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

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

(9). Align doublers with existing rivet

located directly below the forward air scoop at

pattern.

WL 32.00.

(10). Drill doubler to match existing rivet

A. Insulator Padding and Insulation Tape

pattern; deburr holes and remove chips

Inspection

as required.

(Ref. Figure 3−6 and Figure 3−7)

(11). Secure doublers, former, and skin using

(1). Check that the drain hole is free and

wet primer (4, Table 2−4), rivet gun,

clear of obstruction.

and rivets. Install rivets from inside

engine compartment.

(2). Inspect insulator padding and insula−

tion tape for security.

(12). Remove all debris from work area,

inspect installation for discrepancies,

(3). Inspect oil cooler/tank area for possible

and touch up as required with primer.

air gaps and insufficient sealing.

(13). Reinstall removed components in

B. Insulator Padding Replacement

reverse order of removal; inspect

installations for discrepancies.

(1). Remove individual insulator pads by

pulling away from the structure.

14. Underfloor Compartments

(2). Clean insulator attachment surface

Underfloor compartments are those areas

with naphtha (59, Table 2−4). Surface

below fuselage floor level, on both sides of the

must be completely free of oil, grease

center beam and forward of seat structure.

and grit to assure bond.

The left forward area contains electrical

NOTE: Insulator pads are installed with the

equipment and the battery. The right forward

silver reflective material outside and the

area is for utility storage and is lined by an

cushion (red) side against the structure.

area contour−matching thermoplastic contain−

er. The utility compartment is rated for 50

(3). Apply a thin film of adhesive (102) over

pounds (23 kg) maximum weight.

the entire contact surface of either the

structure or the insulator pad.

A. Underfloor Compartment Inspection

(4). Press the surfaces to be bonded togeth−

Inspect electrical harnesses and wiring for

er and work gently from the center

frayed insulation and grounding terminals for

outward in all directions.

corrosion.

(5). Allow the bond to cure approximately

15. Firewall and Sta. 124.00 Insulation

24 hours.

(Ref. Figure 3−5) The engine compartment

C. Oil Cooler/Tank Insulation Tape

forward firewall is insulated on current

Replacement

configuration helicopters and helicopters so

modified to provide heat reduction in the

(Ref. Figure 3−7)On helicopters with a vented

passenger/cargo compartment. Insulator pads

oil cooler/tank compartment, remove any loose

covered with heat reflective material are

tape and seal all gaps between the mast base

bonded to the helicopter structure inside the

support frame and right side of the plenum

engine compartment on the forward firewall

chamber, and between access covers and

and plenum chamber, on the rear passenger/

supporting structure.

cargo compartment firewall and inside the oil

(1). Tape must overlay metal surfaces by a

cooler/tank access cover. In addition, the oil

minimum of 1 inch (2.54 cm).

cooler/tank area at the Sta. 124.00 bulkhead is

sealed with aluminum foil tape between the

(2). Overlay tape on tape a minimum of 1/4

right mast base support frame and the right

inch (6.35 mm).

side of the plenum chamber. An external air

vent and scoop, located on the right side of the

(3). Tape around junction of frame and

fuselage, provides airflow through the sealed−

firewall must extend a minimum of 1

oil cooler/tank area. A small drain hole is

inch (2.54 cm) on both surfaces.

Page 3-13

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

−191

TYPICAL

CUSHION (RED SIDE)

(NOTE 7)

NOTE 6

INSULATOR

PAD

NOTE 4

−171

0.25 IN. (6.35 MM) OVERLAP

DRIVE SHAFT PORT

AS SHOWN

TRIM AS

−71

SHOWN

−72

−11

−21

−51

−211

−81

−31

−82

−91

−61

−41

−62

−92

TAPE

(NOTE 5)

AFT LANDING GEAR CENTER BEAM

NOTE 2

PIERCE FOR

SCREWS (TYP)

−221

FIREWALL (ENGINE SIDE)

(NOTE 1)

0.25 IN. (6.35 MM)

OVERLAP AS SHOWN

OVERLAP

0.38 IN.

ACCESS COVER

INSULATION INSTALLATION

(9.652 MM)

(TYP BACK SIDE)

369H2008

NOTES:

BOND INSULATOR PADS TO STRUCTURE

WITH ADHESIVE (101, TABLE 2−4).

−181

TAPE EDGES OF THE INSULATOR TO THE

LANDING GEAR CENTER BEAM FITTING

WITH TAPE (61, TABLE 2−4).

APPLY TO PASSENGER/CARGO SIDE OF

PLENUM CHAMBER.

NOTE 3

−161

APPLY TO INSIDE (ENGINE COMPT) OF

PLENUM CHAMBER.

APPLY TAPE (67, TABLE 2−4) TO AFT SIDE

OF ALL THREE ACCESS COVERS. APPLY

−131

TWO LAYERS TO RIGHT COVER ONLY.

−141

−161

−151

DISH−IN INSULATOR FOR DRIVE SHAFT

−111

FLANGE RECESS.

INSULATOR PADS ARE INSTALLED WITH

SILVER REFLECTIVE MATERIAL OUTWARDS

FIREWALL AND PLENUM CHAMBER

AND CUSHION (RED) SIDE AGAINST

(PASSENGER/CARGO SIDE)

STRUCTURE.

(NOTE 1)

30−161

Figure 3-6. Insulation Padding

Page 3-14

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

(4). Tape upper corner at oil cooler duct

(59, Table 2−4). Allow to air−dry a

hose to obtain a minimum flow of air

minimum of 30 minutes. Install a 0.50

through corners.

x 40 inch (1.27 x 101.6 cm) strip of

polyurethane tape (42) to the clean dry

(5). Seal all holes with aluminum foil tape

surface. Apply hand pressure to ensure

(62, Table 2−4).

firm contact and trim as required.

(6). Apply strips of nitrite tape (68) to the

(2). Replace adjustable door hinges as

attaching surfaces of the three access

follows:

covers and trim the tape as shown in

Figure 3−6. Apply a double layer of

(a). Remove door from fuselage structure.

tape to the right access cover. Pierce

the tape at all attachment screw holes.

(b). Remove nut, washer and hinge pivot

screw.

16. Engine Access Doors

(c). Carefully press out the hinge pivot

Current type doors have upper and lower door

point spacer and separate the hinge

hinges that allow door fit adjustment. Fore

halves. Retain the two nylon spacers.

and aft adjustment of the doors is made

Rivets must be carefully drilled

possible by slotted holes in the hinges and

CAUTION

out. Removal by the standard

serrated mating surfaces between the hinges

method of drilling and drift punching could

and doors. Lateral adjustment is obtainable by

result in damage to the internal structure

installing laminated shims under the door

and surrounding material.

hinges. Door alignment during closing is

provided by V−type striker blocks (with or

(d). Drill out rivets that secure the

without shims) or spring−type retainers riveted

defective hinge half to the fuselage

to the door frames next to the lower latch, and

structure.

two locating pins that engage holes in the

lower fuselage structure.

(e). Transfer existing hole pattern in

fuselage structure to replacement

A. Engine Access Door Removal

fuselage hinge half and drill out

holes. Install hinge and shim on

(Ref. Section 2)

fuselage structure and secure with

B. Engine Access Door Inspection

replacement rivets.

(1). Check the door hinges, door attaching

(f). Assemble the hinge halves with

hardware, and latches for looseness,

nylon bushings. Press the steel pivot

cracks and damage.

spacer coated with wet primer (4)

through the mating holes. Install

(2). Check the outside edge of door for

pivot screw with washer and nut.

security of bonding between outer and

inner skin. Any separation requires

(g). Install door and check for alignment.

repair.

NOTE:

Install shims under door hinge to ob−

(3). Inspect doors for corrosion, distortion,

tain a firm fit without binding at door−to fu−

breaks or cracks and condition of

selage contact surfaces when the door is

abrasion strip tape along upper inside

closed. Use slotted holes in hinge and ser−

door edge.

rated surfaces to obtain forward and aft ad−

justment. When adjustments are complete,

C. Engine Access Door Repair

tighten screws that secure hinge to access

door.

(Ref. Figure 3−8) Refer to CSP−H−6 for sheet

metal repair procedures.

(h). Refinish repaired area.

(1). Replace worn abrasion strip tape by

(3). Replace defective catches or latch hooks

cleaning the contact area with naphtha

as follows.

Page 3-16

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

Rivets must be carefully drilled

The window retainers are riveted to the

CAUTION

out. Removal by the standard

fuselage structure. Doubler strips are used

method of drilling and drift punching could

along all riveted edges of the early type

result in damage to the internal structure

window.

and surrounding material.

A. Aft Section Window Repair

(a). Drill out rivets and remove defective

latch or catch from engine access

Refer to FAA AC 43.13−1 for repair of plastics.

door or fuselage structure. Replace

Replace the aft section window if it is damaged

defective stops or serrated adjust−

beyond practical repair, according to applicable

ment plates, if required, by drilling

instructions in CSP−H−6.

out attaching rivets.

18. Canopy and Windshield

(b). Locate existing rivet holes and install

replacement latch, catch, door stop or

The canopy and windshield installation forms

adjustment plate. Secure with

the forward part of the fuselage airframe

replacement rivets.

enclosing the pilot’s compartment. The canopy

has three sections: a lower windshield, a

(c). Adjust latches as required for proper

center windshield and an upper windshield.

tension of latch lever to catch without

Each section consists of symmetrical left and

deflecting the door.

right side panels extending from the wind−

shield centerline to the edges of the pilot’s

(d). Refinish area, except latch lever

compartment door frames and the lower edge

assembly, as required.

of the floor structure. The center and lower

sections are clear cast acrylic. The upper

D. Engine Access Door Fit Adjustment

section is smoke−grey−tinted cast acrylic. Each

(Ref. Figure 3−8) Door alignment is provided

panel has Y−section plastic retainers bonded to

by means of V−type striker blocks or spring−

the edges. These retainers are riveted to the

type retainers riveted in the door frames

canopy frame, the fiberglass canopy ventilat−

adjacent to the lower latch.

ing panel and fuselage structure. Early upper

canopy windshields are of slightly thinner

(1). Remove lockwire from threaded

material than the current type and require the

(adjustment) end of hooks.

addition of stiffeners if the helicopter is to be

flown with doors off in excess of 85 knots (98

(2). Loosen all hooks until strikers engage

mph) unless canopy upper windshield assem−

in light contact with no door deflection

blies 369A2405−3 and −4 are replaced with

when the hooks are latched.

360H2410−3 and −4, 0.080 inch (2.032 mm)

(3). Unlatch the doors and tighten all hooks

minimum thickness. Refer to CSP−H−3 for

four to five turns. Check door latching

modification information.

and make additional minor adjust−

A. Canopy Panel Inspection

ments as required.

(4). Install lockwire (2, Table 2−4) in hook

Minor defects or imperfections that do not

threaded end in a manner to allow

impair pilot’s critical visibility, or that obvious−

latching and unlatching without

ly are not signs of impending structural failure

interference.

may be considered as negligible. Negligible

damage includes:

17. Aft Section Windows

(1). Nicks not more than 0.010 inch (0.254

The aft section window installation consists of

mm) deep and occupying an area not

a left and right transparent window of tinted

larger than 0.250 x 0.50 inch (6.35 12.7

gray cast acrylic or plexiglass in a formed

mm); one only per square foot (929 cm2)

plastic retainer. The early type acrylic window

allowed.

panels are installed without retainers. Each

window extends from the top of the cargo door

(2). Scratches not more than 0.010 inch

to the outboard edge of the engine air inlet

(0.254 mm) deep and 5 inches (12.7 cm)

fairing, and between the canted bulkheads.

long.

Page 3-19

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

UPPER CANOPY WINDSHIELD

(TWO SECTIONS)

STIFFENERS (NOTE 2)

FAIRING TAPE

FUSELAGE AFT SECTION

(NOTE 1)

WINDOWS (BOTH SIDES)

CENTER CANOPY WINDSHIELD

(TWO SECTIONS)

LOWER CANOPY WINDSHIELD

(TWO SECTIONS)

OUTSIDE AIR TEMPERATURE INDICATOR

(NOTE 3)

CABIN VENTILATING

PANEL (FIBERGLASS)

NOTES:

1.. FAIRING TAPE NO LONGER USED IN PRODUCTION. IF REMOVED, REINSTALLATION IS NOT REQUIRED PROVIDED

RETAINERS ARE SEALED TO FRAMEWORK WITH SEALING COMPOUND (3, TABLE 2−4).

STIFFENER MODIFICATION HUGHES NOTICE HN−23 IS REQUIRED FOR DOORS−OFF HIGH SPEED FLIGHT IF UPPER

WINDSHIELDS ARE THE EARLY TYPE, 0.060 IN. (1.524 MM) THICKNESS INSTEAD OF THE THICKER CURRENT TYPE.

EARLY LOCATION SHOWN, SEE SECTION 17 FOR CURRENT CONFIGURATION.

30−019E

Figure 3-9. Canopy and Window Installation

(3). Any surface defect such as minute spots

C. Canopy Frame Replacement

or stains that can be removed by light

(Ref. CSP−H−6)

polishing.

19. Pilot and Cargo Doors

(4). Delamination of doubler or stiffener in

not more than one area within each

The two pilot doors and two cargo doors are

square foot of panel.

bonded aluminum alloy frames containing

large smoke−grey−tinted cast acrylic windows

(5). Crazing around delaminated areas less

in extruded plastic retainers. Early type

than 0.010 inch (0.254 mm) deep.

windows are clear cast acrylic. Plastic snap−

vents are installed in each of the four door

windows, inside strengthening doublers. An

(6). Minor punctures in panels (other than

acrylic stop, bonded to the doubler, prevents

windshields and windows) not exceed−

ing 0.020 inch (0.508 mm) diameter.

normal airflow from pulling the snapvent from

the window during flight. These units may be

rotated in the reinforced window holes for

(7). Minor polarization faults (distortion) in

intake or exhaust of ventilating air and may

small areas of windshield near edges.

be pulled inward for complete closure. Dam−

aged snapvents should be replaced; repair is

B. Canopy Panel Repair

not practical. Current type doors are equipped

with an automatic latching mechanism; early

Refer to FAA AC 43.13−lA for repair of plastics.

type doors have a manual latching mecha−

Replace canopy panel if it is damaged beyond

nism. Two door hinges on each door are

practical repair, according to applicable

provided with quick−removal type ball−lock

instructions in CSP−H−6.

hinge pins. Current type cargo doors are

Page 3-20

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

approximately 4 inches (10 cm) higher than

(b).

