CSP-H-2 BASIC HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369H HELICOPTERS

PROPRIETARY RIGHTS NOTICE

The technical data and information contained in this publication is the property of

and proprietary to MD Helicopters, Inc. and is not to be disclosed or reproduced in

whole or in part without the written consent of MD Helicopters, Inc.

RESTRICTED USE

MDHI provides this manual for use by owners, operators and maintainers of MDHI

products and authorized parts. Use by STC or PMA applicants or holders as

documentation to support their certificates is not an authorized use of this manual

and is prohibited. MDHI takes no responsibility for customer’s use of parts

manufactured under an STC or PMA when this manual is used as documentation with

the Federal Aviation Administration to justify the STC or PMA. Use of unauthorized

parts on MDHI products will void the MDHI warranty offered to the customer on

components and may void the warranty on the helicopter.

MD HELICOPTER, INC.

TECHNICAL MANUAL RECOMMENDED CHANGE REPORT

This manual has been prepared and distributed by the Technical Publications Department and is

intended for use by personnel responsible for the maintenance of MDHI Helicopters. Periodic revision

of this manual will be made to incorporate the latest information. If, in the opinion of the reader, any

information has been omitted or requires clarification, please direct your comments to this office via

this form (or a duplicate). An endeavor will be made to include such information in future revisions.

MD Helicopters, Inc.

Bldg 615 M/S G048

4555 East McDowell Road

Mesa, AZ 85215-9734

Telephone:

(800) 310-8539

Technical Publications Order Desk:

(480) 346-6372; FAX:

(480) 346-6821

Technical Publications Changes:

(480) 346-6212; FAX:

(480) 346-6809

Date:

Originator:

Address:

E- Mail:

Manual Title:

Page Number(s):

Chapter Title:

Paragraph Number(s):

ATA Section Number:

Step Number(s):

Issue Date:

Figure Number(s):

Revision No. and Date:

Table Number(s):

Remarks / Instructions:

Page CRi

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGE PAGES, DESTROY SUPERSEDED PAGES

The highest revision number indicates pages changed, added or removed by the current change.

Date of original and revision pages are:

Original .

15 September 1981

Revision 11 .

27 April 1994

Revision 1

15 June 1985

Revision 12 .

10 February 1995

Revision 2 .

14 March 1988

Revision 13 .

23 August 1996

Revision 3 .

15 January 1989

Revision 14

19 May 2000

Revision 4 .

1 November 1989

Revision 15 .

18 August 2000

Revision 5

15 June 1990

Revision 16 .

16 February 2001

Revision 6

1 July 1991

Revision 17

15 May 2001

Revision 7 .

15 October 1992

Revision 18 .

29 January 2003

Revision 8 .

13 September 1993

Revision 19 .

22 June 2005

Revision 9

2 March 1994

Revision 20 .

22 November 2005

Revision 10

5 April 1994

Revision 21 .

25 April 2007

Cover/Title

2−16

Revision 16

Cover/Title

Revision 20

2−17

Revision 18

2−18 thru 2−20 .

Revision 14

Change Request

2−21 thru 30B .

Revision 19

CRi and CRii

N/A

2−31 thru 2−52 .

Revision 14

Temporary Revision

2−53 thru 2−54B .

Revision 19

1 and 2

Revision 21

2−55

Revision 14

List of Effective Pages

2−56

Revision 20

A and B

Revision 21

2−57

Revision 14

2−58

Revision 20

Table of Contents

2−59

Revision 14

i and ii

Revision 19

2−60

Revision 20

Bulletins

2−61 thru 2−79/(2−80 blank) .

Revision 14

Section 3

Revision 19

3−i thru 3−iv

Revision 19

3 thru 5

Revision 14

3−1 thru 3−5

Revision 14

Revision 21

3−6 thru 3−8

Revision 19

7/(8 blank)

Revision 14

3−8A and 3−8B .

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Section 1

3−9 thru 3−39/(3−40 blank) .

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1−i/(1−ii blank) .

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Section 4

1−1

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Revision 14

1−2

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Section 5

5−i and 5−ii

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Section 2

5−1 thru 5−12 .

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2−1 thru 2−7

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Section 6

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6−i and 6−ii

Revision 18

2−12 thru 2−15 .

Revision 14

6−1 thru 6−21/(6−22 blank) .

Revision 15

Page A

LOEP

Revision 21

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

Section 7

9−56 thru 9−58 .

Revision 18

7−i thru 7−vii/(7−viii blank) .

Revision 17

Section 10

7−1 thru 7−14 . .

Revision 16

10−i and 10−ii .

Revision 18

7−15

Revision 19

10−1 thru 10−22

Revision 18

7−16 thru 7−32 .

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Section 11

7−33 thru 7−36A/(7−36B blank) .

Revision 17

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Revision 18

7−37 and 7−38 .

Revision 16

7−39

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11−1 thru 11−32 .

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Section 12

7−43 and 7−44 . .

Revision 19

12−i and 12−ii .

Revision 18

7−45 thru 7−74 . .

Revision 16

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Revision 18

7−75

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Section 13

7−76 thru 7−125

Revision 16

13−i and 13−ii .

Revision 18

7−126

. . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20

13−1 thru 13−12

Revision 18

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Revision 16

Section 14

Section 8

14−i and 14−ii .

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Revision 17

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8−8

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Section 15

8−9 thru 8−10 .

Revision 17

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Revision 18

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Revision 19

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Revision 18

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Section 16

8−16 and 8−17 .

Revision 19

16−i and 16−ii .

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8−27

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Section 17

17−i thru 17−vi . .

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Section 9

17−1 thru 17−78

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Revision 15

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Revision 20

Page B

Revision 20

LOEP

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

TABLE OF CONTENTS

CSP-H-2

Cover/Title Page

Technical Manual Recommended Change Report

Record of Temporary Revisions

List of Effective Pages

Service Bulletins

Introduction

Servicing and General Maintenance

Fuselage

Furnishings

Tailboom and Tail Surfaces

Landing Gear

Main Rotor and Control System

Tail Rotor and Control System

Transmissions and Drives System

Engine Installation and Cooling System

Engine Control Systems

Engine Fuel System

Engine Oil System

Engine Ignition System

Engine Exhaust System

Engine Air Induction System

Instrument Panel and Indicating Systems

Heating and Ventilating Systems

Electrical System

Wiring and Schematic Diagrams

Page i

Contents

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

SERVICE BULLETINS

INDEX

NOTE: As Service Information Notices are re−

3. Scope

issued, they will be identified as Service

The following is an explanation of how to read

Bulletins using the helicopter model desig−

Table 1.

nation as the prefix.

(1). Model Effectivity − The following is a

1. Service Bulletins (Notices)

list of the aircraft models effected by

the following Service Bulletins.

This Index provides a current list of Service

Bulletins (Notices), active and cancelled or

DESIGNATION

superceded.

MODEL

SERVICE DOCUMENT

FAA

Marketing

New SB

Old SIN

2. Active Service Bulletins (Notices)

369H

500C

SB369H-

HN-

Table 1 is a list of Service Bulletins (SB),

(2). Subject − A brief description of the

previously published as Service Information

Bulletin.

Notices (SIN) that have been issued and are

currently active against the 369H Model

(3). Date − Date of the last issuance of the

Helicopter.

Bulletin.

Table 1. ACTIVE SERVICE BULLETINS

369H

SUBJECT

DATE

1.1

Inspection of 369A5400 Tail Rotor Transmission Assembly

10-06-69

1.1*

Addendum x1

10-27-69

Inspection and Possible Retirement of 369A1100-501 Main Rotor Blades

11-19-68

M30223 Kit Installation - Main Rotor Locknut and Retaining Ring

12-8-69

Installation of Dual Bolt - Lower Vertical Stabilizer

4-21-70

M30209 Kit Installation - Engine Fuel Filter Pressure Switch

4-21-70

Modification for Door-Off Flight - 369A2405-3 & -4 Canopy Upper Windshield Assemblies

9-1 1-70

28.1

M50027 Modification Kit - Transmission and Coupling Fan Assembly

3-1-71

M50023 Modification Kit - Heat Control Valve Assembly

12-21-70

34.1

M50438 Modification Kit - Trim Potentiometer, Engine Oil Pressure Gage

6-16-71

M50436 Modification Kit - Engine-Out Warning Horn Support

5-18-71

Rework of 369H8062 Engine Oil Cooler Fan Assembly

8-12-71

New Pressure-Actuated Switch - 369H90118-501 or 369H90140 Automatic Engine Re-ignition Kit Installations

8-23-71

Provision for Drainage of Water Entrapment Areas

8-23-71

40.1

Inspection of Tail Rotor Transmission Output Bevel Gearshaft

12-13-71

Shock-Mounted Vertical-to-Horizontal Stabilizer Strut Assembly

12-17-71

Installation of New V_NE Placards

2-9-72

Modification of Mechanical Release System - 369H90065 Cargo Hook Kit Installation

4-10-72

Modification and Alignment Check - Rotor Brake Installation

5-1-72

Relocation of Engine Fuel Supply Hose

5-1-72

Inspection and Shimming of Cabin Heater Control Valve Assembly

5-31-72

Rework of 369H2048 Door Latching System (Autolatching)

7-24-72

53.1

369A5400 Tail Rotor Gearbox Revised Overhaul Schedule (TBO) and Component Infinite Life (Input Gearshaft

8-7-72

Assembly)

Page 1

BULLETINS

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

Table 1. ACTIVE SERVICE BULLETINS (Cont.)

369H

SUBJECT

DATE

Inspection of 369H6340 and 369H92131 Landing Gear Damper Assembly (Poppet Type)

10-23-72

Valve Housing Modification - Heat Control Valve Assembly, Cabin Heating System Kit Installation

3-1-73

369A5100 Series Main Transmission Assembly (Including Basic and All Dash-Numbered Configuration) - Installation

3-6-73

of New Ring Gear Bolts and Serial Number Identification

Engine Anti-Icing and Cabin Heating System Installations - Conversion from Electrical to Manual Operation

5-1-73

Installation of SCR Assembly - M50036 Auto-Reignition Modification Kit

5-29-73

Periodic Inspection of 369A5174 or 369A5145 Main Transmission Ring Gear Bolts

7-31-73

Installation of M50037 or M50038 Nickel-Cadmium Battery Temperature Sensing Modification Kit

8-6-73

Sealing 369H4534-21 and -22 Skid Mounted Position Lights

3-3-74

Replacement of 369A1613-3 Metal Tail Rotor Blade - Compatibility Criteria

3-4-74

Inspection of 369A2515-3 Frame and Battery

3-25-74

Corrosion Prevention/Inspection - 369A1100-501 Main Rotor Blade

4-15-74

Terminal Inspection/Modification - 369A4530 and 369H4540 Nickel-Cadmium Battery

4-15-74

Installation of Heater System Muffler Assembly

6-10-74

Installation of 369A8136-503 or -701 Fuel Shutoff Valve Control

8-5-74

Installation of M50039 Modification Kit Noise Filter

8-5-74

M50041 Emergency Release Mechanism Modification - 369H90065 Cargo Hook Kit Installation

8-5-74

Inspection of Main Rotor Blade Trailing Edge

8-19-74

74.2

Installation of 369N2697 Aluminum Type Main Rotor Blade Pendulum Weight Vibration Absorber Assembly

9-29-75

Rework or Replacement of 369H8101-3, -5 and 369A8102-3, -5 Fuel Cell Assemblies

8-19-74

Relocation of 369H4508 Magnetic Compass

9-30-74

79.1

Re-greasing Double Row Bearing - 369A7003-3 Main Rotor Swashplate Bearing Assembly

9-24-82

Bendix Service Bulletin No. 109, Dated 10-22-74, Inspection of Flexible Coupling Locknut

11-18-74

Modification of M50042 Fuel Cell Vent System Installation Modification Kit

1-2-75

82.1

Inspection/Repair of Aft Fuselage Skin Cracks

9-26-75

Inspection of 369A1613-Basic and -3 Root Fitting of Metal Tail Rotor Blades

4-15-75

Inspection of 369A8437 Hinges; Engine Air Filter Bypass Door

5-5-75

85.1

Relocation of 369H8144 Fuel Filter Pressure Switch

6-20-75

Tail Rotor Drive System Inspection - Installation of

369A5518-601 Tail Rotor Drive Shaft and Bungee Assembly

4-28-75

Associated with Metal Tail Rotor Blades and Indexing of all Helicopter Tail Rotor Drive Shafts

Inspection and Relocation of 369H8144 Fuel Filter Pressure Switch

6-23-75

Inspection of 369A1710-Basic, -9, -11, 369A6120, 369A1607 and 369CSK22 Fiberglass Tail Rotor Blades

8-28-75

M50047 Modification Kit - Tank Unit Fuel Quantity Rheostat 369A4225-501

11-7-75

Field Modification of M50440 Door Latch Kit

12-1 1-75

Modification for Seating and Belts - (4) Kit Installation, Additional of 369H90035-501 Head and Back Restraint Panels

1-23-76

Field Maintenance of 369A1400-603 to -605 Configuration Main Rotor Damper Assembly

3-1-76

Operational Check and Adjustment of Autolatching Mechanism - Pilot and Cargo Doors

3-1 1-76

Removal of Inboard Tab - 369A1100-501 Main Rotor Blade

4-1-76

Inspection and Repair of 369H8016-1 and -2 Adjustable Upper Engine Mount Assemblies

4-26-76

369H90148 Basic and -501 Configurations Engine Air Particle Separator Filter Assembly Kit Installation - Installation

5-10-76

of New 369H90157 Aft Screen Assembly

Relocation of 369H4515 Outside Air Temperature (OAT) Indicator M30301 Modification Kit

6-18-76

Potting of 369A4580 N₂ Governor Control - Pilot’s and Co-pilot’s Collective Pitch Stick Assemblies

6-18-76

Page 2

BULLETINS

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

Table 1. ACTIVE SERVICE BULLETINS (Cont.)

