:

with a two inch (5.08 cm) insulating sleeve.

D Helicopters (369D) S/N 003 thru 480 may

Do not remove the twine and sleeves unless

require trigger switch rework to accom

wire replacement is required.

modate replacement switch

(Ref.

(2). Detach the rocker switch (S111) by

Figure 204).

removing two screws.

D Rework is not necessary for the following

cyclic grip assemblies; PN 369D27133 or

(3). Unscrew the trigger pin and carefully

A218-964401-00.

withdraw it while holding the trigger

guard and trigger switch (S101) in

(4). If rework is required, perform steps (a).

place. Then remove the trigger guard

thru (c). before continuing.

and switch and separate them with care

(a). Press or pull insert from top of grip.

to prevent distorting or losing the

return spring.

(b). Make template of profile of new

A218-158698-05 trigger switch.

(4). Remove toggle switch (S102). Switch

button is separated from housing by

(c). Using file, blade or equivalent

pressing out the pin.

routing tool, remove material from

lower inside edge of hole for trigger

(5). Unsolder wiring connected to terminals

switch to permit installation of new

on the switch to be disconnected. Tag

switch. Use template to determine

and identify wires to facilitate correct

amount and location of material to be

reconnection.

removed.

Cyclic Stick Grip Reassembly and

(5).

As applicable, secure or attach the

Modification

trigger switch, (trigger guard and

return spring for 369D297846 cyclic

(Ref. Figure 203 and Figure 204)

grips) to the grip housing using the

original attaching hardware.

Consumable Materials

(6).

Apply sealing compound (CM425) to all

(Ref. Section 91−00−00)

open screw holes and insert hole.

Item

Nomenclature

CM217

Isopropyl alcohol

(7).

Secure the grip cap (for 369D297846

cyclic grips) to the grip subassembly

CM314

Varnish, moisture resistant

with six screws; coat the screws with

CM425

Sealing compound

varnish (CM314) before installation

CM703

Tie strap

into grip.

CM815

Solder

(8).

Reinstall grip on stick tube. Using

attached strings, route grip wiring

(1). Clean grip, wiring and switches with

through stick tube and reconnect at

alcohol (CM217). Reconnect all electri

electrical plug.

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CSP-HMI-2

MAINTENANCE MANUAL

ANTI−TORQUE FLIGHT CONTROLS

(TWO AND FOUR BLADE)

DESCRIPTION AND OPERATION

1. Tail Rotor Control Configuration

control pedals with left copilot's dual

controls. Foot rest not installed.

The helicopter may be equipped with either of

two basic pilot's tail rotor foot pedal control

configurations. The tail rotor and control

2. Upper Fuselage and Tailboom Control

linkage to the foot pedals are identical on

Linkage

either basic configuration.

Upper fuselage tail rotor controls consist of

(1). Basic Left-Hand Command Tail Rotor

Sta. 95 bellcrank and support at the front of

Controls. Single left position pilot's tail

the main rotor mast base, Sta. 120 control rod

rotor control pedals. Foot rest can be

and Sta. 142 bellcrank inside the boom fairing.

installed at right side of crew compart

Boom linkage consists of tailboom control rod,

ment in place of right-hand foot pedals.

supported by seven bushings (grommets), and

(2). Basic Right-Hand Command Tail Rotor

Sta. 284 Bellcrank mounted on the tail rotor

Controls. Right position pilot's tail rotor

transmission.

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CSP-HMI-2

MAINTENANCE MANUAL

ANTI−TORQUE FLIGHT CONTROLS

(TWO AND FOUR BLADE)

REMOVAL/INSTALLATION

1. Sta. 120 Control Rod or Sta. 142 Bellcrank

(2). Ensure that slotted bushings are in

Replacement

place at each end of bellcrank; then

position riveted rod end in bellcrank

A. Sta. 120 Control Rod or Sta. 142

and install bolt, two washers, nut and

Bellcrank Removal

cotter pin. Make sure that hump of

bellcrank faces forward.