Install replacement hinges at body

the early type.

attach points with door hinge pins.

(c).

With damaged hinges removed,

A. Pilot and Cargo Door Removal

install doors in closed position. Have

(Ref. Section 2)

an assistant retain door in place by

actuating door handle locking levers.

B. Pilot and Cargo Door Auto-Latching

(d).

If required for door fit, use one−piece

Operational Check

solid aluminum alloy shim, up to

(1). When opening door, apply light

0.040 inch (1.016 mm) maximum

inward force on the door. This will

thickness trimmed flush with hinge

reduce wear of the latching mecha−

outer edges, under upper or lower

nism by overcoming the door seal

hinge (between hinge and door

pressure.

exterior).

(2). Open door and check for smooth

(e).

Mark hinge rivet attach locations

operation of handles and latch mecha−

through existing holes in door. Locate

nism. Check operation of door stop.

and mark blind rivet attach points

(cargo door only).

(3). Close door from inside. Check all inside

latches for correct engagement at latch

(f).

Remove door hinges and check for

and safelock positions of interior and

proper edge distance.

exterior handle.

(g).

Drill holes with a No. 41 drill at

(4). Check that setting interior and exterior

pilot’s door upper and lower hinge aft

handles to safelock position pulls door

attach points. Use a No. 21 drill at

inward for proper closure and sealing.

all other pilot and cargo door attach

points.

(5). Check that key will lock and unlock

door handle.

(h).

On pilot’s door upper hinge, install

rivets with washer’s under bucked

C. Pilot and Cargo Door Manual-Latching

heads.

Operational Check

(i).

Install rivets at remaining pilot’s

(1). When opening door, apply light inward

door attach points.

force on the door. This will reduce wear

(j).

Install two mechanically expanding

of the latching mechanism by overcom−

rivets at aft cargo door hinge attach

ing the door seal pressure

points.

(2). Open door and check for smooth

(k).

Install four rivets at remaining

operation of handles and latch mecha−

attach points.

nism. Check operation of door stop and

springs (if installed).

(l).

Paint as required.

(3). Close door from inside and check

(m).

Install doors and perform an opera−

latching mechanism on inside of door.

tional check.

Inspect the forward latch lever to

ensure that it is within the detent

(2). Replacement of Pilot’s and Cargo Door

position of the main striker plate.

Hinge and Preload Spring

Visually check he remaining latch

(Ref. Figure 3−13)

levers for correct positioning and snug

fit.

NOTE: Preload spring is used only on current

type door hinge installation.

D. Pilot and Cargo Door Hinge Repair

(a). Remove two cotter pins and clevis

(1). Removal of Door Hinges

pins.

(a). Remove door and drill out hinge

(b). Remove door spring first; then

attaching rivets.

preload spring.

Page 3-21

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

(c). Replace preload spring; with longest

(5). Trim retainer as required to provide

flat area outboard and aft in hinge

clearance for door handle and end butt

body recess.

joint.

(d). Replace door spring; with longest flat

(6). For windows with the flat retainer,

area also outboard and aft in body

clamp replacement in position and drill

hinge recess. Forward curved area of

retainer using holes in door flange as a

door hinge presses against preload

guide. 0.380 inch (9.652 mm) minimum

spring inboard curved area, at

engagement and flush fit with window

installed position.

frame. Trim excess if required.

(e). Install hinge pins and cotter pins.

(7). For windows with the angled retainer,

Pins may be installed upward if

clamp window in position and use a

interference does not permit installa−

hole finder to locator holes in door

tion with cotter pin hole down.

reinforcing frame. Mark the retainer;

then remove window assembly and drill

(f). Cover exposed sharp edges of cotter

retainer.

pins and pins with sealer (60,

Table 2−4).

(8). For sealed Windows with the single leg

type retainer:

(3). Replacement of Pilot’s and Cargo Door

Rubber Stop

(a).

Place window in position and check

for 0.380 inch (9.652 mm) minimum

Replace rubber door stop if damaged or

engagement and flush fit with

partially separated. Remove door stops

window frame. Trim excess if re−

by carefully prying bonded rubber out

quired.

of hinge recess. Bond new stop to

forward end of hinge recess with

adhesive (19).

(b).

Use 3M Company #4508 tape (138),

0.50 inch (12.7 mm) width, to replace

original sponge rubber seal. Bond

E. Pilot and Cargo Door Window Repair

seals to retainer and to door frame

using adhesive (69); bond inside of

(Ref. Figure 3−10) Refer to FAA AC 43.13.1

seals to window using sealant (3). Do

For repair of plastics. Replace window as

not stretch seals when bonding.

follows. refer to FAA AC 43.13−1A. Replace

window as follows:

(c).

With retainer and window in position

on door frame, press down firmly and

(1). Remove snap vent from window.

evenly on retainer so that seals are

compressed tightly against window

(2). Drill out rivets attaching window

around full circumference of door

retainers to door structure and remove

frame.

window. Remove two screws, washers

and nuts from door hinge doubler.

(d).

Using a hole finder, locate existing

holes in door reinforcing frame. Mark

(3). If door frame or window is to be reused,

and drill and drill holes in retainer. It

carefully scrape off sealant around edge

is permissible to install new rivets

of door or window frame using a

wooden, plastic or other suitable

between existing holes in rivet

nonmetallic scraper.

pattern.

(4). Repair retainer−to−window bond, if

(9). Rivets window to door using rivets of

applicable, with dichloromethane (38,

appropriate length Note that blind

Table 2−4) or ethylene chloride (39); or

rivets are used for retainers riveted to

use PS−18 or S147 cement (45).

door reinforcing frame.

Page 3-22

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

FLAT RETAINER

(NOTE 2)

WASHER

WINDOW

(NOTE 7)

(NOTE 4)

NOTE 5

DOOR PANEL

ANGLED RETAINER

RETAINER (SINGLE LEG TYPE)

HINGE

(NOTE 2)

DOOR HINGE DOUBLER

NOTE 5

(NOTE 6)

SEAL

RIVET

DOOR HINGE DOUBLER

(NOTE 8)

(NOTE 9)

(NOTE 6)

WINDOW

(NOTE 4)

NOTE 5

HINGE

DOOR PANEL

WINDOW ENGAGEMENT

DOOR PANEL

HINGE

0.38 IN. (9.652 MM) MIN.

TYPES OF WINDOW ATTACHMENT

BUMPER/DEPRESSOR

FUSELAGE DOOR FRAME

(NOTE 10)

NOTE 10

NOTES: (CONT)

CLEAN PLASTIC SURFACES TO BE BONDED WITH ALIPHATIC NAPTHA (58, TABLE 2−4).

REPAIR WINDOW−TO−RETAINER BOND WITH DICHLOROMETHANE (38) OR ETHYLENE

CHLORIDE (39) OR USE PS−18 OR S147 CEMENT (45).

APPLY A 0.060 IN. (1.524 MM) BEAD OF SEALING COMPOUND (3, TABLE 2−4).

ON THIS TYPE, INSTALL DOUBLER AT HINGE LOCATION WITH TWO SCREWS,

WASHERS AND NUTS.

ON THIS TYPE, INSTALL WASHER UNDER SHOP−FORMED RIVET HEAD AT HINGE

LOCATION.

USE 3M COMPANY #4508 TAPE, 0.50 IN. (12.7 MM) WIDTH, TO REPLACE ORIGINAL SPONGE

RUBBER SEAL. BOND SEALS TO DOOR FRAME WITH ADHESIVE (68, TABLE 2−4).

BOND INSIDE OF SEAL TO WINDOW WITH SEALANT (3). DO NOT STRETCH SEAL

WHEN BONDING.

COMPRESS SEAL EVENLY AROUND DOOR FRAME WITH RETAINER IN PLACE; LOCATE

HOLES, DRILL AND RIVET. NEW RIVETS MAY BE INSTALLED BETWEEN HOLES OF

EXISTING RIVET PATTERN.

10. TWO TYPES ARE IN USE;

BUMPER EXTRUSION IS 0.22 IN. (5.588 MM) HIGH WITH 0.060 IN. (1.524 MM) RADIUS.

DEPRESSOR EXTRUSION IS 0.31 IN. (7.874 MM) HIGH WITH 0.030 IN. (0.762 MM) RADIUS.

30−142−2C

Figure 3-10. Pilot’s Door, Auto-Latching (Sheet 2 of 2)

Page 3-24

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

FORWARD CABLE SEGMENT

FORWARD LATCH

MOUNTING CLIP

LATCH COVER

SECOND LATCH

FUSELAGE DOOR FRAME

LATCH COVER

BUMPER

REAR CABLE SEGMENT

STRIKER PLATE

THIRD LATCH

(NOTES 4, 5)

SHIM, 0.063 IN. (1.6002 MM)

MAX. THICKNESS 2024−T3

LATCH COVER

AL ALY AS REQUIRED

BUMPER

LATCH ROD

CURRENT TYPE

FOURTH LATCH

LATCH COVER

4 PLCS

BUMPER/DEPRESSOR

(NOTE 6)

EARLY TYPE

EXTRUDED SEAL FILLER

NOTE 6

FUSELAGE DOOR FRAME

(NOTE 1)

FUSELAGE

BUMPER

DOOR FRAME

NOTE 2

STRIKER PLATE

ANTI−CHAFE TAPE

EXTRUDED SEAL FILLER

(NOTE 1)

NOTES:

FORMED ANGLE SEAL FILLER USED FOR SEALING AS REQUIRED WHEN

STRIKER BASE PLATE

STRIKER PLATE AND BUMPER EDGES ALIGN WITHIN 0.060 IN. (1.524 MM)

FORMED ANGLE SEAL FILLER

EXTRUDED SEAL FILLER USED WHEN EDGE MISALIGNMENT EXCEEDS

(NOTE 1)

0.060 IN. (1.524 MM) OR AS REQUIRED WHEN SHIMMING OR ADJUSTING

AUTOMATIC LATCHING.

LAMINATED SHIM

BEVEL EXTRUDED SEAL FILLER EXTERIOR CORNERS SO THAT MATING FILLER AND

(NOTE 3)

BUMPER EDGES ARE EVEN, REMOVING MATERIAL INDICATED, AT INSTALLATION.

SHIM AS REQUIRED TO A MAXIMUM 0.187 IN. (4.7498 MM) SHIM THICKNESS.

SEAL ALL GAPS BETWEEN BUMPERS, FILLERS AND STRIKER PLATE CORNER JOINTS,

AND ALL OUTER EDGES, USING SEALANT (3, TABLE 2−4) TO HEIGHT OF BUMPER.

STRIKER MAY BE SHIMMED IF REQUIRED. BOND STRIKER (AND SHIMS) TO DOOR FRAME

USING ADHESIVE (19) ACCORDING TO CONTAINER INSTRUCTIONS.

TWO TYPES ARE IN USE:

BUMPER EXTRUSION IS 0.22 IN. (5.588 MM) HIGH WITH 0.060 IN. (1.524 MM) RADIUS.

DEPRESSOR EXTRUSION IS 0.31 IN. (7.874 MM) HIGH WITH 0.030 IN. (0.762 MM) RADIUS.

30−143−1A

Figure 3-12. Cargo Door, Auto-Latching (Sheet 1 of 2)

Page 3-26

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

NOTES: (CONT)

REFER TO TEXT FOR CABLE LENGTH AND FOR SPRING PRELOAD ADJUSTMENTS.

INSTALL OUTBOARD TO ELIMINATE POSSIBILITY OF INTERFERENCE.

BEND ONE TANG OVER NUT AND OPPOSITE TANG OVER CLEVIS END AT

REASSEMBLY, AFTER CABLE LENGTH ADJUSTMENT.

10.

INSTALL, IF REQUIRED, FOR LATCH ADJUSTMENT.

CABLE MOUNTING

11.

SPACER REQUIRED ON CURRENT LOCKS WHICH ARE LONGER THAN EARLY

CLIP

MODEL CAM LOCK.

CABLE SPRING WASHER

COMPRESSION SPRING

PRELOAD

MEASUREMENT

CABLE SPRING WASHER

(NOTE 7)

SPACER

NUT

TAB WASHER

(NOTE 9)

PANEL DOOR

NOTE 8

CLEVIS

(NOTE 7)

SHIM WASHER

(NOTE 10)

ACTUATOR SLIDER

LATCH BLOCK ASSY

LOCK PLATE ASSY (CALLED

NUTPLATE AT OTHER LOCATIONS)

PLAIN WASHER

RETAINING RING

HANDLE

LINK ASSY

WASHER

RETAINING

ESCUTCHEON

SPINDLE

RING LOCK

INSIDE HANDLE ARM ASSY

WASHER

BOSS

SPINDLE

TUBING

SPRING

HOOK

INSIDE HANDLE GRIP

NOTCH

HANDLE TORSION

SET SCREW

SPRING

LATCH ROD END

OUTSIDE

HANDLE

SPACER

CAM

(NOTE 11)

(KEY OPERATED LOCK)

30−143−2F

Figure 3-12. Cargo Door, Auto-Latching (Sheet 2 of 2)

Page 3-27

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

CLEVIS PIN

LATCH STRIKER PLATE

DOOR STRUCTURE

OVERCENTER POINT

LATCH CABLE ASSY

BUSHING

LATCH LEVER

FUSELAGE STRUCTURE

0.00−0.20 IN.

(0.00−5.08 MM)

BUSHING

GAP

SPRING PIN

FORWARD LATCH

LATCH AND STRIKER ENGAGEMENT

PLASTIC WINDOW

FORWARD CABLE SEGMENT

2ND LATCH

SNAPVENT

2ND CABLE SEGMENT

3RD CABLE SEGMENT

4TH LATCH

DRAIN HOLE

FUSELAGE SEAL

DOOR SEAL

SOFT RIVET

NUTPLATE

DOOR STRUCTURE

WINDOW

COVER CLIP

(NOTE 2)

RETAINER

SEAL

LATCH CABLE ASSY

CABLE CLAMP

SHIM

(6 PLCS)

NOTES:

(NOTE 1)

ONE ONLY ON DOOR AT LOCATION C

BLIND RIVET

(EARLY DOOR ONLY).

INTERIOR TRIM COVERS NOT SHOWN.

