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

CSP−HMI−2

MD Helicopters, Inc.

MAINTENANCE MANUAL

6. CIT (Compressor Inlet Temperature)

(4.06 - 5.19 Nm). A slip fit of the rig

Sensor Replacement

pin through the control box, HMU lever

and HMU rig pin hole must be main

(Ref. Figure 202)

tained after final torque of bolt.

A. CIT Sensor Removal

(5). Install control cable end into engine

control box coupling and connect cable

(1). Detach electrical connector from CIT

nut. Torque nut to 50 inch pounds

sensor.

(5.64 Nm).

(2). Remove bolts, washers and CIT sensor.

(6). Rig engine control cable (Ref. Section

76-00-00).

B. CIT Sensor Installation

8. Engine Control Cable Replacement

(1). Install CIT sensor with bolts and

washers. Torque bolts to 36 - 46

(Ref. Figure 202)

inch-pounds (4.06 - 5.19 Nm).

A. Engine Control Cable Removal

(2). Attach electrical connector to CIT

sensor.

(1).

Disconnect control cable nut from

engine control box and remove cable

7. Engine Control Box Replacement

end from control box coupling.

A. Engine Control Box Removal

(2).

Remove screw, washers, spacer, clamp

and nut from control cable in engine

(1). Disconnect engine control cable nut

compartment.

from engine control box and remove

cable end from control box coupling.

(3).

Remove cotter pin, nut, bolt and

washers and disconnect control cable

(2). Remove bolts, washers and engine

from engine throttle bellcrank.

control box from the engine hydrome

chanical control unit.

(4).

Cable with Cable Bulkhead Swivel

- Remove screws, nuts and washers

B. Engine Control Box Installation

attaching control cable bulkhead swivel

to bracket.

NOTE: A 0.1540 in. (3.9116 mm) rig pin or

standard #23 drill must be inserted in rig

(5).

Loosen jam nut. Remove rod end

hole during installation of the engine con

bearing and jam nut.

trol box to the engine hydromechanical con

trol unit to maintain proper alignment.

(6).

Loosen jam nuts above and below

bracket and remove top jam nut and

(1). Install engine control box to engine

flat washer.

hydromechanical control unit with

600N7717-1 nut. Torque nut to 60 - 85

(7).

Pull engine control cable out of bracket.

inch-pounds (6.78 - 9.60 Nm) plus

drag torque. Minimum drag torque is

(8).

Cable with Cable Bulkhead Swivel

15 inch-pounds (1.69 Nm).

- Remove cable bulkhead swivel from

engine control cable.

(2). Measure gap between engine control

box and HMU.

(9).

Remove bottom jam nut from cable.

(3). Peel MHS5079-2346 shim washer for

(10).

Pull engine control cable aft through

gap in step (2). and ensure alignment to

control cable conduit and remove from

maintain full engagements of the

engine compartment.

serrations without binding the controls.

(11).

After cable is removed from helicopter,

(4). Install bolt, washer and shim washer.

refer to Engine Control Cable Shipping

Torque bolt to 36 - 46 inch pounds

and Handling.

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MAINTENANCE MANUAL

B. Engine Control Cable Installation

NOTE: When installing a 600N7714-3 throttle

cable, the 600N7718-1 control cable brack

NOTE: When replacing 600N7714-1 or -3 en

et must be installed for proper control cable

gine control cable with 600N7714-7 cable,

alignment.

doubler

600N7720-1 and doubler

600N7720-3 must be installed on engine

(7). Cable without Cable Bulkhead

control cable bracket 600N7718-1.

Swivel - Install engine control cable in

bracket.

(1). Before installing a new engine control

cable;

(8). Install flat washer and jam nut on

cable. Do not tighten jam nut.

(a). Lay the cable straight.

(9). Install jam nut and rod end bearing on

(b). Grasp one end and shake.

engine control cable. Torque jam nut to

(c). This procedure aligns races and

40 inch pounds (4.51 Nm)

removes any twisting.

(10). Connect rod end bearing to engine

NOTE: When straightened, the cable will have

throttle bellcrank with bolt, washers,

a natural bend or curve.

nut and cotter pin. Torque nut to 30 -

40 inch pounds (3.38 - 4.51 Nm).

(d). Put marks on the cable housing to

show the natural bend plane of the

NOTE: Ensure there are no sharp bends in

cable.

cable when clamping into position.

(2). Push engine control cable through

(11). Install clamp, screw, washers, spacer

control cable conduit from engine

and nut attaching control cable to

compartment forward into the cockpit.

bracket in engine compartment. Torque

nut to 12 - 15 inch pounds (1.35 -

(3). Keep the cable natural bend plane

1.69 Nm).

aligned with the bends required to

route the cable.

(12). Run cable through full range of travel

(4). Install bottom jam nut on engine

to ensure smooth operation.

control cable.

Do not lubricate cable if cable

CAUTION

(5). Cable with Cable Bulkhead Swivel

action is not smooth. Lubricant

- Install cable bulkhead swivel on

attracts dirt which will damage the cable.

engine control cable.

(13). Install control cable end into engine

(6). Cable with Cable Bulkhead Swivel

control box coupling and connect cable

- Install cable bulkhead swivel in

nut. Torque nut to 50 inch pounds

bracket with screws, washers and nuts.

(5.64 Nm).

Torque nuts to 12 - 15 inch pounds

(1.35 - 1.69 Nm).

(14). Rig engine control cable.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

DRIVE BELT

PULLEY

ELECTRICAL

PEDAL

HARNESS

PULLEY

BOLT

MOUNTING

BRACKET

DIRECTIONAL

PEDAL ASSY.

DIRECTIONAL

POTENTIOMETER

COLLECTIVE

ASSEMBLY

POTENTIOMETER

ASSEMBLY

SCREW

WASHER

SCREW

WASHER

ELECTRICAL HARNESS

MOUNTING BRACKET

ELECTRONIC

MOUNTING

CONTROL UNIT

BRACKET

EXISTING

PULLEY

NUTPLATE

PILOT'S

DRIVE BELT

WASHER

COLLECTIVE

STICK

PULLEY TO

BRACKET BOLT

BUSHING

WASHER

BOLT

LBL

126.675

7.52

SCREW

WASHER

LOCK WASHER

BOLT

BONDING

WASHER

JUMPER

ELECTRICAL

46.75

HARNESS

CIT

INLET PLENUM

SENSOR

6G76-006-1

Figure 202. Engine Controls Installation (Sheet 1 of 2)

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CSP−HMI−2

MAINTENANCE MANUAL

ENGINE THROTTLE

NUT

WASHER

BELLCRANK

COTTER PIN

JAM NUT

WASHER

BOLT

ROD END

BEARING

MOUNTING

SCREW

BRACKET

FLAT WASHER

(NOTE 1)

JAM NUT

ELECTRICAL

JAM NUT

CONDUIT

FLAT WASHER

CABLE BULKHEAD

SWIVEL

FLAT WASHER

JAM NUT

CONTROL CABLE

CONDUIT

NUT

ENGINE CONTROL CABLE

RBL

ROD END

10.1

BEARING

SCREW

JAM NUT

FLAT WASHER

BOLT

WASHER

FLAT

SHIM

WASHER

DOUBLER

RIG PIN HOLE

600N7720-1

(NOTE 2)

DOUBLER

FLAT WASHER

600N7720-3

ENGINE

JAM NUT

NUT

CONTROL BOX

ENGINE CONTROL

CABLE

ENGINE HYDROMECHANICAL

INSTALL CABLE END

CONTROL UNIT

INTO ENGINE CONTROL

BOX COUPLING

ENGINE CONTROL CABLE

NOTE:

VIEW ROTATED-LOOKING INBOARD AT RIGHT SIDE

600N7718-1 MOUNTING

BRACKET MUST BE

6G76-006-2E

INSTALLED WHEN INSTALLING

THE 600N7714-3

ENGINE CONTROL CABLE

Figure 202. Engine Controls Installation (Sheet 2 of 2)

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MD Helicopters, Inc.

MAINTENANCE MANUAL

9. Engine Throttle Control Cable Mounting

(2).

Set lever on engine hydromechanical

Bracket Replacement

control unit to idle and insert

0.1535-0.1545 inch (3.8989-3.9243

(Ref. Figure 202)

mm) rig pin (or #23 drill blank) in rig

pin hole (ensure that rig pin engages

A. Engine Throttle Control Cable Mounting

the fuel control gearbox, gear, pointer

Bracket Removal

arm and casting.

(1). Disconnect throttle cable at collective

(3).

Set collective twist grip at idle detent

stick (Ref. Engine Control Cable

position.

Replacement).

(4).

Position the cable in the cable bulkhead

(2). Disconnect throttle cable from bracket

swivel or bracket so that the cable is

(Ref. Engine Control Cable Replace

not binding and tighten the jam nuts.

ment).

Torque jam nuts to 40 inch-pounds

(4.51 Nm).

(3). Remove two nuts, four washers, two

spacers and two bolts securing bracket

(5).

Remove rig pin (or drill blank).

to socket assembly.

(6).

Rotate the throttle twist grip to full and

(4). Slide bracket over end of throttle cable.

shutoff positions and verify that the

hydromechanical control unit lever

(5). Bracket with Doublers - Remove

contacts the stops at both settings.

nuts, washers and screws that attach

(7).

Rotate the throttle twist grip from full

doublers to bracket and remove

to idle positions and verify that the

doublers.

pointer on the hydromechanical control

B. Engine Throttle Control Cable Mounting

unit is between 30-40 degrees.

Bracket Installation

11. Engine Controls Inspection

(1). Bracket with Doublers - Attach

(1). Visually inspect ECU for damage and

doublers to bracket with screws,

security of installation.

washers and nuts. Torque nuts to 12 -

15 inch pounds (1.35 - 1.69 Nm).

(a). Inspect ECU for security of hard

ware. Torque or replace loose or

(2). Slide bracket over end of throttle cable

missing hardware.

and align with bolts holes in socket

assembly.

(b). Inspect electrical connectors, wire

harnesses and bonding jumper for

(3). Install bolts with washers through

chafing or cuts. None allowed.

bracket and socket assembly.

Ensure connectors are securely

attached.

(4). Install spacers, washers and nuts on

bolts (spacers are installed before

(2). Visually inspect collective and direction

washers).

al potentiometers for damage and

security of installation.