(Ref. Figure 401) The Sta. 142 bellcrank and

Sta. 120 control rod must be removed as an

(3). Carefully feed assembled control rod

assembled unit.

and bellcrank through forward air

intake at left side of control mixer

(1). Remove tail rotor control bellcrank

installation while an assistant guides

access door from left side of boom

the assembly through boot support tube

fairing.

to bellcrank support bracket.

(2). Disconnect tailboom control rod from

lower end of Sta. 142 bellcrank.

(4). Position rubber boot in place at Sta.

137.50.

(3). Remove hardware that secures Sta. 142

bellcrank to boom fairing brackets.

(5). Position Sta. 142 bellcrank in support

bracket and install bolt, two washers,

(4). Open hinge-mounted access door on

nut and cotter pin.

engine air inlet aft fairing. Remove

clamp on boot support tube at Sta.

Check Sta. 142 bellcrank for

137.50.

CAUTION

clearance with support struc

ture. Pay particular attention to area above

(5). Disconnect forward end of Sta. 120

369A7951-23 bearing when top of bellcrank

control rod from Sta. 95 bellcrank.

is in forward position. If contact is noted,

machine surface of bellcrank (machine sur

NOTE: Sta. 95 bellcrank must also be detached

face with interference only)

(Ref.

from its support for clearance from air inlet

Figure 801).

fairing for rod-end bolt removal.

(6). Carefully pull forward end of control

(6). Check that slotted bushing is in place

rod and withdraw assembled rod and

in Sta. 95 bellcrank; then install

bellcrank out through boot support tube

forward rod end in bellcrank with bolt

at plenum chamber Sta. 137.50.

(head to left), two washers, nut and

cotter pin.

(7). Disconnect control rod from upper end

of bellcrank.

(7). Reinstall Sta. 95 bellcrank in its

support with bolt, two washers, nut and

B. Sta. 120 Control Rod or Sta. 142

cotter pin.

Bellcrank Installation

(8). Secure rubber boot at support tube with

(Ref. Figure 401) Sta. 142 bellcrank and Sta.

nylon strap. Then clamp tail rotor

120 control rod must be installed as a unit by

pedals in neutral, set free length of

routing assembled end of bellcrank and control

bellows portion of boot at approximately

rod through boot support tube at plenum

5.5 inches and secure end to control rod

chamber station (Sta. 137.50).

with nylon strap.

(1). For access to bellcrank support bracket,

use access door in boom fairing.

(9). Check rigging of tail rotor controls.

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MAINTENANCE MANUAL

STA. 137.50

NOTE 2

BUSHING (GROMMET)

NYLON

(7 PLACES)

STRAP

* STA. 142 BELLCRANK

BEARING

BOOT NOTE 2

STATION 284

BELLCRANK

PIVOT PIN

STA. 120

CONTROL ROD

(NOTE 1)

SPECIAL

WASHER

* STA. 95 BELLCRANK

* SUPPORT

WASHER

NOTE 2

(NOTE 5)

TAILBOOM

CONTROL ROD

(NOTE 3)

BEARING

MAXIMUM ALLOWABLE

LOOSENESS 0.040 IN.

(1.016 MM)

RIVET

BEARING

RIVET

ADAPTER

ROD LENGTH AND BEARING

ANGULARITY - BEFORE RIG

DIMENSION

CONTROL

ANGLE

ROD

INCHES (CM)

STA. 120

45.88

(

IN LINE

NOTES:

116.5352)

TAILBOOM

143.80

63°

MINIMUM OF 0.060 IN. (1.524 MM) CLEARANCE FOR FULL RANGE OF

(365.252)

TRAVEL THRU STA. 137.50 BULKHEADS.

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

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

PART AFTER NUT IS TIGHTENED.

MINIMUM OF 0.010 IN. (0.254 MM) CLEARANCE FOR FULL RANGE OF

TRAVEL BETWEEN BOOM AND TAIL ROTOR TRANSMISSION.

ASTERISK ( * ) INDICATES PARTS THAT MAY BE EITHER ALUMINUM OR

MAGNESIUM ALLOY. FOR ALLOY IDENTIFICATION AND CORROSION

CONTROL (REF. SEC. 20-40-00).