(TYPICAL)

30−047−1C

Figure 3-13. Cargo Door, Manual Latching (Sheet 1 of 2)

Page 3-28

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

FUSELAGE STRUCTURE

CLEVIS PIN

SHIM (AS REQD)

(NOTE 3)

(NOTE 6)

HINGE PIN

PRELOAD SPRING

(NOTE 4)

COTTER PIN

STOP

DOOR SPRING

SPRING PIN

OUTSIDE LATCH HANDLE

BUSHING

(NOTE 7)

DOOR HINGE

HALF

DOOR STRUCTURE

DOOR HINGE

DOOR STRUCTURE

(TYP 2 PLCS)

LATCH CABLE ASSEMBLY

BUSHING

ROD END

BUSHING

LATCH LEVER

INSIDE LATCH HANDLE

SPRING PIN

3RD LATCH AND HANDLE

CARGO DOOR FRAME

SEAL, BUMPER OR DEPRESSOR

(NOTE 5)

NOTES: (CONT)

SEAL BOTH ENDS WITH SEALANT (59, TABLE 2−4)

AT INSTALLATION.

ANTI−CHAFING TAPE

CURRENT DOOR HINGES ONLY.

(TYPICAL)

THREE TYPES ARE IN USE:

A. RUBBER SEAL.

B. BUMPER EXTRUSION 0.22 IN. (5.588 MM) HIGH WITH

0.060 IN. (1.524 MM) RADIUS.

C. DEPRESSOR EXTRUSION 0.31 IN. (7.874 MM) HIGH

WITH 0.030 IN. (0.762 MM) RADIUS.

MAXIMUM 0.040 IN. (1.016 MM) SHIM IF REQUIRED FOR

(NOTES 5B, 5C)

DOOR FIT. ONE−PIECE ALUMINUM ALLOY SHIM TRIMMED

FLUSH WITH HINGE HALF OUTER EDGES.

BUSHING NOT USED ON STEEL DOOR HINGES.

30−047−2D

Figure 3-13. Cargo Door, Manual Latching (Sheet 2 of 2)

Page 3-29

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

(10). Spread a 0.060 inch (1.524 mm) bead of

(c). Apply local pressure to insure

sealant compound (3) around exterior

complete contact between adherents

edge of window and door flange (except

and maintain pressure for a mini−

sealed windows with single leg retain−

mum of 30 seconds.

er) frame.

(6). Remove masking tape and remove

residue with aliphatic naphtha.

(11). On doors originally equipped with

doubler, install doubler over retainer at

G. Window Snapvent Replacement

hinge area with two screws, washers,

and nuts. Drill (No. 21 drill) and ream

(1). Removal of Window Snapvent

(0.166 inch (4.2164 mm) diameter)

Push snapvent outward in window

window panel for screws, using slow

(open position). Grasp open side of

speed drill (700 to 800 rpm).

snapvent and gently squeeze it into an

(12). Install snapvent.

elliptical shape. Slip snapvent out of

window hole at about a 30 degree angle

(13). Remove protective covering and clean

to surface of window.

window.

(2). Installation of Window Snapvent

F. Geon Strip Repair

Grasp open end of snapvent and gently

squeeze it into an elliptical shape. Slip

Fill voids between geon strips and transparen−

snapvent flange into window hole at an

cies as follows.

angle of about 30 degrees to window

surface. Be sure that ends of wire

(1). Measure the insertion depth of acrylic

stiffener are inside window hole.

windshield into geon slot, reject parts

having less than 0.125 inch (3.175 mm)

20. Door Latching Mechanism

insertion. Replace parts with debonding

areas over 8 inches (20 cm) in length.

Current type door latching mechanisms

automatically latches the door when the door

(2). Mask the geon weather strip and

are closed. Early type door latching mecha−

windshield on both sides with 3M

nisms are manually actuated. The automatic

polyethylene masking tape (132,

door latching mechanism (Ref. Figure 3−10),

Table 2−4).

installed within the door panel, consist of four

latching blocks that house spring−loaded latch

(3). Wipe all faying surfaces with aliphatic

bolts and safelock bolts together with actuator

naphtha (59) and air dray for a mini−

sliders. The latch sliders are interconnected by

mum of 15 minutes.

cables and connectors and are moved by

turning the inside or an outside door handle.

(4). For small voids.

The system allows the door to be closed and

safelocked from inside or outside. The handle

(a). Apply cyanoacrylic adhesive (133) to

contains a key−operated cam lock, actuated

all fraying surfaces using syringe if

from outside. Moving the inside handle to the

necessary.

open position will overrides the cam lock and

allow the door to be opened. Movement of

(b). Use light pressure to hold the joint

either handle into safelock position is pre−

closed for a minimum of 2 minutes.

vented until the door is closed and the safelock

bolts are actuated by strikes. This actuation

(5). For large voids, Hysol Super Drop

causes the safelock bolts to clear notches on

Accelerator (134) may be used.

actuator sliders, allowing the sliders and

(a). Apply accelerator to the acrylic

linkage to move into safelock position. The

transparency and air dry for a

pilot’s and cargo door auto−latching mecha−

minimum of 2 minutes.

nisms are essentially the same except for

length of interconnecting cables. The manual

(b). Apply 3CI−1000 adhesive to the geon

door latching mechanism (Ref. Figure 3−11)

weatherstrip only.

consists of four lever type latches and three

Page 3-30

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

lengths of wire−reinforced cable within

(a).

Lubricate all moving parts except

aluminum housing.

lock, with grease (57, Table 2−4) to

prevent binding.

A. Door Latching Mechanism Inspection

and Repair

(b).

Lubricate lock with powdered

graphite (111).

(1). Inspection

(c).

At time of disassembly clean reusable

As applicable to type of installation,

parts except locks, using soft bristle

check the following under magnification

brush dipped in solvent (1). Dry

and strong light:

parts, using clean, lint−free cloth or

dry compressed air at 20 psi (138

(a).

All parts for excessive wear, nicks,

kPa) maximum.

cracks and corrosion.

(d).

Clean key−operated cam locks, using

(b).

Threaded parts for worn, crossed or

dry compressed air at 20 psi (138

otherwise damaged threads.

kPa) maximum.

(c).

Latch block assemblies for broken

(e).

Touch up handles with semigloss

springs and wear on strike contact

black acrylic lacquer (6).

surfaces of latching bolts; and for

undue wear of latch sliders, bolts and

(f).

Eliminate binding by lubricating

bolt rollers.

moving parts, Eliminate persistent

binding in the cables by bending the

(d).

Retaining rings for distortion.

conduits, taking care not to dent or

crease them.

(e).

Cam lock for jamming when key is

operated.

NOTE: Cables are bonded to clamps that are

riveted to the structure. If removal is neces−

(f).

Link assembly for wear or distortion.

sary, rivets must be drilled out.

(g).

Handles for distortion, worn pivot

B. Pilot and Cargo Door Automatic Latch

holes and worn finish.

Replacement

(h).

Escutcheon and handle for dents,

(1).

Perform this procedure with the door in

distortion, or worn finish.

the open position. Handles will be at

(i).

Lock plate assembly for wear,

the latched rest position (Ref.

distortion, thread damage and

Figure 3−1 1).

breakage.

(2).

Remove screws securing cover (Ref.

(j).

Latch block nutplates for thread

Figure 3−12) on door and remove cover.

damage and loose rivets.

(3).

Mark the lock plate so that replacement

(k).

Cables and connector for wear in

latch block can be installed at approxi−

clevis pin holes, thread damage,

mately the same position as the latch

distortion or loose clamps. holes,

that is to be removed.

thread damage, and distortion.

(4).

Remove four screws and washers

(2). Repair

securing latch block to lock plate. Make

note of any washers found between the

Replace worn or damaged parts as

latch block and lock plate. These are

necessary. Disassemble only to extent

adjustment shims and should be

required for replacement of parts. Refer

reinstalled in the same position during

to Figure 3−12 for an exploded view

latch installation.

showing disassembly relationship for

the auto−latching door mechanism, or

(5).

Remove cotter pin, washer and pin

Figure 3−13 for the manually actuated

securing rod or cable end clevis to top of

door latching mechanism. Also perform

latch block. Remove latch block from

following steps as required:

door.

Page 3-31

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

NOTE: The latch rod end below the inside han−

(a). Adjust the door inboard or outboard

dle arm is detached by removing the cotter

by moving the striker plates in their

pin and washer from the latch block link

slotted mounting holes or by the

that attaches rod end to inside handle.

removal or addition of shim washers

Latch movement may be required to disen−

under the latch assemblies.

gage link pin from handle and clevis from

latch block.

(b). Adjust the depth of engagement of

the latch bolts with the striker plates

(6). Install replacement latch block by

by moving the latch assemblies in

performing applicable latch removal

their slotted mounting holes or by

procedures inverse order. Replacement

the removal or addition of shims

latch should be installed at approxi−

under the striker plates.

mate same position from which old

latch was removed.

NOTE: Current type striker plates are also

bonded to door frame structure. If loosening

NOTE: When reconnecting latch rod end or

or removal of these plates is required, clean

cable clevis, the washer and cotter pin

the mating surfaces with naphtha (59,

should be installed outboard to eliminate

Table

2−4) andrebond with adhesive (19)

possibility of interference.

after correct striker plate position is deter−

mined.

(7). Adjust latch engagement and be sure

door closes and seals correctly.

(4). Adjust latch cables and rod for simulta−

C. Pilot and Cargo Door Automatic Latch

neous latch bolt extension and complete

Adjustment

safe−locking as follows.

(Ref. Figure 3−10, Figure 3−12 and

NOTE: Complete safe−locking is that point at

Figure 3−14)

which latch bolt extension is at maximum

and the roller on the safelock trigger is en−

(1). Make a preliminary check of door

gaged in the safelock slot in the latch slide

latching as follows.

(Ref. Figure 3−14). In this position the safe−

lock trigger can be observed to retract when

(a). Pull the door closed from inside. Each

the latch slide is moved slightly in unlatch

of the latch bolts should make

direction.

contact with their respective striker

plates at the same time and latch

(a). With the door in the open position or

evenly. Unequal striking and latching

removed from the helicopter, actuate

indicates that latch assembly or

the latches to safelocked position.

striker plate positions should be

adjusted.

NOTE: With the door open or removed it is nec−

essary to depress all safelock triggers at the

(b). Safelock the door and observe that

same time in order to rotate the latch han−

the door is forced inward for seal

dle to safelock position.

compression at each latch position.

Check that a minimum of 0.125 inch

(b). Remove the clevis pin from the cable

(3.175 mm) of the flat surface (be−

or latch rod of the latch being ad−

yond the angled leading edge) of each

justed. Move the latch slide manually

latch bolt is engaged with the face of

to the complete safelock position and

the striker plate. Unequal safe−lock−

then adjust the cable or latch rod

ing may indicate that the latch

length so that clevis pin can be

cables are not properly adjusted for

reinstalled easily.

complete extension of the latch bolts.

NOTE: The fourth and the forward latches can

(2). Remove the four latch covers.

be individually adjusted without disturbing

(3). Adjust the positions of the latch

the adjustment of the other latches. Howev−

assemblies and/or striker plates as

er, if the second or third latches are adjusted

required, using the following methods.

then all should be checked.

Page 3-32

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

CHANNEL STRIP

INSIDE HANDLE UNLATCHED

ACTION POSITION

INSIDE HANDLE

OUTSIDE HANDLE SAFELOCK

ACTION POSITION

TUBING

OUTSIDE HANDLE

SAFELOCKED POSITION

INSIDE HANDLE LATCHED

STRUCTURAL DOOR FRAME

REST POSITION

(NOTE 3)

LATCH COVER

OUTSIDE HANDLE LATCHED REST POSITION

(NOTE 3)

INSIDE HANDLE

DOOR PANEL

SAFELOCKED POSITION

OUTSIDE HANDLE UNLATCHED

ACTION POSITION

HANDLE POSITIONS

(RIGHT DOOR INSIDE VIEW)

SAFELOCK

ACTION

LATCH CABLE

LATCH SLIDE

BUMPER

DOOR FRAME

SAFELOCK SLOT

SAFELOCK TRIGGER

SAFELOCK ROLLER

LATCH BOLT

STRIKER PLATE

LATCH BOLT ROLLER

(NOTE 1)

0.88 IN. (22.352 MM)

INSIDE HANDLE

UNLATCHED ACTION

NOTE 2

NOTES:

LATCH ENGAGEMENT

CURRENT TYPE STRIKER PLATE SHOWN.

(THIRD LATCH INTERIOR

WHEN LATCH IS COMPLETELY SAFELOCKED, A MINIMUM OF 0.125 IN.

SHOWN FOR CLARITY)

(3.175 MM) OF FLAT SURFACE (BEYOND ANGLED LEADING EDGE) OF

LATCH BOLT MUST BE ENGAGED WITH STRIKER PLATE.

LATCHED REST POSITION APPLIES WITH DOOR OPEN OR CLOSED.

30−144E

Figure 3-14. Latch Engagement for Auto-Latching Door Handle Positions

Page 3-33

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

(c). For complete rigging of all latches,

(f). Reinstall all parts and be sure that

remove clevis pins from all cable and

clevis is engage to the same of

latch rod connections and move all

number of turns as recorded in Step

latch slides to the complete safelock

(b). above.

position. Adjust cable and latch rod

(6). Tighten all clevis retaining nuts and

length for easy installation of clevis

bend tangs of tab washer, one over the

pins. Start with the third latch and

clevis and one over the nut, for safety.

proceed to the second, to the forward

and then to the fourth.

(7). Install washers and cotter pins in all

clevis pins. Washers and cotter pins are

(5). Latch compression spring preload

to be installed on the outboard side to

adjustment should be checked if a

preclude interference with door struc−

change has occurred to affect spring

ture.

preload. Replacement of parts in the

(8). Make a final check of door latching,

stack−up between the upper clevis pin

safe−locking and key−locking. Install

on the third latch and the first cable

the latch covers.

mounting clip (Ref. Figure 3−12) or a

change in position of the cable mount−

(9). Fill in gaps and fair−in the area be−

ing clip is cause for preload adjustment.

tween latch striker plates and bumper

strips at each position, using sealant

(a).

With the main (third) latch in

(3).

safe−locked position measure the

D. Pilot and Cargo Door Manual Latch

distance from the center of the upper

Adjustment

clevis pin to the shoulder of the cable

mounting clip. Add 0.060−0.080 inch

(Ref. Figure 3−11 and Figure 3−13)

(1.524−2.032 mm) to this measure−

ment and record. This is the required

(1). With the door in the open position,

parts stack−up length.

rotate the latch handle to the locked

position.