(5). Torque nuts to 12 - 15 inch-pounds

(1.36 - 1.69 Nm) plus drag torque.

(a). Inspect potentiometers for security of

hardware. Torque or replace loose or

(6). Connect throttle cable (Ref. Engine

missing hardware.

Control Cable Replacement).

(b). Inspect drive belts for cuts and

10. Engine Control Cable Rigging

excessive tension. None allowed.

(Ref. Figure 203)

(c). Inspect electrical connectors and wire

harnesses for chafing or cuts. None

(1). Loosen engine control cable jam nuts at

allowed. Ensure connectors are

cable bulkhead swivel or bracket.

securely attached.

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CSP−HMI−2

MAINTENANCE MANUAL

BOLT

WASHER

RIG PIN HOLE

ENGINE THROTTLE

BELLCRANK

ENGINE

CONTROL BOX

ENGINE

JAM NUT

HYDROMECHANICAL

CONTROL UNIT

REF. ENGINE

CONTROL CABLE

JAM NUT

6G76-050C

Figure 203. Engine Control Cable Rigging

(3). Visually inspect CIT sensor for damage

Do not lubricate cable if cable

CAUTION

and security of installation.

action is not smooth. Lubricant

attracts dirt which will damage the cable.

(b). Inspect engine control box and

(a). Inspect CIT sensor for security of

control cable for security of hard

hardware. Torque or replace loose or

ware. Torque or replace loose or

missing hardware.

(c). Inspect control cable to control box

(b). Inspect electrical connector and wire

connection for security. Torque

harness for chafing or cuts. None

control cable nut.

allowed. Ensure connector is securely

12. Engine Control Cable Shipping and

attached.

Handling

(Ref. Figure 204) The following procedures

(4). Visually inspect engine control box and

should always be used when handling the

control cable for damage and security of

engine control cable. This cable can be

installation.

damaged if handled incorrectly.

A. Control Cable Removal From Shipping

(a). Inspect engine control cable for sharp

Box

bends, chafing, binding (smooth

The control cable is shipped in a “lazy figure 8”

operation through full range of

configuration.

travel), corrosion and dents. None

allowed.

(1). Lift control cable from box.

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MD Helicopters, Inc.

MAINTENANCE MANUAL

(2). Hold the cable upright in both hands.

B. Control Cable Installation into Shipping

Box

(3). Remove the shipping wire.

(Ref. Figure 204) The cable is to be folded into

(4). Starting with the nearest end fitting,

a “lazy figure 8” position whenever it is

pay out the loops of the cable, one at a

shipped.

time.

Never allow cable to be bent

CAUTION

more than 180 degrees effective

(5). Lay the cable straight.

bend angle, this will damage cable.

(6). Grasp one end fitting and shake the

NOTE: The following procedure may require

cable to align the races.

more than one person to perform.

(1). Lay cable flat.

(2). Grasp both ends of cable and gently

bend in opposite directions.

0°

180°

(3). Continue bending until you have a

0°

“figure 8”.

(4). To fit the cable into a shipping box, the

0°

cable may have to be bent into a double

90°

“figure 8”.

0°

76-006-3

(5). Gently wire the cable together in the

center of the “figure 8” to prevent

Figure 204. Effective Bend Angle

damage in shipping or storage.

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CSP-HMI-2

MAINTENANCE MANUAL

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

78-20-00 Engine Exhaust System (250-C20B and 250-C20R/2)

Maintenance Practices

201

1. Description and Operation

201

2. Exhaust System Replacement

201

A. Exhaust System Removal

201

B. Exhaust System Installation

201

Figure 201. Exhaust System Installation

202

3. Exhaust System Inspection

203

A. Tailpipe Inspection

203

B. Supports and Fasteners Inspection

203

C. Clamp Inspection

203

Figure 202. Exhaust System Inspection

204

4. Exhaust System Repairs

205

A. Tailpipe Repair

205

B. Hanger Cushion Repair

205

C. Tailpipe Clamp Repair

205

Figure 203. Exhaust System Repairs (Sheet 1 of 3)

206

Figure 204. Engine Exhaust Extension (500N)

209

78-30-00 Engine Exhaust System (250-C30 and 250-C47)

Maintenance Practices

201

1. Description and Operation

201

2. Exhaust System Replacement

201

A. Exhaust System Removal

201

B. Exhaust System Installation

201

3. Exhaust System Inspection

201

4. Exhaust System Repair

202

Figure 201. Engine Exhaust System Installation

203

Page i

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CSP-HMI-2

MAINTENANCE MANUAL

EXHAUST SYSTEM

MAINTENANCE PRACTICES

1. Description and Operation

clamps. Locate clamp T-bolts at 6

o'clock position. Install washers and

The engine exhaust system consists of left and

nuts. Finger tighten clamp nuts.

right tailpipes attached to the engine by two

clamps and a flexible suspension system.

NOTE: Use only corrosion resistant fasteners.

Suspension hardware allows exhaust system

thermal expansion and contraction. Movement

(3).

Install lower hanger between tailpipe

is absorbed by a spring, upper and lower

aft flanges. Attach tailpipe support link

cushioned hanger assemblies and a pivoted

to airframe fitting. Install bolt, washers

link. The link suspends the tailpipes from an

and nut. Finger tighten nut.

airframe fitting above the exhaust outlet.

(4).

Install upper hanger between tailpipe

2. Exhaust System Replacement

flanges.

(Ref. Figure 201)

(5).

Attach spring hook to upper clip

A. Exhaust System Removal

bushing with two captive washers on

(1). Remove right side thermocouple

each side (Ref. View C).

hardware (Ref. View A).

(6).

Attach lower spring hook to clip

(2).

(500N) Remove clamp from around

bushing between support link and thin

tailpipes.

washer (Ref. View D).

(3). Remove tailpipe clamps.

(7).

Inject sealant (CM423) into cavity

(4). Remove airframe link attaching

around spring attach points. Allow

hardware.

sealant to cure per manufacturers

instructions.

(5). Remove two tailpipes as an assembly.

Cover engine exhaust ducts to

(8).

Torque engine/tailpipe clamp nuts to 15

CAUTION

keep FOD out of turbine section.

- 18 inch-pounds (1.69 - 2.03 Nm).

(6). Install covers on engine exhaust

(9).

Tap around both clamps with a rawhide

outlets.

mallet to seat clamps on flanges.

(7). Remove spring and hangers. Separate

Retorque clamp nuts 15 - 18 inch-

tailpipes.

pounds (1.69 - 2.03 Nm).

B. Exhaust System Installation

(10).

Continue tapping around clamp and

retorquing clamp nut until nut no

Consumable Materials

longer turns when specified torque is

(Ref. Section 91−00−00)

applied.

Item

Nomenclature

(11).

Install thermocouple wire support on

CM423

Sealant

right tailpipe clamp T-bolt with one

washer on each side of support. Install

(1). Remove exhaust duct covers.

nut (Ref. View A). Install thermocouple

wire, clamp, screw, washers and nut on

Support tailpipes during instal

CAUTION

support.

lation. Unsupported tailpipes

could damage mounting flanges or result in

(12).

Torque tailpipe support link nut to 12 -

clamp joint misalignment and subsequent

15 inch-pounds (1.36 - 1.69 Nm).

exhaust gas leakage.

Install cotter pin.

(2). Butt tailpipe flanges up to engine

exhaust duct flanges and install

(13).

(500N) Install clamp around tailpipe.

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MAINTENANCE MANUAL

UPPER HANGER

WIRE

CLAMP

SCREW

SUPPORT

NUT

RH CLAMP T-BOLT

WASHER

WIRE MESH OR

WIREMESH

SILICONE RUBBER

REPLACEMENT

CUSHION

NUT

CUSHION

WASHER

THERMOCOUPLE WIRE

HANGER INSTALLATION

SUPPORT INSTALLATION

(NOTE 1)

SILICONE RUBBER

REPLACEMENT CUSHION

SPRING HOOK

UPPER HANGER

(NOTE 3)

LINK

ASSEMBLY

ONE THIN

WASHERS (2)

WASHER

WASHERS (2)

SPRING HOOK

LOWER HANGER ASSEMBLY

(NOTE 3)

UPPER HANGER SPRING

ATTACHMENT

LOWER HANGER SPRING

ATTACHMENT

EXTENDED TAILPIPE

AIRFRAME TAILPIPE

(500N ONLY)

SUPPORT FITTING

HANGER

TORQUE NUT

TORQUE TAILPIPE CLAMP

RIGHT TAILPIPE

12-15 IN. LBS.

15-18 IN. LBS. (1.69-2.03 NM)

(1.36-1.69 NM)

(NOTE 2)

WASHER

SUPPORT LINK

BOLT

SPRING

ENGINE

EXHAUST

DUCT

CLAMP

(500N ONLY)

HANGER

LEFT TAILPIPE

NOTES:

TYPICAL FOR UPPER AND LOWER HANGERS.

LOCATE T-BOLTS AT 6 O'CLOCK POSITION.

FILL CAVITY BETWEEN SPRING AND WASHERS

G78-0002B

WITH SEALANT (CM423)

Figure 201. Exhaust System Installation

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CSP-HMI-2

MAINTENANCE MANUAL

3. Exhaust System Inspection

(2). Replace damaged hanger cushions.

(Ref. Figure 202)

(3). Check spring for cracks, pits, nicks,

kinks, gouges, evidence of overheating,

A. Tailpipe Inspection

wear and corrosion. Replace a spring

showing such damage.

(1). Inspect tailpipe flanges and duct

interior/exterior surfaces for cracks and

(a). Measure spring free length from hook

broken weld seams.

center to hook center. Spring free

length shall be 6.28 inches (15.951

(a). No cracks allowed across flange.

cm). Replace a stretched spring.

Replace tailpipe.

(b). Anchor one end of spring. Attach an

(b). Weld seams may be repaired pro

accurate weight scale to the other

vided cracks meet limits in the

end. Stretch spring to 7.10 inches

following steps.

(18.034 cm), hook center to center.

(c). Fluorescent penetrant inspect

Spring tension at specified length

suspected cracks to determine crack

must be 8-12 pounds (35.6-53.4 N).

ends and length.

Replace a spring failing tension

requirement.