ADD ONE OR TWO AN960KD516 WASHERS AS REQUIRED FOR CLEARANCE

G67-2000B

Figure 401. Upper Fuselage and Boom Tail Rotor Control Linkage

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MAINTENANCE MANUAL

2. Sta. 284 Bellcrank Replacement

(4). Slowly pull aft end of control rod and

withdraw rod through opening in tail

A. Sta. 284 Bellcrank Removal

rotor transmission mounting frame.

(Ref. Figure 401)

B. Tailboom Control Rod Installation

(Ref. Figure 401)

(1). Disconnect bellcrank from tailboom

control rod.

NOTE: Tailboom control rod is routed through

boom with forward rod end removed.

(2). Disconnect bellcrank from tail rotor

transmission. Disengage bellcrank

(1).

Deleted

pitch control pin from pitch control

housing and remove bellcrank.

(2).

Guide control rod through boom aft

frame opening and carefully route

B. Sta. 284 Bellcrank Installation

through seven bushings (grommets).

Rotate rod slightly to start it through

(Ref. Figure 401)

each grommet.

(1). Insert bellcrank pivot pin into pitch

(3).

Check that slotted bushing is in place

control housing self-aligning bearing.

in lower lug of Sta. 284 bellcrank; then

attach aft rod to bellcrank.

(2). Position bellcrank to align with mating

hole in tail rotor transmission arm and

(4).

Using measurement recorded at time of

install bolt.

rod removal, install forward rod end

bearing. Align rod ends so that bearings

(3). Check that slotted bushing is in place

have equal space for angular throw;

in lower lug of bellcrank; then attach

hold rod end and tighten jam nut.

tailboom control rod to bellcrank with

bolt, two washers, nut and cotter pin.

(5).

Check that slotted bushing is in place

in lower end of Sta. 142 bellcrank; then

(4). Check rigging of tail rotor controls (Ref.

attach forward rod end to bellcrank.

Tail Rotor Controls Rigging).

(6).

Check rigging of tail rotor controls (Ref.

Tail Rotor Controls Rigging).

3. Tailboom Control Rod Replacement

(7).

Close plenum chamber access door.

A. Tailboom Control Rod Removal

4. Sta. 95 Bellcrank and Support

(Ref. Figure 401)

Replacement

(1). Disconnect control rod from Sta. 284

A. Sta. 95 Bellcrank and Support Removal

bellcrank.

(Ref. Figure 401)

(2). Remove tail rotor control bellcrank

access door from left side of boom

(1). Disconnect tunnel-routed control rod

fairing.

from bellcrank.

(3). Accurately measure and record distance

(2). Disconnect bellcrank from support.

between unchamfered edge of forward

rod end bearing jam nut and center of

(3). Disconnect bellcrank from Sta. 120

bearing attach bolt hole. Hold forward

control rod and remove bellcrank.

rod end, loosen jam nut and unthread

control rod from rod end by turning aft

(4). Remove hardware that secures support

end of rod.

to mast structure; remove support.

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MAINTENANCE MANUAL

INITIAL CONTROL ROD LENGTH

STA. 95 BELLCRANK

- BEFORE RIG

CONTROL

DIMENSION L

ROD

INCHES (CM)

TUNNEL-ROUTED

57.95

(147.193)

FLOOR-ROUTED

30.06

(76.3524)

STA. 97.50

(TUNNEL-ROUTED)

CONTROL ROD

RIVET

CONTROLS SUPPORT

BRACKET

MAXIMUM ALLOWABLE AXIAL

SPRING FITTING

PLAY 0.040 IN. (1.016 MM)

AFT EYEBOLT

STA. 63.00

TAIL ROTOR

BUNGEE

IDLER BELLCRANK

SPRING

NOTE 2

FORWARD EYEBOLT

NOTE 1

NOTE 2

FLOOR-ROUTED

CONTROL ROD

NOTE 3

TORQUE TUBE

BUSHING ASSY

* TORQUE TUBE BRACKET

(NOTE 4)

(NOTE 5)

NOTE 1

CONTROL ROD FITTING

NOTE 3

NOTE 1

WASHER

NOTE 4

* LEFT PEDAL

BEARING

NOTE 1

STOP BOLT

* RIGHT PEDAL

JAMNUT

BEARING

NOTE 2

NOTE 3

* PEDAL ARM

NOTE 1

BUSHING

* PEDAL ARM

NOTE 1

(TEFLON-LINED)