369H

SUBJECT

DATE

Inspection of 369A1807-Basic and -5 Tail Rotor Pitch Control Link Assemblies

6-18-76

101

Field Replacement of Lock Fitting - 369A9905 Ground Handling Wheel Assemblies AER-BEA AB 2387

8-10-76

102.3

Inspection of 369A2001-601 Shock-Mounted Stabilizer Strut Assembly and Possible Replacement of 369A2130

12-24-76

Damper Plunger

103.2

Rework of 369A7120 Longitudinal Friction Guide Link - Cyclic Pitch Control Installation

9-12-77

104

M50455 Modification Kit for Fan Assembly - Engine Oil and Compartment Cooling

11-5-76

108

Inspection of Attachment Hardware - Main Rotor Pitch Control Rods to Pitch Housing Assembly

12-24-76

109

100 Hour Inspection of 369A1234-Bsc, -7 Main Rotor Hub, 80-369H1234 Lead-Lag Links and 369H1203 Lead-Lag

12-24-76

Link Assembly

110

Inspection of 369A5506 Tail Rotor Drive Shaft Damper

12-24-76

111.1

Inspection of 369A3511-15 and 369A3511-17 Tailboom Bracket Assemblies - Tail Rotor Transmission Attachment

9-12-77

112

Field Fix for Main Rotor Swashplate Uniball

12-24-76

113

M50049 Modification Kit - Tachometer Generator Assembly

12-24-76

114

Replacement of 23111357 Tavco Solenoid Valve - 369H92036-1/-2 Emergency Float Kits

4-15-77

116

M50450 Wiring Modification Kit - 369H90118-505, -507, -509, -511 Automatic Engine Re-ignition Kit

8-8-77

117

Inspection and Modification of 369H8301 or 710108 Oil Cooler Duct - M50451 Kit Installation

7-22-77

118.2

369A5350-601 Overrunning Clutch Assembly - Inspection of 3695350-11 Clutch Assembly; 369A5361 Ball Bearing

10-27-78

and 369A5368 Seal

119

Door Latch Synchroization Check - Pilot’s and Cargo Doors Autolatching Mechanisms

9-12-77

120

Installation of Auxiliary Drain Valve - Fuel System Installation 369H92255 Drain Kit

10-3-77

121

Inspection of 369H90085 Litter Door Installation

11-30-77

122

Removal of AAE or LSI Model VR204 Capacitor - Voltage Regulator; Installation of 369A4558 or MS24166D1 Varistor

2-6-78

- Landing Light Relay

123

Installation of 369A1907-5 Tail Rotor Pitch Control Links

4-3-78

124

369A92537 Engine Compressor Water Wash Kit Installation - Inspection and Replacement of Rivets

4-14-78

125

Replacement of Plenum Wall Fittings - Torque Pressure Gage Tubing and Engine Oil Pressure Gage Tubing

6-6-78

127

Field Inspection and Corrosion Repair - 369A5500 Main Rotor Drive Shaft

7-5-78

128.1

Inspection and Rework of 369A1725-Basic and 369A1725-5 Tail Rotor Hub

12-8-78

129.1

Installation of 369H90022-501 Anti-Ice Fuel Filter

11-24-80

130

Periodic Inspection of Battery Over-Temperature Warning System

1-10-79

131.1

Replacement of 369A1602 Tail Rotor Drive Fork Hinge Bolt and 369A1603 Nut, New Assembly Procedure for Tail Rotor

9-2-80

Hub and Drive Fork Unit, Periodic Check of Flapping Bolt Preload

132

Field Repair of 369A7170 and 369A7171 Series Cyclic Trim Actuator Assemblies

1-29-79

135

Field Repair of 369A1100 Series Trim Tab - Main Rotor Blade

2-15-79

136

Field Rigging Check of 369A8013 and 369A8051 Series Heater Control Valve Assembly

2-16-79

137

Replacement of Radio Transmit/Intercom Trigger Switch; - Rework of Cycle Stick Grip Assembly

5-10-79

139

Inspection and Repair of 369A3035-11 and 369A3035-15 Tail Control Sta. 142.00 Bellcrank Support

6-1 1-79

140

Inspection of Main Rotor Blade Root Fitting Assemblies; Inspection of Main Rotor Hub Lead-Lag Assemblies

9-5-79

141.1

Installation of Voltage Transient Suppressors

11-26-79

143

Rework of Ground Handling Wheel Assemblies (Float Type)

8-20-79

144

369D290140 Kit Installation - Auxiliary Fairing and Seals Air Filter (Particle Separator)

7-23-79

145.2

100-Hour Periodic Inspection of Fuel Tank Sending Unit and Fuel Low Warning Light Indication System

5-4-81

146

Inspection of 369A7304 Magnesium, 369H2608 Aluminum Collective Torque Tube Support Bracket and 369A7339

8-1-79

Magnesium, 369N2650 Aluminum Collective Bungee Support Bracket

Page 3

BULLETINS

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

Table 1. ACTIVE SERVICE BULLETINS (Cont.)

369H

SUBJECT

DATE

150

369A1800 and 369H1800 Series Tail Rotor Pitch Control Assembly - Seating of Bearing Inner Race; Torque Increase

11-26-79

for 369A1817 Locknut

151

Installation of 369D22099-101 Fiberglass Cabin Heat Duct Assemblies

1-15-80

152

Removal of Filter Gasket - 369H90148 and 369H90148-501 Engine Air Inlet (Particle Separator) Filter Kit Installation

3-3-80

154

Rework of 369A7010 Series One-Way Lock Assembly

6-2-80

155

Polarity Check of Diode Assemblies

6-30-80

156

Identification and Possible Rework of Seat Belt and Shoulder Harness Assemblies

7-1 1-80

157

Conversion from Pressure Switch Activated to EPO Activated Auto-Reignition System

8-1-80

158

Wiring Modification - Untility Light Circuit and Transmission Oil Pressure and Temperature Warning Light Circuit

9-30-80

159

Installation of 369D28300-501 Drain Kit - Engine Oil Tank and Oil Cooler

8-18-80

160

Relocation of Auto-Reignition Controls and Modification of System for Full Time Operation

2-22-83

161

Rework of Static Pressure Tube Installation to Minimize Altimeter Needle Oscillation

12-8-80

162.1

Inspection of 369A7003-3 Swashplate Bearing

9-14-81

163

Sealing of Interface - Abrasion Strip and Main Rotor Blade Skin

1-30-81

164.1

Inspection of Overrunning Clutch Sprag Assembly

5-10-83

165

Field Inspection and Repair of 369A5401 Tail Rotor Transmission Main Housing Assembly

4-15-81

166

Installation of M30287-501 Engine Air Inlet Deflector Kit

4-21-81

167

Shimming Procedure - Gas Producer Interconnecting Torque Tube Assembly

5-4-81

168

Special Inspection of 369A7003-1 Swashplate Bearing Assembly

5-6-81

169

Replacement of 369A7706-3 RPM Governor Lever Control Rod

5-15-81

170

Corrosion Inspection/Treatment of 369A7314 and 369N2648 One-Way Lock Support Assembly

6-4-81

171

Inspection/Modification of BI-16600-12 Breeze Corporation Inc. Hoist

6-18-81

172

Inspection and Torque Requirements - Scroll Mounted Bleed Air Fittings

7-21-81

173

Deactivation of Main Rotor Brake System (if installed); Periodic Inspection of 369A5501 or 369H92564 Tail Rotor Drive

11-2-81

Shaft Forward Flexible Coupling. Installation of Fail Safe Device at 369A5501 or 369H92564 Tail Rotor Drive Shaft

Forward Flexible Coupling Check of Flexible Couplings.

174

369H90123 Series Main Rotor Brake System - Installation of 369D292585 Master Cylinder Stop

8-28-81

175

Inspection of 369A1200 Series Main Rotor Hub Assembly; Inspection of 369A1220 Main Rotor Blade Lead-Lag Pivot

1-4-82

Bolt (Vertical Hinge Pin)

176

Installation of 3569H4237-21 Resistor Board Assembly for Easier Accurate Adjustment of TOT Indicator

2-1-82

177

Instrument Cluster 3-Pack Conversion - AC-to-Rochester

2-15-82

178

Rework of 369A9905-Basic and -3 Ground Handling Wheel Assemblies to Accommodate Installation of New

6-29-82

369D26107 Landing Gear Skid Fittings

179

Replacement of Intercom (ICS) Switch and Jack Assembly

7-1-82

181

New Shimming Procedure - 369A5501 or 369H92564 Tail Rotor Drive Shaft Forward Flexible Coupling With Fail Safe

10-12-82

Device Installed

182

Replacement of Float Inflation System Solenoid Valves with Squib Valves, 369H90121 Series Emergency Float

1-10-83

Assemblies

183

Relocation of 369A8448 Engine Air Inlet Filter Bypass Door Aft Pulley and 369A8447 Bracket, and 369H90152-3

1-10-83

Particle Separator Filter Gasket Inspection

184

Center Passenger Seat, Lap Belt Check; Preflight Check of Passenger Lap Belt and Shoulder Strap Fit and Adjustment

2-15-83

185

Fuel System Service, Maintenance and Testing

3-15-83

186

Fuel Vent System Hose Inspection

5-2-83

187.1

Installation of Collective Stick Support Bracket Reinforcement Strap

11-23-83

Page 4

BULLETINS

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

Table 1. ACTIVE SERVICE BULLETINS (Cont.)

369H

SUBJECT

DATE

187.1

Installation of Collective Stick Support Bracket Reinforcement Strap

11−23−83

188

Installation and Replacement of 084956 Protective sleeve (Speedi−Sleeve) on Tail Rotor Transmission Output

5−21−83

Gearshaft

189.1

Inspection and Overhaul of 369A8104−5 Fuel Shutoff Valve

8−20−84

190

Battery Case Inspection

10−28−83

191

Main Rotor Swashplate Bearing Inspection and Possible Replacement

12−23−83

192

Instrument Cluster 4−Pack Conversion − AC−to−Rochester

2−15−84

193

369A8137−503 and −603 Fuel Shut−Off Valve Control Cable Pull Test

4−9−84

195

Riveting Tip Cap to Tail Rotor Blade

8−27−84

196

Inspection of Landing Gear Feet and Strut

10−1−84

197.2

One−Time Inspection of Tail Rotor Blade Leading Edge Abrasion Strip Bonding; Pilot’s Preflight Check of Tail Rotor

3−23−87

Blade Leading Edge Abrasion Strip

198.1

Corrosion Removal − Main Rotor Drive Shaft ID

10−30−87

199.1

Riveting Tail Rotor Tip Cap−to−Blade

5−1−85

200

Non−Airworthy Parts

3−18−85

201

Exit Warning Decal (Including AC 91−32 Safety In and Around Helicopters)

8−7−85

202

EON Seat Belt Removal

5−15−86

203

Installation of 369D28318 Oil Tank Filler Nozzle Strainer Assembly

4−15−86

205

Inspection/Rework of United Instrument Inc. Altimeter

5−20−86

206.1

Installation/Inspection of Tail Rotor Driveshaft Aft Fail Safe Device

11−28−86

208.1

Daily/Pre−Flight Examination of Main Rotor Blade Leading Edge Abrasion Strip Bonding

9−10−92

209

3659A8010 Engine Oil Pressure and Torque Tube Pull Test

9−15−87

210

Start Pump Wire Routing and Fuel Quantity Sender Inspection

9−15−87

211.6

Inspection of Main Rotor Blade Root Fitting Assemblies; Inspection of Main Rotor Hub Lead−Lag Link Assemblies

1−3−00

212.2

Inspection and Replacement of 369A1602 Tail Rotor Fork Bolt

4−21−89

213

Replacement of 369A8442−Basic Latch Assembly on the Particle Separator Door

12−18−87

214

Main Rotor Hub Strap Pack Lamination Inspection and Tri−Flow Wash Procedure

1−15−88

215.2

Inspection of 369A5352 Outer Race − 369A5350 Overrunning Clutch Assembly

4−11−97

216

One−Time Inspection of 369H5660 Transmission Driveshaft Couplings

4−5−89

217.1

One−Time Inspection and Rework of 369A7007, 369A7009, 369A7011 and 369A7012 Main and Tail Rotor Control

7−21−89

Tubes

218

One−Time Inspection of 369A8352, 369H8306, 369H8025, 369H8024−5 and 369D28651 Aeroquip Hoses

6−12−89

219

Finite Service Life Reduction of 369A1706−Bsc Tail Rotor Tension Torsion Strap Pack Assembly

6−20−89

220

One−Time Inspection of 369A5358 Lockwasher in the Overrunning Clutch Assembly and Inspection of Engine Output

10−27−89

Drive Splines

221

Installation of Oil Flow Restricting Devices into the Engine Oil and Torque Pressure Sensing System

10−27−89

222

Conversion to 369A5350−41 Overrunning Clutch Sub−Assemblies

5−4−90

223

One−Time Replacement of 369A9817 Polycarbonate Cover Assemblies

6−15−90

224

One−Time Replacement of Tail Rotor Blade Pitch Arm Bolt Attaching Nuts

6−15−90

225.1

One−Time Torque Check and Inspection of Main Rotor Blades

5−15−91

226.1

One−Time Installation of 369D24054−3 Warning Decals in the Engine Compartment

9−4−90

227

Inspection of Lead−Lag Link Attach Nuts

9−4−90

228

One−Time Inspection of 369H8407 Engine Bleed Air Tube Flexible Area

11−21−91

Page 5

BULLETINS

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

Table 1. ACTIVE SERVICE BULLETINS (Cont.)

369H

SUBJECT

DATE

229

One−Time Re−Installation of 369A1602 Tail Rotor Fork Bolt

11−21−91

230.1

Pre−flight Check and One−Time Inspection of Tail Rotor Blades

3−3−91

231

One−Time Rework of Main Transmission Oil Cooling Fan Mounting Bracket

2−1−91

232

One−Time Addition of Rivets to Tail Rotor Abrasion Strip

9−27−91

233

Inspection of Overrunning Clutch Outer Race − 369A5352 Overrunning Clutch Assy.

1−17−92

234.1

Inspection/Rework of Fuel Vent System (Helicopters Equipped With 369H8108, 369H8108−501 or 369H8108−503 Fuel

1−17−92

Vent Line Emergency Shutoff Valve)

235

One−Time Inspection/Rework of Engine Air Inlet Area

3−20−92

236

Four−Way Trim Switch Replacement Program

3−10−94

237

Firewall Fuel Fitting Modification

9−26−94

238

Tail Rotor Blade Abrasion Strip Modification

10−26−94

239

Main Rotor Blade Root End Inspection

10−27−95

240

Input Shaft Coupling Assembly Inspection

9−26−97

241.1

T/R Blade, Leading Edge Inspection for Cracks

5−3−99

243R3

M/R Blade Root End Inspection and Termination Action for Suspect M/R Blades

7−13−98

244

Landing Gear Strut Inspection and Fairing Modification

4−7−00

245.2

Main Rotor Blade Assembly Torque Event Inspection

2−2−04

246R1

Tail Rotor Blade Abrasion Strip Tap Test and Modification

1−23−06

Page 6

BULLETINS

Revision 21

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

4. Cancelled or Superceded Service

5. Scope

Information Notices

The following is an explanation of how to read

(1). Table 2 is a list of Service Information

Table 2.

Notices that have been cancelled or

superceded.

(1). HN− 369H Model Helicopters.

(2). Updated information, pertinent to the

Notice, has been incorporated into the

(2). Subject − A brief description of the

appropriate manuals.

