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MD Helicopters CSP-900RMM-2, Servicing And Maintenance

The MD Helicopters CSP-900RMM-2 servicing and maintenance manual is a valuable resource for helicopter owners and technicians. Download this comprehensive manual for free from 88.208.23.73:8080 to ensure the optimal performance and longevity of your aircraft. A must-have guide for all helicopter enthusiasts.

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CSP

−

900RMM

−

2

MD Helicopters, Inc.

Rotorcraft Maintenance Manual

Page 2
Revision 34

28-00-00

trapped between the cell and the helicopter
structure. The liner ribs route leaking fuel for
drainage through fuselage drain holes.

B. Fuel Vents

Two forward and two aft vent/rollover valves
are located on the top side of the fuel cell and
vent fuel to the atmosphere. The single
vent/rollover valves are located at the forward
right corner and the aft left corner of the fuel
cell. The dual vent/rollover valves are located
at the forward left corner and rear right corner
of the fuel cell. The dual vent/rollover valves
are attached to standpipes, which prevent any
fuel from draining overboard. Each single
vent/rollover valve is connected by hoses and
tubes to a dual vent/rollover valve.

Each vent/rollover valve is a normally open
poppet type float valve. The valve automatical­
ly closes to prevent fuel loss through the vent
system. It's primary purpose is to allow the
fuel cell to vent to the atmosphere. It's
secondary function is to close when the
helicopter is outside of an 

85

5

 pitch or roll

angle. The valve also closes when fuel levels in
the fuel cell reach the float.

Flame arrestors are located in the outlet of
each standpipe to prevent any potential flames
from reaching the vent/rollover valves and fuel
cell.

C. Gravity Filler Port Fueling/Defueling

Refueling and defueling is through a gravity
filler port located on the right side of the
fuselage at the forward section of the fuel cell.
A check valve attaches to the filler neck
fitting. The filler neck fitting is secured to the
fuselage. The check valve is located within the
fuel cell. The valve opens when the fuel cap is
removed by pulling a lanyard for refueling and
defueling operations. The valve closes when
the fuel cap is secured to the filler neck fitting
preventing fuel leakage.

An optional “range extender” filler port
increases fuel capacity by 

12 US gallons (45.4

liters)

 by allowing the fuel cell to fill complete­

ly.

(902 CONFIG)

 The lanyard attached to the

fuel cap also opens a flapper valve in the
longitudinal baffle to decrease refueling time.

D. Fuel Sump Drain Valves

Two fuel sump drain valves are located on the
fuel cell sump plate. The sump plate is
centered on the bottom forward portion of the
fuel cell. The drain valves are spring loaded,
normally closed, poppet drain valves. The
valves are actuated by push cables to evacuate
fuel from the fuel cell. Fuel exits the fuselage
through drain hoses.

E. Fuel Quantity Probes

The fuel quantity probes are powered by
24-28 vdc current and consist of two capaci­
tance type sensor probes bolted to the fuel cell
sump plate. The forward and aft gauging
probes output signals are processed by the
Integrated Instrument Display System (IIDS)
to illuminate the fuel quantity bar graph and
digital readout on the IIDS display.

The aft gauging probe has an independently
powered 

24 to 28 Vdc

 fuel low level detector

(thermistor). The fuel low warning indicator on
the IIDS illuminates when the low level
warning detector is activated (

900 CONFIG -

97 to 117 lb (44.0 to 53.1 kg)

 of fuel remain­

ing) (

902 CONFIG -

 

97 to 127 lb (44.0 to

57.6 kg)

 of fuel remaining).

(900 CONFIG - PW207E)

  The left 

FUEL

low level warning tic mark on the IIDS does
not operate for aircraft upgraded from
PW206A to PW207E engines.

The fuel quantity bar graph on the IIDS
displays the fuel quantity status, fuel low
caution bars, and fuel low warning bar. The
fuel quantity bars (green) indicate fuel in 50
pound increments. The fuel low caution bars
(yellow) indicate fuel in 

150 lb (68.0 kg)

increments and illuminate when fuel quantity
is 

151 to 300 lb (68.5 to 136.1 kg)

. The fuel

low warning bar (red) illuminates when fuel
quantity is 

150 lb (68.0 kg)

. The digital

readout displays pounds of available fuel in a
numeric value.

902 CONFIG -

 The forward fuel probe also

has a low level sensor. The forward fuel probe
low fuel warning indicates low fuel in the left
fuel cell cavity. The aft fuel probe low fuel
indicator is for the right cavity. The IIDS
display will identify the warning as left or
right low fuel.

Summary of Contents for CSP-900RMM-2

Page 1: ... 2015 MD Helicopters Inc 4555 East McDowell Road Mesa Arizona 85215 9734 Copyright E 1999 2014 by MD Helicopters Inc All rights reserved under the copyright laws MD Explorer MDHI Model MD900 Rotorcraft Maintenance Manual CSP 900RMM 2 SERVICING AND MAINTENANCE Cover Title Page ...

Page 2: ...anual for use by owners operators and maintainers of MDHI products and authorized parts Use by STC or PMA applicants or holders as documentation to support their certificates is not an authorized use of this manual and is prohibited MDHI takes no responsibility for customer s use of parts manufactured under an STC or PMA when this manual is used as documentation with the Federal Aviation Administr...

Page 3: ...equires clarification please direct your comments to this office via this form or a duplicate An endeavor will be made to include such information in future revisions MD Helicopters Inc Bldg 615 M S G048 4555 East McDowell Road Mesa AZ 85215 9734 Telephone 480 346 6465 800 310 8539 Option 3 E Mail pubs mdhelicopters com Online Orders https mdhelicopters webprint com webprint auth login jspa Date O...

Page 4: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page CRii This page intentionally left blank ...

Page 5: ...ision 24 09 002 Removed by Revision 34 05 001 Removed by Revision 27 09 003 Removed by Revision 34 06 001 Removed by Revision 27 09 004 Removed by Revision 34 06 002 Removed by Revision 28 09 005 Removed by Revision 34 06 003 Removed by Revision 28 09 006 Removed by Revision 34 06 004 Removed by Revision 29 10 001 Removed by Revision 34 06 005 Removed by Revision 29 10 002 Removed by Revision 34 0...

Page 6: ...serted By Date Removed By Rev No Date Inserted By Date Removed By 10 008 Removed by Revision 35 11 001 Removed by Revision 35 12 001 Removed by Revision 35 12 002 Removed by Revision 35 12 003 Removed by Revision 35 13 001 Removed by Revision 36 13 002 Removed by Revision 36 13 003 Removed by Revision 36 14 001 Removed by Revision 36 ...

Page 7: ...r 2003 Revision 21 25 November 2003 Revision 22 10 June 2004 Revision 23 12 October 2004 Revision 24 04 November 2004 Revision 25 06 April 2005 Revision 26 31 October 2005 Revision 27 25 April 2006 Revision 28 14 September 2006 Revision 29 02 February 2007 Revision 30 06 April 2007 Revision 31 03 March 2008 Revision 32 21 July 2008 Revision 33 12 February 2009 Revision 34 22 October 2010 Revision ...

Page 8: ...sion 35 221 thru 223 Revision 28 224 Revision 26 225 thru 227 Revision 28 228 Revision 26 229 Revision 28 230 Revision 34 05 50 00 201 and 202 Revision 34 203 Revision 35 204 thru 268 Revision 34 Chapter 06 i and ii Revision 35 06 00 00 201 Original 202 thru 220 Revision 35 Chapter 07 i and ii Revision 25 07 10 00 201 Revision 13 202 Revision 22 203 and 204 Original Chapter 08 i and ii Revision 32...

Page 9: ...ision 34 426 Revision 35 427 thru 448 Revision 34 601 and 602 Revision 8 Chapter 25 i thru x Revision 35 25 10 00 1 thru 3 4 blank Original 101 102 blank Original 401 thru 414 Original 601 thru 604 Revision 35 25 20 00 1 thru 5 6 blank Original 101 102 blank Original 401 Original 402 Revision 12 403 thru 412 Original 601 thru 604 Revision 35 25 50 00 1 thru 3 4 blank Original 101 102 blank Origina...

Page 10: ...evision 14 406 thru 408 Original 409 thru 412 Revision 32 413 thru 418 Original 419 thru 421 Revision 1 422 thru 436 Original 437 and 438 Revision 24 439 Original 440 Revision 24 441 Revision 14 442 Revision 24 443 Revision 14 444 Revision 24 445 thru 448 Original 449 thru 452 Revision 1 453 and 454 Revision 14 455 Revision 1 456 Revision 14 457 Revision 1 458 thru 460 Revision 27 601 thru 636 Rev...

Page 11: ... 606 Revision 35 53 10 00 1 Revision 13 2 thru 5 6 blank Original 101 and 102 Revision 24 201 and 202 Original 203 Revision 36 204 Revision 18 205 Revision 13 206 thru 214 Revision 20 53 20 00 1 Original 2 thru 6 Revision 25 7 and 8 Original 9 thru 12 Revision 25 13 Original 14 Revision 25 15 Revision 13 16 thru 22 Original 201 Revision 25 202 Revision 34 203 and 204 Revision 23 205 Original 206 t...

Page 12: ...25 105 Revision 35 106 thru 110 Revision 25 63 10 00 401 thru 412 Revision 34 601 thru 603 Revision 36 604 thru 610 Revision 35 611 Revision 36 612 Revision 35 801 thru 803 Revision 34 804 Revision 23 63 20 00 401 Original 402 Revision 25 403 Revision 33 404 Revision 19 405 and 406 Revision 35 407 and 408 Revision 36 409 Revision 35 410 thru 416 Revision 36 417 thru 422 Revision 35 601 thru 610 Re...

Page 13: ...11 Revision 30 412 thru 418 Original 419 Revision 36 420 Revision 27 421 Revision 21 422 thru 424 Original 425 Revision 21 426 Revision 36 427 Revision 21 428 Revision 32 429 Revision 19 430 Revision 36 431 thru 436 Revision 32 437 Revision 35 438 Revision 34 439 and 440 Revision 36 441 Revision 32 442 thru 454 Revision 36 601 thru 605 Revision 35 606 thru 619 Revision 36 620 thru 622 Revision 35 ...

Page 14: ...i and ii Revision 25 75 00 00 1 and 2 Original 201 and 202 Original Chapter 76 i and ii Revision 35 76 00 00 1 thru 8 Revision 35 101 and 102 Revision 23 103 Original 104 thru 111 Revision 29 112 thru 115 Original 116 thru 118 Revision 19 119 Revision 29 120 Revision 19 401 Original 402 thru 407 Revision 28 408 Revision 23 601 Revision 11 602 Revision 13 603 and 604 Revision 19 605 Revision 26 606...

Page 15: ...rds and Markings Chapter 12 Servicing Chapter 18 Vibration and Noise Analysis Airframe Systems Chapter 21 Environmental Control System Chapter 25 Equipment Furnishings Chapter 26 Fire Protection Chapter 28 Fuel System Chapter 29 Hydraulic System Chapter 32 Landing Gear Structure Chapter 52 Doors and Windows Chapter 53 Fuselage Chapter 62 Main Rotor Chapter 63 Transmission and Drive System Chapter ...

Page 16: ... Vent System 21 40 00 Heat Defog System 21 50 00 Air Conditioning System 25 Equipment Furnishings 25 10 00 Crew Compartment Interior 25 20 00 Cabin Compartment Interior 25 50 00 Baggage Compartment Interior Trim 25 55 00 Cargo Hook System 25 60 00 Emergency First Aid Kit 25 60 10 Rescue Hoist 25 70 00 Hinged Avionics Shelf 26 Fire Protection 26 10 10 Fire Overheat Bleed Air Leak Detection Heat Def...

Page 17: ... Anti Torque Fan System 64 30 01 NOTAR Fan Assembly 64 30 02 NOTAR Fan Support Assembly 64 30 03 NOTAR Fan Pitch Assembly 67 Flight Controls 67 00 00 Flight Controls 67 10 00 Rotor Flight Controls 67 10 20 Collective Control Module Cyclic Grip 67 20 00 Anti Torque Directional Flight Controls 71 Powerplant 71 00 00 Powerplant 71 20 00 Engine Mounts 71 60 00 Air Intake 71 70 00 Engine Drains 75 Engi...

Page 18: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page iv Revision 19 Contents This page intentionally left blank ...

Page 19: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual INTRODUCTION Chapter ...

Page 20: ......

Page 21: ...rated Parts List 5 E Shipping Manual 5 F Service Information 5 G Illustrations 5 5 Additional Publications 5 A Engine Manual 5 B Automatic Flight Control System AFCS 5 C Vendor Publications 5 Figure 1 Helicopter Major Components 6 6 ATA Numbering System and Format 7 Figure 2 ATA Numbering System 7 7 Division of Subject Material 7 8 Page Number Blocks 7 9 Figure and Table Numbering 7 10 References ...

Page 22: ...s 201 B Special Hardware Torque Values 201 Figure 201 Special Hardware Torque 202 7 Warning and Caution Statements 202 A Dangerous Materials Warning Statements and Icons 202 B Dangerous Material Disposal 202 8 Directives and Related Manufacturers Publications 202 Table 201 Directives and Related Manufacturers Publications 1 203 9 Optional Equipment 205 Table 202 Optional Equipment List 205 10 Abbr...

Page 23: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 01 00 00 Introduction ...

Page 24: ......

Page 25: ...ay System IIDS To determine which IIDS and EEC are necessary for each engine model reference CSP 900IPL 4 Section 76 00 00 A 900 CONFIG The 900 CONFIG designates Model MD900 serial numbers 90000010 thru 90000051 The 900 CONFIG is the MD900 as originally type certificated B 902 CONFIG The 902 CONFIG designation started at MD900 serial number 90000052 and subse quent The 902 CONFIG incorporates chan...

Page 26: ...ation differences identified with 900 CONFIG or 902 CONFIG for the airframe items and PW206A PW206E OR PW207E for engine configuration differences The Illustrated Parts List CSP 900IPL 4 also reflects the differences Existing MD900 Service Letters and Technical Bulletins are still applicable for the helicopter as required New Service Bulletins and ADs for the MD900 are applicable as required 900 C...

Page 27: ... used as required The landing gear is a horizontal skid type gear and is not retractable It consists of two skid tubes two crosstubes and a pair of hydraulic dampers that connect the tips of the aft crosstube to the aft ends of the skids The crosstubes clamp into saddles in the bottom of the fuselage The skids are bent upward at the front to minimize digging into soft ground in a nose down run on ...

Page 28: ...linkages The hydraulic system components have sufficient strength to withstand combinations of loads resulting from hydraulic pressure vibration temperature variations and torque Flight Controls and Rigging The helicop ter may be equipped with either right hand or left hand control configurations consisting of cyclic collective upper flight controls anti torque controls and a vertical stabilizer c...

Page 29: ...ed with to ensure the continued safe operation of the helicopter Technical Bulletins provide aircraft upgrade information not considered mandato ry by MDHI Technical Bulletins contain information possibly beneficial to the owner operator Service Letters contain information possibly beneficial to the owner operator G Illustrations Ref Figure 1 The majority of illustrations represented in MD 900 man...

Page 30: ...FT HAND EMPENNAGE ASSEMBLY UPPER COWLING AND FAIRINGS POWERTRAIN TAILBOOM ASSEMBLY BAGGAGE COMPARTMENT DOOR ANTI TORQUE FAN ASSEMBLY CABIN DOOR LANDING GEAR ASSEMBLY COCKPIT DOOR FLIGHT CONTROLS FUSELAGE STRUCTURE ASSEMBLY COCKPIT DOOR CABIN DOOR NOTAR ANTI TORQUE CONTROL VERTICAL STABILIZER HORIZONTAL STABILIZER FUEL SYSTEM Figure 1 Helicopter Major Components ...

Page 31: ...ta for instruments electrical and avionics 8 Page Number Blocks Page number blocks used for each section of the Maintenance Manual logically place the material in sequence as follows Two procedures are used for numbering maintenance practices page blocks Maintenance Procedures have either a brief subtopic or a combination of subtopics Description and Operation Fault Isolation Removal Installation ...

Page 32: ... to by a hand in the graphic B Reissue When several changes are included the manual is reissued The preceding issue of the manual then becomes obsolete and must be discarded Changes that are made during a reissue will have no indication of changed information A reissue is considered a new pubblication 12 Service Bulletins and Letters Service information is to be considered part of the manual 13 Ap...

Page 33: ...ontact MDHI Field Service Department for instructions Replace components that show damage or wear more than permitted or that cause incorrect operation or security of an assembly 5 Maintenance Information Requests Address all questions regarding the MD Explorer maintenance to the MDHI Field Service Representative assigned to the geographical area in which the helicopter is operated If a Field Serv...

Page 34: ...wed by warning icons Refer to the Consumable Materials Table Ref CSP SPM Section 91 00 00 Table 201 for the material and related warning symbols Warnings for dangerous material warn personnel of the dangers when they use them Speak to your local safety and health staff if you are not sure about dangerous materials necessary personal protection equipment how to handle dangerous material and emergen...

Page 35: ...RMM 3 CSP 900RMM 3 MDHI Illustrated Parts List IPL CSP 900IPL 4 MDHI Standard Practices Manual CSP SPM MDHI Shipping Manual CSP 900SHP S MDHI Ground Based Maintenance Computer GBMC for PW206A PW206E PW207E CSP 900RMM 2 S1 CSP 900RMM 2 S2 CSP 900RMM 2 S3 Vendor Publications Battery Saft phone 229 245 2838 www saftbatteries com Operating and Maintenance Manual 2386 1 27578 2 Engine Pratt Whitney Can...

Page 36: ...enance Manual PM 965 015 Flight Controls Honeywell or nearest Bendix King Service Center phone 800 257 0726 913 712 2301 KFC 900 AFCS and IFR Avionics Installation Manual 2 006 00750 0000 Honeywell KFC 900 AFCS and IFR Avionics Maintenance Manual Supplement 2 006 00757 0000 Rescue Hoist System Breeze Eastern 700 Liberty Avenue Union NJ USA 07083 8198 Breeze Eastern Operation And Maintenance Manual...

Page 37: ...01300 Commercial Interior Beige With Seats 25 20 00 90000201200 Utility Interior Without Utility Seats 25 20 00 90000201400 Utility Interior With Utility Seats 25 20 00 90000201100 No Utility Interior Without Utility Seats 25 20 00 90000201050 Cargo Hook Configuration 25 55 00 90000304000 Rescue Hoist System 25 60 10 HS 20200 113 Fire Extinguisher Right Hand Cabin Mounted 26 20 10 900N7203000 101 ...

Page 38: ...wer Unit CSP SPM 91 00 00 TI 1000 GPU 24 Exterior Paint 1 CSP SPM 91 00 00 90000001100 Exterior Paint 2 CSP SPM 91 00 00 90000001200 Exterior Paint 3 CSP SPM 91 00 00 90000001300 Custom Paint CSP SPM 91 00 00 90000001400 Main Instrument Panel Single Pilot 95 00 00 90000724110 Main Instrument Panel Dual Pilot 95 00 00 90000724120 Pitot Static Heated Single 95 10 00 90000722110 Aft Battery 96 10 00 ...

Page 39: ...RE DIGITAL DISPLAY in C WHITE ENG OIL TEMP C DD ENGINE OIL LOW TEMPERATURE CAUTION ANNUNCIATOR YELLOW ENG OIL LO TEMP CAUTION ENGINE OIL HIGH PRESSURE WARNING ANNUNCIATOR RED ENG OIL HI PRESS WARNING ENGINE HIGH PRESSURE CAUTION ANNUNCIATOR YELLOW ENG HI PRESS CAUTION ENGINE OIL PRESSURE DIGITAL DISPLAY in PSI WHITE ENG OIL PRESS PSI DD ENGINE OIL LOW PRESSURE CAUTION ANNUNCIATOR YELLOW ENG OIL LO...

Page 40: ...PRESS PSI DD TRANSMISSION LOW OIL PRESSURE CAUTION ANNUNCIATOR YELLOW XSMN LOW OIL PRESS CAUTION TRANSMISSION LOW OIL PRESSURE WARNING ANNUNCIATOR RED XSMN LOW OIL PRESS WARNING FUEL QUANTITY SEGMENTS GREEN FUEL QTY SEGMENTS FUEL LOW CAUTION SEGMENTS YELLOW FUEL LOW CAUTION SEGMENTS FUEL LOW WARNING SEGMENT RED FUEL LOW WARNING SEGMENT FUEL WARNING TICK MARKS RED FUEL WARNING TICK MARKS 900 CONFIG...

Page 41: ...IIDS FAULT ANNUNCIATOR YELLOW IIDS FAULT CAUTION TIME OF DAY DIGITAL DISPLAY WHITE TOD DD OUTSIDE AIR TEMPERATURE DIGITAL DISPLAY in C WHITE OAT C DD Primary Display on IIDS Abbreviation IIDS ALPHANUMERIC DISPLAY IIDS A N display LEFT ENGINE TORQUE DIGITAL DISPLAY WHITE L ENG TORQUE DD RIGHT ENGINE TORQUE DIGITAL DISPLAY WHITE R ENG TORQUE DD LEFT ENGINE EGT DIGITAL DISPLAY WHITE L ENG EGT DD RIGH...

Page 42: ...IDS CONTROL KEYS CLR IIDS ACKNOWLEDGE AND CLEAR DISPLAY KEY IIDS CLR KEY MENU IIDS DISPLAY MENU KEY IIDS MENU KEY IIDS UP ARROW KEY IIDS UP KEY IIDS DOWN ARROW KEY IIDS DWN KEY ENT IIDS ENTER MENU KEY IIDS ENT KEY REC IIDS RECORD KEY IIDS REC KEY DISP IIDS DISPLAY MODE KEY IIDS DISP KEY IIDS Alpha Numeric Display Abbreviations EXHAUST GAS TEMPERATURE EGT GAS GENERATOR SPEED NG POWER TURBINE SPEED ...

Page 43: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL AIRWORTHINESS LIMITATIONS Chapter ...

Page 44: ......

Page 45: ... Contents TABLE OF CONTENTS Para Figure Table Title Page 04 00 00 Airworthiness Limitations A Description and Operation 1 1 Approval of Airworthiness Limitations Section 1 Maintenance Practices 201 1 General 201 2 Mandatory Replacement Time 201 3 Airworthiness Limitations Schedule 201 ...

Page 46: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Page ii Revision 25 04 Contents TABLE OF CONTENTS Cont Para Figure Table Title Page This page intentionally left blank ...

Page 47: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Section 04 00 00 Airworthiness Limitations ...

Page 48: ......

Page 49: ...TE Original Reissue 1 18 December 1997 Revision 1 22 April 1998 Revision 2 24 July 1998 Revision 4 7 May 1999 Revision 6 23 December 1999 Revision 7 22 June 2000 TR 00 002 14 July 2000 Revision 8 10 August 2000 Section 04 00 00 Not Affected This Revision TR 00 002 Previously Signed TR 00 003 13 October 2000 Revision 9 10 November 2000 Section 04 00 00 Not Affected This Revision TR 00 003 Previousl...

Page 50: ...00 Not Affected This Revision Revision 16 19 August 2002 Section 04 00 00 Not Affected This Revision Revision 17 27 September 2002 Section 04 00 00 Not Affected This Revision Revision 18 23 January 2003 Revision 19 20 June 2003 Section 04 00 00 Not Affected This Revision TR 03 001 30 July 2003 Revision 20 5 September 2003 Revision 21 05 December 2003 Section 04 00 00 Not Affected This Revision TR ...

Page 51: ...2006 Revision 27 25 April 2006 Section 04 00 00 Not Affected This Revision TR 05 001 Previously Signed TR06 003 26 June 2006 Revision 28 14 September 2006 Section 04 00 00 Not Affected This Revision TR 06 003 Previously Signed Revision 29 02 February 2007 Section 04 00 00 Not Affected This Revision Revision 30 06 April 2007 TR07 001 29 August 2007 Revision 31 27 February 2008 TR08 002 14 March 200...

Page 52: ...TR09 002 Chapter 04 00 00 Published in TR09 006 27 January 2010 TR10 005 13 May 2010 TR10 007 16 August 2010 Revision 34 30 September 2010 Section 04 00 00 Not Affected This Revision TR09 001 TR09 002 TR10 005 and TR10 007 Previously Signed TR10 008 20 December 2010 Revision 35 21 December 2012 Section 04 00 00 Not Affected This Revision TR10 008 Previously Signed Revision 36 17 March 2015 ...

Page 53: ...ice Upon completion of the 1000 hours of operation the useful life of the component is ended The components specified in this section must be removed from the rotorcraft at the number of hours indicated When a component with a life limit or an assembly that incorporates a component with a life limit is installed on a new or used rotorcraft the nomenclature part number serial number and current rot...

Page 54: ... 14 900F1305600 115 On Condition 14 900F1305600 117 On Condition 14 900F1305600 119 On Condition 14 900F1305600 121 On Condition 14 900F1305600 123 On Condition 14 900 Tailboom Assembly 900F2318021 103 On Condition 14 900F5318022 107 On Condition 14 900 Spring Damping Elastomeric 900F3318201 103 2 000 9 900 Bellcrank Empennage 900F2341712 101 2 700 900FP341712 103 2 700 900 Cartridge Fire Extingui...

Page 55: ...0R1103003 101 18 On Condition 5 900R1103004 101 18 On Condition 5 900R1103005 101 18 10 000 5 900R1103000 105 On Condition 5 900R1103000 107 On Condition 5 900R1103000 109 On Condition 5 900R1103000 111 On Condition 5 900 Centering Bearing Assembly Main Rotor 900R3101001 105 On Condition 15 900R3101001 107 On Condition 15 900 Damper Cap Upper Main Rotor Hub 900R2100005 105 10 000 900R2100005 107 1...

Page 56: ...ssembly Main Rotor 900R2101008 103 1 730 Lower Hub Assembly Main Rotor 900R2101008 105 1 730 Lower Hub Assembly Main Rotor 900R2101008 107 10 750 Lower Hub Assembly Main Rotor 900R2101008 109 10 750 Hub Plate Main Rotor 900R2101018 103 1 730 Hub Plate Main Rotor 900R2101018 105 10 000 900 Striker Plate Droop Stop 900R2101012 103 10 000 20 900 Support Droop Stop 900R2100001 101 1 580 10 900R2100001...

Page 57: ...50 900DF400100 101 1 450 900 Impeller Blower 900D3448004 103 6 885 900D6448004 103 6 885 900 Strut Assembly Mid Aft Truss LH 900F2401300 101 21 532 900F2401300 103 24 158 900 Deck Fitting Assembly Aft Truss LH 900F2401600 103 19 990 900 Deck Fitting Assembly Aft Truss RH 900F2401600 104 19 990 Anti Torque Assembly 900 Blade Assembly Fan NOTAR 900R2442012 101 3 800 900R2442012 103 3 800 900R2442012...

Page 58: ...n Shaft NOTAR 900R2444002 101 10 000 900R2444003 101 10 000 Flight Controls 900 Spring Assembly Gradient Longitudinal 900CF010039 105 260 900C6010039 107 800 900C3010081 101 10 000 900 Spring Assembly Gradient Lateral 900CF010040 105 260 900C6010040 107 800 900C3010082 101 10 000 900 Trim Actuator Assembly 900C3010004 107 10 000 11 900C3010004 113 Conditional 900C3010004 115 Unlimited Life Powerpl...

Page 59: ...hever comes first Ref Section 05 20 10 11 Aircraft Equipped with Autopilots The 900C3010004 107 trim actuator assembly must be overhauled every 5000 hours Aircraft NOT Equipped with Autopilots The 900C3010004 107 trim actuator assembly has no life limit when installed in aircraft not equipped with Autopilots 12 Life of damper may use 30 000 landings instead of 5 000 hours if aircraft logs landings...

Page 60: ... thru February 2008 Cure Date Plus 5 Years 22 Accelerated Life Limit For all rotorcraft SNs 900 000008 thru 000124 that have incorporated Service Bulletin SB900 105 and all rotorcraft SNs 900 000125 thru subsequent time in service is accumulated at an accelerated rate To calculate the accelerated time in service take the actual flight hours of the rotating swashplate and multiply by 1 07 to determ...

Page 61: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL CONTINUED AIRWORTHINESS INSPECTIONS Chapter ...

Page 62: ......

Page 63: ...rrosion Control 4 05 10 00 Continued Airworthiness Component Overhaul A Maintenance Practices 201 1 General 201 2 Overhaul Schedule 201 Table 201 Overhaul Schedule 201 05 20 00 Continued Airworthiness Scheduled Inspection A Description and Operation 1 1 General 1 2 Scheduled Inspections 1 A Special Inspection Schedule 1 B Content of Scheduled Inspection Programs 1 C Airframe Periodic Inspection Pr...

Page 64: ...nnage 217 Table 208 Airframe Periodic Inspection Landing Gear 219 Table 209 Airframe Periodic Inspection Final Inspections 220 05 20 50 Airframe Segmented Inspection Program A Routine Inspection 201 Table 201 Routine Inspection 201 Inspection 1 Nose Section and Cockpit 207 Table 202 Inspection 1 Nose Section and Cockpit Area 1 207 Inspection 2 Cabin 211 Table 203 Inspection 2 Cabin Area 2 211 Insp...

Page 65: ...System Overtorque Conditional Inspection Single Engine Operation 233 Table 208 Transmission and Drive System Overtorque 900 CONFIG Conditional Inspection Both Engines Operative 8 Maximum Engine Torque Differential 235 Table 209 Transmission and Drive System Overtorque 902 CONFIG Conditional Inspection Both Engines Operative 8 Maximum Engine Torque Differential 239 Table 210 Transmission and Drive ...

Page 66: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Page iv Revision 34 05 Contents TABLE OF CONTENTS Cont Para Figure Table Title Page This page intentionally left blank ...

Page 67: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Section 05 00 00 Continued Airworthiness Inspections ...

Page 68: ......

Page 69: ...use by the operator s local aviation regula tory authority A Airworthiness Limitations The Airworthiness Limitations Schedule specifies the mandatory replacement times for time life limited components ref Section 04 00 00 At the listed life limit hours components or assemblies must be removed from the helicop ter and permanently retired from service At the listed inspection interval the components...

Page 70: ... repairs This includes but is not limited to Airworthiness directives Service notices Scheduled inspection records and Life limited components B Additional Documentation Additional documentation is necessary to be available or inside the aircraft during operation This documentation includes but is not limited to Airworthiness and registration certificates Rotorcraft Flight Manual Weight and balanc...

Page 71: ...tion of protective treatment or corrosion d Electrical bonding correctly posi tioned undamaged and applied e Attachments end connections and locking devices are correctly attached 4 Electrical components circuit protec tion devices wiring connectors plugs motors generators actuators relays solenoids and contactors do an inspection for a Cleanliness obvious damage corro sion that components and con...

Page 72: ... refer to CSP SPM Section 20 40 00 A visual inspection to find obvious unsatisfac tory conditions discrepancies This inspection can require cleaning removal of fillets fairings access panels doors etc 1 Do the Visual Corrosion Guide General Check ref CSP SPM Section 20 40 00 2 Do the Visual Corrosion Guide Periodic Inspection ref CSP SPM Section 20 40 00 ...

Page 73: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Section 05 10 00 Continued Airworthiness Component Overhaul ...

Page 74: ......

Page 75: ...uded in the Purchase Agreement for the helicopter the assembly or component 2 Overhaul Schedule Table 201 tabulates the overhaul require ments for components and assemblies with finite overhaul lives The first column Model of the schedule shows which model of helicopter the component overhaul schedule is applicable The second column Component Assembly is a brief description of the assembly or comp...

Page 76: ...inadvertent return to service Parts are applicable only on models under which a service life is listed 2 Refer to Section 04 00 00 for life limited parts 3 Refer to related manufacturer publications for component overhaul requirements ref Section 01 00 00 4 2 500 hour Time Between Overhaul is for seals used in actuator serial numbers 9 thru 11 13 thru 19 21 22 25 26 27 34 thru 37 and 39 After over...

Page 77: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Section 05 20 00 Continued Airworthiness Scheduled Inspection ...

Page 78: ......

Page 79: ...l hourly and calendar inspection requirements The Special Inspections Hourly and Calender must be complied with at the specified interval from the previous inspection or initial issuance date of Airworthiness Certificate for the aircraft The Special Inspection Hourly schedule identifies the additional inspection require ments that must be done at the specified hourly interval The Special Inspectio...

Page 80: ...directives ADs and service bulletins SBs Inspection intervals identified therein are the maximum permitted and must not be exceeded For maintenance scheduling convenience with the exception of an inspection required by the local governing civil aviation authorities Hourly inspection intervals can be extended by ten 10 percent Calender inspection intervals can be extended fourteen 14 days for one 1...

Page 81: ... shows the applicable RMM section and or the SPM and its applicable section s The fourth column is for verification of the performance of the specified inspection All completed inspection schedules must be kept as a permanent part of the helicopter records 9G05 002 1 NOSE SECTION AND COCKPIT 2 CABIN COMPARTMENT 3 UPPER TRANSMISSION DECK 4 MAIN ROTOR 5 POWERPLANT 6 BAGGAGE COMPARTMENT 7 TAILBOOM AN...

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Page 83: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Section 05 20 10 Continued Airworthiness Special Inspections ...

Page 84: ......

Page 85: ...rimary Exhaust Nozzle Assembly Stainless Steel Inspection for Rotorcraft with PW206A Engines Installed 900 Do the Primary Exhaust Nozzle Assembly Stainless Steel Special Inspection Examine primary exhaust nozzle for cracks and defects 78 00 00 100 Hour Main Rotor Flexbeam Inspection PN 900R1103001 109 and 111 Ref Note 1 900 Do the Flexbeam Inspection Examine main rotor flexbeam for cracks delamina...

Page 86: ...embly 64 30 01 900 Examine fan hub sleeves for damage ref Figure 603 Inspection Areas for Fan Hub and Table 603 Fan Hub Damage Limits 64 30 01 Landing Gear 900 Examine skid tube abrasion strips for wear and correct installation Refer to Skid Tube Assembly Inspection 32 00 00 900 If ground handling wheels have been attached to Station 203 forward ground handling attachment pins Examine skid tube up...

Page 87: ... accordance with instructions of Main Rotor Static Mast Inspection 63 10 00 63 30 00 Transmission and Drive System Input Drive Shafts and NOTARr Fan Drive Shaft 900 With only the applicable panels removed and without the removal of the input drive and NOTAR fan drive shaft assemblies do a visual inspection of only those parts you can see during the Input Drive Shaft Inspection and the NOTAR Fan Dr...

Page 88: ...Assembly Upper Bearing Inspection 62 20 00 500 Hour Main Rotor Lower Damper Cap Assembly Inspection Yearly or 500 hours whichever occurs first 900 Examine lower damper cap assemblies for condition and proper installation in accordance with instructions in Main Rotor Hub Assembly Inspection 62 20 00 600 Hour Environmental Control System Air Conditioning Compressor Reduction Gearbox Servicing Yearly...

Page 89: ... Rotor Upper Hub Inspection Ref Note 1 900 Do the Eddy Current Inspection of the Main Rotor Upper Hub Assembly 62 20 00 Main Rotor Support Droop Stop 900 Examine Droop Stop Support in accordance with instructions in Main Rotor Hub Assembly Inspection 62 20 00 Main Rotor Striker Plate Droop Stop Ref Note 1 900 Examine Droop Stop Striker in accordance with instructions in Main Rotor Hub Assembly Ins...

Page 90: ...ric Damping Spring Condition Ref Note 5 900 Do the Elastomeric Damper Condition Test 53 55 00 900 Examine upper and lower endplates Exterior surfaces for apparent defects and general condition Attachment hardware for security For improper movement wiggle 53 55 00 Main Rotor Swashplate Angular Contact Ball Bearing Grease Replacement Ref Note 9 900 Remove angular contact ball bearing and send to MDH...

Page 91: ...amping spring is On Condition but requires a Special Inspection every 100 hours thereafter until deterioration is sufficient to retire assembly 6 Refer to the applicable manufacturer publications ref Section 01 00 00 7 After 1200 hours the Tension Torsion Strap Inspection is required at 300 hour intervals until the life limits of the tension torsion straps are reached 8 If not done before do the V...

Page 92: ...System Air Conditioning Compressor Reduction Gearbox Servicing Yearly or 600 hours whichever occurs first 900 Do the Air Conditioning Compressor Reduction Gearbox Draining and Air Conditioning Compressor Reduction Gearbox Servicing 12 00 00 Environmental Control System Optional Heat Defog System Inspection 900 Do the Heat Defog System Bleed Air Engine Firewall Inspection Examine bleed air engine f...

Page 93: ...ng Gear Landing Gear Cross Tube Inspection 900 Do the Forward Crosstube Inspection and Aft Crosstube Inspection Make sure that forward and aft cross tube spread is within allowable maximum limits 32 00 00 Fuselage Cabin Door Latch Mechanism Rigging Verification 900 Do the Cabin Door Latch Mechanism Rigging Verification 52 00 00 Fuselage Fuselage Internal Structure Inspection 900 Examine cockpit fl...

Page 94: ... mid and aft deck structure longerons intercostals channels and frames Examine flight controls support components Examine roof beam installation components 53 30 00 900 Examine FS 230 50 bulkhead assembly and installation for distortion corrosion apparent defects and security of attachment hardware 53 30 00 Pitot Static System Pitot Static Moisture Drain 900 Do the Static System Moisture Drain Pro...

Page 95: ...tructions in Main Rotor Hub Assembly Inspection 62 20 00 Main Rotor Lower Damper Cap Assembly Inspection Yearly or 500 Hours Whichever Occurs First 900 Examine lower damper cap assemblies for condition and correct installation ref the instructions in Main Rotor Hub Assembly Inspection 62 20 00 Flight Controls Rotor Flight Controls 900 Do the Rotor Flight Controls Rigging Check 67 10 00 Fire Protec...

Page 96: ...sion 62 30 00 5 YEAR Fire Protection Hydrostatic Testing of Fire Extinguisher Containers 900 Do a hydrostatic testing of fire extinguisher containers 26 20 20 Main Rotor Swashplate Angular Contact Ball Bearing Grease Replacement Ref Note 2 900 Remove angular contact ball bearing and send to MDHI for servicing 62 30 00 NOTES 1 The 75 micron filter can be cleaned a maximum of four 4 times Maximum fi...

Page 97: ...Retention Bolt Torque Check 900 After a main rotor blade and blade retention bolt installation do a Blade Retention Bolt Torque Check at these intervals After first flight Every 4 to 10 hours of flight operation after the first flight check until 101 The bolt torque is not less than 800 in lb 90 4 Nm 103 The closing force has not changed more than 10 percent of the recorded final installation forc...

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Page 101: ...sion deck and main rotor Areas 3 and 4 ref Table 204 Powerplant Area 5 ref Table 205 Baggage compartment Area 6 ref Table 206 Tailboom and empennage Area 7 ref Table 207 Landing gear ref Table 208 Final inspections ref Table 209 Make a copy of each table for your inspection records Put your initials on the record after successful completion of each task At the end of each table is a signature bloc...

Page 102: ...lete download and save of IIDS data 95 30 00 900 Make sure you comply with component mandatory retirement Refer to Airworthiness Limitation Schedule and make entries in the Rotorcraft Log Book 04 00 00 900 Make sure you comply with component overhaul Refer to the Overhaul Schedule and make entries in the Rotorcraft Log Book 05 10 00 900 Make sure you comply with applicable Special Inspections Hour...

Page 103: ...900 Examine crew restraints for condition and security of attachment to seats Do a check of the belt adjusters buckles and inertia reels for correct operation 25 10 00 900 Examine crew compartment interior trim for condition and security of attachment 25 10 00 Doors 900 Examine left and right crew doors For condition and damage Door seals for condition and damage Attach hardware and components for...

Page 104: ...detection system is installed 900 Examine detection control units and electrical connections for condition and security 26 10 20 Instruments 900 Remove glare shield and top panel and visually inspect Glare shield and top panel for condition and damage Installation of electrical wiring and instrument connections for condition damage and correct installation Installation of pitot static tubing and c...

Page 105: ...20 60 00 If battery is installed in the nose 900 Examine battery installation Battery case and cover for condition damage and attach hardware for correct installation Vent tubes for condition damage and correct installation Power connection and temperature sensor connection for condition and security 96 10 00 900 Examine external power box or external power relay for condition correct installation...

Page 106: ...ent interior trim for condition and security 25 20 00 Doors 900 Examine left and right cabin doors For condition and damage Door seals for condition and damage Attach hardware and components for condition damage and security 52 00 00 900 Do a check for correct operation of Cabin door latch mechanisms Cabin door rollers 52 00 00 900 Examine cabin door windows and attach seals for condition damage a...

Page 107: ... of insulation and security of attach hardware 21 40 00 900 Do a check of cabin heater control cable for correct operation 21 40 00 Fuel System 900 Do the Fuel Cell Leak Check Pressure Test Method 1 or 2 28 00 00 Fire Protection If optional bleed air leak detection system is installed 900 Examine detection cable and cable attachments for condition and security 26 10 10 Electrical Power 900 Examine...

Page 108: ...aring for indication of grease leakage from the lower grease seal 62 30 00 900 Do the Main Rotor Hub Assembly Inspection Examine damper caps for condition and correct installation Examine striker plates and droop stop rollers for damage condition wear and corrosion Examine pitchcases for damage and the installation of blade bushings and hardware Flexbeams for cracks delamination correct installati...

Page 109: ...rotor brake system is installed 900 Examine rotor brake Head for leakage and security of installation Disc for wear and security of attach hardware Wear groove indicator for indication of too much lining wear Control valve for leakage and security of installation 63 22 00 Powerplant 900 Examine forward left and right engine tubes for fluid leaks condition and security of connections and supports 7...

Page 110: ...900 Examine NACA inlet Door for impact or other damage and condition of seal Door actuator for condition and security Door linkage for condition and security Electrical connector and wire harness for condition and security 71 60 00 Environmental Control System 900 Examine air vent system Water separator and attached ducts for condition and security Fan forward fan mount and aft fan mount for condi...

Page 111: ... a check for correct fluid levels 29 00 00 900 Examine System 1 System 2 hydraulic pumps and pump case drains for leaks condition and security of installation 29 00 00 900 Examine ground support equipment GSE panel and interconnecting tubes for leaks condition security of tube connections support and security of attached hardware 29 00 00 If optional hand pump is installed 900 Examine hand pump fo...

Page 112: ...mp 71 00 00 900 Examine left and right aft engine mounts for condition indication of failure and security of attach hardware 71 20 00 900 Do the Engine NP Overspeed Test Procedure in the applicable Rotorcraft Flight Manual Rotorcraft Flight Manual If optional inlet particle separator system is installed 900 Examine left and right engine inlet air particle separator panels for impact damage conditi...

Page 113: ... exhaust nozzle assembly Inconel For cracks and defects 78 00 00 Environmental Control System If the optional heat defog system is installed 900 Do the Heat Defog System Leak Check Functional Test 21 40 00 Fire Protection 900 Examine area engine deck mounted fire overheat detection system detection cable grommets brackets and cable connectors for condition and security 26 10 20 If the optional fir...

Page 114: ...e Assembly 900 Examine anti torque fan Fan hub for cracks corrosion and security of installation Blades for impact damage and condition Areas of pitch plate that are in view and pitch plate rod end bearing for condition and correct installation of components 64 30 00 900 Examine felt metal seal Correct fan blade tip clearance Felt seal for indication of FOD damage 64 30 00 900 Examine NOTAR drive ...

Page 115: ...at defog system is installed 900 Examine area detection cable and cable attachments for condition and security of installation 26 10 10 If optional fire extinguishing system is installed 900 Examine fire bottles and mounting brackets for condition and correct installation Do a check for correct charge pressure 26 20 20 900 Examine fire bottle discharge and crossflow tubes for condition and securit...

Page 116: ...on and damage installation hardware for correct installation Vent tubes for condition and correct installation Electrical connections for condition and security 96 10 00 900 Examine external power box or external power relay for condition correct installation and security of wiring and electrical connections 96 00 00 Airframe Periodic Inspection Certification Area 6 Baggage Compartment I certify t...

Page 117: ...stomeric Damping Spring Condition Verification Test 53 55 00 900 Examine upper and lower endplates Exterior surfaces for damage and condition Attach hardware for security For incorrect movement wiggle 53 55 00 900 Examine tailboom bumper for deformity condition and security 53 40 00 Flight Controls 900 Examine VSCS actuators mounting brackets control rods and endplate cranks for condition indicati...

Page 118: ...quirement Flight Controls Cont 900 Examine area electrical wiring and electrical component installation for condition support and security of attach hardware 98 00 00 Airframe Periodic Inspection Certification Area 7 Tailboom and Empennage I certify that this aircraft has been inspected in accordance with Airframe Periodic Inspection requirements and is determined to be in an airworthy condition S...

Page 119: ...Examine forward spacer fittings for condition indication of failure and security of attach hardware 32 00 00 900 Examine dampers for leaks condition and security of attachment hardware Do a check for correct fluid level look at fluid level gauge 32 00 00 12 00 00 900 Examine skid tubes for damage and condition Skid tube attach hardware for security 32 00 00 900 Make sure forward and aft cross tube...

Page 120: ...and access panels covers and trim panels removed or opened for inspection Do a check for closure fit and tightness Make sure all loose equipment has been correctly put in storage Do a check of all fluid levels Fill fluid levels that are low Make sure the filler caps are correctly installed and are not loose Post Airframe Periodic Inspection Run Up Ref the latest revision of the applicable RFM for ...

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Page 123: ...y NOTE Logs may be viewed on the IIDS or refer to GBMC User Guide for complete download and save of IIDS data 95 30 00 900 Make sure you comply with component mandatory retirement refer to Airworthiness Limitation Schedule and make entries in the Rotorcraft Log Book 04 00 00 900 Make sure you comply with component overhaul refer to Overhaul Schedule and make entries in the Rotorcraft Log Book 05 1...

Page 124: ... side stop clamp 32 00 00 900 Examine the landing gear for correct installation and condition 32 00 00 900 Examine the landing gear dampers for correct servicing 12 00 00 Main Rotor 900 Examine the main rotor drive plate for correct installation and broken or missing torque stripes 63 10 00 900 Examine the main rotor flexbeams for cracks delamination and damage 62 20 00 900 Examine the main rotor ...

Page 125: ...sion oil cooling system for leaks and condition Transmission for correct oil level and condition Electrical wiring and connectors for correct installation wear and condition Fluid on deck except drain pans that indicate leaks 63 30 00 63 30 00 63 30 00 63 30 00 29 00 00 67 10 00 29 00 00 79 00 00 63 21 00 63 20 00 98 00 00 900 Examine the NOTAR drive shaft Flexible diaphragms and attach flanges fo...

Page 126: ...tor control pulleys drum cable cable ends turnbuckles brackets and attach hardware for condition correct installation corrosion pitting wear and other damage Make sure pulleys turn easily and smoothly Rotating cone and bearing race on inside surface for condition Control bearings turn freely outer races for wear flat spots and correct installation Install rotating cone 67 20 00 Left Side Fuselage ...

Page 127: ...n and cracks Hydraulic manifold for leaks fluid level and filter impending bypass buttons Hydraulic actuators for leaks and correct installation Hydraulic tubes and hoses for leaks wear and correct installation Engine and transmission oil cooling system for leaks and condition Transmission for oil filter impending bypass indication and condition Electrical wiring and connectors for correct install...

Page 128: ...ining pad for indication of too much lining wear warping and pitting Control valve for leaks and correct installation 63 22 00 Landing Gear 900 Inspect the landing gear for correct installation and condition 32 00 00 900 Inspect the landing gear dampers for correct servicing 12 00 00 Touch up all damaged paint as necessary Airframe Segmented Inspection Program Routine Inspection Certification I ce...

Page 129: ...th component mandatory retirement refer to Airworthiness Limitation Schedule and make entries in Log Book 04 00 00 900 Make sure you comply with component overhaul refer to Overhaul Schedule and make entries in Log Book 05 10 00 900 Make sure you comply with all applicable Airworthiness Directives and service bulletins and make entries in Log Book N A 900 Make sure all placards and markings are in...

Page 130: ...ks links and control rods located under the cockpit floor and in the controls closet for condition indication of interference correct installation and control rod bolts installed in the correct direction 67 10 00 Section 1 Parts A D E G H 67 20 00 Engine Controls 900 Inspect mechanical engine control interconnect cables detent modules and area control cables for condition and correct installation ...

Page 131: ... 00 00 53 20 00 900 Inspect instruments for correct markings condition correct operation and security 95 10 00 95 20 00 900 Inspect installation of console installed control panels and avionics equipment for correct markings condition and security 96 00 00 Electrical Power 900 Inspect nose area electrical wiring installation and installation of electrical panels for condition security support and ...

Page 132: ...n floor and bag gage floor panels are securely installed These are stressed panels CAUTION Install all floor and access panels covers and trim panels removed or opened for inspection Do a check of all loose equipment for correct stowage Airframe Segmented Inspection Program Inspection 1 Certification I certify that this aircraft has been inspected in accordance with the Airframe Segmented Inspecti...

Page 133: ... Make sure you comply with component mandatory retirement refer to Airworthiness Limitation Schedule and make entries in Log Book 04 00 00 900 Make sure you comply with component overhaul refer to Overhaul Schedule and make entries in Log Book 05 10 00 900 Make sure you comply with all applicable Airworthiness Directives and service bulletins and make entries in Log Book N A 900 Make sure all plac...