(d). Nonintersecting single line cracks up

to 2.00 inches (5.08 cm) long may be

(4). Inspect hanger/clip rivets and washers

repaired if they do not affect the

for security. Inspect spring hook

forward flange.

bushings, washers and rivets for wear

(e). Intersecting cracks of any length

and security. Replace worn parts.

forming an acute angle and an

Repair loose rivets.

unsupported section may not be

(5). Inspect support link for cracks, corro

repaired.

sion and hole wear exceeding specifica

(2). Repair cracks or separations.

tions (Ref. Figure 202).

(3). Replace an unrepairable tail pipe.

(6).

(500N) Inspect clamp around tailpipes

for security and condition. Fiberglass

(4). Inspect engine and tailpipe flanges for

wrap for fraying and condition of

evidence of gas leakage.

sealant at ends.

(a). Gas leakage may be caused by flange

C. Clamp Inspection

misalignment, loose or improperly

installed flange clamp, cracked,

A failed exhaust duct clamp

CAUTION

warped, nicked, dented, gouged or

may present a serious inflight

distorted flange areas or a combina

problem. Replace any clamp you think is in

tion of causes.

marginal condition.

(5). Straighten flange distortions.

(1). Inspect T-bolt threads for condition.

Repair damaged threads.

(6). Replace a tailpipe having a cracked

forward flange.

(2). Check self locking nut for run-on

torque resistance. Replace a worn nut.

(7). Inspect entire duct for dents, crimps,

creases, wrinkles, sags and bulges.

(3). Inspect strap/channel spotwelds for

security.

(8). Repair distortions.

(4). Check strap for cracks, creases, bends,

B. Supports and Fasteners Inspection

joggles and other evidence of fatigue.

(1). Inspect hanger cushions for wear, tears

Replace clamps showing metal crystalli

and security.

zation or cracks anywhere on the strap.

(a). Inspect braided metal cushions for

(5). Inspect clamp channels for cracks,

spotweld security.

spread or crimp (Ref. Figure 202).

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MAINTENANCE MANUAL

COMPLEX CRACKS AT ACUTE

STOP DRILL HOLE

INTERSECTING ANGLES ARE

0.040 IN. (1.016 MM)

NOT REPAIRABLE

0.190-0.194 IN.

SMALL SIMPLE CRACKS

(TYP)

(4.826-4.9276 MM)

WITH OBTUSE ANGLES

DIA. HOLE

ARE REPAIRABLE

9.80 IN.

(24.892 CM)

REPAIRABLE CRACK LENGTH

2.00 IN. (5.08 CM) MAXIMUM

CRACK REPAIR LIMITS

BUSHING

0.4360 0.4365 IN.

(11.0744-11.0871 MM)

DIA. HOLE

SUPPORT LINK

0.625 IN.

DIMENSIONAL LIM

(15.875 MM)

0.156 IN. (3.9624 MM)

CLAMP STRAP

0.022 0.052 IN.

(0.5588-1.3208 MM)

0.218 IN. (5.5372 MM)

R (TYP)

CHANNEL

40 ±5°

0.50 IN.

ENGINE FLANGE

(12.70 MM)

A - A

CLAMP CROSS-SECTION

CLAMP DIMENSIONAL LIMITS

G78-0003A

Figure 202. Exhaust System Inspection

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MAINTENANCE MANUAL

4. Exhaust System Repairs

NOTE: Either bonded silicone rubber or welded

all metal original equipment cushions may

(Ref. Figure 203)

be installed. Replacement parts may be tab

attached metal or bonded silicone rubber

A. Tailpipe Repair

cushions.

Consumable Materials

(1). Replace original equipment metal

(Ref. Section 91−00−00)

cushions with tabbed metal cushions as

Item

Nomenclature

follows:

CM824

Welding rod

(a). Cut away cushion debris.

(b). Grind spot welds smooth and level

(1). Remove dents and distortions with a

with hanger surfaces.

suitably shaped form-block and mallet.

NOTE: Avoid weakening replacement cushion

(2). Repair cracks meeting repair limits as

tabs. Ensure cushions are correctly located

follows:

prior to bending tabs.

(a). Stop-drill crack ends with a 0.040

(c). Position cushion assembly on hanger.

inch (1.016 mm) diameter drill.

Bend cushion tabs to grip hanger

(b). Remove all carbon and debris from a

(Ref. View B).

one inch area bordering crack with a

(2). Replace original equipment metal

stainless steel brush. Clean inside

cushions with silicone rubber cushions

and outside surfaces.

as follows:

(c). Route out crack a minimum width

(a). Cut away cushion debris.

from end to end to expose bare metal.

(d). Flood back side of weld area with

(b). Grind spot welds smooth and level

inert gas or shield with a suitable

with hanger surfaces.

stainless steel flux.

(c). Clean hanger components and

(e). Tungsten inert gas weld crack with

cushion bond joint-surfaces per

21-6-9 CRES rod or wire (CM824).

sealant manufacturers instructions.

(f). Fluorescent penetrant inspect repairs

(d). Bond cushion to hanger with RTV

for cracks. Weld cracks as required.

106 sealant (CM423). Inject sealant

into cavity around spring attach

B. Hanger Cushion Repair

points. Allow sealant to cure per

manufacturers instructions.

Consumable Materials

C. Tailpipe Clamp Repair

(Ref. Section 91−00−00)

Item

Nomenclature

(1). Chase clamp T-bolt threads with a

CM423

Sealant

10-32NF-38 die or replace clamp, as

required.

Page 205

78-20-00

Revision 22

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

0.06 IN. (1.524 MM) R

(TYP)

0.50 IN. (12.7 MM)

(TYP)

0.85 IN.

DETAIL

(21.59 MM)

NOTE 1

0.25-0.31 IN.

NOTE 1

(6.35-7.874 MM)

LAP

1.00 IN.

(2.54 CM)

5.00 IN.

0.25-0.31 IN.

(12.7 CM) R

(6.35-7.874 MM)

LAP

0.13 IN. (3.302 MM)

(2 PLCS) (TYP)

(NOTE 3)

0.18 IN.

NOTE 1

(4.572 MM)

FAIR FROM ELLIPSE TO SEMI

CIRCLE IN THIS AREA

91°

7.75 IN.

ELLIPSE ROTATED

(19.685 CM)

41°

IN THIS AREA

0.25-0.31 IN.

8.00 IN.

(6.35-7.874 MM)

(20.32 CM)

0.12 IN.

LAP

(3.048 MM

15.78 IN.

(40.082

CM)

STA.

45°

7.75

DUCT AREA TO BE

CONSTANT TO HERE

NOTE 2 (TYP)

26.33 IN.

6.12 IN.

(66.878 CM)

50°

(15.545 CM)

NOTES:

FILLET WELD ALL AROUND, NEAR SIDE.

BUTTWELD.

STITCHWELD. X X X X

G78-0004-1A

Figure 203. Exhaust System Repairs (Sheet 1 of 3)

Page 206

Revision 22

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

0.68 IN. (17.272 MM)

0.16 IN.

(4.064 MM)

(TYP)

10.13-10.38 IN.

(25.7302-26.3652 CM)

0.46 IN. (11.684 MM)

0.92 IN. (23.368 MM)

0.68 IN. (17.272 MM) R

(TYP)

1.00 IN.

(2.54 CM)

T. E. STA

1.75 IN. (4.445 CM)

R (TYP)

STA. 7.75

(TYP)

0.50 IN. (12.7 MM)

4.25 IN. (10.795 CM) R

(TYP)

0.12 IN. (3.048 MM)

2.415 IN.

(TYP)

5.00-5.25 IN. (12.7-13.335 CM)

(6.1341 CM)

(TYP)

0.65-0.97 IN. (16.51-24.638 MM)

1.768 IN.

MINIMUM PREFERRED (TYP)

(4.4907 CM)

B−B

0.647 IN.

(16.4338 MM)

0.922 IN. (23.4188 MM)

1.250 IN.

1.781 IN. (4.5237 CM)

(3.175 CM)

2.519 IN. (6.3983 CM)

3.085 IN. (7.8359 CM)

2.165 IN.

3.441 IN. (8.7401 CM)

(5.4991 CM)

3.562 IN. (9.0475 CM)

2.500 IN.

(6.3500 CM)

C−C

ROTATED 40° C-CLOCKWISE

0.63 IN. (16.002 MM)

2.00 IN. (5.08 CM)

13.76 IN.

(34.9504 CM)

16.25 IN.

(41.275 CM)

2.00 IN. (5.08 CM)

SEAMWELD

1.25 IN. (3.175 CM)

D−D

1.25 IN. (3.175 CM)

G78-0004-2B

Figure 203. Exhaust System Repairs (Sheet 2 of 3)

Page 207

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Revision 22

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

0.06 IN. (1.524 MM) R

(TYP)

0.63 IN. (16.002 MM) R

0.85 IN. (21.59 MM)

20°

(TYP)

1.50 IN. (3.81 CM)

0.19 IN. (4.826 MM)

(TYP)

0.294 IN. (7.4676 MM) CONSTANT

0.289 IN. (7.3406 MM) CONSTANT

(TYP)

0.25 IN. (6.35 MM) R

0.190 IN. (4.826 MM)

FREE DIMENSION

E−E

F−F

1.00 IN. (2.54 CM)

CONTINUOUS SEAMWELD (REF)

SPOTWELD WHERE REQUIRED

0.19 IN. (4.826 MM)

0.31 IN. (7.874 MM) R

1.50 IN. (3.81 CM) (TYP)

0.442-0.562 IN.

0.06 IN. (1.524 MM) R

(11.2268-14.2748 MM) R

(TYP)

G−G

0.18 IN. (4.572 MM)

(TYP)

45° ANGLE FROM

FLAT PATTERN

0.18 IN. (4.572 MM)

H−H

(TYP)

G78-0004-3

Figure 203. Exhaust System Repairs (Sheet 3 of 3)

Page 208

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

EXHAUST SYSTEM

MAINTENANCE PRACTICES

1. Description and Operation

Support aft ends of tailpipe dur

CAUTION

ing installation. Displacement

Engine exhaust is ducted through a tailpipe

from proper mounting position may damage

bolted to the engine exhaust duct flange and

forward mounting flanges.

supported by a flexible link mounting attached

to the aft fuselage. Figure 201 shows the

(3). Place tailpipe over engine exhaust duct

exhaust system and mounting details.

and secure with nuts, nutplate strips,

bolts and washers; torque bolts to 36 -

2. Exhaust System Replacement

46 inch-pounds (4.07 - 5.20 Nm)

plus drag torque.