NOTE 4

* PEDAL BRACKET

NOTE 2

BUSHING

(TEFLON-LINED)

NOTES:

SHIM BETWEEN BRACKET AND BULKHEAD WITH AN960PD416

BUSHING ASSY

(NOTE 4)

AND/OR -416L WASHERS AS REQUIRED FOR ALIGNMENT WITHIN

0.010 IN. (0.254 MM).

NOTE 2

LINK

EDGE OF BUSHING MUST PROTRUDE A MINIMUM OF 0.010 IN.

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

SURFACE OF PART AFTER NUT IS TIGHTENED.

NOTE 2

DIRECTION OF BOLTS IS OPTIONAL.

BEARING

ADJUSTABLE BUSHINGS MUST HAVE A MINIMUM PROTRUSION OF

BELLCRANK

0.002 INCH (0.051 MM) AT EACH END.

INSTALLED WITH BEARING RECESS FACING FITTING.

ASTERISK (*) INDICATES PART THAT MAY BE EITHER MAGNESIUM OR

ALUMINUM ALLOY. FOR ALLOY IDENTIFICATION AND CORROSION

CONTROL (REF. SEC. 20-40-00).

G67-2001-1D

Figure 402. Tail Rotor Pedal Installation (Sheet 1 of 2)

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MAINTENANCE MANUAL

STOP BOLT (2)

NOTE

ADJUSTABLE

JAMNUT

BUSHING ASSEMBLY

NOTE 2

(NOTE 4)

NOTE 3

TORQUE TUBE

SLEEVE

ADJUSTABLE

TORQUE TUBE

BUSHING ASSEMBLY

(NOTE 4)

RIGHT POSITION TAIL ROTOR PEDALS

G67-2001-2A

Figure 402. Tail Rotor Pedal Installation (Sheet 2 of 2)

B. Sta. 95 Bellcrank and Support Installation

C. Tail Rotor Pedal Assembly − General

(Ref. (Ref. Figure 401)

(Ref. (Ref. Figure 402) Tail rotor pedal

(1). Install bellcrank support to mast

installation consists of a pair of adjustable

structure with three bolts, seven

pedals, pedal arms with interconnecting

washers and three nuts. Forward bolt

linkage, pedal mounting bracket for left

requires an extra washer under

control position, torque tube with control rod

bolthead; two thin washers are used at

all three locations. Torque nuts to 80 -

fitting and torque tube mounting bracket.

100 inch-pounds (9.04 - 11.30 Nm).

Forward pressure on right pedal rotates torque

tube, moving control system linkage to

(2). Check that slotted bushings are in

increase tail rotor blade pitch. Pressure on left

place in bellcrank; then attach Sta. 120

pedal decreases tail rotor blade pitch. A

control rod to bellcrank with bolt (head

bungee spring is installed at aft end of

to left).

floor-routed control rod in underseat tail rotor

control linkage. This spring relieves left pedal

(3). Install bellcrank in support.

forces during flight and causes left pedal to

(4). Attach tunnel-routed control rod to

remain at forward position when helicopter is

bellcrank.

on ground and not operating.

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MAINTENANCE MANUAL

NOTE: Parts identified with an asterisk (*)

simplify torque tube alignment during

may be either magnesium or aluminum

reinstallation.

alloy. (Ref. Sec. 20-40-00 for corrosion con

(10). Remove four nuts, eight washers, any

trol and identification of magnesium and

shim washers and four bolts that secure

aluminum alloys).

pedal bracket to bulkhead. Remove

D. Co−Pilot’s Pedal Installation

control pedal installation. Keep shim

washer selection with bracket.

(Ref. Figure 402) The copilot's pedal installa

B. Tail Rotor Pedal Assembly Installation

tion is essentially the same as the pilot's. A

sleeve couples a torque tube extension to the

(Ref. Figure 402)

pilot's torque tube. Dual pedal installation is

also equipped with pedal stop nuts, heel strips,

NOTE: Install both left and right pedal brack

retaining springs and attachment hardware.

ets for right-hand command helicopters.