(b).

Remove clevis and the complete stack

(2). Check all latch levers. The levers

up of parts from the third latch to the

should be positioned at approximately

cable mounting clip. Note and record

90 degrees to the straight door edge

the number of turns required to

and in line with the radius of the

remove clevis so that it can be

curved door edges.

returned to original position without

further adjustment.

(3). Remove nuts, washers and bolts at the

adjustable rod end on each cable

segment.

(c).

Assemble the stack−up with all parts

in contact and the spring in relaxed

(4). Turn adjustable rod ends and change

condition. Measure from the center of

cable length as required to properly

the clevis pin hole to the outer edge

position latch levers with bolt installed

of the last washer and record.

in Step (2).

NOTE: A change in the length of one cable seg−

(d).

Compare this last measurement,

ment can affect the position of all the latch

Step (c)., with the required stack−up

levers. Therefore, start adjustment at the

length recorded in Step (a). above.

forward cable segment and work progres−

Record the amount to be added or

sively to second: then third segments while

subtracted.

maintaining adjusted latch position.

(e).

Adjust stack−up length by the

(5). Close and latch the door. Check that

amount recorded in Step (c). by using

the latch levers rotate past the over−

a longer or shorter spacer and by

center point on striker plates and are in

grinding and filing the spacer as

the position shown in detail B of

required.

Figure 3−13.

Page 3-34

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

(6). Open the door and make adjustment of

(d). Loosen latch block mounting screws

cable rod ends as necessary to meet

far enough to allow raising of latch

requirements of Step (5).

block to disengage link pin from latch

rod end and handle arm. If required,

(7). Check that bushings are installed in

remove the four latch block mounting

latch levers. Install bolts, washers and

screws.

nuts.

NOTE: Marking the location of the latch block

E. Pilot and Cargo Door Auto-Latching

on the lock plate inside the door panel aids

Handle Replacement

reattachment at approximate same posi−

tion.

(1). Replacement of Outside Handle.

(e). Note position of the lock boss and

(a). Open the door.

handle torsion spring to aid reinstal−

lation.

(b). Remove three screws and washers

securing handle escutcheon to door

(f). Remove retaining ring and spindle

exterior. Drive spring pin (if in−

washer securing spindle to the lock

stalled) from handle and slide handle

plate.

from spindle (Ref. Figure 3−12).

(c). Remove escutcheon from handle by

(g). Hold handle, lock boss and torsion

removing retaining ring and handle

spring in position and withdraw

washers.

spindle. Then slide handle, lock boss

and torsion spring out of the lock

(d). Attach replacement handle to

plate. Use care to avoid dropping

escutcheon with handle washers and

parts into the door channel cavity.

retaining ring. Use the maximum

number of handle washers possible

(h). Disassemble handle grip from handle

without impeding free movement

arm by loosening setscrew and

between the handle and the escutch−

sliding grip from arm.

eon.

NOTE: Current cam lock is longer than early

(e). Slide handle on spindle and secure

model cam lock and requires a spacer be−

escutcheon to door with washers and

tween lock flange and outside surface of

screws.

door skin.

NOTE: Spring pin NAS561P4−16 may be

(i). As required, replace key−operated

installed for additional security of handle

cam lock by unscrewing hexagonal

attachment: line drill through exterior door

nut.

handle and door latch shaft (spindle), then

install pin through handle and shaft. Be

NOTE: When the lock is in the locked position,

sure that handles are horizontal when

be sure that the cam has actuated the

mechanism is in the safe−lock position.

hinged lock bar. When lock is in correct posi−

tion, lock it in place by center punching sur−

(2). Replacement of Inside Handle or Cam

face of lock plate assembly close to flat on

Lock.

hexagonal locking nut.

(a). Open the door.

(j). Holding lock boss, torsion spring and

(b). Remove outside handle (Step (1).) but

replacement handle together, slide

do not disassemble escutcheon from

the assembly into position and insert

spindle.

handle.

(c). Remove cotter pin and washer from

(k). Install spindle washer and retaining

link assembly pin connecting latch

ring to secure the spindle in the lock

rod end to link and handle arm.

plate.

Page 3-35

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

(l). Attach one spring hook to ear of lock

check for gaps between window glass,

boss (or in hole of current type boss)

rubber seal and door structure.

and attach the other spring hook at

notch in the lock plate. Use safety−

(6). Replace seal and/or use shorter length

wire to pull the spring hook into

studs to close any gaps. Use longer

plate.

length studs if seal is extruded.

(m). Reconnect link and latch rod end to

22. Pilot and Cargo Door Seal Compression

handle arm with cotter pin and

Check

washer.

Inspect the rubber weather−strip compression

NOTE: Cotter pin and washer should be in−

seal for tight compression between the door

stalled on outboard side of latch rod end to

and frame as follows.

eliminate possibility of interference. Use ex−

tra washers for shimming to eliminate ex−

(1). Open door.

cess play.

(2). Hold a strip of heavy paper against the

door seal so that the strip extends

(n). Secure latch block to lock plate at

approximately 1/4 inch (6.35 mm)

original marked position with four

beyond the seal toward the outside of

screws and washers.

the doorway.

(o). Install outside handle (Step (1).).

(3). While holding the paper strip in place,

close and lock the door.

(p). Check door latching and safe−locking

operation and make any adjustments

(4). Attempt to pull the paper strip from

necessary.

between the door frame and the seal.

The strip should not pull out unless a

21. 369H90085 Litter Door Installation

moderately heavy pull is exerted.

Inspection

NOTE: Correct fit is indicated by an approxi−

mate 0.060 inch (1.524 mm) interference fit

(1).

Visually inspect installation to ensure

between door seal and bumper. Where the

proper condition and security of the

strip can be withdrawn with a light pull, the

quick−release fastener assemblies and

fit of the door against the frame is not suffi−

the rubber seal (gasket) installed

ciently tight to provide an adequate seal.

between the window glass and door

This condition be due to deterioration of the

frame.

weatherstrip compassion seal, deformation

of the door frame, worn hinges or improper

(2).

Remove quick−release fasteners

latching.

securing windows to litter doors and

inspect each fastener for condition and

(5). Repeat steps (1). thru (4). at approxi−

each anchor receptacle in door structure

mately 1 foot (30 cm) increments along

for condition and security of attach−

the length of the door seal.

ment.

A. Pilot and Cargo Door Seal Replacement

(3).

Replace fastener if stud is loose or

worn; replace anchor receptacle and/or

(1). Carefully pull or scrape away damaged

rivets as required.

seal.

(4).

Rebond rubber seal to door structure if

(2). Restore chemical film protection to any

it is not fully intact. Replace seal if it is

base metal exposed during cleaning

worn, cracked or hard.

process.

(5).

Reinstall window assemblies to litter

(3). Clean the seal contact area on metal

doors with quick−release fasteners, then

and rubber seal.

Page

3-36

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

UPPER LATCHES

3.50 IN. (8.89 CM)

8.00 IN. (20.32 CM)

8.00 IN.

BLEND FROM 0.12 IN (3.048 MM)

(20.32 CM)

0.12 IN. 3.048 MM)

DIMENSION TO EDGE OF DOOR

(2 PLCS)

SEAL

PILOT’S DOOR

(LEFT SHOWN)

0.12 IN. 3.048 MM)

0.30 IN.

0.762 MM)

8.00 IN.

0.12 IN.

(20.32 CM)

(3.048 MM)

SEAL

(FLUSH WITH EDGE OF

DOOR AT BOTTOM)

0.35 IN.

0.12 IN.

(8.89 MM)

(3.048 MM)

CARGO DOOR

(LEFT SHOWN)

NOTE 1

FINGER−TYPE

SEAL

SECTION

A−A

0.12 IN.

DOOR REINFORCING

(3.048 MM)

FRAME

0.30 IN.

SEAL

0.762 MM)

NOTE 1

(FLUSH WITH EDGE

OF DOOR AT BOTTOM)

SECTION B−B

(BOTTOM SEAL FINGERS DOWNWARD;

PILOT’S DOORS ONLY)

NOTES:

DO NOT LOCATE SEAL ON RADIUS OF REINFORCING FRAME.

INSTALL SEAL USING ADHESIVE (68, TABLE 2−4) ACCORDING TO

CONTAINER INSTRUCTIONS.

30−168A

Figure 3-15. Door Seal Installation, Current Type

Page 3-37

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

NOTE: The bulb−type seal is installed on the

23. Improved Door Seal Installation

door reinforcing frame with the bulb radius

The following procedure is for installation of

and frame radius coincident

(Ref.

QGR2178 door seals on the cargo/passenger

Figure 3−13) . The finger−type seal is in−

doors.

stalled on the flat door flange at the outer

edge of the reinforcing frame radius. Refer

(1). Remove existing door seals using

to Figure 3−15 for proper location and in−

Desoclean 45 (183, Table 2−4) or

stallation.

naphtha aliphatic (59). Ensure that all

surfaces are clean to allow proper

(4). Carefully align and bond to mounting

adhesion of new seal material. Allow

surface with adhesive (69, Table 2−4)

surface to air−dry a minimum of 15

according to container instructions.

minutes.

NOTE: Seals are to be installed around the

NOTE: Correct seal mounting position results

entire circumference of the aft doors.

in an approximately 0.060 inch (1.524 mm)

interference fit between door seal and bum−

(2).

Prime seal faying surface with red

per.

silicone primer and allow to air−dry a

minimum of 15 minutes.

B. Partially Separated Pilot and Cargo Door

(3).

Apply a thin uniform coat of cyanoa−

Seal Repair

crylic adhesive (133) to faying surface of

door and seal. Allow to air−dry a

(1). Clean the separated area with naphtha

minimum of five minutes.

(59, Table 2−4) and allow to dry for a

(4).

Apply a second thin uniform coat of

minimum of 20 minutes.

cyanoacrylic adhesive to faying surface

of door and seal. Allow to air−dry a

(2). Thoroughly stir adhesive (69).

minimum of five minutes.

(5).

Test glue with clean knuckle. If adhe−

(3). Apply one uniform brush coat of

sive does not transfer to knuckle, press

adhesive to both the rubber seal and

the seal into place.

mating surface contact area. Allow to

dry for 5 minutes and press mating

(6).

Butt joints at forward and aft lower

surfaces together.

locations.

(7).

Maximum gap of 0.030 inch (0.762 mm)

C. Pilot and Cargo Door Frame Anti-Chafing

at butt joints.

Tape Repair

(8).

Miter joints at upper locations.

Inspect the condition of the anti−chafing tape

(9).

Bond mitered joints with adhesive

installed on the pilot’s and cargo compartment

(184).

door frames. For minor repair,remove defective

tape where necessary. Clean frame surface

NOTE: Use glue very sparingly to achieve best

with methyl −ethyl−ketone (22, Table 2−4).

bond.

Replace with polyurethane pressure sensitive

tape (42).

(10). Trim seal flush with edge of door.

Page 3-38

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

Section 4 Furnishings .

4−1

Furnishings

4−1

A. General Description of S / E Differences

4−1

Crew Compartment Seats

4−1

A. Crew Compartment Seat Replacement

4−1

B. Passenger Compartment Seats

4−1

C. Passenger Compartment Seat Replacement

4−1

D. Seat Inspection

4−1

Figure 4−1. Seat Installation − Typical (Sheet 1 of 2)

4−2

Figure 4−2. Early Configuration Seat Belt and Shoulder Harnesses .

4−4

E. Seat Repair

4−5

Seat Belts and Shoulder Harnesses

4−5

A. Seat Belt and Shoulder Harness Replacement

4−5

B. Seat Belt and Shoulder Harness Inspection

4−5

C. Seat Belt Load Testing

4−5

D. Seat Belt and Shoulder Harness Repair

4−5

Interior Trim

4−5

A. Crew Compartment Interior Trim Removal

4−6

B. Crew Compartment Interior Trim Installation

4−6

C. Passenger Compartment Interior Trim Removal

4−6

D. Passenger Compartment Interior Trim Installation

4−6

Figure 4−3. Crew Compartment Interior Trim and Covers (Sheet 1 of

3) .

4−7

E. Interior Trim Inspection

4−10

F. Interior Trim Repair

4−10

Control Covers

4−10

A. Control Covers Removal

4−10

B. Control Covers Installation

4−10

C. Control Covers Inspection

4−10

D. Control Covers Repair

4−10

Figure 4−4. Passenger Compartment Interior Trim and Covers

(Sheet 1 of 3)

4−11

Boltaron Trim Panel Repair

4−14

A. Fiberglass Patch Method

4−14

B. Solvent Bonding Patch Method

4−14

Figure 4−5. Boltaron Panel Repair

4−15

C. Epoxy Adhesive Patch Method

4−16

D. Bond and Rivet Patch Method

4−16

Page 4−i

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

TABLE OF CONTENTS (Cont.)

Para/Figure/Table

Title

Page

E. Main Transmission/Engine Drive Shaft Access Door Assembly .

4−17

F. Main Transmission/Engine Drive Shaft Access Door Assembly Seal

Replacement

4−17

Crew Compartment Floor Trim

4−17

Passenger Compartment Floor Trim

4−17

A. Passenger Compartment Floor Trim Removal

4−17

B. Passenger Compartment Floor Trim Installation

4−17

C. Floor Trim Inspection

4−17

D. Floor Trim Repair

4−17

Figure 4−6. Main Transmission/Engine Drive Shaft Access Door Assembly

4−18

Miscellaneous Furnishings

4−18

A. Stowage Compartment Box

4−18

B. Stowage Compartment Box Replacement

4−18

C. Stowage Compartment Box Repair

4−18

Figure 4−7. Crew and Passenger Compartment Floor Trim .

