369/500/600 Series Temporary Revision

Temporary Revision369/500/600 Series

Manual: CSP-HMI-2, MAINTENANCE MANUALModels: 369D/E/FF - 500/600N HelicoptersIssued: Issued: 31 October 1990Revision 43: 23 December 2009TR10−003: 22 December 2010

FILING INSTRUCTIONS:1. Before you put this temporary revision in the manual, make sure the manual contains all the

revisions from before. Look at the last revision List of Effective Pages.

Do not put this temporary revision in the manual, if the manual does not contain all the revisions from before.

2. To include this temporary revision in the manual, remove old pages and put in new pages asshown below.

Temporary RevisionNumber/Date Section Page Page Revision

TR10−003/22 December 2010 05−10−00 1 and 2 TR10−003

3 Revision 37

4 TR10−003

05−50−00 1 and 2 TR10−003

21−40−00 209 TR10−003

210 Revision 23

25−10−00 201 Revision 23

202 TR10−003

25−15−00 203 Revision 23

204 TR10−003

25−20−00 205 Revision 23

206 TR10−003

25−40−00 201 Revision 23

202 TR10−003

52−10−00 213 Revision 25

214 TR10−003

53−00−00 201 TR10−003

202 Revision 37

53−10−00 201 TR10−003

202 Revision 19

CAUTION

Temporary RevisionNumber/Date Page RevisionPageSection

53−20−00 201 TR10−003

202 Revision 19

53−30−00 205 Revision 38

206 TR10−003

207 Revision 38

208 and 209 TR10−003

210 Revision 38

53−30−30 203 Revision 34

204 TR10−003

CSP-HMI-2MD Helicopters, Inc.MAINTENANCE MANUAL

05-10-00Page 1

TR10-003

CONTINUED AIRWORTHINESSCOMPONENT OVERHAUL/RECOMMENDED REPLACEMENT

1. Component Overhaul or RecommendedReplacement Schedule

Table 1 is the Overhaul Schedule. The listedcomponents or assemblies should be removedfrom the helicopter and overhauled at intervals specified.

Table 2 is the Recommended ReplacementSchedule. The listed components should beremoved from the helicopter and scrapped atintervals specified.

Table 3 is the Kamatics Component OverhaulSchedule. The listed shafts and couplingsshould be removed from the rotorcraft andoverhauled at the interval specified. To beeligible for the program, the shaft or couplingmust be servicable before return to MDHI for

overhaul/exchange. Any shaft or couplingremoved for After Main Rotor Drive SystemSudden Stoppage - Level 2, conditionalinspection requirements (Ref. CSP-HMI-2,05-50-00, Table 1) is not eligible for overhaulor exchange.

Neither the assignment of an airworthinesslife to a component nor failure to assign anairworthiness life constitutes a warranty ofany kind. The only warranty applicable to thehelicopter and any components is thatwarranty included in the Purchase Agreementfor the helicopter or the component.

NOTE: Hours for the 369F Model helicopterswill be the same as the 369FF unless otherwise noted.

Table 1. Component Overhaul Schedule

Component (1) Model Part Number (2) Hours

Main rotor transmission assembly 369D/E/FF − 500N 369D25100 3000369D25100 4000 (12)

369D/E/FF − 500N 369F5100 5000600N 369F5100 3000

Main rotor swashplate assembly 369D/E/FF − 500N 369D27609 2770 (3)(9)600N 600N7630−3 2700 (4)(9)

Main rotor hub assembly 369D/E/FF − 500N 369D21200 2770 (7)(9)600N 600N1200 2700 (7)(9)

Landing gear damper 369D/E/FF − 500N 369D26300369D26301

On Cond. (6)On Cond. (6)

600N 600N6300 On Cond. (6)

Overrunning clutch assembly 369D/E/FF − 500N 369A5350−603369A5350−605

1800 (5)1800 (5)

369D/E/FF − 500/600N 369F5450 1800 (10)(11)

Tail rotor transmission 369D/E369FF

369D25400 48003365

369D/E 369D25300 4800

Starter/Generator (8) 369D/E − 500N 369A4550 1200369FF − 600N 369D28550 1200

NOTES:

(1) Components interchanged between models or configurations must be restricted to the lowest service lifeindicated for the models or configurations affected. Components removed at retirement are to be destroyedor conspicuously marked to prevent inadvertent return to service. Parts are applicable only on modelsunder which a service life is listed.

CSP-HMI-2 MD Helicopters, Inc.MAINTENANCE MANUAL

Page 2

TR10-003 05-10-00

(2) Service life shown for basic part number applied to all dash−numbered versions unless otherwiseindicated.

(3) Bearing assembly must be relubricated every 2 years or 2770 hours, whichever occurs first (Ref.CSP−COM−5, Sec. 62−30−10).

(4) Bearing assembly must be relubricated every 2 years or 2700 hours, whichever occurs first (Ref.CSP−COM−5, Sec. 62−30−60).

(5) Under some operating conditions, overrunning clutch splines may need to be regreased more often than atthe 100−hour intervals and bearings may need to be regreased more often than at the 300−hour intervals.

With no cargo hook attached, inspect and regrease splines every 100 hours and bearing every 300 hours(Ref. Sec. 63−10−00, Installation of Overrunning Clutch Subassembly and CSP−COM−5, Ball BearingInspection and Grease Repack).

With cargo hook attached, inspect sprag assembly, inner race and outer race every 300 hours or 300 hoursof actual hook time when logged separately as per FAR 91.417, regrease clutch splines every 100 hoursand bearing every 300 hours (Ref. Sec. 63−10−00, Installation of Overrunning Clutch Subassembly andCSP−COM−5, Ball Bearing Inspection and Grease Repack).

(6) When inspected per Landing Gear Damper Inspection (Ref. Sec. 32−10−00 for 369D/E/FF − 500N, or Sec.32−10−60 for 600N).

(7) Use only main rotor hubs overhauled by MDHI or approved MDHI Licensees.

(8) Refer to data plate to determine start/generator manufacturer.

(9) The shelf life of bearings preserved with grease is limited to 4 years.

(10) Regrease overrunning clutch bearings every 300 hours (Ref. CSP−COM−5, Sec. 63−10−15).

(11) Interim hours: life extension testing in progress.

(12) The 369D25100 main rotor transmission overhaul time may be extended from a mandatory 3000 houroverhaul time to a mandatory 4000 hour overhaul time, provided, the transmission is operated with MobilSHC626 since last overhaul.The transmission shall not exceed 3000 hours if cargo hook time has reached a quantity of 750 hours.


05-10-00Page 3

Revision 37

Table 2. Component Recommended Replacement Schedule

Component (1) Model Part Number (2) Hours

Tail rotor swashplate (duplex) bearings 369D/E/FF 369D21832 On Cond. (3)(9)

Fan support bearing 500/600N 500N5364 2400 (8)(9)

Pitch plate bearing 500/600N 500N7120 2400 (8)(9)

Thrust bearing cup, upperThrust bearing cone, upper

369D/E/FF − 500N369D/E/FF − 500N

369D21255369D21254

On Cond. (3)(9)On Cond. (3)(9)

Thrust bearing cup, upperThrust bearing cone, upper

600N600N

369D21255369D21254

600 (5)(9)600 (5)(9)

Thrust bearing cup, lowerThrust bearing cone, lower

369D/E/FF − 500N369D/E/FF − 500N

369D21257369D21256

On Cond. (3)(9)On Cond. (3)(9)

Thrust bearing cup, lowerThrust bearing cone, lower

600N600N

369D21257369D21256

5400 (4)(9)5400 (4)(9)

Bearings, oil cooler blower 369D/E/FF − 500/600N369D/E/FF − 500/600N

369H5655−3369H5655−5

12001200

Belt, oil cooler blower 369D/E/FF − 500N 369D25623 1200600N 93920219 1200

Cyclic stick trim switch (7) 369D/E/FF − 500N A218−100646−02 1000

NOTES:

(1) Limited−life or scheduled replacement components interchanged between models or configurations mustbe restricted to the lowest service life indicated for the models or configurations affected. Limited−life orscheduled replacement components removed at retirement are to be destroyed or conspicuously markedto prevent inadvertent return to service. Parts are applicable only on models under which a service life islisted.

(2) Service life shown for basic part number applied to all dash−numbered versions unless otherwiseindicated.