(1). Install pedal bracket with four bolts,

5. Tail Rotor Pedal Assembly Replacement

eight washers and four nuts. Add shim

A. Tail Rotor Pedal Assembly Removal

washers as required at pedal bracket

attachment points to keep centerline

(Ref. Figure 402)

alignment of pedal bracket bearings

within 0.010 inch (0.254 mm). Correct

(1).

Pull two hinge pins from pilot's com

alignment is indicated by free rotation

partment floor access door hinges and

al movement of torque tube after nuts

remove door. Remove access panel from

are tightened.

each side of instrument panel lower

support structure.

(2). Position torque tube bracket over

mating holes in bulkhead and check

(2).

Remove battery (Ref. Chap. 96).

alignment with bulkhead. Add shim

washers as required at bracket attach

(3).

Remove pins securing pedals to pedal

ment points to maintain bearing

arms and remove pedals.

alignment established in step a above.

Install two bolts, four washers and two

(4).

For access to bungee, remove access

nuts.

cover between pilot's seats and/or by

removing left passenger's footwell on

(3). Install forward eyebolt, using same

aft side of canted bulkhead.

number of washers removed, on bungee

and then hook aft end of bungee into

(5).

Block left tail rotor control pedal at full

eyebolt on floor-routed control rod

forward position to relieve tension on

fitting.

bungee.

NOTE: If tail rotor pedal forces are not zero

(6).

Remove eyebolt and washers at Sta. 63

during level flight at 130 to 140 knots, tail

with bungee attached. Keep washers

rotor force adjustment may be accomplished

with eyebolt for reinstallation.

by removing washers as required from the

eyebolt at Sta. 63 bracket.

(7).

Disconnect bungee from eyebolt and

fitting at aft end of floor-routed control

(4). Using spring tension tool install bungee

rod by using spring tension removal

into position at Sta. 63 bracket; install

tool (75, Table 203, 91-00).

washer and nut on eyebolt.

(8).

Remove cotter pin, nut, two washers

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

and bolt that connect floor-routed

then install floor-routed control rod in

control rod to torque tube fitting.

torque tube fitting and install bolt, two

washers, nut and cotter pin.

(9).

Remove two nuts, four washers, any

shim washers and two bolts that secure

(6). Check rigging of tail rotor controls and

torque tube bracket to bulkhead. Keep

pedal-to-canopy clearance (Ref. Tail

shim washer selection with bracket to

Rotor Controls Rigging). Pedals should

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MAINTENANCE MANUAL

clear windows by a minimum of 0.20

(5).

Check that spherical bearings are in

inch (5.08 mm) with 20 pounds (88.96

place; then attach bellcrank to pedal

N) of force applied.

bracket with bolt, two washers, nut and

cotter pin.

6. Dual Tail Rotor Pedal Initial Installation

(6).

Check that slotted bushings are in

place; then fasten each link to bellcrank

(Ref. Figure 402)

with bolt, two washers, nut and cotter

pin.

NOTE: Before pedal installation, remove the

bushing assembly that secures pilot's left

(7).

Check that slotted bushings are in

pedal arm to the torque tube. This will allow

place; then fasten each link in pedal

the tube to rotate far enough to install the

arm lugs with bolt, two washers, nut

bushing assemblies.

and cotter pin.

(1). Thread a stop nut on each of the two

(8).

Install pedal bracket assembly with

stop-bolts and install bolts into

four bolts, eight washers and four nuts.

threaded inserts of pedal bracket.

Add shim washers as required at pedal

bracket attachment points to keep

(2). Locate pedal bracket and pedal arms

centerline alignment of pedal bracket

for correct position on torque tube.

bearings within 0.10 inch (2.54 mm).

Correct alignment is indicated by free

(3). Fasten left pedal arm to torque tube

rotational movement of torque tube

with adjustable bushing assembly;

after nuts are tightened.

install bushing bolt so that shank of the

(9).

Reinstall bushing assembly previously

bolt head end protrudes at least 0.002

removed from the pilot's left pedal arm.

inch. Install nut and torque to 80

inch-pounds (9.04 Nm) plus drag

(10).