Page 134: ...door windows and attach seals for condition damage and correct installation 52 00 00 Flight Controls 900 Inspect area collective cyclic and anti torque flight controls brackets bellcranks links and control rods for condition indication of interference correct installation and control rod bolts installed in the correct direction 67 10 00 Section 1 Parts B D E G H 67 20 00 900 Inspect directional co...

Page 135: ...ll damaged paint as necessary Helicopter must not be moved or flown unless cockpit floor cabin floor and bag gage floor panels are securely installed These are stressed panels CAUTION Install all floor and access panels covers and trim panels removed or opened for inspection Do a check of all loose equipment for correct stowage Airframe Segmented Inspection Program Inspection 2 Certification I cer...

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Page 137: ...nu Record and correct discrepancies as necessary NOTE Logs may be viewed on the IIDS or refer to GBMC User Guide for complete download and save of IIDS data 95 30 00 900 Make sure you comply with component mandatory retirement refer to Airworthiness Limitation Schedule and make entries in Log Book 04 00 00 900 Make sure you comply with component overhaul refer to Overhaul Schedule and make entries...

Page 138: ...ing torque stripe and indication of fretting 62 20 00 Transmission and Drive System 900 Inspect exterior of transmission for condition and security of attached components 63 20 00 900 Inspect transmission lubrication system flexible hoses for leaks damage and security of connections transmission overboard drain hoses for indication of too much leakage condition and security of connections 63 21 00...

Page 139: ...rt and security of attach hardware 29 00 00 Powerplant 900 Inspect forward left and right engine tubes for fluid leaks condition and security of connections and supports 71 70 00 79 00 00 900 Inspect left and right forward engine firewall to plenum seals for condition and security of fire seal clamp 71 00 00 900 Inspect left and right forward engine mounts for damage condition indication of failur...

Page 140: ...condenser duct installations for condition and security 21 50 00 Fire Protection 900 Inspect area engine deck mounted fire overheat detection system detection cable grommets brackets and cable connectors for condition and security 26 10 20 900 Examine detection control units installed in Area 6 and electrical connections for condition and correct installation 26 10 20 Electrical Power 900 Inspect ...

Page 141: ...C User Guide for complete download and save of IIDS data 95 30 00 900 Make sure you comply with component mandatory retirement refer to Airworthiness Limitation Schedule and make entries in Rotorcraft Log Book 04 00 00 900 Make sure you comply with component overhaul refer to Overhaul Schedule and make entries in Log Book 05 10 00 900 Make sure you comply with all applicable Airworthiness Directiv...

Page 142: ... cross tube spread is in permitted limits 32 00 00 900 Do a visual inspection of the sealing compound for the jumper connections crosstubes fuselage fittings saddles and stop clamps for condition and cracks 32 00 00 Touch up all damaged paint as necessary Airframe Segmented Inspection Program Inspection 4 Certification I certify that this aircraft has been inspected in accordance with the Airframe...

Page 143: ...r to GBMC User Guide for complete download and save of IIDS data 95 30 00 900 Make sure you comply with component mandatory retirement refer to Airworthiness Limitation Schedule and make entries in Log Book 04 00 00 900 Make sure you comply with component overhaul refer to Overhaul Schedule and make entries in Log Book 05 10 00 900 Make sure you comply with all applicable Airworthiness Directives ...

Page 144: ...and installations for condition and security of attach hardware 71 60 00 900 Do the Inlet Plenum Inspection and Inlet Particle Separator Functional Test 71 60 00 Engine Bleed Air 900 Inspect bleed air closure plates on engines for correct installation and security of attach hardware 75 00 00 If optional heat defog or inlet particle separator system is installed 900 Do the Heat Defog System Leak Ch...

Page 145: ...ctrical wiring and electrical component installation for condition support and security of attach hardware 98 00 00 Touch up all damaged paint as necessary Airframe Segmented Inspection Program Inspection 5 Certification I certify that this aircraft has been inspected in accordance with the Airframe Segmented Inspection Program Inspection 5 inspection requirements and is determined to be in an air...

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Page 147: ...lete download and save of IIDS data 95 30 00 900 Make sure you comply with component mandatory retirement refer to Airworthiness Limitation Schedule and make entries in Log Book 04 00 00 900 Make sure you comply with component overhaul refer to Overhaul Schedule and make entries in Log Book 05 10 00 900 Make sure you comply with all applicable Airworthiness Directives and service bulletins and mak...

Page 148: ...tional air conditioning is installed 900 EARLY CONFIG Inspect condenser refrigerant tubes condenser attach hardware and condenser blowers for condition and security 21 50 00 Fire Protection If optional heat defog system is installed 900 Inspect area detection cable and cable attachments for condition and security of installation 26 10 10 If optional fire extinguishing system is installed 900 Inspe...

Page 149: ...and cover for condition and damage installation hardware for correct installation vent tubes for condition and correct installation power connection and temperature sensor connection for condition and security 96 10 00 900 Inspect external power box or external power relay for condition correct installation and security of wiring and electrical connections 96 00 00 Touch up all damaged paint as ne...

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Page 151: ...f IIDS data 95 30 00 900 Make sure you comply with component mandatory retirement refer to Airworthiness Limitation Schedule and make entries in Log Book 04 00 00 900 Make sure you comply with component overhaul refer to Overhaul Schedule and make entries in Log Book 05 10 00 900 Make sure you comply with all applicable Airworthiness Directives and service bulletins and make entries in Log Book N ...

Page 152: ... correct direction 67 20 00 900 Examine the thruster and thruster components Do a check for correct thruster cable tension with a tensiometer 67 20 00 Electrical Power 900 Examine area electrical wiring and electrical component installation for condition support and correct installation 98 00 00 Touch up all damaged paint as necessary Airframe Segmented Inspection Program Inspection 7 Certificatio...

Page 153: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Section 05 50 00 Continued Airworthiness Unscheduled Inspection ...

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Page 155: ...in rotor blade to hit the tailboom or upper fairings or cowlings Permanent deformation of the landing gear cross tubes more than permitted limits The lower fuselage lower tailboom surface or thruster to touch the ground Use the Level I inspection schedule in Table 201 if you think there has been a hard landing If you find damage or deformation when you do the necessary maintenance and inspection p...

Page 156: ...copter speak to the Field Service Department at MDHI Mesa Arizona Telephone 1 800 388 3378 or 480 346 6387 DATAFAX 480 346 6813 for inspections and maintenance procedures you need to do 7 Engine Out Low Rotor Functional Check When major maintenance or a modification has been done to the helicopter electrical system do the Engine Out Low Rotor Check ref the latest revision of the applicable Rotorcr...

Page 157: ...aggage compartment for loose assemblies or parts 25 50 00 Landing Gear 900 Examine cross tubes for apparent damage and permanent deformation Make sure the spread of crosstubes is not more than the permitted maximum limits 32 00 00 900 Remove Aft Crosstube Cover Assembly B230 ref Section 06 00 00 and examine aft crosstube for damage and permanent deformation that is more than the permitted limits 3...

Page 158: ...deck mast fittings and adjacent area for damage or deformation 53 30 00 900 Examine upper deck engine mount fittings and adjacent area for damage or deformation 53 30 00 900 Examine underside of fuselage for signs of contact with the ground 53 20 00 900 Examine tailboom for damage Examine lower surface for signs of contact with the ground Examine upper surface for signs of rotor blade strike 53 40...

Page 159: ...s for damage and for signs of hard contact 62 20 00 Transmission and Drive System 900 Examine transmission input drive shaft assemblies Examine for obvious damage and installation Examine hardware for installation Examine for signs of movement at flanges 63 10 00 900 Examine anti torque fan drive shaft assembly Examine for obvious damage and installation Examine installation of fasteners Examine f...

Page 160: ...ol rod and thruster control sector assembly for correct installation damage and deformation 67 20 00 900 Examine thruster for obvious damage or signs of contact with the ground 67 20 00 900 Examine thruster stationary track and rotating cone followers for damage and deformation 67 20 00 900 Do an operational test to make sure the directional controls and rotating cone move correctly 67 20 00 Power...

Page 161: ...MM Section Requirement After Inspection Touch up all damaged paint and exterior markings as necessary Rotorcraft must not be moved or flown unless cockpit floor cabin floor and bag gage floor panels are correctly installed These are stressed panels CAUTION Install all floor and access panels covers and trim panels removed or opened for inspection Do a check for closure fit and tightness Make sure ...

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Page 163: ...uipment Furnishings 900 Do the crew Seat Energy Absorption System EAS Inspection 25 10 00 900 Examine crew restraints as follows Examine for damage and make sure they are correctly attached Do the Seat Restraint System Operational Test 25 10 00 900 Do the cabin Seat Energy Absorption System EAS Inspection 25 20 00 900 Examine passenger restraints as follows Examine for damage and make sure they ar...

Page 164: ...s are tight Examine for indication of leakage 28 20 00 900 Examine tubes as follows Examine for damage and deformation Make sure tube connections are tight Examine for indication of leakage 28 20 00 900 Examine frangible connections as follows Examine for indication of leakage Examine for indication of separation of frangible connection 28 20 00 Hydraulic System 900 Examine hoses as follows Examin...

Page 165: ...pacers Examine components and fasteners for damage and deformation Examine forward fitting spacer fastener holes for damage or deformation If you do not see damage on forward fitting spacer fastener holes do a fluorescent penetrant or dye penetrant inspection 32 00 00 CSP SPM 20 90 00 If permanent deformation of one or both landing gear cross tubes has occurred 900 Remove both forward and aft side...

Page 166: ...s Examine composite components for cracks and delamination Examine bonded or riveted joints for separation 53 10 00 900 Examine cockpit floor substructure and lower section of forward bulkhead as follows Examine composite components for cracks and delamination Examine metal components for damage and deformation Examine bonded or riveted joints for separation 53 10 00 900 Examine baggage floor subs...

Page 167: ...ure torque stripe across aft fuselage fitting and adjacent structure is not broken 53 20 00 900 Examine keel beams fuel cell support ribs and adjacent structure and cabin floor substructure as follows Examine composite components for cracks and delamination Examine metal components for damage and deformation Examine bonded or riveted joints for separation 53 20 00 If upper deck fairings and cowlin...

Page 168: ...ion Examine bolted or riveted joints for separation 53 30 00 900 Examine upper deck substructure as follows Examine components for damage and deformation Examine riveted joints for separation 53 30 00 900 Examine upper deck mast fittings and installation points Examine fittings for damage and deformation Examine riveted joints for separation 53 30 00 900 Examine upper deck engine fittings as follo...

Page 169: ...ti Torque Fan Sudden Stoppage Conditional Inspection 05 50 00 Flight Controls If main rotor blades or main rotor hub shows damage 900 Examine hydraulic servoactuators as follows Examine for indication of too much leakage Examine piston rods for damage or deformation Make sure they are correctly attached 67 10 00 900 Remove access covers and examine all upper deck linkages bellcranks control rods a...

Page 170: ...essary Inspection Powerplant Controls 900 Do the Engine Controls Operational Test 76 00 00 After Hard Landing Level II Inspection Touch up all damaged paint external marks and placards as necessary Rotorcraft must not be moved or flown unless cockpit floor cabin floor and bag gage floor panels are correctly installed These are stressed panels CAUTION Install all floor and access panels covers and ...

Page 171: ... and adjacent structure for damage and deformation 53 30 00 900 Examine upper deck skin panels transmission and engine bays for deformation and buckling 53 30 00 900 Examine upper deck substructure for damage deformation and separation of riveted joints 53 30 00 Main Rotor 900 Remove and examine main rotor blades Examine skin for buckling and cracks Examine for signs of skin delamination Examine b...

Page 172: ...act with main rotor hub 62 20 00 900 Examine main rotor hub assembly Examine upper and lower main rotor hub assemblies for cracks and deformation Examine for installation of hardware 62 20 00 900 Remove and examine drive link assembly Examine for damage and deformation correct freedom of movement Examine installation hardware for damage and deformation Examine bosses on lower hub and swashplate 67...

Page 173: ...on for damage and deformation Examine flanges for deformation elongation of fastener holes and correct installation of nutplates Examine flexible couplings for cracks and deformation of diaphragms Examine flange of transmission input pinion assembly for deformation and elongation of fastener holes 63 10 00 900 Remove and examine anti torque fan drive shaft assembly Examine center section for damag...

Page 174: ... unserviceable 900 Remove transmission for overhaul 63 20 00 900 Remove and examine acoustic isolator Examine for cracks and delamination of elastomeric material Do a magnetic particle inspection of transmission fasteners Do a dye penetrant inspection of coupling teeth on underside of mast base 63 20 00 CSP SPM 20 90 00 Anti Torque Assembly 900 Remove anti torque inlet duct assembly F2 ref Section...

Page 175: ...d manufacturers publications for detailed requirements on inspection of the engine 01 00 00 900 Examine LH and RH engine mounts Examine for damage and deformation Examine fasteners for correct installation 71 20 00 900 Make sure the engine to transmission alignment is correct 71 20 00 After Inspection Touch up all damaged paint and exterior markings as necessary Rotorcraft must not be moved or flo...

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Page 177: ...e shaft assembly Examine center section for damage and deformation Examine flanges for deformation elongation of fastener holes and installation of nutplates Examine flexible couplings for cracks and deformation of diaphragms Examine flange of transmission output pinion assembly for deformation and elongation of fastener holes 63 10 00 If anti torque fan drive shaft shows signs of movement at flan...

Page 178: ... 900 Examine truss strut deck fittings Examine for obvious damage and deformation Examine fasteners for correct installation 63 30 00 Anti Torque Assembly 900 Remove and examine fan assembly access panels for FOD damage Examine anti torque inlet duct assembly F2 Examine center body fairing assembly F3 Examine lower center diffuser F7 Examine lower duct assembly F8 Examine lower section of stator a...

Page 179: ...ng 64 00 00 900 Remove and examine fan assembly Examine blades for impact damage blade tips for damage and signs of contact with felt seal blade root and pitch horns for cracks and deformation Examine tension torsion straps for cracks delamination and bushing installation Examine fan hub and inner rim bushings for damage and deformation Examine pitch plate and pitch plate bushings for damage and d...

Page 180: ...ils of thruster cascade for FOD damage Examine opening and interior of rotating cone for FOD damage 67 20 10 After Inspection Touch up all damaged paint and exterior markings as necessary Rotorcraft must not be moved or flown unless cockpit floor cabin floor and bag gage floor panels are correctly installed These are stressed panels CAUTION Install all floor and access panels covers and trim panel...

Page 181: ...and cracks Examine for signs of skin delamination 62 10 00 900 Examine main rotor hub assembly Examine upper and lower main rotor hub assemblies for cracks and deformation Examine installation of fasteners 62 20 00 900 Examine truss struts Examine for obvious damage and installation Examine for fasteners for looseness 63 20 00 900 Examine drive link assembly Examine for damage and deformation Exam...

Page 182: ...rtorque is a separate exceedance recorded by the IIDS This record will be in engine torque 01 00 00 900 Examine LH and RH engine mounts Examine for damage and deformation Examine for loose fasteners 71 20 00 After Inspection Touch up all damaged paint and exterior markings as necessary Rotorcraft must not be moved or flown unless cockpit floor cabin floor and bag gage floor panels are correctly in...

Page 183: ...eformation and separation of riveted joints 53 30 00 900 Examine anti torque fan mounting frames and adjacent structural components for deformation and separation of riveted joints 53 20 00 900 Examine fan support for damage deformation and loose fasteners 53 20 00 Main Rotor 900 Remove and examine main rotor blades Examine skin for buckling and cracks Examine for signs of skin delamination Examin...

Page 184: ...for damage and deformation 64 00 00 900 Examine mating drive coupling spline on fan support assembly for damage and deformation 64 00 00 900 Examine fan assembly blades for damage and or signs of contact with felt seal 64 00 00 If fan drive coupling and or drive spline on fan support assembly has damage which makes the component unserviceable and or if fan assembly blades have signs of contact wit...

Page 185: ... in engine torque percent 01 00 00 900 Examine LH and RH engine mounts Examine for damage and deformation Examine for loose fasteners 71 20 00 900 Make sure the engine to transmission alignment is correct 71 20 00 After Inspection Touch up all damaged paint and exterior markings as necessary Rotorcraft must not be moved or flown unless cockpit floor cabin floor and bag gage floor panels are correc...

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Page 187: ... damaged replace input pinion 63 20 00 900 Examine transmission acoustic isolators for condition and installation 63 20 00 900 Examine transmission fasteners for condition and looseness Make sure the torque is correct 63 20 00 Above 150 900 Replace input drive shaft and all fasteners 63 10 00 900 Replace transmission assembly 63 20 00 After Inspection Touch up all damaged paint and exterior markin...

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Page 189: ...bove transmission input exceedance threshold value as provided by the IIDS in the Rotorcraft Log Book S1 value N A 900 Replace all input drive shaft fasteners 63 10 00 900 Examine transmission input flange for visible damage If damaged replace input pinion 63 20 00 900 Examine transmission acoustic isolators for condition and installation 63 20 00 900 Examine transmission fasteners for condition a...

Page 190: ...eedance threshold value as given by the IIDS in the Rotorcraft Log Book T1 value N A 900 Examine main rotor drive shaft and drive plate for cracked or broken spline teeth If found replace Main rotor drive plate Main rotor drive plate cover and fasteners Main rotor drive shaft Transmission assembly All eight segmented acoustic isolators 63 10 00 900 Replace main rotor drive shaft if not PN 900D2436...

Page 191: ...solators and transmission fasteners 63 20 00 900 Examine main rotor drive shaft and drive plate spline teeth for cracked or broken spline teeth If found replace transmission assembly and all eight segmented acoustic isolators 63 10 00 900 Replace main rotor drive shaft drive plate drive plate cover and related fasteners 63 10 00 900 Remove and examine anti torque fan drive shaft do not disassemble...

Page 192: ... is found 64 30 00 900 Replace all anti torque driveshaft fasteners 63 10 00 900 Replace transmission all acoustic isolators and related fasteners 63 20 00 900 If not replaced by single engine torque value examine input drive shaft assemblies and fasteners for condition and installation Make sure the torque is correct 63 10 00 After Inspection Touch up all damaged paint and exterior markings as ne...

Page 193: ...ve transmission input exceedance threshold as given by the IIDS in the Rotorcraft Log Book S1 value N A Single Input 140 to 150 900 Record time above transmission input exceedance threshold as given by the IIDS in the Rotorcraft Log Book S1 value N A 900 Replace all input drive shaft fasteners 63 10 00 900 Examine transmission input flange for visible damage If damaged replace input pinion 63 20 0...

Page 194: ...pline teeth If found replace Main rotor drive plate Main rotor drive shaft Main rotor drive plate cover and fasteners Transmission assembly All eight segmented acoustic isolators Transmission fasteners 63 10 00 Averaged Input 126 to 135 900 Record time above transmission input exceedance threshold as given by the IIDS in the Rotorcraft Log Book T1 value N A 900 Replace transmission bolt acoustic i...

Page 195: ... 00 900 If recorded pedal position is greater than 25 magnetic particle examine main rotor drive plate for cracks or related damage If found replace Main rotor drive plate Main rotor drive plate cover and fasteners Transmission assembly All eight segmented acoustic isolators 63 10 00 900 If recorded pedal position is greater than 25 examine drive plate for Fastener hole elongation Material displac...

Page 196: ...is found 63 20 00 64 30 00 900 Replace all anti torque drive shaft fasteners 63 10 00 900 If recorded pedal position is greater than 20 replace main rotor drive shaft if not PN 900D2436530 101 63 10 00 900 If recorded pedal position is greater than 20 examine main rotor drive shaft PN 900D2436530 101 63 10 00 900 If recorded pedal position is greater than 20 examine main rotor drive shaft and driv...

Page 197: ...lines are cracked or broken replace Transmission assembly All eight segmented acoustic isolators 63 10 00 900 If recorded pedal position is greater than 45 and less than 80 replace Main rotor drive shaft Main rotor drive plate Main rotor drive plate cover Main rotor drive plate and cover fasteners 63 10 00 900 If not replaced by single engine torque value examine input drive shaft assemblies and f...

Page 198: ...ine main rotor drive shaft PN 900D2436530 101 63 10 00 900 If recorded pedal position is greater than 16 examine drive plate for Fastener hole elongation Material displacement at or around fastener holes Pitting or fretting around fastener holes Corrosion Replace if a discrepancy is found 63 10 00 900 If recorded pedal position is greater than 16 magnetic particle examine main rotor drive plate fo...

Page 199: ...e transmission all acoustic isolators and related fasteners 63 20 00 900 Replace drive plate fasteners 63 10 00 900 Replace main rotor drive shaft if not PN 900D2436530 101 63 10 00 900 Examine main rotor drive shaft PN 900D2436530 101 63 10 00 900 Examine main rotor drive shaft and drive plate for cracked or broken spline teeth If found replace Main rotor drive plate Main rotor drive shaft Main r...

Page 200: ...orque is correct 63 10 00 After Inspection Touch up all damaged paint and exterior markings as necessary Rotorcraft must not be moved or flown unless cockpit floor cabin floor and bag gage floor panels are correctly installed These are stressed panels CAUTION Install all floor and access panels covers and trim panels removed or opened for inspection Do a check for closure fit and tightness Make su...

Page 201: ...CONFIG CAUTION Single Input 136 or Above 900 Replace transmission all acoustic isolators and related fasteners 63 20 00 After Inspection Touch up all damaged paint and exterior markings as necessary Rotorcraft must not be moved or flown unless cockpit floor cabin floor and bag gage floor panels are correctly installed These are stressed panels CAUTION Install all floor and access panels covers and...

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Page 203: ...ion 62 20 00 900 Examine centering bearings via inboard ends of pitch cases for signs of damage and or delamination of elastomer 62 20 00 900 Examine borescope flex beams Examine for cracks and delamination Examine inboard areas for signs of hard contact with main rotor hub 62 20 00 900 Examine main rotor hub assembly Do an eddy current inspection of the upper hub assembly Examine lower main rotor...

Page 204: ...ith felt seal 900 Do a conditional inspection in accordance with Unscheduled Conditional Inspection Sudden Stoppage Anti Torque Fan 05 50 00 After Inspection Rotorcraft must not be moved or flown unless cockpit floor cabin floor and bag gage floor panels are correctly installed These are stressed panels CAUTION Touch up all damaged paint and exterior markings as necessary Install all floor and acc...

Page 205: ...for damage deformation and separation of riveted joints 53 30 00 Transmission and Drive System 900 Examine main rotor drive plate for damage and deformation and fasteners for correct installation and looseness 63 10 00 900 Examine input drive shaft assemblies Examine center section for damage and deformation Examine flanges for deformation and fastener installation Examine flexible couplings for c...

Page 206: ...2 20 00 900 Examine pitch cases Examine exterior and inboard and outboard ends for obvious damage Examine pitch horns for obvious damage deformation and installation 62 20 00 900 Examine centering bearings via inboard ends of pitch cases for signs of damage and or delamination of elastomer 62 20 00 900 Examine borescope flex beams Examine for cracks and delamination Examine inboard areas for signs...

Page 207: ...with felt seal 64 00 00 If fan assembly blades exhibit signs of contact with felt seal 900 Do a conditional inspection in accordance with Unscheduled Conditional Inspection Sudden Stoppage Anti Torque Fan 05 50 00 Powerplant 900 Refer to related manufacturers publications for engine inspection requirements 01 00 00 900 Examine LH and RH engine mounts Examine for damage and deformation Examine fast...

Page 208: ...e 212 Main Rotor Overspeed 106 to 110 NR Power On Conditional Inspection Cont Registration No Serial No Helicopter Total Hours Model Initial Ref RMM Section Requirement Post Inspection Run Up If Applicable Ref the latest revision of the applicable RFM for cockpit check and engine start procedures ...

Page 209: ... Remove and examine pitch cases Examine for cracks and delamination Examine outboard lug bushings for damage and installation Examine pitch horns for damage deformation and installation 62 20 00 900 Examine centering bearings Examine for damage and deformation Examine snubber bolts for damage or deformation 62 20 00 900 Examine flex beams Examine for cracks and delamination Examine blade bushings ...

Page 210: ...20 00 900 Examine mixer assembly Examine drive link lugs for damage or deformation Make sure there is correct freedom of movement Examine mixer pivot support assemblies for damage deformation and installation of hardware 62 20 00 Transmission and Drive System 900 Examine anti torque fan drive shaft assembly Examine surface along entire length of center section for removal of black anodize scratche...

Page 211: ...flown unless cockpit floor cabin floor and bag gage floor panels are correctly installed These are stressed panels CAUTION Install all floor and access panels covers and trim panels removed or opened for inspection Do a check for closure fit and tightness Make sure all loose equipment has been correctly put in storage Do a check of all fluid levels Fill fluid levels that are low Make sure the fill...

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Page 213: ...mage deformation and separation of riveted joints 53 30 00 Transmission and Drive System 900 Examine input drive shaft assemblies Examine surface along entire length of center section for removal of paint scratches and signs of contact with surrounding components Examine flanges for damage deformation and installation of fasteners Examine flexible couplings for scratches cracks and deformation of ...

Page 214: ...terial Replace bolt isolators and fasteners Do a dye penetrant inspection of coupling teeth on underside of mast base 63 20 00 CSP SPM 20 90 00 900 Do the manual rotation operational test of transmission 63 20 00 If main rotor drive plate fasteners and or a transmission drive shaft shows damage which makes the component unserviceable 900 Remove transmission for overhaul 63 20 00 Main Rotor 900 Rem...

Page 215: ...amine drive link assembly Examine for damage and deformation and make sure there is the correct freedom of movement Examine fasteners for damage and deformation Examine bosses on lower hub and swashplate 67 20 00 900 Examine swashplate assembly Examine pitch link lugs for damage deformation and the bushings are correctly installed Make sure there is correct freedom of movement of rotating and stat...

Page 216: ...for engine inspection requirements 01 00 00 900 Examine LH and RH engine mounts Examine for damage and deformation Examine fasteners for installation 71 20 00 900 Make sure the engine to transmission alignment is correct 71 20 00 After Inspection Rotorcraft must not be moved or flown unless cockpit floor cabin floor and bag gage floor panels are correctly installed These are stressed panels CAUTIO...

Page 217: ...Manual Page 263 Revision 34 05 50 00 Table 215 Main Rotor Overspeed Over 114 NR Power Off Conditional Inspection Registration No Serial No Helicopter Total Hours Model Requirement Ref RMM Section Initial Speak to MD Helicopters Field Service Representatives ...

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Page 219: ...Manual Page 265 Revision 34 05 50 00 Table 216 Main Rotor Overspeed Over 114 NR Power On Conditional Inspection Registration No Serial No Helicopter Total Hours Model Requirement Ref RMM Section Initial Speak to MD Helicopters Field Service Representatives ...

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Page 221: ...tenance Manual Page 267 Revision 34 05 50 00 Table 217 Main Rotor High Vibration During Startup or Shutdown At 35 To 40 NR Registration No Serial No Helicopter Total Hours Model Requirement Ref RMM Section Initial Do the Flexbeam Inspection 62 20 00 ...

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Page 223: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual DIMENSIONS AND AREAS Chapter ...

Page 224: ......

Page 225: ...and Installation Methods 202 C Interior Trim Access Panels 202 D Panel Removal for Scheduled Inspection 202 E Stress Panels 202 Figure 201 Principal Dimensions 203 Figure 202 Station Diagram 204 Figure 203 Inspection Areas 205 Figure 204 Access Methods 206 Figure 205 Nose Access Panels 207 Figure 206 Left Side Access Panels 208 Figure 207 Right Side Access Panels 210 Figure 208 Top View Access Pan...

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Page 227: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 06 00 00 Dimensions and Areas ...

Page 228: ......

Page 229: ...Butt Lines Butt lines BL are vertical planes perpendicu lar to and measured to the left and right along the lateral axis of the helicopter BL 0 00 is the plane at the vertical centerline of the helicop ter 3 Inspection Areas Ref Figure 203 The aircraft has been divided into seven different inspection areas Each area is addressed independently by the 100 hour or annual inspection and the continuous...

Page 230: ...n The type column in each table lists the fastener and the quantity column lists the quantity used to remove or install the door cover panel and fairing is listed C Interior Trim Access Panels Information on interior trim access panels is provided in Section 25 00 00 D Panel Removal for Scheduled Inspection The star sign by an item number in a figure indicates the minimum number of panels to be re...

Page 231: ...nual Page 203 Revision 35 06 00 00 7 33 ft 2 23 m 33 83 ft 10 34 m DIAMETER 9 33 ft 2 84 m 5 33 ft 1 62 m 34 08 ft 10 39 m 12 0 ft 3 66 m 5 91 ft 1 80 m 10 91 ft 3 32 m 40 583 ft 12 37 m 9 17 ft 2 79 m 1 25 ft 0 38 m 9G06 006D Figure 201 Principal Dimensions ...

Page 232: ... 180 160 140 120 100 80 60 STA 155 5 FRAME STA 230 5 FRAME 3 16 220 200 180 120 100 80 60 STA 292 817 WL 147 WL 159 ROOF DECK 60 80 100 120 140 160 180 60 40 20 20 40 60 200 220 240 260 280 300 320 340 360 380 400 420 440 460 60 40 20 20 40 60 60 80 100 120 140 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 STA 199 25 WL 207 97 160 5 0 9G06 007C 480 Figure 202 Station Diagram ...

Page 233: ...nce Manual Page 205 Revision 35 06 00 00 9G06 014 1 NOSE AND COCKPIT 2 CABIN 3 UPPER TRANSMISSION DECK FORWARD FIRE SEAL AND FORWARD 4 MAIN ROTOR 5 POWERPLANT FORWARD FIRE SEAL AND AFT 6 BAGGAGE 7 TAIL TAILBOOM ATTACH AND AFT Figure 203 Inspection Areas ...

Page 234: ...NTERCLOCKWISE LOCK CLOCKWISE UNLOCKED 1 4 TURN SCREW BOLT PULL TO RELEASE DOOR PINS SLEEVE BOLT LEVER ACTION HANDLE CAMLOC 2 PULL 1 PUSH KEYLOC CAMLOC LATCH LOCKED HINGE LOCKED UNLOCKED PUSH TO UNLOCK PUSH TO LOCK LATCH CAMLOC LOCKED HINGE PIN PIN CAMLOC HOOK 1 LIFT LOCK TWO ACTIONS PULL UNLOCK ONE ACTION PUSH 2 LATCH PULL OFF HERE STRUT LIFT HERE TURN AND LOCK CLOSED UNLOCKED LOCKED Figure 204 Ac...

Page 235: ...Nose Access Panels Legend Ref Figure 205 Item No Name Permits Access To Removal and Installation Quantity Type Method Ref Figure 204 N80 Nose Door Battery 2 1 Camloc Keyloc B A N82 Landing Light Window Panel Landing Light Flight Control Rods Avionics Cooling Fan Wire Harness External Power Box 18 Screw L N106 Panel 30 Screw L ...

Page 236: ...Flight Controls 1 14 Keyloc Camloc A B L155 Forward Access Door Assembly LH Main Transmission Access Flight Control Actuators Hydraulic Hand Pump System 1 Hydraulic Manifold Reservoir 3 2 Latch Hinge C D N L166 Passenger Door LH Passenger and Cargo Compartment 1 Lever Action Handle H L170 Access Panel Fuselage Tub outboard of keel beam 12 Camloc U L211 Access Panel Fuselage Tub outboard of keel be...

Page 237: ...OWER W NACA INLET Main Transmission Access Engine Reduction Gearbox Housing 7 Camloc E L220 Inlet Panel Assembly LH Engine Air Inlet Engine Compressor 25 Fastener Sleeve Bolt G L240 APU EPR Door AFT Auxiliary External Power Receptacle 1 Camloc E L260 Engine Cowling Assembly LH Engine Engine Controls 10 Fastener Sleeve Bolt G L262 Baggage Compart ment Door Baggage Compartment behind trim panels Eng...

Page 238: ...8 Avionics Access Panel Assembly RH Electrical Avionics Flight Controls ECS Bleed Air Lines 1 14 Keyloc Camloc A B R155 Forward Access Door Assembly RH Main Transmission Access System 2 Hydraulic Manifold Reservoir 3 2 Latch Hinge C D N R158 Fuel Cap and Adapter Fuel Filler Neck 1 Turn and Lock S R166 Passenger Door RH Passenger and Cargo Compartment 1 1 Lever Action Handle Release Pin H R R185 Fu...

Page 239: ...ction Gearbox Housing 2 5 Hinge Camloc D E N R210 Transmission Access Door Assembly RH UPPER W NACA INLET Main Transmission Access Engine Reduction Gearbox Housing 2 5 Hinge Camloc D E N R210 Transmission Access Door Assembly RH LOWER W NACA INLET Main Transmission Access Engine Reduction Gearbox Housing 7 Camloc E N R220 Inlet Panel Assembly RH Engine Air Inlet Engine Compressor Section 25 Sleeve...

Page 240: ...raulic Servo Actuators Swashplate Mixer 19 4 Screw Bolt L M TL218 Oil Dipstick Hand Hold LH Engine Oil Level and Filler 1 2 Hinge Camlock Q E TR218 Oil Dipstick Hand Hold RH Engine Oil Level and Filler 1 2 Hinge Camlock Q E T220 Swashplate Aft Fairing Assembly Mast Support Transmission Flight Controls ECS Engine Oil Level and Filler 58 4 Screw Bolt L M T240 Upper Inlet Duct Assembly Fan Driveshaft...

Page 241: ... Panels Legend Ref Figure 209 Item No Name Permits Access To Removal and Installation Quantity Type Method Ref Figure 204 B142 Center Access Panel Assembly Throttle Interconnect Cable RH Collective 14 Screw L B178 Sump Access Panel Assembly Fuel Sump Drain Valves 22 Screw L B230 Crosstube Cover Assembly Aft Landing Gear Crosstube Aft 30 Screw L ...

Page 242: ...Method Ref Figure 204 SL1 Upper Tailboom Thruster Fairing Assembly Left Side Horizontal Stabilizer Mount Fitting Stationary Thruster Extension 21 Screw L SR1 Upper Tailboom Thruster Fairing Assembly Right Side Horizontal Stabilizer Mount Fitting Stationary Thruster Extension 21 Screw L S2 Lower Tailboom Thruster Fairing Assembly Horizontal Stabilizer Mount Fitting Stationary Thruster Extension 22 ...

Page 243: ... Light 11 Screw L S4 Thruster End Cover Attachment Bolts For Rotating Thruster 8 Screw L SL5 Center Access Cover LH Horizontal Stabilizer Wiring 10 Screw L SR5 Center Access Cover RH Horizontal Stabilizer Wiring 10 Screw L S6 Leading Edge Cover Center 10 Screw L SL7 Access Cover LH VSCS Actuator 10 Screw L SR7 Access Cover RH VSCS Actuator 10 Screw L SL8 Thruster Extension Fairing Assembly Left Si...

Page 244: ...ity Type Method Ref Figure 204 A160 Cabin Floor Forward Panel Assembly Fuel Cell 69 Screw L A170 Cabin Floor Center Panel Assembly Fuel Cell 89 Screw L A217 Cabin Floor Aft Panel Assembly Fuel Cell Aft Vent Rollover Valves 75 Screw L A235 Baggage Floor Center Panel Crossfeed Valve Condenser Fans Condenser 64 Screw L AL129 Cockpit Outboard Left Floor Panel LH Collective Stick Socket Wire Harness LH...

Page 245: ...re Harness RH Static Port 34 1 Screw Bolt L M AR138 Cockpit Floor Right Access Panel Flight Control Tubes Bellcranks Throttle Cables 35 Screw L AR145 Pilots Collective Base Access Panel Pilots Collective Base Link Assembly and Mounting Bracket 4 Screw L AR155 Cabin Floor Right Forward Access Cover Right Forward Fuel Vent Valve Fuel Cell 12 Screw L AR165 Cabin Floor Right Outboard Panel Fuel Cell F...

Page 246: ...120 Figure 212 Pedestal Access Panels Legend Ref Figure 212 Item No Name Permits Access To Removal and Installation Quantity Type Method Ref Figure 204 PL120 Panel Wire Harness Forward Interconnect Panel Relays Ground Modules 9 Camloc U PR120 Panel Wire Harness Forward Interconnect Panel TB2 TB3 TB4 9 Camloc U ...

Page 247: ...orque Lower Inlet Duct Assembly Plenum Fan Assembly 19 14 Screw Bolt L M F3 Anti Torque Fan Fairing Center Body Assembly Fan Assembly Fan Driveshaft Coupling Support Housing Fan Balance Monitor System Magnetic Pickup and Accelerometer 19 Screw L F4 Anti Torque Middle Inlet Duct Assembly Fan Assembly Plenum Air Inlet 4 19 Screw Bolt L M F5 Anti Torque Fan Upper Duct Assembly Plenum Air Inlet Upper ...

Page 248: ...egend Ref Figure 213 Cont Item No Removal and Installation Permits Access To Name Item No Method Ref Figure 204 Type Quantity Permits Access To Name F8 Lower Access Panel Assembly Diverter 4 Latch P F9 Anti Torque Fan Lower Duct Assembly Fan Assembly and Diverter Fan Control Linkage 18 Screw L ...

Page 249: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual LIFTING AND JACKING Chapter ...

Page 250: ......

Page 251: ...NTENTS Para Figure Table Title Page 07 10 00 Lifting and Jacking A Maintenance Practices 201 1 Lifting and Jacking 201 A Helicopter Hoisting 201 B Component Hoisting 202 Table 201 Approximate Hoisting Weights 202 Figure 201 Helicopter Hoisting 202 C Helicopter Jacking 203 Figure 202 Helicopter Jacking 204 ...

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Page 253: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 07 10 00 Lifting and Jacking ...

Page 254: ......

Page 255: ...aded stud A knurled collar located around the base of the jack pad will provide a hand grip for tightening of the jack pad into the aircraft receivers All receivers are designed and located in such a way as to allow the jack pads to be installed at random into any of the three positions on the aircraft A Helicopter Hoisting Ref Figure 201 Special Tools Ref CSP SPM Item Nomenclature T901 Helicopter...

Page 256: ...onent Weight Lb Kg Complete Helicopter 3350 1520 Kg Blades 200 91 Kg Empennage Assembly 69 32 Kg Engine Complete without oil 285 130 Kg Main Rotor Hub Assembly 160 73 Kg Main Transmission 215 98 Kg Tailboom with bumper 70 32 Kg Thruster 29 13 Kg NOTES 1 Examine aircraft weight and balance record per current Rotorcraft Flight Manual Ref Section 01 00 00 Table 201 for current weight 1 2 5 PL 4 3 9G0...

Page 257: ...ng points located on left and right aft saddle assemblies 7 and 8 NOTE Use of the forward jack pad grease plate allows the jack to adjust to the change in the longitudinal dimension Use of the grease plate is only required if you intend to change the attitude of the aircraft Oil Lubricating C106 4 Using lubricating oil C106 lubricate between forward jack pad grease plates T206 5 This will allow fo...

Page 258: ...SEMBLY 2 PLACES REF 8 8 7 9 9 9 VIEW LOOKING FORWARD 1 5 3 4 6 2 5 1 9G07 001A 1 FORWARD PAD ASSEMBLY ATTACH POINTS 2 RIGHT FORWARD SADDLE ASSEMBLY 3 LEFT FORWARD SADDLE ASSEMBLY 4 FORWARD PAD ASSEMBLY 5 PIN 6 JACK PADS 7 LEFT AFT SADDLE ASSEMBLY 8 RIGHT AFT SADDLE ASSEMBLY 9 JACKS T202 Figure 202 Helicopter Jacking ...

Page 259: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual LEVELING WEIGHT AND BALANCE Chapter ...

Page 260: ......

Page 261: ...avity Limits 201 A Prepare To Weigh Helicopter 201 B Weigh Helicopter 202 Figure 201 Helicopter Jack Points 203 Figure 202 Sample Weight and Balance Report Form 204 Figure 203 Surplus and Missing Equipment Form 205 Figure 204 Basic Weight and Balance Form 206 Figure 205 Sample Basic Weight Check List 207 08 20 00 Leveling A Maintenance Practices 201 1 Helicopter Leveling 201 A Plumb Bob Leveling 2...

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Page 263: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 08 10 00 Weight and Balance ...

Page 264: ......

Page 265: ...01 00 00 Table 201 2 Center of Gravity Limits Center of gravity limits are shown in the Rotorcraft Flight Manual Ref Section 01 00 00 Table 201 A Prepare To Weigh Helicopter Ref Figure 202 and Figure 203 NOTE Weigh helicopter without fuel 1 Connect helicopter to electrical ground Ref Section 10 10 00 2 Defuel helicopter Ref Section 12 00 00 3 Check lubricant level at engine oil tank main rotor gea...

Page 266: ...ss panels are installed Ref Section 06 00 00 6 Jack helicopter Ref Section 07 10 00 7 Level helicopter Ref Section 08 20 00 8 Drain fuel sump Ref Section 12 00 00 NOTE On some helicopters MDHI uses a spe cial jack pad at FS154 0 and lateral 9 3 On other helicopters MDHI uses lateral 0 0 9 Record indication from helicopter weigh system T204 10 Lower helicopter until the three helicopter jack T202 o...

Page 267: ...0 120 140 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 160 WL 106 FLOOR 220 200 180 120 100 80 60 60 40 20 20 40 60 60 40 20 20 40 60 60 80 100 120 140 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 160 480 480 FWD JACK POINT STA 154 1 BL 0 AFT JACK POINTS STA 233 0 BL 23 3 AND 23 3 Figure 201 Helicopter Jack Points ...

Page 268: ...E OR CALIB CORR LB NET WEIGHT LB LONGITU DINAL ARM INCH LATERAL ARM INCH LONGITU DINAL MOMENT IN LB LATERAL MOMENT IN LB Forward NOTE 1 869 7 0 0 869 7 154 1 9 3 134020 8 8088 2 Aft Right 1289 5 0 0 1289 5 233 0 23 3 300453 5 30045 4 Aft Left 887 5 0 0 887 5 233 0 23 3 206787 5 20678 8 TOTAL AS WEIGHED 3046 7 210 5 0 4 641261 8 1278 4 Less Surplus Weight See Table 1 1 8 189 4 10 4 340 9 18 7 Plus ...

Page 269: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 205 Revision 7 08 10 00 9G08 003A MD Helicopters Inc Form HOQ015 Rev 5 00 Figure 203 Surplus and Missing Equipment Form ...

Page 270: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 206 Revision 7 08 10 00 9G08 004A MD Helicopters Inc Form HOQ014 Rev 5 00 Figure 204 Basic Weight and Balance Form ...

Page 271: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 207 Revision 32 08 10 00 9G08 008 Figure 205 Sample Basic Weight Check List ...

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Page 273: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 08 20 00 Leveling ...

Page 274: ......

Page 275: ... T201 Jack Pad Kit T202 Helicopter Jack T205 Plumb Bob 1 Remove closeout panel covering upper aft left hand cabin door beam 4 Ref Section 25 20 00 2 Locate keyhole slot 2 in upper aft left hand cabin door beam 4 3 Attach plumb bob line 5 to keyhole slot 2 4 Remove left cabin carpet Ref Section 25 20 00 from floor area 1 5 Locate unpainted rivet 3 for plumb bob 5 alignment Airframe structure damage...

Page 276: ...al Page 202 Original 08 20 00 9G08 005 3 NOTE 1 4 2 NOTE 2 5 NOTE RIVET LOCATION FS 215 425 BL 26 757 WL 105 953 FS 215 425 BL 26 757 WL 155 025 1 FLOOR AREA 2 KEYHOLE SLOT 3 RIVET 4 UPPER AFT LEFT HAND CABIN DOOR BEAM 5 PLUMB BOB Figure 201 Helicopter Leveling ...

Page 277: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual TOWING Chapter ...

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Page 279: ...vision 25 09 Contents TABLE OF CONTENTS Para Figure Table Title Page 09 00 00 Towing A Maintenance Practices 201 1 Towing Requirements 201 A Helicopter Manual Moving 201 B Helicopter Towing 202 C Helicopter Transport 202 Figure 201 Helicopter Towing and Ground Handling 203 ...

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Page 281: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 09 00 00 Towing ...

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Page 283: ...set 3 forward NOTE The wheel set can be installed in either direction depending on jack handle posi tion 3 Attach ground handling wheel set T101 3 to attach points 2 on skid tubes 1 4 Hold tail up while lowering ground handling wheel set T101 3 5 Jack hydraulic ram which forces wheels down and skids up 6 When the jack is extended a mechani cal safety latch automatically snaps into position to prev...

Page 284: ...and pre flight operations Do not move the rotor blade tip up more than 4 0 ft 1 22 m when the rotor is not in operation And do not move the flexbeam up more than 1 0 in 2 54 cm at the blade attach point Dam age to the flexbeam can occur 8 Avoid short turns which could cause helicopter to turn over A safe minimum turning radius is approximately 20 feet 9 Allow inside wheel to turn not pivot while h...

Page 285: ...adius is approximately 20 feet 4 Release heli porter 4 hand brake When ground handling helicop ter do not lift main rotor blades to clear objects The main rotor should be ro tated to clear objects 5 Ensure cyclic stick is centered and do not exceed the maximum up limits for the main rotor hub flexbeam during ground handling maintenance and pre flight operations 6 Attach heli porter 4 hook up to a ...

Page 286: ......

Page 287: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual PARKING AND MOORING Chapter ...

Page 288: ......

Page 289: ...ral Procedures 202 B Preparation For Flyable Storage 203 C Maintenance During Flyable Storage 203 5 Short Term Storage 204 A General Preparation 204 B Maintenance During Short Term Storage 204 6 Intermediate Storage 204 A General Storage Procedures 205 B General Inspection 205 C Preservation for Intermediate Storage 205 D Maintenance During Intermediate Storage 205 Figure 202 Helicopter Blade Tied...

Page 290: ... H Rotor Hub Cover 204 I Engine Area Cover 204 J Blade Covers 205 K Blade Covers Cold Weather 205 Figure 202 Helicopter Protective Covers 205 10 30 00 Return To Service A Maintenance Practices 201 1 Return to Service 201 A Flyable Storage Depreservation and Activation 201 B Short Term Storage Depreservation and Activation 201 C Intermediate Storage Depreservation and Activation 202 ...

Page 291: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 10 10 00 Parking and Storage ...

Page 292: ......

Page 293: ... Section 09 00 00 4 Allow helicopter to rest on landing gear skid tubes Tiedown rotor blades whenever helicopter is parked to prevent rotor damage from blade flapping as a result of air turbulence from other aircraft or wind gusts The maximum blade tie down load is when the blade tip just begins to deflect downward 5 Secure main rotor blades with blade tiedowns 1 if helicopter is parked in an area...

Page 294: ...r elements must be considered Wet weather conditions promote corrosion rot mildew and mold Perform regular inspections to prevent these deteriorating effects 1 Inspect for rot mildew and mold keep nonmetallic materials clean and dry Ref CSP SPM 2 Inspect and treat for corrosion control Ref CSP SPM 3 Maintain full fuel cell to reduce con densation in the cell Ref Section 12 00 00 When ground handli...

Page 295: ...ion 10 20 00 h Record date engine was placed in flyable storage in helicopter records 3 Hydraulic System a Service hydraulic system to prevent contamination or degradation Ref Section 29 00 00 4 Fuel System a Drain water from fuel cell per current Rotorcraft Flight Manual Ref Section 01 00 00 Table 201 b Fill fuel cells to full capacity Ref Section 12 00 00 5 Airframe a Open window air vents Posit...

Page 296: ...ation oil Oil Preservation C118 a Fill fuel cell to full capacity with preservation oil C118 b Remove preservation oil using defueling procedures Ref Section 12 00 00 7 Remove battery Ref Section 96 10 00 and store in waxed paper and a wood crate 8 Clean battery compartment Ref Section CSP SPM FOD 9 Ensure drain holes are free of debris and kept open during storage period 10 Install engine area co...

Page 297: ...icopter records C Preservation for Intermediate Storage Ref Figure 202 Special Tools Ref CSP SPM Item Nomenclature T108 Blade Tiedown T107 Pitot Cover T106 Upper Deck Cover 1 Clean and preserve engine in accor dance with manufacturers Engine Manual Ref Section 01 00 00 2 Drain fuel cell Ref Section 12 00 00 3 Deleted 4 Rotors and controls will be preserved in accordance with Servicing Ref Section ...

Page 298: ... Manual Page 206 Original 10 10 00 9G10 001 1 6 6 5 2 4 3 1 BLADE TIEDOWN T108 2 PITOT COVER T107 3 UPPER DECK COVER T106 4 ENGINE AREA COVER T2008 5 AFT MOORING TIEDOWNS T104 6 FORWARD MOORING TIEDOWNS T105 Figure 202 Helicopter Blade Tiedowns and Covers ...

Page 299: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 10 20 00 Mooring ...

Page 300: ......

Page 301: ...otor hub flexbeam during ground handling maintenance and pre flight operations 3 Secure helicopter to ramp tiedowns using aft mooring tiedowns 1 and forward mooring tiedowns 2 4 If a paved ramp with tiedown rings are not available park helicopter Ref Section 10 10 00 on an unpaved parking area headed in the direction from which highest forecast winds are expected 5 Secure helicopter using aft moor...