(3) Bearing assembly must be relubricated every 2 years or 2770 hours, whichever occurs first (Ref. Sec.64−30−00, Tail Rotor Swashplate Bearing Regreasing).

(4) Bearing assembly must be relubricated every 2 years or 2700 hours, whichever occurs first (Ref. Sec.62−20−60, Main Rotor Hub Tapered Bearing Grease Repack, Inspection and Replacement).

(5) Bearing assembly must be relubricated every 2 years or 300 hours, whichever occurs first (Ref. Sec.62−20−60, Main Rotor Hub Upper Bearing Grease Repack, Inspection and Replacement).

(6) Deleted

(7) Installed in 369D27133 grip assembly made by Guardian Electric Co., PN A218966714−00 (Ref. Sec.67−10−20, Cyclic Stick Grip Switch Replacement (Standard Grip)).

(8) Bearing assembly must be relubricated every 2 years or 1200 hours, whichever occurs first (Ref. Sec.64−25−30, Anti−Torque Fan Bearing Regreasing).

(9) The shelf life of bearings preserved with grease is limited to 4 years.


Page 4

TR10-003 05-10-00

Table 3. Kamatics Component Overhaul Schedule

Component Part Number Serial Number Initial TBO Date Next Overhaul

Interconnecting Shaft 369D25515 0001 thru 0535 2010 − 2011 2021 (1)

Interconnecting Shaft 369D25515 0536 thru 1070 2012 2022 (1)

Interconnect Shaft 500N5215 0001 thru 0516 2013 2023 (1)





Interconnect Shaft 500N5215 1776 thru 1824 (2) 2018 2028 (1)

Tail Rotor Driveshaft Coupling 369D25501−5 Not Supported

Tail Rotor Driveshaft Coupling 369D25501−7 0001 thru 0493 2010 − 2011 2021 (1)

Tail Rotor Driveshaft Coupling 369D25501−9 0001 thru 0505 2010 − 2011 2021 (1)

Tail Rotor Driveshaft Coupling 369D25501−7 0494 thru 1087 2012 2022 (1)












Tail Rotor Driveshaft Coupling 369D25501−9 5026 thru 5527 (2) 2021 2031 (1)

NOTES:

(1) Interconnect shafts and tail rotor driveshaft couplings will be overhauled at ten (10) year intervals after thisdate.

(2) Subsequent serial number components initial TBO date is ten (10) years from the rotorcraft manufacturedate.


05-50-00Page 1

TR10-003

CONTINUED AIRWORTHINESSCONDITIONAL INSPECTIONS

1. General

This section contains the unscheduled orconditional inspections. You must do thenecessary Maintenance Manual specificinspections and procedures shown in Table 1 tomake sure there is continued airworthiness ofthe helicopter.

Rotorcraft and components involved inaccidents or incidents must be inspectedand/or tested as required to make sure theyare in a condition of safe operation andconform to type design. Accident or incidentparts are exposed to extreme forces, heat orimmersion that can have a serious effect onstructural integrity. In some cases, eventhough inspection indicates the part isacceptable, the part must be removed fromservice and scrapped.

Aircraft and component records must be clearand contain the necessary details to establisha complete parts history. Without a completedocumented parts history, inspection of a partper CSP-HMI-2 is not sufficient to determineif the part is acceptable for installation. This isespecially critical for life-limited components,flight safety critical aircraft parts (FSCAP)and primary load structures.

Damage from accidents and incidents arewide-ranging. The conditional inspectionrequirements in CSP-HMI-2, Chapter 05cannot fully relate to the accident or incidentthat occurred. If you are not sure whatinspections and/or tests are required to makesure the rotorcraft or parts are in a conditionof safe operation and conform to type design,do the following. Record all informationregarding the accident or incident and contactthe MDHI Field Service Department for thenecessary inspection/tests and maintenanceprocedures.

If there is an incident with your helicopter notshown in this section, record all informationregarding the incident and speak to the FieldService Department at MDHI, Mesa, Arizona.Telephone 1-800-388-3378 or (480) 346-6387.DATAFAX: (480) 346-6813 for inspections andmaintenance procedures you need to do.

It is possible you will need to do more than oneof the inspections or procedures shown inTable 1 of this section. Do all inspections thatare applicable.

NOTE: Refer to the applicable Rolls-Royce Engine Operation and Maintenance Manual(Ref. Section 01-00-00, Table 201) for detailed requirements on inspection of the engine for specific or unique conditions comparable to those listed.

� All components, assemblies, or partsthat are removed for overhaul or repair must be identified with thecause for removal.

� All other components, assemblies, orparts that need to be replaced, mustbe discarded.

2. Hard Landing

A hard landing is an incident or accident inwhich the helicopter hits the ground withsufficient force to cause:

� main rotor blade to hit the tailboom or upperfairings or cowlings.

� permanent deformation of the landing gearmore than permitted limits.

� the lower fuselage, lower tailboom surface,tailrotor, or thruster to touch the ground.

Use the schedule of inspections in Table 1,Conditional Inspections, After Hard Landing ifyou think a hard landing has occurred.

3. Overspeed

Overspeed is an incident in which the rotorspeed (NR) is more than the limits shown inthe applicable Rotorcraft Flight Manual. Usethe schedule of inspections in Table 1, Conditional Inspections, After Main Rotor Overspeed when an overspeed has occurred.

WARNING


Page 2

TR10-003 05-50-00

4. Overtorque

Overtorque is an incident in which the maintransmission torque loads are more than thepermitted limits. Use the schedule of inspections in Table 1, Conditional Inspections, AfterMain Transmission Overtorque BeyondTransient Limits when an overtorque hasoccurred.

5. Sudden Stoppage

Sudden stoppage is a rapid deceleration of themain rotor, rotor drive system, tail rotor, oranti-torque fan.

Sudden stoppage of the main rotor and rotordrive system is caused when the main rotorblades hit the ground, water, snow, thickvegetation, or other object of sufficient mass tocause deceleration. Sudden stoppage of themain rotor and rotor drive system can alsooccur during a hard landing if the blades hitthe fuselage or the tailboom. Use the scheduleof inspections in Table 1, Conditional Inspections, After Main Rotor Blade/Drive SystemSudden Stoppage when sudden stoppage of themain rotor has occurred.

Sudden stoppage of the tail rotor is causedwhen the tail rotor blades hit the ground,

water, snow, thick vegetation, or other object ofsufficient mass to cause deceleration. Use theschedule of inspections in Table 1, ConditionalInspections, After Tail Rotor Blade Strikewhen sudden stoppage of the tail rotor hasoccurred.

6. Lightning Strike

When you think there has been a lighteningstrike on the helicopter, use the schedule ofinspections in Table 1, Conditional Inspections, After Lightening Strike inspectionprocedures.

7. Conditional Inspection Table

� Inspections in this table are for MDHI369D/E/FF and 500/60N helicopters only.The first column of the table denotes whichmodel helicopter the inspections areapplicable to.

� The second column of the table has a shortdescription of the necessary inspection orprocedure.

� The third column of the table shows, ifapplicable, the manual or section that hasthe specific inspection or procedure.


21-40-00Page 209

TR10-003

(11). Remove wood dowel if used to aligninternal parts; then rotate pulleythrough full travel several times toassure ease of operation and positiveclosing of ball valve. A valve torquecheck, step (18). below, is made afterthe timing belt is installed.

(12). Install cold air pulley and washer onshaft.

(13). Install cold air pulley and shaft assembly into valve housing.

(14). Attach cold air vane to shaft using twoscrews.

(15). Rotate ball valve pulley fully counterclockwise to full stop.

(16). Rotate cold air pulley so that the vaneis 45 degrees from fully closed, or alignyellow rigging marks, if present.

(17). Install a serviceable timing beltbetween pulleys while maintainingvalve position located in steps (15).and(16). above.

(18). Check valve operation by applying 6 -11 inch-ounces (0.0423 - 0.0777 Nm)of torque on the ball valve shaft. If theball valve does not operate within thisrange, change thickness of shimsbetween the valve elbow and housing asrequired. Shims are provided inch 0.015inch (0.381 mm), 0.010 in. (0.254 mm),and 0.005 inch (0.127 mm) thicknesses.