(Ref. Figure 201)

(4). Install duct with duct clamp link

A. Exhaust System Removal

standing vertical.

(1). Detach tailpipe from engine exhaust

(5). When viewed from left side of helicop

duct by removing:

ter. turn torsion spring adjuster 150

±15 degrees clockwise and engage

(a). Six nuts, bolts, and 12 washers from

spring pin in nearest hole in adjuster.

exhaust pipe side flanges.

(6). Tighten tensioning bolt to adjust

(b). Two nutplate strips, 14 bolts and

spring.

washers from exhaust pipe fore and

aft flanges.

(7). Inspect for no contact between top of

exhaust and firewall retainer clips at

(2). Loosen the tensioning bolt passing

Sta. 155.75 fuselage ring.

through the hanger torsion spring

mandrel.

NOTE: If installing a new exhaust gasket, the

exhaust bolts should be retorqued after first

(3). Disengage the adjuster from the spring

flight. If bolts are found to be loose, retorque

pin.

after every flight until bolts retain torque.

Whenever tailpipes are re

CAUTION

moved, cover engine exhaust

3. Exhaust System Inspection

ducts with clean covers to prevent entry of

(Ref. Figure 201)

foreign materials into turbine section of en

gine.

(1). Inspect for cracks and broken weld

seams.

(4). Remove tailpipe and gasket.

(2). Inspect for dents and bends.

(5). Visually inspect bottom of upper aft

section firewall for contact marks with

(3). Using flashlight and mirror, look in

discoloration, holes or tears. Pay

engine bay through engine access doors

particular attention to firewall blanket

and look through engine oil filter access

retainer clips at Sta. 155.75 fuselage

cutout.

ring.

(a). Inspect top of engine exhaust duct for

B. Exhaust System Installation

contact marks and bottom of upper

(1). Remove protective cover from engine

aft section firewall for contact marks

exhaust duct.

with discoloration, holes or tears. Pay

particular attention to firewall

(2). Install gasket onto engine exhaust

blanket retainer clips at Sta. 155.75

flange.

fuselage ring.

Page 201

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Revision 38

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

4. Exhaust System Repair

(a). Using stainless steel brush, thor

oughly clean at least 1 inch (2.54 cm)

on all sides of cracked area. Cleaning

(Ref. Figure 201)

should remove all carbon from both

inner and outer surfaces and from

crack itself.

Consumable Materials

(b). Weld, using inert arc method, with

(Ref. Section 91−00−00)

rod (CM824). Shield back side of weld

Item

Nomenclature

with inert gas or suitable stainless

CM824

Welding rod

steel flux.

(c). Repair single cracks less than 2

inches (5.08 cm) in length by stop-

(1). Repair dents and bends using a form

drilling 0.040 inch (1.016 mm)

block and suitable mallet.

diameter hole at termination of each

end of crack. This method of repair

does not apply to intersecting cracks

(2). Repair cracks and breaks in tailpipes as

that form an acute angle leaving an

follows:

unsupported section.

Page 202

Revision 35

78-30-00

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

79-00-00 Engine Oil Supply System (369D/E/FF - 500/600N)

Description and Operation

201

Engine Oil Supply System Description and Operation

201

A. Oil Supply System Description

201

B. Oil Supply System Operation

201

Figure 201. Engine Oil Supply System Schematic Diagram

202

Engine Oil Supply System Fault Isolation

203

Table 201. Engine Oil Supply System Fault Isolation

203

Oil Cooler Flushing

204

Figure 202. Oil Cooler Flush Equipment and Arrangement

205

Oil Tank Replacement

205

A. Oil Tank Removal

205

B. Oil Tank Installation

205

Oil Tank Sight Plug Replacement

206

A. Oil Tank Sight Plug Removal

206

B. Oil Tank Sight Plug Installation

206

Oil Temperature Sender Replacement

206

Oil Cooler Replacement

206

A. Oil Cooler Removal

206

B. Oil Cooler Installation

207

Oil Tank Return Hose Replacement

207

A. Oil Tank Return Hose Removal

207

B. Oil Tank Return Hose Installation

207

Figure 203. Engine Oil Supply System (Sheet 1 of 2)

208

Oil Supply Lines and Fittings Replacement

210

10. Oil Cooler Duct Replacement

210

A. Oil Cooler Duct Removal

210

B. Oil Cooler Duct Installation

210

11. Oil Tank Inspection

210

12. Oil Cooler Inspection

210

Table 202. Oil System Hardware Torque Values

210

Figure 204. Engine Oil Cooler Installation

211

13. One Time Mandatory Hose Inspection (369D Serial Numbers 0003D thru

0374D, Only)

212

14. Oil Lines and Fittings Inspection

212

15. Oil Tank Repair

212

16. Oil Cooler Repair

212

Page i

79 Contents

Revision 23

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

17. Oil Cooler Duct Repair

212

79-10-10 Airframe-Mounted Engine Scavenge Oil Filter

(369D/E/FF - 500N)

Maintenance Practices

201

1. Description and Operation

201

2. Scavenge Oil Filter Check

201

3. Scavenge Oil Filter Element Replacement

201

4. Scavenge Oil Filter Bypass Indicator Test

201

Figure 201. Facet Scavenge Oil Filter Assembly

202

Initial Installation

901

1. Scavenge Oil Filter Initial Installation

901

2. Post Installation Inspection

902

Figure 901. Scavenge Oil Filter Installation

903

Page ii

Revision 23

79 Contents

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

ENGINE OIL SUPPLY SYSTEM

DESCRIPTION AND OPERATION

1. Engine Oil Supply System Description

(3). The oil cooler is an all aluminum,

and Operation

radiator-type heat exchanger. A

thermostat in the oil cooler set at 140 -

A. Oil Supply System Description

180°F (60 - 82°C) returns cold oil

directly to the tank, bypassing the

(1). MDHI helicopters feature a dry sump,

cooler until the oil has reached operat

air cooled, recirculating engine oil

ing temperature. The oil cooler also

system consisting of an oil tank, oil

features a pressure-relief bypass valve

temperature sender, oil cooler/heat

that opens at 25-30 psi (172-207 kPa)

exchanger and air duct, thermostat,

and a one way ball type check valve

drain valve, check valve, hoses, tubes,

mounted on the oil cooler inlet fitting

fittings and attaching hardware.

that prevents oil from flowing back into

the engine after shut down.

B. Oil Supply System Operation

(4). A fiberglass duct guides cooling air

(1). Hot oil scavenged from the engine is

from the oil cooler blower to the oil

pumped through a one way check valve

cooler.

into the oil cooler. Oil cooler blower air

at ambient temperature is ducted

(5). The oil supply system drain valve is

through the cooler/heat exchanger. The

mounted on a bracket below the oil

oil cooler reduces oil temperature to

cooler. Tubes from the oil tank, oil

approximately 185°F (86°C). Cooled oil

cooler and overboard drain are con

is returned to the oil tank. Oil drawn

nected to the drain valve which is

from the tank by the suction side of the

spring-loaded closed.

engine driven pump is then distributed

NOTE: DN-72.1 discloses installation proce

through the engine under pressure to

dures modifying early 369D helicopter oil

cool and lubricate moving parts. The

tank and cooler drains for easier access.

heated oil drains into various engine

sumps, and the cycle is repeated.

(6). All oil supply system hoses and tubes

are lightweight assemblies incorporat

(2). An all welded, spherical aluminum

ing permanent fittings. Hoses installed

alloy oil tank is fitted with a filler neck,

near the engine are equipped with fire

optional filler neck strainer, locking

shields.

cap, vent tube, oil inlet and outlet

fittings, temperature sender, sight plug

(7). Refer to the applicable Allison Engine

and mounting support bosses. A

Operation and Maintenance Manual for

replaceable sight plug provides oil

specific engine oil system information

quantity information at a glance.

(Ref. Sec. 01-00-00).

Page 201

79-00-00

Revision 23

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

TANK DRAIN

BULKHEAD

TUBE

FIREWALL

ELBOW

UNION

DRAIN

PORT

UPPER

INLET

OIL COOLER BLOWER

CONNECTOR

ENGINE-TO-COOLER

PORT

OIL HOSE

CHECK

CLAMP (2)

VALVE

COLLER DUCT

ELBOW

COOLER

DRAIN

OIL TANK

TUBE

LOWER CONNECTOR

RETURN HOSE

ENGINE OIL

COOLER DRAIN

COOLER OUTLET

TANK DRAIN

PORT

TIE STRAP (2)

CURRENT CONFIGURATION

THERMOSTATIC

DIFFUSER

VALVE

ENGINE-TO-FILTER

GASKET

OIL HOSE

SHIELD

SPACER

SHIELD

FILTER-TO-COOLER

OIL HOSE

DEFLECTOR

ENGINE OIL

COOLER

FIREWALL

SCAVENGE OIL FILTER

(NOTE)

GASKET

EARLY CONFIGURATION

STA. 124.00

TANK DRAIN

COOLER INLET AND

TUBE

DRAIN CONNECTIONS

CAUTION:

AT REMOVAL OR INSTALLATION OF CHECK

LOCKWIRE

VALVE OR HOSE, FLATS ON PORT SHOULD

BE HELD TO PREVENT DEFORMATION OF

COOLER FRAME.

UNION

NOTE:

DRAIN

APPLICABLE TO ALL ALLISON 250-C20R/2

PORT

ENGINES. OPTIONAL EQUIPMENT FOR

ALLISON 250-C20B AND C30 ENGINES.

BRACKET

INLET PORT

DRAIN VALVE

(SEE CAUTION)

FILTER-TO-

COOLER OIL

O-RING

HOSE (NOTE)

ENGINE-TO-COOLER

OIL HOSE

CHECK VALVE

GROMMET

O-RING

DRAIN HOSE

COOLER DRAIN VALVE

EARLY CONFIGURATION

G79-0004

Figure 201. Engine Oil Supply System Schematic Diagram

Page 202

Revision 23

79-00-00

MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

2. Engine Oil Supply System Fault Isolation

Table 201. Engine Oil Supply System Fault Isolation

Symptom

Probable Trouble

Corrective Action

Low or zero oil pressure.