Page 302: ...ping as a result of air turbulence from other aircraft or wind gusts The maximum blade tie down load is when the blade tip just begins to deflect downward Blade tiedowns 5 are socks which fit over the blade tip with or without the blade covers installed Each blade tiedown is made of heavy nylon and weighs approximately two pounds 0 9 kg each Each blade tiedown 5 is fitted with a generous length of...

Page 303: ...NOTAR Boom Cover The MD Explorer boom cover 1 is a tubular cover made of nylon The cover weighs approximately five pounds 2 kg 1 Attach boom cover 1 to thruster using side release buckles E NOTAR Thruster Cover Ref Figure 202 Special Tools Ref CSP SPM Item Nomenclature T2010 NOTAR Thruster Cover The MD Explorer thruster cover 2 encloses the thruster cone and chokes tightly around the base near the...

Page 304: ...stallation Red Left Green Right 3 Attach upper rear corners to snap head screws placed in existing screw holes on lower edge of particle separator inlet 4 Attach straps at lower rear corners to rear struts 5 Tighten special rope in top and bottom hems to insure against wind chaffing 6 A large bright red pocket is sewn in the cover 4 for the pitot tube H Rotor Hub Cover Ref Figure 202 Special Tools...

Page 305: ...e aid of a lightweight rope attached to the open end 2 Tighten covers 7 at blade root with attached straps and buckles 3 The small opening at the blade tip bottom allows attachment of tiedown ropes K Blade Covers Cold Weather Ref Figure 202 Special Tools Ref CSP SPM Item Nomenclature T2012 Blade Covers Cold Weather The MD Explorer cold weather blade covers 8 are similar to the standard blade cover...

Page 306: ......

Page 307: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 10 30 00 Return To Service ...

Page 308: ......

Page 309: ...for storage B Short Term Storage Depreservation and Activation Special Tools Ref CSP SPM Item Nomenclature T2008 Engine Area Cover T108 Blade Tiedown T107 Pitot Cover T106 Upper Deck Cover 1 Remove protective covers T2008 T107 and T106 stow in designated location 2 Open all doors and ventilate helicopter Ref Section 06 00 00 3 Remove tiedowns T108 and stow with other covers 4 Service and connect b...

Page 310: ...ystem in accordance with Ref Section 29 00 00 7 Transmission oil and lubrication pump filter assembly are to be replaced for aircraft that have been in storage in excess of a year without operation Ref Section 63 21 00 8 Install main rotor blades Ref Section 62 10 00 9 Check fuel system for presence of water and drain as necessary 10 Fill fuel cell as necessary with approved fuel Ref Section 12 00...

Page 311: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual PLACARDS AND MARKINGS Chapter ...

Page 312: ......

Page 313: ...t Decal Installation Sheet 1 of 2 206 Figure 203 Cockpit and Cabin Door Exit Decals Sheet 1 of 2 Part of Interior Trim Installation 208 Figure 204 Cabin and Baggage Decal Installation Sheet 1 of 2 210 Figure 205 Upper Deck Decal Installation Sheet 1 of 2 212 Figure 206 Hydraulic GSE Panel Part of Hydraulic System Installation 214 Figure 207 Main Rotor Pitch Case Decal Part of Main Rotor Installati...

Page 314: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Page ii Revision 26 11 Contents TABLE OF CONTENTS Cont Para Figure Table Title Page This page intentionally left blank ...

Page 315: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 11 00 00 Placards and Markings ...

Page 316: ......

Page 317: ...r different areas of decal placement on the helicopter Exterior Decal Installation Ref Figure 201 Cockpit Decal Installation Ref Figure 202 Cockpit and Cabin Door Exit Decals Part of Interior Trim Installation Ref Figure 203 Cabin and Baggage Compartment Decal Installation Ref Figure 204 Upper Deck Decal Installation Ref Figure 205 Hydraulic System GSE Panel Decal Part of Hydraulic System Installa...

Page 318: ...s doors etc the decal must be cut out to provide proper draining or ease of opening or removing of doors plates etc 3 Where a decal is applied over a skin lap one skin overlapping another the decal must be cut so that it lies flat and makes a positive bond Adhesive Epoxy C407 Adhesive Epoxy C411 4 Seal edges of all exterior decals with epoxy adhesive C407 and only those exterior upper deck engine ...

Page 319: ...7 13 16 17 17 15 16 13 17 15 22 NOTE 1 5 NOTE 1 14 NOTE 1 BL 0 000 WL 147 000 8 NOTE 2 26 NOTE 1 NOTES 1 MINIMUM EXTERIOR DECAL INSTALLATION 2 LEFT HAND SHOWN RIGHT HAND TYPICAL 3 WITH FUEL SYSTEM RANGE EXTENDER INSTALLED 4 WITH SUPPLEMENTAL FUEL SYSTEM INSTALLED 5 ALTERNATE LOCATION 23 NOTE 1 NOTE 1 NOTE 1 2 3 NOTE 1 14 NOTE 1 14 NOTE 1 14 NOTE 1 9G11 001 1E 14 NOTE 3 28 NOTE 4 23 NOTES 4 AND 5 2...

Page 320: ...8 PUSH INFORMATION 9 NO PUSH INFORMATION 10 EXTERIOR COCKPIT DOOR RIGHT SIDE 11 EXTERIOR COCKPIT DOOR LEFT SIDE 12 28 VDC LOCATION 13 JACK PAD 14 NO STEP INFORMATION 1 FUEL FILL LOCATION 9G11 001 2G OPEN SAFELOCK SLAM KEY LOCK SAFELOCK key lock SLAM OPEN SAFELOCK key lock SLAM OPEN 2 REGISTRATION NUMBER WHITE RH 3 REGISTRATION NUMBER WHITE LH Figure 201 Exterior Decal Installation Sheet 2 of 3 ...

Page 321: ...SM 26 FUEL CAP DECAL 25 EXTERIOR CABIN DOOR INSTRUCTION LEFT SIDE NEW CONFIGURATION LATCH MECHANISM 27 RANGE EXTENDER 9G11 001 3 CAUTION DISCONNECT ELECTRICAL WIRING BEFORE REMOVING BOOM 28 FUEL FILL LOCATION SUPPLEMENTAL FUEL SYSTEM PROD CERT NO TYPE CERT NO SERIAL NO MODEL NO MESA AZ HELICOPTER SYSTEMS MCDONNELL USEABLE CAP 158 5 U S GALS WITH RANGE EXTENDER INSTALLED 24 EXTERIOR CABIN DOOR INST...

Page 322: ...anual Page 206 Revision 26 11 00 00 A B B C C D D A B C D 4 5 5 B E E 6 E E 9 9G11 002 1G 2 1 3 7 8 G G G G A A WITH SUPPLEMENTAL FUEL SYSTEM INSTALLED 1 1 12 13 14 15 C D 10 0 25 IN 1 23 IN 31 24 MM 6 35 MM Figure 202 Cockpit Decal Installation Sheet 1 of 2 ...

Page 323: ... COGNIZANT AIRWORTHINESS AUTHORITY 7 MAIN CABIN DECAL 8 MD900 COCKPIT VNE CARD INFORMATION 9 OPERATIONS RECORD HOLDER 9G11 002 2E 10 CYCLIC CENTERING AUXILIARY FUEL SYSTEM USE MAIN FUEL DOWN TOo 700 LBS BEFORE SELECTING AUX FUEL TRANSFER DO NOT USE AUX FUEL TRANSFER BELOW MAIN FUEL OF 300 LBS 11 INSTRUCTION SUPPLEMENTAL FUEL TRANSFER 12 OPERATION SUPPLEMENTAL FUEL TRANSFER PUMP ON 13 OPERATION SUP...

Page 324: ...sion 26 11 00 00 COCKPIT DOOR FRAME LOOKING OUTBOARD RIGHT SIDE 1 2 3 2 3 3 1 2 RIGHT SHOWN LEFT OPPOSITE 9G11 008 1A 4 5 4 5 PUSH FOR FRESH PULL FOR RECIRC HANDLE POSITION DOOR OPEN Figure 203 Cockpit and Cabin Door Exit Decals Sheet 1 of 2 Part of Interior Trim Installation ...

Page 325: ...Inc Rotorcraft Maintenance Manual Page 209 Revision 26 11 00 00 4 5 6 6 7 7 4 5 3 9G11 008 2 4 EARLY CONFIGURATION CURRENT CONFIGURATION Figure 203 Cockpit and Cabin Door Exit Decals Sheet 2 of 2 Part of Interior Trim Installation ...

Page 326: ...n 26 11 00 00 9G11 003 1B A A B B A A B B C C D D D D E E E E FS 230 50 FS 230 50 WL 106 00 RBL 19 99 LBL 19 99 FS 248 00 FS 155 50 FS 155 50 FS 155 50 FS 130 50 1 2 3 3 4 5 5 6 6 5 5 5 5 5 C C 3 3 3 8 TOP OF DECAL 5 5 Figure 204 Cabin and Baggage Decal Installation Sheet 1 of 2 ...

Page 327: ...NG WARNING SEAT ATTACH ONLY NO TIEDOWN ROTATING FAN BLADES INSPECTION ACCESS ONLY CAUTION CAUTION GCU VOLTAGE REGULATION CONSULT MAINTENANCE MANUAL FOR PROPER ADJUSTMENT THIS PANEL MUST BE SECURED PRIOR TO JACKING TOWING OR FLYING THE AIRCRAFT REPLACE DOOR BEFORE FLIGHT AND JACKING AIRCRAFT CAUTION DO NOT CONNECT OR DISCONNECT UNIT WHILE GENERATOR IS IN MOTION WITHOUT OPENING GCU AND GENERATOR FIE...

Page 328: ...ntenance Manual Page 212 Revision 26 11 00 00 A A A A B B C C B B C C FS 155 50 WL 160 00 FS 155 50 1 1 2 NOTE 3 4 5 6 NOTE 7 NOTE 1 6 NOTE NOTE LEFT HAND SHOWN RIGHT HAND TYPICAL 9G11 004 1B 8 Figure 205 Upper Deck Decal Installation Sheet 1 of 2 ...

Page 329: ...LINE WITH GREASE CONFORMING TO SYNTECH 3913 G1 AIRCRAFT MUST BE PROPERLY GROUNDED AND BATTERY DISCONNECTED PRIOR TO SERVICING WARNING FAILURE TO PROPERLY INSTALL ALIGN AND TORQUE FUEL OIL AND AIR TUBES AND FITTINGS COULD RESULT IN AN ENGINE FAILURE REFER TO THE APPLI CABLE MANUAL FOR PROPER INSTAL ATION AND TORQUE PROCEDURES FLUID MIL H 83282 MAX RATED SUPPLY PRESSURE 1000 PSI 6 895 kPa MAX FLOW R...

Page 330: ...nce Manual Page 214 Revision 26 11 00 00 MD HELICOPTERS INC MD HELICOPTERS INC 900H7801501 103 9G11 006A Figure 206 Hydraulic GSE Panel Part of Hydraulic System Installation 9G11 007 Figure 207 Main Rotor Pitch Case Decal Part of Main Rotor Installation ...

Page 331: ...rs Inc Rotorcraft Maintenance Manual Page 215 Revision 26 11 00 00 SERVICE CARRIER SPLINE WITH GREASE CONFORMING TO SYNTECH 3913 G1 9G11 005 Figure 208 Transmission and Drive Service Decal Part of Transmission and Drive System ...

Page 332: ...enance Manual Page 216 Revision 26 11 00 00 1 CABIN HEAT 2 FOOT HEAT 3 COCKPIT HEAT DEFOG LOOKING INBOARD RIGHT SIDE OF COCKPIT 3 1 2 9G11 009 FOOT HEATER PULL FOR HEAT COCKPIT HEAT DEFOG PULL FOR HEAT Figure 209 Heat Defog System Decal Installation ...

Page 333: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual SERVICING Chapter ...

Page 334: ......

Page 335: ... Ports for Fuel Servicing 208 2 Fuel 208 A Fuel System Servicing Precautions 208 Figure 205 Gravity Fill Port for the Main Fuel Tank 209 B Servicing of the Main Fuel Tank 209 Figure 206 Gravity Fill Port for the Supplemental Fuel Tank 210 C Servicing of the Supplemental Fuel Tank 210 3 Defuel the Fuel System 211 A Defuel the Main Fuel Cell at the Gravity Fill Port 211 B Defuel the Main Fuel Cell a...

Page 336: ...rake Caliper Servicing 218 Figure 212 Rotor Brake Caliper Servicing 218 7 Powerplant 219 A Engine Oil System Draining 219 B Engine Oil System Filling Replenishing 219 Figure 213 Engine Oil Filler 220 C Fuel Catch Can Optional 221 Figure 214 Fuel Catch Can 221 D Engine Compressor Wash Desalination 221 E Engine Compressor Wash Performance Recovery 222 Figure 215 Engine Wash Panel 222 8 Rotorcraft 22...

Page 337: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 12 00 00 Servicing ...

Page 338: ......

Page 339: ... requirements for the engine fuel and oil filters and rotorcraft battery 9G12 002E 1 2 3 9 10 5 4 8 13 6 11 7 12 6 5 14 15 1 ECS AIR CONDITIONER REFRIGERANT EARLY CONFIG SHOWN 2 ECS AIR CONDITIONER SYSTEM OIL 3 ECS COMPRESSOR REDUCTION GEARBOX OIL 4 FUEL SYSTEM FUEL 5 HYDRAULIC SYSTEM GSE PANEL 6 HYDRAULIC SYSTEM MANIFOLD RESERVOIR HYDRAULIC FLUID 7 HYDRAULIC SYSTEM OPTIONAL HAND PUMP RESERVOIR HY...

Page 340: ...imeters C117 Hermetic Oil RG20 RS20 DHPR R 134A 4 5 5 5 Fluid Ounces 140 160 Cubic Centimeters 3 Compressor Reduction Gearbox Oil C106 Lubricating Oil 3 1 0 Fluid Ounces 30 Cubic Centimeters Fuel System 4 Fuel C113 Aviation Turbine Fuel JP 4 JP 5 MIL DTL 5624 146 2 Gallons 4 158 5 Gallons 4 5 29 4 Gallons 6 553 4 Liters 4 600 0 Liters 4 5 111 3 Liters 6 C114 Aviation Turbine Fuel Jet A Jet A 1 AST...

Page 341: ...Drive System 9 Main Transmission Lubrication Oil C106 8 C122 9 Lubrication Oil Lubrication Oil 3 8 Mobil SHC 626 9 10 0 Quarts 10 0 Quarts 9 5 Liters 9 5 Liters Rotor Brake 10 Hydraulic Fluid C112 Hydraulic Fluid 7 1 2 Pints 0 6 Liters 14 Rotor Brake Caliper C120 Spray Lubricant N A As Required As Required Powerplant 11 Engine Lubrication Oil C106 Lubrication Oil 11 2 11 1 3 Gallons 5 1 Liters 12 ...

Page 342: ... only Total main fuel cell capacity is approximately 2 5 gallons 9 5 liters more 5 With range extender installed on main fuel cell 6 Post TB900 030 Total additional fuel with supplemental fuel cell installed 7 MIL PRF 83282 hydraulic fluid supercedes MIL H 83282 type fluid 8 MIL PRF 23699 is used only in transmission assemblies 900D1400004 and 900D1400005 Do not blend with other oils 9 MOBIL SHC 6...

Page 343: ... the exterior surfaces of components 4 Do not let unwanted materials dirt sand contamination or moisture get in the system 5 The receiver dehydrator must be replaced each time the AC system is opened B AC System Servicing EARLY CONFIG Ref Figure 201 Consumable Materials Ref CSP SPM Item Nomenclature C116 Oil Daphne Hermetic R12 C806 Refrigerant R12 Special Tools Ref CSP SPM Item Nomenclature T701 ...

Page 344: ...3 8 Remove access panels A235 AR250 and AL250 to get access to the condens er ref Section 53 20 00 9 Remove right aft station 230 00 bulkhead baggage compartment interior trim panels to get access to the AC tube assemblies ref Section 25 50 00 10 Examine evaporator condenser compressor receiver dehydrator and all fittings and tube connections for leaks 11 Repair connections and components with lea...

Page 345: ...ion of the system Use only a qualified mechanic or pilot to start and operate the en gines 19 Start the right engine ref applicable RFM Rotor Blades 20 Set the AC VENT switch to COOL LOW position on the UTILITY PAN EL a If the AC compressor does not operate refer to the Fault Isolation Troubleshooting Table 101 ref Section 21 50 00 b A two second time delay will occur before the compressor and con...

Page 346: ... requirements and management of refrigerants can result in damage to the air conditioning system NOTE Obey all government and local regula tions with you fill and evacuate the AC sys tems with refrigerant substances 1 Remove Access Panel L155 to get access to the AC service ports ref Section 53 30 00 2 Remove caps 1 and 2 from service ports Schrader valve on inlet and outlet tubes 3 Service air co...

Page 347: ...uated from system as measured in Step 4 a Do not add more than 5 5 oz 160 cc total Refrigerant R 134A C815 14 Accurately and carefully meter refriger ant through refrigerant recovery and recycling station T701 a Add 2 5 lb 1 1 kg R 134A refriger ant C815 for a system requiring R 134A 15 Inspect system for leaks with electronic leak detector T702 16 Repair leaking connection that can be tightened O...

Page 348: ...ant recovery and recycling station T701 23 Install caps 1 2 from service ports Schrader valve on inlet and outlet tubes 24 If necessary install Access Panel T155 ref Section 53 30 00 25 If necessary install Access Panel L210 ref Section 53 30 00 26 Install Access Panel L155 27 If necessary install Access Panel R210 ref Section 53 30 00 28 If necessary install Access Panel L155 ref Section 53 30 00...

Page 349: ...Let lubricating oil C106 drain into container 6 Install new packing 7 on drain plug 6 7 Install drain plug 6 with packing 7 in compressor 1 8 Torque drain plug 6 10 to 25 in lb 1 13 to 2 82 Nm 9 Safety drain plug 6 with new lockwire C702 10 Close Access Panel R210 ref Section 06 00 00 E Fill the AC Compressor Reduction Gearbox Ref Figure 203 Consumable Materials Ref CSP SPM Item Nomenclature C106 ...

Page 350: ...sult in injury to personnel and or damage to the rotorcraft 1 Only approved personnel can fuel the rotorcraft 2 Clothing that makes static electricity cannot be used by personnel 3 Open flames and smoking are not permitted in the refueling area 4 At least one fully charged 50 lb 23 kg CO2 fire extinguisher must be available near the work area 5 The fuel vehicle must be parked 20 feet 6 meters mini...

Page 351: ...ion Con densation can have an effect on rotorcraft performance 1 Ground the fuel nozzle or fuel vehicle to ground port 4 or another bare metal surface 2 Remove filler cap 2 NOTE There is an optional locking fuel cap that can be installed on the gravity fill port A key is necessary to lock or open the fuel cap Do not fill the fuel tank if the lanyard is broken 3 Put lanyard 3 in the slot of the ada...

Page 352: ...s Fuel helicopter with correct fuel as soon as possible after landing to prevent moisture condensation Con densation can have an effect on rotorcraft performance 1 Ground the fuel nozzle or fuel vehicle to ground port 4 or another bare metal surface 2 Remove filler cap 2 NOTE There is an optional locking fuel cap that can be installed on the gravity fill port A key is necessary to lock or open the...

Page 353: ...uck with defueling capabilities a Drain the fuel into a suitable storage container b Drain the remaining fuel at the sump drain ref Procedure 3 B 6 Remove the hose from gravity fill port 7 Install filler cap 2 8 If the fuel cell is to stay empty for more than 5 days do the fuel cell preserva tion procedure ref Section 10 10 00 B Defuel the Main Fuel Cell at the Sump Drain Obey all fuel system serv...

Page 354: ... dures 3 A or 3 B 8 If the fuel cell s are to stay empty for more than 5 days do the fuel cell preservation procedure ref Section 10 10 00 FLUID TEMP 40 C 95 C FULL REFILL EMPTY FULL 4 3 5 FLUID TEMP 40 C 95 C MANIFOLD RESERVOIR EARLY CONFIG 1 2 HAND PUMP MINIMUM OIL LEVEL 9G12 005B F U L L R E F I L L R E F I L L EMPTY F U L L 6 VIEW LOOKING DOWN MANIFOLD RESERVOIR CURRENT CONFIG REFILL 1 HAND PU...

Page 355: ... NOTE Servicing is complete when the hydrau lic manifold fluid level sight gauges 5 are at the correct level g Stow pump handle 4 5 Close access panels L155 and R155 ref Section 06 00 00 B Service the Hydraulic System with Ground Support Equipment GSE Cart Ref Figure 207 Consumable Materials Ref CSP SPM Item Nomenclature C112 Hydraulic Fluid Special Tools Ref CSP SPM Item Nomenclature T2001 Hydrau...

Page 356: ... nected b Apply 500 psig 3448 kPa to the hydraulic system with hydraulic mule T2001 c Cycle all hydraulic actuators at least 15 cycles as you simultaneously turn the main rotor head five times minimum in the direction of normal blade travel NOTE During the bleed of the hydraulic sys tem make sure the hydraulic fluid C112 level does not go below the REFILL line of the fluid level sight gauge on the...

Page 357: ...om fill port 2 2 Attach hydraulic fluid service unit T111 of 50 psi minimum to fill port 2 NOTE Use a standard 37 female flared fitting to connect to fill port 2 Hydraulic Fluid C105 3 Fill the reservoir of damper 1 with hydraulic fluid C105 in reservoir 4 Open bleed valve 3 slightly 5 Let hydraulic fluid C105 bleed out until there are no air bubbles in the flow 6 Close bleed valve 3 7 Continue to...

Page 358: ...A too full transmission can cause very high pressure fluctuations Oil Lubricating C122 Oil Lubricating C106 3 Add the correct lubricating oil to transmission 4 Examine the quantity of oil in the transmission at sight gage 4 NOTE Keep oil level between ADD and 1 2 FULL 5 Close filler cap 3 6 Close Access Panel R210 ref Section 06 00 00 B Drain the Main Transmission Ref Figure 209 Special Tools Ref ...

Page 359: ...0 2 Carefully remove both seals from bearing 3 Inspect seals for damage a No damage permitted 4 Install bearing between grease tool Part A and Part B with a 4 inch 10 24 threaded bolt washers and wing nut Either part number 500N or 900R bear ings can be installed The 500N bearings use aircraft grease C107 The 900R bearings use grease C104 NOTE This procedure provides 100 grease fill During operati...

Page 360: ...ing 1 Open Access Panel R155 ref Section 06 00 00 NOTE The rotor brake reservoir is located on the top forward deck 2 Remove filler cap 1 Hydraulic Fluid C112 3 Fill reservoir to top of sight glass 2 with hydraulic fluid C112 4 Install filler cap 1 5 Close Access Panel R155 ref Section 06 00 00 E Rotor Brake Caliper Servicing Ref Figure 212 Consumable Materials Ref CSP SPM Item Nomenclature C120 L...

Page 361: ...ld TL218 or TR218 ref Section 06 00 00 Oil Lubricating C106 Do not mix different brands or types of oil their chemical structure may make them incompatible If different brands or types of oil become mixed drain entire oil system and refill with new oil Record oil brand and type in the Rotor craft Log Book and the applicable engine log book NOTE Check oil level 10 minutes after engine shutdown to r...

Page 362: ...o close and lock the cap d Make sure the cap handle is in the lock position NOTE The writing on the cap handle must be toward the front of the engine ref Figure 213 View A 5 Close oil dipstick hand hold TL218 or TR218 ref Section 06 00 00 VIEW LOOKING AFT CHIP DETECTOR OIL FILTER IMPENDING BYPASS INDICATOR 9G12_009A OIL FILLER DIPSTICK VIEW ROTATED NOTE SOME ENGINE DETAIL OMITTED FOR CLARITY WRITI...

Page 363: ...or Wash Rig T406 1 Adapter NOTE At or above 365F 25C use drinking qual ity water for desalination wash Below 365F 25C use rinsing solution ref P WC Maintenance Manual Direc tives and Related Manufacturer Publica tions Section 01 00 00 Water source pressure must be 60 to 82 psi 414 to 565 kPa Use correct rinsing solution mixture Engine temperature must be below 65_C 150_F To prevent damage turn off...

Page 364: ...nual Directives and Re lated Manufacturers Publications Sec tion 01 00 00 At or above 365F 25C use drinking qual ity water for the rinse Below 365F 25C use a rinse solution ref P WC Maintenance Manual Directives and Related Manufacturer Publications Section 01 00 00 The cleaning and rinse solution pressure must be 60 to 82 psi 414 to 565 kPa Use correct cleaning and rinsing solution mixture Engine...

Page 365: ...to dry the engine and remove flammable fumes 11 Disconnect adapter T406 1 from the engine wash panel 12 Do this procedure on the other engine 13 Close Access Panel R210 ref Section 06 00 00 Obey the starter limits ref ap plicable RFM Damage to the starter can occur 14 Operate the engines at idle for at one minute minimum to dry the engines ref applicable RFM 8 Rotorcraft A Operation in a Corrosive...

Page 366: ...3 4 Examine bottle 2 for cracks and indications of leakage a No cracks or leaks are permitted 5 Fill bottle 2 a For operation in temperatures above 325F 05C fill with deionized or distilled water Alcohol Isopropyl C419 b For operation in temperatures equal to or below 325F 05C mix 50 by volume isopropyl alcohol C419 with deionized or distilled water 6 Install tubing 3 thru cap of bottle 2 7 Instal...

Page 367: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual VIBRATION AND NOISE ANALYSIS Chapter ...

Page 368: ......

Page 369: ...ack And Balance 201 A Installing Main Rotor Blade Tracking Targets 201 Figure 201 Main Rotor Blade Tracking Target Installation 201 B Main Rotor Ground Track Adjustment 202 C Main Rotor Hover Track Adjustment 202 D In Flight Rotor Tracking 202 E Pitch Change Link Adjustment 203 Figure 202 Pitch Change Link Adjustment 203 Figure 203 Main Rotor Blade Tab Adjustment 204 F Main Rotor Blade Tab Adjustm...

Page 370: ... ROTORCRAFT MAINTENANCE MANUAL Page ii Revision 35 18 Contents TABLE OF CONTENTS Cont Para Figure Table Title Page 3 Main Rotor Autorotation RPM 210 A Autorotation RPM Adjustment 210 Figure 206 Autorotation RPM Chart Sheet 1 of 2 211 ...

Page 371: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 18 00 00 Vibration and Noise Analysis ...

Page 372: ......

Page 373: ...installed Typically the BMS will be able to provide balance corrections that will bring the vibration levels into tolerance within two flights if the starting vibration level is no greater than 0 5 IPS Inches Per Second B NOTAR Anti Torque System Vibration Monitoring Ref Figure 1 Anti torque fan failure modes that would be detected by the BMS include Deteriorating fan blade airfoil or loss of blad...

Page 374: ...ly warning of system component progressive failures This information can be used by maintainers to isolate failed or failing components NOTAR VIBRATION SENSOR 9G18 001A IIDS UNIT ROTOR VERT VIB POWER ROTOR VERT VIB SIGNAL NOTAR AZIMUTH SIGNAL NOTAR VIBPOWER NOTAR VIB SIGNAL ROTOR AZIMUTH SIGNAL ROTOR LAT VIB POWER NOTAR AZIMUTH SENSOR ROTOR LATERAL VIBRATION SENSOR ROTOR AZIMUTH SENSOR ROTOR VERTI...

Page 375: ...mper s 62 20 00 One per revolution vertical beat Beat may appear throughout entire flight regime becoming more pronounced at higher airspeeds Main rotor blades out of track Track main rotor blades 18 00 00 Autorotation rpm low Blade pitch is too high Pitch links are too short Lengthen pitch links equally 18 00 00 Autorotation rpm high Blade pitch is too low Pitch links are too long Shorten pitch l...

Page 376: ...hematics electrical wiring diagrams serviceability checks and other detailed procedures in this and other chapters of the manual Table 102 Anti Torque System Troubleshooting Fault Probable Cause Corrective Action Ref Section Unusual excessive or high frequency vibration Damaged fan blade worn bearings damaged fan blade tension torsion straps or missing balance studs Inspect and replace damaged com...

Page 377: ...ction the rotor turns 1 Release rotor brake refer to current Rotorcraft Flight Manual Ref Section 01 00 00 Table 201 2 Turn main rotor until swashplate interrupter 2 is positioned above azimuth sensor 1 3 Remove screw 3 from forward rotor blade 4 4 Install blade tracking target 6 number one on blade tip Torque screw 5 Repeat steps 3 and 4 to install blade tracking targets 6 numbered two three four...

Page 378: ... key to select BALANCE MONITOR from first level menu and press ENT 5 Use the key to select MAIN ROTOR TRACK from second level menu and press ENT Display changes to FLASH STROBE BLD SPREAD ON 6 Point strobe light at main rotor blade tips and press trigger Record vertical position of each rotor blade tracking tip NOTE Move strobe light in a W pattern while pointed at blade tip path in front of aircr...

Page 379: ... Procedure 1 H E Pitch Change Link Adjustment Ref Figure 202 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire 1 Remove and discard lockwire from nuts 3 Loosen nuts NOTE To increase blade pitch turn pitch change link barrel left shorten To de crease blade pitch turn barrel right length en If you turn barrel one flat you will change track approximately one inch 2 Adjust pitch change ...

Page 380: ... Install tab bending tool 4 on trim tab Do not bend tab more than 0 085 inch 2 16 mm from 0 5 Bend tab up or down as necessary NOTE Trim tab is very sensitive Only small amounts of force are necessary to bend tab One mil is equal to 0 001 inch 0 03 mm 6 Remove tab bending tool T902 and trim tab gauge Record changes G Main Rotor Balance On Ground Rotor Vibrations 1 Start aircraft refer to current R...

Page 381: ...location is an alternative location and can be used along with the pitch case location Blade number one is located above nose of helicopter when swashplate interrupter is above azimuth sensor Blades number 2 3 4 and 5 are numbered in sequence op posite the direction the rotor turns 1 Find main rotor blade indicated by Main Rotor Solutions Options Menu procedure Ref CSP 900RMM 3 Section 95 30 00 NO...

Page 382: ... Solutions Options Menu procedure Ref CSP 900RMM 3 Section 95 30 00 2 Find the correct quantity of weight to add or remove 3 Remove nuts 5 washers 2 balance weights 3 if installed screws 1 and washers 2 NOTE No more than 8 each 900R2101024 101 or 16 each 900R2101024 103 balance weights approximately 218 grams can be installed at each hub weight location Install the same quantity of balance weights...

Page 383: ...edure You can also look at the torque indication on the IIDS and move directional control pedals to get the lowest torque indication This will give you an accurate indication the fan is at minimum pitch 3 Do the NOTAR Balance Collect Data Menu procedure Ref CSP 900RMM 3 Section 95 30 00 4 Do the Display NOTAR Measurements Menu procedure Ref CSP 900RMM 3 Section 95 30 00 NOTE No more than 0 15 IPS ...

Page 384: ...tion panels ref Section 25 50 00 2 Remove anti torque fan diffuser lower half ref Section 53 00 00 3 Number balance studs 2 on anti torque fan 1 with a permanent marker ref Figure 205 4 Add or remove balance weights 4 ref Table 201 recorded from the NOTAR Balance Solutions Menu Procedure ref CSP 900RMM 3 Section 95 30 00 NOTE Thickness of balance weights 4 on bal ance stud 1 cannot be more than 0 ...

Page 385: ...mber Thick inch I D inch O D inch Weight Grams AN960 416L 0 032 0 265 0 500 0 572 AN960C416 0 063 0 265 0 500 1 144 AN960KD416 0 063 0 265 0 500 0 407 AN960KD416L 0 016 0 265 0 500 0 103 MHS306 225 0 032 0 263 0 528 0 667 MHS306 225H 0 063 0 263 0 528 1 355 MHS306 225L 0 016 0 263 0 528 0 339 MHS306 226 0 032 0 263 0 619 1 015 MHS306 226H 0 063 0 263 0 619 2 029 MHS306 226L 0 016 0 263 0 619 0 507...

Page 386: ...e stick full down Refer to note on Sheet 2 of Figure 206 for alternative collec tive position at higher gross weights 3 Record main rotor RPM and density altitude 4 Refer to autorotation RPM chart in Figure 206 for correct rotor RPM NOTE To increase autorotation RPM lengthen pitch change links decrease blade pitch To decrease autorotation RPM shorten pitch change links increase blade pitch If you ...

Page 387: ... 95 97 99 101 103 105 107 94 96 98 100 102 104 106 108 EXAMPLEDENSITY ALTITUDE 500 FEET EXAMPLE ROTORCRAFT WEIGHT 4920 LBS EXAMPLE ROTORCRAFT WEIGHT 4920 LBS DENSITY ALTITUDE 500 FT MAIN ROTOR RPM FOR THIS WEIGHT AND DENSITY ALTITUDE SHOULD BE SET BETWEEN 101 AND 102 NR WITH COLLECTIVE CONTROL LEVER FULL DOWN DENSITY ALTITUDE FT MD900 AUTOROTATION RPM CHART COLLECTIVE SET TO 0 Figure 206 Autorotat...

Page 388: ...E SET TO 10 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 EXAMPLEROTORCRAFT WEIGHT 5860 LBS EXAMPLE ROTORCRAFT WEIGHT 5860 LBS DENSITY ALTITUDE 500 FT MAIN ROTOR RPM FOR THIS WEIGHT AND DENSITY ALTITUDE SHOULD BE SET BETWEEN 102 AND 103 NR WITH COLLECTIVE CONTROL LEVER SHOWN AT 10 CLP ON THE IIDS ALPHA NUMERIC DISPLAY EXAMPLE DENSITY ALTITUDE 500 FEET DENSITY ALTITUDE FT ...

Page 389: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual ENVIRONMENTAL CONTROL SYSTEM Chapter ...

Page 390: ......

Page 391: ...aintenance Practices 201 1 Vent System 201 A Vent System Inspection 201 Figure 201 Vent System 202 2 Water Separator Assembly 203 A Water Separator Assembly Removal 203 B Water Separator Assembly Installation 203 Figure 202 Water Separator 203 3 Vent System Fan 204 A Vent System Fan Removal 204 B Vent System Fan Installation 204 Figure 203 Recirculating Fan 204 Figure 204 Vent Air Supply Plenum As...

Page 392: ...ol Cable 1 E Aft Cabin Heat Ejector 1 F Heat Defog Bleed Air Tubes 1 G Heat Defog Valve 1 H Heat Defog Control Cable 2 I Heat Defog Ejector 2 J Plenum Heat Defog Hoses 2 K Defog Manifolds 2 L Foot Heater Control Cable 2 M Foot Heater Valves 2 Figure 1 Heat Defog System 3 Figure 2 Heat Defog System Schematic 4 Fault Isolation 101 1 Heat Defog System Troubleshooting 101 Table 101 Heat Defog System T...

Page 393: ... System Flow Control Valve Single Ball Installation 408 9 Flexible Heater Control Cable Assembly 408 A Flexible Heater Control Cable Assembly Removal 408 B Flexible Heater Control Cable Assembly Installation 409 Figure 403 Cabin Heat Ejector Single Ball Flow Control Valve Flexible Heater Control Cable 410 10 Engine Bleed Air Check Valve 900 CONFIG 411 A Engine Bleed Air Check Valve Removal 411 B E...

Page 394: ...Tube Assembly Replacement Sheet 1 of 2 421 Inspection Test 601 1 Heat Defog System Inspection 601 A Heat Defog System Bleed Air Engine Firewall Inspection Area 5 601 B Heat Defog Tube Assemblies Inspection Area 6 601 C Under Floor Tube Assemblies Inspection Area 1 and 2 601 D Control Cables Inspection Area 1 and 2 601 E Aft Cabin Heat Ejector Inspection Area 2 602 F Flow Control Single Ball Valve ...

Page 395: ...gram CURRENT CONFIG 7 Fault Isolation 101 1 Air Conditioning System Troubleshooting 101 Table 101 Air Conditioning System Troubleshooting 101 Figure 101 Air Conditioning System Vapor Cycle Cooling System EARLY CONFIG 103 Figure 102 Air Conditioning System Vapor Cycle Cooling System CURRENT CONFIG 104 Figure 103 Air Conditioning System Wiring Diagram Sheet 1 of 2 105 Figure 104 Utility Control Pane...

Page 396: ...Expansion Valve EARLY CONFIG 410 A Expansion Valve Removal 410 B Expansion Valve Installation 410 8 Expansion Valve Strainer EARLY CONFIG 411 A Strainer Removal 411 B Strainer Installation 411 9 Evaporator Inlet Shroud EARLY CONFIG 411 A Inlet Shroud Removal 411 B Inlet Shroud Installation 411 10 Thermostatic Switch EARLY CONFIG 411 A Thermostatic Switch Removal 411 B Thermostatic Switch Installat...

Page 397: ...Condenser Installation 419 19 Condenser Inlet Screen EARLY CONFIG 420 A Inlet Screen Removal 420 B Inlet Screen Installation 420 20 Condenser Exit Screen EARLY CONFIG 420 A Exit Screen Removal 420 B Exit Screen Installation 420 Figure 407 Removal and Installation of the Condenser CURRENT CONFIG 422 21 Condenser CURRENT CONFIG 423 A Condenser Removal 423 B Condenser Installation 423 Figure 408 Remo...

Page 398: ...ceiver Dehydrator to Deck Hose Removal 434 H Receiver Dehydrator to Deck Hose Installation 434 I Baggage Closet to Deck Tube Removal 434 J Baggage Closet to Deck Tube Installation 434 K Deck to Baggage Closet Tube Removal 435 L Deck to Baggage Closet Tube Installation 435 M Upper Deck Elbow Removal 435 N Upper Deck Elbow Installation 435 O Baggage Closet Tube Removal 435 P Baggage Closet Tube Inst...

Page 399: ...e Installation 440 S Tee to Right Condenser Tube Removal 440 T Tee to Right Condenser Tube Installation 440 Figure 410 Removal and Installation of Low Pressure Lines EARLY CONFIG 442 30 Low Pressure Lines EARLY CONFIG 443 A ECS Mid Section to Low Pressure Switch Tube Removal 443 B ECS Mid Section to Low Pressure Switch Tube Installation 443 C ECS Evaporator to Mid Section Tube Removal 443 D ECS Ev...

Page 400: ...nt Para Figure Table Title Page F Evaporator Fan Inspection 601 G Three Way Valve Duct Assembly Inspection 601 H Three Way Valve Control Cable Inspection 601 I Line and Tube Assemblies Inspection 602 J Condenser Assembly Inspection 602 K Condenser Fan Inspection EARLY CONFIG 602 L Condenser Scoop EARLY CONFIG 602 ...

Page 401: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 21 20 00 Vent System ...

Page 402: ......

Page 403: ...ent fan is mounted at fuselage station 185 5 on the right side of the transmission deck A five position AC VENT switch controls the vent fan and air condition ing VENT LOW provides vent air at a low setting VENT HIGH provides air at a high setting selected from the center console utility panel assembly D Air Supply Plenum The air supply plenum distributes the air flow from the inlet duct and vent ...

Page 404: ...NLET WATER SEPARATOR FLEXIBLE AIR DUCTING GASPER ASSY PASSENGER COMPARTMENT GASPER ASSY PASSENGER COMPARTMENT GASPER ASSY PASSENGER COMPARTMENT GASPER ASSY CREW STATION AIR DUCTING 9G21 012B FLEXIBLE AIR DUCTING FLEXIBLE AIR DUCTING DUCT ASSY ROOF DECK SERIAL NUMBERS 0039 SUBSEQUENT AIR DUCTING CABLE HANDLE BRACKET ASSEMBLY GASPER ASSY COCKPIT AIR DUCTING GASPER ASSY OVERHEAD CREW STATION AIR DUCT...

Page 405: ...anual Comprehensive wiring diagrams are available in the Rotorcraft Maintenance Manual CSP 900RMM 3 Ref Section 98 40 00 Table 101 Vent System Troubleshooting Fault Probable Cause Corrective Action Ref Section Vent fan inoperative Circuit Breaker VENT EVAP CB18 Open Replace or reset VENT EVAP circuit breaker CB18 as required 20 60 00 Faulty AC VENT switch Remove and replace vent switch 96 00 00 Op...

Page 406: ... RELAY 22 B2 B1 X2 X1 A1 A2 CB18 VENT EVAP 28VDC CA1 COOL HI COOL LO 3 OFF 4 VENT LO VENT HI 1 2 2 1 VENT HI 4 VENT LO COOL LO COOL HI CA2 CA3 COOL HI COOL LO 4 VENT LO VENT HI 1 2 A C D E 3 OFF 3 OFF D E A B A606 UTILITY CONTROL PANEL A620 ELECTRICAL LOAD CENTER A413 RECIRCULATING FAN A612 FWD INTERCONNECT PANEL E E E E GS106 J GS104 D J1 J1 P172 P171 W124 W123 W306 W123 9G21 025A 5 5 5 Figure 10...

Page 407: ...rioration Repair or replace as required 8 Inspect fan assembly for cleanness 9 Inspect fan mounting brackets for cracks Repair or replace as required 10 Inspect electrical connector for corro sion Verify fan for two speed opera tion 11 Inspect air plenum duct assemblies for cracks tears deterioration deforma tion and security Repair or replace as required 12 Inspect distribution flexible ducts for...

Page 408: ...13 14 1 RECIRCULATING FAN 2 VENT AIR SCOOP 3 FRESH AIR INLET 4 WATER SEPARATOR 5 CABIN AIR DUCTING 6 GASPER ASSEMBLY PASSENGER COMPARTMENT 7 VENT AIR SUPPLY PLENUM 8 DOOR PILLAR PLENUM 9 AIR DUCTING CREW COMPARTMENT 10 OVERHEAD GASPER CREW COMPARTMENT 11 AIR DUCTING DOOR FRAME 12 GASPER ASSEMBLY CREW STATION 13 CABLE HANDLE BRACKET ASSEMBLY 14 GASPER ASSEMBLY COCKPIT 15 BULKHEAD PLENUM ASSEMBLY Fi...

Page 409: ...er separator assembly 3 and align with screw holes or suds on deck 2 Install screws 7 washers 8 and nuts 6 Torque screw 7 and nuts 6 3 Two washers must be used between water separator and transmission deck if round head rivets interfere with installation of separator Sealing Compound C208 4 Apply a fillet of sealing compound C208 at junction of water separator base legs and deck Ref CSP SPM Sectio...

Page 410: ...ing Ref CSP SPM Section 20 50 00 2 Install recirculating fan 4 in mounting bracket 7 and 8 with screws 5 and washers 6 Torque screws 5 Sealing Compound C205 3 Remove old sealant and clean faying surfaces Apply sealing compound C205 to cover faying surfaces between mounting brackets and deck structure Ref Section 20 50 00 4 Connect ducts 2 and 3 to recirculating fan and secure with hose clamps 1 To...

Page 411: ... 4 Vent Air Supply Plenum Assembly A Vent Air Supply Plenum Assembly Removal Ref Figure 204 1 Open left forward access door assembly L155 Ref Section 06 00 00 2 Remove cabin compartment interior roof panels Ref Section 25 20 00 3 Remove hose clamps 1 and disconnect flexible ducts 2 and 3 from vent air supply assembly 4 4 Remove clamps 5 and disconnect plenum assembly flexible ducts 6 from gasper a...

Page 412: ...rs 1 Place vent air supply plenum assembly 4 in position and install screws 9 and washers 10 through roof deck duct assembly 8 Torque screws 9 Sealing Compound C205 2 Apply sealing compound C205 to cover faying surfaces between duct and deck structure Ref CSP SPM Section 20 50 00 3 Connect plenum assembly flexible ducts 6 to gasper assembly plenum caps 7 with hose clamps 5 Torque hose clamps 5 4 C...

Page 413: ...BLY PLENUM CAP 13 GASPER NUT 14 PASSENGER GASPER ASSEMBLY 15 PLENUM CAP CLAMP 16 CLAMP BAND TYPE 17 DOOR PILLAR PLENUM 18 TIE DOWN STRAP Figure 205 Gasper Assemblies 5 Gasper Assembly Crew Station A Gasper Assembly Crew Station Removal Ref Figure 205 NOTE This task is typical for left and right crew station gasper removal 1 Remove crew station side gasper assembly by removing screws 1 from side ga...

Page 414: ...and secure with hose clamp 3 Torque clamp 3 4 Install crew compartment interior center beam main covers Ref Section 25 10 00 7 Gasper Assembly Passenger Compartment A Gasper Assembly Passenger Compartment Removal Ref Figure 205 1 Gain access to gasper assembly by removing cabin compartment interior roof panels Ref Section 25 20 00 2 Remove hose clamp 10 securing flexible duct 11 to gasper assembly...

Page 415: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 21 40 00 Heat Defog System ...

Page 416: ......

Page 417: ...ent Foot Heater Control Cable Controls foot heater valve position A Engine Bleed Air Check Valve The engine bleed air check valve is an in line check valve that prevents reverse flow of bleed air into the engine compressor of a failed engine The bleed air check valve attaches to the bleed air fitting B Flow Control Shutoff Valve The flow control shutoff valve is a normally closed solenoid valve co...

Page 418: ...al reinforcement Located in the lower left and right cockpit fuselage section the hoses route bleed air from the heat defog ejector to the heat defog manifolds and foot heaters K Defog Manifolds The defog manifolds are located below the cockpit wind screens The defog manifolds are constructed of composite material The defog manifold allows heated air to blow against the pilot and copilot wind scre...

Page 419: ...EAT DEFOG EJECTOR HEAT DEFOG CONTROL CABLE ENGINE BLEED AIR HOSES MAIN BLEED FITTING ENGINE BLEED AIR CHECK VALVE FLOW CONTROL SHUTOFF VALVE ENGINE DECK FITTING FLEXIBLE HEATER CONTROL CABLE HEATING SYSTEM FLOW CONTROL VALVE SINGLE BALL AFT CABIN HEAT EJECTOR FOOT HEATER VALVE ENGINE BLEED AIR CHECK VALVE 9G21 016A HEAT DEFOG PLENUM HOSE Figure 1 Heat Defog System ...

Page 420: ...ENGER COMPARTMENT PASSENGER COMPARTMENT EJECTOR ENGINE ENGINE CHECK VALVES START UP LOCK OUT HEAT ON OFF SWITCH DEFOGGING MANIFOLDS FOOT HEATER FOOT HEATER CONTROL VALVE FLOW CONTROL VALVE FLOW CONTROL VALVE FLOW CONTROL SHUTOFF VALVE ON OFF 9G21 022 PILOT HEAT EJECTOR Figure 2 Heat Defog System Schematic ...

Page 421: ...ove and replace flow control shutoff valve 21 40 00 No heat defog bleed air with switch set to ON position Defective wiring circuit between circuit breaker and flow control shutoff valve Test and repair wiring circuit 20 60 00 Fire overheat bleed air leak detection system shut down heat defog system through IIDS See Note Find heat defog bleed air leak and repair leak 21 40 10 26 10 10 Defective fl...

Page 422: ... Caution Warn ing panel when heat defog system is operating and does not automatically shut off bleed air HEAT switch is in the OVRD position Place HEAT switch to OFF position 21 40 00 NOTES 1 The IIDS automatically disables heat defog in the event of fire overheat bleed air leak indication IIDS illuminates CAB HEAT on Caution Warning IIDS panel interrupts electrical ground of flow control shutoff...

Page 423: ...ONNECT PANEL UTILITY CONTROL PANEL TB4 5 TB2 1 L M K J S R N P A D C B 92 19 34 HEAT DEFOG INSTALLED D C TB302 2 F E D C B A S2 5 2 OVRD OFF K J B 13 7 22 BLD AIR HEAT ZJ HEAT ON OFF BLUE WIRE WHITE WIRE OFF ON CAB HEAT SWITCH 28VDC A699 A2 A612 A606 A601 900 CONFIG CB12 5A W122 W124 W123 W311 W124 9G21 023B 6 4 3 1 P128 J2 CIRCUIT BREAKER PANEL 13 BLD AIR HEAT R DC BUS A601 902 CONFIG CB36 5A Fig...

Page 424: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 104 Original 21 40 00 9G21 033 Figure 102 Utility Control Panel Heat Defog ...

Page 425: ...2 nuts 14 and washers 13 from tangs attaching heat defog ejector to structure and remove ejector B Heat Defog Ejector Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C801 Foam 900 CONFIG C709 Tape Adhesive 900 CONFIG C610 Rubber Expanded 902 CONFIG C710 Tape Glass Fabric 902 CONFIG 1 Attach heat defog ejector to structure with screws washers and nuts Torque nuts 2 In...

Page 426: ...g nut 22 from heat defog valve to heat defog tube assembly 9 902 CONFIG Disconnect coupling nut 22 from heat defog valve to heat defog ejector 7 and remove valve B Heat Defog Valve Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C801 Foam 900 CONFIG C709 Tape Adhesive 900 CONFIG C610 Rubber Expanded 902 CONFIG C710 Tape Glass Fabric 902 CONFIG 1 900 CONFIG Install th...

Page 427: ...ation Ref Figure 401 1 Install jam nut and washer on upper heat defog control cable 2 Install cable through cable mounting bracket and install lower washers and jam nuts on lower threaded area heat defog cable 3 Upper threaded area to be approxi mately two inch above mounting bracket Tighten jam nuts by hand Do not torque jam nuts at this time 4 Insert cable through hole in cockpit floor and throu...