Notice.

(3). If the Notice is superceded by another

Notice, it will be noted in the Subject

(3). Date − Date the Notice was cancelled

column after the description.

or superceded.

Table 2. CANCELLED OR SUPERCEDED SERVICE INFORMATION NOTICES

369H

SUBJECT

DATE

194

Oil Pressure and Torque Pressure Fire-Wall Fitting Check (Superceded by HN-209)

9-15-87

204

Main Rotor Hub Strap Pack Inspection (Superceded by HN-214)

1-15-88

207

Tail Rotor Elastomeric Bearing Shimming Procedure

7-1 1-86

242

M/R Blade Root End Inspection (Superceded by HN-243R3)

7-13-98

Page 7/(8 blank)

BULLETINS

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

Section 1 Introduction .

1−1

Proprietary Rights

1−1

This Handbook and Your Helicopter

1−1

Model Configuration

1−1

369H Helicopter Description

1−1

Figure 1−1. Helicopter − Major Components

1−2

Scope

1−3

Organization of Handbook Contents

1−3

Associated MDHI Manuals

1−3

A. Optional Equipment Manual

1−3

B. Inspection Requirements

1−3

C. Component Overhaul Manual

1−3

D. Structural Repair Manual

1−3

E. Illustrated Parts Catalog

1−3

Engine Data

1−3

MDHI Publications Changes and Revisions

1−4

A. Revision

1−4

B. Reissue

1−4

C. Reprint

1−4

D. Service Information Notices and Letters

1−4

10. Application of Warnings, Cautions and Notes

1−5

11. Service and Operations Report Form 1601

1−5

Page 1−i/(1−ii blank)

Revision 16

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

SECTION 1

INTRODUCTION

1. Proprietary Rights

constructed primarily of aluminum alloy. The

main rotor is the four−bladed, fully articulated

MD Helicopters, Inc. proprietary rights are

type. The tail rotor is two bladed, anti−torque,

included in the information disclosed herein.

and semi−ridged type. Power from the turbo−

Recipient, by accepting this document, agrees

shaft engine is coupled to the main and tail

that neither this document nor any part

rotors by driveshafts and two transmissions.

thereof shall be reproduced or transferred to

The driveshaft from the engine to the main

other documents or used or disclosed to others

transmission incorporates an overrunning

for manufacturing or any other purpose,

(one−way) clutch that permits free wheeling of

except as specifically authorized in writing by

the main rotor for autorotational descent.

MD Helicopters, Inc. All rights are reserved

under the copyright laws by MD Helicopters,

The fuselage (incorporating a central frame

Inc.

work consisting of a mast support structure,

two bulkheads and a center beam) is a

2. This Handbook and Your Helicopter

semimonocoque structure that is divided into

three main sections.

Hughes 500 (Model 369H) Series Helicopter,

Manufactured by Hughes Helicopter Inc..

Culver City, California, now MD Helicopter,

The forward section includes a pilot’s compart−

Inc., Mesa, Arizona, are produced in three

ment and a cargo/passenger compartment. The

model configurations.

pilot’s compartment is normally equipped with

seating for the pilot and one or two passengers.

3. Model Configuration

The seat on the left side of the pilot’s compart−

ment (when looking forward) is the pilot’s seat

Model 369HM (500M International Military)

(command position) except in Model 369HM

Model 369HS (500S Standard) and

helicopters where the pilot’s seat is on the

Model 369HE (500E Executive).

right side. The cargo compartment in back of

the pilot compartment contains provisions for

Except for interior trim upholstery and floor

installation of two additional passenger seats.

coverings, equipment furnishings, paint finish

The cargo compartment seats may be easily

and other details described in Section 4, the

folded out of the way or completely removed

500S and 500E are essentially identical

for the accommodation of cargo.

helicopters.

The main differences are the type and ar−

The aft section includes the structure for the

rangement of interior furnishings and

tailboom attachment and houses the engine.

equipment, the pilot’s flight control position,

and the variety of special or optional (kit)

The lower section is divided by the center

equipment installed in the individual helicop−

beam and provides a housing for the two fuel

ter. Normally, the 500S has the standard trim

cells.

package and the 500E has the executive trim

package.

The tailboom is a monocoque structure of

The basic design features and performance

aluminum alloy frames and an aluminum alloy

characteristics of each model configuration are

skin. The tailboom serves as the supporting

essentially the same.

structure to which the horizontal stabilizer,

the upper and lower vertical stabilizers, and

369H Helicopter Description

the tail rotor transmission and tail rotor are

attached. In addition, the tailboom houses the

(Ref. Figure 1−1) The MDHI 369H helicopter is

tail rotor transmission, driveshaft and the tail

a turbine−powered, rotor wing aircraft,

rotor blade angle control rod.

Page 1-1

Revision 15

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

The main rotor group consists of four rotor

Removal

blades, a fully articulated main rotor hub

Inspection (Other than Daily or Periodic)

assembly that incorporates offset flapping

Disassembly

hinges, a scissors assembly and a swashplate,

Reassembly

and associated mixer control mechanisms. The

Installation

main rotor blades are secured to the rotor hub

Adjustment (Other than System Rigging or

assembly with standard hardware and/or by

Tracking)

quick−release lever type pins that permit easy

Repair

and fast removal of the blades.

7. Associated MDHI Manuals

The landing gear is the horizontal, skid type,

Information beyond the scope of the Mainte−

attached to the fuselage at 12 points; it is

nance Manual may be found in these basic

non−retractable. The struts, from the fuselage

associated manuals which are prepared as

to the skids, are covered with aerodynamic

separate publications but should always be

fairings. Nitrogen−charged landing gear

kept and used with this manual:

dampers, between the struts and structure, act

A. Optional Equipment Manual

as shock absorbers to cushion landings.

CSP−H−3, Appendix A, contains descriptive

5. Scope

and maintenance information on the various

accessory and system equipment options

MDHI maintenance manuals provide system

available for each of the three helicopter model

descriptions, servicing and maintenance

configurations.

procedures, periodic and special inspections,

B. Inspection Requirements

overhaul schedules, limited life component

replacement schedules, and weight and

CSP−H−4, Appendix B, contains the daily and

balance calculations.

recurrent inspections that must be performed

on a repetitive cycle basis to verify that the

This manual is one of a group of publications

helicopter is airworthy. CSP−H−4 B also

that form the information file for the helicop−

includes special inspections, overhaul and

ter. The maintenance and inspection proce−

retirement schedule for components that have

dures are to be used for the 369H helicopters

a limited hourly life between overhaul periods

only. Study the contents to gain an under−

or for retirement, and weight and balance

standing of the arrangement and use of this

procedures.

and associated manuals before working on the

C. Component Overhaul Manual

aircraft.

CSP−H−5, Appendix C, contains overhaul

6. Organization of Handbook Contents

instructions for major components such as

main transmission, tail rotor transmission,

The contents of this handbook are grouped into

overrunning clutch, etc.

Sections as outlined by the Table of Contents.

D. Structural Repair Manual

Each Section of this manual has its own Table

of Contents and List of Figures. The content of

CSP−H−6, Appendix D, contains helicopter

each Section is organized to provide compre−

structural maintenance and repair informa−

hensive coverage on an entire system, on a

tion.

major assembly or on a group of equipment

E. Illustrated Parts Catalog

items that are similar or associated. Mainte−

nance procedures for each component, assem−

The 369 Series Illustrated Parts Catalog

bly or system are presented in sequence.

(CSP−H−7) provides, by means of text and

Instructions for all or part of the following

companion illustrations, complete definition of

maintenance functions are included as

all repair parts and spare items available for

applicable.

all configurations of the helicopter. Use

Troubleshooting

CSP−H−7 for parts procurement only.

Operational Check

8. Engine Data

Rigging Check

Tracking

The Model 250 Series gas turbine engines are

Balancing

manufactured by the Allison Engine Company

Page 1-3

Revision 15

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

Inc.. Refer to the applicable Allison Engine

(a).

Red Border Notices: The red border

Repair and Maintenance Manual and the

notices deal with critical items that

Illustrated Parts Catalog supplied with the

must be corrected. These notices are

engine for specific engine maintenance

mandatory and require a record of

information. Fault isolation and maintenance

accomplishment. They may be

procedures for the helicopter/engine interface

re−occurring (flight−time or calendar)

systems are in divisions specified by the index.

or one−time only notices.

9. MDHI Publications Changes and

(b).

Blue Border Notices: The blue border

Revisions

notices are not mandatory and can be

accomplished at the owner/operator’s

Changes in the helicopter, equipment, mainte−

discretion. When instructed, these

nance practices, procedures and additional

notices may require a record of

information developed by experience affect

accomplishment. These notices deal

manual content. To ensure that MDHI

manuals continue to reflect current changes,

with non−critical or optional items

revised information is provided by one or more

only.

of the following communications:

(c).

Service Bulletins: The Service

A. Revision

Bulletin deal with critical items that

must be corrected. These bulletins

Alteration of portions of the handbook by the

are mandatory and require a record

replacement, addition and/or deletion of pages

of accomplishment. They may be

is accomplished by revision. The List of

re−occurring (flight−time or calendar)

Effective Pages (LOEP) that accompanies each

or one−time only notices. The service

revision identifies all affected pages; such

bulletin replaces the red border

pages should be removed from the handbook

notice.

and destroyed. Added or replacing pages

should then be inserted and checked against

the LOEP.

(d).

Technical Bulletin: The Technical

Bulletins are not mandatory and can

B. Reissue

be accomplished at the owner/opera−

tor’s discretion. When instructed,

When large numbers of changes are involved,

these bulletins may require a record

the handbook is reissued. The preceding issue

of accomplishment. These bulletins

of the handbook then becomes obsolete and

deal with non−critical or optional

should be discarded.

items only. the technical bulletin

C. Reprint

replaces the blue border notice.

When large numbers of changes are involved,

(e).

For a complete listing and explana−

the manual is reprinted to include all prior

tion of current and cancelled notices,

revisions.

refer to Service Information Notices

D. Service Information Notices and Letters

Index.

Service information is to be considered as part

(2). Service Information Letters are strictly

of the handbook.

information only. They may inform the

(1). Service Information Notices and

owner/operator of options available,

Bulletins are broken into two categories

up−coming notices, warranty/repair

as follows:

changes, etc.

Page 1-4

Revision 15

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

10. Application of Warnings, Cautions and

11. Service and Operations Report Form 1601

Notes

MDHI Service and Operations Report Form

Throughout this manual, and associated

1601 may be used to report to MD Helicopters,

manuals, Warnings, Cautions and Notes are

Inc. in detail any service difficulties encoun−

used to emphasize instructions or information

tered with any MDHI helicopter. Use of the

considered to be unusual or critical.

form is encouraged and recommended to

WARNING and CAUTION statements are

enable MDHI to provide owners and operators

always placed before the information or

improved service, support and product

instructions to which they apply.

improvements. The form also serves as a

convenient detailed record for owners and

A NOTE may appear in the text either before

operators. Copies of the form may be procured

or after instructions to which it applies,

by contacting the Product Support Dept.

depending on the relative significance of the

information.

The conditions that warrant use of Warnings,

Cautions and Notes are defined as follows:

Operating procedures and

WARNING

practices which, if not strict−

ly observed, may result in personal in−

jury, or loss of life.

Operating procedures and prac−

CAUTION

tices which, if not strictly ob−

served, may result in damage to or destruc−

tion of equipment.

NOTE: An operating procedure or condition

that is essential to highlight.

Page 1-5/(1-6 blank)

Revision 16

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

Section 2 Servicing and General Maintenance .

2−1

Maintenance and Operational Check Requirements and Precautions

2−1

Figure 2−1. Principal Dimensions

2−2

Helicopter Fundamentals

2−3

A. Principal Dimensions

2−3

B. Airframe Stations Locations

2−3

C. Component Weights for Hoisting

2−3

Table 2−1. Approximate Maximum Hoisting Weights of Components .

2−3

Helicopter Ground Handling

2−3

A. Use of External Power

2−3

B. Hoisting

2−3

Figure 2−2. Hoisting, Jacking and Leveling

2−4

C. Jacking

2−5

D. Leveling

2−5

E. Parking

2−5

F. Mooring

2−5

G. Ground Handling Wheels

2−6

H. Helicopter Moving and Towing

2−6

Figure 2−3. Ground Handling Wheels

2−7

Table 2−2. Ground Support Equipment and Special Tools .

2−8

Figure 2−4. Parking and Mooring

2−12

Servicing

2−13

A. Fuel System Filling

2−13

B. Fuel System Draining

2−13

C. Engine Oil System Filling

2−13

Figure 2−5. Servicing Points

2−14

D. Engine Oil System Draining (with Sta. 137.50 Bulkhead Drain

Ports Installed)

2−14

E. Engine Oil System Draining (with Drain Valve Installed) .

2−14

F. Engine Oil System Flushing

2−15

G. Main Rotor and Tail Rotor Transmission Filling

2−15

H. Main Rotor Transmission Draining

2−15

Main Rotor Transmission Oil System Flushing

2−16

J. Tail Rotor Transmission Draining

2−16

K. Tail Rotor Transmission Oil System Flushing

2−16

L. One−Way Lock Control system Servicing

2−16

Table 2−3. Component Servicing and Materials

2−17

Page 2−i

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

Battery Handling and Servicing Precautions

2−18

Battery Servicing

2−18

Battery Charging

2−19

A. Normal Battery Charging

2−19

B. Battery Deep Cycling

2−20

Table 2−4. Maintenance Materials

2−21

Access and Inspection Provisions

2−31

A. Main Gearbox Access Cover

2−31

B. Main Transmission Drain Assembly (used with Shaft−Driven Blower) .

2−31

Figure 2−6. Access and Inspection Provisions (Sheet 1 of 6) .

2−32

C. Main Transmission Cover

2−38

D. Main Transmission Cover Assembly Seals Replacement .

2−39

E. Cargo Compartment Aft Bulkhead Access Covers

2−39

Figure 2−7. Main Rotor Transmission Cover Seals Installation .