4−19

D. Cargo Tiedown Fittings

4−20

E. Cargo Tiedown Fitting Inspection

4−20

F. Pilot’s Compartment Canopy Frame Trim and VNE Card Cover .

4−20

G. Helicopter Checklist

4−20

H. VNE Card and Holder (Bracket Mounted)

4−20

Magnetic Compass Card

4−20

J. Operation Record Holder

4−20

K. Heat Duct and VNE Card Cover

4−20

L. Heat Duct and VNE Card Cover Replacement

4−20

M. Heat Duct and VNE Card Cover Removal

4−20

N. Heat Duct and VNE Card Cover Installation

4−21

O. Heat Duct and VNE Card Cover Inspection

4−21

P. Heat Duct and VNE Card Cover Repair

4−21

Q. Ashtrays

4−21

R. Passenger Compartment Upper Convenience Panel (Without Trim) .

4−21

S. Passenger Compartment Upper Convenience Panel (Standard Trim) .

4−21

T. Folding Table Assembly (Executive Trim)

4−21

Figure 4−8. Basic Helicopter Furnishings

4−22

U. Passenger Compartment Lower Convenience Panel (Executive Trim) .

4−23

V. Passenger Compartment Upper Convenience Panel (Executive Trim) .

4−23

W. Pilot’s Compartment Footrest

4−23

X. Pilot’s Compartment Footrest Replacement

4−23

Page 4−ii

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

SECTION 4

FURNISHINGS

1. Furnishings

B. Passenger Compartment Seats

The MDHI Model 369HS (500S) Helicopter is

The passenger/cargo compartment contains

the standard configuration of the Model 369H

two single or a bench type seat for accommo−

Helicopter Series, manufactured by Hughes

dating two passengers.

Helicopter, now MD Helicopters, Inc. The

Model 369HE (500E) is an executive configura−

The seat consists of a tubular structure that

tion, Model 369HS (500S) is a standard

supports a cushioned and upholstered seat

configuration. The 500S and 500E differ from

bottom and seat backrest or optional nylon

other Series 500 Helicopters primarily as

mesh seat without cushions.

described below.

Seat cushions with standard trim are uphol−

A. General Description of S / E Differences

stered and trimmed with vinyl.

Except for interior trim upholstery and floor

Seats with executive trim are upholstered and

coverings, equipment furnishings, paint finish

trimmed with leather.

and the other details described in this section,

the 369S and 369E are essentially identical to

The seat cushion and backrest can be de−

the basic helicopter configuration. Normally,

tached. The seats can be folded to provide

the 369S has the standard trim package and

additional room in the cargo compartment and

the 369E has the executive trim package.

are easily removable from the floor and

Furnishing variations between models include

bulkhead attach points by quick−disconnect

a passenger/cargo compartment folding table,

fittings on the seat tubular structure. The

passenger steps, and different ashtray

later configuration seat structure incorporates

locations and passenger/cargo convenience

an adjustable feature at the seat structure leg.

panels.

C. Passenger Compartment Seat

2. Crew Compartment Seats

Replacement

(Ref. Figure 4−1) The crew compartment

equipped with single controls has a three−

(1). Release quick−disconnect fitting at

place arrangement to accommodate the pilot

bulkhead and then at floor points.

and two passengers. The seat consist of a

left−side, right−side and center seat bottom,

(2). To install the seats, position seat(s) in

each with a seat backrest. Seat cushions with

place and allow quick disconnects to

standard trim are upholstered and trimmed

lock in place first at floor points and

with vinyl. Seats with executive trim are

then at bulkhead fittings.

upholstered and trimmed with leather. Velcro

fastener strips on the underside of the seat

D. Seat Inspection

and on the fuselage structure secure the seats

(1). Inspect seating material for cuts, loose

in place.

stitching and for other evidence of

A. Crew Compartment Seat Replacement

unserviceable condition.

(1). Clear the seat of seat belts and shoul−

(2). Inspect quick disconnect on seat

der harness.

structure for correct operation and

damage that might prevent positive

(2). Lift seats away from fuselage structure

locking.

to release Velcro fastener hook from

Velcro pile strips.

(3). Inspect the various Velcro fastener hook

(3). To install the seats, position seating in

and pile strips installed on seat struc−

place and press down so Velcro fasten−

ture and fuselage structure for security

ers mate.

of attachment and condition.

Page 4-1

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

INERTIA REEL (2)

SEAT BACK CUSHION

SEAT BACK

NOTE 1

AFT SUPPORT FITTING AND

VELCRO STRIP

HEIGHT ADJUSTMENT

FASTENER (TYP)

SEAT BOTTOM

LOCKPIN

CUSHION

PASSENGER

LOWER FRAME

COMPARTMENT

INERTIA REEL (2)

NYLON MESH

FLOOR STRUCTURE

RELEASE PIN

FORE AND AFT

SUPPORT LEG AND

ADJUSTMENT HOLES

HEIGHT ADJUSTMENT

INERTIA REEL

HARNESS MUST UNREEL IN

DIRECTION SHOWN

NOTE 2

SEAT BACK

41° ±3°

CUSHION

90° LIMITS OF

CUTOUT IN ALUM.

HOUSING

NOTE 1

VELCRO STRIP FAS−

TENER (TYP)

NOTES:

SHOWN WITHOUT CUSHION

FOR CLARITY.

CENTER CUSHIONS AND SEAT

SEAT BOTTOM

BELTS ONLY FOR 3−PLACE

CUSHION

SEATING.

CREW

INERTIA REEL

COMPARTMENT

SEAT STRUCTURE

41−007−1A

Figure 4-1. Seat Installation - Typical (Sheet 1 of 2)

Page 4-2

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

SHOULDER STRAP FITTING

SNAP END FITTING

(HOOK UP)

PASSENGER/CARGO COMPARTMENT

AFT BULKHEAD

SHOULDER

SNAP END FITTING

STRAP

(HOOK DOWN)

FITTING

SNAP END FITTING

NYLON WEBBING

(HOOK UP)

SHOULDER STRAP

SNAP END

FITTING (HOOK

ADAPTER

DOWN)

(NOTE 1)

SNAP END

INBOARD

FITTING

SEAT BELT

(HOOK UP)

FITTING

CANTED BULKHEAD

NYLON WEBBING SEAT BELT

OUTBOARD SEAT

BELT FITTING

SHOULDER

SNAP END FITTING

BUCKLE

STRAP

(HOOK UP)

FITTING

LATCH

NYLON WEBBING

ADAPTER

SNAP END FITTING

SHOULDER STRAP

ADAPTER

(HOOK DOWN)

(NOTE 1)

ADAPTER

(NOTE 1)

PASSENGER/CARGO COMPARTMENT

SNAP END FITTING

(HOOK UP)

SNAP END FITTING

(HOOK UP)

SNAP END FITTING

(HOOK DOWN)

ADAPTER

SNAP END FITTING

BUCKLE

(HOOK DOWN)

SNAP END FITTING

(HOOK DOWN)

OUTBOARD SEAT BELT FITTING

LATCH

SNAP END FITTING

(HOOK DOWN)

ADAPTER

(NOTE 1)

LATCH

BUCKLE

NYLON WEBBING SEAT BELT

INBOARD SEAT

BELT FITTING

PILOT’S COMPARTMENT

NOTES:

SLIDE BAR HARNESS LENGTH AD−

JUSTER.

SEATS AND INTERIOR TRIM NOT

41−012A

Figure 4-2. Early Configuration Seat Belt and Shoulder Harnesses

Page 4-4

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

E. Seat Repair

B. Seat Belt and Shoulder Harness

Inspection

(1). Lap−stitch frayed or worn upholstery.

(1). Inspect seat belts and shoulder har−

(2). Replace unserviceable Velcro fastener

nesses for worn or frayed condition and

hook and pile strips. Install new Velcro

loose stitching.

pile and hook strips to mate, and bond

(2). Inspect snap−end fitting for cracks,

with cement (91, Table 2−4).

excessive wear, corrosion and deforma−

NOTE: Loosened Velcro fasteners can be reacti−

tion.

vated for adhesion by wiping the original

(3). Check for freedom from binding, ease of

adhesive with methyl ethyl ketone (MEK)

adjustment, and operation as applica−

(22).

ble.

3. Seat Belts and Shoulder Harnesses

C. Seat Belt Load Testing

(Ref. Figure 4−1 and Figure 4−2) Seat belts

Perform seat belt load testing in accordance

and shoulder harnesses are provided at the

with FAA AC 43.13−1A and TSO−C22.

five seat positions.

D. Seat Belt and Shoulder Harness Repair

The early configuration seat belts and shoul−

(1). Replace shoulder harness or seat belt if

der harnesses are fabricated of nylon webbing

webbing is excessively worn or there is

with sewn−in buckles, attachment fittings and

loose stitching.

adjusters.

(2). Polish out minor nicks and scratches,

Later configuration seat belts and shoulder

restore protective finish to aluminum

harnesses have sewn−in snap end fittings and

parts and renew paint finish as neces−

buckles, and are equipped with inertia reels at

sary.

each seat position.

4. Interior Trim

Crew compartment shoulder harness inertia

reels and fittings are attached to the canted

(Ref. Figure 4−3 and Figure 4−4) The trim

bulkhead with a bolt, nut and washer.

panels are fabricated from thermoplastic

material and are contoured to cover the

Executive trim seat belts pass through a

interior fuselage structure, doors and door

semi−rigid cover and seat cushion and frame

frames. The interior trim panels provide the

in the passenger compartment.

interior finish, insulation for the compartment

interior and also provide mounting surfaces for

A. Seat Belt and Shoulder Harness

convenience items.

Replacement

Trim panels furnished with early configuration

(1). Early configuration seat belts and

executive trim are flocked. Trim installed on

shoulder harnesses are removed by

early configuration helicopters are attached

unfastening the snap−type end fittings

with Hedlok semi−rigid interlocking nylon

from structure attachments.

fasteners and attaching screws.

(2). Remove later configuration seat belts

Trim installed in later configuration helicop−

by unfastening the snap−type fitting

ters are attached with upholstery screws that

from special fittings.

fasten to mating rivnuts and isolator nut

mounts on the fuselage structure.

(3). Remove nut, bolt and washer securing

inertia reel and fitting to bulkhead. If

Later configuration trim have access doors at

required, remove access door on right

hinge pin locations and in lower right and left

side outboard trim panel to unsnap seat

panels for access to fuselage structure seat belt

belt fitting.

fittings.

(4). Install seat belts and shoulder har−

The map case trim cover panel located on the

nesses in reverse order of removal.

central control tunnel contains a map case

Page 4-5

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

pocket and provisions for an optional untility

(3). Connect electrical wires for utility light

light.

when installing map case trim cover on

canted Sta. 78.50.

On later configuration helicopters, crew

C. Passenger Compartment Interior Trim

compartment doors use trim only on the lower

Removal

area.

(1). Identify trim panels, applicable attach−

On helicopters equipped with standard trim,

ing devices and locations.

the upper convenience panel trim cover

contains panel provisions for optional heating

(2). Remove all screws used to secure trim

and lighting items. The forward bulkhead

panel.

standard trim panel contains two literature

(3). On helicopters where trim panels use

pockets and an ashtray and cigarette lighter.

Hedlok fasteners, remove all visible

On helicopters furnished with executive trim,

attachment screws and gently lift off

the upper convenience panel cover contains a

trim panel to disengage fasteners.

blank panel with provisions for an optional

NOTE: The upper convenience panel cover

utility light. The forward bulkhead executive

must be removed before the transmission

trim panel assembly contains two folding

cover panel can be lowered. Release fasten−

tables, literature pockets and convenience

ers and push panel slightly upwards; then

panel.

pivot lower end to clear the bulkhead. Re−

move the transmission cover trim panel by

On later configuration helicopters, passenger

rotating forward end downward.

compartment doors use trim only on the lower

area. A later transmission cover panel contains

(4). Disconnect electrical wires from

two cover plugs for access to the main trans−

ashtray and cigarette lighter when

mission drain and chip detector plugs.

removing forward bulkhead trim panel.

A. Crew Compartment Interior Trim Removal

(5). Disconnect electrical wires from

optional utility light when removing

(1). Identify trim panels, applicable attach−

upper convenience panel trim cover

ing devices, and attaching devices, and

panel.

attaching screws.

(6). Remove passenger compartment seats

(2). Remove all attaching screws securing

when removing lower bulkhead trim

trim panel. On early configuration

panel.

helicopters where Hedlok fasteners are

D. Passenger Compartment Interior Trim

used, remove all visible attaching

Installation

screws; then gently pry and lift off the

selected trim panel.

(1). Identify all trim panels, applicable

attaching devices and locations. Refer

(3). Disconnect electrical wires from untility

to Passenger Compartment Interior

light when removing map case trim

Trim Removal and install in reverse

cover from canted Sta. 78.50.

order.

B. Crew Compartment Interior Trim

(2). Position trim panels with Hedlok

Installation

fasteners in place.

(3). Press on panel to engage all Hedlok

(1). Identify trim panels, applicable attach−

fasteners. Install applicable screws.

ing devices, and the number and

approximate location of attaching

(4). Connect electrical wires to ashtray and

screws.

cigarette lighter assembly when

installing forward bulkhead trim panel.

(2). Position trim panels using Hedlok

fasteners in place and engage all

(5). Connect electrical wires to optional

Hedlok fasteners. Install applicable

utility light when installing upper

screws.

convenience panel trim cover panel.

Page 4-6

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

CONTROLS TUNNEL

TRIM COVER

VELCRO FASTENER

SCREW (2 PLCS)

REMOVEABLE PLUG (FOR

OPTIONAL UTILITY LIGHT)

MAP CASE TRIM COVER

DNZ HEDLOK ON

MAP POCKET

MTG PAD

(NOTE 2)

DNZ HEDLOK ON MOUNTING PAD (2 PLCS)

(EARLY CONFIGURATION)

SCREW

(2 PLCS)

DNZ HEDLOK ON

STANDOFF (4 PLCS)

SCREW (2 PLCS)

HEDLOK − FASTENER

GROMMET

MOUNTED

DNZ HEDLOK ON STANDOFF

(4 PLCS) AND ATTACHING

SCREW (4 PLCS)

ONE PIECE

UPPER SIDE PANEL

(LEFT SHOWN)

CREW COMPARTMENT

FORWARD PANEL

ROTATED

SCREW WITH MATING

NUT MOUNT (3 PLCS)

SCREW MOUNTED

ASSIST STRAP

ASSIST

HANDLE

ROTATED

SCREW WITH MAT−

ING NUT MOUNT

TWO PIECE

(NOTE 1)

SCREW WITH

SCREW WITH MATING

MATING RIVNUT

RIVNUT (1 PLC)

SCREW WITH MATING

NUT MOUNT (8 PLCS)

41−013−2B

Figure 4-3. Crew Compartment Interior Trim and Covers (Sheet 2 of 3)

Page 4-8

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

E. Interior Trim Inspection

of the controls cover group, is located on the

left of the cyclic controls cover. The base of the

(1). Inspect trim panels for teats, cuts,

case is hinge−mounted to the fuselage struc−

breaks or other evidence of an unser−

ture and allows the case to swing open.

viceable condition. Inspect underside of

trim panels for the condition and

A. Control Covers Removal

security of insulation.