NOTE: Final total shim thickness should notexceed dimension C (step (c).) by more than0.10 inch (2.54 mm).

(19). If rigging marks have not been applied,paint a yellow index mark, 1/16 inch(1.59 mm) wide, on pulley and housing(Ref. Figure 201).

(20). Reinstall and actuator belt pulley onball valve using three screws (Ref.Figure 201). Note that the screwlocated 180 degrees from the riggingpinhole is 1/8 inch (3.175 mm) longerthan the others. Remove rigging pininstalled in step (10). above. Safetyscrews to each other with lockwire.

9. Heating System Muffler and Ducts Repair

Consumable Materials(Ref. Section 91−00−00)

Item Nomenclature

CM432 DichloromethaneCM433 Ethylene chloride

Repair of heat system ducting will dependupon the type of material used in the sectionthat requires repair. Rubber hose or flexiblefiberglass hose that is torn, flattened, ordeteriorated must be replaced. When removingducting for repair or replacement, use illustration as a guide (Ref. Figure 205).

(1). Repair rigid fiberglass or muffleraccording to the fiberglass repairprocedures outlined in the SRM, exceptuse fire-retardant resin.

(2). Repair rigid polycarbonate plasticsections by bonding a patch accordingto the criteria and methods specified foracrylic plastic in FAA AC 43.13-1B,Aircraft Inspection and Repair forStandard Sheet Metal Repair. Usedichloromethane (CM432) or ethylenedichloride (CM433) as the bondingagent.

(3). Repair small areas of rib or seamseparation in plastic sections byinjecting ethylene dichloride (CM433)into the void area and clampingtogether under light pressure.


Page 210

Revision 23 21-40-00

G21-4005

DIFFUSERASSEMBLY

NOTES: 1. REMOVE ADHESIVE BACKING COVER AND INSTALL PADS

WHERE INTERFERENCE MAY EXIST BETWEEN HOSE AND STRUCTURE.

2. INSURE THAT HEATER HOSE DOES NOT CONTACT OIL FLEX LINES OR STRUCTURE.

SCOTCH FOAM PAD

OIL FLEX LINE(NOTE 2)

GROMMET

DUCTHOSE

GROMMET

STANDOFF

CLAMP CLAMP

DUCT ASSEMBLY

COLD AIR MANIFOLD

MUFFLER

COLD AIR HOSE

CLAMPCONVENIENCE PANEL

HEATING VALVE

DUCTING INSTALLATION

Figure 205. Hose and Ducting Installation


25-10-00Page 201

Revision 23

UPHOLSTERED SEATSMAINTENANCE PRACTICES

1. Upholstered Crew Seat Replacement

(Ref. Figure 201, Figure 202 and Figure 204)Upholstered Seats for the 369D/E/FF -500/600N Helicopters are the same. Theaddition of the mid position bench seat isunique to the Model 600N.

(1). Clear seats of seat belts and shoulderstraps.

(2). Lift seat cushions away from fuselageseat structure to release Velcro stripand fasteners.

(3). To replace, position seat cushions sothat Velcro fastener strips mate. Applyslight pressure to secure seat cushionsin place.

2. Upholstered Passenger Aft Bench SeatReplacement

(Ref. Figure 201 or Figure 202)

(1). Clear seats of seat belts and shoulderstraps.

(2). Release seat quick-disconnect fittingsat bulkhead, then at floor points.

NOTE: For height adjustment, install ball-lockpins in desired position at support legs andbulkhead fittings. For fore and aft adjustment, move and secure seat back at desiredposition on lower frame.

(3). To replace, position bench seat so thatquick-disconnect fittings align withfloor and bulkhead attach points.

(4). Lock seat in place, first at floor fittingsthen at bulkhead fittings.

3. Mid Bench Seat Assembly Replacement(600N)

(Ref. Figure 204)

A. Mid Bench Seat Removal

(1). Remove quick release pins that attachseat support fittings to floor rails.

(2). Remove seat assembly.

B. Mid Bench Seat Installation

(1). Install seat assembly in aircraft.

(2). Align seat support fittings with floorrails.

(3). Install quick release pins to secure seatassembly to floor.

4. Upholstered Passenger Individual SeatReplacement

(Ref. Figure 205)

(1). Clear seat of seat belts and shoulderstraps.

(2). Remove ball-lock pins from bulkheadattach fittings.

(3). To replace, position seats so thatquick-disconnect pins align withbulkhead attach points and lock seatsin place.

5. Upholstered Seat Inspection

(Ref. Figure 201, Figure 202 and Figure 204)

(1). Inspect upholstery material for cuts,loose stitching or other unserviceablecondition.

(2). Inspect Velcro fastener strips forsecurity of attachment and condition.

(3). On passenger seat structure, inspectquick-disconnect mechanisms forproper operation or damage that mayprevent positive locking.

A. Upholstered Seat Cleaning

(Ref. Sec. 20-20-00, Fuselage Interior Trimand Upholstery Cleaning)


Page 202

TR10-003 25-10-00

6. Upholstered Seat Repair


Item Nomenclature

CM219 Methyl-ethyl-ketoneCM405 Adhesive

(1). Lapstitch frayed or worn upholstery.

MEK solvent is flammable.Use only in well-ventilated

area and away from heat and flame.

NOTE: Loosened Velcro strips may be reactivated for adhesion by wiping original adhesive film with MEK (CM219).

(2). Replace unserviceable Velcro fastenerstrips. Install new Velcro strips to mate.Bond in place with adhesive (CM405).

(3). Make minor welded or riveted sleeve-type repairs on tubular structureaccording to FAA AC 43.13-1B Inspection and Repair for Standard SheetMetal Repair.

7. Optional Mid Business Seat Replacement(600N)

(Ref. Figure 206) This option replaces thestandard mid bench seat with two fore and aft

adjustable seats attached through four seattracks that allow seat location adjustment overa 10 inch span when seats are facing forward.

NOTE:� With the seats in the full aft position and

facing forward, the rear passenger seatsbecome unusable for passenger seating.

� The seats are removable and may beplaced in the aft facing position.

� In the aft facing position, only two seatlocations are available.

A. Business Seat Removal

(1). Remove quick release pins that attachseat support fittings to floor rails.

(2). Remove seat assembly.

B. Business Seat Installation

(1). Install seat on tracks with forwardguide pin in track cutout first.

(2). Once seat guide pin is in track, slideseat forward until 2 rear guide pins arein the track cutouts.

(3). When installing seat facing aft, tiltseat-back full forward duringinstallation.

WARNING


25-15-00Page 203

Revision 23

NYLON MESH

SEAT BACK (FOLDS FORWARD)

AFT SEAT

SEAT FITTING ANDHEIGHT ADJUSTMENT

SEAT BOTTOM(FOLDS FOR STOWAGE)

UPPER HINGE POINT

LOWER HINGE POINT

QUICK DISCONNECT(AT REAR OF LEGS)

PASSENGER INDIVIDUAL MESH SEAT HEIGHT ADJUSTMENT

FOLDING SEAT BACK AND LEGS SEAT STOWAGE

G25-1004

Figure 202. Passenger Individual Mesh Seat Adjustment and Storage


Page 204

TR10-003 25-15-00

7. Mesh Seats Cleaning

(Ref. Sec. 20-20-00, Fuselage Interior Trimand Upholstery Cleaning)

8. Mesh Seats Repair


Item Nomenclature

CM234 Solvent, dry-cleaningCM405 Adhesive

Repair of seats is limited to the following:

(1). Lap stitch frayed or torn nylon webbing, or replace if damaged beyondrepair.

(2). Install new rubber pads.

(3). Clean seat mounting plate with cleancloth dampened with solvent (CM234).

(4). Apply cement (CM405) and attach padto seat mounting plate.

(5). Replace damaged nutplates.

(6). Minor weld repairs may be performedaccording to FAA AC 43.13-1B Inspection and Repair for Standard SheetMetal Repair.

SEAT BACK

FRAME

AFT SUPPORT FITTING ANDHEIGHT ADJUSTMENT

FLOOR STRUCTURE

NYLON MESHBALL-LOCK PIN

SUPPORT LEG ANDHEIGHT ADJUSTMENT

FORE AND AFTADJUSTMENT HOLES

RELEASE PIN

G25-1005

Figure 203. Passenger Bench Mesh Seat Adjustment


25-20-00Page 205

Revision 23

5. Crew Seat Belt/Harness Replacement WithManual Lock Option (369D/E/FF − 500N)

(Ref. Figure 204 and Figure 205)

(1). Remove seatbelts by unfastening snaptype end fittings from bulkheadstructure fittings.