Page 428: ...m 5 1 COTTER PIN 2 WASHER 3 HEAT DEFOG CONTROL CABLE CLEVIS END 4 CLEVIS PIN 5 HEAT DEFOG VALVE 6 RETAINER 7 HEAT DEFOG EJECTOR 8 JAM NUT 9 WASHER 10 MOUNTING BRACKET 11 HEAT DEFOG TUBE ASSEMBLY 12 SCREW 13 WASHER 14 NUTS 15 SEAL 16 FLEXIBLE THREADLESS COUPLING 17 SPACER FITTING 0 875 INCH 18 FOAM C801 900 CONFIG RUBBER C610 902 CONFIG 19 ADHESIVE TAPE C709 900 CONFIG GLASS FABRIC TAPE C710 902 CO...

Page 429: ...ing compound C205 Ref Section 20 50 00 4 Connect defog manifold to heat defog plenum to outlet hose with hose clamp Torque hose clamp 5 Foot Heater Valve A Foot Heater Valve Removal Ref Figure 402 NOTE This task is typical for left or right Foot Heater Valve removal 1 Disconnect foot heater cable 8 from foot heater valve 7 2 Remove screws 10 and washers 11 attaching foot heater valve to bracket 3 ...

Page 430: ... 402 NOTE This task is typical for left or right Foot Heater Cable removal 1 Disconnect foot heater cable 8 from foot heater valve 7 2 Loosen jam nuts on foot heater cable remove cable from slot in cable bracket 16 3 Remove jam nut 13 and washer 14 from foot heater cable and remove cable through cable mounting bracket 15 B Foot Heater Cable Installation Ref Figure 402 NOTE This task is typical for...

Page 431: ...e aft cabin heat ejector B Aft Cabin Heat Ejector Installation Ref Figure 403 Consumable Materials Ref CSP SPM Item Nomenclature C801 Foam 900 CONFIG C709 Tape Adhesive 900 CONFIG C610 Rubber Expanded 902 CONFIG C710 Tape Glass Fabric 902 CONFIG 1 Install screws and washers through fuselage frame into ejector mounting bracket Torque screws Position ejector as far inboard as possible 2 Install scre...

Page 432: ...ube assemblies Ref Threadless Flexible Coupling Seal Installation 2 Put flow control valve in its installed position 3 900 CONFIG Install flexible coupling assemblies spacers and retainers on flow control valve 4 902 CONFIG Connect coupling nuts to flow control valve Torque nuts NOTE Wrap tube connections with insulation and tape Overlap insulation on tube and line assemblies one inch 5 Install in...

Page 433: ...nd washer on control cable top end put control cable through handle and install washer and nut 5 Adjust nuts until center of handle is 0 39 in 9 91 mm from end of cable Torque nuts 20 25 in lb 2 26 2 82 Nwm 6 Adjust cable until flow control valve arm touches stop in both the fully closed and fully open position 7 Tighten cable plug sufficiently to prevent movement of joint 8 Torque nut 15 to apply...

Page 434: ...STALLATION ROTATED 900 CONFIG 36 16 15 16 14 13 4 6 7 12 21 20 19 22 18 9G21 018B 0 39 IN 9 91 mm 23 2 PL 24 2 PL 1 2 2 3 REF 4 23 2 PL 24 2 PL 5 8 8 29 31 30 26 27 29 28 27 26 25 8 10 10 11 9 17 32 AN FLARED FITTINGS 902 CONFIG 33 2 PL 34 35 Figure 403 Cabin Heat Ejector Single Ball Flow Control Valve Flexible Heater Control Cable ...

Page 435: ...T TUBE COUPLING 34 HANDLE 35 CABLE PLUG 36 NUT 37 ANGLE 10 Engine Bleed Air Check Valve 900 CONFIG A Engine Bleed Air Check Valve Removal Ref Figure 404 NOTE This task is typical for left or right en gine 1 Open L260 or R260 Ref Section 06 00 00 2 Disconnect hose assembly 4 or 5 from check valve 2 3 Remove check valve 2 4 Remove boss seal 3 B Engine Bleed Air Check Valve Installation Ref Figure 40...

Page 436: ...nnect flexible couplings 13 and retainers 12 from shutoff valve 17 Remove shutoff valve 4 Keep spacer fittings 14 Remove and discard seals 15 B Flow Control Shutoff Valve Assembly Installation Ref Figure 404 1 Install flexible coupling seals Ref Threadless Flexible Coupling Seal Installation 2 Put shutoff valve in its installed position 3 Install flexible coupling assemblies spacers and retainers ...

Page 437: ...lve and deck tube assembly 8 Remove tube assembly B Valve to Deck Tube Assembly Installation Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C211 Sealing Compound Corrosion Inhibitive 1 Install new gaskets on top and bottom of engine deck between deck assembly and tube flanges a Install bolts in tube assembly flange through engine deck and flange of tube assembly Torque bolts Sea...

Page 438: ...E TO VALVE HOSE ASSEMBLY RH 5 ENGINE TO VALVE HOSE ASSEMBLY LH 6 HEAT DEFOG INBOARD FIREWALL TUBE ASSEMBLY 7 FITTING FIREWALL TO ENGINE 8 FITTING MAIN BLEED 9 NUT 10 FLAT WASHER S 11 BOLT 12 RETAINER 13 THREADLESS FLEXIBLE COUPLING 14 SPACER FITTING 0 875 INCH 15 SEAL 16 ELECTRICAL CONNECTOR P520 17 BLEED AIR FLOW CONTROL SHUTOFF VALVE 18 TUBE ASSEMBLY FLOW CONTROL SHUTOFF VALVE TO FITTING 19 TUBE...

Page 439: ...ly anti seize compound C220 to bleed air fitting and install check valve Torque check valve 3 Apply anti seize compound C220 to check valve and connect hose to check valve Torque coupling nut 500 600 in lb 56 5 67 8 Nwm 4 Close L260 or R260 Ref Section 06 00 00 14 Flow Control Shutoff Valve Assembly 902 CONFIG A Flow Control Shutoff Valve Assembly Removal Ref Figure 405 1 Open R260 Ref Section 06 ...

Page 440: ...insulation panel Ref Section 25 50 00 4 Remove clamp from tube 15 5 Disconnect coupling nuts 18 from shutoff valve 13 and bulkhead union 16 6 Remove tube 15 B Valve to Deck Tube Assembly Installation Ref Figure 405 1 Install tube on valve and bulkhead union 2 Connect coupling nuts Torque coupling nuts 500 600 in lb 56 5 67 8 Nwm 3 Install clamp 4 Install right aft station 230 00 bulk head baggage ...

Page 441: ...D RH SIDE INBOARD FIREWALL ASSEMBLY 350 400 in lb 39 53 45 18 N m 460 500 in lb 51 96 56 48 N m 500 600 in lb 56 5 67 8 N m 4 REF 8 14 13 18 10 PL 15 16 7 REF 17 19 20 21 10 500 600 in lb 56 5 67 8 N m 500 600 in lb 56 5 67 8 N m 500 600 in lb 56 5 67 8 N m 500 600 in lb 56 5 67 8 N m 2 3 1 4 10 8 2 3 1 5 9 11 7 11 6 12 Figure 405 Engine Bleed Air Check Valve Flow Control Shutoff Valve 902 CONFIG ...

Page 442: ...IREWALL TUBE ASSEMBLY 7 NUT BULKHEAD UNIVERSAL FITTING 8 FITTING MAIN BLEED 9 FITTING FIREWALL TO ENGINE 10 FLAT WASHER 11 ELBOW ASSEMBLY 90 DEG 12 ELECTRICAL CONNECTOR P520 13 BLEED AIR FLOW CONTROL SHUTOFF VALVE 14 TUBE ASSEMBLY FLOW CONTROL SHUTOFF VALVE TO FITTING 15 TUBE ASSEMBLY VALVE TO DECK 16 UNION FLARED BULKHEAD 17 TUBE ASSEMBLY 18 NUT TUBE COUPLING CRES 19 NUT TUBE COUPLING ALUMINUM 20...

Page 443: ... body 2 T703 or T703 1 with seal cup end facing tapered end on tool body 2 Insert tool body 2 into tube end carefully slide seal assembly for flexible coupling onto tube end using tool sleeve 3 3 Using seal reforming tool 4 T703 2 or T703 3 install over tube end and seal 4 Push in and turn seal reforming tool 4 until seal bottoms tapered end of reforming tool 5 Ensure seal is not damage after inst...

Page 444: ... Remove tube assembly B Heat Defog Tube Assembly Installation Ref Figure 407 NOTE This task is typical for tubes in the heat defog bleed air system installation Consumable Materials Ref CSP SPM Item Nomenclature C801 Foam 900 CONFIG C709 Tape Adhesive 900 CONFIG C610 Rubber Expanded 902 CONFIG C710 Tape Glass Fabric 902 CONFIG 1 900 CONFIG Install threadless flexible coupling seals with the cup fa...

Page 445: ...N ON TUBE ASSEMBLIES ONE INCH DO NOT OVERLAP AT STA 180 25 AND STA 204 50 TUBE CONNECTION BUTT FOAM INSULATION AND TAPE AGAINST EXISTING INSULATION TO ALLOW FOR INSTALLATION OF HEAT DEFOG INSIDE AND OUTSIDE SHIELDING 5 CLAMPS TO BE INSTALLED APPROXIMATELY WHERE SHOWN FLEXIBLE COUPLING ASSEMBLY TYPICAL INSTALLATION 21 PL NOTE 3 4 ROTATED STA 180 25 204 50 NOTE 2 3 4 NOTE 5 TYPICAL 17 PL 1 3 5 7 11 ...

Page 446: ... NOTE 1 3 NOTE 3 NOTE 3 18 19 20 17 12 21 18 19 2 PL 20 12 17 21 26 21 12 13 12 13 22 12 13 24 2 PL 25 23 STA 230 50 9G21 031 2A 900 CONFIG 902 CONFIG 900 CONFIG 902 CONFIG NOTE 3 TYPICAL INSTALLATION OF INSULATION AND TAPE AT TUBE CONNECTION 13 12 Figure 407 Heat Defog Tube Assembly Replacement Sheet 2 of 2 ...

Page 447: ...HIELD MID 8 INSIDE SHIELD AFT 9 OUTSIDE SHIELD AFT 10 INSIDE SHIELD VERTICAL 11 OUTSIDE SHIELD VERTICAL 12 FOAM C801 900 CONFIG RUBBER C610 902 CONFIG 13 ADHESIVE TAPE C709 900 CONFIG GLASS FABRIC TAPE C710 902 CONFIG 14 FLEXIBLE COUPLING ASSEMBLY 15 RETAINER 16 SEAL 17 CUSHIONED SUPPORT CLAMP 18 SCREW 19 WASHER 20 NUT 21 TUBE ASSEMBLY 22 AIR TEE ASSEMBLY 23 BULKHEAD BODY FITTING 24 WASHER TEFLON ...

Page 448: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 424 Revision 28 21 40 00 This page intentionally left blank ...

Page 449: ...erior trim insulation panels Ref Section 25 50 00 2 Inspect roof to valve tube insulation and tape for tears and cuts that are through to tube Inspect for indication of an air leak If necessary repair or replace 3 Inspect Sta 230 03 tube insulation and tape for tears and cuts that are through to tube Inspect for indication1 of an air leak If necessary repair or replace 4 Inspect tubes for conditio...

Page 450: ...og Ejector Inspection Area 1 1 Open N82 N106 and B142 Ref Section 06 00 00 2 Inspect ejector for cracks and separa tion No damage allowed 3 Inspect ejector for security If necessary repair or replace 4 Inspect control cable for kinks crushed sleeve and corrosion Inspect for galling and indication of wear If necessary repair or replace 5 Close N82 N106 and B142 Ref Section 06 00 00 H Heat Defog Val...

Page 451: ... 5 HEATER DEFOG VALVE FLOW CONTROL 6 HEATER DEFOG CONTROL CABLE 7 BLEED AIR TUBE 8 AFT CABIN HEAT EJECTOR 9 UNION PERMASWEDGE FITTING 900 CONFIG 10 MAIN BLEED AIR FIREWALL FITTING 11 LH ENGINE BLEED AIR CHECK VALVE 12 ENGINE BLEED AIR TUBES 13 RH ENGINE BLEED AIR CHECK VALVE 14 FLOW CONTROL SHUTOFF VALVE 15 ENGINE DECK FITTING 16 FLEXIBLE HEATER CONTROL CABLE 17 HEATING SYSTEM FLOW CONTROL VALVE S...

Page 452: ...1 31 RH FIREWALL ENGINE DECK RBL 11 78 FS 248 97 BL 0 00 VIEW LOOKING DOWN 902 CONFIG VIEW LOOKING INBOARD RH SIDE 902 CONFIG 4 REF 8 9 14 10 PL 17 2 3 1 4 8 2 3 1 5 7 11 2 PL 6 14 REF 1 3 4 5 6 7 8 2 3 1 9 10 12 13 2 15 7 PL 16 900 CONFIG 16 Figure 602 Engine Bleed Air Check Valve Flow Control Shutoff Valve ...

Page 453: ...K VALVE 3 BOSS SEAL 4 ENGINE TO VALVE HOSE RH 5 ENGINE TO VALVE HOSE LH 6 HEAT DEFOG INBOARD FIREWALL TUBE 7 FIREWALL FITTING 8 MAIN BLEED FITTING 9 BLEED AIR FLOW CONTROL SHUTOFF VALVE 10 TUBE FLOW CONTROL SHUTOFF VALVE TO FITTING 11 ELBOW 12 BOLT 13 GASKETS 14 NUT COUPLING CRES 15 THREADLESS FLEXIBLE COUPLING 16 TUBE VALVE TO DECK 17 NUT COUPLING ALUMINUM ALLOY ...

Page 454: ...low rate Air flow rate must be less than 2 0 cfm 56 6 L m 11 If the air flow rate is more than 2 0 cfm 56 6 L m continue functional test as follows a check all tube connections and fittings above the engine deck for leaks b Apply liquid leak detector C809 to the flow control shutoff valve firewall fittings main bleed air fitting and tube and hose connectors c Make sure there are no air leaks aroun...

Page 455: ...ose Compound Anti Seize C220 18 Apply anti seize compound C220 to right engine check valve 19 Connect hose to check valve Torque coupling nut 500 600 in lb 56 5 67 8 Nwm 20 Remove plug from left engine hose 21 Apply anti seize compound C220 to left engine check valve 22 Connect hose to check valve Torque coupling nut 500 600 in lb 56 5 67 8 Nwm 23 Close L260 and R260 Ref Section 06 00 00 24 Instal...

Page 456: ...RE GAUGE APPROXIMATELY 6 FT OF FLEXIBLE AIR HOSE FEMALE QUICK CONNECT MALE QUICK CONNECT AIR FLOW METER RANGE 0 4 CFM 0 115 L m MINIMUM PRECISION 5 PRESSURE GAGE RANGE 0 150 PSIG 0 1034 kPa MINIMUM PRECISION 5 SHOP AIR SUPPLY PRESSURE 100 120 PSIG 689 827 kPa SHOP AIR SUPPLY PLUG AIR SUPPLY ADAPTER Figure 603 Heat Defog Leak Check Functional Test ...

Page 457: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 21 50 00 Air Conditioning System ...

Page 458: ......

Page 459: ...sor Assembly Compresses the air conditioning refrigerant The compressor changes the refrigerant from a low pressure and temperature gas to a high pressure and temperature gas Lines and Tubing Transfer the refrigerant through the air conditioning system Condenser Fans EARLY CONFIG The two fans provide ambient airflow across the condenser Cooling Blowers CURRENT CONFIG The two blowers provide ambien...

Page 460: ...e core tubes of the condenser The air flows around the core tubes to remove heat from the refrigerant gas Condensation occurs as the gas cools The high pressure gas becomes a liquid The high pressure refriger ant liquid then goes to the evaporator G Receiver Dehydrator EARLY CONFIG The receiver dehydrator is on the right side of the transmission deck It is on the high pressure line after the conde...

Page 461: ...through the evaporator The three way valve opens to let warm cabin air or fresh air go into the fresh air vent system ducts The low pressure gas in the evaporator cools the air that flows over the evaporator N Evaporator Fan The evaporator fan is on the right side of the evaporator A two speed 28 Vdc electric motor energizes the evaporator fan The fan starts the airflow that moves the cabin air or...

Page 462: ...VALVE DUCT ASSEMBLY WATER SEPARATOR HIGH PRESSURE GAUGE SWITCH RECEIVER DEHYDRATOR COMPRESSOR UNIVERSAL BULKHEAD FITTING LOW PRESSURE GAUGE SWITCH CONDENSER FANS CONDENSER LINES AND TUBING EVAPORATOR EVAPORATOR FAN AIR PLENUM DUCT 9G21 015B THERMOSTATIC SWITCH CONDENSER SCOOP EMI FILTERS Figure 1 Air Conditioning System EARLY CONFIG ...

Page 463: ...G21_040 WATER SEPERATOR 3 WAY VALVE 3 WAY VALVE DUCT ASSEMBLY 3 WAY VALVE CONTROL CABLE EVAPORATOR FAN EVAPORATOR THERMOSTATIC SWITCH AIR PLENUM DUCT LINES AND TUBING COMPRESSOR HIGH PRESSURE GUAGE SWITCH RECIEVER DEHYDRATOR RH CONDENSER SERVICING PORTS SIGHTGLASS Figure 2 Air Conditioning System CURRENT CONFIG ...

Page 464: ...Ï ÏÏÏÏÏÏÏÏÏÏÏÏ È È ÎÎ ÎÎ ÏÏ ÈÈ ÈÈ RECIRCULATING AIR INLET FROM CABIN FAN 3 WAY VALVE RECEIVER DRYER CONDENSER OVERBOARD DRAIN OVERBOARD CONDENSER FANS COMPRESSOR ASSEMBLY LOW PRESSURE SWITCH HIGH PRESSURE SWITCH EVAPORATOR CABIN PASSENGER COMPARTMENT CREW PILOT COMPARTMENT AIR OUTLET 4 PLACES HIGH PRESSURE LIQUID HIGH PRESSURE GAS LOW PRESSURE GAS LOW PRESSURE LIQUID RAM AIR IN 9G21 020A THERMAL E...

Page 465: ...CIRCULATING AIR INLET FROM CABIN FAN 3 WAY VALVE RECEIVER DRYER CONDENSER OVERBOARD DRAIN OVERBOARD LH COOLING BLOWER COMPRESSOR ASSEMBLY LOW PRESSURE SWITCH HIGH PRESSURE SWITCH EVAPORATOR CABIN PASSENGER COMPARTMENT CREW PILOT COMPARTMENT AIR OUTLET 4 PLACES HIGH PRESSURE LIQUID HIGH PRESSURE GAS LOW PRESSURE GAS LOW PRESSURE LIQUID RAM AIR IN 9G21 039 THERMAL EXPANSION VALVE OVERBOARD DRAIN THE...

Page 466: ......

Page 467: ...ngine operation See Note 1 Circuit breaker COMP CB17 open Replace or reset COMP circuit breaker CB17 as necessary 96 00 00 Defective air condition disable relay K7 5 Replace the relay 96 00 00 Open wire between relay K7 5 X2 and P104 ZF on the IIDS Do a test on the wires for a serviceable condition Make repairs as necessary 20 60 00 Defective compressor solenoid Replace the compressor 21 50 00 Def...

Page 468: ...r CNDSR FAN 2 CB26 is open Replace or reset circuit breaker CNDSR FAN 2 CB26 as necessary 96 00 00 Defective rotor select A C VENT fan switch S3 Replace the switch 96 00 00 Defective wiring Do a test on the wires for a serviceable condition Make repairs as necessary 20 60 00 Suction line or low pressure line has ice on the other side of the thermal bulb position Defective thermostatic expansion va...

Page 469: ...Y VALVE 3 3 WAY VALVE DUCT ASSEMBLY 4 WATER SEPARATOR 5 HIGH PRESSURE GAUGE SWITCH 6 RECEIVER DEHYDRATOR 7 COMPRESSOR 8 UNIVERSAL BULKHEAD FITTING 9 LOW PRESSURE GAUGE SWITCH 10 AIR PLENUM 11 LINES AND TUBING 12 EVAPORATOR 13 EVAPORATOR FAN 14 THERMOSTATIC SWITCH 15 CONDENSER 16 CONSENDER FAN 17 EMI FILTERS Figure 101 Air Conditioning System Vapor Cycle Cooling System EARLY CONFIG ...

Page 470: ...TROL CABLE 2 3 WAY VALVE 3 3 WAY VALVE DUCT ASSEMBLY 4 WATER SEPARATOR 5 HIGH PRESSURE GAUGE SWITCH 6 RECEIVER DEHYDRATOR 7 COMPRESSOR 8 LOW PRESSURE GAUGE SWITCH 9 AIR PLENUM 10 LINES AND TUBING 11 EVAPORATOR 12 EVAPORATOR FAN 13 THERMOSTATIC SWITCH 14 CONDENSER 15 SIGHT GLASS Figure 102 Air Conditioning System Vapor Cycle Cooling System CURRENT CONFIG ...

Page 471: ... P171 W123 W124 P377 J5 J3 J8 ELECTRICAL LOAD CENTER J2 J3 K7 3 4 K7 5 21 CB17 COMP CB19 EVAP CB18 VENT EVAP TB1 3 M TB1 3 L U T R W S C A 22 V X2 X1 28VDC A2 A3 A1 B1 B3 B2 B2 B3 B1 A1 A3 A2 28VDC 28VDC X2 X1 K8 3 4 CONDENSER FAN 2 RELAY K8 1 2 A2 A3 A1 X1 X2 TIME DELAY 2 0 SEC RELAY 28VDC 28VDC AIR COND DISABLE RELAY X2 X1 A1 A3 A2 A620 A E J N T B F K P W CB56 CNDSR FAN 1 15A 15A 5A 20A 20A UTI...

Page 472: ... 28V DC 28V DC A B C A B C TB301 TB301 M L U T R W S C A E D C F K100 POWER RELAY B2 B1 X2 X1 A1 A2 D C A B D F E A B COMPRESSOR SOLENOID B D D B A A A404 EVAPORATOR FAN PS2 PS1 A411 CONDENSER FAN A412 CONDENSER FAN A E E E E E W123 W305 W304 W304 W125 A B S302 THERMOSTATIC SWITCH 9G21 024 2C RED BLACK GREEN GND SP3 SP2 SP1 A680 FAN EMI FILTER 1 A681 FAN EMI FILTER 2 SP6 SP5 SP4 RED BLACK GREEN GN...

Page 473: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 107 Revision 34 21 50 00 9G21 034 Figure 104 Utility Control Panel Air Conditioning System ...

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Page 475: ... tee a Torque the cap 3 Remove AC compressor drive pad drain hose 4 and install pressure caps on the flared tube union and flared tube tee a Torque the caps 4 Install the engine accessory drive cover and gasket a Torque the nuts C Compressor Assembly Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C106 Oil Lubricating 1 If the rotorcraft was operated without the comp...

Page 476: ...nnect outlet hose 2 a Torque the fitting of outlet hose 2 230 to 260 in lb 25 99 to 29 38 Nm 9 Connect Electrical Connector SP1 5 The receiver dehydrator must be replaced each time the com pressor is removed or the AC system is opened An early failure of the compressor can occur 10 Remove and replace the receiver dehydrator ref Procedure 22 11 Service compressor reduction gearbox ref Section 12 00...

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Page 478: ... 6 5 9G21 030B 16 1 REF 7 8 2 REF 9 1 3 WAY VALVE DUCT 2 3 WAY VALVE CABLE 3 SPLIT GROMMET 4 CABLE HANDLE BRACKET 5 WASHER 6 SCREW 7 WASHER 8 COTTER PIN 9 WASHER 10 JAM NUT 11 CABLE BRACKET 12 V BAND CLAMP 13 EVAPORATOR FAN 14 BAND CLAMP 15 BULKHEAD TO VALVE DUCT 16 SEPARATOR TO VALVE DUCT Figure 402 Removal and Installation of Three Way Valve Cable and Duct ...

Page 479: ... Nm 4 Install washer 9 and forward jam nut 10 5 Put cable 2 through cable bracket 11 6 Install washer 9 and aft jam nut 10 7 Connect cable 2 washers 7 and new cotter pin 8 8 Adjust linkage of cable 2 to get full travel of duct 1 9 Torque jam nuts 10 270 to 300 in lb 30 50 to 33 90 Nm Sealing Compound C205 10 Environmentally seal split grommet 3 and cable 2 with sealing compound C205 ref CSP SPM Se...

Page 480: ...0 00 VIEW ROTATED 8 9 1 5 3 10 6 3 3 4 7 2 5 3 9G21 021C 3 5 1 EVAPORATOR FAN REF IPL 21 50 00 FIG 1 AND FIG 2 2 WASHER 3 WASHER 4 SCREW 5 SCREW 6 SCREW 7 FLEXIBLE DUCT 8 ELECTRICAL CONNECTOR P516 9 V BAND CLAMP 10 3 WAY VALVE DUCT Figure 403 Removal and Installation of the Evaporator Fan ...

Page 481: ...gure 403 Consumable Materials Ref CSP SPM Item Nomenclature C205 Sealing Compound 1 Prepare mating surfaces of evaporator fan 1 and the upper deck for an electrical bond ref CSP SPM Section 20 50 00 2 Install washers 2 between the upper deck and evaporator fan 1 NOTE Only install washers 2 with the 101 evaporator fan 3 Install evaporator fan 1 with washers 3 and screws 4 5 a Torque screws 4 5 20 t...

Page 482: ... REF 27 32 29 28 38 33 5 REF 15 REF 1 REF 34 35 NOTES 1 GASPER PLENUM SHOWN FOR ROTORCRAFT SERIAL NUMBER 900 00039 AND SUBSEQUENT OR EARLIER SERIAL NUMBERS THAT HAVE COMPLETED SL900 035 2 NUTS ARE INSTALLED ON ROTORCRAFT SERIAL NUMBER 900 00010 AND 900 00011 ONLY 3 INSTALL TEMPERATURE PROBE APPROXIMATELY AS SHOWN PROBE MUST BE 0 0 TO 0 2 INCH 0 TO 5 MM BELOW THE MATING SURFACE OF THE EVAPORATOR VI...

Page 483: ... 30 00 2 Remove band clamp 2 3 Disconnect duct 3 from outlet shroud 1 4 Remove nuts 19 if installed washers 18 and screws 17 5 Remove screws 23 and washers 24 6 Remove outlet shroud 1 and gasket 11 B Outlet Shroud Installation Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C205 Sealing Compound 1 Install gasket 11 outlet shroud 1 washers 24 and screws 23 a Torque screws 23 20 to...

Page 484: ...lled in expansion valve 6 Install adapter 5 a Torque adapter 5 230 to 260 in lb 25 99 to 29 38 Nm 7 Connect tube 6 to adapter 5 a Torque the captive nut of tube 6 230 to 260 in lb 25 99 to 29 38 Nm 8 Put sense element 35 against tube 7 at the 3 or 9 o clock position no more than 12 inch 305 mm along tube 7 from its connection to evaporator 15 NOTE Do not put rubber between sense ele ment 35 and tu...

Page 485: ...moval Ref Figure 404 1 Remove evaporator 15 ref Procedure 6 A 2 Remove band clamp 25 3 Disconnect duct 21 from inlet shroud 26 4 Remove inlet shroud 26 B Inlet Shroud Installation Ref Figure 404 1 Put inlet shroud 26 in position 2 Connect duct 21 to inlet shroud 26 3 Install band clamp 25 4 Install evaporator 15 ref Procedure 6 B 10 Thermostatic Switch EARLY CONFIG A Thermostatic Switch Removal Re...

Page 486: ...llation Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C205 Sealing Compound 1 Install bracket 10 with washers 9 and screws 8 a Torque screws 8 20 to 25 in lb 2 26 to 2 82 Nm 2 Apply sealing compound C205 to mating surfaces washers 9 and screws 8 3 Install inlet shroud 26 ref Procedure 9 B ...

Page 487: ...33 34 NOTES 1 GASPER PLENUM SHOWN FOR HELICOPTER SERIAL NUMBER 900 00039 AND SUBSEQUENT OR EARLIER SERIAL NUMBERS THAT HAVE COMPLETED SL900 035 2 NUTS ARE INSTALLED ON HELICOPTER SERIAL NUMBER 900 00010 AND 900 00011 ONLY 3 INSTALL TEMPERATURE PROBE APPROXIMATELY AS SHOWN PROBE MUST BE 0 0 TO 0 2 INCH 0 TO 5 0 MM BELOW THE MATING SURFACE OF THE EVAPORATOR 0 22 0 28 INCH 5 6 7 1 MM 2 68 2 74 INCH 6...

Page 488: ... Ref Figure 405 1 Remove Access Panel T155 ref Section 53 30 00 2 Remove band clamp 22 3 Disconnect duct 18 from inlet shroud 23 4 Remove screws 20 and washers 21 5 Remove inlet shroud 23 and gasket 13 B Inlet Shroud Installation Ref Figure 405 1 Install gasket 13 inlet shroud 23 washers 21 and screws 20 a Torque screws 20 2 Connect duct 18 to inlet shroud 23 3 Install band clamp 22 4 Install Acce...

Page 489: ...be 25 at the 3 or 9 o clock position no more than 12 inch 305 mm along tube 25 from the outlet of evaporator 12 10 Put rubber C610 35 around sense element 34 and the full length of tube 25 11 Wind glass fabric tape C710 36 on rubber C610 35 The receiver dehydrator must be replaced each time the com pressor is removed or the AC system is opened An early failure of the compressor can occur 12 Remove...

Page 490: ...atic Switch Removal Ref Figure 405 1 Remove outlet shroud 1 ref Proce dure 14 A 2 Remove nuts 40 screws 38 and washers 39 3 Carefully straighten the temperature probe as you pull it through grommet 41 4 Remove thermostatic switch 19 B Thermostatic Switch Installation Ref Figure 405 1 Install thermostatic switch 19 with screws 38 washers 39 and nuts 40 a Torque nuts 40 20 to 25 in lb 2 26 to 2 82 N...

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Page 492: ...torcraft Maintenance Manual Page 418 Revision 34 21 50 00 9G21 049 1 18 10 17 16 15 20 19 14 13 TUB REF 2 A412 J1 A411 J1 7 5 3 P500 23 24 22 21 12 12 11 11 9 8 4 P501 6 Figure 406 Removal and Installation of the Condenser EARLY CONFIG ...

Page 493: ...ct Electrical Connector P500 or P501 3 4 3 Install Access Panel A235 ref Section 53 20 00 17 Condenser Transition Duct EARLY CONFIG A Condenser Transition Duct Removal 1 Remove condenser fans 1 ref Proce dure 16 A Condenser Fan Removal 2 Remove screws 6 washers 5 and duct 7 B Condenser Transition Duct Installation 1 Install washers 5 screws 6 and duct 7 a Torque screws 6 20 to 25 in lb 2 26 to 2 8...

Page 494: ...reen Installation Ref Figure 406 1 Pre SB900 012 Put inlet screen 17 and stand 18 in position for installa tion Post SB900 012 Put shim 15 scoop 16 inlet screen 17 and stand 18 in position for installation 2 Install washers 19 and screws 20 Sealing Compound C205 a Install screws 20 wet with sealing compound C205 b Torque screws 20 12 to 15 in lb 1 36 to 1 69 Nm plus locking torque 3 Install conden...

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Page 496: ...NE ADDITIONAL WASHER CAN BE ADDED UNDER BOLT HEAD FOR CLEARANCE 3 3 PL VIEW ROTATED 1 NOTE 2 4 3 PL NOTE 5 REF 13 12 13 1 BOLT REF IPL 63 21 00 FIG 2 2 WASHER 3 WASHER 4 BOLT 5 HEAT EXCHANGER 6 CONDENSER 7 INLET TUBE 8 OUTLET TUBE 9 WASHER 10 BOLT 11 INLET COOLING DUCT 12 BOLT 13 WASHER 14 WASHER 15 BOLT 16 HEAT EXCHANGER MOUNT 17 ELECTRICAL BOND JUMPER Figure 407 Removal and Installation of the C...

Page 497: ... Resistant NOTE This task is typical for the left or right condensers 1 Prepare mating surfaces of electrical bond jumper 17 condenser 6 and heat exchanger mount 16 for an electrical bond ref CSP SPM Section 20 50 00 2 Install condenser 6 on inlet cooling duct 11 with washers 2 and bolts 1 3 Put condenser 6 and inlet cooling duct 11 between heat exchanger 5 and heat exchanger mounts 16 4 Install e...

Page 498: ...ced each time the com pressor is removed or the AC system is opened An early failure of the compressor can occur 10 Replace the receiver dehydrator ref Procedure 22 11 Service AC system ref Section 12 00 00 12 Install forward fairing support ref Section 53 30 00 13 Install access panels T155 and T220 ref Section 53 30 00 CAUTION ...

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Page 500: ...ce Manual Page 426 Revision 35 21 50 00 3 7 REF 4 1 REF 5 REF 7 1 5 9G21 052A 2 9 4 PL 10 4 PL 11 4 PL EARLY CONFIG 2 12 3 4 2 8 6 REF 1 REF 8 REF CURRENT CONFIG 12 9 4 PL 10 4 PL 11 4 PL 8 6 Figure 408 Removal and Installation of the Receiver Dehydrator ...

Page 501: ...r dehydrator 1 B Receiver Dehydrator Installation Ref Figure 408 The receiver dehydrator must be replaced each time the com pressor is removed or the AC system is opened An early failure of the compressor can occur 1 Install clamps 2 on bracket 12 2 Put receiver dehydrator 1 with clamps 2 on bracket 12 3 Install clamps 2 on receiver dehydra tor 1 a Torque the captive screws of clamps 2 18 in lb 2 ...

Page 502: ...n on the upper deck 2 Attach bracket 12 with washers 9 screws 10 and nuts 11 a Torque screws 10 20 to 25 in lb 2 26 to 2 82 Nm Sealing Compound C205 3 Environmentally seal between the edges of bracket 12 and the upper deck with sealing compound C205 ref CSP SPM Section 20 50 00 4 Environmentally seal screws 10 and washers 9 with sealing compound C205 ref CSP SPM Section 20 50 00 5 Install receiver...

Page 503: ...F 14 2 PL 26 REF 30 REF 1 2 3 1 12 16 14 15 8 8 17 8 8 8 8 18 19 22 29 30 31 20 21 11 11 9 10 6 7 9G21 006 1A 13 3 2 2 2 5 3 8 5 2 2 3 2 3 TYPICAL 3 PL 3 2 1 4 3 2 4 1 2 5 28 2 PL 23 4 PL 24 4 PL 24 25 EARLY CONFIG 1 4 1 4 1 4 26 27 TYPICAL TYPICAL 8 2 PL 1 1 Figure 409 AC System Installation Sheet 1 of 2 ...

Page 504: ...6 49 35 45 40 50 14 2 PL 15 2 PL 34 REF 26 REF 45 REF VIEW ROTATED CURRENT CONFIG 36 37 4 PL 38 4 PL 38 4 PL 39 4 PL 17 8 40 41 15 2 PL 42 48 47 2 PL 13 51 52 53 51 52 53 56 57 58 59 60 61 57 58 59 60 66 67 9G21 006 2A 54 55 68 VIEW ROTATED 56 57 58 59 60 61 57 58 59 60 62 63 3 PL 64 2 PL 65 62 63 3 PL 64 2 PL 65 Figure 409 AC System Installation Sheet 2 of 2 ...

Page 505: ...AL CONNECTOR P503 52 LOW PRESSURE SWITCH 53 PACKING 54 FITTING 55 TEE 56 LOOP CLAMP 57 SCREW 58 LOOP CLAMP 59 WASHER 60 NUT 61 CLAMP 62 NUT 63 WASHER 64 WASHER 65 ELBOW 66 ELECTRICAL CONNECTOR P502 67 HIGH PRESSURE SWITCH 68 TEE 69 LH CONDENSER 70 RH CONDENSER 24 Low Pressure Switch A Low Pressure Switch Removal Ref Figure 409 1 Open Access Panel R210 ref Section 06 00 00 2 Evacuate AC system ref ...

Page 506: ...n 06 00 00 2 Evacuate AC system ref Section 12 00 00 3 Disconnect inlet hose 29 or 32 4 Remove nut 5 screw 3 washers 2 and loop clamp 4 5 Remove screws 57 washers 59 loop clamps 56 and 58 nuts 60 and inlet hose 29 or 32 B Inlet Hose Installation Ref Figure 409 1 Connect inlet hose 29 or 32 2 Install washers 2 59 screws 3 57 loop clamps 4 56 58 and nuts 5 60 a Torque nuts 3 Torque the captive nuts ...

Page 507: ...ompressor can occur 4 Remove and replace the receiver dehydrator ref Procedure 22 5 Service AC system ref Section 12 00 00 6 Install access panels L155 and L210 ref Section 53 30 00 C High Pressure Switch to Mid Section Tube Removal Ref Figure 409 1 Remove access panels L155 L210 and R210 ref Section 53 30 00 2 Evacuate AC system ref Section 12 00 00 3 Disconnect tube 19 from union 8 and tee 68 4 ...

Page 508: ...d replace the receiver dehydrator ref Procedure 22 2 Connect hose to receiver dehydrator and elbow 3 Torque hose nuts 230 to 260 in lb 25 99 to 29 37 Nm 4 Service AC system ref Section 12 00 00 5 Install Access Panel R210 ref Section 53 30 00 I Baggage Closet to Deck Tube Removal Ref Figure 409 1 Remove baggage compartment roof insulation as necessary ref Section 25 00 00 2 Remove baggage compartm...

Page 509: ...Upper Deck Elbow Removal Ref Figure 409 NOTE Removal of upper deck elbow is typical 1 Remove Access Panel R210 ref Section 53 30 00 2 Remove baggage compartment roof insulation as necessary ref Section 25 00 00 3 Evacuate AC system ref Section 12 00 00 4 Disconnect tube 20 or 21 from elbow 65 5 Disconnect hose 30 or 31 from elbow 65 6 Remove nut 62 elbow 65 and washers 63 64 N Upper Deck Elbow Ins...

Page 510: ...nnect tube to unions 2 Torque tube nuts 230 to 260 in lb 25 99 to 29 37 Nm The receiver dehydrator must be replaced each time the com pressor is removed or the AC system is opened An early failure of the compressor can occur 3 Remove and replace the receiver dehydrator ref Procedure 22 4 Service AC system ref Section 12 00 00 5 Install baggage compartment right outboard floor panel ref Section 53 ...

Page 511: ...ed each time the com pressor is removed or the AC system is opened An early failure of the compressor can occur 3 Remove and replace the receiver dehydrator ref Procedure 22 4 Service AC system ref Section 12 00 00 5 Install baggage compartment floor center panel ref Section 53 20 00 29 High Pressure Tubes CURRENT CONFIG A Evaporator to Sight Glass Tube Removal Ref Figure 409 1 Remove Access Panel...

Page 512: ...0 in lb 25 99 to 29 38 Nm The receiver dehydrator must be replaced each time the com pressor is removed or the AC system is opened An early failure of the compressor can occur 4 Remove and replace receiver dehydra tor 26 ref Procedure 22 5 Service AC system ref Section 12 00 00 6 Install Access Panel L155 ref Section 53 30 00 G Mid Section to Receiver Dehydrator Tube Removal Ref Figure 409 1 Remov...

Page 513: ...m The receiver dehydrator must be replaced each time the com pressor is removed or the AC system is opened An early failure of the compressor can occur 3 Remove and replace receiver dehydra tor 26 ref Procedure 22 4 Service AC system ref Section 12 00 00 5 Install Access Panel L210 ref Section 53 30 00 M Right Condenser to Tee Tube Removal Ref Figure 409 1 Remove access panels L210 and R210 ref Se...

Page 514: ... High Pressure Switch to Tee Tube Installation Ref Figure 409 1 Connect high pressure switch to tee tube 46 to tees 47 68 a Torque captive nuts of tube 46 230 to 260 in lb 25 99 to 29 38 Nm The receiver dehydrator must be replaced each time the com pressor is removed or the AC system is opened An early failure of the compressor can occur 2 Remove and replace receiver dehydra tor 26 ref Procedure 2...

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Page 516: ...Maintenance Manual Page 442 Revision 34 21 50 00 9G21 047 13 1 REF 3 REF 5 7 4 REF 16 2 REF 6 7 8 17 13 11 12 5 REF 10 9 6 REF 10 15 16 REF 9 11 14 9 15 16 REF 6 REF 10 11 12 Figure 410 Removal and Installation of Low Pressure Lines EARLY CONFIG ...

Page 517: ...e steps a Wind rubber C610 on surface of tube 5 b Wind glass fabric tape C710 on rubber C610 2 Connect tube 5 to union 7 and tee 4 3 Install clamps 10 on tube 5 4 Attach clamp 10 to bracket 13 with screw 9 washer 11 and nut 12 a Torque screw 9 20 to 25 in lb 2 26 to 2 82 Nm 5 Attach clamps 10 15 to bracket 13 with screw 9 washer 11 and nut 12 a Torque screw 9 20 to 25 in lb 2 26 to 2 82 Nm 6 Torqu...

Page 518: ...s fabric tape C710 on rubber C610 NOTE Do not put glass fabric tape C710 on forward 1 00 inch 25 4 mm of rubber C610 3 Connect tube 6 to unions 7 4 Install clamps 10 on tube 6 5 Attach clamps 10 15 to bracket 13 with washer 11 and screw 9 a Torque screw 9 20 to 25 in lb 2 26 to 2 82 Nm 6 Attach clamps 10 15 to bracket 14 with washer 11 and screw 9 a Torque screw 9 20 to 25 in lb 2 26 to 2 82 Nm 7 ...

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Page 520: ...age 446 Revision 34 21 50 00 9G21 048 14 1 REF 2 REF 7 3 REF 17 REF 8 9 18 14 12 13 6 REF 11 10 7 REF 11 16 17 REF 10 12 15 10 16 17 REF 7 REF 11 12 13 12 12 4 REF 5 REF 6 REF 11 10 12 15 8 6 Figure 411 Removal and Installation of Low Pressure Lines CURRENT CONFIG ...

Page 521: ...these steps a Wind rubber C610 on surface of tube 5 b Wind glass fabric tape C710 on rubber C610 2 Connect tube 6 to union 8 and tee 3 3 Install clamps 11 on tube 6 4 Attach clamp 11 to bracket 14 with screw 10 washers 12 and nut 13 a Torque screw 10 20 to 25 in lb 2 26 to 2 82 Nm 5 Attach clamp 11 to bracket 15 with washer 12 and screw 10 a Torque screw 10 20 to 25 in lb 2 26 to 2 82 Nm 6 Torque ...

Page 522: ...ric tape C710 on rubber C610 NOTE Do not put glass fabric tape C710 on forward 1 00 inch 25 4 mm of rubber C610 3 Connect tube 7 to unions 8 4 Install clamps 11 on tube 7 5 Attach clamps 11 16 to bracket 15 with washer 12 and screw 10 a Torque screw 10 20 to 25 in lb 2 26 to 2 82 Nm 6 Attach clamps 11 16 to bracket 14 with screw 10 washer 12 and nut 13 a Torque screw 10 20 to 25 in lb 2 26 to 2 82...

Page 523: ...ace as necessary D High Pressure Switch Inspection 1 Inspect high pressure switch for corrosion None permitted 2 Inspect high pressure switch for serviceable condition Repair or replace as necessary E Low Pressure Switch Inspection 1 Inspect low pressure switch for corro sion None permitted 2 Inspect low pressure switch for service able condition Repair or replace as necessary F Evaporator Fan Ins...

Page 524: ...mount flange None permitted 2 Inspect for cracks None permitted 3 Inspect for loose or missing hardware Repair or replace as necessary 4 Inspect attach fitting for evidence of leakage a If leakage has occurred evacuate system b Remove repair or replace leaking or non serviceable fittings c Service air conditioning system Ref Section 12 00 00 K Condenser Fan Inspection EARLY CONFIG 1 Inspect conden...

Page 525: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual EQUIPMENT FURNISHINGS Chapter ...

Page 526: ......

Page 527: ...y 401 A Crew Seat Assembly Removal 401 B Crew Seat Assembly Installation 401 2 Seat Cushions Back Rest and Pan 401 A Seat Cushion Removal 401 B Seat Cushion Installation 401 3 Restraint System 401 A Restraint System Harness Removal 401 B Restraint System Harness Installation 401 4 Adjustment Rail Assembly Crew Seat 402 A Adjustment Rail Assembly Removal 402 B Adjustment Rail Assembly Installation ...

Page 528: ... Holder Installation 405 13 Forward Roller Assembly 405 A Forward Roller Assembly Removal 405 B Forward Roller Assembly Installation 405 14 Aft Roller Assembly 406 A Aft Roller Assembly Removal 406 B Aft Roller Assembly Installation 406 15 Side Tube 406 A Side Tube Removal 406 B Side Tube Installation 406 16 Tie Tube Assembly 406 A Tie Tube Assembly Removal 406 B Tie Tube Assembly Installation 406...

Page 529: ...10 B Carpet Trapping Strip Installation 410 25 Carpet Cockpit Floor 410 A Carpet Removal 410 B Carpet Installation 410 26 Lower Panel Left Hand 410 A Lower Panel Left Hand Removal 410 B Lower Panel Left Hand Installation 410 27 Top Panel Assembly Left Hand 411 A Top Panel Removal 411 B Top Panel Installation 411 28 Lower Panel Right Hand 411 A Lower Panel Right Hand Removal 411 B Lower Panel Right...

Page 530: ... Trim 413 Inspection Test 601 1 Crew Compartment 601 A Seat Inspection Area 1 601 B Seat Energy Absorption System EAS Inspection 601 Figure 601 Seat EAS Inspection 602 C Seat Restraint System Inspection Area 1 602 D Trim Inspection Area 1 603 E Seat Operational Test 604 F Seat Restraint System Operational Test 604 25 20 00 Cabin Compartment A Description and Operation 1 1 Equipment Furnishings Gen...

Page 531: ...sulation Panel Removal 403 B Insulation Panel Installation 403 5 Wall Panels 902 CONFIG Business 403 A Wall Panel Removal 403 B Wall Panel Installation 403 6 Acoustic Insulation Roof 403 A Acoustic Insulation Removal 403 B Acoustic Insulation Installation 403 7 Cabin Carpet Commercial and Business 403 A Cabin Carpet Removal 403 B Cabin Carpet Installation 403 8 Forward and Aft Roof Panels Commerci...

Page 532: ... and Trapping Strip 406 A Door Panel and Trapping Strip Removal 406 B Door Panel and Trapping Strip Installation 406 17 Window Reveal 406 A Window Reveal Removal 406 B Window Reveal Installation 406 Figure 403 Cabin Compartment Interior Trim Commercial Business 407 18 Cabin Carpet Utility 408 A Cabin Carpet Removal 408 B Cabin Carpet Installation 408 19 Roof Panel Utility 408 A Roof Panel Removal ...

Page 533: ...Compartment Interior Trim A Description and Operation 1 1 Baggage Compartment Interior 1 Figure 1 Baggage Compartment Interior Trim Sheet 1 of 2 2 Fault Isolation 101 1 Interior Troubleshooting 101 Table 101 Seat Assemblies Troubleshooting 101 Removal Installation 401 1 Insulation Panel Trim 401 A Insulation Panel Removal 401 B Insulation Panel Installation 401 2 Closeout Panel Assemblies 401 A Cl...

Page 534: ...tachment 401 D Cargo Hook System Installation 401 Figure 401 Cargo Hook System 402 2 Cargo Hook Cockpit Mechanical Release Cable Assembly 403 A Cargo Hook Cockpit Mechanical Release Cable Assembly Removal 403 B Cargo Hook Cockpit Mechanical Release Cable Assembly Installation 403 3 Cargo Hook Cockpit Mechanical Release Bracket 403 A Cargo Hook Cockpit Mechanical Release Bracket Removal 403 B Cargo...

Page 535: ...ergency First Aid Kit 1 A First Aid Kit 1 B First Aid Kit Contents 1 Maintenance Practices 201 1 First Aid Kit 201 A First Aid Kit Inspection 201 25 60 10 Rescue Hoist A Description and Operation 1 1 Rescue Hoist 1 A Description 1 B Operation 2 Maintenance Practices 201 1 Rescue Hoist Installation 201 A Install Hoist Support And Strut 201 Figure 1 Hoist System Installation 202 B Assist Handel Inst...

Page 536: ... Electrical System Functional Test 601 Repair 801 1 Repair Instructions 801 25 70 00 Hinged Avionics Shelf A Description and Operation 1 1 Hinged Avionics Shelf 1 Figure 1 Hinged Avionics Shelf 2 Maintenance Practices 201 1 Hinged Avionics Shelf 201 A Hinged Avionics Shelf Removal 201 B Hinged Avionics Shelf Installation 201 2 Avionics Shelf Channel 201 A Avionics Shelf Channel Removal 201 B Avion...

Page 537: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Section 25 10 00 Crew Compartment ...

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Page 539: ...ontal fore and aft adjustment of 3 inches with seven positions The seat adjustment controls are located at the center of the seat During fore and aft adjustment of the seat the automatic tilting feature tilts the seat back from 18 degrees in the fore most position to 20 degrees in the rear most position The seat assemblies are comprised of a formed tubular structure sheet metal seat pan with remov...