(1). Separate the Velcro fastened−attached

(2). Inspect underside of trim panels for

fabric dust cover from cyclic cover and

broken, damaged, or missing Hedlok

locate the four interior attaching screws

fasteners, as applicable.

at the base.

(3). Inspect fuselage structure for loose,

(2). Remove interior attaching screws.

damaged, or missing mating Hedlok

(3). To remove cyclic control cover, remove

fasteners or isolator nut mounts, as

crew compartment seats and four

applicable.

screws atop the seat structure.

(4). Inspect Velcro fasteners used to secure

B. Control Covers Installation

trim panels for serviceable condition.

(1). Identify all control covers, applicable

F. Interior Trim Repair

attaching devices, and the number and

(1). Remove and replace broken or missing

approximate location of attaching

Hedlok fastener of trim panels or on

screws.

fuselage structure.

(2). Install cyclic control cover over cyclic

(2). Remove and replace broken or missing

controls linkage and install the four

isolator nut mounts, as applicable.

inside interior attaching screws.

(3). Remove and replace unserviceable seat

(3). Install attaching screws atop the

fitting cover installed on aft section

fuselage seat structure.

lower bulkhead trim panel.

(4). Attach Velcro−fastened cloth dust cover

(4). Rebond loose insulation material on

to cyclic control cover.

underside of trim panel or on fuselage

(5). Install crew compartment seating.

structure with cement (91, Table 2−4).

C. Control Covers Inspection

(5). Remove and replace unserviceable

Velcro fastener hook and pile strips.

(1). Inspect control covers for tears, cuts,

Install new Velcro pile and hook strip to

breaks or other evidence of an unser−

mate; bond with cement.

viceable condition.

NOTE: Loosened Velcro fasteners can be reacti−

(2). Inspect condition of dust cover, grom−

vated for adhesion by wiping the original

met and Velcro fasteners on cyclic stick

film with MEK (22).

control cover.

5. Control Covers

D. Control Covers Repair

(Ref. Figure 4−3) The crew compartment

(1). Remove and replace unserviceable

control cover consist of a cyclic stick control

Velcro fastener hook and pile strips

cover, headset cover and a collective stick

installed on cyclic stick control cover

cover. The cyclic control cover is mounted to

and dust cover. Install new Velcro hook

the forward portion of the seat structure and

and pile to mate; bond with (91,

covers the control linkage and friction controls.

Table 2−4).

A cutout with a flexible cloth dust cover is

provided in the cover at the cyclic base. The

(2). Remove and replace worn or torn

control cover has cutout provisions for optional

Velcro−fastened cloth dust cover on

dual controls. The headset case, a component

cyclic controls cover.

Page 4-10

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

TRANSMISSON COVER PANEL

INSTALLATION

PLUG BUTTON

MAIN TRANSMISSION DRAIN COVER

PLUG (CURRENT STANDARD TYPE)

CHIP DETECTOR

SCREW (8 PLCS)

COVER PLUG

PLUG BUTTON

ISOLATOR NUT MOUNT

(BOTH SIDES)

SCREW MOUNTED

MAIN TRANSMIS−

SION COVER

PASSENGER COMPARTMENT

PANEL

SIDE PANEL (RH)

DNZ HEDLOK FASTENER ON

STAND−OFF (3 PLCS) AND AT−

PLUG BUTTON

TACHING SCREWS (3 PLCS) OR

ATTACHING SCREWS WITH MAT−

ING RIVNUTS (6 PLCS)

DNZ HEDLOK ON

MOUNTING PAD (4 PLCS)

MAIN TRANSMISSION

ISOLATOR NUT MOUNT

DRAIN COVER PLUG

INSTALLATION (TYP)

(CURRENT EXECUTIVE

TYPE)

DNZ HEDLOK ON

HEDLOK FASTENER

STAND−OFF (4 PLCS)

MOUNTED

DNZ HEDLOK FASTENER ON

STRUCTURE

PASSENGER COMPARTMENT

STAND−OFF (3 PLCS) AND AT−

SIDE PANEL (LH)

TACHING SCREWS (3 PLCS) OR

ATTACHING SCREWS WITH MAT−

ING RIVNUTS (6 PLCS)

ISOLATOR NUT MOUNT

INSTALLATION (TYP)

41−015−1C

Figure 4-4. Passenger Compartment Interior Trim and Covers (Sheet 1 of 3)

Page 4-11

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

DNZ HEDLOK ON

STAND−OFF (3 PLCS)

PASSENGER COMPARTMENT

DOOR TRIM PANEL

SCREW (5 PLCS)

DNZ HEDLOK ON

MOUNT PAD

VELCRO PILE

DOOR STRUCTURE

BLANK COVER

RIVNUT

VELCRO HOOK

DOOR TRIM PANEL

DNZ HEDLOK ON

SCREW (5 PLACES)

(AUTO−LATCH DOOR)

MOUNT PAD OR

SCREW (2 PLCS)

CONVENIENCE

PANEL COVER

DNZ HEDLOK ON

STAND−OFF

HEDLOK

UPPER BULKHEAD

PANEL (RH)

INSTALLATION

UPPER BULKHEAD PANEL (RH)

SCREW MOUNTED

(EARLY

(CURRENT

CONFIGURATION)

UPPER BULKHEAD

PANEL (LH)

UPPER BULKHEAD PANEL (LH)

ISOLATOR NUT MOUNT

LOWER BULKHEAD PANEL

SCREW (5 PLCS)

SEAT FITTING COVER

DNZ HEDLOK

ON STAND−OFF

SEAT FITTING COVER

LOWER BULKHEAD PANEL

(5 PLCS)

SCREW (5 PLCS)

DNZ HEDLOK ON

STAND−OFF (5 PLCS)

41−015−2A

Figure 4-4. Passenger Compartment Interior Trim and Covers (Sheet 2 of 3)

Page 4-12

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

6. Boltaron Trim Panel Repair

(3). Deburr stop drill(s) and clean any

jagged area of crack.

(Ref. Figure 4−5)

(4). Select a piece of boltaron material,

A. Fiberglass Patch Method

same contour of area to be patched.

Plating surfaces must provide a snug

(1).

Remove damaged panel.

fit. Patch material to overlap damaged

area a minimum of 1 inch (25.4 mm) in

(2).

Stop drill end(s) of crack.

all directions.

(3).

Deburr stop drill(s) and clean any

(5). Clean mating surfaces with aliphatic

jagged area of crack.

naphtha (59, Table 2−4). Ensure

surfaces are free from oil, grease or

(4).

Cut patch from fiberglass cloth to

other contaminates.

overlap damaged area or crack, mini−

mum 1 inch in all directions.

(6). Assemble patch, when possible, with

mating surface of patch in contact with

(5).

Cut second patch to overlap first,

panel but without application of

minimum 0.50 inch (12.7 mm) in all

pressure.

directions. If required, cut third patch

to overlap second, minimum 0.50 inch

Bonding solvent, tetrahy−

(12.7 mm) in all directions.

WARNING

drofuran, is a flammable liq−

uid; care must be exercised in handl−

(6).

Abrade surface of panel, in area to be

ing.

patched, with emery cloth (49,

Table 2−4).

Solvent shall be applied careful−

CAUTION

ly so no excess material will run

(7).

Clean surface by wiping with cloth,

over other surfaces and mar the finish.

dampened not saturated, with solvent

(10).

(7).

Inject tetrahydrofuran (46) between

mating surfaces by means of syringe or

(8).

Place panel in horizontal position. Tape

eye dropper.

around area to be repaired with

masking tape, to catch residual resin.

(8).

On larger parts, solvent shall be

applied evenly to mating surfaces with

(9).

Apply glass cloth (159) to panel, one ply

brush.

at a time.

(9).

Assemble mating surfaces as quickly as

(10).

Apply resin (160) to material with a

possible by firmly pressing together.

brush or squeegee.

(10).

Apply clamps to assembly, immediately

(11).

Continue adding material and resin

after solvent application, with sufficient

until desired thickness has been

pressure to force out air bubbles.

achieved.

(11).

After forcing out bubbles, adjust clamps

(12).

Allow repair to cure, minimum 45

to minimum pressure required to hold

minutes at 265° ±10°F (129° ±5°C). As

parts together.

alternate, heat lamp may be used,

minimum 2 hours.

(12).

If solvent has evaporated at or near

NOTE: Heat lamp should be placed a minimum

edge of patch, apply more solvent in

of 12 inches from fiberglass repair area.

accordance with step (7).

B. Solvent Bonding Patch Method

(13).

Leave clamps in place for a minimum of

20 minutes.

(1). Remove damaged panel.

(14).

Allow the panel to cure for 24 hours

(2). Stop drill end(s) of crack.

prior to reinstallation.

Page 4-14

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

C. Epoxy Adhesive Patch Method

MS20426A4 Countersunk Rivets

MS20470A4 Universal Rivets

(1).

Remove damaged panel.

(1). Cut patch to proper size.

(2).

Stop drill end(s) of crack.

(2). Determine rivet spacing.

(3).

Deburr stop drill(s) and clean any

(a). Rivet spacing to be 4−6 times rivet

jagged area of cracks.

diameter.

(4).

Select a piece of boltaron material,

(b). Minimum edge distance to be 2X

same contour of area to be patched.

rivet dia. +0.030 inch (0.762 mm).

Mating surfaces must provide a snug

Example: For #4 rivet, min. edge

fit. Patch to overlap damaged area a

distance is 0.028 inch (0.711 mm).

minimum of one inch (25.4 mm) in all

Rivet diameter 0.125 in. (3.175 mm)

directions.

X 2 +0.030 in. (0.762 mm) = 0.280 in.

(7.112 mm)

(5).

Lightly abrade mating surfaces with

(3). Lay out rivet pattern on patch and drill

emery cloth (49, Table 2−4) and clean

holes. Position patch on panel and drill

with solvent (10).

holes.

(6).

Air dry for 30 minutes at ambient

(4). Deburr all holes on both sides of patch

temperature. Apply adhesive (19)

and panel.

within 2 hours of drying.

(5). Countersink holes on patch if

(7).

Thoroughly mix equal parts, by weight,

MS20426A4 rivets are to be used.

of adhesive. Color should be uniform

(6). Comply with the following procedures if

green. Use unwaxed disposable contain−

using solvent bonding method (tetrahy−

er and wooden tongue depressor or

drofuran).

metal spatula for mixing. Pot life of

mixed adhesive is 45 minutes at

(a). Perform step (5). of Fiberglass Patch

ambient temperature.

Method.

(b). Set patch in place, using a minimum

(8).

Spread thin uniform layer, 0.002−0.010

amount of clecos required to hold

inch (0.051−0.254 mm), of adhesive

patch in contact with panel without

lightly on mating surfaces and clamp

applying too much pressure (Ref: step

lightly together.

(6).).

(9).

Wipe excess adhesive from bond line.

(c). Perform steps (7). thru (9).

(d). Install clamps per steps (10). and

(10).

The clamps are to remain in place for 8

(11). Keep all clamps in place for a

hours minimum at ambient tempera−

minimum of 20 minutes. Perform

ture or 2 hours at 160° ±10°F (71°

step (12). if necessary.

±5°C).

NOTE: If gap exists between patch and panel,

(11).

Allow panel to cure for 24 hours prior to

perform step (7). in immediate area of each

installation.

rivet hole with a gap prior to installing riv−

ets

D. Bond and Rivet Patch Method

(e). Rivet patch to panel.

The following procedure may be used in

(f). Allow panel to cure for a minimum of

conjunction with one of the above bonding

24 hours prior to installation.

procedures. If cracks are excessive and/or a

piece of boltaron isn’t available that fits

(7). Comply with the following procedures if

contour in area to be repaired, rivets may be

using the epoxy adhesive method

used to help secure patch to panel.

(scotchweld EA 1838A4−8).

Page 4-16

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

(a). Perform steps (5). thru (7). of Fiber−

8. Passenger Compartment Floor Trim

glass Patch Method.

(Ref. Figure 4−7) The passenger compartment

(b). Spread a thin uniform layer,

floor is furnished with standard or executive

0.002−0.010 inch (0.051−0.254 mm),

trim. The floor trim consists basically of a

of adhesive on mating surfaces. Try

form−fitted plastic two−section floor trim panel

to keep adhesive out of the rivet

with floor covering. Floor covering for execu−

holes.

tive trim is carpeting. Floor covering for

standard trim is a plastic vinyl material. The

(c). Install the patch on the panel with

area below the forward bulkhead trim panel

clecos.

and the control access door is also trimmed.

Foot support fairings are only trimmed on

(d). Rivet the patch to the panel.

executive models. A trim flap (lower left)

encloses the electrical receptacle recess and is

(e). Wipe excess adhesive from bond line

secured in placed with Velcro fasteners.

and from around the rivets.

A. Passenger Compartment Floor Trim

(f). Allow the panel to cure for 24 hours

Removal

prior to installation.

(1). Remove passenger compartment seats.

E. Main Transmission/Engine Drive Shaft

Access Door Assembly

(2). Remove cargo tiedown fittings (when

installed).

(Ref. Figure 4−6) The Access Door Assembly is

(3). Pry and lift trim panel from floor

made of 0.093 inch (2.362 mm) thick boltaron

structure.

plastic, on some models pre−impregnated

layers of fiberglass cloth form the access door.

(4). Remove foot support fairings and

The door provides access to the air cooler

controls access door (Ref. Sec. 2).

blower fan assembly and engine to transmis−

sion drive shaft.

B. Passenger Compartment Floor Trim

Installation

F. Main Transmission/Engine Drive Shaft

Access Door Assembly Seal

(1). Clear floor of seat belts and check that

Replacement

floor structure is clean and free of

debris.

MEK is highly flammable

WARNING

and toxic. Use only in well

(2). Place trim panel over floor structure

ventilated area and away from heat

and press in place.

and flame.

(3). Install passenger compartment seats.

(1). Remove seal from access door; remove

(4). Install foot support fairings, if required,

seal residue from access door using a

and controls access door (Ref. Sec. 2).

cloth dampened with MEK (22,

Table 2−4).