Install pedals on pedal arms and secure

torque, do not allow bolt to turn.

with pins provided.

(4). Check that each end of bushing pro

(11).

Install heel strips with pins, washers

trudes at least 0.002 inch (0.051 mm). If

and cotter pins. Direction of pin head is

not, loosen nut and repeat prior step.

optional.

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MAINTENANCE MANUAL

ANTI−TORQUE FLIGHT CONTROLS

(TWO AND FOUR BLADE)

ADJUSTMENT/TEST

1. Tail Rotor Controls Rigging

(b). Sta. 95 bellcrank: Centerline of

tunnel-routed control rod attach bolt

should be 4.30 ±0.090 inches (109.22

(Ref. Figure 501) The tail rotor control system

±2.286 mm) above mast base struc

must be re-rigged immediately after replace

ture.

ment of linkage that cannot be accurately

measured (by trammeling, etc) before it is

(c). Sta. 142 bellcrank: Centerline of

installed in the tail rotor control system, or if

tailboom control rod attach bolt

helicopter operation reveals a rigging deficien

should be 4.75-5.09 inches

cy.

(120.65-129.286 mm) from aft face of

Sta. 137.50 bulkhead. For access to

bellcrank, remove tail rotor control

Special Tools

bellcrank access door.

(Ref. Section 91−00−00)

Item

Nomenclature

(3).

Loosen rod end jam nut at forward end

of tailboom control rod.

ST606

T/R swashplate rigging tool

(4).

On tail rotor transmission, remove

hardware attaching tailboom control

Remove pilot's pedals and copi

rod to inboard end of Sta. 284 bellcrank.

CAUTION

lot's (if installed) to prevent pos

(5).

Tie back tail rotor rotating boot. Place

sible contact with lower windshield during

midtravel portion of swashplate rigging

rigging sequence.

tool (ST606) between swashplate and

tail rotor fork split-ring retainer (B,

NOTE: Control rod end bearing adjustments

Figure 501). Make sure that rigging

are to be made to nearest half turn that pro

tool contacts ring and not fork.

duces correct rigging. When tightening jam

(6).

Turn tailboom control rod at aft end.

nut at adjustable end of a control rod, al

Adjust rod length to nearest half turn of

ways hold rod end with a wrench to prevent

rod end that allows swashplate rigging

jamming of bearing. Never reinstall a used

tool to just slide between split-ring

cotter pin; always install a new one.

retainer and swashplate.

(1). Disconnect bungee spring at aft end of

(7).

Recheck that centerline of tailboom

floor-routed control rod (Ref.

control rod forward attach bolt remains

Figure 402).

4.75-5.09 inches (120.65-129.286 mm)

from aft face of Sta. 137.50 bulkhead.

Also check forward rod end for not less

(2). Using two pieces of wood and C-clamp

than one and one-half exposed threads

or rope, secure pilot's foot pedal arms so

with jam nut snug against rod. If either

they are aligned (A, Figure 501). With

condition does not exist, disconnect

pilot's foot pedals clamped in neutral

forward end of Sta. 120 control rod and

and control rod lengths adjusted (Ref.

readjust both control rods until Sta. 142

Figure 401 and Figure 402), control

bellcrank position and exposed threads

system bellcrank positions may be

of both control rods are within toler

checked as follows:

ance.

(a). Tail rotor idler bellcrank (pilot's

(8).

Ensure that slotted bushing is in place

compartment): Centerline of aft arm

in bottom ear of Sta. 284 bellcrank and

should be 90 ±2 degrees to Sta. 78.50

inboard ear of Sta. 95 bellcrank.

bulkhead.

Connect control rods (Ref. Figure 401).

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MAINTENANCE MANUAL

0.250 IN. (6.35 MM)

MAX. MISALIGNMENT

NOTES:

BETWEEN PEDALS

ROTATING BOOT NOT SHOWN. NORMALLY IT

IS TIED BACK TO LOCATE RIGGING TOOL.

TAILBOOM CONTROL ROD AND STA. 120 CONTROL

ROD LENGTHS ARE ADJUSTED FOR CORRECT

CLAMPING BLOCKS

MID-TRAVEL RIGGING.