Page 540: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 2 Original 25 10 00 9G25 001 RESTRAINT SYSTEM ATTENUATION TUBES Figure 1 Crew Seat Assemblies ...

Page 541: ...ER BEAM COVER HOOK TAPE TOP PANEL ASSEMBLY CARPET PANEL SIDE PANEL ASSEMBLY LOWER PANEL ASSEMBLY CLOSET PANEL ASSEMBLIES CENTER BEAM COVER COAT HOOK HOOK TAPE CARPET PANEL HOOK TAPE CARPET TRAPPING STRIP CARPET TRAPPING STRIP LIGHT ASSEMBLIES 9G25 002A INTERIOR DOOR PANEL COAT HOOK Figure 2 Crew Compartment Interior Trim ...

Page 542: ......

Page 543: ... Crew seat does not adjust forward or aft Malfunction of seat adjustment lever Localize damaged components and replace 25 10 00 Release mechanism did not disengage allowing seat to move from last set position Adjust cable tension so release will pull locking pin mechanism from last engaged position Lubricate release mechanism if unserviceable remove and replace Binding of cable mechanism Replace c...

Page 544: ......

Page 545: ...hion 41 down against hook tape fasteners of seat pan assembly 39 to secure 3 Restraint System A Restraint System Harness Removal Ref Figure 401 1 Remove crew seat assembly 4 2 Remove back rest 40 and pan seat 41 cushions Ref Section 25 10 00 3 Remove nut 7 washers 8 14 and 16 bushing 15 and bolt 9 attaching lap harness 10 to seat back assembly 42 4 Remove nut 7 washers 8 14 and 16 bushing 15 and s...

Page 546: ...and bolts 18 attaching inertia reel 11 and shoulder harness 10 to seat back assembly 42 5 Remove seat pan assembly 39 Ref Section 25 10 00 6 Remove nuts 7 washers 8 and 14 bushings 15 and screws 17 attaching side tubes 25 to seat back assembly 42 7 Remove nuts 7 washers 8 and 29 and bolts 30 attaching diagonal supports 44 to fixed fitting assemblies 32 NOTE When removing bolts 34 tension springs 5...

Page 547: ...d 14 and nuts 7 attaching side tubes 25 to seat pan 39 3 Install screws 37 washers 33 and nuts 20 attaching harness locking handle assembly 38 to seat pan assembly 39 4 Install screws 36 washers 33 and nuts 20 attaching lock system assem bly 47 to seat pan 39 5 Install seat pan 41 cushion Ref Section 25 10 00 6 Install crew seat assembly 4 in aircraft 7 Upright Support Assembly A Upright Support A...

Page 548: ...w nuts 20 attaching lock system assem bly 47 to aft rail holder assembly 45 2 Install aft rail holder assembly 45 Ref Section 25 10 00 3 Install screws 36 washers 33 and new nuts 20 attaching lock system assembly 47 to seat pan assembly 39 4 Install crew seat assembly 4 in aircraft 10 Diagonal Support A Diagonal Support Removal Ref Figure 401 1 Remove crew seat assembly 4 2 Remove and discard cott...

Page 549: ...tie tube assembly 50 and forward roller assembly 49 to forward rail holder 46 4 Remove forward rail holder 46 B Forward Rail Holder Installation Ref Figure 401 1 Align forward roller assembly 49 in upright support assembly 43 and route pull up cable 12 around roller assembly 49 2 Install bolt 31 washers 8 and 51 and nut 27 attaching support assembly 43 tie tube assembly 50 and forward roller assem...

Page 550: ...mbly 42 B Side Tube Installation Ref Figure 401 1 Install screws 17 bushings 15 washers 8 and 14 and nuts 7 attaching side tubes 25 to seat back assembly 42 2 Install screws 17 bushings 24 washers 8 and 14 and nuts 7 attaching side tubes 25 to seat pan assembly 39 3 Install back rest 40 and pan seat 41 cushions Ref Section 25 10 00 4 Install crew seat assembly 4 in aircraft 16 Tie Tube Assembly A ...

Page 551: ...n tube 54 up and out of fixed fitting assembly 32 NOTE When removing bolts 34 tension springs 55 will fall down inside of upright support assemblies 43 6 Remove nuts 20 washers 33 and bolts 34 attaching fitting assemblies 32 to upright support assemblies 43 7 Slide seat back assembly 42 and fitting assemblies 32 up and off of support assembly 43 8 Remove fitting assembly 32 B Fixed Fitting Assembl...

Page 552: ...5 007A 12 2 2 13 VIEW LOOKING FORWARD 20 4 PL 19 4 PL 18 4 PL 4 20 2 PL 33 2 PL 36 2 PL 47 20 2 PL 33 4 PL 37 2 PL 38 32 20 33 34 7 8 22 23 21 50 35 52 53 54 49 46 26 27 8 51 31 48 44 REF 26 27 8 29 28 45 7 8 29 30 44 7 8 14 15 17 25 42 41 39 43 7 8 14 24 17 3 43 40 7 8 14 16 15 17 20 33 18 47 20 33 18 54 7 8 56 55 12 REF Figure 401 Crew Seat Assembly ...

Page 553: ...LT 19 General Soft Insulation Panel Removal Some components in this section require removal of soft interior insulation panels in order to gain access to the components attaching hardware The following procedure explains the basic task of their removal and installation NOTE Most soft insulation panels are held only with hook tape fasteners Others may be held with hook tape and captive fasten ers A...

Page 554: ...ove screws 7 and washers 8 that attach carpet trapping strip 9 to floor 2 Remove trapping strip 9 B Carpet Trapping Strip Installation Ref Figure 402 1 Align carpet trapping strip 9 with holes in floor 2 Install screws 7 and washers 8 attaching trapping strip 9 25 Carpet Cockpit Floor A Carpet Removal Ref Figure 402 1 Loosen heel rest assemblies Ref Section 67 20 00 2 Remove screws 7 and washers 8...

Page 555: ...anel 15 and hook tape fasteners with mating surface hook tape attachments 2 Press panel 15 surface against hook tape fasteners to attach 30 Main Covers Center Beam LH and RH A Main Covers Center Beam Removal Ref Figure 402 1 Disengage captive fasteners that attach center beam main covers 14 to frame 2 Remove main covers 14 B Main Covers Center Beam Installation Ref Figure 402 1 Align center beam m...

Page 556: ... Section 52 00 00 2 Remove screws 26 and 27 that attach interior door handle 25 and remove handle 3 Remove decorative caps 28 screws 29 and washers 30 that attach door panel 24 to door assembly 4 Remove panel 24 B Door Panel Installation Ref Figure 402 1 Align door panel 24 with cockpit door assembly and install washers 30 screws 29 and decorative caps 28 2 Install interior door handle 25 and atta...

Page 557: ...raft Maintenance Manual Page 413 Original 25 10 00 9G25 008A 4 1 2 22 20 21 5 12 14 EACH SIDE 19 13 23 12 REF 3 11 10 7 8 6 9 15 17 16 12 PL 8 12 PL 19 18 14 EACH SIDE 24 7 PL 28 29 30 25 26 27 7 PL Figure 402 Crew Compartment Interior Trim ...

Page 558: ...L INBOARD 7 SCREW 8 WASHER 9 CARPET TRAPPING STRIP 10 CARPET 11 LH LOWER PANEL 12 LH TOP PANEL ASSEMBLY 13 RH LOWER PANEL 14 CENTER BEAM MAIN COVER 15 SIDE PANEL 16 SCREW 17 CENTER BEAM FORWARD COVER 18 RH TOP PANEL ASSEMBLY 19 ROOF PANEL 20 SCREW 21 WASHER 22 HEAD SET JACK SUPPORT 23 IN FILL PANEL 24 DOOR PANEL 25 DOOR HANDLE INTERIOR 26 SCREW 27 SCREW 28 DECORATIVE CAP 29 SCREW 30 WASHER ...

Page 559: ...0 inch 38 1 mm across the seam and a width of 2 00 inch 50 8 mm along the seam Adhesive Paste Acrylic C422 b Make sure the hook tape fasteners on the seat pan are correctly attached 1 If loose bond with adhesive paste C422 c Make sure loop tape fasteners on cushions are correctly attached 5 Examine attenuation tubes for condi tion as follows NOTE It is not necessary to do maintenance on or lubrica...

Page 560: ...d c Inertia reel for damage wear and smooth operation as follows 1 Make sure harness strap cannot be pulled out of inertia reel when fully extended 2 With tension released harness strap must automatically retract back into reel mechanism 3 Apply a sudden forward pull on seat belt or shoulder strap to make sure inertia reel locks 4 Examine handle and cable of manual lock system for condition and co...

Page 561: ...oleum products can damage the belts and straps Do not use methyl ethyl ketone cleaning solvent C420 or ace tone C436 to clean belts and straps These solutions can damage the belts and straps a Clean belts and straps with a mild detergent warm water and a soft bristled brush Do not dry the belts and straps in the sun on or near a radiator or with a hot air dryer Damage to the fab ric can occur b Le...

Page 562: ...on is 1 57 inch 39 9 mm 7 Make sure you can read the placards and decals 8 Make sure placards and decals are correctly installed 9 Examine checklist and magnetic compass card for condition 10 Make sure you can read checklist and magnetic compass card E Seat Operational Test 1 Operate seat adjust lever under front of crew seat 2 Make sure position lock pin mechanism releases 3 Hold lock mechanism u...

Page 563: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Section 25 20 00 Cabin Compartment ...

Page 564: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL This page intentionally left blank ...

Page 565: ... interior The cabin compartment is also equipped with a 28 Vdc utility outlet and headset plug in jack A Cabin Seats Ref Figure 1 The cabin seats are interchangeable indepen dently removed and installed without tools The seats are nonadjustable with an energy attenuating structure and three point restraint system The cabin seats are located in the cabin compartment Each cabin seat support tube ass...

Page 566: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 2 Original 25 20 00 9G25 018A THREE POINT RESTRAINT SYSTEM ATTENUATION TUBES FOUR POINT RESTRAINT SYSTEM Figure 1 Cabin Seat Assemblies ...

Page 567: ...l 25 20 00 THRESHOLD THRESHOLD CABIN CARPET CABIN FLOOR CLOSEOUT PANEL 9G25 003 1B LIGHT SUPPORT PLATE AREA LIGHT FWD ROOF PANEL AFT ROOF PANEL PSU AFT PSU FWD CENTER ROOF PANEL LIGHT SUPPORT UNIT LIGHT SUPPORT UNIT Figure 2 Cabin Interior Trim Commercial Business Sheet 1 of 2 ...

Page 568: ...nce Manual Page 4 Original 25 20 00 9G25 003 2A WINDOW REVEAL TRAPPING STRIP DOOR PANEL FWD BULKHEAD PANEL SIDEWALL PANEL SIDEWALL PANEL AFT BULKHEAD PANEL BAGGAGE CLOSEOUT PANEL PULL HANDLE Figure 2 Cabin Interior Trim Commercial Business Sheet 2 of 2 ...

Page 569: ...F PANELS VENT GASPER AREA LIGHT CLOSEOUT PANELS VENT GASPER CLOSEOUT PANEL THRESHOLD THRESHOLD CARPET FLOOR STRUCTURE HOOK TAPE HOOK TAPE HOOK TAPE AFT BULKHEAD PANEL HEAT VENT FWD BULKHEAD PANEL SIDE PANEL HOOK TAPE DOOR STRUCTURE TRAPPING STRIP DOOR TRIM SIDE PANEL HOOK TAPE PULL HANDLE Figure 3 Cabin Interior Trim Utility ...

Page 570: ......

Page 571: ... of the manual Table 101 Seat Assemblies Troubleshooting Fault Probable Cause Corrective Action Ref Section Cabin seat does not close up into stowed position Hinging mechanism is binding or damaged Isolate problem component remove and replace 25 20 00 Restraint system does not lock or release properly Malfunction of buckle mechanism Replace harness assembly 25 20 00 Wear cut or deterioration in a ...

Page 572: ......

Page 573: ...nt harness 13 to seat tubes 2 Remove nuts 4 washers 5 9 and 10 bushings 7 and bolts 6 that attach lap restraint harness 13 to seat tubes B Restraint System Installation Ref Figure 401 1 Install bolts 6 bushings 7 washers 5 9 and 10 and nuts 4 attaching lap restraint harness 13 to seat tubes 2 Install bolts 8 bushings 12 washers 5 and 11 and nuts 4 attaching shoulder restraint harness 13 to seat tu...

Page 574: ...NT HARDWARE PATTERN TYPICAL HARDWARE PATTERN TYPICAL 13 1 3 2 1 1 BROWNLINE FITTING 2 ATTENUATION TUBE SEAT ASSEMBLY 3 ANCHOR PLATES 4 NUT 5 WASHER 6 BOLT 7 BUSHING 8 BOLT 9 WASHER 10 WASHER 11 WASHER 12 BUSHING 13 RESTRAINT HARNESS Figure 401 Cabin Seats Restraint System 1 1 CABIN SEAT FABRIC ASSEMBLY 2 BOWLINE KNOT 3 CORD 4 SEAT PAN 5 TIE DOWN STRAPS 6 SHRINK SLEEVE Figure 402 Cabin Seat Fabric ...

Page 575: ...tallation Ref Figure 403 1 Align wall panel 19 and hook tape fasteners with mating surface hook tape attachments Press surfaces together to secure 2 Engage captive fasteners if applicable 6 Acoustic Insulation Roof A Acoustic Insulation Removal Ref Figure 403 NOTE Acoustic insulation 23 sections pil lows of various sizes are individually in serted into the airframe roof structure cavi ties 1 Remov...

Page 576: ...tion 1 Align center roof panel 6 with adja cent passenger service units PSU 7 and interior perimeter support struc tures 2 Install pull pins 4 and guide pins 5 to secure panel 6 in place 3 Install hardware securing roof panel to support structure 10 Area Light Cabin Roof A Area Light Removal Ref Figure 403 1 Remove screws 8 and 22 that attach area light 10 to light support unit 9 and light support...

Page 577: ...assenger service unit PSU panels 7 Disconnect electrical connections from area light units 10 3 Remove screws 13 and washers 12 that attach Fwd and Aft PSU panels 7 to roof structure B PSU Panels Installation Ref Figure 403 1 Install electrical connections to area light units 10 2 Install screws 13 and washers 12 attaching passenger service unit PSU panels 7 to roof structure 3 Install light suppo...

Page 578: ...able screws 15 and washers 12 that attach lower door panel 16 and trapping strip 17 to door frame 18 2 Remove door panel 18 and trapping strip 17 B Door Panel and Trapping Strip Installation Ref Figure 403 1 Install screws 15 and washers 12 decorative caps and washers if applicable attaching trapping strip 17 and lower door panel 16 to door frame 18 17 Window Reveal A Window Reveal Removal Ref Fig...

Page 579: ...Maintenance Manual Page 407 Original 25 20 00 18 20 17 16 15 19 19 6 6 4 6 5 14 14 14 7 7 3 1 2 8 11 12 13 12 9G25 009B 22 11 12 21 21 12 10 9 12 43 PL 11 43 PL 23 23 24 25 25 25 25 Figure 403 Cabin Compartment Interior Trim Commercial Business ...

Page 580: ...4 and washers 5 that attach vent gasper closeouts 6 to roof support brackets 2 Disengage hardware that attaches roof panel 7 to closeout panels 8 3 Remove roof panel 7 by pulling down from hook tape fasteners B Roof Panel Installation 1 Align roof panel 7 with hook tape fasteners in closeout panels 8 and press together to secure 2 Engage hardware that attaches roof panel 7 to closeout panels 8 3 I...

Page 581: ...d washers 5 that attach closeout panels 8 to roof support structure B Closeout Panels Installation 1 Install screws 4 and washers 5 attaching closeout panels 8 to roof support structure 2 Install light support plate 12 Ref Section 25 20 00 3 Install roof panel 7 Ref Section 25 20 00 23 Door Panel and Trapping Strip A Door Panel and Trapping Strip Removal Ref Figure 404 1 Remove screws 4 that attac...

Page 582: ... Maintenance Manual Page 410 Original 25 20 00 16 17 14 15 13 13 13 9G25 015A 8 8 7 8 11 6 4 5 6 8 1 9 PL 3 2 13 18 2 9 2 PL 10 2 PL 12 4 5 PL 5 45 PL 4 45 PL 5 4 PL 4 4 PL 5 4 PL 4 4 PL 18 19 Figure 404 Cabin Compartment Interior Trim Utility ...

Page 583: ... 00 Legend Ref Figure 404 1 SCREW 2 CARPET THRESHOLD 3 CABIN CARPET 4 SCREW 5 WASHER 6 VENT GASPER CLOSEOUT 7 ROOF PANEL 8 CLOSEOUT PANEL 9 SCREW 10 SCREW 11 AREA LIGHT 12 LIGHT SUPPORT PLATE 13 INSULATION PANEL 14 SCREW 15 WASHER 16 TRAPPING STRIP 17 LOWER DOOR PANEL 18 DOOR FRAME 19 PULL STRAP ...

Page 584: ......

Page 585: ...mitted 4 Repair corrosion to a maximum depth of 0 010 inch 0 25 mm ref CSP SPM 5 Make sure seat fabric is clean 6 Examine seat fabric for tears cuts or other damage a The maximum permitted separation at fabric seams is 0 875 inch 22 23 mm across seam and a width of 1 00 inch 25 4 mm along seam 7 Examine seat support straps for wear cuts or tears NOTE Light wear frays and rough spots caused by norm...

Page 586: ...eaning solvent C420 or ace tone C436 to clean straps These solutions can damage the straps a Clean straps with a mild detergent warm water and a soft bristled brush Do not dry the straps in the sun on or near a radiator or with a hot air dryer Damage to the fabric can oc cur b Let air dry c Replace straps with visible particles or stains embedded in the fabric B Seat Energy Absorption System EAS I...

Page 587: ... incorrect operation of the adjust mechanism h Replace a belt or strap with ultravi olet UV light damage NOTE UV damage can include warps in the fabric color fade of the fabric rigidness or deterioration of the fibers i Replace a belt or strap with an illegible or missing label 3 Examine belts and straps for contamin ation dirt and stains Do not let oil or grease get on the belts or straps Petrole...

Page 588: ... for cuts tears correct installation or other unserviceable conditions 5 If installed examine overhead passen ger service units for correct operation and damage a Make sure air vent gaspers move freely and are not clogged b Do a operational check of each light c No damage permitted 6 Make sure you can read the placards and decals 7 Make sure placards and decals are correctly installed E Seat Opera...

Page 589: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 25 50 00 Baggage Compartment Interior Trim ...

Page 590: ......

Page 591: ...cured to the floor area Soundproofing was added with the business interior option 902 CONFIG between the baggage and cabin areas and around the anti torque fan assembly A portion of the roof insulation can be removed to gain access to the electrical services panel which is installed in the roof structure A universal area light is installed to the left hand side wall to provide light to the baggage...

Page 592: ...Page 2 Original 25 50 00 9G25 005 1A ROOF INSULATION PANEL HOOK TAPE SIDE INSULATION PANEL HOOK TAPE HOOK TAPE HOOK TAPE HOOK TAPE HOOK TAPE HOOK TAPE CARPET THRESHOLD HOOK TAPE HOOK TAPE HOOK TAPE HOOK TAPE Figure 1 Baggage Compartment Interior Trim Sheet 1 of 2 ...

Page 593: ... 25 50 00 9G25 005 2A INTERIOR DOOR PANEL LIGHT ASSEMBLY DOOR LATCHING MECHANISM HOOK TAPE INTERIOR SOFT PANEL PANEL ASSEMBLY BAGGAGE DOOR ASSEMBLY HOOK TAPE NOTE NOTE NOTE STANDOFFS AND ATTACHING HARDWARE ON ORIGINAL CONFIGURATION Figure 1 Baggage Compartment Interior Trim Sheet 2 of 2 ...

Page 594: ......

Page 595: ...e simplified system schematics electrical wiring diagrams serviceability checks and other detailed procedures referred to in this and other chapters of the manual Comprehensive wiring diagrams are available in the Rotorcraft Maintenance Manual CSP 900RMM 3 Ref Section 98 40 00 Table 101 Seat Assemblies Troubleshooting Fault Probable Cause Corrective Action Ref Section Loose Unsecured interior pane...

Page 596: ......

Page 597: ...gure 401 1 Remove specific soft insulation panels 1 that may cover closeout panel 2 2 Disengage captive fasteners 3 that attach closeout panels 2 to mounting surfaces 3 Remove closeout panels 2 B Closeout Panels Installation Ref Figure 401 1 Align closeout panel 2 with mounting surfaces 2 Engage captive fasteners 3 attaching closeout panels 2 3 Press soft insulation panels 1 up against hook tape f...

Page 598: ...rs 18 if installed original configuration that attach door trim panel 7 or pull trim panel 7 up and away from hook tape fasteners 8 new configuration from inside door assembly 3 Remove trim panel 7 B Door Trim Panel Installation Ref Figure 401 1 Align door trim panel 7 with inside door assembly hook tape fasteners 8 new configuration 2 Press panel 7 down against fasteners 8 to secure or install wa...

Page 599: ...ce Manual Page 403 Original 25 50 00 6 4 5 1 1 9G25 016B 7 15 9 12 10 11 13 13 13 14 14 14 16 17 14 ROTATED 8 2 1 3 3 8 18 19 NOTE NOTE STANDOFFS AND ATTACHING HARDWARE ON EARLY CONFIGURATION 20 Figure 401 Baggage Compartment Interior Trim Soundproofing ...

Page 600: ...50 00 Legend Ref Figure 401 1 INSULATION PANEL 2 CLOSEOUT PANEL 3 FASTENER 4 SCREW 5 CARPET THRESHOLD 6 CARPET 7 TRIM PANEL 8 HOOK TAPE 9 SCREW 10 LENS 11 AREA LIGHT ASSEMBLY 12 SCREW 13 SCREW 14 WASHER 15 LIGHT COVER 16 MOUNTING BRACKET 17 NUT 18 WASHER 19 SCREW 20 SOUNDPROOFING KIT ...

Page 601: ...allic components For cleaning procedures Ref CSP SPM NOTE Minor repairs may be made to these panels to prevent continuing degradation by using clear adhesive tape C714 to cover the damaged area and draw a tear or hole closed Adhesive Paste Acrylic C422 2 Inspect panels and fuselage structure for missing or loose hook tape fasteners If loose reattach to structure with adhesive paste C422 3 Inspect ...

Page 602: ......

Page 603: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 25 55 00 Cargo Hook System ...

Page 604: ......

Page 605: ...H saddle assembly PN 900F2361610 108 installed 2 Operation There is a load indication feature displayed on the IIDS alphanumeric display thru a menu selection The primary means of releasing the load from the cargo hook is via an electrical release switch located on either the RH of LH com mand station cyclic grip The release switch when actuated will annunciate HOOK OPEN on the IIDS display Second...

Page 606: ...AL CONNECTOR MANUAL RELEASE CABLE CONNECTION ELECTRICAL RELEASE CONNECTOR AFT Saddle clamp fwd saddle clamp QUICK RELEASE PIN SEE NOTE PIN LINK CABLE LOAD BEAM QUICK RELEASE PIN SEE NOTE FORWARD PIN LINK CABLE ELECTRIC CARGO HOOK RELEASE cyclic grip rotated MECHANICAL RELEASE LEVER SERVICE LOOP LINK ASSEMBLY LINK ASSEMBLY note MAKE SURE QUICK RELEASE PIN HEAD FACES UP AFTER INSTALLATION CARGO HOOK...

Page 607: ...ctive hook release switch Replace switch 25 55 00 Faulty ground Attach ground wire 98 00 00 Faulty cargo hook circuit breaker Replace circuit breaker 96 00 00 Faulty wiring Repair or replace wiring 98 00 00 Cargo hook operates electrically by release switch but fails to operate mechanically by manual release lever Manual release cable adjusted incorrectly Adjust cable 25 55 00 Broken or disconnect...

Page 608: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 102 Revision 25 25 55 00 This page intentionally left blank ...

Page 609: ...cargo hook 7 4 Remove and discard cotter pin 17 Remove nut 18 washer 19 and bolt 15 that attach load cell 20 to hook connector 14 C Cargo Hook Reattachment Ref Figure 401 1 Install bolt 15 washer 19 and nut 18 attaching load cell 20 to hook connector 14 2 Install bolt 16 washer 19 and nut 18 attaching load cell 20 to cargo hook 7 3 Install bolts 12 washers 11 and nuts 10 attaching clevis 13 to hoo...

Page 610: ... HEAD FACES UP AFTER INSTALLATION IF INSTALLED REF SB900 073 1 CARGO HOOK ELECTRICAL CONNECTOR 2 LOAD INDICATOR ELECTRICAL CONNECTOR 3 MECHANICAL RELEASE CONTROL CABLE CONNECTOR 4 QUICK RELEASE PINS 5 FWD AND AFT PIN LINKS 6 CARGO HOOK CABLES 7 CARGO HOOK ASSEMBLY 8 LANDING GEAR SADDLE CLAMP ASSEMBLIES 9 COTTER PIN 10 NUT 11 WASHER 12 BOLT 13 CLEVIS 14 HOOK CONNECTOR 15 BOLT 16 BOLT 17 COTTER PIN ...

Page 611: ...bly 3 to cargo hook cockpit mechanical release bracket 2 by installing washer 5 and jam nut 4 5 Install cargo hook cockpit mechanical release cable assembly handle 1 6 Secure cable assembly 3 with tiedown straps 12 3 Cargo Hook Cockpit Mechanical Release Bracket A Cargo Hook Cockpit Mechanical Release Bracket Removal Ref Figure 402 1 Remove cargo hook cockpit mechanical release cable assembly hand...

Page 612: ...013 12 3 14 12 13 PILOT S SIDE SHOWN COPILOT S SIDE SIMILAR 2 1 5 4 3 2 8 13 9 7 11 10 6 1 HANDLE 2 BRACKET 3 CABLE ASSEMBLY 4 JAM NUT 5 WASHER 6 WASHER 7 WASHER 8 NUT 9 NUT 10 BOLT 11 LOOP CLAMP 12 TIEDOWN STRAP 13 CABLE SUPPORT CLIP 14 FUSELAGE DOUBLER Figure 402 Cargo Hook Mechanical Release ...

Page 613: ...ive Epoxy C411 4 Apply epoxy adhesive C408 or epoxy adhesive C411 around edges of doubler 1 and position on inside floor of fuselage NOTE Rivets may be installed from either side of structure 5 Install rivets 2 attaching doubler 1 to floor of fuselage NOTE When installing wire harness W314 3 make provision for drip loops and excess slack Connector keyway is to be positioned to wards front of aircr...

Page 614: ...IRE HARNESS INSTALLED 1 11 12 GROUND J600 P600 10 6 13 VIEW LOOKING UP AT BOTTOM OF AIRCRAFT 5 4 1 DOUBLER 2 RIVET 3 WIRE HARNESS W314 4 ELECTRICAL RELEASE CONNECTOR 5 LOAD INDICATOR CONNECTOR 6 MECHANICAL RELEASE CONNECTOR 7 SCREW 8 WASHER 9 NUT 10 SHORTING PLUG 11 SHORTING PLUG 12 DUST CAP 13 DUMMY RECEPTACLE Figure 403 Wire Harness W314 Cargo Hook ...

Page 615: ... for general condition and security 6 Examine hook for cracks corrosion and overall general condition No damage permitted 7 Examine hook for security and function of mechanism a Make sure the release action fully retracts when activated under various load and attitude conditions B Cargo Hook Inspection 1 Examine cargo hook for dirt grit or foreign objects that can bind or cause incorrect operation...

Page 616: ...M 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 602 Revision 34 25 55 00 INSPECT FOR CRACKS BOTH SIDES LUG 9G25 024 AFT LH SADDLE ROTATED 90 CCW AFT RH SADDLE OPPOSITE Figure 601 Aft Saddle Inspection ...

Page 617: ...does not contaminate bushing or insert of aft LH and RH saddles 3 Remove paint from lug to saddle radius area of aft LH and aft RH saddles ref CSP SPM Section 20 40 00 Paint Removal Chemical 4 Examine lug to saddle radius area with a 10X magnification glass for cracks a No cracks permitted 5 Touch up lug to saddle radius area of aft LH and aft RH saddles a Apply a chemical coating ref CSP SPM Sect...

Page 618: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 604 Revision 34 25 55 00 9G25 02 DIM D DIM C DIM B Figure 602 Cargo Hook Cable Measurements ...

Page 619: ... the CARGO HOOK HOOK circuit breaker is pressed to full in the closed position 2 Make sure the manual release knob on the left side of the hook assembly is serviceable without a load attached NOTE This test must be done with the roto rcraft operated in a low hover position be cause the cargo hook hangs below the land ing gear skid tubes Make sure that the load beam on the cargo hook is engaged in ...

Page 620: ...nstallation and security of mechanical release cable electrical release and load indication wire harness and connectors 3 Make sure the manual release knob on the left side of the hook assembly is operational without a load attached 4 On ELECTRICAL MASTER panel set POWER switch to BAT EXT position 5 Activate electrical release on the command station cyclic control grip to do a check of the release...

Page 621: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 25 60 00 Emergency Equipment ...

Page 622: ......

Page 623: ... forefinger The kit is located in the right hand side wall stowage pocket of the baggage area B First Aid Kit Contents Periodically check kit contents to ensure an adequate supply of medical items Purchase individual items locally Kit contents include a direction sheet and the following eight packaged items adhesive and plain bandage compresses iodine swabs ammonia inhalants burn ointment tourni q...

Page 624: ......

Page 625: ...MAINTENANCE MANUAL Page 201 202 blank Original 25 60 00 EMERGENCY EQUIPMENT MAINTENANCE PRACTICES 1 First Aid Kit A First Aid Kit Inspection 1 Ensure that kit is stocked with minimal first aid supplies within shelf life specified by manufacturer ...

Page 626: ......

Page 627: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 25 60 10 Rescue Hoist ...

Page 628: ......

Page 629: ...evolutions Divide this number by 334 to determine full hoist cycles Variable Speed Controller is a highly efficient speed control which incorporates the latest PWM Pulse Width Modulated speed control techniques Hoist speed control is accom plished by a speed command applied to the controller from either the variable speed operator control or the constant speed priority override pilots control swit...

Page 630: ...bracket is provided on the hand grip to facilitate stowing the pendant in the aircraft The pendant is equipped with an electrical connector for interfacing with the Controller 250 lb 600 lb control two position maintained toggle switch used to signal the System for either the 250 lb mode or 600 lb mode Direction Speed control mechanism contains and actuats two switches and a potentiometer Two of t...

Page 631: ...hing the load select switch to the 600 lb mode Hoist operation can continue in the 600 lb mode and the high speed mode should not be selected until the present load is removed from the cable An over temperature sensing switch is embedded in the winding of the electric motor at a temperature critical location Prolonged operation of the hoist system under high temperature ambients exceeding design l...

Page 632: ......

Page 633: ...ock nuts 21 Ensure no load is attached to hoist without strut assembly 23 in position and secured at upper and lower points NOTE To eliminate possible rattle of strut as sembly 23 during flight strut may be lengthened by rotating rod end bearing 30 out one half turn 7 Attach lower end of strut assembly 23 to lower strut fitting assembly with quick release pin 24 8 Attach lanyard 31 with screw 32 w...

Page 634: ...25 X2 26 22 16 23 10 2 PL 20 2 PL 7 2 PL X2 21 2 PL 12 4 PL 13 4 PL 11 3 2 3 15 4 PL 7 4 PL 9 2 PL 6 3 PL 7 3 PL 8 3 PL 5 4 PL 7 4 PL 1 14 2 PL 13 2 PL REF 2 9K25 014A 24 FS 230 5 30 4 REF 22 32 33 34 31 29 28 18 23 LOWER STRUT FITTING 36 35 42 2 PL 40 2 PL X 2 39 2 PL 37 4 PL 38 4 PL 40 4 PL X 2 Figure 1 Hoist System Installation ...

Page 635: ...amp 41 18 inches from end of support tube 4 measured along bottom of support tube to bottom edge of clamp using bolts 37 washers 39 and nuts 38 2 Install handle 43 into forward clamp 41 using bolt 40 washers 39 and nut 38 NOTE Adjust aft clamp 42 position to pre vent binding occuring between clamp and support tube 4 3 Install aft clamp 42 on handle 43 using bolt 40 washers 39 and nut 38 4 Secure a...

Page 636: ...SEMBLY 7 AFT CLIP ASSEMBLY 8 SCREW 9 WASHER 10 LOWER FAIRING 11 END CAP ASSEMBLY 2 Guard Installation RH A Skid Guard Installation Ref Figure 3 Consumable Materials Ref CSP SPM Item Nomenclature C207 Sealing Compound Fuel Resistant C302 Finish Enamel White NOTE This installation is only done when the aircraft is configured with both Rescue Hoist and Air Cruiser Emergency Floats to gether 1 Positio...

Page 637: ...menclature C207 Sealing Compound Fuel Resistant NOTE This installation is only done when the aircraft is configured with both Rescue Hoist and Air Cruiser Emergency Floats to gether 1 Position and secure mating surfaces of Velcro hook 4 on cover 2 to velcro pile 5 area on float bag 3 2 Remove original hoist skid guard and replace with hoist float skid guard 9 3 Extend straps 6 around float bag 3 a...

Page 638: ... Maintenance Manual Page 206 Revision 17 25 60 10 9K25 029 11 2 PL 1 2 9 REF 6 SECTION A A RH SIDE VIEW LOOKING INBOARD RH SIDE VIEW LOOKING DOWN 3 A A FWD UP FWD INBD UP INBD 6 4 PL 8 7 REF 1 REF 2 4 5 10 6 PL Figure 4 Float Guard Installation ...

Page 639: ... connectors P524 P525 and P526 from aircraft connectors J524 J525 and J536 Ref CSP 900RMM 3 98 30 00 3 Detach harness connector P8 from hoist assembly 22 and connector P2 from controller assembly 16 4 Remove bolt 27 washer 25 and lock nut 26 and detach upper end of strut assembly 23 from lower attach point of aft bracket assembly 2 Ensure no load is attached to hoist without strut assembly 23 in p...

Page 640: ... G Float Guard Removal Ref Figure 4 NOTE This installation is only done when the aircraft is configured with both Rescue Hoist and Air Cruiser Emergency Floats to gether 1 Remove tie wraps as required and remove straps 6 2 Position and secure mating surfaces of Velcro hook 4 on cover 2 to velcro pile 5 area on float bag 2 ...

Page 641: ...ing Ref Figure 1 NOTE With the fairings installed a flash light and mirror are required to verify the fluid level through the sight gauge 1 Ensure fluid level is at or above minimum level through the sight gauge window 2 Add approved fluids as required Ref Figure 1 and Table 1 OIL LEVEL SIGHT GAUGE MINIMUM OIL LEVEL 9K25 004 A Figure 1 Fluid Level Sight Gauge Location ...

Page 642: ...PECIFICATION MATERIAL MANUFACTURER Hoist Assembly Oil MIL L 7808 Staufer Jet I Stauffer Chemical Co 380 Madison Avenue New York NY 10017 American PQ Lubricant 6899 American Oil and Supply Co Mobil Avrex S Turbo 256 Mobil Oil Co Brayco 880H Bray Oil Co 1925 Marianna Street Los Angeles CA 90032 Exxon Turbo Oil 2389 Exxon Co ...

Page 643: ... is lowered and CABLE PAYOUT display registers correct reading A drag load of approximately 20 pounds must be applied to the cable when hoisting to prevent cable from becoming loose and fouling drum Apply drag load with gloved hand or use a clean heavy cloth to protect hand and cable 10 On collective control module hold HOIST switch in UP position until cable returns to original position Do not al...

Page 644: ......

Page 645: ...pters Inc Rotorcraft Maintenance Manual Page 801 802 blank Revision 17 25 60 10 RESCUE HOIST SYSTEM REPAIR 1 Repair Instructions See Related Vendors Publications Hoist Manufacturers Manual for repairs Ref 01 00 00 Table 202 ...

Page 646: ......

Page 647: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 25 70 00 Hinged Avionics Shelf ...

Page 648: ......

Page 649: ... the ceiling area above the baggage compart ment The left and right sides are typical The shelves hold their respective left and right side Electronic Engine Control EEC units When required the shelves can swing down from a forward located hinge mechanism for mainte nance and or removal of the EEC s 902 CONFIG hinged avionics shelf is identical to the 900 CONFIG shelf with the exception of the 100...

Page 650: ...e 2 Original 25 70 00 LEFT SIDE SHOWN RIGHT SIDE TYPICAL SHELF TEE AVIONICS CLIP AFT OUTBOARD BRACKET FWD OUTBOARD BRACKET SUPPORT ASSEMBLY HINGE HALF HINGE HALF INTERCOSTAL INTERCOSTAL SHELF ANGLE SHELF ASSEMBLY SHELF CHANNEL 9G25 017 Figure 1 Hinged Avionics Shelf ...

Page 651: ...lt 1 and washer 2 that secure hinged avionics shelf 8 to avionics shelf channel 5 2 Remove bolt 1 washer 2 and nut 3 that secure channel 5 to upper avionics shelf tee 9 3 Remove channel 5 B Avionics Shelf Channel Installation Ref Figure 201 1 Prepare surface for electrical bond Ref CSP SPM 2 Install bolt 1 washer 2 and nut 3 securing avionics shelf channel 5 to upper avionics shelf tee 9 Torque nu...

Page 652: ... MD Helicopters Inc Rotorcraft Maintenance Manual Page 202 Original 25 70 00 LEFT SIDE SHOWN RIGHT SIDE TYPICAL 9G25 011 1 10 2 2 1 1 10 6 1 2 8 5 2 3 2 1 2 3 2 3 7 4 4 7 9 2 1 2 1 Figure 201 Hinged Avionics Shelf ...

Page 653: ... 4 Hinged Avionics Shelf A Hinged Avionics Shelf Inspection 1 Inspect hinged avionics shelf for security of installation 2 Inspect shelf and attaching brackets for cracks corrosion or any other type of damage or deformation Scratches or gouges are allowed up to 0 006 inch 0 152 mm Corrosion spots up to 0 010 inch 0 254 mm in depth shall be removed and repaired Ref CSP SPM 3 Verify that shelf assem...

Page 654: ......

Page 655: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual FIRE PROTECTION Chapter ...

Page 656: ......

Page 657: ...rheat Bleed Air Leak Detection System Cable Test 201 2 Overheat Bleed Air Leak Detection Cable Heat Defog 202 A Overheat Bleed Air Leak Detection Cable Removal 202 B Overheat Bleed Air Leak Detection Cable Installation 202 Figure 201 Overheat Bleed Air Leak Detection Cable Installation Heat Defog 203 3 Overheat Bleed Air Leak Detection Control 204 A Overheat Bleed Air Leak Detection Control Remova...

Page 658: ...204 A Engine Fire Overheat Detection Cable Removal 204 B Engine Fire Overheat Detection Cable Installation 204 Figure 202 Engine Fire Overheat Detection Cable Typical 205 4 Deck and Engine Fire Overheat Control Typical 206 A Fire Overheat Control Unit Removal 206 B Fire Overheat Control Unit Installation 206 Figure 203 Deck and Engine Fire Overheat Control Units 206 26 10 30 Smoke Detection System...

Page 659: ...ional Fire Extinguisher Brackets 202 A Removal Left Right Sides Typical 202 B Installation Left Right Sides Typical 202 Figure 202 Cabin Mounted Emergency Fire Extinguisher Right Hand Shown Left Hand Typical 203 7 Removal Installation of the Optional Cabin Mounted Brackets 204 A Removal Left Right Sides Typical 204 B Installation Left Right Sides Typical 204 8 Inspection Check 204 A Emergency Fire...

Page 660: ...3 A Hydrostatic Testing Of Fire Bottle 203 B Weight Verification Of Fire Bottle 203 5 Shipment of Fire Bottles and Discharge Cartridges 203 A Shipment of Charged Fire Bottles 203 B Shipment of Discharge Cartridge 203 6 Fire Bottle Assembly 204 A Fire Bottle Assembly Removal 204 B Fire Bottle Assembly Installation 204 7 Fire Extinguisher Discharge Cartridge 205 A Discharge Cartridge Removal 205 B D...

Page 661: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 26 10 10 Overheat Bleed Air Leak Detection Heat Defog System ...

Page 662: ......

Page 663: ...ductor that forms the basis of operation for the detection cable The cable functions as a temperature averag ing device its absolute or base resistance being a function of the surrounding ambient temperature As the cable temperature rises its resistance drops until it reaches a predeter mined set point of the control unit at which point the warning CAB HEAT is displayed on the Integrated Instrumen...

Page 664: ...Inc Rotorcraft Maintenance Manual Page 2 Revision 4 26 10 10 OVERHEAT CONTROL HEAT DEFOG BLEED AIR LINE OVERHEAT DETECTION CABLE DETECTION CABLE RUBBER GROMMET 9G26 001 Figure 1 Overheat Bleed Air Leak Detection Heat Defog System ...

Page 665: ... overheat control unit 26 10 00 Fault in overheat Bleed air leak detection See Notes Circuit breaker BLD AIR LEAK CB 6 not set on Electrical Load Center Set or reset circuit breaker 96 00 00 Faulty circuit breaker Replace circuit breaker 96 00 00 Detector cable center conductor high resistance Test detector cable 26 10 00 Detector cable low insulation resistance Test detector cable 26 10 20 Faulty...

Page 666: ...DETECT TEST E B G K C F A E E J 63 64 65 76 77 78 DETECTOR LEAK FAULT 63 57 LEAK DETECT DETECTOR TEST ZN 28VDC 14 A2 IIDS A612 A669 A601 900 CONFIG CB6 BLD AIR LEAK 5A W122 W309 W124 W124 9G26 011B TB3 8 A D C B R1 25K 25W LOOP FDL4 BLEED AIR LEAK DETECTION CABLE LOOP B LOOP A CALIBRATION RESISTOR EXTERNAL CALIBRATION RTN CIRCUIT BREAKER PANEL P128 J2 L ESS BUS 14 A601 902 CONFIG CB36 BLD AIR LEAK...

Page 667: ... hardware Electrical connector for corrosion and security 10 Inspect connector couplings for safety wire and security 11 Install right baggage compartment outboard floor panel AR250 Ref Section 06 00 00 12 Install soft insulation interior trim panel on aft right side of FS 230 5 bulkhead Ref Section 25 50 00 13 Install cabin floor panel AR165 Ref Section 06 00 00 14 Install cockpit floor access pa...

Page 668: ...tection cable from bleed air line and remove cable B Overheat Bleed Air Leak Detection Cable Installation Do not exceed minimum bend radius 0 750 inch 19 05 mm 1 Install detection cable from baggage compartment through FS 230 5 bulkhead and holes in each structure to FS 155 5 bulkhead NOTE Cable does not need to be in contact with bleed air line 2 Wrap detection cable 3 turns around horizontal len...

Page 669: ...OKING OUTBOARD RIGHT SIDE 9G26 013 5 1 8 7 6 2 6 9 9 4 3 5 70 80 in lb 7 9 9 0 N m 65 75 in lb 7 3 8 5 N m 70 80 in lb 7 9 9 0 N m 65 75 in lb 7 3 8 5 N m 1 ELECTRICAL CONNECTOR P1 2 ELECTRICAL CONNECTOR P2 3 ELECTRICAL CONNECTOR P160 4 OVERHEAT BLEED AIR LEAK CONTROL UNIT 5 OVERHEAT BLEED AIR LEAK DETECTION CABLE 6 MOUNTING NUT 7 RUBBER GROMMET 8 TIEDOWN STRAP 9 HEAT DEFOG BLEED AIR LINES Figure ...

Page 670: ...k detection control and spacers 4 and remove control from bulkhead B Overheat Bleed Air Leak Detection Control Installation 1 Prepare surface for electrical bond Ref CSP SPM 2 Install bleed air leak detection control onto bulkhead with spacers and screws Torque screws 3 Attach electrical connector P160 to bleed air leak detection control 4 Install cockpit floor panels AR138 and AR129 Ref Section 0...

Page 671: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 26 10 20 Deck and Engine Area Fire Overheat Detection System ...

Page 672: ......

Page 673: ...0 750 inch 19 1 mm All metal surfaces within the systems electri cal connectors are ceramic coated or surface coated to eliminate the possibility of false alarm due to a bridging action of conducting materials The use of a continuous loop enables the system to be monitored for open circuit condition In the event of a single cable break the system remains operational The cable is a temperature aver...

Page 674: ... DETECTOR CONTROL UNITS TOP TO RIGHT ENGINE MIDDLE TO DECK BOTTOM TO LEFT ENGINE DECK FIRE DETECTION CABLE FIRE DETECTION CABLE INTERCONNECTS LEFT ENGINE FIRE DETECTION CABLE RIGHT ENGINE FIRE DETECTION CABLE LEFT ENGINE a b 9G26 006 Figure 1 Fire Overheat Detection Cable Deck and Engine Area ...

Page 675: ...gine Area Fire Overheat Detection System Troubleshooting Fault Probable Cause Corrective Action Ref Section Fault in fire overheat detection system See Notes Circuit breaker XMSN F D CB 3 not set Set or reset circuit breaker 96 00 00 Faulty circuit breaker Replace circuit breaker 96 00 00 Circuit breaker L ENG F D CB 4 not set Set or reset circuit breaker 96 00 00 Faulty circuit breaker Replace ci...

Page 676: ...indicator indicates a normal functional system No flash of FIRE WARNING indicates a fault in the system that failed to flash Each is connected to a separate fire control unit circuit test through the IIDS ACFTFALT 1 Transmission fire detect fault ACFTFALT 2 Left engine fire fault or ACFTFALT 3 Right engine fire fault will appear on IIDS fault log alpha numerical display for the failed detection sy...

Page 677: ...5 65 64 LOOP B LOOP A PWR GND CALIBRATION RESISTOR EXTERNAL CALIBRATION RTN CHASSIS GROUND 28VDC TEST FAULT FIRE LOOP B LOOP A 28VDC PWR GND CALIBRATION RESISTOR CHASSIS GROUND TEST FAULT FIRE R ENG TEST R ENG FIRE FAULT R ENG FIRE L ENG TEST L ENG FIRE FAULT L ENG FIRE CB4 L ENG FIRE 5A 5A BAT BUS T T T T T T T T T T T T A601 900 CONFIG A2 IIDS A602 A103 A102 W122 W123 W124 W125 W124 W124 W124 9G...

Page 678: ......

Page 679: ... as required 8 Inspect detection cable for missing deteriorated and secure rubber grommets Repair of replace as re quired 9 Install engine cowling assembly L260 or R260 Ref Section 06 00 00 B Deck and Engine Fire Overheat Detection Cable Test Special Tools Ref CSP SPM Item Nomenclature T1002 Milli Ohm Meter T1012 Megohmmeter Digital Analog 1 Detach connectors at both ends of cable 2 Verify the cab...

Page 680: ...quick release clamps Remove screws 4 washers 5 and nuts 6 B Deck Fire Overheat Detection Cable Installation NOTE Replace any unserviceable Z brackets grommets or quick release clamps Apply sealing compound C205 to faying surface of replaced Z brackets Sealing Compound C205 1 Replace unserviceable Z brackets 2 Install replacement quick release clamps using screws washers and nuts Torque nuts Do not...

Page 681: ...in lb 7 9 10 2 N m 65 75 in lb 7 3 8 5 N m 1 DECK FIRE OVERHEAT DETECTION CABLE 2 QUICK RELEASE CLAMP 3 RUBBER FIRE DETECTOR GROMMET 4 SCREW 5 WASHER 6 NUT 7 Z BRACKET 8 ELECTRICAL CONNECTOR J475 9 ELECTRICAL CONNECTOR J477 10 CONNECTOR MOUNTING NUTS 11 ELECTRICAL CONNECTOR J475 FDL P2 12 ELECTRICAL CONNECTOR J477 FDL P1 Figure 201 Deck Fire Overheat Detection Cable ...

Page 682: ... unserviceable quick release clamps remove screws 7 washers 8 and nuts 9 B Engine Fire Overheat Detection Cable Installation Do not exceed minimum bend radius 0 750 inch 19 05 mm 1 Form fire detection cable to fit original mounting locations NOTE Replace unserviceable grommets and quick release clamps 2 Install replacement quick release clamps using screws washers and nuts Torque nuts 3 Place grom...

Page 683: ... 5 N m 70 90 in lb 7 9 10 2 N m 65 75 in lb 7 3 8 5 N m 1 ELECTRICAL CONNECTOR RIGHT ENGINE J474 2 ELECTRICAL CONNECTOR RIGHT ENGINE J476 3 RIGHT ENGINE DETECTION CABLE 4 ELECTRICAL CONNECTOR LEFT ENGINE J473 5 ELECTRICAL CONNECTOR LEFT ENGINE J479 6 MOUNTING NUT 7 SCREW 8 WASHER 9 NUT 10 LEFT ENGINE DETECTION CABLE 11 QUICK RELEASE CLAMP 12 FIRE DETECTOR RUBBER GROMMET 13 Z BRACKET Figure 202 Eng...

Page 684: ...4 B Fire Overheat Control Unit Installation 1 Install control on bracket assembly with screws and washers Torque screws 2 Attach electrical connector transmis sion deck P370 left engine P371 or right engine P372 to fire overheat control 3 Install right aft cabin interior trim panel Ref Section 25 20 00 4 Install right aft cabin passenger seat Ref Section 25 20 00 1 2 5 6 4 3 9G26 003A NOTE THE UPP...