2−39

F. Pilot Compartment Floor Access Doors

2−40

G. Fuel Cell Access Doors

2−40

H. Controls Tunnel Cover

2−41

Engine Air Inlet Forward Fairings

2−41

J. Engine Air Inlet Fairing Access Doors

2−42

K. Aft Section Air Inlet (Tail Rotor Drive) Access Door

2−42

L. Controls Access Door and Foot Support Fairings

2−42

M. Pilot’s Seat Cover

2−43

N. Outboard (LH) Collective Stick Cover and Wiring Cover .

2−43

O. Fuel Vent Cover

2−43

P. Fuel Filler Shield

2−43

Q. Boom Bolts Access Doors and Tail Rotor Control Bellcrank Access Door

2−43

R. Exterior Lights Covers

2−44

S. Cargo Swing/Hook Fairing Cover

2−44

T. Instrument Panel Fairings

2−44

U. Instrument Panel Lower Section Side Cover Panels

2−44

V. Instrument Panel Lower Section Front Cover Panel

2−44

W. Pilot and Cargo Doors

2−45

X. Engine Access Doors

2−45

Helicopter Cleaning

2−45

A. Fuselage Interior Trim and Upholstery Cleaning

2−45

B. Airframe Exterior and Rotor Blade Cleaning

2−46

C. Transparent Plastic Cleaning

2−46

Page 2−ii

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

D. Battery Cleaning

2−46

E. Battery Electrolyte Spillage Cleaning

2−47

F. Transmission Lubrication Pump Oil Filter Cleaning

2−47

Figure 2−8. Transmission Lubrication Pump Oil Filter

2−47

G. Engine Fuel and Oil Filter Cleaning

2−48

H. Engine Compression Cleaning

2−48

Engine Air Inlet Screen Cleaning

2−48

10. Corrosion Control

2−48

A. Standard Practices for Corrosion Prevention

2−48

B. Magnesium Alloy Corrosion

2−49

C. Aluminum Alloy Corrosion

2−49

D. Alloy Steel Corrosion

2−50

E. Temporary Anti−Corrosion Measures

2−50

F. Corrosion Arresting on Main Rotor Blades

2−50

G. Main Rotor Hub Corrosion Prevention (Tri−Flow Wash Procedure) .

2−50

H. Magnesium Alloy Exterior Surface Touch−Up Treatment .

2−51

Aluminum Alloy Exterior Surface Touch−Up Treatment .

2−51

J. Steel Alloy Exterior Surface Touch−Up Treatment

2−51

11. Paint Finish

2−52

A. Paint Removal

2−52

B. Paint Touch−Up

2−52

12. Main Rotor Blade Paint

2−53

A. Main Rotor Blade Paint Removal

2−53

B. Main Rotor Blade Paint Application

2−54

13. Metal Tail Rotor Blade Paint

2−54

A. Metal Tail Rotor Blade Paint Removal

2−54

B. Metal Tail Rotor Blade Paint Application

2−54A

14. Fluid Leak Analysis

2−54A

A. Main Rotor or Tail Rotor Transmission Oil Leaks

2−54A

B. Engine Oil Leaks

2−54B

C. Landing Gear Damper Hydraulic Fluid Leaks

2−54B

Figure 2−9. Checking Overrunning Clutch Oil Level

2−54B

D. Overrunning Clutch Oil Leak Analysis and Servicing

2−55

E. One−Way Lock (Uniloc) Fluid Leak

2−55

15. Preservation and Storage

2−56

A. Flyable Storage (No Time Limit)

2−56

Page 2−iii

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

B. Storage up to 45 Days

2−56

C. Storage up to 6 Months

2−57

16. Torque Data

2−58

A. Torque Wrenches

2−58

17.

Torque Wrench Load Application

2−58

18.

Installation, Staking or Swaging Force Needed for Bearings .

2−60

19.

Useful Conversion Data

2−60

20.

Related Publications

2−60

21.

Maintenance Information Requests

2−60

22.

Inspection Practices and Technical Definitions

2−60

23.

Service and Operations Report Form 853

2−60

Table 2−5. Recommended Standard Torques for Tension−Type Nut:

Min. and Max. Torque Values; AN310, AN365, MS20365, MS21042,

NAS1021, NAS1291, NAS679

2−61

Table 2−6. Recommended Standard Torques for Shear−Type Nut:

Min. and Max. Torque Values; AN320, AN364, MS20364, NAS1022,

MS21083

2−62

Table 2−7. Self−Locking Nut Minimum Run−On Torque Values .

2−63

Table 2−8. Minimum Breakaway Torque For Used Self−locking Bolts or Screws .

2−63

Table 2−9. Special Torques

2−64

Table 2−10. Temperature Convervision

2−67

Table 2−11. Conversion of Inches to Millimeter

2−68

Table 2−12. Conversion of Millimeter to Inches

2−68

Table 2−13. Conversion of Fractional Inches to Decimals and Millimeter .

2−69

Table 2−14. Conversion of U.S. Measure used in Servicing and Maintenance .

2−69

Table 2−15. Related Publications and Directives

2−70

Figure 2−10. Technical Definitions

2−73

Table 2−16. Technical Definitions

2−74

Page 2−iv

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

SECTION 2

SERVICING AND GENERAL MAINTENANCE

1. Maintenance and Operational Check

and loose cable ends are properly in−

Requirements and Precautions

sulated and stowed to prevent the

possibility of shorting. Serious inju−

All maintenance on the helicopter is to be

ry or death could result from volt−

accomplished in compliance with the following

ages present in electrical wiring of

requirements and precautions.

the electrical system or associated

equipment.

(1).

All maintenance and operational checks

that require operation of the helicopter

D Install bungee installation tool (26,

must be preformed in accordance with

Table 2−2) before disconnecting any

requirements and limitations specified

pilot’s collective stick hardware (Ref.

in the MDHI 369 Owners Manual and

Sec. 7). There is strong bungee spring

pressure present in the stick linkage;

the applicable optional equipment

if suddenly released, spring reaction

supplement to the Owners Manual for

in the linkage can cause personnel

the specified model helicopter.

injury, or parts damage.

(2).

After performance of maintenance or

modification (disassembly, cleaning

CAUTION

parts, parts replacement, repair,

D Whenever work is performed near the en−

reassembly, installation, etc.) the

gine air inlet, use care to prevent entry of

affected parts, assemblies installa−

foreign objects. Tape covers of cardboard

tion(s) or system(s) are to be inspected

for discrepancies and an operational

or other suitable material in place over

check is to be preformed. Should

the engine inlet or screen in the plenum

maintenance questions arise, refer to

chamber and also the oil cooler air inlets.

Table 2−15.

Do not remove covers until work is com−

pleted and any debris is thoroughly

(3).

Cautions and Warning statements

cleaned out of the area. After removing

throughout this HMI are provided to

covers, verify that area around base of

promote safe maintenance of the

mast, inlet plenum, and entire plenum

helicopter as defined in Section 1. To

chamber is free from foreign material.

avoid repetitious appearance in text,

D Use care when drilling and removing riv−

certain precautions that should always

eted rod ends from control rods. Tighten

be observed will not always be stated at

jam nut before drilling or riveting; the rod

each possible point of application.

end is steel and the rod is aluminum.

Cautions and warnings of this nature

are listed below to emphasize that

D When working on the belt−drive blower,

appropriate compliance is required at

the impeller must be hand− held for re−

moval and installation of the pulley at−

all times even though the precautionary

tachment nut. Do not hold impeller

statement are not repeated. Always

blades with tool or other devices. Tool

comply with the following precautions.

damage can affect precision balance of

impeller as well as cause physical dam−

WARNING

age. Do not use any type of holding device

that will place strain on the blower scroll.

D Before disconnecting, removing,

Impeller is balanced to within 0.03 inch

installing or connecting components

ounce (0.0002 Nm). Slight impeller de−

of the electrical system or associated

formation or damage can cause impeller

equipment with electrical wiring,

imbalance.

check that all electrical power is

OFF. If units are not immediately re−

D Do not use vibration dampers for turning

placed, ensure all electrical connec−

main rotor or handholds. Such use can

tors are suitably capped and stowed

damage vibration damper bracket.

Page 2-1

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

2. Helicopter Fundamentals

receptacle. Any source of external 28 volt,

direct−current power may be connected

A. Principal Dimensions

provided the negative terminal of the plug

mates with the negative terminal of the

Principal dimension are shown in Figure 2−1.

receptacle and the amperage available is

B. Airframe Stations Locations

sufficient. Engine starting requirements are

approximately 375 amperes minimum.

Reference is occasionally made to ‘‘station" and

‘‘waterline" throughout the handbook. To assist

Before connecting external pow−

CAUTION

in locating the components being discussed,

er, make certain that the heli−

refer to the station diagram provided in

copter main electrical power selector switch

CSP−H−6. Station and waterline references

is in the OFF position. After power is con−

are also necessary for weight and balance

nected to the receptacle, the power switch

procedures.

must be at the EXT position to connect ex−

ternal power to the helicopter electrical sys−

C. Component Weights for Hoisting

tem.

The maximum weight for large components

NOTE: The positive (+) and negative (−) voltage

that may require hoisting are listed in

terminals are clearly marked on the base of

Table 2−1.

the receptacle to prevent reversing of polar−

ity if a standard auxiliary power plug is not

Table 2-1. Approximate Maximum Hoisting

available.

Weights of Components

B. Hoisting

Wgt

Item

Lb/kg

(Ref. Figure 2−2) Observe the following

precautions during any hoisting operation.

Tailboom

14/6

Main Rotor Hub

58/26

Use a hoist of no less than 3500

CAUTION

pound (1598 kg) capacity when

Main Transmission

79/36

hoisting the complete helicopter. Use hoist−

Engine (built up)

170/77

ing equipment of sufficient capacity (mini−

mum twenty−percent over−rate) to hoist the

Helicopter (less engine)

1000/455

heavier components if handled separately.

Helicopter (less main rotor hub,

(Ref. Table 2−1 for approximate weights.)

swashplate, scissors, and rotor blades)

998/453

(1). Install hoisting adapter (1, Table 2−2)

Helicopter (complete)

1170/531

on main rotor hub so that the four

hoisting eyebolts fit into the slots on the

3. Helicopter Ground Handling

hoisting adapter.

Ground handling of the helicopter includes

(2). Install the four clevis pins.

hoisting, jacking, leveling, parking and

mooring. The following paragraphs present the

(3). Attach cable from overhead hoist to the

instructions and precautions for all ground

adapter eye.

handling functions.

(4). Secure a line to the tailboom. Have an

A. Use of External Power

assistant hold the line to keep the

helicopter from swinging.

An external receptacle is located at the right

side of the pilot’s compartment seat structure.

(5). Hoist slowly and smoothly to maintain

The right door must be opened to use the

a steady lifting force.

Page 2-3

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

C. Jacking

(7). After leveling helicopter, remove plumb

bob, reinstall trim and carpet and close

(Ref. Figure 2−2) Provisions for jacking the

compartment door.

helicopter are provided by two forward (side)

E. Parking

jacking point fittings and an aft jacking pad.

(Ref. Figure 2−4) To park the helicopter for

NOTE: When the helicopter is jacked from one

short intervals, perform steps (1). thru (4). For

side only, a cushioned saddle−type support

longer duration parking, also perform steps

should be placed under the tailboom at the

(5). and (6).

boom jacking fitting location for extra stabil−

ity.

To prevent rotor damage from

CAUTION

blade flapping

(droop stop

(1). Install jacking fittings (2, Table 2−2) in

pounding) as a result of air turbulence from

the fuselage jacking points. Secure the

other aircraft landing or taking off, or sud−

jacking fittings with the locking pins

den wind gusts, rotor blades should be se−

that are secured to the fuel cell access

cured whenever the aircraft is parked.

doors.

(1). Locate the helicopter slightly more than

(2). Place suitable jacks under jacking

blade clearance from near−by objects.

fittings, and under aft jacking pad.

(2). Apply friction to lock the cyclic stick so

(3). Raise the helicopter to the desired

that the friction control knobs are

height.

positioned on the lateral and longitudi−

nal travel stop guides as follows:

D. Leveling

neutral laterally (center of slot), and

one−third from full aft longitudinally

(Ref. Figure 2−2) Leveling is accomplished by

(one−third up from bottom of slot).

causing a plumb bob to intersect register

marks inscribed on the target plate located on

NOTE: If not all ready accomplished, apply a

the cargo compartment floor

paint mark on the edge of the guide to locate

the neutral position for future reference.

NOTE: Access to plumb line support bracket

(3). Locate the helicopter on the most level

and target plate on floor of passenger/cargo

ground available.

compartment requires removal of trim on

right side of controls tunnel and floor carpet

(4). Secure the main rotor blades as follows.

in aft compartment.

(a). Turn blades until they are at 45

(1). Suspend plumb line from bracket on

degrees angle to the fuselage center−

right side of controls tunnel at Sta.

line.

92.64, BL +6.20.

(b). Install blade socks (3, Table 2−2) on

all blades.

(2). Adjust plumb line swing to leveling

target plate on floor of passenger/cargo

When securing tiedown cords,

compartment.

CAUTION

take up slack but do not exert

bending loads on blades.

(3). With weight of helicopter supported by

load cells or jacks, adjust appropriate

(c). Secure blade sock tiedown cords to

jack until plumb line is centered.

fuselage jacking fittings.

(4). Adjust side jacks to level helicopter

(5). Install engine air inlet cover assembly

laterally.

(46 on engine air inlet front fairing.

(6). Install engine exhaust outlet cover (47)

(5). Adjust tailboom jack to level helicopter

on exhaust tailpipes.

longitudinally.

F. Mooring

(6). Recheck lateral and longitudinal levels

until the plumb bob exactly aligns with

(Ref. Figure 2−4) Whenever severe storm

marks on target plate.

conditions or wind velocities higher than 40

Page 2-5

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

knots are forecast, the helicopter should be

(2). With ground handling wheels in the

hangared or evacuated to a safer area. If these

retracted position, align and engage the

precautions are not possible moor the helicop−

skid fittings.

ter in the following manner.

(3). Install jack handle in the wheel

(1). Park helicopter and remove main rotor

assembly socket, install lock pin, and

blades and install engine inlet and

rotate handle downward to lower the

exhaust covers.

wheels and raise the helicopter.

Hold downward pressure on

(2). Install pitot tube cover (4, Table 2−2).

WARNING

jack handle until the extend

lock snaps into lock position. If the lock

(3). Fill fuel tank (if possible).

is not properly engaged and the handle

is released, the upward swing of the

(4). Apply friction to lock the cyclic and

handle could cause serious personal in−

collective sticks.

jury.

(5). Secure the helicopter to the ground by

(4). Check that the extend lock is engaged;

attaching restraining lines (cable or

then release downward pressure and

rope) between the jacking fittings and

remove jack handle.

stakes or ground anchors.

(5). Install second ground handling wheel

G. Ground Handling Wheels

assembly in the same manner.

(Ref. Figure 2−3) Standard ground handling

(6). At regular intervals, the ground

wheels, available as a special tool (6,

handling wheels tire pressure should be

Table 2−2), are used for moving the helicopter.

checked for 80−90 psi (552−621 kPa)

The handling wheels consist of two, two−

and the wheel bearings lubricated with

wheeled jacking assemblies that can be

grease (18, Table 2−4).

straddle−mounted to the left and right landing

gear skids by use of the existing ground

H. Helicopter Moving and Towing

handling wheel fittings. The wheels are

manually lowered with detachable jack handle.