Oil tank empty.

Top off oil supply tank (Ref. Sec.

12−00−00).

Oil line restriction.

Inspect, clean or replace plumbing.

Restricted oil filter element.

Clean oil filter per Allison Operation

and Maintenance Manual.

Defective sensor or indicator.

Replace sensor and, or indicator.

Oil pressure regulator valve

Adjust regulator per Allison

improperly adjusted.

Operation and Maintenance Manual.

Contaminated oil.

Inspect filter and chip detectors.

Drain and flush oil system. Refill

system (Ref. Sec. 12−00−00).

Sudden oil pressure reduction or

Low oil quantity.

Check oil level and service system

pressure fluctuations.

(Ref. Sec. 12−00−00).

Oil contamination.

Inspect filter and chip detectors.

Drain and flush system. Replace oil

(Ref. Sec. 12−00−00).

Oil leak.

Repair or replace hoses, tubes or

engine components as required.

Defective sensor or indicator.

Replace sensor and, or indicator.

Oil filter or pressure regulator valve

Clean oil filter; adjust pressure

restriction.

regulator valve. Replace valve if oil

pressure can not be adjusted (refer

to applicable Allison Operation and

Maintenance Manual).

Defective oil pump.

Replace oil pump per applicable

Allison Operation and Maintenance

Manual.

High oil pressure.

Defective indicator.

Replace indicator.

Pressure regulator valve out of

Adjust pressure regulator valve per

adjustment.

Allison Operation and Maintenance

Manual.

Abnormally high oil temperature

Defective temperature sensor or

Replace temperature sensor and/or

indication.

indicator.

Oil cooler bypass valve stuck closed.

Repair or replace oil cooler.

Oil cooler air passages blocked or

Repair or replace oil cooler.

damaged.

Oil cooler oil passages blocked or

Inspect oil filter and chip detectors.

damaged.

Repair or replace oil cooler.

Oil cooler blower intake air blockage.

Open intake airway.

Oil cooler blower failed or impeller

Repair or replace blower.

damaged.

Page 203

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Revision 23

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

Table 201. Engine Oil Supply System Fault Isolation

Symptom

Probable Trouble

Corrective Action

Abnormally low oil temperature

Defective temperature sensor or

Replace temperature sensor and/or

indication.

indicator.

Oil cooler bypass valve stuck open. Repair or replace oil cooler.

Oil consumption exceeds 6.5 oz. Leakage; loose fittings or

Repair or replace fittings and

(192.21 cc) per hour.

connections.

Restricted vent lines.

Inspect and clean as necessary.

Defective engine bearing oil seals.

Repair or replace engine.

Chip detector warning light on.

Contaminated oil.

Inspect engine chip detectors per

Allison Operation and Maintenance

Manual.

3. Oil Cooler Flushing

(a). Start with solvent (CM234) to flush

oil cooler interior. Initially reverse

(Ref. Figure 202)

solvent flow through cooler by

Connecting hose from pump dis

charge port to oil cooler outlet port.

Consumable Materials

(Ref. Section 91−00−00)

(b). Connect hose from storage tank to

Item

Nomenclature

inlet port of oil cooler.

CM226

Cleaning compound, alkaline waterbase

(c). Start cleaning equipment pump.

CM234

Solvent, dry-cleaning

Flush cooler for 30 minutes, or until

solution appears clean after passing

through unit.

NOTE: Maintain the engine oil cooler per the

following steps. For additional information,

(d). Shut down equipment and drain oil

refer to manufacturer's publications (Ref.

cooler.

Sec. 01-00-00). Where a conflict exists be

tween this manual and manufacturer's pub

NOTE: If metal particles are found, clean

lication, information in this manual super

screens with solvent (CM234) and blow dry

sedes manufactures data.

with clean, dry, filtered, low pressure com

pressed air.

(1). Remove thermostat, elbows, unions and

O-rings. Plug all openings.

(4). Examine filter screens for metal or

other foreign particles after flushing

Use only oil cooler manufactur

the unit per the following steps.

CAUTION

er's recommended cleaning so

lutions or a substitute that is stated as safe

(a). Flush oil cooler with compound

for use on aluminum. Copper or copper nick

(CM226) in direction opposite to

el cleaning compounds or solutions may cor

normal flow for 30 minutes.

rode the oil cooler. Cleaning equipment that

has been used with an unknown material, or

(b). Reverse hoses and flush oil cooler for

a known corrosive cleaning solution must be

10-15 minutes in normal flow

thoroughly flushed with the recommended

direction.

solution prior to use on the oil cooler.

(c). Rinse oil cooler with solvent (CM234)

(2). Steam clean oil cooler exterior surfaces.

for 10 minutes.

(3). Attach oil cooler to flushing setup

(5). Check filter screens. Replace oil cooler

shown. Flush oil cooler as follows:

if additional metal particles are found.

Page 204

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CSP-HMI-2

MAINTENANCE MANUAL

HYDRAULIC PRESSURE GAUGE

100 MESH SCREEN

INLET

HYDRAULIC PRESSURE GAUGE

COOLER

PRESSURE RELIEF VALVE

(SET FOR 75 PSI)

TANK

100 MESH SCREEN

OUTLET

CENTRIFUGAL PUMP

(28 - 56 GPM; 75 PSI

FULL-FLOW FILTER

DISCHARGE PRESSURE)

OUT

G79-0002

Figure 202. Oil Cooler Flush Equipment and Arrangement

4. Oil Tank Replacement

(a). Install vent hose on tank.

(b). Install unions and O-rings on oil

(Ref. Figure 203)

return and supply hoses and tank

A. Oil Tank Removal

drain tube fittings.

(c). Install oil temperature sender and

(1). Drain oil system (Ref. Sec. 12-00-00).

gasket. Torque sender body to 100 -

(a). Remove engine oil cooler duct.

150 inch-pounds (11.30 - 16.95

Nm). Install lockwire. Torque wire

(b). Disconnect hose between tank and

terminal nut to 12 - 25 inch-

vent. Disconnect supply, return and

pounds (1.36 - 2.82 Nm).

tank drain lines from oil tank fit

(d). Install sight plug (Ref. Oil Tank

tings. Allow tank to drain dry.

Sight Plug Replacement).

(c). Disconnect oil temperature sender

(2). Position engine oil tank on Sta. 124.00

wires and remove sender.

firewall and secure with bolts and

washers.

(d). Remove oil filler seal, oil tank cap

retaining plate and oil tank.

(a). Install oil tank filler seal and retain

ing plate. Ensure filler seal fits over

(e). Unfasten and remove oil tank.

oil tank filler neck and is secure with

attaching hardware (Ref. Figure 203,

B. Oil Tank Installation

Detail B).

(1). Assemble tank as follows:

(b). Install oil tank filler seal clamp.

Page 205

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Revision 23

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

(3). Connect the following oil lines and

(4). Install oil tank (Ref. Oil Tank Replace

torque (Ref. Table 202, Oil System

ment).

Hardware Torque Values).

6. Oil Temperature Sender Replacement

(a). Connect return hose between engine

NOTE: 369A4533-BSC sensor is compatible

and cooler.

with the 369D296305-21, -23 and -31

(b). Connect supply hose between tank

instrument clusters only. 369A4533-3 sen

and engine.

sor is compatible with the 369D296305-33,

-35 and -37 instrument clusters only.

(c). Connect drain tubes to oil tank

fittings.

(1). Switch off and disconnect all electrical

power.

(d). Install O-ring and connect vent hose

(2). Drain oil tank.

between tank and engine.

(3). Disconnect electrical wire from oil

(e). Install oil cooler duct.

temperature sender, break lockwire and

remove sender from oil tank fitting.

5. Oil Tank Sight Plug Replacement

(a). Install oil temperature sender and

(Ref. Figure 203)

gasket. Torque sender body to 100 -

150 inch-pounds (11.30 - 16.95

Consumable Materials

Nm). Install lockwire. Torque wire

(Ref. Section 91−00−00)

terminal nut to 12 - 25 inch-

Item

Nomenclature

pounds (1.36 - 2.82 Nm).

CM125

Oil

(4). Fill oil tank (Ref. Sec. 12-00-00).

CM126

Oil, turbine

(5). Start engine (Ref. Pilot's Flight Manu

al). Check for oil leakage and tempera

A. Oil Tank Sight Plug Removal

ture gauge operation.

(1). Drain oil system.

(6). Install aft bulkhead access cover.

(2). Remove oil tank (Ref. Oil Tank Replace

7. Oil Cooler Replacement

ment).

(Ref. Figure 204)

(3). Break lockwire and remove sight plug.

Consumable Materials

B. Oil Tank Sight Plug Installation

(Ref. Section 91−00−00)

Item

Nomenclature

NOTE: Liquid level decal is applied after plug

is installed and torqued.

CM125

Oil

CM126

Oil, turbine

(1). Install a new O-ring on sight plug.

Coat O-ring and sight plug threads

with clean engine oil (CM125) or

A. Oil Cooler Removal

(CM126). Torque sight plug to 80 - 90

Avoid oil cooler damage. Use a

inch-pounds (9.04 - 10.17 Nm);

CAUTION

backup wrench to support oil

lockwire.

cooler port bosses when unfastening or

(2). Project a pencil line from the oil tank

torquing threaded fittings.

upper mount through the centers of

(1). Drain oil system (Ref. Sec.

nutplate and sight plug (Ref.

12-00-00).

Figure 203, view A).

(a). Remove oil cooler duct.

(3). Install sight plug decal on plug face

with decal water line (WL) marks

(b). Disconnect oil return hose from elbow

aligned with pencil line.

at cooler outlet fitting. Remove elbow.

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

(c). Remove cooler drain tube. Remove

(g). Install tank return hose elbow in

drain union and O-ring from cooler

cooler outlet port. Connect oil tank

inlet port.

return hose.

(d). Remove check valve.

(h). Install oil cooler duct (Ref. Oil Cooler

Duct Installation).

(e). Disconnect engine power turbine

cooling air duct from oil cooler

(i). Service tank with oil (CM125) or

deflector. Remove deflector from

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

cooler mounting flange.

(2). Operate engine per Pilot's Flight

(f). Remove oil cooler.