Page 685: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 26 10 30 Smoke Detection System ...

Page 686: ......

Page 687: ...ects the detector to the A620 Electrical Load Center 3 and the A652 Audio Select Panel 4 thru the A675 Audio Intercon Assembly 5 B Operation Ref Figure 202 Refer to the wiring diagram and the applicable Rotorcraft Flight Manual RFM for operation of the smoke detection system 1 3 4 5 9g26 022 1 SMOKE DETECTOR REF IPL 26 10 30 FIG 1 2 WIRING HARNESS NOT SHOWN 3 A620 ELECTRICAL LOAD CENTER REF IPL 96...

Page 688: ... 3 GS302 K GS304 G A620 ELEC LOAD CENTER P378 J4 B C W44A22 EMI 3 SMOKE DETECTOR FIRE HRD CB31 CB32 BAT BUS 5A 5A W50A22 EMI 3 W45B22 EMI 3 E E1 SMOKE TEST W45C22N EMI 3 S R P N W49B22 EMI 3 AUDIO INTCON ASSY A675 11 A652 AUDIO SELECT PANEL J1 ALERT 1 20 21 050 P501 W44B22 EMI 3 W45A22 EMI 3 Figure 202 Smoke Detector Wiring Schematic 2 Smoke Detector Removal and Installation Ref Figure 203 A Remov...

Page 689: ...s 3 with washers 4 and nuts 5 2 Torque nuts 5 sufficiently to prevent the axial movement of smoke detector 2 3 Connect Electrical Connector P852 9G26 021 250 280 THRU BAGGAGECOMPARTMENT DOOR OPENING 1 2 3 4 5 P852 1 WIRING HARNESS REF IPL 26 10 30 FIG 1 2 SMOKE DETECTOR 3 STUD 4 WASHER 5 NUT Figure 203 Smoke Detector Removal And Installation ...

Page 690: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 204 Revision 34 26 10 30 3 Inspection and Test Refer to the applicable RFM to do a test of the smoke detector system ...

Page 691: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 26 20 10 Emergency Fire Extinguisher Hand Held ...

Page 692: ......

Page 693: ...nd discharges 14 oz 0 40 kg of a unique blend of Halon 1211 1301 extinguish ing agent ref Section 01 00 00 2 Fault Isolation A Fire Extinguishers The troubleshooting procedures in Table 201 are a summary of emergency fire extinguisher faults probable causes and corrective actions Table 201 Emergency Fire Extinguisher Troubleshooting Fault Probable Cause Corrective Action Ref Section Fire extinguis...

Page 694: ...ure 201 A Removal 1 Remove screws 3 washers 4 and bracket 2 B Installation 1 Install bracket 2 with screws 3 and washers 4 5 Removal Installation of the Optional Cabin Mounted Emergency Fire Extinguisher s Ref Figure 202 A Removal Left Right Sides Typical 1 Unfasten clasp of fire extinguisher bracket 2 2 Remove fire extinguisher 3 B Installation Left Right Sides Typical 1 Hang extinguisher 3 on br...

Page 695: ...2 3 4 4 5 5 6 6 7 7 9G26 019 5 5 1 CABIN MOUNTED BRACKET REF IPL 26 20 10 FIG 2 AND FIG 3 OR FIG 4 2 FIRE EXTINGUISHER BRACKET 3 14 OZ 0 40 KG FIRE EXTINGUISHER 4 BONDED STUD 5 WASHER 6 SELF LOCKING NUT 7 SCREW Figure 202 Cabin Mounted Emergency Fire Extinguisher Right Hand Shown Left Hand Typical ...

Page 696: ...turer instructions to service the fire extinguishers 1 Examine the fire extinguisher for signs of damage corrosion pitting or other conditions which can prevent operation 2 Visually examine the nozzle to make sure there are no obstructions 3 Make sure of the pressure gauge indication on 2 5 lb 1 13 kg fire extinguisher and date of last service 4 Weigh the fire extinguisher a Compare to manufacture...

Page 697: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 26 20 20 Fire Extinguisher System ...

Page 698: ......

Page 699: ...ed in the OFF position The cartridges are fired when the bottle discharge switch on the fuel system panel is placed in the primary or alternate position C System Tubing Discharge tubes flow extinguishing agent from the primary valve outlet port red to the engine deck through fitting Distribution tubes flow extinguishing agent and incorporate two openings each for emitting the agent The cross flow ...

Page 700: ...TION TUBE RIGHT SIDE DISTRIBUTION TUBE LEFT SIDE REF ENGINE DECK REF ENGINE DECK DISCHARGE TUBE OUTLET PORT DISCHARGE TUBE OUTLET PORT CROSS FLOW TUBES FIRE BOTTLE ASSEMBLY BLUE PORT ALTERNATE CARTRIDGE RED PORT PRIMARY CARTRIDGE 9G26 007 PRESSURE GAUGE FILLER PORT Figure 1 Fire Extinguisher System ...

Page 701: ...cceptable pressure limits Container leaking Replace fire bottle 26 20 20 Faulty gauge Replace fire bottle 26 20 20 Fire bottle gauge indicates below 250 psig 1724 kPa TANK PRESS LO not displayed on IIDS Faulty wiring Test and repair wiring 1 98 00 00 Faulty gauge Replace fire bottle 26 20 20 Faulty IIDS Replace IIDS 95 30 00 Cartridge did not discharge extinguishing agent FUEL SHUTOFF valve switch...

Page 702: ...ARTRIDGE PRIMARY LEFT CARTRIDGE CB32 FIRE HRD RTN PRESSURE LO 28VDC RTN B A A B B A A B C A C A TANK PRESS LO Z 10 24 22 9 BAT BUS 5A 2 4 6 8 10 7 5 3 1 Y D C B A S6 L FUEL SHUTOFF SWITCH S7 R FUEL SHUTOFF SWITCH OFF OFF 5 2 4 ALT 6 PRI 1 ALT 3 PRI 1 CLOSED 3 OPEN 4 SELECT 6 OFF 2 5 5 2 6 OFF 4 SELECT 3 OPEN 1 CLOSED A2 A604 FWD INTERCONNECT PANEL W125 W125 W307 W122 A704 A705 9G26 008A ENGINE FUE...

Page 703: ...as required Maximum allowed dent depth 0 063 in per 1 0 in 0 063 mm per mm average dent diameter or scratch depth 0 005 in 0 125 mm 8 Inspect discharge tube assemblies for dents scratches and unserviceable condition Maximum allowed dent depth depth 0 015 in 0 381 mm or scratch depth 0 0035 in 0 0889 mm 9 Inspect crossflow tube assemblies for dents scratches and unserviceable condition Maximum allo...

Page 704: ...trap to wrist of test technician 5 Thread discharge cartridge with shunt plug cover installed into discharge cartridge safety chamber T2026 6 Remove shunt plug cover T1006 7 Using digital multimeter T1003 measure discharge cartridge bridgewire resistance Pin A to Pin B 0 90 1 10 ohms Replace cartridge if required 8 Install shunt plug cover onto discharge cartridge 9 Remove discharge cartridge from...

Page 705: ...bottle 5 Shipment of Fire Bottles and Discharge Cartridges Special Tools Ref CSP SPM Item Nomenclature T1006 Shunt Plug Cover A Shipment of Charged Fire Bottles NOTE A fire bottle that is past the hydrostatic test due date can be transported or shipped in the charged condition if it was filled be fore the hydrostatic test due date Pressurized fire bottles are clas sified as an EXPLOSIVE MA TERIAL ...

Page 706: ... Right bottle assembly a Detach connectors P508 from red port primary discharge cartridge 9 P509 blue port alternate discharge cartridge 10 and pressure gage P512 11 b Install T1006 shunt plug covers to primary and alternate discharge cartridges c Disconnect crossflow tube assemblies 12 and 4 and right side discharge tube assembly 13 4 Remove screws 18 and washers 19 from fire bottle mounting supp...

Page 707: ...ge must be installed in red coded discharge port Blue coded discharge cartridge must be installed in blue coded discharge port Fire Extinguisher 1 Install discharge cartridge into fire bottle discharge outlet port Torque cartridge 90 100 in lb 10 16 11 29 N m and safety with lockwire C702 2 Remove shunt plug cover T1006 3 For installation of fire extinguisher discharge cartridge in position a Left...

Page 708: ...gine cowl assemblies L260 or R260 Ref Section 06 00 00 2 Remove screws 20 washers 21 and nuts 22 from upper and lower support clamps 23 and remove clamps 3 Loosen distribution tube assembly connector nut 17 to deck fitting 30 or 31 and remove distribution tube B Distribution Tube Assembly Installation NOTE This task is typical for left and right Distribution Tube Assembly installation 1 Install di...

Page 709: ... Manual Page 207 Revision 4 26 20 20 9G26 015 18 3 PL 19 3 PL 28 24 RH 25 LH 8 16 15 10 1 6 20 21 22 23 20 21 22 23 27 26 20 21 22 23 20 21 22 23 17 2 PL 13 14 9 12 4 2 7 5 LOOKING FORWARD LOOKING AFT 3 11 28 29 30 31 32 Figure 202 Fire Extinguisher System ...

Page 710: ...ONNECTOR P508 PRIMARY DISCHARGE CARTRIDGE RH 10 ELECTRICAL CONNECTOR P509 ALTERNATE DISCHARGE CARTRIDGE RH 11 ELECTRICAL CONNECTOR P512 PRESS GAUGE RH 12 TUBE ASSEMBLY CROSSFLOW 13 TUBE ASSEMBLY DISCHARGE RIGHT SIDE 14 PRIMARY OUTLET RED PORT RIGHT FIRE BOTTLE 15 ALTERNATE OUTLET BLUE PORT RIGHT FIRE BOTTLE 16 PRESSURE GAUGE RIGHT FIRE BOTTLE 17 NUT DECK FITTING 18 SCREW 19 WASHER 20 SCREW 21 WASH...

Page 711: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual FUEL SYSTEM Chapter ...

Page 712: ......

Page 713: ...el System Schematic 902 CONFIG 8 Fault Isolation 101 1 Fuel System Troubleshooting 101 Table 101 Fuel System Troubleshooting 101 Figure 101 Fuel Pressure Switch Wiring Diagram 105 Figure 102 Fuel Boost Pump Wiring Diagram 105 Figure 103 Fuel Boost Pump Wiring Schematic 106 Figure 104 Fuel Quantity Gauging Probes Wiring Diagram 900 CONFIG 106 Figure 105 Fuel Quantity Gauging Probes Wiring Diagram 9...

Page 714: ...aped Check Valve Installation 411 Figure 403 Centrifugal Fuel Booster Pump 412 4 Centrifugal Fuel Booster Pump Cartridge Replacement 413 A Fuel Booster Pump Cartridge Removal 413 B Fuel Booster Pump Cartridge Installation 413 Figure 404 Centrifugal Fuel Booster Pump Cartridge Only Replacement 415 5 Forward Fuel Gauging Probe 415 A Forward Fuel Gauging Probe Removal 415 B Forward Fuel Gauging Probe...

Page 715: ...ure 411 Fuel Vent System 430 13 Fuel Sump Drain Valve 431 A Fuel Sump Drain Valve Removal 431 B Fuel Sump Drain Valve Installation 431 14 Fuel Sump Drain Valve Control Assembly Fwd and Aft 431 A Fuel Sump Drain Valve Control Assembly Removal 431 B Fuel Sump Drain Valve Control Assembly Installation 432 Figure 412 Fwd and Aft Fuel Sump Drain Valve and Drain Valve Control Assembly 432 15 Fuel Cell F...

Page 716: ...oses and Shrouds 448 A Fuel Supply Tubes Hoses and Shrouds Removal 448 B Fuel Supply Tubes Hoses and Shrouds Installation 448 23 Lower Fuel Supply Hoses and Shrouds 900 CONFIG 449 A Lower Fuel Supply Hoses and Shrouds Removal 449 B Lower Fuel Supply Hoses and Shrouds Installation 450 24 Lower Fuel Supply Hoses and Shrouds Supplemental Fuel System Option 900 CONFIG 451 A Lower Fuel Supply Hoses and...

Page 717: ...heck Pressure Test 900 CONFIG 615 B Fuel Supply Vapor Shroud Leak Check Pressure Test 900 CONFIG With Supplemental Fuel System 616 Figure 604 Fuel Supply Vapor Shroud Leak Check Pressure Test 902 CONFIG 618 C Fuel Supply Vapor Shroud Leak Check Pressure Test 902 CONFIG 619 6 Operational Tests for the Fuel System 620 A Operation Test of the Fuel System 620 Figure 605 Fuel System Panel Electrical Ma...

Page 718: ... Snag Damage 801 B Inner Liner Outer Ply Damage 801 C Damage Limitations 801 28 10 00 Supplemental Fuel System Option A Description and Operation 1 1 General 1 2 Supplemental Fuel Tank Installation 1 3 Supplemental Fuel System Fuel Supply 1 4 Supplemental Fuel System Fuel Vent 1 5 Supplemental Fuel System Fuel Quantity 1 Figure 1 Supplemental Fuel System Installation Sheet 1 of 2 2 Fault Isolation...

Page 719: ...ank Removal 408 B Supplemental Fuel Tank Installation 409 8 Supplemental Fuel Check Valve CURRENT CONFIG 409 A Supplemental Fuel Check Valve Removal 409 B Supplemental Fuel Check Valve Installation 410 Figure 403 Supplemental Fuel System Installation Sheet 1 of 3 411 9 Supplemental Fuel Tank Foam Support 414 A Supplemental Fuel Tank Foam Support Removal 414 B Supplemental Fuel Tank Foam Support In...

Page 720: ...606 Figure 602 Supplemental Fuel Transfer Operational Test 607 Modification Repair 801 1 Main Fuel Tank Cover Modification 801 Figure 801 Main Fuel Tank Cover Modification 801 2 Aft Vent Tube Modification 802 Figure 802 Aft Vent Tube Modification 802 3 Right Outboard Baggage Floor Panel Modification 803 Figure 803 Right Outboard Baggage Floor Panel Modification 803 4 Supplemental Fuel Tank Support...

Page 721: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 28 00 00 Fuel System ...

Page 722: ......

Page 723: ... extender is 1014 lb 460 kg 149 0 US gallons 564 0 liters of fuel 994 lb 451 kg 146 2 US gallons 553 4 liters useable fuel Fuel cell capacity with range extender is 1097 lb 498 kg 161 2 US gallon 610 2 liters of fuel 1078 lb 489 kg 158 5 US gallons 600 liters useable fuel The cell is constructed of a two ply layer of flexible high tenacity Nitrile coated woven nylon fabric coatings adhesive and a ...

Page 724: ...liters by allowing the fuel cell to fill complete ly 902 CONFIG The lanyard attached to the fuel cap also opens a flapper valve in the longitudinal baffle to decrease refueling time D Fuel Sump Drain Valves Two fuel sump drain valves are located on the fuel cell sump plate The sump plate is centered on the bottom forward portion of the fuel cell The drain valves are spring loaded normally closed p...

Page 725: ... from the fuel supply Two bleed holes located in the canister cover are covered by an umbrella check valve The umbrella valve permits fuel vapors in the pump cartridge assembly to escape avoiding impeller cavitation The canister cover umbrella check valve also prevents fuel leakage when the cartridge assembly is removed The impeller is driven directly by the dc motor shaft The bearings in the dc m...

Page 726: ...The limit switches are positioned near each end of the actuator s rotational travel to interrupt motor power and illuminate a valve position indicator lamp on the IIDS display Fuel Crossfeed Valve 900 CONFIG PW206A The fuel crossfeed shutoff valve is a 28 vdc two position motor actuated valve The valve is normally closed and is controlled by a pilot activated switch on the fuel system control pane...

Page 727: ... PL HOSE ASSY RIGHT HOSE ASSY LEFT FUEL FILLER AFT FUEL PROBE SINGLE VENT ROLLOVER VALVE 2 PL GRAVITY FILL PORT FUEL CELL SUMP DRAIN CONTROLS 2 PL FUEL PRESSURE SWITCH ASSY 2 PL FUEL CROSSFEED SHUT OFF VALVE ASSY FWD FUEL PROBE FUEL BOOSTER PUMP 2 PL AFT FUEL VENT STANDPIPE FORWARD FUEL VENT STANDPIPE FUEL SHUT OFF VALVE 2 PL 9G28 002C NOTE FUEL CROSSFEED SYSTEM REMOVED ON 900 CONFIG HELICOPTERS C...

Page 728: ... ROLLOVER VALVE 2 PL AFT FUEL VENT STANDPIPE DUAL VENT ROLLOVER VALVE LEFT ENGINE FEED TUBE ASSY FUEL SHUTOFF VALVE 2 PL ENGINE DECK FRANGIBLE VALVE 2 PL FUEL CELL SUMP DRAIN CONTROLS 2 PL FORWARD FUEL PROBE FUEL VENT STANDPIPE CHECK VALVE 2 PL JET PUMP 2 PL FUEL BOOSTER PUMP 2 PL TEE FITTING 2 PL SELF SEALING FRANGIBLE VALVE 2 PL Figure 2 Fuel System 902 CONFIG ...

Page 729: ...PL CHECK VALVE 2 PL SUMP DRAIN VALVE 2 PL FUEL QTY PROBE 2 PL LOW LEVEL INDICATOR ON AFT PROBE SUMP OVBD DRAIN 2 PL FUEL BOOST PUMP 2 PL SUMP DRAIN CABLE VENT OVBD DRAIN 2 PL FLAME ARRESTOR 2 PL FUEL FILLER ASSY TO FWD RH VENT SYS FUEL PRESSURE SWITCH 2 PL FUEL SHUTOFF VALVE 2 PL GRAVITY FILL VALVE RH FUEL FEED SYS RH FUEL FEED VAPOR SHROUD 9G28 001A 1 FUEL CROSSFEED SYSTEM REMOVED ON 900 CONFIG H...

Page 730: ... AND RIGHT SUMP DRAIN VALVE 2 PL FUEL CELL LOW FUEL LEVEL SENSOR 2 PL CENTER BAFFLE CENTER BAFFLE FUEL BOOST PUMP 2 PL FEED SUPPLY TO RIGHT ENGINE FUEL SUPPLY TO LEFT ENGINE TEE FITTING 2 PL RH FUEL TRANSFER TUBING LH FUEL TRANSFER TUBING JET PUMP 2 PL CHECK VALVE 2 PL FUEL TRANSFER SYSTEM FUEL CELL OUTLET VAPOR SHROUD FWD LH VENT SYS LH FUEL FEED VAPOR SHROUD LH FUEL FEED SYS FUEL FEED FRANGIBLE ...

Page 731: ...uminated on IIDS panel with boost ON Set CROSSFEED valve switch to ON open position and turn opposite side booster pump ON If low fuel pressure remains illuminated Faulty fuel pressure switch Replace fuel pressure switch 28 00 00 Disconnected or ruptured fuel supply line in fuel cell Verify fuel supply lines security and condition Repair or replace parts as required 28 00 00 Faulty wiring between ...

Page 732: ...l supply line in fuel cell Replace fuel supply line 28 00 00 Contaminated fuel Perform Contaminated Fuel Cell Procedure 28 00 00 Fuel cell frangible valve closed off fuel supply Check frangible valve indicators for closure 28 00 00 FUEL impending bypass caution segments illuminated on IIDS panel Clogged engine fuel filters Replace engine fuel filters Bench check fuel filter caution light pressure ...

Page 733: ... 28 00 00 Fuel leaking past O ring of pump drain plug Replace O ring 28 00 00 Fuel leaking past O ring of fuel quantity probe Replace O ring 28 00 00 Loose or broken fuel cell attachment fittings Inspect and repair or replace as required 28 00 00 Fuel cell leak Pressure test remove and repair or replace cell as required 28 00 00 FUEL QUANTITY INDICATION ERRORS FUEL low level warning s illuminated ...

Page 734: ...right fuel quantity probe Replace aft right fuel probe 28 00 00 Faulty wiring circuit between fuel quantity probe and IIDS Test and repair wiring circuit 20 60 00 28 00 00 FUEL quantity LB digital display readout does not match actual known fuel quantity Loose or faulty wiring or connections on fuel quantity transmitter probes Inspect test and repair wiring 20 60 00 Faulty forward or aft left or r...

Page 735: ...toff valve limit switches Replace fuel shutoff valve 28 00 00 Faulty wiring between circuit breaker fuel shutoff valve and IIDS panel Test and repair wiring 20 60 00 W122 E GS305 J P173 J2 J3 J1 P171 P170 P104 J4 P105 J5 E GS306 J J6 P172 J1 P350 P351 J1 15 5 5 16 B A B A X Y RIGHT FUEL PRESS LOW LEFT FUEL PRESS LOW W123 W124 W125 LH FUEL PRESSURE SWITCH FWD INTERCONNECT PANEL A2 A612 A115 A114 II...

Page 736: ...8 A8 A5 A4 D C H A B F G D C A B A7 A6 A5 A4 A2 A1 A3 A2 A1 24 23 62 24 23 6 FUEL PROBE FWD LO FUEL PROBE FWD HI FUEL LOW DISCRETE FUEL PROBE AFT LO FUEL PROBE AFT HI 28VDC PWR RTN FUEL PROBE FWD LO FUEL PROBE FWD HI FUEL LOW DISCRETE FUEL PROBE AFT LO FUEL PROBE AFT HI PWR RTN LOW FUEL 28VDC PWR RTN 28VDC CB14 FUEL PROBE CB1 FUEL LOW 5A 5A W122 W123 W124 W125 W127 W124 W128 W124 AFT FUEL PROBE FW...

Page 737: ... RIGHT HI 28VDC IN 28 VDC RTN FUEL PROBE LEFT LO FUEL PROBE LEFT HI RIGHT FUEL LOW DISCRETE FUEL PROBE RIGHT LO FUEL PROBE RIGHT HI 28 VDC RTN LOW FUEL 28VDC PWR RTN 28VDC CB22 FUEL PROBE CB1 5A 5A BAT BUS W122 W123 W124 W125 W127 W124 W128 RIGHT FUEL PROBE LEFT FUEL PROBE FWD INTERCONNECT PANEL A2 A612 A104 A107 A601 A620 ELECTRICAL LOAD CENTER CIRCUIT BREAKER PANEL P P P P P P P P P P P P P P P ...

Page 738: ...28 VDC PWR RTN P R O B E P R O B E AFT FUEL PROBE A107 Figure 106 Fuel Quantity Probes Schematic 900 CONFIG P1 P1 5 D C H A B F G 3 4 8 1 28VDC PWR RTN PWR RTN 28VDC LEFT FUEL PROBE A107 100 mA 0 2 5 0V DIFFERENTIAL FUEL QUANTITY SIGNAL LOW LEVEL DISCRETE LOW LEVEL DETECTOR 0 2 5 0V DIFFERENTIAL FUEL QUANTITY SIGNAL 9G28 059A HI LO HI LO E LOW FUEL 28 VDC PWR RTN P R O B E P R O B E RIGHT FUEL PRO...

Page 739: ... 1 3 CLOSED OPEN 5A 5A 5A 6 5 4 3 2 1 SEL OPEN CLOSED C SH2 B SH2 W125 W124 W125 W124 FUEL SHUTOFF VALVE CROSSFEED LH FUEL SHUTOFF VALVE A604 A119 A117 ENGINE FUEL CONTROL PANEL A601 A116 RH FUEL SHUTOFF VALVE E E E GS307 H GS305 K GS303 C J1 C E G D F H A A SH2 W125 W126 M M M 9G28 028 1A CIRCUIT BREAKER PANEL S4 FUEL CROSSFEED SWITCH S6 L FUEL BOOST SWITCH S7 R FUEL BOOST SWITCH CB8 XFD VLV CB7 ...

Page 740: ... 14 13 15 14 17 18 4 3 1 2 3 4 W V X W U V LEFT FUEL VALVE CLOSED LEFT FUEL VALVE OPEN RIGHT FUEL VALVE CLOSED RIGHT FUEL VALVE OPEN FUEL XFEED VALVE OPEN FUEL XFEED VALVE CLOSED W123 B SH1 C SH1 FWD INTERCONNECT PANEL A2 A612 IIDS A SH1 W125 9G28 028 2A Figure 108 Fuel Shut Off and Crossfeed Valve Wiring Diagram 900 CONFIG PW206A Sheet 2 of 2 ...

Page 741: ...0 K P131 J1 P128 J2 Y E A H F D G E C C E G D F H A 5 4 X X V U V U CLOSED OPEN SEL 1 2 3 4 5 6 5A 5A 6 5 4 3 2 1 SEL OPEN CLOSED A SH2 B SH2 W124 W125 W124 LH FUEL SHUTOFF VALVE A604 A117 ENGINE FUEL CONTROL PANEL A601 A116 RH FUEL SHUTOFF VALVE W125 M M 9G28 060 1A CIRCUIT BREAKER PANEL S6 L FUEL SHUTOFF SWITCH CB7 L FUEL VLV CB12 R FUEL VLV Figure 109 Fuel Shut Off Valve Wiring Diagram 902 CONF...

Page 742: ...UEL VALVE OPEN RIGHT FUEL VALVE CLOSED RIGHT FUEL VALVE OPEN W123 B SH1 A SH1 FWD INTERCONNECT PANEL A2 A612 IIDS W125 9G28 060 2 W124 Figure 109 Fuel Shut Off Valve Wiring Diagram 902 CONFIG 900 CONFIG PW207E Sheet 2 of 2 9G28 031A SHUTOFF VALVE SHOWN IN MID POSITION DE ENERGIZED CLOSE INDICATOR CLOSE COMMON OPEN OPEN INDICATOR Figure 110 Fuel Shut Off Valves Crossfeed Valve Wiring Schematic Typi...

Page 743: ...l sump drains 3 Remove cabin seats if applicable Ref 25 20 00 Cabin Seat Assembly Removal 4 Remove carpet if applicable Ref 25 20 00 Cabin Carpet Removal 5 Remove cabin floor panels AL165 AR165 and A170 Ref 53 20 00 Cabin Floor Outboard Panel Removal and Cabin Floor Center Panel Removal 6 Remove fuel cell access covers Ref 28 00 00 Fuel Cell Access Cover Removal 7 Remove check valves and jet pumps...

Page 744: ...ly hoses for deteriora tion collapsed or kinked hoses No damage allowed 23 Inspect fuel supply hose clamps for security and deterioration Repair or replace as required 24 Inspect fuel quantity probes for security 25 Inspect the engine fuel filter elements Ref Pratt Whitney Maintenance Manual Replace as required 26 Install fuel transfer in line check valves in accordance with instructions in Fuel C...

Page 745: ...cannot be unclogged Alcohol Isopropyl C419 10 Clean all internal fuel cell surfaces with lint free cloth moistened with isopropyl alcohol to remove foreign object contamination Air dry for 15 minutes 11 Inspect fuel cell baffles for security and flapper valves for freedom of move ment 12 Inspect fuel cell baffle lacing cord for fraying or loose fibers Replace if required 13 Inspect fuel cell longi...

Page 746: ...les for evidence of contamination b If evidence of fuel contamination is found repeat Contaminated Fuel Cell Procedures until no contamina tion exists 24 Install carpet if applicable Ref 25 20 00 Cabin Carpet Installation 25 Install cabin seats if applicable Ref 25 20 00 Cabin Seat Assembly Installation 26 Fuel helicopter Ref 12 00 00 Main Fuel Tank Fueling ...

Page 747: ...3 Remove sealant from bolt heads 23 14 Remove bolts 23 and washers 24 15 Remove and discard o ring 25 16 Disconnect booster pump wire har nesses 10 Figure 403 as follows a Remove screw 16 from left booster pump and disconnect A111 Q12D16 wire positive terminal b Remove screw 16 from right booster pump and disconnect A112 Q13C16 wire positive terminal c Remove screw 17 from left booster pump push u...

Page 748: ...als Ref CSP SPM Item Nomenclature C207 Sealing Compound Fuel Resistant C109 Grease Special Tools Ref CSP SPM Item Nomenclature T801 Fuel Cell Rod 1 Remove all unwanted material from fuel cell space NOTE If fuel cell is new do the steps that fol low before you install fuel cell 2 Install fuel drain valves 3 Install fuel supply hoses clamps screws and washers Torque screws 4 Install centrifugal fuel...

Page 749: ...tall flexible coupling 8 16 Install fuel cell frangible valves 17 Install single and dual vent rollover valves 18 Install forward and aft fuel quantity probes 19 Connect forward and aft fuel sump drain valve controls 20 Connect booster pump wire harness 10 Ref Figure 403 as follows a Install A111 Q12D16 wire and screw to left booster pump positive terminal Torque screw b Install A112 Q13C16 wire a...

Page 750: ...55 A160 AL165 AR165 A170 A217 AL230 and AR230 Ref Section 53 20 00 24 Install panel B178 Ref Section 06 00 00 25 Do the fuel cell leak check pressure test 26 Do the fuel quantity indicating system functional test 27 If necessary install carpet Ref Section 25 20 00 28 If necessary install cabin seats Ref Section 25 20 00 ...

Page 751: ...nance Manual Page 405 Revision 14 28 00 00 9G28 022 1C 1 2 3 11 18 17 11 10 9 6 7 5 8 17 14 16 15 16 12 13 12 FUEL CROSSFEED SYSTEM REMOVED ON 900 CONFIG HELICOPTERS CONVERTED TO PW207E ENGINES NOTE NOTE Figure 401 Fuel System 900 CONFIG Sheet 1 of 3 ...

Page 752: ...SP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 406 Original 28 00 00 14 16 15 16 12 2 PL 7 6 17 5 3 4 11 2 1 17 11 10 18 9 8 9G28 022 2A Figure 401 Fuel System 902 CONFIG Sheet 2 of 3 ...

Page 753: ...SSEMBLY 6 CENTRIFUGAL FUEL BOOSTER PUMP 7 FUEL SUPPLY CHECK VALVE 8 FORWARD FUEL GAUGING PROBE 9 AFT FUEL GAUGING PROBE 10 FUEL CELL FRANGIBLE VALVE 11 SINGLE VENT ROLLOVER VALVE 12 FUEL PRESS SWITCH INTERCONNECT TEE FITTING 13 CROSS FEED SHUT OFF VALVE 14 LH FUEL SHUT OFF VALVE 15 RH FUEL SHUT OFF VALVE 16 ENGINE DECK FRANGIBLE VALVE 17 DUAL VENT ROLLOVER VALVE 18 FUEL VENT SYSTEM 19 SCREW 20 WAS...

Page 754: ...al bonding Ref CSP SPM Grease C109 2 Lubricate O rings 4 with grease C109 and install on fuel cell cover 3 3 Install fuel cell access cover 3 on fuel cell 4 Attach electrical bonding jumper 5 in original location on fuel cell cover with bolt 1 and washer 2 5 Install remaining bolts 1 and washers 2 Torque bolts Sealing Compound C207 6 Apply sealing compound C207 over bonding jumper area attachment ...

Page 755: ... A111 Q12D16 wire from left booster pump positive terminal A112 Q13C16 wire from right booster pump positive terminal b Remove hex head screw 17 push up on shut off lever arm so screw will turn freely Disconnect A111 Q35A16N and Q35B16 wire from left booster pump negative terminal A112 Q36A16N and Q36B16 wire from right booster pump negative terminal 8 Remove and discard lockwire Remove bleeder dr...

Page 756: ...cal bond Ref CSP SPM Finish Enamel Black C303 2 Paint alignment stripe on fuel booster pump at same location as removed pump use black finish enamel C303 Grease C109 3 Lubricate packing with grease C109 and install on fuel booster pump Do not touch or damage red um brella shaped check valve on top of fuel booster pump Fuel booster pump failure can occur 4 S N 0008 0032 Carefully install fuel boost...

Page 757: ...ooster pump as follows a Lubricate packing with grease C109 and install on reducer b Install reducer Torque reducer 380 405 in lb 42 9 45 8 Nwm c Install tee Torque tee 230 260 in lb 26 29 4 Nwm d Install reducer and tube nut Torque tube nut 230 260 in lb 26 29 4 Nwm e Connect tube Torque tube nut 50 65 in lb 5 65 7 34 Nwm 13 Connect fuel hose Torque fuel supply hose nut 230 260 in lb 26 29 4 Nwm ...

Page 758: ... 28 1 FUEL HOSE 2 FUEL BOOSTER PUMP 3 FUEL SUPPLY CHECK VALVE 900 CONFIG PW206A 4 PACKING 900 CONFIG 5 REDUCER BUSHING 900 CONFIG 6 PACKING 900 CONFIG 7 BOLT 8 WASHER 9 PACKING 10 WIRE HARNESS A111 LEFT A112 RIGHT 11 PACKING 12 BLEEDER DRAIN PLUG 13 PACKING 14 BLEEDER DRAIN PLUG 15 BOLT 16 SCREW 17 HEX HEAD SCREW 18 SUPPORT RING 19 LAMINATED SHIM 20 BOLT 21 BOLT 22 UNION 900 CONFIG WITH PW206E PW2...

Page 759: ...al A112 Q36A16N and Q36B16 wire from right booster pump negative terminal Aviation Turbine Fuel 3 Rotate fuel shut off lever arm 180 out of the way of the pump cartridge This lever shuts off fuel to the pumping cavity Upon removal of the pump cartridge approximately 1 pint 0 473 liters of fuel will be lost Drain fuel into suitable container 4 Remove and discard lockwire securing bleeder drain plug...

Page 760: ...cartridge Torque bleeder drain plug 7 7 Secure bleeder drain plug 7 with lockwire C702 8 Rotate fuel shut off lever arm 180 to align with the pump cartridge negative terminal 9 Visually check for fuel leaks Do not over torque terminal screws 10 Attach wire harness 10 Ref Figure 403 a Attach short straight slot screw 16 and A111 Q12D16 wire to left booster pump positive terminal A112 Q13C16 wire to...

Page 761: ...on 12 00 00 2 Remove cabin seats if applicable Ref Section 25 20 00 3 Remove carpet if applicable Ref Section 25 20 00 4 Remove cabin floor panels AL165 AR165 A170 Ref Section 53 20 00 System Contamination 5 Remove LH forward fuel cell access cover Ref Section 28 00 00 6 Remove sump access panel assembly B178 Ref Section 06 00 00 7 900 CONFIG Detach forward fuel gauging probe connector P1 A104 6 f...

Page 762: ...Ref Section 28 00 00 NOTE Fuel helicopter Ref Section 12 00 00 in conjunction with fuel quantity indicating system functional test 10 Perform fuel quantity indicating system functional test Ref Section 28 00 00 11 Install carpet if applicable Ref Section 25 20 00 12 Install cabin seats if applicable Ref Section 25 20 00 6 Aft Fuel Gauging Probe A Aft Fuel Gauging Probe Removal Ref Figure 405 Aviat...

Page 763: ...7 Install sump access panel assembly B178 Ref Section 06 00 00 8 Install cabin floor panels AL165 AR165 A170 Ref Section 53 20 00 9 Perform fuel cell leak check pressure test Ref Section 28 00 00 NOTE Fuel helicopter Ref Section 12 00 00 in conjunction with fuel quantity indicating system functional test 10 Perform fuel quantity indicating system functional test Ref Section 28 00 00 11 Install car...

Page 764: ...7 4 PL 1 FORWARD LEFT SIDE FUEL GAUGING PROBE 2 AFT RIGHT SIDE FUEL GAUGING PROBE 3 FUEL BOOSTER PUMP 4 HOSE ASSEMBLY BOOSTER TO FUEL CELL OUTLET 5 TEE 6 PACKING 7 REDUCER 8 PACKING 9 REDUCER 10 TUBE NUT 11 BRACKET ASSEMBLY 12 BOLT 13 WASHER 14 CLAMP 15 BOLT 16 SPACER 17 WASHER 18 CHECK VALVE 19 PACKING 20 BUSHING 21 PACKING 22 JET PUMP 23 TUBE ASSEMBLY BOOSTER TO JET PUMP 24 TUBE ASSEMBLY JET PUM...

Page 765: ...Item Nomenclature C109 Grease C229 Sealant Conductive 1 Prepare filler neck surface for electrical bonding Ref CSP SPM Sealant Conductive C229 2 Apply sealant C229 between range extender if installed fuel filler neck flange and fuselage faying surfaces Ref CSP SPM 3 Install bolts 3 and washers 4 through range extender if installed filler neck flange 5 and aircraft outer skin Torque bolts Grease C1...

Page 766: ...epare fill port check valve assembly and fuel cell fitting faying surfaces for electrical bonding Ref CSP SPM Grease C109 2 Lubricate O ring 11 with grease C109 and install on check valve assembly 14 3 Align check valve to correct orientation marked UP on valve Install check valve assembly in fuel cell with nuts 13 and washers 12 Torque nuts 4 Connect check valve lanyard 2 to fuel filler cap lanya...

Page 767: ... INBD RIGHT SIDE 902 CONFIG 1 FUEL FILLER CAP 2 LANYARD 3 BOLT 4 WASHER 5 FILLER NECK FLANGE 6 GRAVITY FILLER NECK 7 O RING 8 FLEXIBLE COUPLING 9 FUEL CELL FITTING 10 O RING 11 O RING 12 WASHER 13 NUT 14 CHECK VALVE ASSEMBLY 15 CENTER BAFFLE CHECK VALVE 902 CONFIG 16 RETAINER PACKING BACKUP Figure 407 Gravity Fill Port Filler Neck and Check Valve ...

Page 768: ...ture C229 Sealant Conductive 1 Prepare range extender and fuel filler neck surfaces for electrical bonding Ref CSP SPM Sealant Conductive C229 2 Apply sealant C229 between range extender flange 6 fuel filler neck flange 5 and fuselage faying surfaces Ref CSP SPM 3 Install bolts 3 and washers 4 through range extender flange 6 fuel filler neck flange 5 and aircraft outer skin Torque bolts 4 Connect ...

Page 769: ...onding jumpers 3 from float rollover valve System Contamination 7 Remove remaining bolts 5 and washer 6 attaching float rollover valve 8 to fuel cell 8 Remove float rollover valve and discard O ring 9 B Single Port Fuel Vent Float Rollover Valve Installation Ref Figure 409 NOTE This task is typical for LH aft and RH forward Single Port Fuel Vent Float Rol lover Valve installation except where note...

Page 770: ...n 53 20 00 Ref Section 53 20 00 10 Perform fuel cell leak check pressure test Ref Section 28 00 00 11 Install carpet if applicable Ref Section 25 20 00 12 Install cabin seats if applicable Ref Section 25 20 00 13 Fuel helicopter Ref Section 12 00 00 1 2 3 4 5 6 7 8 9 9 2 1 3 5 6 8 RIGHT HAND FWD LEFT HAND AFT 7 9G28 019 1 BOLT 2 WASHER 3 ELECTRICAL BONDING JUMPER 4 PLUG 5 BOLT 6 WASHER 7 VENT HOSE...

Page 771: ...ansition duct from float rollover valve and elbow duct 10 and remove from bulkhead 7 Remove bolt 1 and washer 2 and disconnect electrical bonding jumpers 3 from float rollover valve 8 System Contamination 8 Remove remaining bolts 6 and washers 7 attaching float rollover valve to fuel cell 9 Remove float rollover valve and discard O ring 9 B Dual Port Fuel Vent Float Rollover Valve Installation Ref...

Page 772: ...r C242 to faying surfaces and allow to dry NOTE If necessary float rollover valve bolts can be loosened to allow transition duct installation Retorque bolts after installa tion e Apply sealing compound C206 to faying surfaces Install transition duct and grommet through bulkhead and connect to float rollover valve and elbow duct Allow sealing compound to cure before fueling aircraft 9 Apply sealing...

Page 773: ...IDE S N 0033 SUBS AND PRIOR BY MODIFICATION AFT RIGHT SIDE AND EARLY MODEL FORWARD LEFT SIDE 11 10 12 12 1 BOLT 2 WASHER 3 ELECTRICAL BONDING JUMPER 4 VENT TUBE ASSEMBLY 5 VENT HOSE 6 BOLT 7 WASHER 8 DUAL VENT ROLLOVER VALVE 9 O RING 10 ELBOW DUCT 11 TRANSITION DUCT 12 EDGE GROMMET Figure 410 Dual Port Fuel Vent Float Rollover Valve ...

Page 774: ...uct and grommets b Disconnect transition duct from float rollover valve and elbow duct and remove from bulkhead c Disconnect elbow duct from transi tion duct and fuel vent hose and remove from bulkhead B Fuel Vent Components Installation Ref Figure 411 NOTE This task is typical for Fuel Vent Sys tem Components installation Consumable Materials Ref CSP SPM Item Nomenclature C206 Sealing Compound C2...

Page 775: ... Apply sealing compound C206 to faying surfaces e Install elbow duct and grommet through bulkhead Connect fuel vent to elbow duct Secure with lockwire C702 f Install transition duct and grommet through bulkhead and connect to float rollover valve and elbow duct Allow sealing compound to cure before fueling aircraft 6 Install cabin floor panels AL155 AR155 A160 AL165 AR165 A170 A217 AL230 AR230 Ref...

Page 776: ...E ASSEMBLY 2 STAND PIPE ASSEMBLY FWD 3 FLAME ARRESTOR 4 STAND PIPE ASSEMBLY AFT 5 FUEL VENT HOSE 6 FUEL VENT FAIRING 7 SCREW 8 WASHER 9 BONDING CLAMP 10 BONDING JUMPER 11 LOCKING WASHER 12 NUT 13 SCREW 14 WASHER 15 CUSHIONED CLAMP 16 BRACKET ANGLE WITH NUT 17 THREADED STANDOFF COMPOSITE BASE 18 SINGLE VENT ROLLOVER VALVE 19 DUAL VENT ROLLOVER VALVE 20 STAND PIPE ASSEMBLY FWD 21 TRANSITION DUCT 22 ...

Page 777: ...n fuel drain valve 9 2 Install fuel drain valve in fuel cell Torque drain valve 3 Insert forward drain control cable assembly 3 or aft drain control cable assembly 4 into drain valve Install bolt 7 washer 6 and clamp 5 Torque bolt 4 Install rubber tubing C608 10 on drain valve and secure with lockwire C702 5 Install sump access panel assembly B178 Ref Section 06 00 00 6 Fuel helicopter Ref Section...

Page 778: ...sembly 4 Torque bolt Sealing Compound C206 4 Apply sealing compound C206 to form a fillet seal around control cable assembly flange and helicopter skin Ref CSP SPM 5 Fasten control cable assembly to outer skin of helicopter with screws 1 and washers 2 Torque screws 6 Apply sealing compound C206 over heads of screws Ref CSP SPM 7 Install sump access panel assembly B178 and close fuel drain access p...

Page 779: ... ers and flange surfaces of frangible valve flange junction with keel beam Ref CSP SPM 10 Remove bolts 7 and washers 8 attaching vapor shroud to keel beam and fuel cell NOTE During removal of frangible valve take precaution to retain gasket 14 between fuel cell outlet fitting and keel beam 11 Remove vapor shroud 1 and spacer 11 from frangible valve 3 hose assembly 12 Disconnect fuel hose assembly ...

Page 780: ...hing vapor shroud to keel beam and fuel cell Torque bolts Sealing Compound C205 9 Apply sealing compound C205 to faying surfaces of vapor shroud and keel beam and heads of bolts Ref CSP SPM 10 Connect frangible valve 3 hose assembly to fuel interconnect tee fitting 4 Torque hose nut Grease C109 11 Lightly lubricate shroud box tube end with grease C109 and connect vapor shroud hoses 1 to vapor shro...

Page 781: ... REF FUEL CELL 9G28 011 REF KEEL BEAM 902 CONFIG 2 1 FUEL LINE VAPOR SHROUD 2 VAPOR SHROUD BOX 3 FRANGIBLE VALVE HOSE ASSEMBLY 4 INTERCONNECT TEE FITTING 5 DRAIN TUBING CONNECTOR 6 RUBBER TUBING C606 7 BOLT 8 WASHER 9 BOLT 10 WASHER 11 VAPOR SHROUD SPACER 12 FUEL HOSE ASSEMBLY 13 O RING 14 GASKET Figure 413 Fuel Cell Frangible Valve ...

Page 782: ...lockwire remove shroud box cap 17 and remove tube fitting cap 18 from interconnect tee fitting if replacing fitting 10 Remove bolts 3 and washers 4 attaching fuel interconnect tee fitting 10 to vapor shroud box 9 Remove fuel interconnect tee fitting B Fuel Interconnect Tee Fitting Installation Ref Figure 414 NOTE This task is typical for LH and RH Fuel Interconnect Tee Fitting installation Consuma...

Page 783: ...00 16 Perform fuel supply vapor shroud leak check pressure test Ref Section 28 00 00 17 Close baggage compartment door L262 Ref Section 06 00 00 18 Fuel helicopter Ref Section 12 00 00 17 Fuel Pressure Switch Assembly A Fuel Pressure Switch Assembly Removal Ref Figure 414 NOTE This task is typical for LH and RH Fuel Pressure Switch removal Aviation Turbine Fuel 1 Defuel helicopter Ref Section 12 0...

Page 784: ...or shroud box 9 and vapor shroud box cover 2 surface for electri cal bonding Ref CSP SPM Grease C109 3 Lubricate O ring 11 lightly with grease C109 and install on fuel pressure switch assembly 12 4 Install fuel pressure switch assembly 12 with vapor shroud box cover 2 in fuel interconnect tee fitting 10 Torque fuel pressure switch Sealant Electrically Conductive C230 5 Apply sealant C230 to faying...

Page 785: ...ask is typical for LH and RH Fuel Shut Off Valve Assembly removal Aviation Turbine Fuel Make sure shut off valve is in OPEN position Take precau tions to catch residual fuel when removing shut off valve 1 Open baggage compartment door L262 Ref Section 06 00 00 2 Remove baggage compartment interior trim roof insulation panel Ref Section 25 50 00 3 Remove left Electronic Engine Control EEC Ref Secti...

Page 786: ... 60 00 Fluorosilicone Compound C222 d Apply fluorosilicone compound C222 to back of connector and wires and allow to cure 2 Prepare vapor shroud box 5 and fuel shut off valve 8 surface for electrical bonding Ref CSP SPM Sealant Electrically Conductive C230 3 Apply sealant C230 to faying surface between vapor shroud box assembly 5 and structural bulkhead Ref CSP SPM 4 Install fuel shut off valve as...

Page 787: ...900 CONFIG A Crossfeed Fuel Shut Off Valve Assembly Removal Ref Figure 416 Aviation Turbine Fuel 1 Defuel helicopter Ref Section 12 00 00 2 Open baggage compartment door L262 Ref Section 06 00 00 3 Remove baggage compartment floor panels A235 AL250 AR250 Ref Section 53 20 00 4 Remove and discard lockwire and detach connector 1 from crossfeed fuel shut off valve cover assembly 8 5 Remove bolts 2 an...

Page 788: ... surface for electrical bonding Ref CSP SPM Sealant Electrically Conductive C230 3 Apply sealant C230 to faying surface between vapor shroud box assembly 10 and structure Ref CSP SPM 4 Install crossfeed fuel shut off valve assembly 9 in vapor shroud box 10 with bolts 4 and washers 5 Torque bolts 5 Connect hose assemblies 6 and 7 to fittings on crossfeed fuel shut off valve assembly 9 Torque hose n...

Page 789: ...ansmis sion access door assembly L210 or R210 Ref Section 06 00 00 3 Remove cabin roof panels Ref Section 25 20 00 Residual Fluids System Contamination 4 900CONFIG Disconnect male ratcheting fitting of engine fuel feed hose 1 from frangible valve 2 fitting Pull back on end to disengage ratchet then unscrew 5 902 CONFIG Disconnect engine fuel feed hose a Remove and discard lockwire from engine fuel...

Page 790: ... with lockwire C702 6 Perform fuel booster pump operational test Ref Section 28 00 00 and check for fuel leakage Sealing Compound C207 Release Agent C417 7 Verify the integrity of sealing compound C207 seal on vapor shroud box flanges part of fuselage structure If there are voids in seal repair or replace as follows a Apply sealing compound C207 to vapor shroud box flanges as required Ensure that ...

Page 791: ...5 RIGHT HAND LEFT HAND 8 9 HAND TIGHTEN HAND TIGHTEN 9G28 007A 4 6 4 9 REF FUSELAGE STRUCTURE REF FUSELAGE STRUCTURE 1 MALE RATCHETING FITTING 2 ENGINE DECK FRANGIBLE VALVE 3 VAPOR SHROUD COVER ASSEMBLY 4 BOLTS 5 WASHER 6 FUEL TUBE LINES 7 BOLT 8 WASHER 9 O RING Figure 417 Engine Deck Frangible Valves 900 CONFIG ...

Page 792: ... duct from top of FMU vapor shroud box e Open FMU vapor shroud box f Remove and discard lockwire from vapor shroud hose 4 Disconnect vapor shroud hose g Remove and discard lockwire and disconnect lower end of engine fuel feed hose 3 from frangible valve 2 fitting h Disconnect upper end of fuel feed hose assembly from engine driven fuel pump elbow fitting i Remove fuel feed hose assembly with vapor...

Page 793: ...28 00 00 and check for fuel leakage g Connect vapor shroud hose and secure with lockwire C702 h Close FMU vapor shroud box 5 i Install screws attaching FMU fuel shroud box to FMU connector j Connect vapor shroud duct to top of FMU vapor shroud box Secure vapor shroud duct with lockwire C702 k Perform fuel supply vapor shroud leak check pressure test Ref Section 28 00 00 l Install aft swashplate fa...