(1). Manually move the helicopter on

Either the straight handle (7) or the offset

ground handling wheels by balancing

handle (8) may be used depending on clearance

the tail boom and pushing on the rear

requirements. The wheels are held in down

fuselage portion of the airframe.

position (helicopter raised on wheels) by a

mechanical lock. The wheels are equipped with

The helicopter should always be

CAUTION

tow bar attach fittings. Attach the ground

towed at slowed speeds, not over

handling wheels as follows:

5 mph, except in extreme emergency condi−

tions. Do not allow the front end of the skid

NOTE: Special optional ground handling

tubes to drag on the ground. Avoid sudden

wheels (5) are used for moving the helicop−

stop and starts, and short turns which could

ter when equipped with option emergency

cause the helicopter to turn over. Allow the

floats (Ref. CSP−H−3). If helicopter with ex−

inside wheels to turn (not pivot) while the

tended gear is tilted back on the tail skid to

helicopter is being turned. The proper mini−

install ground handling wheels, approxi−

mum turning radius is approximately 20 ft.

mately one pint of oil is trapped in the tail

(6 M).

rotor gearbox. This condition will give a

false sight gage oil level indication after re−

(2). Towing the helicopter on ground

turn to a level attitude. The oil will return to

handling wheels by attaching a suitable

normal after ground runup.

tow bar to the two bar fittings. If the

tow bar is not equipped to keep the

(1). Position ground handling wheel

front ends of the skid tubes from

assembly over the skid tube at the

dragging, have an assistant balance the

location of the skid fitting.

helicopter at the tail boom.

Page 2-6

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-2. Ground Support Equipment and Special Tools

NOTE: Most of the equipment and tool items in this table are used to support and maintain all configurations of the

369H helicopter, except when an asterisk symbol ( * ) is part of the item number to indicate limited use. Limited

applications noted in the Application or Use column. Special tools used only for major disassembly-repair

and/or overhaul of components are listed in applicable section of CSP-H-3. See end of table for explanation

of deltas and daggers.

Item

Part No.

Nomenclature

Application or Use

No.

369A9904-501

Hoisting adapter

Hoisting entire helicopter or removing main

rotor.

369A2010

Jacking fittings

Jacking, leveling or tie down of helicopter.

369D2661

Blade socks

Main rotor blade tie downs.

369H4009

Pitot tube cover

Pitot tube protection.

369H90126

Ground handling wheels

Ground handling of helicopter equipped with

(one side)

utility or emergency floats. (Ref. CSP-H-3)

369A9905

Ground handling wheel

Ground handling of helicopter.

(one side less handle)

369H9801

Handle-Jack assembly ground

Raising and lowering helicopter with ground

handling (straight)

handling wheels.

369A9906

Handle-Jack assembly, ground

Raising and lowering helicopter with ground

handling (offset)

handing wheels when addition clearance is

required.

369H9925

Collective rigging fixture

Rigging of main rotor collective controls

(369HE and 369HS only).

369A9927

Collective rigging fixture

Rigging of main rotor collective controls

(369HM only).

369A9930

Mixer rigging plate

Rigging of main rotor collective and cyclic

controls.

369A9929-9

Longitudinal rigging fixture

Rigging of main rotor cyclic controls (369HE

and 369HS only).

369A9929-5

Longitudinal rigging fixture

Rigging of main rotor cyclic controls (369HM

only).

369A9928-9

Lateral rigging fixture

Rigging of main rotor cyclic controls (369HE

and 369HS only).

369A9928-5

Lateral rigging fixture

Rigging of main rotor cyclic controls (369HM

only).

369A9926-7 or

Main rotor blade tracking high intensity

Tracking of main rotor blades.

369A9926-5 (1)

strobe light installation and assembly

369A9958

Main rotor blade tab bending tool

Adjusting main rotor blade tab angle for

blade track.

369H9928

Main rotor blade tab bending tool

Adjusting main rotor blade tab angle for

blade track.

369A9934-601

Main rotor mast nut wrench

Loosening/Torquing of main rotor mast nut.

(replaced by 21)

369A9934

Main rotor mast nut wrench

Loosening/Torquing of main rotor mast nut

(non-slotted mast only).

Page 2-8

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-2. Ground Support Equipment and Special Tools (Cont.)

Item

Part No.

Nomenclature

Application or Use

No.

369A9829

Main rotor wrench assembly

Loosening/Torquing of main rotor mast nut.

369A9932

Hub puller

Breaking loose main rotor hub from mast.

369A9932 (2)

369A9949

Torque wrench adapter

Checking main rotor damper first stage

friction.

369A9933

Main rotor hub driver

Seating main rotor hub.

369A9933-5 (3)

369A9983

Torque wrench adapter

Torque tailboom attachment bolts.

369A9936

Bungee installation tool

Holding collective bungee spring in

compression for bungee removal and

installation.

369A9985

Bungee spring compression tool rod

Removing bungee installation tool and

and channel

disassembling bungee spring assembly.

369A9931 or

Tail rotor swashplate rigging tool

Rigging of tail rotor controls (fiberglass

369A9931-3

blades).

369A9931-5

Tail rotor swashplate rigging tool

Rigging of tail rotor controls (metal blades).

369A9937

Torque wrench adapter

Installing tail rotor nut.

369A9999 (4)

Tail rotor balancing kit

Strobe light analysis for balancing installed

tail rotors.

FRDH 101

Torque wrench adapter

Installing main rotor drive shaft bolts and

eyebolts.

RXT20-5

HYTIP insertion/extraction tool (mfg by

Installing and removing HYTIP electrical

(extraction)

Burndy, Norwalk, Connecticut)

contacts into and from terminal block

RTM20-9

modules.

(insertion)

M8ND &

HYTOOL M8ND (catalog No. Y14

Manual crimping of MINILOK and MODILOK

N14HTC

MRC); Die-Sets N22PCT-1 & -2, and

terminal block contact tips on electrical wire

N14HCT (mfg: same as item No. 33)

harness leads.

107-0970

Hand-operated crimping tool (Catalog

Hand crimping of removable contacts in

No. 107-0970) with positioners

rectangular connectors.

(Catalog No. 107-0976 and

107-0977)(mfg by Winchester

NOTE: Tool conforms to MS-3191-2

Electronics, Division of Litton

(MIL-T-22520, Class 1).

Industries, Main St. and Hillside Ave,

Oakville, Connecticut 06779)

107R1001 and

Removable contact removal tool

Removing and inserting removable contacts

107-1015

(Catalog No. 107R1001) and insertion

from and into inserts of rectangular

tool (Catalog No. 107-1015) (mfr:

connectors.

same as item No. 25)

Deleted

369A9948

Engine stand

Support for removal or replacement engine.

369A8009

Engine hoist

Removing and replacing engine in airframe.

Page 2-9

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-2. Ground Support Equipment and Special Tools (Cont.)

Item

Part No.

Nomenclature

Application or Use

No.

369A6001-

Left landing gear foot drill jig

Enlarging holes in left lockbolt-type landing

50506-1

gear struts for installation of

machine-bolt-attached skids.

369A6001-

Right landing gear foot drill jig

Enlarging holes in right lockbolt- type

50506-2

landing gear struts for installation of

machine-bolt-attached skids.

CIET 20

Insertion/extraction tool, No. 20 Wire

Connecting and disconnecting No. 20 Wire

Mate connector (mfd. by I. T. T.

Mate electric connectors.

Cannon Electric, 3208 Humbolt St.,

Los Angeles, Calif. 90031)

CIET 16

Insertion/extraction tool, No. 16 Wire

Connecting and disconnecting No. 16 Wire

Mate connector (mfr: same as No. 42)

Mate electrical connectors.

369A9822-5

Locknut torque wrench adapter

Installing and removing tail rotor

swashplate-to-control housing bearing nut.

369A9922-3

Pitch control assembly holding block

Holding tail rotor swashplate while removing

and installing nut.

369H9803

Engine air inlet cover

Covering for engine air inlet front fairing.

369H9804

Engine exhaust outlet cover

Covering for engine exhaust tailpipes.

369A1710-

Fiberglass tail rotor blade, static

Determination of fiberglass blade static

80901

balance moment fixture

balance moment.

369A9825

Pitch bearing stud wrench

Removing main rotor hub pitch bearing pivot

pin.

369A9826

Stud nut wrench

Holding main rotor hub pitch bearing pivot

pin nut.

369H9807

Main transmission drain hose

Draining main transmission oil.

2312-G

Turbine temperature indicating system

Test and calibration of the TOT indicating

test set (Barfield Instrument Corp.)

system.

BH112JA-36

Jetcal tester (Howell Instrument Inc.)

Test and calibration of the TOT indicating

system.

369A1600-

Bushing wrench

Installation and torquing tail rotor hub

80902

threaded bushing.

83006-809-

Arbor press fixture, 369A7951-5

Installing bearing in tail rotor pitch control

00090-1

bearing

link.

83006-809-

Staking tool, 369A7951-5 bearing

Staking bearing in tail rotor pitch control link.

00090-15

83006-809-

Staking tool, (pilot and punch), pitch

Installing bearing and swage ring in pitch

00068

control assembly double row bearing

control housing.

369A7951-45

WSI-HT-12AS

Installation tool, WSI-B-12AS

Installing grommets for tail rotor control rod.

grommet (mfd. by Western Sky

Industries, 21300 Cloud Way,

Hayward, CA 94545)

269A9232

Plug, 269A5050-18 bearing removal.

Removing double-row bearing from tail

rotor pitch control housing.

Page 2-10

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-2. Ground Support Equipment and Special Tools (Cont.)

Item

Part No.

Nomenclature

Application or Use

No.

Chadwick-Helmuth Balancer /

Equipment for tracking and balancing of

Analyzer Instrument Kit

dynamic components. Main/Tail rotor

vibration analyzer.

369D29999

Main rotor and tail rotor balance spare

Used with Item 59 to balance tail rotor and

kit

main rotor.

830006-809-

Arbor press fixture for 369A7951-15

Installation of bearing in main rotor blade.

00090-8

bearing

830006-809-

Staking tool for 369A7951-15 bearing

Staking of bearing in main rotor blade.

00090-20

36-D-284

Prop protractor

Measure angle of incidence.

NOTE:

(1) Main rotor blade tracking equipment 369A9926-7 and -5 each contain a strobe light 369A9925, magnetic

pickup 369A9944, one set of interrupters, a set of tracking cap reflectors and associated mounting

hardware. The 369A9942-27, -29, -31 and -33 Tip Cap Assemblies are to be ordered as replacement

for the 369A9942-7, -9, -11, and -13 and the 369A9942-501 Tip Cap Assemblies.

(2) Handle, frames and puller nut same as 369A9932; -31 thrust pad replaces -3 thrust pad.

(3) Hammer and handle same as 369A9933; -7 driver -3 driver.

(4) Tail rotor balancing equipment 369A9999 contains a vibration analyzer 369A9801, protractor assembly

369A9979, acceleration mounting bracket 369A9920 and associated attachment and balancing

hardware.

Page 2-11

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

4. Servicing

B. Fuel System Draining

Fuel draining should be accomplished with

(Ref. Figure 2−5) Servicing of the helicopter

includes replenishment of fuel, changing or

helicopter as level as possible.

replenishment of oil and other such mainte−

(1). Fuel system may be defueled in either

nance functions. Fuels, oils, others servicing

of two ways:

materials and capacities are listed in

Table 2−3. Observe the following precautions

To avoid possible damage to fuel

when servicing the fuel system.

CAUTION

pump, do not operate fuel pump

with fuel tanks drained.

Turn off electrical switches

WARNING

and disconnect external

(a). Defuel through filler port using a

power from the helicopter.

pump.

(1). The helicopter must be electrically

(b). Open system drain valves on fuselage

grounded prior to refueling or defuel−

underside and in engine compart−

ing. The possibility of static discharge

ment.

(difference in electrical potential) and

presence of fuel vapors always presents

(2). Fuel supply line drain valves are spring

fire and explosion hazards.

loaded type and open by pushing valve

and attached drain line.

(2). The refueling vehicle should be parked

(3). Fuel cells drain valve is spring−loaded

a minimum of 20 ft. (6 M) from the

closed and is opened by pressing

helicopter during the fueling operation.

internal plunger.

Before starting the fueling operation,

always ground the fueling nozzle or fuel

C. Engine Oil System Filling

truck to the GROUND HERE recep−

tacle or to another bare metal location.

The engine oil filler cap is on the right side of

the helicopter. A liquid level plug for checking

Use extreme care when apply−

the oil level in the tank is visible through a

CAUTION

ing any type of lubricant

transparent window near the filler.

(grease, oil, dry−film, etc) in the vicinity of

teflon bearings. Most lubricant will form a

NOTE:

dirt retaining film or have other detrimental

D Before adding oil, the oil container must

effects that can cause rapid detertioration of

be shaken to ensure proper mixture of the

bearing surfaces.

anti−foaming additive.

A. Fuel System Filling

D If sight gauge does not permit positive de−

termination, remove filler cap and visual−

The fuel system has two fuel cells that are

ly check the oil level.

interconnected for simultaneous flow venting.

(1). Check oil level within 15 minutes of

The fuel filler cap is on the right side of the

engine shutdown; replenish if low.

helicopter.

(2). If engine oil level is low after helicopter

(1). Refuel helicopter with correct fuel as

has set for more than 15 minutes;

soon after landing as possible to

prevent moisture condensation and to

(a). Run engine for at least one minute at

keep the helicopter as heavy as possible

ground idle.

in case of winds.

Ensure engine oil pressure is at−

(2). Keep fuel nozzle free of all foreign

CAUTION

tained when starting engine

matter.

(Ref. applicable Pilot’s Flight Manual).

(3). Check filler cap for security after

(b). Shut down engine, check oil level,

fueling.

replenish if low.

Page 2-13

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

NOTES:

MAIN TRANSMISSION

SELF−CLOSING VALVE 50−60 IN. LB. (5.65−6.78 NM);

FILLER

CHIP DETECTOR (WITHOUT KNURLED DETECTOR

KNOB) 40−50 IN. LB. (4.52−5.65 NM).

MAIN TRANSMISSION

ENGINE LOWER CHIP DETECTOR 60−80 IN. LB.

LIQUID LEVEL

DRAIN (NOTE 1)

(6.78−9.04 NM).

PLUG

BREATHER−FILLER 45−55 IN. LB. (5.08−6.21 NM).