C. Floor Trim Inspection

(2). Install new seal.

(1). Inspect floor trim panel for cuts,

breaks, or other evidence of an unser−

7. Crew Compartment Floor Trim

viceable condition.

D. Floor Trim Repair

(Ref. Figure 4−7) The crew compartment floor

is furnished with either standard or executive

(1). Repair loose or torn plastic vinyl floor

trim. The standard trim uses a fire resistant

covering material or carpeting by using

vinyl floor covering material. The executive

new application of double−backed−faced

trim consist of fire resistant carpeting. The

tape (90, Table 2−4).

plastic vinyl material and carpeting are

secured to the floor area with double−backed−

(2). Repair loose or torn floor covering or

faced tape and bonded to the two floor access

carpeting on access doors by rebonding

doors.

with cement (91).

Page 4-17

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

NOTES 2 AND 3

NOTE 1

NOTES 2 AND 3

NOTE 1

NOTES:

NE−71A ADHESIVE−BACKED NITRILE BUTALINE TAPE.

MIL−R−6130 & MIL−R−6130D TYPE II, GRADE A COND.

SOFT (ARMSTRONG TYPE DE−41 OR EQUIVALENT).

NS 210−2400 ELASTIC EXTRUSION (SILICONE RUBBER SPONGE)

31−340

Figure 4-6. Main Transmission/Engine Drive Shaft Access Door Assembly

(3). Replace unserviceable Velcro fasteners

B. Stowage Compartment Box Replacement

on the electrical receptacle recess trim

flap.

(1). Raise pilot’s compartment floor right

access door. Remove tape covering

9. Miscellaneous Furnishings

screwheads and 10 screws and washers

to release stowage box.

A. Stowage Compartment Box

(Ref. Figure 4−8) The stowage compartment

(2). Install replacement stowage box and

box is a bonded, stitched and riveted thermo−

secure with screws and washers. Cover

plastic box with a uniformly distributed load

screwheads with tape (42, Table 2−4).

capacity of 50 pounds (23 kg) maximum. It is

Close and latch access door.

located under the pilot’s compartment floor on

the right side.

C. Stowage Compartment Box Repair

NOTE: Helicopters equipped with certain op−

tional communications and avionics instal−

Perform fiberglass repair of stowage compart−

lations will not have a stowage compart−

ment box according to applicable instructions

ment box installed.

in CSP−H−6, HMI Appendix D.

Page 4-18

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

D. Cargo Tiedown Fittings

place or riveted to the center canopy frame on

the early configuration.

(Ref. Figure 4−8) The cargo tiedown fittings

are formed of 0.250 inch (6.35 mm) diameter,

I. Magnetic Compass Card

U−shaped steel rods, with ends flattened. The

The magnetic compass card contains calibra−

flats are drilled to accept a quick−release pin

tion information for the specific compass

for attaching the fitting to the cargo floor. The

installed in the helicopter.

pin is secured to the fitting with a 4 inch

(10.16 cm) lanyard. Cargo tiedown fittings can

J. Operation Record Holder

be fastened to the cargo floor at any of 12

locations for various cargo loads.

(Ref. Figure 4−9) The operation record holder

with a transparent window is attached to the

E. Cargo Tiedown Fitting Inspection

outboard side of the right instrument panel

fairing on later configuration helicopters. On

(1). Check for cracks or deformation.

early configuration helicopters, the holder is

attached to the lower right front of the pilot’s

(2). Check that quick−release pin functions

seat structure.

properly and that lanyard is secure.

K. Heat Duct and V_NE

Card Cover

F. Pilot’s Compartment Canopy Frame Trim

and V_NE Card Cover

(Ref. Figure 4−9) The heat duct and V_NE card

cover assembly provides interior trim for the

(Ref. Figure 4−9) On all later configuration

canopy frame and a mounting surface for the

helicopters, trim is provided for the canopy

V_NE card. A wire pin on the V_NE card is used

center frame in the pilot’s compartment. The

to mount the card to the cover. The pin

trim is screw−mounted to the canopy frame

installation enables the V_NE card to be flipped

and consists of an upper and lower section,

for a view of either side. Velcro fasteners

and a V_NE card cover that provides the trim

secure the V_NE card in the desired viewing

joint. On certain configuration helicopters, the

position. Several configuration of the heat duct

magnetic compass is mounted to the trim just

and V_NE card cover are installed. On a

above the instrument panel. When electroni−

helicopter equipped with an electrically

cally activated engine anti−icing and cabin

controlled engine anti−icing system (Ref. Sec.

heat control systems are installed, the V_NE

11) and cabin heating system (Ref. CSP−H−3),

card cover also provides the mounting surface

an engine de−ice switch and a cabin heat

for the ENGINE DE−ICE and CABIN HEAT

switch are mounted to the heat duct and V_NE

switches. The trim sections also function as

card cover assembly. The cover may be secured

heat ducts when the optional heating system is

to the canopy frame with Hedlok fasteners or

installed. When the heating system is not

attaching screws.

installed, removable end−caps enclose the

upper and lower ends of the trim.

L. Heat Duct and V_NE Card Cover

Replacement

G. Helicopter Checklist

(Ref. Figure 4−9)

The helicopter checklist contains instructions

M. Heat Duct and V_NE Card Cover Removal

for an interior check, engine starting, engine

runup and stopping the engine. The checklist

(1). Remove screws securing heat duct and

is stored with the magnetic compass card in

V_NE card cover assembly to canopy

the map case trim cover on the upper forward

frame.

side of the central controls tunnel in the crew

compartment.

(2). On early configuration helicopters

where Hedlok fasteners are used on the

H. V_NE Card and Holder (Bracket Mounted)

cover, gently pry and lift cover off

canopy frame.

(Ref. Figure 4−8 and Figure 4−9) The V_NE

(Velocity to Never Exceed) card is held by a

(3). On covers that have side−mounted

holder directly above the hood of the instru−

switches, disconnect wiring for engine

ment console. The holder may be bonded in

de−ice switch (Ref. Sec. 11). Refer to

Page 4-20

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

CSP−H−3 for wiring of the optional

Q. Ashtrays

cabin heat switch.

(Ref. Figure 4−4 and Figure 4−8) The crew

N. Heat Duct and V_NE Card Cover

compartment is equipped with an ashtray and

Installation

cigarette lighter located in the lower portion of

the instrument panel.

(1). On cover assemblies that have side−

On helicopters with standard trim, an ashtray

mounted switches, connect electric

and cigarette lighter is installed on the

wires for engine de−ice switch (Ref. Sec.

forward bulkhead trim panel. On helicopters

11). Refer to CSP−H−3 for wiring of the

furnished with executive trim, the ashtray and

optional cabin heat switch.

cigarette lighter assembly is mounted on the

forward bulkhead trim panel as part of the

(2). Where Hedlok fasteners are used on the

lower convenience panel.

cover, position in place and engage

fasteners.

On early configuration helicopters without

interior trim, an ashtray and cigarette lighter

(3). On screw−mounted cover assemblies,

assembly is installed on the forward bulkhead.

reinstall mounting screws.

R. Passenger Compartment Upper

O. Heat Duct and V_NE Card Cover Inspection

Convenience Panel (Without Trim)

(Ref. Figure 4−9)

(Ref. Figure 4−4) On early configuration

helicopters without interior trim, a plastic

(1). Inspect cover for tears, cracks, breaks

convenience panel is located above the

or other evidence of unserviceable

compartment forward bulkhead. The conve−

condition and legibility.

nience panel provides mounting facilities for

utility light switch, heated air outlet diffuser

(2). Check that the V_NE card mounting is

valve and two head set connectors (all optional

secure. Check that Velcro fasteners are

equipment). Six screws attach the panel to the

not defective.

fuselage structure. Plugs and covers are

supplied with the panel when optional

equipment is not installed.

(3). On covers using the Hedlok fasteners

installation, check that fasteners on

S. Passenger Compartment Upper

cover and mating fasteners on canopy

Convenience Panel (Standard Trim)

frame are not defective.

(Ref. Figure 4−4) On helicopters with standard

P. Heat Duct and V_NE Card Cover Repair

trim, the upper convenience panel is contained

in the convenience panel panel trim cover. The

(Ref. Figure 4−9)

convenience panel provides mounting facilities

for a utility light switch, heated air outlet

(1). Replace defective or illegible V_NE cards.

diffuser valve and two headset connectors. Six

Replace unserviceable Velcro fastener

screws attach the panel to the convenience

strips on card or at card cover location.

panel trim cover. Plugs and covers are supplied

Install new Velcro fastener strips to

with the panel when the optional equipment is

mate. Bond in place with cement (91,

not installed.

Table 2−4).

T. Folding Table Assembly (Executive Trim)

(2). Remove and replace broken or missing

Hedlok fasteners.

(Ref. Figure 4−4) On helicopters with executive

trim, two folding tables are provided in the

(3). Repair or replace loose or illegible

passenger/cargo compartment for passenger

switch bezels. Bond bezel to cover with

use. The folding tables are installed on the

adhesive (19).

compartment forward bulkhead trim panel.

Page 4-21

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

U. Passenger Compartment Lower

(3). Position replacement foot rest on floor

Convenience Panel (Executive Trim)

support bulkhead and install four bolts,

sixteen washers and four nuts. When

(Ref. Figure 4−4) On helicopters with executive

necessary, use thin aluminum washers

trim, the passenger/cargo compartment is

to shim between footrest and bulkhead

equipped with a lower convenience panel. The

attach points to obtain fourpoint

panel is mounted in the compartment forward

contact before tighten bolts.

bulkhead trim panel. The convenience panel

contains an ashtray and cigarette lighter

(4). Reinstall stowage compartment box.

assembly, heat diffusers and provisions for an

optional heat control selector knob and two

Y. Pilot’s Compartment Footrest Inspection

headset connectors.

Inspect the foot rest for security and service−

V. Passenger Compartment Upper

able condition.

Convenience Panel (Executive Trim)

Z. Pilot’s Compartment Footrest Repair

(Ref. Figure 4−3) On helicopters with executive

trim, the convenience panel trim cover

Perform weld repair of the foot rest tubing

contains provisions for an optional utility light

according to FAA AC 43.13−1A, Aircraft

(Ref. CSP−H−3). When the optional utility

Inspection and Repair.

light is not installed in the trim cover, a

AA. Passenger Step

removeable plug is used.

(Ref. Figure 4−9) The executive trim helicopter

W. Pilot’s Compartment Footrest

is furnished with a removable passenger step,

(Ref. Figure 4−9) The pilot’s compartment foot

that readily attaches to the helicopter side

rest consist of welded aluminum alloy tubes

jacking points, to make entering or leaving the

attached to the floor support bulkhead (Sta.

cargo/passenger compartment more conve−

44.65) at the right side of the compartment.

nient. The step assembly consists of a step

plate attached to a tubing arm with a step

X. Pilot’s Compartment Footrest

support pin and is rated for 340 pounds (154

Replacement

kg). A locking pin on the step support pin

ensures security of the step in the jacking

(1). Remove stowage compartment box.

point when the step is installed. The step may

(2). Remove four bolt and nuts, and sixteen

be stowed in the cargo/passenger compartment

washers to release foot rest.

when not in use.

Page 4-23

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

TABLE OF CONTENTS

Para/Figure/Table

Title

Page

Section 5 Tailboom And Tail Surfaces .

5−1

Tailboom Assembly

5−1

Troubleshooting Tailboom and Tail Surfaces

5−1

Tailboom Assembly Replacement

5−1

A. Tailboom Assembly Removal

5−1

B. Tailboom Assembly Installation

5−1

Table 5−1. Troubleshooting Tailboom and Tail Surfaces

5−1

Tailboom Assembly Inspection

5−2

Tailboom Assembly Repair

5−2

Tail Surfaces

5−2

Figure 5−1. Empennage and Boom Assembly

5−3

Figure 5−2. Tailboom Removal and Installation

5−4

Stabilizer Sheet Metal Repair

5−5

Upper Vertical Stabilizer Replacement

5−5

A. Upper Vertical Stabilizer Removal

5−5

B. Upper Vertical Stabilizer Installation

5−5

Upper Vertical Stabilizer Inspection

5−5

10. Upper Vertical Stabilizer Repair

5−5

11. Horizontal Stabilizer Replacement

5−5

A. Horizontal Stabilizer Removal

5−5

B. Horizontal Stabilizer Installation

5−5

Figure 5−3. Empennage Removal and Installation (Sheet

1 of

2) .

5−6

12. Horizontal Stabilizer Inspection

5−8

13. Horizontal Stabilizer Repair

5−8

14. Lower Vertical Stabilizer Replacement

5−8

A. Lower Vertical Stabilizer Removal

5−8

B. Lower Vertical Stabilizer Installation

5−9

15. Lower Vertical Stabilizer Inspection

5−9

16. Lower Vertical Stabilizer Repair

5−9

17. Stabilizer Strut Replacement

5−10

A. Stabilizer Strut Removal

5−10

B. Stabilizer Fixed Strut Installation

5−10

C. Stabilizer Damped Strut Installation

5−10

D. Damped Stabilizer Strut Disassembly

5−11

E. Damped Stabilizer Strut Re−Assembly

5−11

18. Stabilizer Strut Inspection

5−11

Page 5−i

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

SECTION 5

TAILBOOM AND TAIL SURFACES

1. Tailboom Assembly

(5). Disconnect connector of chip detector

wiring, and optional night lighting

(Ref. Figure 5−1) The boom assembly, a

system wiring if installed. Disconnect

monocoque structure of aluminum skin over

knife splice by hand or use appropriate

forged aluminum frames, houses the tail rotor

connector insertion/extraction tool (42

drive shaft and tail rotor control rod, and

or 43, Table 2−2) for wire mate type

supports the horizontal and vertical stabilizer

connector (Ref. Section 19).

tail surfaces. The horizontal stabilizer is

mounted at an upward angle of 25 degrees.

(6). Remove the nuts, washers and bolts

The tail surfaces stabilize the helicopter and

that attach boom to fuselage and

maintain it in a relatively level attitude during

remove boom.

high speed forward flight. (CSP−H−3 contains

information on optional exterior lights.)

B. Tailboom Assembly Installation

2. Troubleshooting Tailboom and Tail

(1). Support tailboom so that mating

Surfaces

bulkheads are flush.