(2). Remove inertia reel, with harness, fromfiberglass mount by loosening four boltsand upper ferrule nut.

(3). Install seatbelts by fastening snap typeend fittings to bulkhead structurefittings.

(4). Install inertia reel, with harness, tofiberglass mount with ferrule nut andfour bolts, nuts and washers.

G25-2006A

CONTROL HEAD ROTATED90° CW FOR CLARITY

UPPER FERRULE NUT

INERTIAREEL ASSY

AUTOMATIC MANUAL LOCK

CABLE

LOWERFERULE

NUT

CONTROL ASSYADJUSTER(TYP)

TAB RELEASE(TYP)

0101935-1 SHOULDERHARNESS ASSY

1.88-2.12 IN. (4.776-5.385 CM)WIDE WEBBING

END FITTINGADJUSTER

LINK LATCH

2.88-3.12 IN. (7.315-7.925 CM)WIDE WEBBING LAP BELT ASSY(0101936-1 ASSY)

ADJUSTER

Figure 204. Webbed Shoulder Harness and Seat Belt Installation with Manual Inertia Reel Lock (369D)


Page 206

TR10-003 25-20-00

LOW SHOULDER BEAM INSTALLATION HIGH SHOULDER BEAM INSTALLATION G25-2005

Figure 205. Crew Inertia Reel Installation with Manual Inertia Reel Lock (369D/E/FF − 500N)

6. Seat Belt/Inertia Reel Testing

(Ref. Pull tests of seat belts and shoulder strapharnesses shall be accomplished in accordancewith FAA AC 43.13-1B, Aircraft Inspectionand Repair for Standard Sheet Metal Repairand TSO C22.

7. Seat Belt/Inertia Reel Inspection

Ensure center passenger lapbelt is installed with tongue

portion to the right of the seat andbuckle portion to the left. (Quick release of the lap belt and shoulder strapmay be impaired if the assembly is improperly installed.) If tongue andbuckle portions are reversed, removeand reinstall in correct positions anddocument reinstallation in ComplianceRecord of Helicopter Log Book.

(1). Pull seat belt or shoulder strap out ofinertia reel to full extended length.Ensure harness strap cannot be pulledout of inertia reel. With tension re

leased, harness strap should automatically reel back into reel. Exert a suddenforward pull on seat belt or shoulderstrap to ensure inertia reel locks.

(2). Inspect inertia reels, snap end fittings,adjusters, links, buckles, latches andbelt attachment fittings for cracks,wear, corrosion and deformation. Checkfor freedom from binding, ease ofadjustment and operation as applicable.If doubt exists as to strength, performpull test (Ref. Seat Belts/Inertia ReelTesting).

(3). Inspect shoulder harnesses and seatbelts for worn, frayed or deterioratedcondition, and loose stitching.

(4). (Manual Lock Option) Check mechanical inertia lock mechanism for properoperation, with handle up and withhandle down. Inspect fiberglass mountsfor cracking and separation. Inspectlaminates for debonding.

WARNING


25-40-00Page 201

Revision 23

MISCELLANEOUS FURNISHINGSMAINTENANCE PRACTICES

1. Crew Compartment MiscellaneousFurnishings Replacement

Methods for removal and installation areobvious for most miscellaneous furnishingitems. Some maintenance instructions areprovided in the following procedures.

Crew compartment furnishings for the 600NHelicopter are the same as for the 369D/E/FF- 500N Helicopters.

A. Stowage Box

Access to stowage box is thru crew compartment right side floor access door (Ref. Sec.52-50-00).


Item Nomenclature

CM117 Grease

NOTE: Helicopters equipped with certain optional communications and avionics installations do not have stowage box installed.

When installing replacement stowage box,cover screwheads with tape (CM717).

B. Heat Duct

The heat duct consists of an upper and lowersection with a magnetic compass mounted onthe lower section just above the instrumentpanel. The anti-icing control (Ref. Sec.75-10-00) and cabin heat control (Ref. Sec.21-40-00) mount on the upper section of theheat duct. Removal of magnetic compass is notrequired for removal of heat duct. However,wiring to the light must be disconnected at thesplices.

C. Foot Rest (L/H Command)

For access to foot rest attaching hardware,remove stowage box. Position replacement footrest on floor support bulkhead and installattaching hardware. When necessary, useadditional thin aluminum washers to shim

between foot rest and bulkhead for correctfour-point contact.

D. Ash Receiver and Cigarette Lighter Panel

(1). The cigarette lighter panel may beremoved by releasing four turnlockfasteners.

(2). Disassembly of the cigarette lighter andpanel for maintenance purposes isshown in the figure.

2. Passenger Compartment MiscellaneousFurnishings Replacement

Methods for removal and installation areobvious for most miscellaneous furnishingitems. Some maintenance instructions areprovided in the following procedures.

Passenger compartment furnishings for the600N Helicopter are the same as for the369D/E/FF - 500N Helicopters except, whereapplicable, panels and ducting is 30 incheslonger.

A. Convenience Panel Replacement (R/HCommand)

(1). Remove attachment screws. Lowerpanel and disconnect any wiring andheat valve connectors before removingpanel.

(2). Reinstall using reverse procedure.

3. Passenger Step Assembly Description

(Ref. Figure 203) Due to the extended fuselageof the 600N Helicopter, the addition of anelongated passenger step is unique to thisaircraft. The step is secured at two positionson each side of the fuselage, as compared toone position on the 369D/E/FF - 500NHelicopters. The step is available in either ahigh or low step configuration depending onthe landing gear option installed.

4. Passenger Step Assembly Inspection

(1). Inspect step attach point(s) for securityof installation and general condition.


Page 202

TR10-003 25-40-00

(2). Inspect ”no skid” surface of step forgeneral condition. Replace or reattach ifworn excessively.

5. Passenger Step Assembly Replacement

A. Passenger Step Assembly Removal

(1). Gain access to passenger step assemblyattaching hardware under floor covering of passenger/cargo compartment.

(2). Remove quick release pin(s) that securestep assembly in mounting hole(s).

(3). Remove step assembly.

B. Passenger Step Assembly Installation

(1). Align and insert passenger stepassembly into mounting hole(s) infuselage.

(2). Insert quick release pin(s) to securestep assembly.

(3). Secure floor covering in passenger/cargocompartment.

6. Passenger Step Assembly Repair

The passenger step has black, non-slip,pressure-sensitive, safety-walk tape appliedto the upper surface of the step plate.


Item Nomenclature

CM220 Naphtha aliphaticCM724 Tape, non-slip

(1). To replace worn or lost safety-walktape, carefully scrape away damagedtape. Remove all residual adhesive bywiping with naphtha (CM220) wettedcloth.

(2). Install new tape (CM724) and pressfirmly into place. Expel air bubbles bypressing down tape from center out tothe edges.

7. Miscellaneous Furnishings Inspection

(1). Inspect for cracks, breaks or otherunserviceable condition.

(2). Inspect helicopter checklist andmagnetic compass card for conditionand legibility.

(3). Inspect for loose, damaged or missingrivnuts and other attaching hardwareas applicable.

8. Miscellaneous Furnishings Repair

(1). Repair cracks or breaks in thermoplastic material (Ref. Sec. 20-30-00,Boltaron Trim Panels Repair).

(2). Perform minor weld and rivet repairsaccording to FAA AC 43.13-1B Inspection and Repair for Standard SheetMetal Repair.


52-10-00Page 213

Revision 25

G52-1003-3A

WITNESS HOLE

PIN

LATCHSLIDER

LATCHHOUSINGLATCH BLOCK

ASSEMBLY

LATCHSLIDER

0.050 INCH (1.27 MM) MAXGAP BETWEEN DOORSTRIKER PIN AND HOOKLATCH WHEN DOORCLOSED AND LATCH INREST POSITION.

Figure 203. Door Handle Positions and Latch Engagement (Sheet 3 of 3)

(3). Check latch blocks, latch sliders, doorwaffle and striker pin assemblies forany nicks, dents, scratches, chippedpaint or other evidence of contactcaused by misalignment of door latchesor striker pin assemblies.