Page 794: ... lockwire Disconnect LH or RH vapor shroud hose 1 2 from LH or RH fuel interconnect tee fitting vapor shroud box 3 4 and LH or RH fuel shut off valve vapor shroud box 5 6 b Pull vapor shroud hose back and disconnect upper end of LH or RH engine feed tube assembly 7 8 from union 12 c Disconnect lower end of LH or RH engine feed tube assembly 7 8 from LH or RH fuel interconnect tee fitting 9 10 d Re...

Page 795: ... shroud box cover surface for electrical bonding Ref CSP SPM 3 Apply sealant C230 to faying surfaces between vapor shroud box cover and vapor shroud box and install vapor shroud box cover assembly with bolts 19 and washers 18 Torque bolts 4 Fuel helicopter if necessary Ref Section 12 00 00 5 Install electrical load center Ref CSP 900RMM 3 Section 96 00 00 6 Install hinged avionic shelf Ref Section...

Page 796: ...nd Shrouds Installation Ref Figure 419 NOTE This task is typical for LH and RH low er fuel supply hoses and shrouds Consumable Materials Ref CSP SPM Item Nomenclature C207 Sealing Compound Fuel Resistant C230 Sealant Electrically Conductive C702 Lockwire 1 Install lower fuel supply hose NOTE Orient spacer slot down on horizontal runs or aft on vertical runs a Install spacers 17 on LH or RH fuel su...

Page 797: ...uel supplemental fuel tank Ref Section 12 00 00 2 Open baggage compartment door L262 Ref Section 06 00 00 3 Remove baggage compartment floor panels A235 AR250 AL250 Ref Section 53 20 00 4 Remove supplemental fuel tank Ref Section 28 10 00 5 Remove forward supplemental fuel tank foam supports Ref Section 28 10 00 6 Remove lower fuel supply hose a Remove vapor shroud box cover assemblies from LH or ...

Page 798: ... Ref CSP SPM f Connect LH or RH vapor shroud hose 21 22 to LH or RH interconnect tee fitting vapor shroud box 3 4 Secure vapor shroud hose with lockwire C702 g Install cushioned support clamp 16 around fuel supply vapor shroud hose at location of center spacer with bolt 25 washers 14 and nut 15 Torque nut Ref CSP SPM Sealing Compound C205 h Install modified grommet 29 into end of vapor shroud with...

Page 799: ... Revision 14 28 00 00 23 20 23 12 7 LH 8 RH 16 17 23 25 14 14 15 16 14 14 13 17 15 21 2 7 LH 8 RH 22 24 18 19 18 19 18 19 9 LH 10 RH 6 5 1 4 11 3 9G28 025 1C 900 CONFIG PW206A 900 CONFIG PW206A 900 CONFIG PW206A Figure 419 Fuel Supply Tubes Hoses and Shrouds Sheet 1 of 3 ...

Page 800: ...RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 454 Revision 14 28 00 00 9G28 025 2A 902 CONFIG 900 CONFIG PW206E 900 CONFIG PW207E 26 27 Figure 419 Fuel Supply Tubes Hoses and Shrouds Sheet 2 of 3 ...

Page 801: ...OTE 4 NOTE 3 NOTE 4 NOTES 1 FUEL COMPARTMENT OVERBOARD VENT AND ALL REMOVABLE HARDWARE IS REMOVED 2 PREPARED FOR ELECTRICAL BOND 3 SEALANT 4 CROSSFEED VALVE SHROUD BOX BOX COVER BOX DRAIN AND ALL REMOVABLE HARDWARE IS REMOVED 5 ONE FLANGE OF GROMMET IS REMOVED 900 CONFIG WITH SUPPLEMENTAL FUEL SYSTEM VIEW LOOKING FORWARD Figure 419 Fuel Supply Tubes Hoses and Shrouds Sheet 3 of 3 ...

Page 802: ...POR SHROUD BOX CROSSFEED VALVE 900 CONFIG PW206A 12 UNION FITTING 13 PAN HEAD BOLT 14 WASHER 15 NUT 16 CUSHIONED SUPPORT CLAMP 17 SPACER 18 WASHER 19 PAN HEAD BOLT 20 CROSSFEED SHUT OFF VALVE 900 CONFIG PW206A 21 LOWER LH VAPOR SHROUD HOSE 900 CONFIG PW206A 22 LOWER RH VAPOR SHROUD HOSE 900 CONFIG PW206A 23 LOWER LH FUEL SUPPLY HOSE ASSEMBLY 900 CONFIG PW206A 24 LOWER RH FUEL SUPPLY HOSE ASSEMBLY ...

Page 803: ...enance Manual Page 457 Revision 1 28 00 00 9G28 040 1 WL 147 003 2 3 2 3 6 3 WL 146 560 WL 146 560 2 30 25 50 WL 147 000 2 30 25 50 WL 101 000 WL 101 000 10 7 13 3 LOOKING FWD 2 3 Figure 420 Fuel Supply Tube Spacer Installation Location Sheet 1 of 2 ...

Page 804: ...emove end cap 2 from housing 1 2 Remove spring 3 poppet 4 O ring 5 and static seal 6 Discard O ring and static seal Alcohol Isopropyl C419 3 Clean components with isopropyl alcohol C419 4 Inspect components for contamination None allowed 5 Inspect poppet for damage None allowed 6 Inspect the surfaces that the O ring and static seal seat against for damage None allowed B Assembly 1 Wipe clean the s...

Page 805: ...ressure to 30 psig 207 kPa Alcohol Isopropyl C419 3 Submerge check valve in isopropyl alcohol C419 or suitable fluid 4 Check for air leakage None allowed 5 Connect the manometer T2014 4 between the pressure source and the end cap 2 Alcohol Isopropyl C419 6 Submerge check valve in isopropyl alcohol C419 or suitable fluid NOTE Check for air flow from outlet port while you apply pressure 7 Slowly app...

Page 806: ...obstruction from orifice 3 Alcohol Isopropyl C419 3 Clean the ejector tube 2 nozzle assembly 1 and orifice 3 with isopropyl alcohol C419 4 Inspect nylon thread locking pellet 4 for condition and security If nylon thread locking pellet is unserviceable replace jet pump B Jet Pump Assembly Ref Figure 422 NOTE Make sure there is friction from the ny lon thread locking pellet If there is no fric tion ...

Page 807: ... probe electrical connector for serviceable condition bent or broken pins frayed or broken wires a Repair or replace components as necessary 7 Open Access Panel R185 ref Section 06 00 00 8 Do a check of the drain valve control cable for correct operation and freedom of movement 9 Examine the sump drain valves for leakage a No leakage of fuel from the sump drain valves is permitted for 5 minutes af...

Page 808: ...the prop er installation of the cell Do periodic inspections to find indications of fuel vent system failure or leakage Aviation Turbine Fuel NOTE Do a Fuel Cell Leak Check Pressure Test to find leaks in the fuel system If the pressure test does not indicate leakage a visual inspection is not necessary Do a fuel cell internal visual inspection when floor panels are removed for other maintenance If...

Page 809: ...panels AL155 AR155 A160 AL165 AR165 A170 A217 AL230 and AR230 ref Section 53 20 00 NOTE Use installation tool T801 through hole in the cabin floor panel to lift the top of the fuel cell for installation of screws to support the fuel cell to floor panel Install the vapor seal plug in the floor panel hole ref Section 53 20 00 As an alternate method use high grade steel all thread rods with large sur...

Page 810: ...d bulkhead as required ref Section 25 10 00 and interior trim panel aft bulkhead station 230 0 right side as required ref Section 25 20 00 5 Do an inspection of the fuel vent tubes a Examine the fuel vent tubes for cracks dents nicks and corrosion b Examine the hose connections for cracks cuts tears punctures and collapsed hoses c Examine the installation of the clamps d No damage is permitted e R...

Page 811: ... installation 1 Repair or replace components as necessary e Close Access Panel L210 or R210 ref Section 06 00 00 B Inspection of the Vapor Shroud Box Cover Assembly and Vapor Shroud Hose Aviation Turbine Fuel 1 Open Access Door L262 ref Section 06 00 00 The rotorcraft must be defueled before both access panels AL165 and AR165 are removed Structural damage can occur if both of these panels are re m...

Page 812: ...LUG OPENINGS 56 INCH 142 24 CM 28 INCH 71 12 CM 0 INCH 0 00 CM TO MANOMETER MANOMETER ADAPTER PLUG SHUTOFF VALVE 2 5 PSIG REGULATOR FILTER 10 MICRON FILTER PRESSURE GAUGE REGULATED OUTLET VALVE TAPE OR PLUG OPENING 9G28 043 2B SUPPL Y AIR IN PREFERRED METHOD SHUTOFF VALVE T FITTING Figure 601 Fuel Cell Leak Check Pressure Test Method 1 ...

Page 813: ...re that all fuel lines have been connected 4 Make sure there is no damage to the fuel system components The FUEL SHUTOFF valve switch arms the fire extinguish ing system Make sure BOTTLE DIS CHARGE switch is set in the OFF position 5 Make sure that the LH and RH engine fuel shut off valves are in the CLOSED position on the FUEL SYSTEM control panel 6 Make sure the fuel filler cap is tight 7 Plug c...

Page 814: ...leak a Open Access Panel R185 ref Section 06 00 00 b Do a test of the fuel drain valves c Remove Access Panel B178 ref Section 06 00 00 d Do a test of the fuel pumps fuel gauging probes and fuel drain valves e Remove the interior trim panels of Station 155 left forward bulkhead as required ref Section 25 10 00 f Remove the interior trim panel aft of the bulkhead Station 230 0 right side as require...

Page 815: ...elf Make sure access panels A160 A170 and A217 are installed before you apply air pressure 24 Examine all fittings and components for leaks a Tighten loose fittings replace dam aged seals or components as neces sary b Do the fuel cell leak check pressure test again 25 If the test is successful slowly release the air pressure from the fuel cell 26 Remove adapter from auxiliary fuel port 27 Install ...

Page 816: ...42 24 CM 28 INCH 71 12 CM 0 INCH 0 00 CM TO MANOMETER MANOMETER SHUTOFF VALVE 2 5 PSIG REGULATOR FILTER 10 MICRON FILTER PRESSURE GAUGE REGULATED OUTLET VALVE TAPE OR PLUG OPENINGS 9G28 043 1B SUPPL Y AIR IN ALTERNATE METHOD SHUTOFF VALVE T FITTING Figure 602 Fuel Cell Leak Check Pressure Test Method 2 ...

Page 817: ...UEL SHUTOFF valve switch arms the fire extin guishing system Make sure BOTTLE DIS CHARGE switch is OFF 5 Make sure that the LH and RH engine fuel shut off valves are in CLOSED position on the FUEL SYSTEM panel 6 Make sure the fuel filler cap is tight 7 Plug cap or tape shut the aft fuel vent system outlet vent fairing Make sure access panels A160 A170 and A217 are installed ref Section 53 20 00 be...

Page 818: ...e Access Panel A235 ref Section 53 20 00 NOTE If an air conditioning condenser exit screen is installed use the exit screen for ac cess instead of Access Panel A235 Leave one screw loosely installed m Do a test of the vent connections and vapor shroud system and fuel supply system if necessary n Do the vapor shroud press test 1 If necessary correct leaks in vapor shroud system 2 Put caps on the va...

Page 819: ...craft Maintenance Manual Page 613 Revision 34 28 00 00 23 Disconnect the test equipment 24 Remove the plug cap or tape from the aft fuel vent system outlet vent fairing 25 Install access panels A160 A170 A217 and AR165 ref Section 53 20 00 ...

Page 820: ...enance Manual Page 614 Revision 34 28 00 00 9G28 035 1 CAP PLUG OR CLAMP SHUT CAP PLUG OR CLAMP SHUT CAP PLUG OR CLAMP SHUT CAP PLUG OR CLAMP SHUT APPLY AIR PRESSURE Figure 603 Fuel Supply Vapor Shroud Leak Check Pressure Test 900 CONFIG Sheet 1 of 2 ...

Page 821: ...quid Special Tools Ref CSP SPM Item Nomenclature T2014 4 Manometer T2014 5 Adapter T2014 6 Regulator Air Pressure The rotorcraft must be defueled before both access panels AL165 and AR165 are removed Structural damage can occur if both of these panels are re moved with fuel in the rotorcraft Panel AL165 or AR165 can be removed individual ly without a defuel of the rotorcraft 1 Pre TB900 003 Remove...

Page 822: ...menclature T2014 4 Manometer T2014 5 Adapter T2014 6 Regulator Air Pressure NOTE This functional test is typical for LH or RH Fuel Vapor Shroud System Repeat test for the opposite side fuel vapor shroud sys tem The rotorcraft must be defueled before both access panels AL165 and AR165 are removed Structural damage can occur if both of these panels are re moved with fuel in the rotorcraft Panel AL16...

Page 823: ... Inc Rotorcraft Maintenance Manual Page 617 Revision 34 28 00 00 7 Pre TB900 003 Install access panels AL165 AR165 A235 AL250 and AR250 ref Section 53 20 00 Post TB900 003 Install access panels L211 and R211 ref Section 06 00 00 ...

Page 824: ...0 00 APPLY AIR PRESSURE CAP PLUG OR CLAMP SHUT CAP PLUG OR CLAMP SHUT APPLY AIR PRESSURE AIRFRAME FUEL FILTER OPTION SHOWN CAP PLUG OR CLAMP SHUT CAP PLUG OR CLAMP SHUT APPLY AIR PRESSURE APPLY AIR PRESSURE 9G28 054A Figure 604 Fuel Supply Vapor Shroud Leak Check Pressure Test 902 CONFIG ...

Page 825: ...20 00 Post TB900 003 Remove access panels L211 and R211 ref Section 06 00 00 5 Disconnect the left or right vapor shroud drain hose 0 250 in ID rubber hose from the engine drain hose tee fitting 6 Plug or clamp shut the drain hose 7 Apply and maintain a constant 0 2 0 7 psig 1 38 kPa or 4 0 to 8 0 inch 10 2 to 20 3 cm of water regulated air pressure to the left or right fuel cell frangible valve o...

Page 826: ...shing system is NOT installed disregard caution relating to fire bottle discharge in operational test a On the FUEL SYSTEM panel 1 Make sure the FUEL SHUTOFF BOTTLE DISCHARGE switch is set to OFF 2 Make sure the CROSSFEED switch 900 CONFIG is set to OFF 3 Make sure the L BOOST switch is set to OFF 4 Make sure the R BOOST switch is set to OFF b On the IIDS display observe 1 Right engine fuel pressu...

Page 827: ...ed 2 900 CONFIG Crossfeed valve segment white is illuminated 3 Right engine fuel pressure seg ments white are illuminated k On the FUEL SYSTEM panel 1 900 CONFIG Set the CROSS FEED switch to OFF 2 Set the L BOOST switch to ON l On the IIDS display observe 1 Left engine fuel pressure segments white are illuminated 2 900 CONFIG Crossfeed valve segment white is not illuminated 3 Right engine fuel pre...

Page 828: ...ITION WHITE FUEL SHUTOFF VALVE YELLOW NOTE FUEL SHUTOFF VALVE YELLOW NOTE ÍÍ ÍÍ D INDICATES LOW FUEL PRESSURE ON BOTH FUEL BOOSTER PUMPS OR BOTH BOOSTER PUMPS IN OFF POSITION RED GREEN LOW FUEL WARNING TICK RED LOW FUEL CAUTION SEGMENT YELLOW FUEL QUANTITY SEGMENTS FUEL QUANTITY DIGITAL DISPLAY WHITE E LOW FUEL PRESSURE LEFT BOOSTER PUMP WITH NORMAL FUEL PRESSURE ON RIGHT BOOSTER PUMP A NORMAL FUE...

Page 829: ...E YELLOW NOTE FUEL SHUTOFF VALVE YELLOW NOTE ÍÍ C INDICATES LOW FUEL PRESSURE ON BOTH FUEL BOOSTER PUMPS OR BOTH BOOSTER PUMPS IN OFF POSITION RED GREEN LEFT LOW FUEL WARNING TICK RED LOW FUEL CAUTION SEGMENT YELLOW FUEL QUANTITY SEGMENTS FUEL QUANTITY DIGITAL DISPLAY WHITE D LOW FUEL PRESSURE LEFT BOOSTER PUMP WITH NORMAL FUEL PRESSURE ON RIGHT BOOSTER PUMP A NORMAL FUEL PRESSURE WITH CROSSFEED V...

Page 830: ...ccidental engine start or fire 4 On the FUEL SYSTEM panel a Set the LEFT guarded FUEL SHUTOFF switch to ON b Set the L BOOST switch to ON c The booster pump must operate audibly 5 Make sure that the left engine low fuel pressure yellow segments on the IIDS display are not illuminated NOTE A row of white segments indicate nor mal fuel pressure and alternating white and yellow offset segments indica...

Page 831: ...he IIDS panel when the valve is in transit between the open and closed position and remain off after reach ing the open position 4 On the ELECTRICAL MASTER panel set the POWER switch to OFF C Operational Test of the Crossfeed Shut Off Valve 900 CONFIG Ref Figure 605 and Figure 606 1 On the FUEL SYSTEM panel set the CROSS FEED switch to ON a The valve must operate audibly b The white segment bar wi...

Page 832: ...inal axis between stations 155 00 and 213 00 6 Use helicopter jack T202 to jack rotorcraft evenly to get a 5 nose down simulated flight attitude on the inclinometer scale placed longitudinally on the cabin floor and level laterally across the cabin floor 7 Stabilize the rotorcraft with wooden blocks under landing gear skid tubes as required 8 For rotorcraft that are defueled add to the fuel cell 2...

Page 833: ...IC WEIGHT IN THIS EXAMPLE 6 71 SPECIFIC WEIGHT 6 71 X 2 6 U S GALLONS 17 45 LBS OF JET A FUEL AT 80 F 27 C 6 71 X 2 83 U S GALLONS 18 99 LBS OF JET A FUEL AT 80 F 27 C Figure 608 Typical Fuel Density Weight vs Temperature Fahrenheit Celsius 1 US Gallon 3 785 Liters 11 Apply 24 to 28 Vdc external power to rotorcraft 12 Make sure that IIDS and FUEL PROBE circuit breakers on ESSEN TIAL BUS panel and ...

Page 834: ...on ELEC TRICAL MASTER panel to BATT EXT 17 Add an additional 18 US gal 68 137 L to the fuel cell as measured from a calibrated fuel truck metering system 18 Alternate Method a Calculate fuel to be added by weight b Add an additional 18 US gal 68 137 L to the fuel cell 19 Make sure the FUEL low level warning tick marks red indicators are not illuminated 20 Return the aircraft to normal ground attit...

Page 835: ...reakers on ELECTRICAL LOAD CENTER panel are activated 5 Make sure the right FUEL low level warning tick mark red indicator is illuminated 6 Make sure the left FUEL low level warning tick mark red indicator is not illuminated 7 Fuel must remain on left side of fuel cell for 30 minutes without bleeding to the right side a Make sure the right FUEL low level warning tick mark red indicator continues t...

Page 836: ...ell cavity from the left keel beam flange to the right keel beam flange 2 Support the fuel cell access cover fittings so that they are 1 5 to 1 7 inch 38 to 43 mm below the bottom of the straightedge 3 Do a check of the cord tension between the grommets and hangers a The cord cannot move more than 0 25 to 0 50 inch 6 4 to 12 7 mm as measured perpendicular to the lacing b If the cord is too loose m...

Page 837: ...2 CORD 1 CORD 3 HANGER TYP FILLER NECK TOP VIEW LOOKING DOWN CENTER AFT BAFFLE FORWARD BAFFLE 18 INCH OPTIONAL CORD 1 END POINT AND CORD 5 AND CORD 4 CORD 5 CORD 4 GROMMET TYP CORD GROMMET TYP HANGER TYP 0 25 TO 0 50 INCH 6 4 TO 12 7 MM FOR WARD BAFFLE AFT BAFFLE Figure 610 Fuel Cell Baffles and Cord Routing 902 CONFIG ...

Page 838: ...00RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 632 Revision 34 28 00 00 9g28 081 GROMMET TYP TIE TIGHTEN HANGER TYP TIGHTEN BOWLINE KNOT HALF HITCH KNOT Figure 611 Bowline and Half Hitch Knots ...

Page 839: ...ft red low fuel warning tick mark illuminates ref Section 12 00 00 8 Install the filler cap ref Section 12 00 00 9 Make sure the IIDS fuel quantity display is between 173 and 213 lb 78 5 and 96 6 kg 10 Make sure the right low fuel warning tick mark is not illuminated The step that follows will arm the fire extinguishing system 11 Set the left and right FUEL SHUT OFF switches on FUEL SYSTEM control...

Page 840: ...the IIDS L BST PMP R BST PMP RH FUEL LOW and LH FUEL LOW circuit breakers on the ELECTRICAL LOAD CENTER panel are activated 8 Make sure the IIDS FUEL VLV R FUEL VLV L and FUEL PROBE circuit breakers on the ESSENTIAL BUS panel are activated 9 Remove the filler cap and secure the lanyard in the slot provided in the filler cap adapter 10 Defuel the rotorcraft until the left or right red low fuel warn...

Page 841: ...tion on the IIDS must increase 27 Wait for left low fuel warning tick mark to illuminate 28 Immediately set the R BOOST switch to OFF 29 Stop the stopwatch or timer 30 The recorded time must be less than 6 minutes 31 Set the POWER switch on the ELEC TRICAL MASTER panel to OFF 32 Remove 24 to 28 Vdc external power from the rotorcraft ref Section 96 00 00 33 Remove helicopter from wooden blocks and ...

Page 842: ...4 Make sure the FUEL LOW 900 CONFIG circuit breakers on the ELECTRICAL LOAD CENTER panel are activated 5 Set the POWER switch on the ELEC TRICAL MASTER panel to BATT EXT 6 Defuel and drain the fuel cell sump of all fuel with the rotorcraft at a normal ground attitude ref Section 12 00 00 7 Make sure the FUEL low level warning tick marks red indicators flash 8 Add 18 US gal 68 1 L to the fuel cell ...

Page 843: ...with other fuel cell manufacturers A Scuff Mark Chafing or Snag Damage 1 Scuff marks chafing or snag damage on one of the two inner liner layer or outer ply layer example layer miss ing exposed cord not damaged and adjacent area can be buffed cleaned have a layer of cement applied and be air dried for 8 hours a Repairs can be done with approved room temperature adhesives recom mended by the fuel c...

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Page 845: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 28 10 00 Supplemental Fuel System Option ...

Page 846: ......

Page 847: ...n indicator light mounted in the cockpit illuminates when the toggle switch is in the on position Fuel is transferred to the main fuel tank through a fitting in the aft left vent rollover valve mounting plate CURRENT CONFIG A one way check valve internal to the supplemental fuel tank prevents fuel from flowing from the supple mental fuel tank to the main fuel tank when the transfer pump is not on ...

Page 848: ...10 00 9G28 064 1 SUPPLEMENTAL FILLER NECK FUEL VENT VALVE EXISTING MAIN FUEL CELL FUEL VENT FLOAT ROLLOVER VALVE FUEL QUANTITY TRANSMITTER SUPPLEMENTAL FUEL CELL FUEL TRANSFER LINE FUEL TRANSFER LINE FUEL LEVEL CONTROL VALVE Figure 1 Supplemental Fuel System Installation Sheet 1 of 2 ...

Page 849: ...EXISTING AFT FLAME ARRESTOR EXISTING AFT VENT FAIRING FUEL TRANSFER LINE SUMP DRAIN PLUG TRANSFER PUMP FUEL QUANTITY TRANSMITTER FLOAT SUPPLEMEN TAL FUEL CELL CHECK VALVE GRAVITY FILL PORT GRAVITY FILL PORT AIRCRAFT DML BAGGAGE FLOOR VENT FLOAT ROLLOVER VALVE VENT LINE 230 5 BULKHEAD CHECK VALVE FUEL TRANSFER LINE AUX MAIN LEVEL CONTROL VALVE LEVEL CONTROL VALVE SUPPORT EXISTING MAIN FUEL CELL 9G2...

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Page 851: ... bond CSP SPM Obstruction in supplemental fuel transfer system Remove supplemental fuel transfer system components as required to remove obstruction 28 10 00 Faulty fuel level control valve Replace fuel level control valve 28 10 00 Faulty transfer pump Replace transfer pump 28 10 00 Fuel does not transfer into main tank with transfer switch on and transfer light Not Illuminated Faulty wiring betwe...

Page 852: ...e indicator 95 00 00 Uncommanded fuel transfer from supplemental to main tank Check valve not installed in suppelmental tank Install check valve 28 10 00 Faulty check valve in supplemental tank Replace replace check valve 28 10 00 D A 9G28 069A DS2 SP1 SEND INSTRUMENT PANEL AUX FUEL QTY IND LT A620 ELECTRICAL LOAD CENTER C FUEL XFER PUMP INDICATOR LT ON 3 AUX FUEL XMIT CB33 AUX FUEL CB61 1A 5A J2 ...

Page 853: ... Remove connector 8 from cover 7 10 Disconnect fuel transfer hose 5 from transfer pump fitting 7 Ref Figure 403 11 Remove bolts 2 washers 3 Ref Figure 401 and remove pump 1 from fuel tank 12 Remove fitting 7 and packing 73 Ref Figure 403 from transfer pump and discard packing B Supplemental Fuel Transfer Pump Installation Ref Figure 401 and Figure 403 Consumable Materials Ref CSP SPM Item Nomencla...

Page 854: ...re C702 9 Connect wire harness to transfer pump connector 10 Install support hat channel Torque bolts Ref CSP SPM 11 Install baggage floor Ref Section 53 20 00 12 Perform supplemental fuel tank leak pressure test 13 Perform supplemental fuel quantity operational test 14 Service fuel tank as required Ref Section 12 00 00 LBL 7 81 WL 93 407 9G28 074 1 2 3PL 3 3PL 4 7 5 6 8 1 TRANSFER PUMP 2 BOLT 3 W...

Page 855: ... Installation Ref Figure 402 Consumable Materials Ref CSP SPM Item Nomenclature C113 Fuel Aviation Turbine C216 Sealant Fuel Resistant Special Tools Ref CSP SPM Item Nomenclature T1002 Milli Ohm Meter Aviation Turbine Fuel NOTE Lubricate new packing with aviation turbine fuel C113 1 Install new packing onto filler neck adapter NOTE If may be necessary to remove supple mental fuel tank cover and as...

Page 856: ...System Gravity Fill Check Valve Removal Ref Figure 402 1 Remove Fuel Tank Filler Neck Adapter 14 2 Pull gravity fill check valve 19 from fuel tank through keel beam and remove 3 Remove packing 20 and discard B Supplemental Fuel System Gravity Fill Check Valve Installation Ref Figure 402 Consumable Materials Ref CSP SPM Item Nomenclature C113 Fuel Aviation Turbine Special Tools Ref CSP SPM Item Nom...

Page 857: ...ve bolts 3 and washers 4 from filler neck mounting flange 9 Remove nut ring assembly 18 and filler neck 2 B Supplemental Fuel System Filler Neck Installation Ref Figure 402 Special Tools Ref CSP SPM Item Nomenclature T1002 Milli Ohm Meter 1 Align filler neck mounting flange with hole in fuselage and install screws and washers Torque screws Ref CSP SPM 2 Slide filler hose centered over gap between ...

Page 858: ...RAVITY FILL PORT 15 BOLT HEX HEAD CLOSE TOLERANCE 16 CLAMP HOSE 17 WASHER FLAT 18 NUT RING ASSEMBLY 19 CHECK VALVE FUEL GRAVITY FILL PORT 20 PACKING PREFORMED 21 PACKING PREFORMED Figure 402 Supplemental Fuel System Filler Neck 5 Supplemental Fuel System Quantity Transmitter A Supplemental Fuel System Quantity Transmitter Removal Ref Figure 403 1 Defuel supplemental fuel tank Ref Section 12 00 00 ...

Page 859: ...fuel tank leak pressure test 7 Perform supplemental fuel quantity operational test 8 Service fuel tank as required Ref Section 12 00 00 6 Supplemental Fuel Tank Cover A Supplemental Fuel Tank Cover Removal Ref Figure 403 1 Defuel supplemental fuel tank Ref Section 12 00 00 2 Remove baggage compartment floor Ref Section 53 20 00 3 Remove bolts 18 and 33 and remove hat support channel 17 4 Disconnec...

Page 860: ...SPM 8 Using milli ohm meter T1002 test fuel tank cover for a class C electrical bond Ref CSP SPM Environmental seal is not required 9 Install quantity transmitter 10 Slide vent hose to equally cover gap between vent tubes and install lockwire C702 11 Connect wire harness to transfer pump connector 12 Install support hat channel Torque bolts Ref CSP SPM 13 Install baggage floor Ref Section 53 20 00...

Page 861: ...t allow sealant to protrude above packing 8 Allow sealant to cure completely prior to installing fuel tank 9 Carefully lower fuel tank into cavity aligning drain plug with drain hose 10 Insert vent tube into vent hose and install two wraps of lockwire C702 11 Thread loose ends of nylon cord through ferrule on fuel tank and lacing brack ets Secure cord with truckers knot 12 Connect fuel transfer ho...

Page 862: ...n valve points in direction of fuel flow in system Aviation Turbine Fuel NOTE Lubricate new packing with aviation turbine fuel C113 1 Install new check valve with new packing on bulkhead tube fitting Torque check valve Ref CSP SPM 2 Using milli ohm meter T1002 test check valve for a class S electrical bond Ref CSP SPM 3 Attach pump to auxiliary cell outlet hose to check valve Torque hose Ref CSP S...

Page 863: ...4 157 1 4 6 7 73 8 3PL 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2PL 24 2PL 27 28 74 30 32 4PL 35 36 37 38 X 2 39 40 68 41 45 46 33 4PL 34 4PL 29 5PL 67 5PL 25 20PL 26 20PL 42 2PL 43 2X 2PL 44 2PL 35 32 2PL 31 32 4PL RH KEEL BEAM REF 32 4PL 5 77 31 2PL 10 12 in lb 1 13 1 36 N m Figure 403 Supplemental Fuel System Installation Sheet 1 of 3 ...

Page 864: ...OKING DOWN LOOKING UP LOOKING DOWN LOOKING INBOARD LH SIDE FS 235 50 FS 230 50 5 48 70 49 50 71 47 69 53 72 54 55 14 52 51 53 SUPPLEMEN TAL FUEL TANK LBL 12 000 LOOKING DOWN FS 230 500 SUPPLEMEN TAL FUEL TANK CURRENT CONFIGURATION EARLY CONFIGURATION 77 79 80 47 69 78 48 70 49 Figure 403 Supplemental Fuel System Installation Sheet 2 of 3 ...

Page 865: ...ual Page 413 Revision 19 28 10 00 LOOKING OUTBOARD RH SIDE RBL 24 00 RBL 24 00 FS 230 50 9G28 065 3 56 2PL 57 58 REF 63 64 65 66 62 58 6PL 59 6PL 60 6PL 57 61 RH KEEL BEAM REF WL 104 21 2 3 9 76 75 Figure 403 Supplemental Fuel System Installation Sheet 3 of 3 ...

Page 866: ...RENT RETURN 47 NUT TUBE BULKHEAD FITTING 48 FITTING TUBE BULKHEAD 49 HOSE ASSEMBLY FUEL TRANSFER SUPPLEMENTAL TANK TO MAIN TANK 50 PLUG DRAIN SCREW THREAD 51 DRAIN HOSE SUPPLEMENTAL FUEL 52 CLAMP HOSE 53 SUPPORT FUEL TANK SUMP 54 PACKING PERFORMED O RING 55 HOSE ADAPTER 56 DOUBLER KEEL BEAM WEB 57 CLOSEOUT LOWER FUEL 58 BRACKET 59 SCREW HEX HEAD CRUCIFORM RECESS 60 WASHER FLAT 61 COVER NECK FUEL G...

Page 867: ...BOARD 3 FOAM SUPPORT AFT RH 4 FOAM SUPPORT FORWARD RH 5 FOAM SUPPORT FORWARD 6 FOAM SUPPORT LOWER RH 7 FOAM SUPPORT LOWER CENTER 8 FOAM SUPPORT LOWER SUMP 9 FOAM SUPPORT LOWER LH 10 FOAM SUPPORT FORWARD LH Figure 404 Supplemental Fuel Tank Foam Support Installation 10 Supplemental Fuel Transfer System A Supplemental Fuel Transfer System Removal Ref Figure 405 1 Defuel supplemental and main fuel ta...

Page 868: ...own after instal lation 3 Install check valve into aft LH main fuel tank vent rollover valve mounting plate Torque check valve Ref CSP SPM 4 Lubricate new packing with aviation turbine fuel C113 5 Install nut onto bulkhead elbow and install new packing onto elbow 6 Install bulkhead elbow into check valve Torque jam nut Ref CSP SPM 7 Attach fuel level control valve to support bracket Torque bolts R...

Page 869: ...er baggage floor panel Ref Section 53 20 00 23 Perform main and supplemental fuel tank leak check pressure test 9G28 066 FS 230 500 WL 104 400 2 1 3 4 5 17 4PL 18 4PL 19 4PL 20 6 7 2PL 9 16 14 4PL 15 4PL 13 8 10 11 12 7 REF 6 REF 4 REF 1 MAIN FUEL TANK 2 SUPPLEMENTAL FUEL TANK 3 HOSE SUPPLEMENTAL TANK TO MAIN TANK 4 ELBOW FUEL TRANSFER 5 VALVE VENT ROLLOVER MAIN TANK 6 CHECK VALVE 7 PACKING PREFOR...

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Page 871: ...n floor LH aft access cover AL230 Ref Section 53 20 00 4 Inspect elbow fitting at main fuel tank vent rollover valve mounting plate for evidence of leakage None allowed 5 Inspect fuel transfer hose for deteriora tion collapse kinked of loss of torque No damage allowed 6 Inspect fuel filler neck installation for evidence of fuel leakage Replace components as required Aviation Turbine Fuel System Co...

Page 872: ...Ref Section 28 00 00 7 Install cabin floor panels A170 and A217 Ref Section 53 20 00 8 Perform Fuel Cell Leak Check Pressure Test Ref Section 28 00 00 9 Fuel helicopter as required Ref Section 12 00 00 D Supplemental Fuel Cavity Inspection Aviation Turbine Fuel 1 Remove supplemental fuel tank 2 Remove supplemental fuel tank support foam 3 Inspect supplemental fuel tank and filler neck installation...

Page 873: ...ure gage and a shut off valve Ensure baggage floor is installed with a minimum of ev ery other screw 10 Ensure supplemental fuel filler cap is tightly secured 11 If new fuel cell is installed slowly apply 2 0 psig 13 8 kPa using air pressure regulator T2014 6 56 inches of water as measured on the manometer T2014 4 to the hose and hold for 10 minutes as a precautionary measure This will allow air t...

Page 874: ...fuel transfer hose 20 Reconnect vent hose to vent tube and secure with lockwire C702 21 Reconnect fuel transfer hose to elbow fitting Torque fitting Ref CSP SPM 22 Reinstall aft left main fuel tank vent rollover valve access panel AL230 Ref Section 53 20 00 23 Reinstall baggage floor panels Ref Section 53 20 00 BL 0 00 FS 235 532 1 2 2PL 3 9G28 075 1 VENT HOSE 2 LOCKWIRE 3 VENT TUBE Figure 601 Sup...

Page 875: ...eter T2014 6 Regulator Air Pressure 1 Ensure supplemental fuel filler cap is tightly secured NOTE Using the Test Method 2 tests both the main and supplemental fuel tanks si multaneously 2 Perform Fuel Cell Leak Check Pressure Test Test Method 2 for main fuel tank Ref Section 28 00 00 3 If leakage exceeds the amount allow able apply liquid leak detector C809 to areas suspected of leaking 4 Test mos...

Page 876: ...83 U S gal 314 L Ref Section 12 00 00 2 Fill the supplemental fuel tank full Ref Section 12 00 00 3 Verify the IIDS and FUEL PROBE circuit breakers on the A601 essential circuit breaker panel are in Ref Section 96 00 00 4 Verify the AUX FUEL XMIT and AUX FUEL circuit breaker on the A620 electrical load center is in Ref Section 96 00 00 5 Apply electrical power to the aircraft Ref Section 96 00 00 ...

Page 877: ...STALLED ANYWHERE WITHIN SIGHT OF THE PILOT AUXILIARY FUEL SYSTEM USE MAIN FUEL DOWN TO 700 LBS BEFORE SELECTING AUX FUEL TRANSFER DO NOT USE AUX FUEL TRANSFER BELOW MAIN FUEL OF 300 LBS 2 1 1 FUEL TRANSFER INDICATOR LIGHT 2 FUEL TRANSFER SWITCH 3 SUPPLEMENTAL FUEL QUANTITY INDICATOR Figure 602 Supplemental Fuel Transfer Operational Test ...

Page 878: ......

Page 879: ... a replacement it is necessary to order a standard access cover and modify it The modification consists of drilling four 4 holes for mounting the level control valve support 1 Using referenced figure locate holes in access cover 2 Drill holes with a number forty 40 2 5 mm pilot drill 3 Enlarge holes in access cover to 0 281 0 010 in 7 14 0 25 mm and deburr holes 4 Touch up holes in accordance with...

Page 880: ...ent part number than a non mo dified vent tube For a replacement it is necessary to order a standard vent tube part number 900P2662013 and modify it The modification consists of trimming the vent tube and touch up of bare aluminum 1 Remove vent tube Ref Section 28 00 00 2 Mark vent tube for modification in accordance with referenced figure 3 Cut vent tube at mark and deburr 4 Touch up bare aluminu...

Page 881: ...r 900F2305507 and modify it The modification consists of trimming the panel touch up of bare aluminum riveting two doublers along the cutout and installing nutplates 1 Mark panel using old panel or new doublers 2 Trim panel using aviation metal snips 3 Deburr and blend edges 4 Locate doublers along edge of cutout 5 Drill doubler and nutplate rivet holes and deburr 6 Touch up bare aluminum Ref CSP ...

Page 882: ... loose hook loop tape C720 with sealant C216 5 Fill all areas where foam supports are unsupported due to structural and component protrusion with foam tape C718 6 Build up thickness of tape to allow approximately 30 percent compression after fuel tank installation 5 Supplemental Fuel Tank Cavity Vapor Barrier Repair Consumable Materials Ref CSP SPM Item Nomenclature C216 Sealant Fuel Resistant C71...

Page 883: ... and washers 13 Remove fuel tank cover 7 Remove and discard packing 8 7 Disconnect and remove existing pump to auxiliary cell outlet hose 8 Remove nut 16 and washer 15 from bulkhead tube fitting 9 Install washer 14 four washers 15 and nut 16 on bulkhead tube fitting Torque nut Ref CSP SPM Upon installation of check valve insure arrow on valve points in direction of fuel flow in system NOTE Lubrica...

Page 884: ...19 28 10 00 9G28 079 FS 235 532 BL 0 000 5 1 2 7 8 6 9 4PL 11 3 4PL 4 4PL 12 13 RH KEEL BEAM REF 10 2PL FS 230 500 SUPPLEMEN TAL FUEL TANK 18 17 19 16 15 14 SUPPLEMENTAL FUEL TANK REF TRANSFER PUMP REF BULKHEAD TUBE FITTING REF Figure 804 Supplemental Fuel Check Valve Modification ...

Page 885: ...EL TANK 8 PACKING 9 LOCKWIRE 10 HOSE CONNECTION FUEL VENT 11 TUBE ASSEMBLY FUEL VENT 12 BOLT HEX HEAD CLOSE TOLERANCE 13 WASHER FLAT 14 WASHER FLAT 15 WASHER FLAT 4 16 NUT TUBE BULKHEAD FITTING 17 CHECK VALVE 18 HOSE PUMP TO AUX CELL OUTLET 19 PACKING PREFORMED 17 Install baggage floor Ref Section 53 20 00 18 Perform supplemental fuel tank leak pressure test 19 Perform supplemental fuel quantity o...

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Page 887: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual HYDRAULIC SYSTEM Chapter ...

Page 888: ......

Page 889: ...stem 1 Wiring Diagram 103 Figure 102 Hydraulic System 2 Wiring Diagram 104 Maintenance Practices 201 1 Hydraulic System Inspection Test 201 A Hydraulic System Inspection 201 B Hydraulic System Pressure Leak Test 201 C Hydraulic System Static Leak Test 202 D Hydraulic System Operational Test Aircraft Ground Run 202 E Hydraulic System Functional Test with GSE Pressure 202 Figure 201 Hydraulic System...

Page 890: ...cer 212 A Hydraulic Pressure Transducer Removal 212 B Hydraulic Pressure Transducer Inspection 212 C Hydraulic Pressure Transducer Installation 212 8 Hydraulic Temperature Switch 213 A Hydraulic Temperature Switch Removal 213 B Hydraulic Temperature Switch Inspection 213 C Hydraulic Temperature Switch Installation 213 Figure 204 Hydraulic Manifold Reservoir 214 9 Manifold Filter Bypass Delta P Ind...

Page 891: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 29 00 00 Hydraulic System ...

Page 892: ......

Page 893: ...n ing system s pressure decreases to between 200 psig and 400 psig Fluid is carried through drilled passages to the contact face of each piston shoe for lubrication cooling and hydrostatic balance This hydro static balance reduces bearing contact pressures minimizing friction and wear Other parts are lubricated and cooled with this fluid as it circulates at 0 02 to 0 08 gpm through the pump and re...

Page 894: ...l checks When open the valve short circuits supply pressure to return reducing system pressure to approximately 200 psig EARLY CONFIG The fluid sampling valve provides for fluid samples to be taken while the system is fully pressurized The valve nozzle is fitted with a protective cap attached to a security chain The quantity indicator provides visual indication of reservoir fluid quantity The indi...

Page 895: ...AND PUMP OPTIONAL GSE PANEL MANIFOLD RESERVOIR VARIABLE DELIVERY PUMP VARIABLE DELIVERY PUMP MANIFOLD RESERVOIR GSE PANEL COLLECTIVE SERVO ACTUATOR LONGITUDINAL SERVO ACTUATOR LATERAL SERVO ACTUATOR DIRECTIONAL SERVO ACTUATOR SYSTEM 1 SYSTEM 2 9G29 005A Figure 1 Hydraulic System Block Diagram ...

Page 896: ... PRESSURE INDICATORS FILTER IMPENDING BYPASS EARLY CONFIG CURRENT CONFIG FLUID TEMP 40 C 95 C REFILL EMPTY FULL FULL REFILL VIEW ROTATED LOOKING DOWN FLUID TEMP 40 C 95 C F U L L R E F I L L R E F I L L EMPTY F U L L LOOKING INBOARD HIGH PRESSURE RELIEF VALVE RETURN FILTER BY PASS VALVE BLEED VALVE FILTER BOWL PRESSURE FILTER BOWL RETURN ISOLATION VALVE TEMPERATURE SWITCH Figure 2 Hydraulic System...

Page 897: ...0 micron wire screen covers the bottom of the reservoir and can be removed for cleaning The pump assembly consists of two pumping gears and the speed increasing gear located in a housing The pump housing also contains the reservoir drain A manually operated selector valve is mounted internally in the housing The selector valve lever provides for selection of system 1 or system 2 for servicing The ...

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Page 899: ...it breaker 96 30 00 Faulty switch S5 A606 Utility Control Panel Replace switch 96 30 00 1 HYD not present on IIDS during System 1 self test Open ground between GS107 J and P429 B Test and repair wiring 98 00 00 Faulty test solenoid Replace solenoid 28 vdc not present at K1 7 8 B2 Test and repair wiring 98 00 00 CB 48 inoperative Replace circuit breaker 96 30 00 Faulty switch S5 A606 Utility Contro...

Page 900: ...Faulty pressure transducer on A401 Manifold 1 Replace transducer 29 00 00 Faulty wiring between A401 Hydraulic Manifold 2 P423 and A2 IIDS P103 Test and repair wiring 98 00 00 HYD 2 present on IIDS and low pressure reading present on alpha numeric display Faulty pump Internally worn Test pump output pressure with mechanical gauge and repair or replace pump as necessary 29 00 00 Loose broken fittin...

Page 901: ...31 32 18 17 16 15 R D C B A A B B A HYD OIL PRESS HI HYD OIL PRESS LO HYD OIL PRESS 1 EXCIT LO HYD OIL PRESS 1 EXCIT HI HYD OIL TEMP 1 HI CB48 5A CFU RIGHT GENERATOR BUS SYS 1 SYS 2 OFF 3 2 1 6 SEE ELECTRICAL INTERCONNECT DIAGRAM 98 40 00 6 6 S5 HYD TEST SWITCH MANIFOLD RESERVOIR 1 A612 FWD INTERCONNECT PANEL A400 A2 IIDS A620 ELECTRICAL LOAD CENTER W124 W123 W129 W123 W124 W123 W123 A606 UTILITY ...

Page 902: ...85 84 83 84 85 86 87 18 17 16 15 R W Y X V U T A B B A A B C D HYD OIL TEMP 2 HI HYD OIL PRESS 2 EXCIT HI HYD OIL PRESS 2 EXCIT LO HYD OIL PRESS 2 LO HYD OIL PRESS 2 HI CB48 CFU 5A RIGHT GENERATOR BUS SYS 1 SYS 2 OFF 3 2 1 6 SEE ELECTRICAL INTERCONNECT DIAGRAM 98 40 00 6 6 S5 HYD TEST SWITCH A612 FWD INTERCONNECT PANEL A401 MANIFOLD RESERVOIR 2 A612 FWD INTERCONNECT PANEL A2 IIDS A620 ELECTRICAL L...

Page 903: ... mating rubber cushions just contact when reinstal ling rubber cushioned tubing clamp blocks 3 Inspect for chafed deteriorated cut frayed and or cracked hoses None allowed 4 Inspect for loose broken and or cracked clamps None allowed 5 Inspect manifold reservoir fluid level Service as required Replace contami nated filters 6 Inspect electrical components a Foreign objects and corroded bent broken ...

Page 904: ...inches in diameter D Hydraulic System Operational Test Aircraft Ground Run 1 Ground run helicopter per current Rotorcraft Flight Manual Ref Section 01 00 00 Table 201 2 Perform hydraulic system check per current Rotorcraft Flight Manual Ref Section 01 00 00 Table 201 3 Shut down helicopter per current Rotorcraft Flight Manual Ref Section 01 00 00 Table 201 E Hydraulic System Functional Test with G...

Page 905: ...nance Manual Page 203 Original 29 00 00 9G29 012 SYSTEMS 1 AND 2 SHOWN SEPARATELY FOR CLARITY SYSTEM NO 2 SYSTEM NO 1 2 3 1 1 2 3 4 1 GSE PANEL 2 MANIFOLD RESERVOIR 3 VARIABLE DELIVERY PUMPS 4 DIRECTIONAL ACTUATOR Figure 201 Hydraulic Systems 1 and 2 ...

Page 906: ...sig Use extreme care when adjust ing hydraulic pressure to avoid damage to the helicopters hydraulic system 5 Preset hydraulic mule pressure before applying pressure to helicopter system Refer to applicable rigging test instructions for proper pressure setting 6 On helicopters with 900H381502 105 hydraulic manifolds rapidly increase pressure from 0 250 psi to prevent fluid venting overboard due to...

Page 907: ...gs and caps for cracks rounded flats and damaged threads None allowed 2 Inspect GSE panel for dents nicks cracks and corrosion None allowed 3 Inspect coupling cap lanyards for wear and security of attachment No damage allowed C Hydraulic GSE Panel Installation Ref Figure 202 Consumable Materials Ref CSP SPM Item Nomenclature C112 Hydraulic Fluid C232 Sealant 1 Put GSE panel in its installed positi...

Page 908: ...a System No 1 pump is on transmis sion forward left hand accessory drive pad b System No 2 pump is on transmis sion forward right hand accessory drive pad 3 Place rags on transmission deck beneath hydraulic pump to catch hydraulic fluid spills Hydraulic Fluid C112 4 Empty both system reservoirs through manifold bleed valve 5 Slowly loosen pump pressure hose 1 at pump until fluid begins to seep fro...

Page 909: ...Inspect accessory drive pad seal for leaks Leakage rate must not exceed 2cc per hour or one drop per minute 6 Inspect hoses for nicks cuts chafing and stripped threads None allowed C Hydraulic Pump Installation Ref Figure 203 Consumable Materials Ref CSP SPM Item Nomenclature C112 Hydraulic Fluid C702 Lockwire 1 Remove FOD cover from transmission accessory drive pad Hydraulic Fluid C112 2 Mount pu...

Page 910: ...tting 7 Safety all hose fittings with lockwire C702 8 If necessary service both hydraulic systems Ref Section 12 00 00 9 Pressure leak test both hydraulic systems Ref Section 29 00 00 10 Install swashplate forward fairing assembly T155 Install and close forward access door L155 or R155 Ref Section 06 00 00 9G29 007 NOTE PUMP PORT FITTINGS AND ATTACHING HARD WARE 9 8 1 2 3 4 5 6 4 PL 7 4 PL 8 1 PUM...