Manual. Inspect oil system for leaks.

(g). Remove lockwire and separate

8. Oil Tank Return Hose Replacement

shields from cooler, if installed.

B. Oil Cooler Installation

Consumable Materials

(Ref. Section 91−00−00)

Avoid oil cooler damage. Use a

Item

Nomenclature

CAUTION

backup wrench to support oil

CM125

Oil

cooler port bosses when unfastening or

CM126

Oil, turbine

torquing threaded fittings.

(1). Install oil cooler per the following steps.

A. Oil Tank Return Hose Removal

Refer to manufacturer's publications for

additional information as required (Ref.

(1). Remove trim and R/H bulkhead access

Sec. 01-00-00). This information

panel.

supersedes cooler manufacturer's data

wherever conflicting information exists.

(2). Drain oil supply system.

(a). On Harrison coolers only, position

Avoid oil cooler damage. Use a

shields on sides of oil cooler so that

CAUTION

backup wrench on oil cooler port

outboard shield without tab is

boss when removing or installing oil line fit

adjacent to oil inlet port. Secure

tings.

shields with one lockwire wrap

around cooler.

(3). Disconnect hose from oil cooler OUT

port elbow.

(b). Position oil cooler on firewall and

secure with attaching hardware.

(4). Remove oil cooler OUT port elbow.

(c). Position deflector on cooler mounting

(5). Disconnect hose from oil tank IN port

flange and secure with screws and

union. Remove union.

washers. Connect engine power

turbine cooling duct to oil cooler

B. Oil Tank Return Hose Installation

deflector.

(1). Lubricate male threads with clean

(d). Coat check valve threads with oil

engine oil (CM125) or (CM126) prior to

(CM125) or (CM126); Install check

installation. Thread hose straight end

valve.

fitting into oil tank. Attach opposite end

to oil cooler.

NOTE: Torque all oil cooler hardware per Oil

System Hardware Torque Values (Ref.

(2). Torque hose ends per Oil System

Table 202).

Hardware Torque Values (Ref.

Table 202).

(e). Install union and O-ring in cooler

drain port.

(3). Install bulkhead panel and trim.

(f). Connect cooler drain tube.

(4). Enter compliance in helicopter records.

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MAINTENANCE MANUAL

OIL COOLER

BLOWER

SIGHT PLUG

OIL TANK

O-RING

TANK-TO-ENGINE

VENT HOSE

OIL TANK

OIL COOLER

DRAIN

TANK-TO-ENGINE

CURRENT CONFIGURATION

OIL HOSE

TO ENGINE

CHECK VALVE

DRAIN TUBE

ENGINE-TO-FILTER

ENGINE-TO-COOLER

HOSE

FILTER-TO-COOLER

HOSE

OIL HOSE

OVERBOARD

DRAIN TUBE

SCAVENGE OIL FILTER INSTALLATION

(NOTE 1)

EARLY CONFIGURATION

SIGHT PLUG

UPPER MOUNT

DECAL

NUTPLATE

WL 48.63

NOTES:

(NOTE 1)

WL - WATERLINE.

APPLICABLE TO ALL

ALLISON 250-C20R/2 ENGINES.

OPTIONAL EQUIPMENT FOR ALLISON

PROJECTED LINE

250-C20B AND 250-C30 ENGINES.

WL LOCATOR

MARKS

SIGHT PLUG ALIGNMENT

(LOOKING INBOARD)

G79-0003-1

Figure 203. Engine Oil Supply System (Sheet 1 of 2)

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CSP-HMI-2

MAINTENANCE MANUAL

OIL TANK OUTLET

FITTING

OIL TANK

UNION

FILLER

STA. 124.00

FIREWALL

OIL TANK

TANK VENT HOSE

RETURN TUBE

OIL TANK SUPPORT

OIL TANK

BUSHING

RETURN HOSE

OIL TEMPERATURE

O-RING

SENSOR (NOTE 1)

OIL TANK

ENGINE OIL

(ALLISON 250-C20R/2 ENGINE)

COOLER DUCT

WASHER

OIL TANK

TANK DRAIN TUBE

INLET PORT

O-RING

UNION

TANK-TO-ENGINE

OIL HOSE

VENT HOSE

OIL TANK INSTALLATION

(ALLISON 250-C20B ENGINE)

CAP RETAINING PLATE

CLAMP

FILLER SEAL

OIL TANK FILLER SEAL

INSTALLATION

G79-0003-2

Figure 203. Engine Oil Supply System (Sheet 2 of 2)

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MAINTENANCE MANUAL

9. Oil Supply Lines and Fittings

(3). Remove attaching hardware from

Replacement

diffuser. Lift diffuser to separate from

cooler flange. Retain spacers.

(Ref. Figure 203)

B. Oil Cooler Duct Installation

Consumable Materials

Over tightening bolts can crack

(Ref. Section 91−00−00)

CAUTION

duct flange.

Item

Nomenclature

(1). Align diffuser on oil cooler flange with

CM125

Oil

spacers and gasket. Secure with

CM126

Oil, turbine

attaching hardware.

(a). Place lower connector on cooler duct

(1). Drain system before removing oil lines.

elbow, then slide connector over

diffuser. Secure lower connector to

NOTE:

cooler duct elbow and diffuser with

D Lubricate all fitting threads with oil

tie-straps.

(CM125) or (CM126) prior to installation.

(b). Place upper connector on cooler duct

D Torque hardware per Oil System Hard

elbow, then install elbow over oil

ware Torque Values (Ref. Table 202).

cooler blower scroll. Slide upper

Avoid oil system damage. Use a

connector over scroll; secure with

CAUTION

backup wrench to support

clamps.

bosses, fittings and subassemblies when un

fastening or torquing all threaded compo

11. Oil Tank Inspection

nents.

(1). Check oil tank for obvious damage,

(2). Install oil lines and fittings.

corrosion, evidence of leakage and

security.

10. Oil Cooler Duct Replacement

(2). Repair or replace oil tank as required.

(Ref. Figure 203)

12. Oil Cooler Inspection

A. Oil Cooler Duct Removal

(1). Inspect engine oil cooler for cracks,

(1). Remove clamps and separate cooler

corrosion, damaged or bulged plates,

duct elbow from oil cooler blower.

broken welds, clogged airways, oil leaks

Remove upper connector.

and security. Inspect all hoses and

fittings for oil leaks and security.

(2). Remove tie straps and separate cooler

duct elbow from diffuser. Remove lower

(2). Repair or replace oil cooler and compo

connector.

nents as required.

Table 202. Oil System Hardware Torque Values

Item

Torque

1/4 inch (6.35 mm) OD tube nuts

40 − 65 inch−pounds

(4.52 − 7.34 Nm)

5/16 inch (7.94 mm) OD tube nuts

60 − 80 inch−pounds

(6.78 − 9.04 Nm)

1/2 inch (12.70 mm) OD tube nuts

150 − 200 inch−pounds

(16.95 − 22.60 Nm)

1/4 inch (6.35 mm) OD hose nuts

70 − 120 inch−pounds

(7.91 − 13.56 Nm)

5/16 inch (7.94 mm) OD hose nuts

85 − 180 inch−pounds

(9.60 − 20.34 Nm)

1/2 inch (12.70 mm) OD hose nuts

210 − 420 inch−pounds

(23.73 − 47.45 Nm)

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MAINTENANCE MANUAL

TANK DRAIN

BULKHEAD

TUBE

FIREWALL

ELBOW

UNION

DRAIN

PORT

UPPER

INLET

OIL COOLER BLOWER

CONNECTOR

ENGINE-TO-COOLER

PORT

OIL HOSE

CHECK

CLAMP (2)

VALVE

COLLER DUCT

ELBOW

COOLER

DRAIN

OIL TANK

TUBE

LOWER CONNECTOR

RETURN HOSE

ENGINE OIL

COOLER DRAIN

COOLER OUTLET

TANK DRAIN

PORT

TIE STRAP (2)

CURRENT CONFIGURATION

THERMOSTATIC

DIFFUSER

VALVE

ENGINE-TO-FILTER

GASKET

OIL HOSE

SHIELD

SPACER

SHIELD

FILTER-TO-COOLER

OIL HOSE

DEFLECTOR

ENGINE OIL

COOLER

FIREWALL

SCAVENGE OIL FILTER

(NOTE)

GASKET

EARLY CONFIGURATION

STA. 124.00

TANK DRAIN

COOLER INLET AND

TUBE

DRAIN CONNECTIONS

CAUTION:

AT REMOVAL OR INSTALLATION OF CHECK

LOCKWIRE

VALVE OR HOSE, FLATS ON PORT SHOULD

BE HELD TO PREVENT DEFORMATION OF

COOLER FRAME.

UNION

NOTE:

DRAIN

APPLICABLE TO ALL ALLISON 250-C20R/2

PORT

ENGINES. OPTIONAL EQUIPMENT FOR

ALLISON 250-C20B AND C30 ENGINES.

BRACKET

INLET PORT

DRAIN VALVE

(SEE CAUTION)

FILTER-TO-

COOLER OIL

O-RING

HOSE (NOTE)

ENGINE-TO-COOLER

OIL HOSE

CHECK VALVE

GROMMET

O-RING

DRAIN HOSE

COOLER DRAIN VALVE

EARLY CONFIGURATION

G79-0004

Figure 204. Engine Oil Cooler Installation

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MD Helicopters, Inc.

MAINTENANCE MANUAL

13. One Time Mandatory Hose Inspection

(1). Remove sight plug, oil temperature

(369D Serial Numbers 0003D thru 0374D,

sender, unions and hoses.

Only)

(2). Flush tank with solvent (CM234).

(1). Remove trim and aft R/H bulkhead

access panel.

(3). Oxy-acetylene weld all cracks, loose

fittings, open seams, and tubes with

(2). Locate return hose between oil cooler

welding rod (CM825).

and tank. Check part number. Part

number 369D28309 hose must be

(4). Blend scratches and nicks with fine grit

replaced with a part number

aluminum oxide abrasive cloth

369D28311-3 hose assembly per

(CM802).

instructions in `Removal and Installa

tion'.

(5). Touch up reworked surfaces with

chemical film (CM206).