NOTE: Extreme temperatures may cause doorseal to swell or door seal-to-door framebonding failure. Door seal protrusionscaused by swelling or bonding failure mayinterfere with latching function.

(4). Check door seal and repair as required.

(5). Close door firmly from inside helicopter.Check that all four latch hooks engagetheir striker pins and that there is notmore than 0.050 inch (1.27 mm)between each hook and striker pin.

(6). Move handle to lock (full down). Withdoor locked, use flashlight to checkwitness hole on each latch block. Note

that semi-circle cutout on latch slider isfully seated around pin on latch block.

(7). Move handle to open. Note that all fourlatch hooks extend fully from theirlatch blocks and fully disengage theirstriker pins, allowing the door to open.Handle should spring back to restposition when released.

15. Autolatching Pilot and Cargo DoorsOperational Check

NOTE: When opening door, apply light inwardforce on door. This reduces wear of latchingmechanism by overcoming door seal pressure.

(1). Open and close door to check for smoothoperation of handles and latch mechanism. Check operation of door stop.

(2). Close door from inside. Check all insidelatches for correct engagement at latchand safelock positions of interior andexterior handle. (Ref. Figure 203).


Page 214

TR10-003 52-10-00

(3). Check that setting interior and exteriorhandles to safelock position pulls doorinward for proper closure and sealing.

(4). Check that key locks and unlocks doorhandle.

16. Door−Latching Mechanism Inspection (AllSystems)

(Ref. Figure 202 and Figure 203)

Make following checks with magnificationglass and strong light:

(1). All parts for excessive wear, nicks,cracks and corrosion.

(2). Threaded parts for worn, crossed orotherwise damaged threads.

(3). Early latch block assemblies for brokensprings and wear on strike contactsurfaces of latching bolts; and for unduewear of latch sliders, bolts and boltrollers. Current latch block assembliesfor wear, damage or distortion of latchsliders and latch hook.

(4). Cam lock for jamming when key isoperated.

(5). Link for wear or distortion.

(6). Handles for distortion, worn pivot holesand worn finish.

(7). Escutcheon and handle for looseness,distortion, thread damage and breakage.

(8). Lockplate assembly for wear, distortion,thread damage and breakage.

(9). Latch block nutplates for threaddamage and loose rivets.

(10). Rods and clevis for wear in clevis pinholes, thread damage, and distortion.

17. Anti−Chafing Tape on Door Frame Repair

(Ref. Figure 208) Inspect condition of anti-chafing tape installed on pilot's and cargocompartment door frames. For minor repair,remove defective tape where necessary. Cleanframe surface with MEK (CM219). Replacewith polyurethane pressure-sensitive tape(CM717).


Item Nomenclature

CM219 Methyl-ethyl-ketoneCM717 Tape, pressure sensitive

18. Window Replacement

A. Early Style Window Replacement

(Ref. Figure 205) For repair of plastics refer toFAA AC 43.13-1B. Replace window as follows:


Item Nomenclature

CM415 CementCM418 Cement, epoxyCM425 Sealing compoundCM432 DichloromethaneCM433 Ethylene chlorideCM717 Tape, pressure sensitive

(1). Remove snapvent from window (Ref.Snapvent Replacement).

(2). Drill out rivets attaching windowretainers to door structure and removewindow. Remove two screws, washersand nuts from door hinge doubler.

(3). If door frame or window is to be reused,carefully scrape off sealant around edgeof door or window frame using awooden, plastic or other suitablenonmetallic scraper.

(4). Repair retainer-to-window bond, ifapplicable, with dichloromethane(CM432) or ethylene chloride (CM433);or use PS-18 or S147 cement (CM415).

(5). Trim retainer as required to provideclearance for door handle and end buttjoint.

(6). Place window in position and check for0.380 inch (9.652 mm) minimumengagement and flush fit with windowframe. Trim excess if required.

(7). Use 1/2 inch (12.70 mm) pressure-sensitive tape (CM717) on edge of window.Bond seals to retainer and to door


53-00-00Page 201

TR10-003

FUSELAGEMAINTENANCE PRACTICES

1. Fuselage − General

(Ref. Figure 201) The helicopter fuselageconsists of three major structural sections; theforward, lower and aft fuselage sections. Forclassification and definition of types ofnegligible damage, and for guidelines definingextent of damage requiring repair or replacement, (Ref. Stressed Sheet Metal Panels,Non-Stressed Sheet Metal Panels andTable 201).

(Ref. Figure 202) The fuselage of the 600Nhelicopter is a stretched version of the 500NSeries helicopter with numerous upgrades andimprovements. (shaded areas indicate newsections to fuselage) The longer cabin area ofthe 600N greatly increases passenger and/orcargo carrying capacity. Upper deck areafairings and covers were added or modified toaccommodate control surfaces or air inletpassages.

The tailboom on the 600N helicopter isessentially the same as the 500N Series, onlylonger. The vertical stabilizers or endplates arelonger than on the 500N model, providing anincreased control surface area.

An extended passenger step alongside thepassenger/cargo compartment allows for easyentrance and exit through either mid or aftcabin doors.

2. Stressed Sheet Metal Panels

Stressed sheet metal panels consist primarilyof helicopter fuselage skins and bulkhead

webs. The most-highly-stressed skin sectionsare those that form the cylindrically-taperedtailboom assembly (Ref. Sec. 53-40).

NOTE: No damage can be considered negligible. All damage shall be repaired upon detection.

3. Stressed Sheet Metal Panel Inspection

Cracks, tears or punctures in stressed sheetmetal panels that do not exceed 0.20 inch (5.08mm) diameter and can be removed by drillingout with 1/4 inch (6.35 mm) or smallerdiameter drill do not require structuraldoublers. If cracks, tears or punctures exceed0.20 inch (5.08 mm) diameter, they are to berepaired or the panel must be replaced perinstructions in FAA AC 43.13-1B and FAA AC43.13-2B Inspection and Repair for StandardSheet Metal Repair and Alterations andStructural Repair Manual.

4. Non−Stressed Sheet Metal Panels

Non-stressed sheet metal members consistprimarily of hinged covers and doors, exceptfuel cell access and controls access doors,which are stressed (Ref. Stressed Sheet MetalPanels).

5. Negligible Damage Inspection

(Ref. Table 201) Panels damaged in excess ofnegligible damage limits (Ref. Table 201)should be repaired, or damaged panel shouldbe replaced per instructions in FAA AC43.13-1A & 2A and CSP-SRM-6 (StructuralRepair Manual).


Page 202


Table 201. Negligible Damage Inspection − Fuselage

Area *DamageMaximum

DepthMaximum Length

or Surface Remarks

Stressed sheetmetal panels.

No unrepaired damageallowed. (For tailboom, Ref. Sec.53−40).

Non−stressed sheetmetal panels.

Dents. Small dents allowed.**

Scratches/nicks. Minor scratches/nicksallowed.**

Cracks. Smaller of 0.250inch (6.35 mm) orone−fourth panelwidth.

Must be one inch or morefrom any attachment fittingand/or panel edge.

Main rotor mast. No unrepaired damageallowed (Ref. Figure 201)

Firewalls. No unrepaired damageallowed.

Fuselage fittings. Longitudinalscratches, dents, andnicks.

0.010 inch(0.254 mm)

15% of fittinglength.

After polishing or repair.

Transverse scratches,dents, and nicks.

0.010 inch(0.254 mm)

10% of fittingthickness.

After polishing or repair.

NOTES:

* All damage to fuselage exceeding limits given requires repair or replacement of effected panel orcomponent.

** Dents, scratches and nicks that penetrate aluminum protective coating (4% of panel thickness with paint orother surface finishes removed) will allow corrosion of aluminum panel, and should be repaired.


53-10-00Page 201

TR10-003

WINDSHIELDS AND AFT SECTION WINDOWSMAINTENANCE PRACTICES

1. Windshields

Center and lower windshield panels areclearest acrylic (Ref. Figure 201 andFigure 202). Upper windshield panels aresmoke-grey-tinted cast acrylic. The centerwindshield panels are approximately 0.100inch (2.540 mm) thick.

2. Aft Section Windows

For repair of plastics, Ref. FAA AC 43.13-1B.Replace aft section window if it is damagedbeyond practical repair, according to applicableinstructions in Structural Repair Manual.