LIQUID LEVEL

PLUG

OVERBOARD OIL

DRAIN LINE

ONE−WAY LOCK

RESERVOIR

ENGINE ACCESSORY

GEARBOX DRAIN

(NOTE 2)

BREATHER−FILLER

(NOTE 3)

ENGINE OIL

TANK FILLER

FUEL SUPPLY LINE

DRAIN VALVE

EXTERNAL POWER

RECEPTACLE

LIQUID LEVEL

PLUG

OIL SUPPLY

GROUND

FUEL SYSTEM

FUEL CELLS

DRAIN VALVE

RECEPTACLE

FILLER

DRAIN VALVE

TAIL ROTOR

TRANSMISSION DRAIN

(NOTE 1)

30−006C

Figure 2-5. Servicing Points

NOTE:

(5). To drain residual oil from engine

accessory gearbox drain, remove wire

D Motoring engine can draw oil from the oil

lead and lower chip detector. Use

tank to the gearbox, giving low oil level

suitable container to catch oil. Check

indications.

that detector O−ring is serviceable

D If engine oil level indicates a low condi−

(replace if necessary); reinstall detector,

tion after setting overnight, engine check

torque to 50 − 60 inch−pounds (5.65 −

valve may be leaking oil from tank to en−

6.78 Nm) and reconnect wire lead.

gine gearcase.

E. Engine Oil System Draining (with Drain

(3). Ensure oil tank filler cap is securely

Valve Installed)

tightened immediately after servicing.

(1). Remove sound insulation from cargo

D. Engine Oil System Draining (with Sta.

compartment aft bulkhead right−hand

137.50 Bulkhead Drain Ports Installed)

access door (Ref. Figure 2−6). Remove

the right−hand access door.

(1). Open engine access doors.

(2). Place a suitable container under the

(2). Place suitable container under engine

overboard oil drain line where it exits

oil tank drain and remove engine oil

the fuselage underside at the firewall.

tank filler cap.

(3). Remove cap from oil tank filler. Pull out

(3). Remove engine oil tank drain cap.

knurled spring−loaded button to open

valve in engine oil drain line just below

(4). After draining oil from tank, reinstall

cooler. Rotate button and valve poppet

engine oil tank drain cap and oil tank

so that locking pin rest on shoulder of

filler cap.

pin slot.

Page 2-14

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

(4). After draining the oil from the tank,

(a). Fill main transmission by lifting

reinstall the filler cap and close oil

breather−filler cap and inserting

drain valve; ensure that poppet pin is in

spout of oil can into opening. Check

stop slot.

that spring−loaded cap closes when

oil can spout is removed.

(5). Install access door and sound insula−

(b). Fill tail rotor transmission by remov−

tion.

ing lockwire, unscrewing breather−

filler and pouring oil into transmis−

(6). To drain approximately 1/2 pint (0.23 L)

sion. Check that filler O−ring is

of residual oil from engine accessory

serviceable (replace if necessary),

gearbox drain (Ref. Figure 2−5) remove

reinstall breather−filler and torque to

the wire lead and the lower chip

45 − 55 inch−pounds (5.08 − 6.21

detector. Use a suitable container to

Nm); secure with lockwire.

catch the oil. Check that detector

packing is serviceable (replace if

NOTE: Breather− filler plugs that have the

necessary), reinstall detector, torque to

threaded insert are installed with the

50 − 60 inch−pounds (5.65 − 6.78

breather hole rearward.

Nm), and reconnect wire lead.

H. Main Rotor Transmission Draining

F. Engine Oil System Flushing

(1). If installed, remove circular drain cover

plug and padding for main transmis−

The following procedure is for flushing oil that

sion from forward underside of trans−

as been contaminated or when changing the

mission cover panel. Otherwise remove,

type of oil.

in order, sound insulation, gearbox

access cover, transmission drain

(1). Drain oil from engine, oil tank and oil

assembly and main transmission cover).

cooler (Refer to Engine Oil System

(2). Position a suitable (min. 4 qt/4 L)

Draining).

container under main transmission

drains or drain current configuration

(2). Replace engine oil filter(s) (Ref. Allison

transmission using transmission drain

Operation and Maintenance Manual)

hose (41, Table 2−2).

NOTE: Two types of chip detector are installed

(3). Refill engine oil system (Refer to Filling

on the main transmission. The current type

− Engine Oil System).

chip detector have a knurled knob to remove

electrical chip detector probe. Hand−tighten

(4). Operate engine for five minutes, shut

knob when reinstalling.

down and repeat steps (1). thru (3).

(3). Remove wire leads, lockwire, chip

G. Main Rotor and Tail Rotor Transmission

detector and self−closing valves.

Filling

NOTE: The self−closing valve need not be re−

moved if special drain hose is used. Insert

Transmission (gearbox) oil should be replaced

hose fitting and turn to drain oil.

with new oil whenever it is drained from the

gearbox.

(4). If damaged, replace O−rings used with

chip detector and self−closing valves.

NOTE: Inspection of internal ring gear bolts is

(5). After oil has drained, install self−clos−

required after oil is drained from the main

ing valve and chip detectors. Torque

rotor transmission, at intervals specified in

chip detector,without the knurled chip

CSP−H−4, before refilling with oil.

detector probe knob, 40 − 50 inch−

pounds (4.52 − 5.65 Nm). Lockwire

(1). Check transmission oil level in liquid

valve to gearbox and detector to valve.

level plug.

Reconnect wire leads.

(2). Replenish with correct oil until the

(6). If used, reinstall padding and circular

level reaches FULL on the plug.

drain cover plug on forward underside

Page 2-15

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

transmission cover panel. Otherwise,

to gearbox and detector to valve.

reinstall, in order, the main transmis−

Reconnect wire lead.

sion cover, the drain assembly, the main

(5). Wipe dry any oil spillage with a clean

gearbox access cover and the sound

cloth moistened with solvent (1,

installation.

Table 2−4).

NOTE:

K. Tail Rotor Transmission Oil System

D If equipped with a metal filter, the main

Flushing

transmission filter should be cleaned

whenever the oil is drained.

The following procedure is for flushing oil that

as been contaminated or when changing the

D If equipped with a paper filter, the main

type of oil.

transmission filter should be replaced

whenever the oil is drained.

(1). Drain oil from tail rotor transmission

(Ref. Tail Rotor Transmission Drain−

I. Main Rotor Transmission Oil System

ing).

Flushing

(2). Refill tail rotor transmission (Ref. Main

The following procedure is for flushing oil that

Rotor Transmission and Tail Rotor

as been contaminated or when changing the

Transmission Filling).

type of oil.

(3). Operate aircraft for five minutes, shut

(1). Drain oil from transmission and oil

down and repeat steps (1). and (2).

cooler (Ref. Main Rotor Transmission

Draining).

L. One-W ay Lock Control system Servicing

(2). If equipped with a metal filter, clean

(1). To check oil level, remove control access

the transmission oil filter (Ref. Trans−

cover.

mission Lubrication Pump Oil Filter

Cleaning). If equipped with a paper

NOTE: Reservoir should be 1/2 to 3/4 full.

filter, replace the filter.

(2). If oil level in reservoir is low, lift filler

(3). Refill transmission oil system (Ref.

cap and add oil as needed.

Main Rotor Transmission and Tail

(3). Reinstall pilot’s seat cover.

Rotor Transmission Filling).

NOTE:

(4). Operate aircraft for five minutes, shut

down and repeat steps (1). thru (3).

D If oil level is consistently low, one− way

lock should be repaired to stop oil leakage

J. Tail Rotor Transmission Draining

(Ref. Component Overhaul Manual).

(1). Position suitable container under the

D Hydraulic fluid leakage from any part of

tail rotor transmission drain.

one− way lock is not permissible. When

leakage is observed, assembly should be

(2). Remove wire lead, lockwire, chip

overhauled (Ref. Component Overhaul

detector and self−closing valve

Manual) as required and a serviceable

unit installed. If leaking one−way lock is

(3). If damaged, replace packings used with

not replaced when leakage occurs, contin−

chip detector and self−closing valve.

uation in service may result in mechani−

(4). After oil has drained install self−closing

cal malfunction that could be hazardous

valve and chip detector. Lockwire valve

to flight safety.

Page 2-16

Revision 16

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-3. Component Servicing and Materials

Item

Component

Capacity

Material

No.

Tail Rotor Transmission (1)(2)(5)

0.5 U.S. Pt. (0.23 Liter)

MIL-L(PRF)-23699

(3)

Mobil Oil SHC 626 (3)(6)

Main Transmission

4 U.S. Qt (3.78 L)

Refer to Item 1

Engine Oil Tank (4)

3 U.S. Qt (1.32 L)

Refer to Allison Engine

Operation and Mainte-

nance Manual

Fuel Cells

Standard nonself-sealing cells

Capacity

64.0 U.S. Gal. (242 Liters)

Refer to Appropriate

(416.0 pounds)

Pilot’s Flight Manual

Usable

62.1 U.S. Gal. (235 Liters)

Refer to Appropriate

(403.5 pounds)

Pilot’s Flight Manual

Optional self-sealing cells

Capacity

62.0 U. S. Gal. (234 Liters)

Refer to Appropriate

(402.0 pounds)

Pilot’s Flight Manual

Usable

59.9 U.S. Gal. (226.8 Liters)

Refer to Appropriate

(389.5 pounds)

Pilot’s Flight Manual

Overrunning Clutch

-11, -21, -31

1.52 U.S. Oz. (45cc)

MIL-L (PRF)-23699 (3)

-41,

-51

1.01 U.S. Oz. (30cc)

One-W ay Lock

0.67 U.S. Oz. (20 cc)

MIL-H-5606

Battery (Nicad)

As required

MS36300 or 0-B-41

Distilled Water

NOTES:

(1) Oils approved for use in MDHI 369 Series Helicopter main and tail rotor transmissions are synthetic

compounds having Ryder Gear Value in excess of 2500 pounds.

(2) Not a preferred lubricant for MDHI transmissions. Use MIL-L-7808 lubricating oil in transmissions only

when other oils listed are not available.

(3) Approved for use above -40°F (-40°C).

(4) For Model 250 Series engine oil change requirements and restrictions on mixing oils, refer to Allison

Commercial Service Letters.

CAUTION: Mixing of oils within an oil series not in the same group is permitted only in an emergency. Use

of mixed oils (oils not in the same group) in an engine is limited to five hours total running time. Adequate

maintenance records must be maintained to ensure that the five hour limit is not exceeded. Mixing of oils

from different series is not permitted.

(5) Listed is the basic Military Specification only. Check the specification sheet for the latest alpha change

letter to determine whether the materials being used conform.

(6) Mobil oil SHC 626 can be formulated such that it may have two different colors. The oil can still be mixed

with no adverse effects.

Page 2-17

Revision 18

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

5. Battery Handling and Servicing

do not use potassium hydroxide

Precautions

solution.

(5). The state of charge of a nickel−cad−

The electrolyte used in nick−

mium can not be determined by either

WARNING

el− cadmium batteries con−

the specific gravity of the electrolyte

tains potassium hydroxide, a casuistic

nor the battery voltage. The specific

chemical agent. Serious burns will re−

gravity will remain the same whether is

sult if the electrolyte contacts skin. Ex−

charged are discharged or the electro−

plosive gases may be released from the

lyte mix contains potassium hydroxide

battery during charging. Before re−

or is contaminated with potassium

moving the battery from the helicopter,

carbonate. The voltage will not change

make sure that the power selector

appreciably until the battery is almost

switch is in the OFF position. Removal

completely discharged.

or installation of the battery connector

while the battery is under load may re−

(6). If sulfuric acid has been inadvertently

sult in explosions, electrical arcing or

mixed with the electrolyte in the

possible severe personal burns.

battery, the upper areas of the cells will

appear greenish in color. In such cases,

(1).

Satisfactory battery operation is largely

the battery must be replaced.

dependent upon proper operation of the

helicopter voltage regulator. Battery

6. Battery Servicing

problems may often be prevented or

Battery servicing consist of replenishing any

eliminated by maintaining the voltage

electrolyte water that may have been lost

regulator setting at the precise voltage

through normal gassing, venting or over−

specified.

charging. Lost water should be replaced with

pure distilled water only. Never use potassium

(2).

Nickel−cadmium batteries contain an

hydroxide solution.

electrolyte mixture of potassium

hydroxide and distilled water. Chemi−

The electrolyte level should be

CAUTION

cally, this is just the opposite of an acid.

checked only after the battery

Take every possible step to keep the

has been fully charged and then allowed to

nickle−cadmium battery as far away as

rest (stand idle) for a period of two hours. If

possible from the lead−acid type of

the helicopter has operated continuously for

battery. Do not use the same tools and

a minimum of one hour or more, the battery

materials (screwdrivers, wrenches,

may be considered fully charged.

syringes, gloves, apron, etc.) for both

(1). Turn power selector switch OFF.

types of batteries. Anything associated

with the lead−acid battery, even the air,

(2). Raise pilot compartment floor left

must never come in contact with the

access door and remove battery cover.

nickel−cadmium battery or its electro−

lyte. Even a trace of sulfuric acid fumes

Use care to avoid damaging bat−

CAUTION

from a lead−acid battery may result in

tery temperature sensing wires

damage to the nickel−cadmium battery.

and switch connections during cleaning and

servicing.

(3).

A low electrolyte does not necessarily

(3). Wipe tops of cells with clean cloth and

indicate that the water must be added

remove filler vent caps.

to the cells. The electrolyte level in the

cell will vary, depending upon battery’s

(4). Check electrolyte level in each cell. A

state of charge.

gage will be seen at the the bottom of

each filler cavity. The gage may be a

(4).

During operation of the battery, some

rod, a ball, or an orange−colored strip

water is lost from the electrolyte as a

with two notches in the sides. The

result of normal gassing, venting, or

electrolyte level should be just above

overcharging. This loss should be

the rod or ball, or between the notches

replaced with pure distilled water only;

in the orange stripe.

Page 2-18

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Do not add distilled water if the

or the battery case, and after any idle period of

CAUTION

battery has remained idle for

ninety (90) days or more.

more than two hours after flight (charging).

NOTE: Follow the manufacturer’s operating

The electrolyte level will drop in a longer

instruction for the battery charger; however,

time interval and any water would result in

all voltage values, discharge rates, and

overfilling.

charging schedules given (Ref. Battery Deep

NOTE: If electrolyte level has lowered to the ex−

Cycling) shall apply in event of conflict with

tent that it is not visible, remove battery

the constant potential battery charger

from helicopter for bench charging and serv−

instructions.

icing.

A. Normal Battery Charging

(5). Using a thoroughly clean bulb−type

Review the battery handling

syringe that has never been used for

WARNING

and servicing precautions

servicing a lead−acid battery, add pure

(Ref. Battery Handling and Service

distilled water as necessary to raise the

Precautions) before preforming the fol−

electrolyte 1/4 − 3/8 inch (6.35−9.525

lowing charging operations.

mm) above baffle (between level holes

or above nylon rod gage, as applicable).