(Ref. Table 5−1)

NOTE: Prior to tailboom installation, coat

threads of external wrenching bolts and at−

3. Tailboom Assembly Replacement

taching nuts with lubricant (25, Table 2−4).

(Ref. Figure 5−2)

(2). Slide countersunk washers on external

A. Tailboom Assembly Removal

wrenching bolts with countersunk side

facing bolt heads.

(1). Remove the tail rotor transmission and

drive shaft (Ref. Section 9).

If washers are installed back−

CAUTION

wards, structural failure may

(2). Remove the tail rotor control rod (Ref.

result due to insufficient surface in bearing

Section 8).

that can cause spreading or cracking of

washers and result in loss of clamp−up

(3). Position suitable cradles under the

torque.

tailboom at the canted Sta. 209.78

frame fitting and the forward stabilizer

(3). Install bolts through aft section

boom mounting frame.

fuselage frame into boom frame and

place flat washer(s) on each bolt as

To avoid damage, ensure that

CAUTION

required for correct bolt grip. Use no

the boom is properly supported

more than three flat washers under

before removing the boom attach bolts

each nut. Install nuts and torque only

(4). Open the boom bolts access doors and

the nuts to 200 − 240 inch−pounds

remove the bond jumper from the boom.

(22.60 − 27.12 Nm).

Table 5-1. Troubleshooting Tailboom and Tail Surfaces

Symptom

Probable Trouble

Corrective Action

High-frequency vibration Loose lower vertical stabilizer On stabilizer attached with adjustable bolt,

retorque to 25-40 inch-pounds (2.82-4.52 Nm).

On stabilizers attached with two bolts, retorque to

90-1 10 inch-pounds (10.17-12.43 Nm)

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

Sections 8, 9, and 10.)

Page 5-1

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

NOTE: Bolts may be reversed for access to

(2). Replacement − Defective Tail Rotor

torque nuts. Torque wrench adapter (25,

Control Rod Grommets:

Table 2−2) is used for torquing.

Replacement of control rod grommets

(4). Install bond jumper to boom and

may require removal of tailboom

connect chip detector wiring. Connect

frames. Refer to CSP−H−5 for available

night lighting wiring if used.

information on replacement grommets

with increased service life and for

(5). Install the tail rotor transmission and

grommet replacement.

drive shaft.

(6). Install the tail rotor and control rod.

6. Tail Surfaces

(7). Check rigging of tail rotor control.

(Ref. Figure 5−3) Helicopter tail surfaces

consist of a vertical and horizontal stabilizer

(8). Install boom bolts access doors.

attached to the aft end of the tailboom. A fixed

or a damped strut interconnects the horizontal

4. Tailboom Assembly Inspection

stabilizer and the upper vertical at their

approximate midpoints.

(Ref. Figure 5−2)

The stabilizers are constructed of beaded

(1). Inspect the boom interior skin and

aluminum alloy sheet metal skin over formed

frames for corrosion and cracks.

sheet metal ribs. Each stabilizer is supported

by a forged aluminum attached fitting.

(2). Check the attaching nuts and bolts in

the boom canted Sta. 197.78 frame

fitting for security.

The upper stabilizer incorporates a 5−degree

twist which improves the tail rotor (anti−

(3). Inspect the tail rotor control rod

torque) pedal neutral position during cruise

grommets in the boom frames for

flight.

evidence of deterioration.

The upper end of the skid attaches to the lower

(4). Inspect the bond jumper for security

stabilizer and gearbox mounting frame. The

and corrosion.

tail skid is formed from an aluminum tube

which tapers from its attach point in the root

(5). Inspect the boom exterior for loose or

to a curved end just below the bottom rib of the

missing rivets.

lower stabilizer.

(6). Inspect the boom stabilizer and gearbox

Ensure the countersunk wash−

mounting frames for cracks, security of

CAUTION

ers used with the internal

attachment and elongated holes.

wrenching bolts that attach the tail surfaces

are installed with the beveled edge facing

5. Tailboom Assembly Repair

the bolt head. If washers are installed back−

wards, structure failure may result due to

Refer to CSP−H−5 for sheet metal repair.

insufficient surface in bearing that can

cause spreading or cracking of the washers

NOTE: The most highly stressed skins on the

and result in loss of clamp−up torque.

helicopter are the two panels that form the

monocoque boom assembly

(Ref.

Figure 5−1).

NOTE: MDHI Service Information Notice

HN−42 provides instructions for optional re−

(1). Negligible Damage:

work of an existing fixed strut to the

damped strut configuration which is de−

There is no damage that can be consid−

signed to decrease vibration effects on the

ered negligible. All drainage must be

stabilizer resulting from a tail rotor out−of−

repaired upon detection.

balance condition.

Page 5-2

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

FWD STABILIZER BOOM

MOUNTING FRAME

CANTED

STA. 209.78

SELF−LOCKING NUT

FLAT WASHER (CRES)

NUT 200−240 IN. LB

(NOTE 3)

(22.60−27.12 NM)

PLAIN HEX NUT

(NOTE 4)

FLAT WASHER (AL−ALY

UNTREATED)

SPRING LOCKWASHER

FLAT WASHER(S) (NOTE 2)

BOND JUMPER

SPRING LOCKWASHER

NOTE 1

FLAT WASHERS

(AL−ALY UNTREATED)

FLAT WASHER

(NOTE 2)

ACCESS HOLE

COUNTERSUNK WASHER

CHIP DETECTOR WIRING

TAIL LIGHT WIRING

EXTERNAL WRENCHING BOLT

BOOM FITTING

(REF OPTIONAL)

(NOTE 4)

ACCESS HOLE

BRACKET

NOTES:

FLAT WASHER

ENSURE GROUND CONTACT SURFACE IS CLEAN

BEFORE BOND JUMPER INSTALLATION. AFTER

SPRING LOCKWASHER

INSTALLATION, COAT EXPOSED BARE METAL GROUNDED

FLAT WASHER (CRES) (NOTE 3)

AREA WITH LAQUER (47, TABLE 2−4).

NOTE 1

BOND JUMPER

THREE FLAT WASHERS MAX UNDER NUT. ADD CSK

FLAT WASHER

WASHERS UNDER BOLT HEAD AS REQUIRED.

(AL−ALY UNTREATED)

CRES−STAINLESS STEEL.

COAT THREADS WITH LUBRCANT (25, TABLE 2−4) PRIOR

TO INSTALLATION.

30−062E

Figure 5-2. Tailboom Removal and Installation

Page 5-4

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

7. Stabilizer Sheet Metal Repair

(7). Position access plates at each end of

fixed strut and attach with screws and

(1). Negligible Damage:

washers.

Shallow scratches, nicks, light corrosion

9. Upper Vertical Stabilizer Inspection

deposits, and smooth contour dents that

blend into surrounding surfaces are

(Ref. Figure 5−3)

considered negligible damage and

(1). Inspect metal skin for holes, cracks,

require only normal corrosion control

loose rivets or corrosion.

and paint finish maintenance.

(2). Inspect attach fitting for cracks, loose

(2). Repairable Damage:

rivets or corrosion.

Repair stabilizer sheet metal according

(3). Inspect attach bolts and mating holes

to applicable instructions in CSP−H−5.

for evidence of wear caused by loose−

ness in service. Inspect questionable

8. Upper Vertical Stabilizer Replacement

bolts or attach fittings by the dye−

(Ref. Figure 5−3)

penetrant or magnetic particle method,

as applicable.

A. Upper Vertical Stabilizer Removal

(4). Inspect bonding jumper for security,

(1). Remove stabilizer strut.

corrosion and fraying.

(2). Remove forward attach bolts and

10. Upper Vertical Stabilizer Repair

countersunk washers and nuts that

Perform repair of the upper vertical stabilizer

secure stabilizer to tailboom structure;

remove bonding jumper and upper

according to applicable instructions in CSP−

vertical stabilizer.

H−5.

B. Upper Vertical Stabilizer Installation

11. Horizontal Stabilizer Replacement

(Ref. Figure 5−3)

(1). Place upper vertical stabilizer in

position on tailboom. Install bonding

A. Horizontal Stabilizer Removal

jumper, forward attach bolt, counter−

sunk washer and bushing. Countersunk

(1). Remove tail rotor transmission and

side of washer must face bolthead; do

drive shaft (Section 9).

not tighten.

(2). Remove stabilizer strut.

(2). Insert external wrenching bolts with

(3). Remove three bolts, washers, nuts and

counter−sunk washers through mount−

bushing; remove bonding jumper and

ing holes; countersunk side of washer

horizontal stabilizer.

must face bolthead. Install two new

nuts and washers; do not tighten.

B. Horizontal Stabilizer Installation

(3). Install strut; do not tighten strut bolts.

(1). Place horizontal stabilizer in position

on tailboom. Install a countersunk

(4). Torque forward attach bolt to 50 − 70

washer and bushing on external

inch−pounds (5.65 − 7.91 Nm).

wrenching bolt; countersunk side of

washer must face bolthead. Insert bolt

NOTE: Torque values for the nuts may be ap−

in forward mounting hole; do not

plied to the corresponding bolthead at the

tighten. Install bonding jumper.

high limit of the tolerance in cases where

the nut is not accessible.

(2). Install a countersunk washer on each of

the other external wrenching bolts;

(5). Torque the two nuts to 170 − 200

countersunk side of washer must face

inch−pounds (19.21 − 22.60 Nm).

the bolthead. Insert bolts through aft

(6). Torque the strut bolts to 50 − 70

mounting holes and install a nut and

inch−pounds (5.65 − 7.91 Nm).

washer on each bolt; do not tighten.

Page 5-5

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

50−70 IN. LB

(5.65−7.91 NM)

50−70 IN. LB

FLANGED

(5.65−7.91 NM)

BUSHING

FLANGED BUSHING

BONDING JUMPER

BONDING

JUMPER

380−410 IN. LB

(42.93−46.32 NM)

170−200 IN. LB

STRUT

(19.21−22.60 NM)

STABILIZER AND

ADJUSTABLE BOLT

GEARBOX MOUNTING

25−40 IN. LB

FRAME

(2.82−4.52 NM)

(NOTES 1, 2)

UPPER VERTICAL

STABILIZER

HORIZONTAL STABILIZER

BONDING

JUMPER

BOLT

(NOTE 1)

SPACER

90−110 IN. LB

(NOTE 3)

(10.17−12.43 NM)

SPACER

(NOTE 3)

BONDING JUMPER

LOWEER VERTICAL

STABILIZER

DUAL BOLT INSTALLATION

BOLT

NOTES:

TAIL SKID

DIRECTION OF BOLT HEAD OPTIONAL.

AFTER TORQUING, 0.030 IN. (0.762 MM) MIN. GAP TO

EXIST UNDER BOLT HEAD, UNDER NUT, OR IN TOTAL.

CURVED SIDE OF SPACER MUST FACE STABILIZER.

ASTERISK ( * ) INDICATES COUNTERSUNK WASHER.

30−061−1B

Figure 5-3. Empennage Removal and Installation (Sheet 1 of 2)

Page 5-6

Revision 14

MD Helicopters, Inc.

CSP−H−2

500 Series − Basic HMI

(3). Install strut between horizontal and

(3). Reapply the 75 pound (34 kg) down−

upper vertical stabilizer. Use

ward load to stabilizer tip. Inspect spar

MS21250−04004 bolts and MS20002C4

web and upper flange through access

washers; do not tighten bolts at this

holes for cracks, using flashlight. Pay

time.

particular attention to area around first

rivet at each side of bead.

(4). Torque forward mounting bolt to 50 −

70 inch−pounds (5.65 − 7.91 Nm).

NOTE: If spar cracking is noted, horizontal sta−

bilizer must be replaced.

NOTE: Torque values for the nuts may be ap−

(4). Smooth the inspection hole edges to

plied to the corresponding bolthead at the

eliminate surface irregularities. Cover

high limit of the tolerance in cases where

holes with masking tape, or equivalent,

the nut is not accessible.

in place of patching.

(5). Torque the two remaining nuts to 380 −

NOTE: Smooth the access hole edges to remove

410 inch−pounds (42.93 − 46.32 Nm).

possible stress risers. At each subsequent

300−Hour Inspection, remove tape and in−

(6). Tighten strut rut attachment bolts.

spect skin area around holes for possible

(7). Install access plates at each end of fixed

cracks; repair as required (HMI Appx D).

strut with screws and washers.

Re−tape holes

(5). Replace all loose (working) rivets with

(8). Reinstall tail rotor transmission and

correct length CR2249NS−4 or OCKLP−

drive shaft.

B4 rivets.

12. Horizontal Stabilizer Inspection

(6). Check tail rotor balance.

(Ref. Figure 5−3)

NOTE: A tail rotor badly out of balance imposes

excessive stabilizer fatigue loads.

(1). Apply an approximate 75 pound (34 kg)

downward load to horizontal stabilizer

(7). Inspect metal skin for cracks, holes or

tip and visually check for the following:

corrosion.

(8). Inspect attach fitting for cracks, loose

(a). Abnormal deflections.

rivets or corrosion.

(b). Any motion between skin and rivets

(9). Inspect attach bolts and mating holes

on upper surface across first three

for evidence of wear caused by loose−

skin beads out−board of strut attach

ness in service. Replace questionable

fitting.

bolts and dye−penetrant inspect

questionable attach fittings as applica−

If either one of the above condi−

CAUTION

ble.

tions is noted, perform steps (2).

thru (6). below; otherwise, no further action

(10). Inspect bonding jumper for security,

is required.

corrosion and fraying.

(2). Cut three 1 inch (25.4 mm) diameter

13. Horizontal Stabilizer Repair

holes through bottom of skin surface

Perform repair of the horizontal stabilizer

with the center line of the holes 2.0

according to applicable instructions in CSP−

inches (50.8 mm) aft of the spar rivet

H−5.

line at following locations.

14. Lower Vertical Stabilizer Replacement

(a). First hole midway between chordwise

row of rivets and first bead outboard

(Ref. Figure 5−3)

of strut attach fitting.

A. Lower Vertical Stabilizer Removal

(b). Second hole midway between first

(1). Remove bonding jumper.

and second bead.

(2). On helicopters with adjustable bolt

(c). Third hole between second and third

installation, loosen the adjustable bolt

bead.

until it is free but do not remove.

Page 5-8

Revision 14

CSP-H-2 BASIC HANDBOOK OF MAINTENANCE INSTRUCTIONS FOR MDHI 369H HELICOPTERS - page 3