(Ref. Figure 204) On the 600N helicopter the”Aft Section Windows” refer to the upper midsection windows located above the midpassenger/cargo doors. On the 500 Serieshelicopters this area was referred to as the”Aft Section”.

3. Aft Section Windows Replacement

(Ref. Figure 204)

A. Aft Section Windows Removal

(1). Remove old sealing compound fromaround edge of window and windowseal.

(2). Using a blunt plastic spatula or probe,pull back flap of window seal andgradually work window out from underflap of seal.

(3). Remove seal and clean for re-installation of window.


Item Nomenclature

CM425 Sealing compound

B. Aft Section Windows Installation

(1). Install window seal around periphery ofwindow opening in fuselage.

(2). Using a blunt plastic spatula or probe,gradually work edge of window underflap surface of window seal.

(3). Maintain pressure on window untilentire perimeter of window is underseal.

(4). Apply an even amount of sealingcompound (CM425) to form a watertight seal around window seal tofuselage and from window seal towindow.

4. Windshield Frame Replacement


Item Nomenclature

CM305 Lacquer, acrylicCM425 Sealing compound

For older model helicopters with riveted-inwindshields, remove or replace windshieldaccording to applicable instructions in theStructural Repair Manual.

A. New−Style Windshield Installation

(1). Install windshields in place and installhardware (Ref. Figure 203 andFigure 204).

(2). After normal installation of windshield,grind two screws flush with nuts (Ref.Figure 203).

(3). Touch-up with lacquer (CM305).

(4). Seal all windshield seams with sealingcompound (CM425).

5. Windshield Inspection

Minor defects or imperfections that do notimpair pilot's critical visibility, or that obviously are not signs of impending structural failuremay be considered as negligible. (For allowabledamage limits, Refer to Table 201.)

6. Windshield Repair

For repair of plastics, Ref. FAA AC 43.13-1B.Replace windshields if damage beyond


Page 202


practical repair, according to applicableinstructions in Structural Repair Manual.

7. Water Leak Prevention


Item Nomenclature

CM425 Sealing compound

If water leakage through geon strips of theforward canopy occurs, remove any existingsealant using a plastic or other non-metallicscraper which will not scratch the canopyglass. Apply 0.060 inch (1.524 mm) bead ofsealant (CM425) along gaps between geonstrips. Apply sealant as directed by sealantmanufacturer.

8. Geon Strips Repair


Item Nomenclature

CM220 Naphtha aliphaticCM414 Adhesive, cyanoacrylic / AcceleratorCM722 Tape, polyethylene

Fill voids between geon strips and transparencies as follows:

(1). Measure the insertion depth of acrylicwindshield into geon slot, reject parts

having less than 0.125 inch (3.175 mm)insertion. Replace parts with debondingareas over 8 inches (20.32 cm) inlength.

(2). Mask the geon weatherstrip andwindshield on both sides with tape(CM722).

(3). Wipe all faying surfaces with aliphaticnaphtha (CM220) and dry for a minimum of 15 minutes.

(4). For small voids:

(a). Apply adhesive (CM414) to all fayingsurfaces using syringe if necessary.

(b). Use light pressure to hold the jointclosed for a minimum of 2 minutes.

(5). For large voids:

(a). Apply accelerator to the acrylictransparency and air dry for aminimum of 2 minutes.

(b). Apply adhesive to the geon weatherstrip only.

(c). Apply local pressure to insurecomplete contact between adherentsand maintain pressure for a minimum of 30 seconds.

(d). Remove tape and remove excessresidue with aliphatic naphtha.

Table 201. Negligible Damage of Canopy/Windshield

Area DamageMaximum

Depth

MaximumLength or

Surface Area Remarks

Canopy and Windshield. Nicks 0.010 inch(0.254 mm)

0.250 inch(6.35 mm)

One per square footonly.

Scratches 0.010 inch(0.254 mm)

5.000 inch(12.7 cm)

Spots or stains If removable by lightpolishing.

Panels (not windshields orwindows).

Punctures 0.200 inch(5.08 mm) dia

Windshield. Polarization faults(distortion)

Small area near edges.


53-20-00Page 201

TR10-003

LOWER CENTER FUSELAGEMAINTENANCE PRACTICES

1. Lower Center Fuselage − General

(Ref. Figure 201) Lower center fuselage isthose areas below fuselage floor level (WL13.10) on both sides of the center beam andbetween Sta. 78.50 and Sta. 124.00.

(Ref. Figure 202) The Lower Center Fuselagefor the Model 600N helicopter is similar to thatof the 500 Series helicopters except for theadditional stretched or extended fuselage�plug� station. The extended lower centerfuselage section is located at Sta. 78.50(designated P. Sta. 0.00 thru 30.00) (Ref.Section 06-00-00). Additional floor accesscovers for the fuel cell are also containedwithin this section of fuselage.

2. Lower Center Fuselage Inspection

(1). Ref. FAA AC 43.13-1B Aircraft Inspection and Repair for Standard SheetMetal Repair and Structural RepairManual for standard sheet metalrepair.

(2). Inspect electrical harnesses and wiringfor frayed insulation and groundingterminals for corrosion.

(3). If cargo floor is bent or punctured,remove appropriate fuel cell accesscover and inspect fuel cell.

(4). Perform repair (Ref. Fuel Tank SupportSkins Repair (Fuel Cells Removed)).

3. Fuel Tank Support Skin Inspection (FuelCells Removed)

(1). Check security of fiberglass skinattachment to support angles andbrackets.

(2). Inspect anti-abrasion tape for securityof adhesion over rivet heads, all sharpedges and lap joints.

(3). Negligible damage (Ref. Table 201,53-00-00).

4. Fuel Tank Support Skins Repair (FuelCells Removed)


Item Nomenclature

CM711 Tape, pressure sensitive

(1). Repair fuel tank support skins according to applicable instructions in FAAAC 43.13-1A & 2A or Structural RepairManual.

(2). Cover exposed rivet heads with 10 milby 1 inch (2.54 cm) tape (CM711) toprevent chafing fuel cell fabric.


Page 202


FLOOR WEB(0.016 IN. (0.4064 MM)

2024-T3 AL ALY)

CENTER BEAM

STIFFENER(0.020 IN. (0.508 MM)7075-T6 AL ALY)(TYPICAL 8 PLCS)

STIFFENERS(0.032 IN. (0.8128 MM)

7075-T6 AL ALY)(TYPICAL 7 PLCS)

WEB (0.016 IN. (0.4064 MM)7075-T6 AL ALY)

DOUBLER (0.032 IN. (0.8128 MM)7075-T6 AL ALY)

STIFFENER(0.032 IN. (0.8128 MM)

7075-T6 AL ALY)STA 119.67 RIB (0.025 IN. (0.635 MM)7075-T6 AL ALY)

WL 13.10

124.00 LOWER FRAME(0.020 IN. (0.508 MM)

15-7 CRES)STA 113.85 RIB (0.025 IN. (0.635 MM)7075-T6 AL ALY)

STIFFENERS(0.020 IN. (0.508 MM)

2024-T3 AL ALY) STA 108.04 RIB (0.025 IN. (0.635 MM)7075-T6 AL ALY)

DOUBLER(0.025 IN. (0.635 MM)

2024-T3 AL ALY) STA 102.23 RIB (0.025 IN. (0.635 MM)7075-T6 AL ALY)

WEB (0.016 IN. (0.4064 MM)

2024-T3 AL ALY)STA 90.61 RIB

(0.040 IN. (1.016 MM)7075-T6 AL ALY) JACK FITTING

(PART OF STA 96.42 RIB)DOUBLER (0.050 IN. (1.270 MM)

7075-T6 AL ALY)DOUBLER

(0.050 IN. (1.270 MM)7075-T6 AL ALY)

CARGO HOOK FITTING(IF APPLICABLE)

STA 96.42 RIB ASSY(0.050 IN. (1.270 MM)7075-T6 AL ALY)

STIFFENER(0.032 IN. (0.8128 MM)

7075-T6 AL ALY) STA 84.70 RIB(0.032 IN. (0.8128 MM)

7075-T6 AL ALY)CANT STA 78.50LOWER FRAME

(0 040 IN (1 016 MM) G53-2002A

Figure 201. Lower Center Fuselage (369D/E/FF − 500N)


53-30-00Page 205

Revision 38

TAIL ROTOR DRIVE SHAFT FAIRING

REMOVABLE PANEL

CANTED STA. 124.00CHANNEL

ENGINE AIR INLETINSTALLATION

(PLENUM CHAMBER)

FORWARD ENGINEAIR INLET PANEL

DRAIN FITTING

ENGINE AIRINLET PAN

WATERLINE 34.96 RIB

AFT SECTION UPPER FIREWALL(NOTE)

ENGINE AIR INLET SIDE PAN

AFT SECTION FORWARD FIREWALL(NOTE)

G53-3008A

NOTE: AFT SECTION FIREWALL IS A REMOVABLE ASSEMBLY. BOTTONHEAD FASTENERSARE WITHDRAWN FROM INSIDE SURFACE OF FIREWALL SHELL TO REMOVE

369D/E/FF SHOWN

Figure 202. Firewall and Aft Section

A. Firewall, Station 124.00 Insulation andSoundproofing

(Ref. Figure 201, Sheet 1 of 2) Engine compartment forward firewall is insulated andsoundproofed for heat and noise reduction inpassenger/cargo compartment.