ST606, TABLE 3, SEC. 91-00-00

STOP NUT

RIGHT STOP BOLT

LEFT STOP BOLT

PEDAL ARM ALIGNMENT AND

STOP BOLT ADJUSTMENT

SWASHPLATE

NON-ROTATING

RIGGING TOOL

BOOT

(NOTE 3)

TAILBOOM CONTROL ROD

(NOTE 2)

TAIL ROTOR FORK

SPLIT-RING

RETAINER

BELLCRANK ACCESS DOOR

STA. 120 CONTROL ROD

MID-TRAVEL RIGGING

(NOTE 2)

(NOTES 1, 2)

RIGHT PEDAL RIGGING

LEFT PEDAL RIGGING

G67-2002B

Figure 501. Rigging − Tail Rotor Control System

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MAINTENANCE MANUAL

(9). Check witness holes for proper thread

(15). Operate pedals through full range of

engagement. Align rod ends to get

travel. While controls are being moved,

approximately equal angular throw in

check that there is never less than

bellcranks; tighten jam nuts.

0.060 inch (1.524 mm) clearance around

Sta. 120 control rod where it passes

through structure at Sta. 137.50 and

(10). Remove clamping device from foot pedal

that there is never less than 0.010 inch

arms.

(0.254 mm) clearance around tailboom

control rod where it exits between boom

(11). Loosen jam nuts on pedal stop bolts (A,

and tail rotor transmission.

Figure 501). Screw in pedal stop bolts

approximately 0.50 inch (12.70 mm).

(16). Connect bungee spring between aft end

of floor-routed control rod and Sta. 63

Use care when actuating pedals

bracket (Ref. Figure 402) and check

CAUTION

to avoid possibility of damaging

that pilot's left pedal moves to its

tool or windshield.

normal forward position.

NOTE: Adjust copilot's pedal stop bolts to

(17). Install Sta. 142 bellcrank access door.

match pilot's pedal travel, 0.001-0.003 inch

(0.025-0.076 mm) gap between stop bolts

2. Tail Rotor Bungee Adjustment

and pedals.

(Ref. (Ref. Figure 502)

(12).

Adjust right pedal stop bolt (A,

Figure 501) so that when pedal arm is

(1).

2-Bladed bungee adjustment:

held against stop, right pedal portion of

swashplate rigging tool just slides

between split-ring retainer and

(a). Increase pedal force by removing

swashplate (view C). Fit should be tight

washers from under bungee spring

enough to support weight of tool.

eyebolt.

Without changing adjustment of bolt or

tool fit, tighten jam nut on stop bolt.

(b). If tail rotor pedal forces are not zero

during level flight at 130 - 140 knots,

tail rotor force adjustment may be

(13).

Adjust left pedal stop bolt (A,

accomplished by removing a desired

Figure 501) so that when pedal arm is

number of AN970-3 washers.

held against stop with 20 - 25 pounds

(88.96 - 111.20 N) pressure (or pull on

right pedal), left pedal portion of

(2).

4-bladed bungee adjustment:

swashplate rigging tool just slides

between split-ring retainer and

(a). Adjust tail rotor pedal force by

swashplate (view D). Fit should be tight

tightening or loosening the 0.120

enough to support weight of tool.

inch (3.048 mm) thread adjustment

Without changing adjustment of bolt or

on bungee female bearing assembly.

tool fit, tighten jam nut on stop bolt.

Remove swashplate rigging tool and

(b). Tighten to maximum 0.120 inch

restore rotating boot to normal installed

(3.048 mm) thread adjustment on

position.

bungee female bearing assembly

increases pedal force approximately

(14).

Reinstall pedals. Slowly press outboard

five pounds; loosening decreases

pedal to its full forward travel position

pedal force.

against stop bolt. With not more than

20 pounds pressure applied, upper and

(c). Bungee spring may be attached to

lower edges of pedal must clear canopy

any of four holes in fitting. If exces

glass by not less than 0.20 inch (0.508

sive left pedal force is required,

mm).

position spring at lower hole.

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HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369D/E/FF-500/600N HELICOPTERS (ISSUED: 1990) - page 25