(1). If battery is installed in the helicopter,

If there is surplus electrolyte, replace

turn power selector switch OFF and

the battery or remove the battery and

remove battery.

service it in accordance with manufac−

(2). Clean battery (Ref. Battery Cleaning).

turer’s instructions.

(3). Inspect battery for any damage that

NOTE: If a battery with surplus electrolyte is

would require battery replacement or

serviced, it must be checked for serviceabili−

repair.

ty according to manufacturer’s instructions

before reinstallation and reuse in the heli−

Do not add distilled water to the

CAUTION

copter

electrolyte prior to charging,

even if the electrolyte is not visible. The

(6). Reinstall filler vent caps.

electrolyte level will raise as charging prog−

resses.

(7). Reinstall battery cover, mounting

screws and washers; close and latch

(4). Charge the battery as follows:

access door.

NOTE: The following procedure provide

7. Battery Charging

instructions for charging with the constant

potential method. When charging by the

Nickel−cadmium battery charging is accom−

constant charging method, disregard the

plished by either the normal charging method

procedure in steps (a). and (b). below and

or the deep−cycling method, depending upon

charge the battery according to battery and

the circumstance. Normal battery charging

battery charger manufacturer’s instruc−

consist of charging the battery by the constant

tions. Charging is accomplished with cell

potential method or the constant current

filler vent caps installed. Temperature of

method and adjusting the electrolyte level if

battery may rise during charging.

required. Normal battery charging is accom−

(a). Using a constant potential charger,

plished when the need arises. Deep cycling

charge battery for 30 minutes taking

consists of intentionally discharging and then

care to maintain a constant and

recharging the battery, adjusting the electro−

accurate charging voltage of 28.0 to

lyte level, checking the battery output capabili−

28.5 Vdc for the full charging period.

ty (capacity discharge test), and again recharg−

ing. Deep cycling should be accomplished on a

(b). If necessary, monitor and manually

new battery before it is installed in the

adjust charging voltage to prevent

helicopter, if required, and at the inspection

any drop or rise in charging voltage.

intervals specified in CSP−H−4. Deep cycling

should also be accomplished after battery

(5). Switch charger OFF and then discon−

repairs such as replacement of individual cells

nect battery from charger.

Page 2-19

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

(6). Remove filler vent caps and check

NOTE: Nominal individual cell voltage is 1.25

electrolyte level. Replenish with pure

volts for a normal, disconnected, fully

distilled water (Ref. Table 2−3) if

charged cell.

necessary, taking care not to over−fill.

(7). Replace and tighten filler vent caps.

(6). Switch charger OFF and then discon−

nect battery charger.

B. Battery Deep Cycling

Review the battery handling

WARNING

(7). Allow battery to rest for a minimum of

and servicing precautions

one hour maximum and a maximum of

(Ref. Battery Handling and Service

2 hours; adjust electrolyte level.

Precautions) before preforming the fol−

lowing charging operations.

(1).

Perform normal charging (Ref. Normal

(8). If electrolyte level is adjusted, recon−

Battery Charging).

nect battery to charger and allow the

battery continue charging for thirty

(2).

Connect a 9 ohm resistance (9 ohm, 200

minutes.

watt−resistor or three 3 ohm, 75 watt

resistors in series) across the battery

terminals and allow the battery to

If battery temperature exceeds

CAUTION

discharge for approximately 12 hours,

room temperature during initial

or until the battery voltage decrease

charging, battery temperature must be al−

below one volt.

low to decrease to room temperature before

recharging the second time.

(3).

Remove 9 ohm load resistance from

battery and loosen cell filler vent caps.

(9). After allowing battery temperature to

(4).

Charge battery until charging drops

decrease to room temperature, repeat

below 0.30 ampere.

the procedures described in steps (2).

(5).

While continuing to charge the battery

thru (8). above to cycle the battery a

at a rate less than 0.30 ampere, use an

second time.

accurate voltmeter to measure the

voltage across the terminals of each

individual battery cell. Each individual

NOTE: When making the individual cell volt−

cell should be within 0.05 volt of the cell

age measurement the second time, the volt−

voltage specified below for applicable

age of each individual cell must measure

charging voltage.

within the voltage limits specified in step e

above. If the voltage of any individual cell

Charging Voltage

Cell Voltage

does not measure within the specified volt−

(volts dc)

age limits, the cell must be discarded. Re−

place a defective cell according to instruc−

28.0

1.47

tions.

28.1

1.48

28.2

1.48

(10). Switch charger off and then disconnect

28.3

1.49

battery from charger.

28.4

1.49

28.5

1.50

(11). Tighten cell filler vent caps.

Page 2-20

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-4. Maintenance Materials

Item

Specification

Commercial Products (2)

Material

No.

No. (1)

Name/No.

Mfr

Solvent, dry-cleaning

P-D-680

(3)

Lockwire (diameter as

MS200995C

CRES Safety wire

required)

(3)

Sealing compound

MIL-S-8802

890

Coast Pro Seal

(color as noted)

MIL-S-8516

3C-3007

Churchill Chemical Corp.

Class II

Los Angeles, CA

PR1422

Product Research

A1/2 Type I

RTV 730

Dow Corning

Type I

Midland, MI

Primer

MIL-P-85582

(3)

Chromic Acid solution

(4)

Dow #19 or equivalent

Dow Chemical Co.

(pH 2.6 to 3.4):

magnesium touch up

Lacquer, acrylic

MDM 15-1083

Black #17038

(3)

(Fed-Std-595)

Black #37038

Parchment #20371

Green #34151

Blue #15102

Blue #35044

Brown #30140

Primer, catalyzed acrylic

(Refer to item No. 6

(yellow)

Chemical film and

MIL-C-5541B

Iridite 14-2

Richardson Co.

chemical film materials

(Class 2, unless

Al-coat

Allied-Kelite Products Division

for aluminum and

noted. Grade and

2400 E. Devon Ave.

aluminum alloys.

type optional.)

Alodine 1201

Des Plaines, IL

Abrasive paper, silicon

P-P-101

(3)

carbide (grade as noted)

Surface cleaner

TT-C-490 or

WO #1

Turco Products, Inc.

(pre-painted solution with

MIL-C-10578,

Wilmington, CA

phosphoric acid base)

Type II

Page 2-21

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-4. Maintenance Materials (Cont.)

Item

Specification

Commercial Products (2)

Material

No.

No. (1)

Name/No.

Mfr

Paint remover

TT-R-248

Turco 5851 #A202

Turco Products, Inc.

(acid type for epoxy)

Cee-Bee Chemical Company

Paint remover

MIL-R-25134

(3)

(solvent type)

Plastic bead, spherical 20

Poly Plus 20/30

Polyrock Co.

- 30 mesh

(6)

4763 Murrita Ave.

Chino, CA 91710

Abrasive Cleaning Equip.

20122 State Rd.

Cerritos, CA 92701

Abrasives Unlimited

4653 S. 33^rd St.

Phoenix, AZ 85040

Thinner, acrylic-

MIL-T-19544

Prepsol

E. I. DuPont Co.

nitrocellulose lacquer

(Dupont 3919)

Los Angeles, CA

Corrosion preventive,

MIL-C-8188

aircraft gas turbine

engine, synthetic base

Masking tape, pressure

UU-T-106

#216

3M Co.

sensitive

(High temp)

St. Paul, MN

Protective coating

MIL-C-6799

Type 1

Tape, pressure sensitive,

PPP-T-60

3M Co.

water-proof for

Class I

packaging and sealing

(width and thickness as

noted)

Silicone adhesive/

MIL-S-8660B

DC 4

Dow Corning

sealant

G-624 Silastic

General Electric

Silicone Products Dept

Waterford, NY

Grease, oscillating

MIL-G-25537

Aero Shell 14

Shell Oil Co.

bearing

TG-4851

Texaco Inc.

Adhesive, epoxy,

MIL-A-52194

Scotch-W eld

3M Co.

non-structural

EC 1838 (Part A&B)

Commercial

A-1 177-B

B. F. Goodrich

Abrasive cloth, aluminum

P-C-451

(3)

oxide (grade as noted)

Page 2-22

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-4. Maintenance Materials (Cont.)

Item

Specification

Commercial Products (2)

Material

No.

No. (1)

Name/No.

Mfr

Grease

MIL-G-81322

Mobil Grease 28

Mobil Oil Company

Aero Shell 22

Shell Oil Company

Braycote 622

Castrol Industries

1001 W. 31 st St.

Downers Grove, IL 60515

(630) 241-4000

(800) 621-2661

Methyl-ethyl-ketone

TT-M-261

(3)

(MEK)

Crocus cloth

P-C-458

(3)

Adhesive, silicone rubber

Silastic 140

Dow Corning

Lubricant, solid film

MIL-L-8937

Lubri-Bond 220

Electro-film Inc.

MIL-L-23398

(3)

7116 Laurel Canyon Blvd.

HMS 4-1078

P.O. Box 106,

Type I/XI

No. Hollywood, CA

Molykote 3402

Product Techniques, Inc.

(3)

511 E. 87^th Pl.

Los Angeles, CA

Kal-Gard AD

Kal-Gard Coating & Mfg. Co.

(3)

16616 Shoenborn Street

Sepulveda, Ca. 91343

Pera-Silk G

Highway 52 N.W.

(3)

West Lafayette, IN 47906

Grease, aircraft and

MIL-G-23827

Braycoat 627

Bray Oil Company

instrument

9950 Flair Drive

El Monte, CA

Aero Shell 7

Shell Oil Company

Exxon 5114EP

Exxon Co.

Houston, TX

Acetone

O-A-51

(3)

Surface primer, locking

MIL-S-22473

Locquic

Loctite Inc.,

compound (grade and

702 No. Mountain Road,

form optional)

Newington, CT 06111

Sealing, locking and

MIL-S-22473

Loctite #35 or RC/609

Loctite, Inc.

retaining compounds;

MIL-R-46082

single component (grade

as noted)

Twine, nylon

MIL-T-713

(3)

Page

2-23

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-4. Maintenance Materials (Cont.)

Item

Specification

Commercial Products (2)

Material

No.

No. (1)

Name/No.

Mfr

Insulation sleeving,

MIL-I-631

(3)

electrical (vinyl tubing;

Type F, Form

size as noted)

U, Grade A,

Class I,

Category 1

Tape, pressure sensitive

PPP-T-66

Scotch Cal

3M Co.

(width and thickness as

Type I, Class A

#471 VEF

noted)

Loctite remover (for

Oakite 156

Oakite Product Inc.,

disassembled parts)

Los Angeles, CA

Petrolatum

VV-L-236

(3)

(petroleum jelly)

Lubricating oil, general

VV-L-800

(3)

purpose, preservative

Antiseize compound,

MIL-A-907

high temperature

Lacing cord, high

Type T-333

Warren Wire Co.

temperature

Dichloromethane

MIL-D-6998

(3)

(methylene chloride)

Ethylene chloride

MIL-E-10662

(3)

(ethylene dichloride EDC)

Gasket material

Scotchfoam

3M Co.

(adhesive on one side

# 4304

only)

Tape, pressure sensitive

PPP-T-97

(3)

adhesive, filament

reinforced

Tape, pressure sensitive

#Y8560

3M Co.

polyurethane (width as

noted)

Adhesive (epoxy),

Lefkoweld Type 109

Leffingwell Chemical Co.,

nonstructural

Resin/LM-52

Whittier, CA.

Activator

Barrier material, grease

MIL-B-121

(3)

proof

Type I, Gr A,

Class 2

MIL-B-131

Class 1

Cement

MIL-A-8576B

PS-18 S147

Rohm and Haas Co.

Swedlow, Inc.

Tetrahydrofuran (THF)

Foremost-McKesson Corp.

Chemical Dept.

Los Angeles CA

Page 2-24

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-4. Maintenance Materials (Cont.)

Item

Specification

Commercial Products (2)

Material

No.

No. (1)

Name/No.

Mfr

Lacquer, clear, aluminum

MIL-L-6066

clad alloy surfaces

Solder, tin alloy, rosin

QQ-S-571

(3)

core

(Composition

SN60WRP2

Emery cloth, fine

(3)

Patching material

5187

Uniroyal, Inc.

(inside/outside)

Fuel Container Dept.

Mishawaka, IN

Patching material

5200

Uniroyal Inc.

(outside only)

Soap paste

P-S-560

(3)

Cheesecloth

(3)

Cement

MIL-A91 17

EC-678

3M Co.

Solvent

3339

Uniroyal

Vinyl tape and activator

Tape: Scotch Cal

3M Co.

#455 Activator:

Scotch Title A-2

Grease

130A

Lubriplate Manufacturing

Grease

930A

Lubriplate Manufacturing

Naphtha, aliphatic

TT-N-95

(3)

Sealant

HT-4

1,1,1, Trichloroethane

O-T-620

(3)

technical inhibited

Tape, aluminum foil

# 425

3M Co.

Detergent, general

MIL-O-16791

(3)

purpose

Hydrofluoric Acid

O-H-795

(3)

Nitric Acid

O-N-350

(3)

Brazing flux, paste

O-F-499

(3)

Brazing alloy, silver base

MIL-B-15395

(3)

Tape, nitrile rubber

NE-71A

Armstrong Cork Co.

Lancaster, PA

Adhesive, bonding,

EC1300L

3M Co.

vulcanized (synthetic

rubber-to-steel)

Corrosion preventive

MIL-C-16173

Braycote

Bray Oil Company

compound, solvent

Grade 3

cutback, cold application

Isopropyl alcohol

TT-I-735

(3)

Page

2-25

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-4. Maintenance Materials (Cont.)

Item

Specification

Commercial Products (2)

Material

No.

No. (1)

Name/No.

Mfr

Zinc chromate putty,

MIL-P-81 16

Compound 3998

Fuller-O’Brien Paints

general purpose

Santa Fe Springs, CA

Non-slip tape, pressure

P-D-00455

(3)

sensitive, medium grade

(black)

Electric tape, plastic

MIL-I-7798

# 33

3M Co.

Cleaning compound,

MIL-C-25769

alkaline waterbase

Acetylene, technical

BB-A-106

(3)

grade

Oxygen, industrial grade

BB-O-925

(3)

Type I, Grade B

Welding rod, corrosion

MIL-T-9821B

21-6-9

Johnston Stainless Welding

and heat resisting alloys

or C

Rods

(Class or type as noted)

Nitronic 40

13729 E. Rosecrans

Santa Fe Springs, CA

Teflon tape

# 520

Permacel

# 48

3M Co.

Use item 19

Fiberglass repair kit

Cordokit RK-10

Ferro Corp.

Composites Division

34 Smith St.

Norwalk, CT 06852

Epoxy resin with catalyst,

MIL-R-9300

(3)

low pressure laminating

Type I

Adhesive

Epon 919

Shell Chemical Co.