5. Firewall and Plenum ChamberSoundproofing Panel Inspection

(Ref. Figure 201, Sheet 1 of 2 and Figure 202)

(1). Remove trim (Ref. Sec. 25-30-00,Interior Trim Replacement) for accessto passenger/cargo compartmentfirewall areas. Open engine accessdoors to inspect engine compartmentpanels.

(2). Check for defective, torn, loose ormissing panels.

(3). Inspect aft firewall for security, punctures and corrosion.

(4). Check that all individual panels aresecurely attached to firewall andplenum areas with no loose edges.

(5). Check panels in passenger compartment of defects, tears, looseness, ormissing panels.

(6). For applicable repairs refer to PlenumChamber Hole Sealing reference.

A. Engine Air Inlet Fairing

The engine air inlet fairing on top of thefuselage structure directs ambient outside airto the engine air inlet and oil cooler blower.The fairing installation consists of a forwardfairing section and an aft fairing section. Rightand left halves of forward fairing are removable. The aft fairing is riveted to fuselagestructure. A UHF/VHF antenna is bonded tothe aft vertical face and is part of aft fairing.


Page 206

TR10-003 53-30-00

6. Engine Air Inlet (Plenum Chamber)Inspection

(1). For access, open bypass door on rightside of engine air inlet and enginecompartment access doors for view ofrear side of plenum (Ref. Figure 202).

(2). Inspect all panels for evidence ofcorrosion, security of rivets and punctures.

(3). Inspect engine air shield mounting clipsfor secure attachment.

(4). Inspect aft section strut for rivetcorrosion and edge clearance where itpasses through cutout in forward panel.For applicable repairs (Ref. Aft SectionStrut Repair).

(5). Ensure that removable forward panelsare secure. Inspect rubber seals forsecurity and partial compression.

(6). Inspect drive shaft tube fairing fordents, buckled or wrinkled areas andsigns of corrosion.

(7). Close engine compartment access doorsand two air inlet access doors.

A. Upper Aft Section General Repair

Ref. FAA AC 43.13-1B and FAA AC 43.13-2BInspection and Repair for Standard SheetMetal Repair and Alterations and StructuralRepair Manual for additional repair procedures.

B. Aft Fuselage Fittings

Mast support structure fitting and fuselageboom fairing frame fitting are critical fatigue-loaded parts. Any damage in excess of negligible limits specified in (Ref. Aft Section StrutRepair) requires replacement of part.

C. Aft Fuselage Fittings General Repair

Repair of cast and forged fittings should onlybe temporary and be performed only whenreplacement components are not immediatelyavailable. Replacement of bushings or insertsthat become part of fitting assembly areconsidered insertion repairs. (Insertion repairsare described in FAA AC 43.13-1B and FAAAC 43.13-2B Inspection and Repair forStandard Sheet Metal Repair and Alterationsand Structural Repair Manual.)

(1). Negligible Damage (Ref. Table 201,53-00-00).

(2). Replacement. Replace fittings accordingto Structural Repair Manual.

7. Aft Section Strut Repair

Repair of strut is limited to smoothing outminor dents, scratches or nicks. Replace strutif it is badly damaged according to StructuralRepair Manual.

8. Silver Brazing Procedure − Upper FirewallShell Patch

(Ref. Figure 203)


Item Nomenclature

CM234 Solvent, dry-cleaningCM721 Tape, aluminum foilCM817 Brazing fluxCM818 Brazing alloy

(1). Remove aft section upper firewall (Ref.Upper Firewall Replacement).

(2). Remove tape and ceramic fiber blanketsfrom firewall shell.

(3). Clean firewall shell with stiff bristlebrush moistened with solvent (CM234)and wipe dry with clean, dry cloth.

(4). Smooth out rigidized pattern in area onwhich patch will be brazed.

(5). Cut suitable repair patch for Type 321stainless steel sheet in thickness rangeof 0.0015-0.0018 inch (0.0381-0.04572mm).

(6). Contour patch to match contour offirewall shell repair area.

Use only stainless steel wirebrush in next step. Particles

from bristles of other metals can contaminate the patch area and cause brazing tofail.

(7). Use stainless steel wire brush to cleanand abrade inner and outer surfaces ofstainless steel patch and firewall.

CAUTION


53-30-00Page 207

Revision 38

G53-3006

STA. 197.78 BOOM FAIRINGCANTED FRAME FITTING

BOOM FAIRING RING

AFT SECTION STRUT

AFT SECTIONUPPER FIREWALL

ENGINE AIR INLETINSTALLATION

(PLENUM CHAMBER)

Figure 203. Major Bulkheads and Structural Members − Aft Fuselage

(8). Rinse patch and firewall shell thoroughly with clean water and allow toair dry.

(9). Coat surfaces to be joined with a thineven coating of silver alloy brazing flux(CM817).

(10). Use clamp or other suitable device tohold patch in place during brazingoperation.

Use extreme care not to overheat and burn through firewall

shell.

(11). Braze patch in place with Class 8 silverbrazing alloy (CM818), using suitabletorch to heat patch area to temperaturemoderately above 1295°F (707°C) flowpoint of brazing alloy.

(12). Allow joint to cool for at least 60seconds before removing clampingdevice.

CAUTION


Page 208

TR10-003 53-30-00

(13). Remove flux by immersing repairedarea in water at 160°-212°F(72°-101°C) for 40 minutes.

(14). Thoroughly rinse in clear, runningwater; air dry, or wipe dry with clean,dry cloth.

(15). Install ceramic blanket on outer surfaceof firewall shell.

(16). Install aft section upper firewall shell(Ref. Upper Firewall Replacement).

(17). Install tape (CM721) on flanges offirewall shell.

9. Plenum Chamber Hole Sealing

(Ref. Figure 203)


Item Nomenclature

CM418 Cement, epoxyCM424 Sealing compoundCM713 Tape, pressure sensitive

All tape must be applied to outside of inlet surfaces, so that

any subsequently loosened tape cannot enter plenum chamber to cause engine damage.

(1). Using 10 mil by 1 inch (2.54 cm)pressure-sensitive tape (CM713), tapeall 0.130 inch (3.302 mm) diameter orlarger holes.

(2). Using sealant (CM424), seal all holesless than 0.130 inch (3.302 mm)diameter.

(3). Rebond loose rubber seals with adhesive (CM418) according to containerinstructions.

10. Forward Fuselage Section StructureRework

(Ref. Figure 204) The following information isa procedure for installing support assembliesto the fuselage frame structure to providereinforcement at the forward attach points forthe engine inlet fairing assemblies.


Item Nomenclature

CM318 Primer

(1). Remove engine inlet forward fairingassemblies from helicopter (Ref. EngineInlet Fairing Replacement).

(2). Remove interior trim panels and wireharnesses, as applicable, to gain accessto work area at forward area at forwardattach nutplate assembly for L/H andR/H engine inlet forward fairings.

(3). Remove existing forward nutplate (forboth L/H and R/H fairing assemblies)from fuselage frame structure.