14. Oil Lines and Fittings Inspection

(6). Install sight plug, oil temperature

(1). Inspect tubes and hoses for uniform

sender, unions and hoses.

diameter, interference with adjoining

structure and the following:

16. Oil Cooler Repair

(a). Inspect tubes for kinks or dents

which could obstruct oil flow. Dents

Consumable Materials

may not exceed 0.015 inch (0.381

(Ref. Section 91−00−00)

mm) deep.

Item

Nomenclature

CM206

Chemical coating

(b). Look for cracks. No tubing cracks are

allowed.

CM802

Abrasive cloth, aluminum oxide

CM825

Welding rod

(c). Inspect coupling nut threads for

Cross-thread damage. No thread

damage allowed.

(1). Replace a defective thermostatic valve.

(d). Inspect tubing for chafe damage in

(2). Straighten bent cooling fins with a pair

excess of 0.010 inch (0.254 mm) deep.

of duckbill pliers ground to fit between

No chafe damage allowed on or near

cooling tubes.

flared tubing end.

(3). Weld all small holes, cracked seams or

(e). Look for nicks in excess of 0.010 inch

loose fittings with welding rod (CM825).

(0.254 mm) depth.

(4). Smooth scratches and nicks with fine

(f). Replace any tubes exceeding damage

grit aluminum oxide abrasive cloth

limits.

(CM802). Touch up surface with

chemical film (CM206).

15. Oil Tank Repair

17. Oil Cooler Duct Repair

Consumable Materials

(Ref. Section 91−00−00)

NOTE: Repairs must not restrict airflow, pre

Item

Nomenclature

vent proper mating or interfere with instal

lation.

CM206

Chemical coating

CM234

Solvent, dry-cleaning

(1). Repair cooler duct per standard

CM802

Abrasive cloth, aluminum oxide

fiberglass repair procedures in the

CM825

Welding rod

structural repair manual (CSP-

SRM-6).

Page 212

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CSP-HMI-2

MAINTENANCE MANUAL

AIRFRAME−MOUNTED ENGINE SCAVENGE OIL FILTER

MAINTENANCE PRACTICES

Description and Operation

(7). Install a new oil filter element.

(1). The optional scavenge oil filter is

3. Scavenge Oil Filter Element Replacement

installed in the return line between the

(Ref. Figure 201)

engine and oil cooler. The scavenge

filter supplements the engine oil filter

and provides the capacity to keep the

Consumable Materials

oil clean enough to operate extended

(Ref. Section 91−00−00)

hours (Ref. applicable Rolls-Royce

Item

Nomenclature

Maintenance Manual, Sec. 72-00-00,

CM701

Lockwire CRES

Table 602) between changes.

(2). The 10 micron filter element keeps

(1). Open engine access doors.

otherwise recirculated microscopic

(2). Break lockwire and remove bowl and

carbon and metal particles from

filter element. Inspect element, bowl

accumulating in the cooler, supply tank,

seal and inside of bowl. Clean bowl as

engine or on magnetic plugs.

required. Replace seal as required.

(3). The filter body is equipped with a

(3). Install a new filter element.

bypass valve and red impending bypass

warning indicator that extends when

(4). Hand tighten bowl snug into filter body.

differential pressure across the filter

Lockwire (CM701) bowl.

element reaches 6-8 psid (41-55 kPa).

(5). Motor engine until oil pressure is

The indicator is inoperative until the oil

indicated. Check oil quantity and top off

temperature exceeds 85-115°F

oil tank as required.

(30-46°C). The filter bypass valve opens

at 9-11 psid (62-76 kPa).

(6). Start and operate engine at idle for five

minutes per Pilot's Flight Manual. Shut

Scavenge Oil Filter Check

down engine and check for oil leaks.

(Ref. Figure 201)

(7). Enter filter element change in helicop

ter records.

(1). Open engine access doors.

4. Scavenge Oil Filter Bypass Indicator Test

(2). Inspect red bypass indicator button on

bottom of filter bowl. Button extension

(Ref. Figure 201)

indicates a filter element impending

bypass condition.

Consumable Materials

(Ref. Section 91−00−00)

(3). Press and turn indicator button 90° to

Item

Nomenclature

reset.

CM701

Lockwire CRES

(4). Operate engine per Pilot's Flight

Manual until engine oil reaches normal

Special Tools

operating temperature.

(Ref. Section 91−00−00)

Item

Nomenclature

(5). Shut down engine. Check indicator

ST408

Test tool

button.

(6). If button has reappeared, investigate

(1). Open engine access doors.

cause of filter bypass condition per the

applicable Rolls-Royce Operation and

(2). Break lockwire and remove filter bowl

Maintenance Manual.

and element. Inspect element and

Page 201

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MD Helicopters, Inc.

MAINTENANCE MANUAL

inside of bowl per the applicable

will not reset, contact Facet Enter

Rolls-Royce Operation and Mainte

prises, Inc., or your authorized Facet

nance Manual.

distributor (Ref. Sec. 01-00-00).

(3). Install Facet test tool (ST408) and

NOTE: The bypass indicator is functioning

reinstall bowl without lockwire.

properly if it extends.

NOTE: Bypass indicator remains inoperative

until oil temperature exceeds 85-115°F

(6). Shut down engine per Pilot's Flight

(30-46°C).

Manual. Remove filter bowl and test

tool. Clean filter bowl as required.

(4). Operate engine per Pilot's Flight

Manual until engine oil reaches normal

operating temperature and filter bypass

(7). Install a new seal kit and filter ele

indicator extends (about 10 minutes).

ment. Hand tighten bowl snug into

filter body. Lockwire (CM701) bowl.

Bypass indicator and bowl are

CAUTION

matched assemblies and factory

(8). Press and turn indicator button 90° to

set. Do not attempt to adjust or replace by

reset.

pass indicator assembly.

(5). If bypass indicator fails to extend or

(9). Drain and service engine oil system.

HEAD ASSY

SCREEN

REDUCER

SEAL

BOWL ASSY

FILTER ELEMENT

BYPASS INDICATOR

G79-1001

Figure 201. Facet Scavenge Oil Filter Assembly

Page 202

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MD Helicopters, Inc.

CSP-HMI-2

MAINTENANCE MANUAL

AIRFRAME−MOUNTED ENGINE SCAVENGE OIL FILTER

INITIAL INSTALLATION

1. Scavenge Oil Filter Initial Installation

(9). Locate two vertical stiffeners located on

RBL 8.500 and RBL 15.250.

(Ref. Figure 901)

(10). Locate flanged horizontal stiffener on

WL 24.750. Stiffener is installed across

Consumable Materials

helicopter centerline between left and

(Ref. Section 91−00−00)

right BL 8.500 vertical stiffeners.

Item

Nomenclature

Avoid fatigue concentrations.

CM219

Methyl-ethyl-ketone

CAUTION

Do not scratch, score or gouge

CM318

Primer

firewall when removing insulation.

CM721

Tape, aluminum foil

(11). Remove insulation between RBL 8.500

and RBL 15.250 vertical stiffeners

Prevent installation errors and

beginning at WL 24.750 and down

CAUTION

equipment damage. Study in

about 6 inches (15.24 cm). Retain

stallation instructions before beginning

insulation.

work. Contact Facet Enterprises, Inc. for ad

Do not position mounting brack

ditional information (Ref. Sec. 01-00-00).

CAUTION

ets and filter lower than the

hoses will reach. Install filter so that line

(1). Disconnect external electric power. Set

connections can be made without straining

all switches OFF. Disconnect battery.

hoses.

(2). Open engine access doors.

(12). Locate and clamp LH mounting bracket

within 0.1250-0.3125 inch

(3). Drain engine oil tank, lines and cooler

(3.1750-7.9375 mm) of WL 24.75

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

horizontal stiffener with bracket flange

facing inboard.

(4). Disconnect electrical plug from engine

gear case chip detector. Remove chip

(13). Locate and clamp RH mounting bracket

detector from gear case. Bag parts for

level with LH bracket and flange facing

reinstallation.

inboard.

(5). Disconnect scavenge oil line from gear

(14). Locate and clamp filter mounting plate

case OUT port union (Ref. Sec.

to brackets with plate flanges facing aft

79-00-00). Remove and discard union.

and triangular hole pattern pointing

up.

Avoid oil cooler damage. Use a

CAUTION

(15). Position filter on its mounting plate and

backup wrench on oil cooler port

loosely install spacers, bolts, washers

boss when removing or installing oil line fit

and nuts.

tings.

(16). Install O-ring on engine oil OUT port

(6). Disconnect scavenge oil hose from oil

reducer. Install and torque reducer per

cooler IN port check valve union.

requirements of the applicable Allison

Remove union from oil cooler check

Operation and Maintenance Manual.

valve. Discard union and hose.

Prevent oil cooler damage. Use a

(7). Unclamp wire bundle on BL 15.250

CAUTION

backup wrench on oil cooler

vertical stiffener. Bag clamp hardware

check valve while torquing reducer.

for reuse.

(17). Install O-ring on oil cooler IN port

(8). Locate airframe centerline on firewall

reducer. Relieve lightening hole for

bulkhead in engine compartment.

additional clearance as required. Install

Page 901

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MAINTENANCE MANUAL

reducer in oil cooler check valve and

(28). Install chip detector and torque to 60 -

torque to 280 - 305 inch-pounds

80 inch-pounds (6.78 - 9.04 Nm).

(31.64 - 34.46 Nm).

(29). Attach chip detector electrical connector

(18). Loosely install hose between engine

to chip detector.

gear case OUT port and filter IN port

(30). Select a location for filter bypass

with 90° hose fitting attached to filter.

indicator reset label in plain view on

upper LH corner of RH engine access

(19). Loosely install hose between filter OUT

door. Activate label adhesive with MEK

port and oil cooler IN check valve with

(CM219).

90° fitting attached to filter.

NOTE: Reposition brackets and filter as re

2. Post Installation Inspection

quired to relieve any strain on hoses before

It is possible to install the fil

drilling mounting bracket holes through

WARNING

ter with its IN and OUT

stiffeners. Relocate and drill three new filter

ports reversed. This condition renders

mounting bracket bolt holes when addition

both the impending bypass indicator

al hose strain relief is required.

and filter bypass valve inoperative.