Pittsburgh, PA

Fuel cell repair kit

RK3CL

Uniroyal

Rod, welding

QQ-R-566

(3)

CLFS RA12 or

RA143 (4043)

5% silicon

Solder, tin alloy, acid core

QQ-S-571

(3)

Insulation sleeving,

MIL-L-3190

(3)

electrical, fiberglass (size

as applicable)

Lubricant, solid film

MIL-L-46010

(3)

Tape, pressure sensitive

4104

3M Co.

(width as noted)

Tape, double-faced

E-706

Arno Adhesive Tapes Inc.,

Los Angeles, CA

Cement

C-1 11

Sta-Bond Corp.

Gardena, CA

Page 2-26

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-4. Maintenance Materials (Cont.)

Item

Specification

Commercial Products (2)

Material

No.

No. (1)

Name/No.

Mfr

Adhesive, polyurethane

U-136, (AC AAAA)

Sta-Bond Corp.

Tape

#850

3M Co.

Filler, resin

Epon 960F

Shell Chemical Co.

Filler, resin

#RP1257-3

Ren Plastics Inc.

Rubber cement

MIL-A-5092

(3)

Preservative oil, hydraulic

MIL-H-6083

Ref. Table 2-3

Grease

GD 568-S

GC Electronics,

Los Angeles, CA

Insulation varnish

Glyptal 1201

General Electric

Insulation Dept.,

Schenectidy, NY

100

Vinyl plastic tape

#330

Technical Tape Co.

New Rochelle, NY

101

Rust inhibitor spray

WD-40

Rocket Chemical Co.,

(aerosol)

Inc., San Diego, CA

102

Adhesive

MIL-A-46106,

RTV732

Dow Corning Corp.

Type I

103

High temperature tape

Temp-R

Insulectro Co.

(thickness as noted)

1410 W. Olympic

Los Angeles, CA

104

Corrosion preventive oil

Steelgard 1301

Harry Miller Corp.

Philadelphia, PA

105

Use item 17

106

Sealant

#5220

Fiber-Resin Corp.

170 W. Providencia Ave.

Burbank, CA

107

Epoxy coating

Poly-EP

Detroit Graphite Co.

Detroit, MI

108

Thinner (for item 107)

Poly-EP

Detroit Graphite Co.

109

Primer Resin (paint base

Q-881

Bee Chemical Company

for polycarbonate plastic)

Gardena CA

110

Thinner (for item 109)

T-80679

Bee Chemical Co.

111

Graphite, powdered

(3)

112

Tape

Temp R Tape

Connecticut Hard Rubber Co.

(Type TV)

New Haven, CT

113

Parting agent

Fre-Kote 33

Fre-Kote Inc.

114

Slip-Spray

E. I. DuPont Co.

Los Angeles, CA

115

Fastener tapes, nylon

Velcro

American Velcro, Inc.

hook and pile

Dow and Manchester St.

Manchester, NH

Page 2-27

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-4. Maintenance Materials (Cont.)

Item

Specification

Commercial Products (2)

Material

No.

No. (1)

Name/No.

Mfr

116

Kerosene

VV-K-21 1

(3)

117

Anti-seize compound,

MIL-T-5544

Thread Lube

Parker-Hannifin

low temperature

17325 Euclid Ave.

Cleveland, OH 44112

118

Fluorocarbon dry

S-122

Miller-Stephenson

lubricant

Chemical Co., Inc.

1001 E. First St.

Los Angeles, CA

119

Foam tape, adhesive

4104Y

3M Co.

backing

92772

120

Cement

2210

3M Co.

121

Adhesive (epoxy)

EA9330.3

Hysol Division

EA9314

Dexter Corporation

Pittsburg, CA

122

Adhesive

444R

Coast ProSeal

123

Tape, pressure sensitive

#471

3M Co.

124

Potting compound

MIL-S-8516B

727

Coast ProSeal

3C-737

Churchill Chemical Corp.

Vernon, CA

PR1201

Product Research Co.

125

Seal rubber extrusion

MIL-R-6855

1317

Rubbercraft Corp.

(main transmission)

Class I Grade 60

Torrance, CA

126

Paper, fine abrasive

(3)

127

Adhesive (2-part mix)

EC3549

3M Co.

128

Coating, logo white

Q881 (Color No. 484)

Bee Chemical Co.

129

Thinner (for item 128)

T-80695

Bee Chemical Co.

130

Paint

(5)

Advance Coating and Chemicals

2213 N. Tyler

S. El Monte, CA 91733

131

Epoxy primer /

1-1G-69 /

Advance Coating and Chemicals

Catalyst reducer

1-1H-75

132

Polyethylene tape

#483

3M Co.

133

Adhesive - cyanoacrylic

Hysol Super Drop

Hysol Division

(used for bonding acrylic

Cyanoacrylic

windows to geon strips)

3CI-1000

134

Accelerator (for item 133)

Hysol Super Drop

Hysol Division

Accelerator

135

Plastic steel

Devcon A

Devcon Corp.

Danvers, MA 01923

136

Tape, pressure sensitive

#471

3M Co.

137

Molybdenum disulfide

MIL-L-7866

powder, lubricant

Page 2-28

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-4. Maintenance Materials (Cont.)

Item

Specification

Commercial Products (2)

Material

No.

No. (1)

Name/No.

Mfr

138

Tape, pressure sensitive

#4508

3M Co.

(dimensions as noted)

139

Spray lubricant

Moly-Dee

Arthur Withrow

5511 District Blvd.

Los Angeles, CA

140

Adhesive primer

HMS 16-1069

Liquid primer

MDHI

Class I

141

Fluorocarbon release

6611N

E.I. DuPont Co.

agent, dry film lubricant

142

Sealer

HMS 16-1068

EA9313

Hysol Division

Dexter Corporation

143

Lubricant

LPS3

LPS Research laboratories Inc.

2050 Cotner Ave.

Los Angeles, CA

144

Cement

Grip

Talor Industries

City of Industry, CA

145

Catalyst reducer

1-1H-75

Advance Coating and Chemicals

146

Metal protector, aerosol

Molykote

Dow Corning Corp.

147

Wash primer

MIL-C-8514

(3)

148

Enamel, epoxy

MDM 15-1100

Black #37038

(3)

(Fed-Std-595)

Type II

White #37769

Tan #20318

Parchment #20371

Red #11958

Green #34151

Gray #36231

Yellow #13655

149

Lubricant, spray

Tri-Flow

Costa Mesa Lubricant

P.O. Box 125

Olive Branch, MS 38645

150

Washing compound with

Zip Wax (2)

Turtle Wax Inc.

wax

5565 W. 73^rd St.

Chicago, IL 60638

151

Sealant

RTV106 (2)

General Electric

152

Tape

CT93C

Jones Industrial Supply

Culver City, CA

153

Tube, silicone

No. 4

Varflex Corp.

(H.A.I.)

Rome, NY

154

Sleeve, vinyl

No. 2

Borden Chemical

Resinate

Compton, CA

155

Thread sealant

P412

Permacel

156

Epoxy cement

Hughes HP16-1

Type II

Dow Corning Corp.

EC 1300L

Page

2-29

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-4. Maintenance Materials (Cont.)

Item

Specification

Commercial Products (2)

Material

No.

No. (1)

Name/No.

Mfr

157

Dry lubricant

MIL-L-46010A

Ecoalube

Everlube Corp.

No. 642

North Hollywood, CA

158

Leak detector, liquid

MIL-L-25567C

Leak-T ec

American Gas and Chemical Co.

Type I

Cresskill, NJ

159

Fiberglass cloth,

MIL-C-9084

(3)

0.022, 2 ply

No. 181

160

Polyester laminating

MIL-R-7575

(3)

resin

161

Sealing compound,

RTV11

General Electric

silicone

162

Dykem, red of blue

SP1100

Dykem Company

8501 Delport Dr.

St. Louis, MO 63114

163

Tape, duct

(3)

164

Xylene

(3)

165

Adhesive

A-4000

Dow Corning Corp.

166

Primer

A-4004

Dow Corning Corp.

167

Catalyst

xy22

Dow Corning Corp.

168

Adhesive, epoxy,

EC2216 2 Part

3M Co.

non-structural

Resin: B (White)

Activator: A (Gray)

169

Adhesive

Stabond G-304

Sta-Bond Corp.

170

Varnish, moisture

MIL-V-173

(3)

resistant

Type II

171

Sealing compound

MIL-S-81733

PR-1431 Type IV

Product Research

PR- 1436G Type II-

PR-1436GB-2

172

Cement

Uniroyal #3230

Uniroyal Inc.

Engineering Systems Dept.

Mishawaka, Indiana 46544

173

Repair kit, non-self-

Uniroyal

sealing cell

#RK-10-34

174

Patch material, self-

Uniroyal #5241/5241

sealing cell, exterior

sandwich

175

Alcohol, denatured

O-E-760

Type I

176

Catalyzed epoxy primer

Type I and Type II

Advance Coating and Chemicals

177

Pre-treatment

MIL-P-15328

(3)

178

Kit, dye penetrant

MIL-I-25135

(3)

179

Tape, pressure sensitive

Y-9132-B

3M Co.

sponge rubber

Page 2-30

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

Table 2-4. Maintenance Materials (Cont.)

Item

Specification

Commercial Products (2)

Material

No.

No. (1)

Name/No.

Mfr

180

Adhesive, epoxy

EA9314

Part A & B

181

Tubing, vinyl, clear

PVC tubing

Sea Wire and Cable Inc.

Size 2 GA

P.O. Box 647

Clear 105C

Madison, AL 35758

1-800-633-7210

182

Release agent

TC7-527

EDP Industries

2055 E. 223 Street

Long Beach, CA 90810

225

Ram Chemical Co.

Gardena, CA

183

Cleaner

Desoclean 45

DeSoto Aerospace Coating, Inc.

1608 4th. St.

Berkley, CA 90621

(818) 549-7823

184

Adhesive

HMS16-1 149, T-5

Sta-Bond Corp.

185

Dielectric compound

DC4

Dow Corning Corp.

NOTES:

(1) Numbers are U.S.A. Specifications and Standards. Prefix symbols are defined as follows: AMS - American

Material Standard; MS - Military Standard; MIL - Military Specification; Single, double or triple alpha prefix

of same letter - Federal Specification; AN - Air Force-Navy Aeronautical Standard; NAS - National

Aerospace Standard.

(2) Primary selection. Any equivalent material may be used as an alternate selection.

(3) Use best comparable grade material when conformity of available materials of same type with listed

Specification No. cannot be determined.

(4) Several types of original protective treatment are used on magnesium alloy parts. With paint removed,

treatment process should be identifiable from coating appearance as outlined in following table. Parts

should not be reprocessed either completely or partially without first contacting MDHI Customer Service

Department. However, regardless of original process used, chromic acid brush-on treatment (Dow #19, or

equivalent) is acceptable for touchup of coatings removed by abrasion, scratches or rework.

(5) When ordering paint from Advance Coating and Chemicals, specify each paint by type (i.e., acrylic, epoxy,

polyurethane), by color, and by AC part number. Also include compatible HS or Fed. Std. No. to ensure that

correct type and color paint is provided. The color code numbers for finish paints used on new Model 369

helicopters are now being entered in helicopter log books prior to delivery of aircraft. Owners/operators of

earlier models should check sales order for paint numbers listed and enter them in some log books, or

sales orders. If so, ensure when ordering Advance Coating paints that AC No. and SA No. are compatible.

(6) Do not use over 50 psig air pressure for abrasive cleaning method. Mask or shield threaded areas or

critical surfaces where damage may result from abrasive blasting.

Page 2-30A

Revision 19

MD Helicopters, Inc.

CSP−H−2

500 Series - Basic HMI

8. Access and Inspection Provisions

(c). Inspect cover gasket for deterioration

or missing sections.

(Ref. Figure 2−6)

(3). Installation: (With main transmission

Any time maintenance work is

cover and drain assembly already

CAUTION

to be preformed near the engine

installed − shaft−driven blower.)

air inlet, use care to prevent entry of foreign

Position access cover and secure by

objects that might later be sucked into the

engaging turnlock fasteners.

compressor. Tape covers of cardboard or oth−

er suitable material in place over the engine

B. Main Transmission Drain Assembly (used

inlet screen in the plenum chamber. Plug

with Shaft-Driven Blower)

the oil cooler inlets. Covers should not be re−

moved until work is completed and debris is

thoroughly cleaned out of the area. Remov−

The main transmission drain assembly is a

able access doors and covers are provided in

clear polycarbonate plastic yoke−type collector

the helicopter for servicing, inspection, re−

that provides an overboard drain for water or

moval, installation and adjustment of com−

oil seepage from the transmission input pinion

ponents. Except for stress areas, the access

oil seal. Foam gaskets cushion and seal the

provisions provided in the outer fuselage,

amounting edges. The drain assembly must be

the pilot’s compartment, the cargo compart−

removed before the main transmission cover

ment and at bulkhead stations have turn−

can be removed.

lock fasteners. Screws are used to secure ac−

cess door in stress areas. Liquid level plugs

(1). Removal: (With main transmission

allow ‘‘sight" inspection of the lubricant lev−

cover removed.)

els of the main transmission, engine oil tank

and tail rotor transmission.

(a). Remove the two screws, two bolts

and washers securing the drain

A. Main Gearbox Access Cover

assembly to the structure, transmis−

sion shroud mount and blower scroll.

Different main gearbox access covers are used

with the shaft−driven and belt−driven oil

cooler blower installations. The cover provides

(b). Remove the one nut and washer from

access to the main transmission, oil cooler

the scroll stud under the drain outlet

blower and engine−to−transmission drive

tube. Lift drain assembly from

shaft. A silicone−rubber−sponge gasket along

shroud mount.

the upper edge of the fiberglass cover provides

a water−and dust−tight seal. Turnlock

(c). Unless replacing drain assembly,

fasteners secure the cover to the structure.

leave drain hose lockwired and

With the shaft−driven blower the cover must

attached.

be removed before the main transmission

drain assembly or the transmission cover can

be removed.

(2). Inspection: Inspect drain assembly for

cracks, gaskets for deterioration and

outlet tube for internal obstruction.

(1). Removal: Disengage turnlock fasteners

and remove cover.

(3). Installation: (With main transmission

(2). Inspection:

cover installed.)

(a). Inspect cover for cracks or other

(a). Position drain assembly on the

visible damage.

transmission shroud. Check that the

short plastic drain tube from the

(b). Inspect turnlock fasteners and

transmission input pinion seal drain

receptacles for improper fastening

port enters the drain assembly outlet

action.

tube port.

Page 2-31

Revision 14

CSP-H-2 BASIC HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369H HELICOPTERS - page 1