(4). Inspect upper fuselage skin for cracksor damage at area of forward nutplateattachment holes. Also inspect repairdoublers if, previously installed, onupper fuselage skin.

NOTE: If cracking or damage to fuselage skinor repair doublers is noted, perform the following:

(a). Stop drill all cracks or removedamaged skin area or damagedrepair doublers prior to rework.Perform all work in accordance withFAA AC 43.13-1B and FAA AC43.13-2B Inspection and Repair forStandard Sheet Metal Repair andAlterations and Structural RepairManual.

(b). Field fabricate and install doublerson outer fuselage skin. Drill0.196-0.204 inch (4.978-5.182 mm)diameter hole in each doubler tomatch existing hole in fuselage skinfor fairing attach screw. Use existingrivet pattern as shown; installMS20470AD3 rivets with primer(CM318).

(c). Prime and paint double to matchfinish color of helicopter.

(5). Inspect fuselage frame structure(channel) for cracks or damage atforward nutplate attach areas.

CAUTION


53-30-00Page 209

TR10-003

NOTE: If no cracking or damage to fuselageframe is noted, install 80-369D22400-3 and-4 support assemblies at FWD side of framestructure using rivets. Drill holes in supportassemblies for nutplates and for conduitclearances as required. Install nutplaterivets (MS20470AD3) through support,frame, upper skin and doubler, if installed.

(6). If cracking or damage to fuselage frameis noted, perform the following:

(a). Stop drill all cracks or removedamaged area prior to installation ofrepair angles and support assemblies. Perform all work in accordancewith FAA AC 43.13-1B and FAA AC43.13-2B Inspection and Repair forStandard Sheet Metal Repair andAlterations and Structural RepairManual.

(b). Field fabricate and install repairangles at AFT side of fuselage framestructure (channel) and install80-369D22400-3 and -4 supportassemblies at FORWARD side offrame structure using MS20470AD3rivets. Drill 0.096 inch (2.4384 mm)diameter holes in angles to matchsupport assemblies.

(c). Drill holes in support assemblies andrepair angles for nutplates and forconduit clearance as required. Installnutplate rivets through support,frame, angle, upper skin and doubler,if installed.

(7). Check installation of 80-369D22400-3and -4 assemblies and repair anglesand doublers, if installed, for discrepancies.

(8). Reinstall removed components.

11. Transmission Compartment Air Baffle,Seal and Cover Initial Installation

(Ref. Figure 205) (Serial No. 0003D thru0333D only)


Item Nomenclature

N/A Calking compoundCM425 Sealing compoundCM712 Tape, pressure sensitive

(1). Remove engine air inlet forwardfairings.

(2). Remove cooling fan inlet screen.

(3). Remove aft compartment interior trimpanels and blower access door.

(4). Install PN 369D26541-19 upper baffleassembly as follows;

(a). Position baffle between main transmission and mast support structure.Align four attach holes in baffle withexisting holes in structure.

(b). Install baffle with screws, washersand nuts. Seal screw heads withsealant (CM425).

(5). Install PN 369D26542 lower baffle toupper baffle with two screws andwashers at matching nutplates in upperbaffle.

(6). Disconnect 5/8 inch (15.875 mm)diameter drain tube at mast supportbase and insert tube though hole inbaffle. Safetywire drain tube to structure.

(7). Reinstall blower access door.

(8). Position and install PN 369D26543-11and -12 seal assemblies at lower baffleand blower access door as shown.Install seal assemblies with screws andwashers at matching clipnuts on lowerbaffle and on blower.

NOTE: If excessive gap, 0.060 inch (1.524 mm)or more, exists between structure and rubber extrusion on seals, fill gap by bondingstrip of adhesive-backed gasket to structure.


Page 210


(9). Position PN 369D26545-11 and -21cover assemblies as shown; align coverattach holes with existing fairing attachnutplates. Temporarily secure coverassemblies with screws and washers, 5places each.

(10). Using caulking compound, seal all gapsbetween fuselage structure and baffle;seal and cover assemblies.

(11). Remove screws securing cover assemblies. Reinstall engine air inlet forwardfairings.

(12). Reinstall aft compartment trim.

(13). For helicopters equipped with RotorBrake Kit, perform the following;

NOTE: Not applicable if modified rotor brakehandle trim cover panel has already been installed.

(a). Carefully trim modified trim coverpanel assembly (for LH or RH rotorbrake handle assembly). Locate anddrill screw attach holes in modifiedpanel.

(b). Slide modified trim panel boot overbrake handle. Align screw holes andcheck panel for fit. Remove panel andmake minor trim adjustments asrequired.

(c). Install panel if removed and securepanel with attaching hardware.

(d). Push panel boot aft on brake handleapproximately two inches and securewith fastener tape.

Table 201. Weight and Balance Data

Weight Arm Moment

lbs (kg) inches (cm) in−lbs (kg−mm)

+1.5 (+0.681) 110.2 (279.908) +169 (+1947.0828)


53-30-30Page 203

Revision 34

PARTICLE SEPARATOR/BYPASS DOOR FRAME

MID UPPERSTRUCTURE

ENGINE PLENUMACCESS COVER

CONTROLS FAIRING

FORWARD INLETFAIRINGS

ENGINE INLET SCREEN ORPARTICLE SEPARATOR

MAST SUPPORT STRUCTURE

EXTENDED FUSELAGEROOF BEAMS OF 600N

3040--0101013011--010303

6G53-055

Figure 202. Upper Aft Section Fuselage (600N)


Page 204

TR10-003 53-30-30

(6). Inspect aft section strut for rivetscorrosion and edge clearance where itpasses though cutout in forward panel.

(7). Inspect engine air cooling inlet screenfor damage, seal deterioration andsecurity.

(8). Inspect fan transmission driveshafttube fairing and access panel for dents,buckled or wrinkled areas and signs ofcorrosion.

(9). Inspect the fan inlet screen mesh forcondition and security.

(10). If fan inlet screen needs repair, rewelded using 0.063 inch (1.600 mm)annealed cres 302 or 304 wire perAMS5336 or AMS5639.

(11). Visually inspect through the fan inletscreen for security of the transmissionfairing and FOD.

(12). Ensure that forward removable inletfairings and engine access doors aresecure.

A. Upper Aft Section General Repair

(Ref. FAA AC 43.13-1B and FAA AC 43.13-2BInspection and Repair for Standard SheetMetal Repair and Alterations and StructuralRepair Manual for additional repair procedures.

3. Upper Fuselage Controls Fairing (600N)

The Upper Fuselage Controls Fairing coversthe flight control rods that travel longitudinally aft along the roof of the fuselage for therotor collective and cyclic controls.

4. Upper Fuselage Controls FairingReplacement (600N)

The Upper Fuselage Controls Fairing is madeof a lightweight Kevlar fabric and is used onthe 600N installation only.

A. Upper Fuselage Controls FairingRemoval

(1). Remove hardware that attaches upperfuselage controls fairing to mountingsurfaces.

(2). Remove controls fairing.

B. Upper Fuselage Controls FairingInstallation

(1). Inspect upper fuselage controls fairingfor cracks, delaminations and overallgeneral condition.

(2). Position controls fairing to align withholes in mounting surfaces.

(3). Install attaching hardware.

5. Engine Inlet Fairings Replacement

The R/H and L/H engine inlet fairings aremade of a lightweight Kevlar fabric and areused on the 500/600N installation only.

A. Engine Inlet Fairing Removal

(1). Remove hardware from left-hand inletfairing and remove fairing.

(2). Remove hardware from right-handinlet fairing and remove fairing.

B. Engine Inlet Fairing Installation

(1). Inspect fairings for cracks, delaminations and condition of pressure sensitive tape.

(2). Install right-hand inlet fairing andattaching hardware.

(3). Install left-hand inlet fairing andattaching hardware.

(4). Ensure that 1-1/2 threads protrudethrough nutplates.

6. Anti−Torque Fan Air Inlet ScreenReplacement

A. Fan Air Inlet Screen Removal

(1). Remove attaching hardware andremove air inlet screen.

B. Fan Air Inlet Screen Installation

(1). Install air screen and attachinghardware.

7. Fan Hub and Transmission Cover FairingReplacement

A. Fan Hub and Transmission CoverRemoval

(1). Remove attaching hardware on the fanhub transmission fairing.

Documents

369/500/600 Series Temporary Revision