Subsequent clogging of the outlet port

(20). Unclamp and move filter and mounting

screen will not provide any visual indi

plate assembly out of the way.

cation. If allowed to continue, the oil

Avoid fatigue concentrations.

flow reduction could have a disastrous

CAUTION

Do not scratch, score or gouge

effect on the engine and oil system

firewall while drilling stiffeners.

components.

(1). Ensure that the engine gear case oil

(21). Ensure bracket upper edges are lined

OUT port hose is connected to the

up and level. Drill three 0.189 inch

scavenge oil filter IN port. Ensure that

(4.8006 mm) diameter bolt holes

the filter OUT port hose is connected to

through left and right brackets and

the oil cooler IN port.

airframe stiffeners.

(2). Check for adequate hose clearances

(22). Unclamp brackets and deburr holes.

near structure and engine.

Coat holes with primer (CM318).

(3). Inspect attaching hardware for security

(23). Install brackets with bolts, washers and

and line connections for correct torque

nuts. Install wire harness clamp under

values.

upper right bolt.

(4). Service engine oil system (Ref. Sec.

(24). Attach insulation to firewall with

12-00-00).

aluminum foil tape (CM721).

(5). Connect battery.

(25). Torque three filter mounting nuts to 50

- 55 inch-pounds (5.65 - 6.21 Nm).

(6). Pick up tools and debris before closing

engine access doors.

(26). Attach filter mounting plate to airframe

brackets with bolts, washers and nuts.

(7). Operate engine per Pilot's Flight

Manual and inspect installation for oil

(27). Torque hose nuts to 280 - 305 inch-

leaks prior to releasing helicopter for

pounds (31.64 - 34.46 Nm).

flight.

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CSP-HMI-2

MAINTENANCE MANUAL

CHARTS

CONSUMABLE MATERIALS AND SPECIAL TOOLS

1. General

D CM601 - Rubber Material

This chapter provides a table of Consumable

D CM701 - Lockwire, Fasteners and Tape

Materials and a table of Special Tools used on

the 500/600N Series Helicopter.

D CM801 - Miscellaneous Materials

The information in each table is divided into

3. Special Tools

groups. Within each group, materials or tools

Table 3 identifies special tools, necessary for

are identified by a number. Numbers have a

maintenance operations.

prefix of CM identifying a consumable

material, or a ST identifying a special tool. CM

Each tool is assigned an ST number, with an

and ST numbers are used throughout the

associated part number, descriptive title and

maintenance manual, allowing quick reference

function.

for Consumable Materials and Special Tools.

4. Manufacturer/Supplier Number

2. Consumable Materials

Table 2 lists Manufacturer/Supplier (Vendor)

Table 1 lists Consumable Materials, such as

Number with address. Table 2 is used with

fuels and oils used to support repair or

Table 1, Consumable Materials.

servicing procedures.

Table 4 lists Tool Manufacturer/Supplier

Consumable materials are assigned a CM

(Vendor) Number with address. Table 4 is used

number, with associated material name,

with Table 3, Special Tools.

specification number and commercial name.

D ST101 - Ground Handling

The following consumable materials are

approved for use on the 500/600N Series. Do

D ST201 - Jacking and Leveling

not use replacement materials unless equal in

quality and grade. Refer to notes at the end of

D ST301 - Main Transmission

Table 1.

D ST401 - Engine

For additional servicing information, such as

capacities Refer to Section 12-00-00.

D ST501 - Flight Controls

D CM101 - Lubricants

D ST601 - Anti-Torque

D CM201 - Solvents, Cleaners and Corrosion

D ST701 - Main Rotor

Preventative Compounds

D ST801 - Fuel

D CM301 - Paints, Primers and Coating

Compounds

D ST901 - Track and Balance

D CM401 - Adhesives, Cements and Sealants

D ST1001 - Electrical/Instrument/Avionic

D CM501 - Composite Materials

D ST2001 - Miscellaneous

Page 1

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Revision 23

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MD Helicopters, Inc.

MAINTENANCE MANUAL

Table 1. Consumable Materials

Item

Specification No. (1)

Vendor

No.

Material

Type Class Grade

Commercial Name/No. (2)

(Table 2)

Lubricants

CM101

Solid film lubricant

MIL-L-46010

(3)

CM102

Solid film lubricant

MIL-L-46010A

Ecoalube No. 642

MS27

CM103

Solid film lubricant

MIL-L-8937

Lubribond A

MS25

MIL-L-23398

Molyspray Type PT-101

MS63

HMS 4-1078 1

CM104

Lubricant, spray

Tri-Flow

MS37

Break-Free

MS43

CM105

Lubricant, spray

Moly-Dee

MS9

CM106

Fluorocarbon dry lubricant

S-122

MS53

CM107

Fluorocarbon release agent (dry

6611N

MS24

film lubricant)

CM108

Graphite, powdered

(3)

CM109

Molybdenum disulfide powder

MIL-L-7866

(3)

lubricant

CM110

Grease

GD568-S

MS35

CM111

Grease, aircraft

MIL-G-81322

Mobil Grease 28

MS54

Aero Shell 22

MS73

Braycote 622

MS13

CM112

Anti-seize compound high tem

MIL-PRF-907E

(3)

perature

CM113

Anti-seize compound low tem

MIL-T-5544

Thread Lube

MS59

perature

CM114

Petrolatum (petrolatum jelly)

MIL-G-6032

MS22

VV-P-236

MS70

MS81

CM115

Grease, oscillating bearing

MIL-G-25537

Aero Shell 14

MS73

MIL-A-8623

A-1177-B

MS12

CM116

Grease, aircraft and instrument

MIL-G-23827

Braycoat 627

MS13

Exxon 5114EP

MS28

Aero Shell 7

MS73

CM117

Grease

MIL-G-23872

(3)

CM118

Grease

930A

MS47

CM119

Grease

130A

MS47

CM120

Oil, corrosion preventive

Steelgard 1301

MS36

CM121

Preservation oil (general pur

VV-L-800

MS13

pose)

CM122

Preservative oil, hydraulic

MIL-H-6083

(3)

CM123

Hydraulic fluid

MIL-H-5606

(3)

CM124

Kerosene

VV-K-211

(3)

Page 2

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CSP-HMI-2

MAINTENANCE MANUAL

Table 1. Consumable Materials (Cont.)

Item

Specification No. (1)

Vendor

No.

Material

Type Class Grade

Commercial Name/No. (2)

(Table 2)

CM125

Oil (4) (7)

Pre-SB369D-209,

MS54

SB369E-104,

SB369F-090,

SB500N-045,

SB600N-053:

Mobil SHC 626 (6)

Post-SB369D-209,

SB369E-104,

SB369F-090,

SB500N-045,

SB600N-053:

Mobil AGL (6)

CM126

Oil, turbine (4) (5)

MIL-L (PRF)-23699

(3)

CM127

Grease, YSAS Actuator

168043

MS90

Solvents, Cleaners and Corrosion Preventative Compounds

CM201

Protective coating

MIL-C (PRF)-6799

(3)

CM202

Metal protector, aerosol

Molykote

MS22

CM203

Potting compound

MIL-S (PRF)-8516G

MS77

CM204

Compound, corrosion preventa

MIL-C (PRF)-16173E

Braycote

MS10

tive

MS13

MS88

CM205

Dielectric compound

DC-4

MS22

CM206

Chemical coating

MIL-C-5541

Iridite 14-2

MS67

Al-Coat

MS85

Alodine 1201

CM207

Chromic acid solution (pH 2.6 to

Dow #19 or equivalent

MS22

3.4, magnesium touchup)

CM208

Barrier material (grease-proof)

MIL-B (PRF)-121G

(3)

MIL-B (PRF)-131L

CM209

Putty, general purpose

MIL-P (PRF)-8116

Compound 3998

MS32

CM210

Corrosive preventive (aircraft

MIL-C (PRF)-8188

(3)

gas turbine, synthetic base)

CM211

Solvent

3339

MS82

CM212

Releasing agent

TC7-527

MS26

CM213

Releasing agent

225

MS64

CM214

Releasing agent

MIL-P (PRF)-23377

MS14

HMS 20-1245

MS17

CM215

Parting agent

Slip-Spray

MS24

Fre-Kote 33

MS31

Page 3

91-00-00

TR12-001

CSP-HMI-2

MD Helicopters, Inc.

MAINTENANCE MANUAL

Table 1. Consumable Materials (Cont.)

Item

Specification No. (1)

Vendor

No.

Material

Type Class Grade

Commercial Name/No. (2)

(Table 2)

CM216

Loctite remover (for disas

Oakite 156

MS17

sembled parts)

MS57

MS74

CM217

Isopropyl alcohol

TT-I-735

(3)

CM218

Alcohol, denatured

O-E-760

(3)

CM219

Methyl-ethyl-ketone

TT-M-261

(3)

CM220

Naphtha aliphatic

TT-N-95

(3)

CM221

Xylene

(3)

CM222

1,1,1-Trichloroethane

O-T-620

(3)

CM223

Acetone

O-A-51

(3)

CM224

Soap paste

P-S-560

(3)

CM225

Detergent, general purpose

MIL-O-16791

(3)

CM226

Cleaning compound, alkaline

MIL-C-25769

(3)

waterbase

CM227

Washing compound with wax

Turtle™ Zip Wax

(3)

CM228

Surface cleaner (pre-paint solu

TT-C-490

WO#1

MS79

tion with phosphoric acid base)

MIL-C-10578

CM229

Paint remover (acid-type for

TT-R-25134

MS79

epoxy)

CM230

Paint remover (solvent-type)

MIL-R-25314

(3)

CM231

Plastic bead, spherical 20 - 30

Poly Plus 20/30 (8)

MS1

mesh

MS2

MS61

CM232

Rust inhibitor spray

WD-40

MS68

CM233

Rust inhibitor spray

LPS3

MS46

CM234

Solvent, dry-cleaning

P-D-680

(3)

CM235

Cleaner

Desoclean 45

MS17

CM236

Paint remover

Turco 5351 (T-5469)

MS79

Paints (9), Primers and Coating Compounds

CM301

Pre-treatment

MIL-P-15328

(3)

CM302

Epoxy primer /

1-1G-69 /

MS3

Catalyst reducer

1-1H-75

CM303

Wash primer

MIL-C-8514

(3)

Page 4

TR12-001

91-00-00

HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369D/E/FF-500/600N HELICOPTERS (ISSUED: 1990) - page 31