Page 911: ... Install protective caps on all electrical connectors and receptacles Residual Fluids 7 Disconnect tube and hose fittings from manifold a Disconnect hose from manifold PMP PRESS port fitting 7 b Disconnect hose from manifold PMP SCT port fitting 8 c Disconnect tube from manifold BL port fitting 9 d Disconnect hose from manifold CS DR port fitting 10 e Disconnect tube from manifold PRESS port fitti...

Page 912: ... per manufacturer s instructions and apply a fillet bead of sealant along edge of manifold to deck mating surface Hydraulic Fluid C112 3 Connect tube and hose fittings to manifold a Remove protective caps from all hydraulic lines and manifold fluid port fittings Lubricate threads of manifold fluid port fittings with clean hydraulic fluid C112 b Connect GSE return tube to manifold GSE RTN port 14 T...

Page 913: ...luid level sight glass Removal procedures are typical for either assembly 1 Open transmission forward access door assembly L155 or R155 Ref Section 53 30 00 2 Depress and hold spring loaded lock lever located on the manifold above filter bowl assembly Hydraulic Fluid C112 3 Loosen filter bowl from manifold using hex flats at bottom of bowl 4 After locking flange at top of filter bowl is clear of l...

Page 914: ...raulic Fluid C112 3 Drain all hydraulic fluid as practical from manifold reservoir through bleed valve 4 Cut and discard lockwire from pressure transducer 2 5 Detach electrical connector a P428 on manifold reservoir No 1 b P423 on manifold reservoir No 2 Residual Fluids 6 Remove transducer 2 and perform Hydraulic Pressure Transducer Inspection Ref Section 29 00 00 B Hydraulic Pressure Transducer I...

Page 915: ...ch Inspection 1 Inspect electrical connector for damage None allowed 2 Inspect electrical receptacle for damage None allowed 3 Inspect temperature switch and manifold for stripped or damaged threads None allowed C Hydraulic Temperature Switch Installation Ref Figure 204 NOTE This task is typical for System 1 left side and System 2 right side except where noted Consumable Materials Ref CSP SPM Item...

Page 916: ...RE SWITCH 2 PRESSURE TRANSDUCER 3 SYSTEM SELECT SOLENOID 4 BYPASS DELTA P INDICATOR 5 ISOLATION VALVE 6 FILTER BOWLS 7 PUMP PRESSURE PMP PRESS PORT 8 PUMP SUCTION PMP SCT PORT 9 BLEED BL PORT 10 CASE DRAIN CS DR PORT 11 SYSTEM PRESSURE PRESS PORT 12 SYSTEM RETURN RTN PORT 13 GSE PRESSURE GSE PRESS PORT 14 GSE RETURN GSE RTN PORT 15 BOLT 16 WASHER Figure 204 Hydraulic Manifold Reservoir ...

Page 917: ...se 4 Make sure the bypass delta P indica tor has reset is in 5 Install the manifold reservoir filter bowl and a new filter element 6 Close Access Door L155 or R155 ref Section 06 00 00 B Removal Ref Figure 205 NOTE This task is typical for System 1 and System 2 unless differently noted 1 Open Access Door L155 or R155 ref Section 06 00 00 2 Remove lockwire C702 from screws 10 3 Remove screws 10 and...

Page 918: ...17 18 17 12 14 13 19 4 PL 9g29 016A 1 HYDRAULIC MANIFOLD RESERVOIR REF IPL 29 00 00 FIG 2 2 BLEED VALVE 3 PACKING 4 PACKING 5 BYPASS DELTA P INDICATOR 6 PACKING 7 PACKING 8 PACKING 9 WASHER 10 SCREW 11 COVER 12 SOLENOID 13 FLANGE 14 GASKET 15 SPRING 16 PLUNGER 17 RETAINER 18 PACKING 19 SCREW Figure 205 Removal and Installation of the Bleed Valve ...

Page 919: ...29 00 00 Procedure 1 B 9 Close Access Door L155 or R155 ref Section 06 00 00 10 Bleed Valve NOTE These procedures are typical for System 1 and System 2 If there is a difference it will be shown in the procedures A Removal Ref Figure 205 1 Open Access Door L155 or R155 ref Section 06 00 00 2 Remove lockwire C702 from bleed valve 2 3 Remove bleed valve 2 4 Remove packings 3 4 a Discard packings 3 4 ...

Page 920: ...move solenoid 12 9 Remove plunger 16 and spring 15 10 Remove retainers 17 and packing 18 from solenoid 12 a Discard packing 18 and retainers 17 B Installation Ref Figure 205 Consumable Materials Ref CSP SPM Item Nomenclature C112 Hydraulic Fluid C216 Sealant Fuel Resistant C702 Lockwire 1 Apply hydraulic fluid C112 to new packing 18 2 Install new retainers 17 and packing 18 on solenoid 12 3 Instal...

Page 921: ...ansmission deck Hydraulic Fluid C112 12 Service the hydraulic system ref CSP 900RMM 2 Section 12 00 00 13 Do the Hydraulic System Pressure Leak Test ref Section 29 00 00 Procedure 1 B a Make sure there are no leaks 14 Close Access Door L155 or L155 ref Section 06 00 00 15 Do the Hydraulic System Operational Test ref Section 29 00 00 Procedure 1 D ...

Page 922: ...ystem No 1 d Disconnect System No 2 fill tube 4 from lower port fitting of pump 1 and install protective caps on open fittings of tube and lower outlet port of pump e Remove bolts 5 and washers 6 to remove pump from transmission deck 4 Install protective caps on open tube fittings 3 and 4 5 Remove container and clean all spilled hydraulic fluid from transmission deck B Inspection 1 Inspect tube en...

Page 923: ...nd 4 and port fittings of pump 1 Hydraulic Fluid C112 2 Install hydraulic hand pump a Align pump 1 with nutplate holes on left hand edge of transmission deck just aft of hydraulic system GSE panel b Install bolts 5 and washers 6 Torque bolts c Lubricate threads of pump port fittings with clean hydraulic fluid C112 d Connect System No 2 pump fill tube 4 to lower port fitting of pump 1 Torque tube f...

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Page 925: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual LANDING GEAR Chapter ...

Page 926: ......

Page 927: ...r Assembly Troubleshooting 101 Table 101 Standard Landing Gear Assembly Troubleshooting 101 Removal Installation 401 1 Forward LH and RH Side Stop Clamp Assemblies 401 A Removal 401 B Installation 401 Figure 401 Removal and Installation of the Forward Stop Clamps 402 Figure 402 Removal and Installation of the Aft Stop Clamps 404 2 Landing Gear Aft LH and RH Side Stop Clamp Assemblies 405 A Removal...

Page 928: ... Crosstube 413 J Installation of the Forward Crosstube 414 Figure 405 Skid Tube Assemblies 416 8 Assembly and Disassembly of the LH and RH Skid Tube Assemblies 417 A Removal of the Forward Abrasion Strips 417 B Installation of the Forward Abrasion Strips 417 C Removal of the Mid Abrasion Strips 417 D Installation of the Mid Abrasion Strips 417 E Removal of the Aft Abrasion Strips 418 F Installatio...

Page 929: ...Mating Surfaces of the Crosstubes and Stop Clamps 612 H Inspection of the Internal Surfaces of the Crosstubes 612 Figure 610 Insertion Points for the Aft and Forward Crosstubes 613 Repairs 801 1 Landing Gear Damper Assemblies 801 A Drain Port Repair 801 Figure 801 Location of Damper Drain Ports 801 Figure 802 Skid Tube Repairable Sections 802 2 Left Hand and Right Hand Skid Tube Assemblies 802 A B...

Page 930: ...OF CONTENTS Cont Para Figure Table Title Page 32 40 00 Ground Handling Wheels A Maintenance Practices 201 1 Ground Handling Wheel Set 201 A Description and Function 201 B Tires 201 C Steel Rims 201 D Main Frame Body 201 E Hydraulic Jack 201 F Attach Cradle 201 Figure 201 Ground Handling Wheel Set 202 ...

Page 931: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 32 00 00 Landing Gear Assembly ...

Page 932: ......

Page 933: ...ches to the fuselage at FS 154 0 and BL 9 275 by the forward saddle assembly The aft crosstube is attached to the fuselage at FS 233 0 and BL 23 25 by the aft saddle assembly The forward and aft crosstubes provide elastic deformation during normal landings The crosstubes provide energy attenuation and permanent deformation during severe landings C Forward and Aft Saddle Assemblies The forward and ...

Page 934: ... indicator 1 is a rotating shaft which shows through a 120 pie shaped window When the reservoir is filled the window shows green with a very thin wedge of red showing to the first notch 2 on the housing The thin wedge of red shows the reservoir is not completely full to allow for fluid expansion G Skid Tubes The skid tubes are 7075 T6 aluminum alloy tubes that are attached to the forward and aft c...

Page 935: ...ssembly Troubleshooting Fault Probable Cause Corrective Action Ref Section Unusual or too much vibration Damper damage Saddle assembly pad damage Side stop clamp pad damage Examine saddle pads side stop clamp pads and or landing gear damper assemblies 32 00 00 Incorrect ground attitude Crosstube damage Examine forward and aft crosstubes 32 00 00 Landing gear damper assembly low Fluid level low Dam...

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Page 937: ...ng Compound Corrosion Inhibitive C225 Sealing and Locking Compound C247 Petroleum Wax Preferred C245 Conductive Grease Alternative C246 Conductive Oil Alternative 1 Prepare forward stop clamp 1 and jumper 2 for an electrical bond to the contact surface of forward crosstube 3 ref CSP SPM Section 20 20 00 Petroleum Wax C247 Conductive Grease C245 Conductive Oil C246 2 Apply petroleum wax C247 or alt...

Page 938: ...on of the elastomer pad of the compression pad 7 6 Tighten jam nut 4 to lock round end bolt 6 Sealing and Locking Compound C225 7 Apply sealing and locking compound C225 to jam nut 4 flat washer 5 and round end bolt 6 9G32 027 3 8 REF ENVIRONMENTAL SEALING COMPOUND 7 8 5 4 6 9 10 2 1 11 12 RIGHT SIDE SHOWN LEFT SIDE TYPICAL 1 FORWARD STOP CLAMP REF IPL 32 00 00 FIG 1 2 JUMPER 3 FORWARD CROSSTUBE 4...

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Page 940: ...E TYPICAL 2 REF 6 7 3 6 5 4 AFT 7 TO 13 9 REF RIGHT SIDE SHOWN LEFT SIDE TYPICAL 1 AFT CROSSTUBE REF IPL 32 00 00 FIG 1 2 FUSELAGE FITTING NO IPL REF 3 BRACKET 4 JUMPER REF IPL 32 00 00 FIG 1 5 BOLT 6 WASHER 7 NUT 8 AFT STOP CLAMP 9 PAD REF IPL 32 00 00 FIG 6 10 BOLT REF IPL 32 00 00 FIG 1 11 COUNTERSUNK WASHER 12 FLAT WASHER 13 NUT 14 SKID TUBE ASSEMBLY Figure 402 Removal and Installation of the ...

Page 941: ...p 8 end of jumper 4 and aft crosstube 1 for an electrical bond ref CSP SPM Section 20 50 00 Petroleum Wax C247 Conductive Grease C245 Conductive Oil C246 2 Apply petroleum wax C247 or altern atives to the mating surfaces of aft crosstube 1 and aft stop clamps 8 Make sure countersunk washer 11 is next to head of bolt 10 before you install jumper 4 Incorrect as sembly can cause electrical problems 3...

Page 942: ... SHOWN RIGHT SIDE TYPICAL 6 REF 5 REF 13 12 12 15 14 14 16 21 4 REF 2 REF 21 20 18 17 17 18 19 19 LEFT SIDE SHOWN RIGHT SIDE TYPICAL 7 10 8 9 9G32 007 1D 4 3 3 20 REF 16 REF REF ENVIRONMENTAL SEALING COMPOUND REF ENVIRONMENTAL SEALING COMPOUND Figure 403 Removal and Installation of the Landing Gear Assembly ...

Page 943: ...ng 6 NOTE If necessary remove forward side clamps ref Procedure 1 A 3 Remove bolts 15 flat washers 14 ends of jumpers 13 countersunk washers 12 and forward saddles 16 from forward fuselage fittings 6 4 Remove bolts 19 flat washers 18 countersunk washers 17 and aft saddles 20 from aft fuselage fittings 4 5 Remove landing gear assembly 1 B Installation Ref Figure 403 Consumable Materials Ref CSP SPM...

Page 944: ...Removal Ref Figure 403 NOTE This task is typical for the aft LH or RH saddle assemblies 1 Remove bolts 19 washers 17 18 and aft saddle 20 from aft fuselage fitting 4 B Installation Ref Figure 403 NOTE This task is typical for the aft LH or RH saddle assemblies Consumable Materials Ref CSP SPM Item Nomenclature C211 Sealing Compound Corrosion Inhibitive 1 Install countersunk washers 17 flat washers...

Page 945: ...a saddle pad 21 from a fuselage fitting 4 6 remove landing gear assembly 1 ref Procedure 3 A 2 To remove a saddle pad 21 from a aft saddle 20 or forward saddle 16 remove the applicable saddle ref Procedure 4 A or Procedure 5 A respectively 3 Remove saddle pad 21 from fuselage fitting 4 6 or saddle 16 20 4 Remove remaining epoxy adhesive C411 or instant adhesive C444 B Installation Ref Figure 403 C...

Page 946: ...9 LEFT SIDE SHOWN RIGHT SIDE TYPICAL 2 1 2 3 6 6 5 18 17 1 AFT CROSSTUBE REF IPL 32 00 00 FIG 2 2 DAMPER ASSEMBLY 3 LH SKID TUBE 4 RH SKID TUBE 5 FORWARD CROSSTUBE 6 FORWARD SPACER FITTING 7 COUNTERSUNK WASHER 8 BOLT 9 FLAT WASHER 10 NUT 11 FLAT WASHER 12 BOLT 13 COUNTERSUNK WASHER 14 BOLT 15 FLAT WASHER 16 NUT 17 COUNTERSUNK WASHER 18 BOLT 19 FLAT WASHER 20 BOLT Figure 404 Assembly and Disassembl...

Page 947: ...ary jack the rotorcraft until skid tubes 3 4 clear the ground ref Section 07 10 00 2 Remove sealant from heads of bolts 8 12 3 Remove nuts 10 flat washers 9 countersunk washers 7 and bolts 8 4 Remove bolts 12 and washers 11 5 Remove forward spacer fitting 6 B Installation of the Forward Spacer Fittings Ref Figure 404 NOTE This task is typical for the left or right forward spacer fittings Consumabl...

Page 948: ...14 flat washers 15 and nuts 16 3 Install countersunk washers 17 and bolts 18 a Torque bolts 18 100 to 140 in lb 11 30 to 15 82 Nm b Safety bolts 18 with lockwire C702 4 Attach damper assembly 2 to skid tube assembly 3 or 4 with washers 19 and bolts 20 5 Apply masking tape to drain ports of damper assembly 2 Sealing Compound C211 Do not put sealing compound C211 in the drain ports of damper assembl...

Page 949: ...nt from heads of bolts 14 18 2 Remove lockwire from bolts 18 3 Remove bolts 14 18 washers 13 15 17 and nuts 16 from damper assem blies 2 and aft crosstube 1 4 Remove aft crosstube 1 H Installation of the Aft Crosstube Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire C211 Sealing Compound Corrosion Inhibitive 1 Align the bolt holes of aft crosstube 1 and damper assemb...

Page 950: ...le Materials Ref CSP SPM Item Nomenclature C211 Sealing Compound Corrosion Inhibitive 1 Align the bolt holes of forward cross tube 5 and forward spacer fittings 6 2 Install countersunk washers 7 bolts 8 flat washers 9 and nuts 10 Sealing Compound C211 3 Environmentally seal all external mating parts with sealing compound C211 ref CSP SPM Section 20 50 00 ...

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Page 952: ...G32 007 3B 9 8 8 6 8 9 9 8 7 9 8 8 10 8 10 5 10 9 7 8 9 8 10 8 7 LEFT SIDE SHOWN RIGHT SIDE TYPI CAL 1 1 SKID TUBE REF IPL 32 00 00 FIG 3 2 FORWARD ABRASION STRIP 3 WASHER 4 SCREW 5 MID ABRASION STRIP 6 BOLT 7 BOLT 8 WASHER 9 SLEEVE SPACER 10 NUT 11 AFT ABRASION STRIP 12 WASHER 13 SCREW Figure 405 Skid Tube Assemblies ...

Page 953: ...n the forward abrasion strip to mate with the screw holes in the skid tube a Torque screws 4 ref CSP SPM 20 10 00 Sealing Compound C213 2 Install a fillet seal around all external mating parts and fasteners with sealing compound C213 ref CSP SPM Section 20 50 00 3 If necessary lower the rotorcraft ref Section 07 10 00 C Removal of the Mid Abrasion Strips Ref Figure 405 NOTE This task is typical fo...

Page 954: ...skid tube as semblies 1 Install aft abrasion strip 11 with washers 12 and screws 13 a Torque screws 13 ref CSP SPM Section 20 10 00 Sealing Compound C213 2 Install a fillet seal around all external mating parts and fasteners with sealing compound C213 ref CSP SPM Section 20 50 00 3 If necessary lower the rotorcraft ref Section 07 10 00 G Removal of a Ground Handling Attach Point Ref Figure 405 NOT...

Page 955: ... 3 10 for cracks dents gouges and corrosion a No cracks dents gouges or corrosion permitted 4 Examine forward and aft saddle fastener holes for damage deformation and corrosion a No damage deformation or corrosion permitted 5 Examine forward and aft saddle bushing holes for damage deformation and corrosion a No damage deformation or corrosion permitted 6 Examine saddle pads 7 15 for deterioration ...

Page 956: ...4 5 6 9 LEFT SIDE SHOWN RIGHT SIDE TYPICAL 1 AFT CROSSTUBE REF IPL 32 00 00 FIG 2 2 AFT FUSELAGE FITTING NO IPL REF 3 AFT SADDLE REF IPL 32 00 00 FIG 1 4 BOLT 5 COUNTERSUNK WASHER 6 FLAT WASHER 7 SADDLE PAD 8 FORWARD CROSSTUBE REF IPL 32 00 00 FIG 2 9 FORWARD FUSELAGE FITTING NO IPL REF 10 FORWARD SADDLE REF IPL 32 00 00 FIG 1 11 BOLT 12 COUNTERSUNK WASHER 13 JUMPER 14 FLAT WASHER 15 SADDLE PAD Fi...

Page 957: ...Inspection Ref Figure 602 1 Examine side stop clamps 1 for cracks dents gouges and corrosion a No cracks dents gouges or corrosion permitted 2 Examine side stop clamps 1 for missing bolts 6 washers 5 7 and nuts 8 a Replace missing bolts 6 washers 5 7 and nuts 8 3 Examine jumpers 2 for corrosion a No corrosion permitted 4 Examine environmental sealing compound of jumper 2 terminals for cracks a No ...

Page 958: ...compound of jumper 2 terminals for cracks a No cracks permitted 5 Examine jumper 2 bolt holes for damage deformation and corrosion a No damage deformation or corrosion permitted 6 Remove side stop clamps 2 ref Section 32 00 00 Removal Installa tion 7 Examine dowel pin 7 hole for damage deformation and corrosion a No damage deformation or corrosion permitted 9G32 028 3 8 REF ENVIRONMENTAL SEALING C...

Page 959: ...ing gear assembly for inspec tion and repair ref Repairs or replacement 2 If there is no damage install the side stop clamps ref Removal Installation 2 Examine the aft crosstube for indica tions of contact with the fuselage fittings and the aft saddle assemblies a If there are indications of contact replace the aft crosstube 3 Examine the aft crosstube bolt holes for damage deformation and corrosi...

Page 960: ...magnification glass 1 If there is damage remove the landing gear assembly for inspec tion and repair ref Repairs or replacement 2 If there is no damage install the side stop clamps ref Removal Installation 2 Examine the forward crosstube for indications of contact with the fuselage fittings or the front saddle assemblies a If there are indications of contact replace the forward crosstube 3 Examine...

Page 961: ...nuts 5 bolts 3 7 and washers 2 4 6 3 Examine mating surfaces of forward spacer fitting 1 to forward crosstube 9 for damage deformation and corrosion a No damage deformation or corrosion permitted 4 Examine bolt 3 holes of forward spacer fitting 1 and forward crosstube 9 for damage deformation and corrosion a No damage deformation or corrosion permitted 5 Examine bolt 7 holes of forward spacer fitt...

Page 962: ...evel indicator 1 is between the first notch 2 and second notch 3 of the window a The reservoir is near full when the window shows green NOTE When the reservoir is full the window shows green with a very thin wedge of red at the first notch 2 This is because the reser voir is not completely full to let the fluid ex pand b The reservoir is near empty when the window shows red 2 If the red has reache...

Page 963: ...cracks dents gouges or corrosion permitted 2 Examine dampers 1 for too much leakage a Too much leakage not permitted 3 Examine dampers 1 for missing nuts 5 11 bolts 3 7 9 and washers 2 4 6 8 10 a Replace missing nuts 5 11 bolts 3 7 9 and washers 2 4 6 8 10 4 Make sure there is a clearance between damper cover and inner cover a Replace damper 1 if there is binding or interference 5 Examine mating s...

Page 964: ...CH 33 02 CM 9 10 11 11 10 12 12 10 11 11 10 9 14 15 15 10 9 12 10 7 6 5 7 6 12 INCH 30 48 CM 10 INCH 25 40 CM 18 5 INCH 46 99 CM 1 SKID TUBE REF IPL 32 00 00 FIG 7 2 PLUG 3 STEP 4 LARGE STEP 5 FORWARD ABRASION STRIP 6 WASHER 7 SCREW 8 MIDDLE ABRASION STRIP 9 BOLT 10 WASHER 11 SPACER 12 NUT 13 AFT ABRASION STRIP 14 WASHER 15 SCREW Figure 609 Skid Tube Inspections ...

Page 965: ... skid tubes 1 for missing skid tube plugs 2 a Replace missing skid tube plugs 2 9 Examine skid tube plugs 2 for cracks a No cracks permitted 10 Examine steps 3 or large steps 4 for corrosion cracks loose rivets and wear a No corrosion loose rivets or wear permitted 11 Examine skid tube abrasion strips 5 8 13 to skid tube 1 bolt holes for damage deformation and corrosion a No damage deformation or ...

Page 966: ...ove nut 2 flat washer 3 bolt 4 and countersunk washer 5 from the damper assembly and aft crosstube 1 3 Remove nut 7 flat washer 8 bolt 9 and countersunk washer 10 from the forward spacer fitting and forward crosstube 6 Moisture can collect in the inter nal diameter of the crosstubes in environments with high moisture and very high ambient temperature differen tials 4 Examine the internal surfaces ...

Page 967: ...al Page 613 Revision 36 32 00 00 9G32 035 1 AFT CROSSTUBE REF IPL 32 00 00 FIG 2 2 NUT 3 FLAT WASHER 4 BOLT 5 COUNTERSUNK WASHER 6 FORWARD CROSSTUBE 7 NUT 8 FLAT WASHER 9 BOLT 10 COUNTERSUNK WASHER Figure 610 Insertion Points for the Aft and Forward Crosstubes ...

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Page 969: ...t damage adjacent material when you remove unwanted material or sealing compound C211 1 Remove unwanted material or sealing compound C211 from the drain ports with a brush scribe or other instru ment 2 Make sure the drain ports are open after the repair 9G32 026 DRAIN PORTS BOTH SIDES 0 300 INCH 7 62 MM APPROX 0 030 INCH 0 76 MM APPROX Figure 801 Location of Damper Drain Ports CAUTION ...

Page 970: ...rrosion in repairable sections A B C and D ref CSP SPM Section 20 40 00 Mechanical Defects NOTE Material removal and repair procedure can be done one time only on a surface a Material removed from the surface of Section A cannot be deeper than 0 010 inch 0 25 mm b Material removed from the surface of Section B cannot be deeper than 0 010 inch 0 25 mm c Material removed from the surface of Section ...

Page 971: ...Lint NOTE You can use nonslip tape C713 as an alternative for nonslip coating compound C324 1 Apply masking tape adjacent to the repair area Solvent Cleaning C423 2 Clean the repair area with a clean non lint cloth C802 moist with cleaning solvent C423 a Clean the area again and again until the cloth stays clean Coating Compound Nonslip C324 3 Fully mix the nonslip coating compound C324 ref the ma...

Page 972: ...M SS DIM AC DIM SS 9g32_03 3 REPAIRABLE AREA TYPICAL OUTBOARD INBOARD DIM SS DIM RO DIM RA MATING SURFACE OF SADDLE ASSEMBLY DIMENSION AC 21 05 INCH 534 7 MM DIMENSION AI 1 00 INCH 25 4 MM DIMENSION AO 6 00 INCH 152 4 MM DIMENSION RA 4 50 INCH 114 3 MM DIMENSION RO 3 50 INCH 88 9 MM DIMENSION SS 1 00 INCH 25 4 MM Figure 804 Repair of the Aft Crosstube ...

Page 973: ...sion RA 3 Remove corrosion and repair mechanical defects within the repairable area a Do a blend repair with a scour ing pad C817 or No 400 or 600 abrasive paper b Do not remove more than 0 020 inch 0 51 mm of the base metal c Polish the repaired area with No 600 abrasive paper 4 Do a fluorescent penetrant inspec tion of Area A ref CSP SPM Section 20 90 00 a If there are cracks replace the aft cro...

Page 974: ...F AREA F BL 0 00 9g32_03 4 REPAIRABLE AREA TYPICAL OUTBOARD INBOARD DIM SS DIM RO DIM RA MATING SURFACE OF SADDLE ASSEMBLY DIMENSION FC 7 08 INCH 179 8 MM DIMENSION FI 1 00 INCH 25 4 MM DIMENSION FO 6 00 INCH 152 4 MM DIMENSION RA 4 50 INCH 114 3 MM DIMENSION RO 3 50 INCH 88 9 MM DIMENSION SS 1 00 INCH 25 4 MM Figure 805 Repair of the Forward Crosstube ...

Page 975: ...imension RA 3 Remove corrosion and repair mechanical defects within the repairable area a Do a blend repair with a scour ing pad C817 or No 400 or 600 abrasive paper b Do not remove more than 0 020 inch 0 51 mm of the base metal c Polish the repaired area with No 600 abrasive paper 4 Do a fluorescent penetrant inspec tion of Area A ref CSP SPM Section 20 90 00 a If there are cracks replace the aft...

Page 976: ...al Page 808 Revision 36 32 00 00 9G32 035 1 AFT CROSSTUBE REF IPL 32 00 00 FIG 2 2 NUT 3 FLAT WASHER 4 BOLT 5 COUNTERSUNK WASHER 6 FORWARD CROSSTUBE 7 NUT 8 FLAT WASHER 9 BOLT 10 COUNTERSUNK WASHER Figure 806 Insertion Points for the Aft and Forward Crosstubes ...

Page 977: ...8 to the internal surface a Pull the wand back to the insertion point at approximately 12 inch sec 30 5 cm sec 7 Do steps 2 thru 6 again on the opposite side 8 Let corrosion inhibitor C218 dry ref the manufacturer instructions 9 Install countersunk washers 5 bolts 4 flat washers 3 and nuts 2 Sealing Compound C211 10 Environmentally seal all external mating parts with sealing compound C211 ref CSP ...

Page 978: ...r C218 7 Do steps 1 thru 6 a again on the opposite side 8 Let corrosion inhibitor C218 dry ref manufacturer instructions 9 Install countersunk washer 10 bolt 9 flat washer 8 and nut 7 Sealing Compound C211 10 Environmentally seal all external mating parts with sealing compound C211 ref CSP SPM Section 20 50 00 ...

Page 979: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 32 40 00 Ground Handling Wheels ...

Page 980: ......

Page 981: ...ervals examine tire pressure and inflate to 65 psi 2 Inspect tires for wear and cuts none allowed C Steel Rims The steel rims rotate on a spindle by means of an inner and outer tapered roller bearing with an external grease fitting on the hub for periodic servicing 1 Inspect wheels for cracks and defects none allowed 2 At regular intervals yearly repack wheel bearings D Main Frame Body The main bo...

Page 982: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 202 Original 32 40 00 9G32 017A VIEW ROTATED 1 GROUND HANDLING WHEEL SET T101 Figure 201 Ground Handling Wheel Set ...

Page 983: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual DOORS AND WINDOWS Chapter ...

Page 984: ......

Page 985: ... Door Assembly 401 A Cockpit Door Assembly Removal 401 B Cockpit Door Assembly Installation 401 2 Cockpit Door Assembly Quick Removal 401 A Cockpit Door Assembly Quick Removal 401 B Cockpit Door Assembly Quick Installation 402 3 Cockpit Door Assembly With Outside Quick Release Pins 402 A Cockpit Door Assembly Removal With Outside Quick Release Pins 402 B Cockpit Door Assembly Installation With Out...

Page 986: ...chanism Cockpit Original Configuration 407 A Door Latch Mechanism Removal Original Configuration 407 B Door Latch Mechanism Installation Original Configuration 408 14 Door Latch Mechanism Cockpit New Configuration 409 A Door Latch Mechanism Removal New Configuration 409 B Door Latch Mechanism Installation New Configuration 409 15 Cockpit Door Window 410 A Window Removal 410 B Window Installation 4...

Page 987: ... 418 24 Cabin Door Door Stop 418 A Door Stop Removal 418 B Door Stop Installation 419 25 Cabin Door Stop Pad 419 A Stop Pad Removal 419 B Stop Pad Installation 419 26 Lower Forward Cabin Door Pivot Lug 419 A Pivot Lug Removal 419 B Pivot Lug Installation 419 27 Pivot Lug Vertical Track Roller 419 A Pivot Lug Vertical Track Roller Removal 419 B Pivot Lug Track Vertical Roller Installation 419 28 Pi...

Page 988: ... Assembly Installation 429 35 Strut Bracket Hinge Half 429 A Strut Bracket Hinge Half Removal 429 B Strut Bracket Hinge Half Installation 429 36 Strut Bracket 430 A Strut Bracket Removal 430 B Strut Bracket Installation 430 37 Door Latch Mechanism Baggage 430 A Door Latch Mechanism Removal 430 B Door Latch Mechanism Installation 430 38 Lower Hinges Door and Spoiler 431 A Lower Hinge Removal 431 B ...

Page 989: ...ion 601 1 Doors Windows 601 A Doors Windows Inspection 601 Figure 601 Window Damage Limits 602 2 Doors Operational Test 602 A Cockpit Doors Operational Test 602 B Cabin Doors Operational Test 602 C Baggage Door Operational Test 603 3 Door Latch Mechanism Rigging Verification 603 A Cockpit Door Latch Mechanism Rigging Verification Original Configuration 603 B Cockpit Door Latch Mechanism Rigging Ve...

Page 990: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Page vi Revision 32 52 Contents TABLE OF CONTENTS Cont Para Figure Table Title Page This page intentionally left blank ...

Page 991: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 52 00 00 Doors and Windows ...

Page 992: ......

Page 993: ...h door assembly Currently there is an optional door with quick release pins on the outside This option door does not come with gas struts Ref CSP 900RMM 2 Section 01 00 00 Optional Equipment List 3 Cabin Passenger Door Assemblies Ref Figure 3 and Figure 4 The cabin doors consist of a graphite epoxy inner and outer skin adhesively bonded together to form a box section assembly The cabin doors opera...

Page 994: ...t Maintenance Manual Page 2 Original 52 00 00 9G52 003 A A A A B B C C VIEW LOOKING OUTBOARD LEFT SIDE B B C C DOOR HINGE COCKPIT DOOR RELEASE MECHANISM GAS STRUT COCKPIT DOOR RELEASE MECHANISM COCKPIT SIDE DOOR Figure 1 Cockpit Door Assembly ...

Page 995: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 3 Original 52 00 00 COCKPIT SIDE DOOR WINDOW 9G52 002 Figure 2 Crew Door Window ...

Page 996: ... Original 52 00 00 C C C C D D E E E E D D B B B B DOOR UPPER TRACK FITTING TRACK ROLLER DOOR CARRIAGE TRACK ROLLER PIVOT LUG ASSY LOWER FWD CABIN DOOR TRACK ROLLER CABIN DOOR CARRIAGE LINK ASSY LOWER AFT CABIN DOOR CABIN SIDE DOOR 9G52 004A Figure 3 Cabin Door Assembly ...

Page 997: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 5 Original 52 00 00 CABIN SIDE WINDOW 9G52 001 Figure 4 Cabin Door Window ...

Page 998: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 6 Original 52 00 00 9G52 006 Figure 5 Baggage Door Assembly ...

Page 999: ...or disengage Verify latch mechanism rigging and adjust as necessary Doors do not close completely Door seal may be deformed and restricting door from closing properly Replace door seal 52 00 00 Door handle is not lined up with slam position on door decal Re activate door handle mechanism to the open position release and try to close again Some other obstruction may be inhibiting hinge or door trac...

Page 1000: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 102 Revision 22 52 00 00 This page intentionally left blank ...

Page 1001: ...Aircraft C715 Lockwire 1 Align hinge mechanism 8 of cockpit door assembly 2 with door fork assembly 13 Grease Aircraft C107 2 Apply aircraft grease C107 to bush ings 7 and bolts 6 3 Install bushings 7 bolts 6 washers 5 and nuts 4 securing door assembly 2 to fork assembly 13 4 Tighten nuts and install new cotter pins 5 Activate door release handle 16 to permit attachment of door restraint end fitti...

Page 1002: ...side Quick Release Pins NOTE Helicopters equipped with outside quick release pins do not have a gas strut installed A Cockpit Door Assembly Removal With Outside Quick Release Pins Ref Figure 401 Outside Removal from outside the helicop ter 1 Open cockpit door assembly 2 Disengage and remove snap pin 82 from removable restraint assembly 83 3 Move door restraint aside 4 Replace door snap pin into re...

Page 1003: ...r end of gas strut 9 up away from pivot post ball fitting 33 to remove 3 Pull upper end of gas strut 9 up away from pivot post ball fitting 33 to remove B Gas Strut Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C107 Grease Aircraft Grease Aircraft C107 1 Ensure that pivot post ball fittings 33 are lubricated with aircraft grease C107 prior to installation of gas st...

Page 1004: ...pull rod assemblies 7 Activate cockpit door release handle 16 and verify insertion of pull rods 11 into retaining boss 12 8 Install cockpit door assembly 2 Ref Section 52 00 00 6 Fork Assembly Cockpit Door A Fork Assembly Removal Ref Figure 401 NOTE Left and Right side are typical 1 Remove cockpit door assembly 2 Ref Section 52 00 00 2 Activate cockpit door release handle 16 to disengage pull rod ...

Page 1005: ...it door release stop bracket 19 to cockpit door release shaft 20 2 Remove rivets 21 that attach stop bracket 19 to fuselage door frame and remove bracket 19 B Stop Bracket Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C310 Primer Primer C310 1 Wet install rivets 21 with primer C310 attaching cockpit door release stop bracket 19 to fuselage door frame 2 Install wash...

Page 1006: ...CSP SPM Item Nomenclature C310 Primer C715 Lockwire 1 Insert cockpit door release shaft 20 into cockpit door release flanged fitting 23 and secure with tubular spring pin 22 2 Install cockpit door release handle 16 Primer C310 3 Wet install rivets 21 with primer C310 attaching cockpit door release stop bracket 19 to fuselage door frame 4 Install washer 18 and nut 17 attaching stop bracket 19 and d...

Page 1007: ...t C310 Primer C715 Lockwire Grease Aircraft C107 1 Install cockpit door release handle 16 using aircraft grease C107 Primer C310 2 Wet install rivets 21 with primer C310 attaching cockpit door release stop bracket 19 to fuselage door frame 3 Install washer 18 and nut 17 attaching stop bracket 19 and handle 16 to cockpit door release shaft 20 4 Safety door release handle 16 to airframe using lockwi...

Page 1008: ...ust support plate assemblies 41 so that when installed they will line up with holes in doors 6 Tighten hex fittings 48 at each position 7 Install screws 39 and washers 38 attaching support plate assemblies 41 and cable assembly 49 to door frame 8 Install clevis pin 50 and cotter pin 51 attaching link 52 to housing assembly 42 bellcrank Ensure that notch in link faces in towards housing assembly 9 ...

Page 1009: ...or panel Ref Section 25 10 00 3 Remove and discard cotter pin 80 Remove clevis pin 77 and washers 78 and 79 that attach clevis 67 exten sion spring 71 and connecting tube 76 4 Remove and discard cotter pin 70 Remove clevis pin 68 and washer 69 that attaches clevis 75 to upper latch block assembly 40 5 Remove screw 72 washer 73 and spacer 74 that attaches extension spring 71 to door 6 Remove and di...

Page 1010: ...per latch block 40 protrudes fully full LOCK position NOTE Verify protrusion by pushing the bolt in and confirming that there is no more than 0 010 in 0 254 mm of play 15 Adjust connecting tube 76 so that bottom attachment hole lines up with hole on clevis 67 16 Install clevis pin 77 washers 78 and 79 and cotter pin 80 connecting clevis 67 extension spring 71 and connect ing tube 76 17 Ensure all ...

Page 1011: ...0 1 Clean old sealant from around door frame and clean surface with cleaning solvent C420 2 Install new window seal 32 around edge of window 26 transparency 3 Mask off window 26 transparency to minimize contact from squeeze out of silicone compound C221 Silicone Compound C221 4 Apply silicone compound C221 around door frame that mates to surface of seal Spread evenly using small brush 5 Install wi...

Page 1012: ...ce Manual Page 412 Revision 20 52 00 00 25 25 1 25 14 15 12 11 16 11 12 10 9 3 4 5 7 13 6 13 14 15 6 7 3 4 5 29 27 28 8 27 30 31 32 33 24 16 23 20 19 21 24 22 3 34 9G52 007 1 35 36 81 81 17 18 33 26 2 Figure 401 Cockpit Door Window Assembly Sheet 1 of 4 ...

Page 1013: ...9 4 PL 39 2 PL 37 4 PL 38 4 PL 40 38 2 PL 41 50 51 53 54 55 58 53 54 55 49 63 56 53 54 55 58 59 53 54 55 53 54 55 60 59 REF LOCK POSITION SLAM POSITION OPEN POSITION 9G52 007 2 VIEW LOOKING DOWN 45 47 52 42 44 46 35 36 43 57 57 52 62 61 57 48 48 48 57 ORIGINAL CONFIGURATION Figure 401 Cockpit Door Window Assembly Sheet 2 of 4 ...

Page 1014: ...E REPLACE EXISTING SCREWS AND WASHERS AT THESE LOCATIONS TO FILL HOLES VIEW A A A 9G52 007 3 UPPER AND LOWER LATCH BLOCKS ARE TYPICAL 72 73 71 REF 76 77 78 REF 67 79 80 74 65 66 64 42 44 47 45 43 2 PL 36 46 35 69 68 40 70 75 A 76 REF 71 60 67 NOTE 57 58 40 68 69 70 REF 75 NOTE Figure 401 Cockpit Door Window Assembly Sheet 3 of 4 ...

Page 1015: ...M 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 415 Revision 20 52 00 00 11 85 12 9G52 007 4 VIEW LOOKING INBOARD VIEW LOOKING OUTBOARD 82 83 84 86 Figure 401 Cockpit Door Window Assembly Sheet 4 of 4 ...

Page 1016: ... HANDLE 47 INTERIOR DOOR HANDLE 48 HEX FITTING 49 CABLE ASSEMBLY 50 CLEVIS PIN 51 COTTER PIN 52 LINK 53 CLEVIS PIN 54 WASHER 55 COTTER PIN 56 CLEVIS ASSEMBLY 57 HEX NUT 58 CLEVIS 59 CLEVIS 60 TURNBUCKLE ROD 61 CLEVIS PIN 62 SPACER 63 RETURN SPRING 64 CLEVIS PIN 65 WASHER 66 COTTER PIN 67 CLEVIS 68 CLEVIS PIN 69 WASHER 70 COTTER PIN 71 EXTENSION SPRING 72 SCREW 73 WASHER 74 SPACER 75 CLEVIS 76 CONN...

Page 1017: ...19 Lower Aft Cabin Door Link A Lower Aft Cabin Door Link Removal Ref Figure 402 1 Remove nut 6 washers 7 bolt 8 and bushing 9 2 Remove nut 11 washers 12 and 13 bolt 14 and bushing 15 Remove link 10 B Lower Aft Cabin Door Link Installation Ref Figure 402 Consumable Materials Ref CSP SPM Item Nomenclature C107 Grease Aircraft Grease Aircraft C107 1 Install bushings use aircraft grease C107 2 Put lin...

Page 1018: ...riage Track Roller A Horizontal Track Roller Removal Ref Figure 402 1 Remove cabin door 2 Remove nut 11 washer 32 if installed washer 33 post 37 and pin rivet or screw 36 B Horizontal Track Roller Installation Ref Figure 402 Consumable Materials Ref CSP SPM Item Nomenclature C310 Primer 1 Install post in track roller Primer C310 2 Apply primer C310 to mating surfaces of post and carrage 3 While pr...

Page 1019: ...move pivot lug 29 B Pivot Lug Installation Ref Figure 402 Consumable Materials Ref CSP SPM Item Nomenclature C107 Grease Aircraft Grease Aircraft C107 1 Apply aircraft grease C107 to bush ing 2 Put pivot lug in its installed position 3 Install bushing pin rivet washers and nut Torque nut 4 Install cabin door 27 Pivot Lug Vertical Track Roller A Pivot Lug Vertical Track Roller Removal Ref Figure 40...

Page 1020: ... 56 washers 54 bolts 48 and 69 and support plates 57 and 70 5 Remove and discard cotter pins 49 Remove washers 44 and clevis pins 50 Disconnect tubes 46 and 47 6 Remove tubes 46 and 47 7 Remove screws 58 and 59 and washers 54 Remove inner door handle 60 8 Remove and discard cotter pin 43 Remove clevis pin 52 Disconnect tube 53 9 Remove clevis 66 and nut 67 10 Remove and discard cotter pin 49 Remov...

Page 1021: ... washers Torque screws 19 Connect tube 47 to bottom bolt Install clevis pin washer and cotter pin 20 Adjust clevis in tube 47 until bottom bolt extends 1 28 in 32 5 mm below door frame 21 When adjustment is correct connect tube 47 and install clevis pin washer and cotter pin 22 Put inner door handle in its installed position and install screws and wash ers Torque screws 23 Turn inner handle clockw...

Page 1022: ...stall handle housing handle and screws Torque screws 3 Turn handle to SAFELOCK position 4 Install clevis in tube 9 with approxi mately one half of clevis in tube 5 Put tube 9 in its installed position 6 Connect tube 9 to handle housing and Install clevis pin washer and cotter pin 7 Adjust clevis in tube 9 until bellcrank will be approximately 80 degrees from horizontal 8 Connect tube 9 to bellcran...

Page 1023: ...l corner of cabin window 22 until corner pops out of seal 23 on internal side 2 Keep pressure near point window is still engaged in seal push window out of seal 3 Remove seal B Window Installation NOTE Smooth door seal on door frame by hand to get full length of seal on frame 1 Install window seal on door frame Grease Fluorosilicone C121 2 Apply fluorosilicone grease C121 to window seal NOTE Keep ...

Page 1024: ... 402 Consumable Materials Ref CSP SPM Item Nomenclature C310 Primer A Cabin Door Fitting Removal 1 Remove screws 73 Remove cabin door fitting 74 B Cabin Door Fitting Installation Primer C310 1 Put cabin door fitting in its installed position Install screws install wet with primer C310 Torque screws 12 15 in lb 1 36 1 69 Nwm ...

Page 1025: ...nance Manual Page 425 Revision 32 52 00 00 35 35 38 34 34 29 31 31 32 32 25 12 12 33 11 24 26 35 39 32 34 12 12 42 40 27 41 5 4 28 3 5 9G52 008 1C 2 17 17 16 23 5 5 22 22 23 1 Figure 402 Cabin Door Window With EARLY CONFIG Latch Mechanism Sheet 1 of 2 ...

Page 1026: ...2 14 12 15 33 11 11 33 13 12 11 36 20 19 18 6 7 8 9 58 54 4 PL 60 59 59 65 54 51 50 44 49 53 68 47 67 66 52 43 50 44 49 68 46 62 64 63 61 49 44 53 68 50 69 44 43 70 47 45 55 54 56 54 57 43 44 45 46 55 54 56 54 48 71 59 54 72 59 54 LEFT SIDE SHOWN 73 4 PL 74 Figure 402 Cabin Door Window With EARLY CONFIG Latch Mechanism Sheet 2 of 2 ...

Page 1027: ...E OR SCREW OR BOLT 32 WASHER EARLY CONFIG 33 WASHER 34 POST 35 TRACK ROLLER 36 PIN RIVET OR SCREW 37 DOOR POST 38 SPACER 39 PIN RIVET OR BOLT 40 QUICK RELEASE PIN 41 DOOR STOP 42 DOOR UPPER FITTING 43 COTTER PIN 44 WASHER 45 CLEVIS PIN 46 TOP CONNECTING TUBE 47 BOTTOM CONNECTING TUBE 48 TOP BOLT 49 COTTER PIN 50 CLEVIS PIN 51 BELLCRANK 52 CLEVIS PIN 53 CENTER CONNECTING TUBE 54 WASHER 55 SCREW 56 ...

Page 1028: ... 7 6 12 11 8 10 26 28 2 PL 27 4 PL 3 4 PL 9 REF 4 14 18 REF 17 2 PL 3 2 PL 15 19 11 12 18 REF 18 20 12 1 12 11 22 23 17 2 PL 3 2 PL 16 4 PL 3 4 PL 25 19 11 12 24 21 REF 21 11 23 13 13 12 11 2 3 PL 3 3 PL 9G52 015A 9 13 9 REF 16 4 PL 3 4 PL 29 Figure 403 Cabin Door Bolting System CURRENT CONFIG ...

Page 1029: ...gure 404 1 Align baggage door assembly 30 with upper and lower door hinge halves 2 Install bolt 1 washers 2 3 and 4 and nut 5 joining upper door hinge 29 and upper fuselage hinge 28 3 Install bolt 6 washers 2 3 and 7 and nut 5 joining lower spoiler hinge 34 and lower door hinge 35 34 Door Strut Assembly A Door Strut Assembly Removal Ref Figure 404 1 Remove nut 5 washer 3 and bolt 8 that attach doo...

Page 1030: ... 23 and 24 and guide assemblies 19 to door assembly 30 7 Remove nut 51 and washers 49 and 50 that attach bellcrank 47 to crank spindle 8 Remove nuts 68 washers 67 and bolts 66 that attach exterior handle assembly 48 9 Remove nuts 22 washers 20 and bolts 21 that attach mounting bracket assembly 42 to door assembly 30 B Door Latch Mechanism Installation Ref Figure 404 Consumable Materials Ref CSP SP...

Page 1031: ... attaching rod end 63 to lower bolt rod assembly 54 16 Install washer 58 and compression spring 65 on lower bolt rod assembly 54 17 Insert bolt rod assembly 54 into lower guide assembly 19 18 Install clevis pin 60 washer 61 and cotter pin 62 attaching upper end of connecting tube 52 to bellcrank 47 19 Rotate rod end 63 in connecting tube 52 until 19 60 0 50 in 49 78 1 27 cm dimension measured from...

Page 1032: ...r assembly 30 Ref Section 52 00 00 40 Upper Hinge Fuselage A Upper Fuselage Hinge Removal Ref Figure 404 1 Remove door assembly 30 Ref Section 52 00 00 2 Remove nuts 14 washers 2 and bolts 39 and 40 that attach upper fuselage hinge 28 and shims 25 3 Remove hinge 28 and shims 25 B Upper Fuselage Hinge Installation Ref Figure 404 1 Align hinge 28 and shims 25 and install bolts 39 and 40 washers 2 an...

Page 1033: ...PL 67 2 PL 66 2 PL 9G52 009 1A 14 2 2 15 16 32 31 8 3 5 33 9 30 41 23 18 2 14 9 10 12 10 11 20 22 21 20 2 14 52 REF 24 17 18 17 36 47 55 56 57 56 63 64 19 52 54 53 42 51 50 49 48 47 42 52 46 69 44 45 44 2 PL 45 2 PL 43 2 PL 60 61 62 52 58 59 65 60 61 62 Figure 404 Baggage Door Assembly Sheet 1 of 2 ...

Page 1034: ... Inc Rotorcraft Maintenance Manual Page 434 Revision 22 52 00 00 9G52 009 2B 27 38 37 34 5 3 7 6 2 38 37 35 27 2 14 13 2 14 14 2 25 3 5 28 25 2 40 2 39 1 2 4 38 2 29 26 26 2 14 71 70 Figure 404 Baggage Door Assembly Sheet 2 of 2 ...

Page 1035: ...BLY 43 STOP STUD 44 WASHER 45 NUT 46 PAWL 47 BELLCRANK 48 EXTERIOR HANDLE ASSEMBLY 49 WASHER 50 WASHER 51 NUT 52 CONNECTING TUBE ASSEMBLY 53 UPPER BOLT ROD ASSEMBLY 54 LOWER BOLT ROD ASSEMBLY 55 CLEVIS PIN 56 WASHER 57 COTTER PIN 58 WASHER 59 COMPRESSION SPRING 60 CLEVIS PIN 61 WASHER 62 COTTER PIN 63 ROD END 64 HEX NUT 65 COMPRESSION SPRING 66 BOLT 67 WASHER 68 NUT 69 BOLT 70 HINGE STOP 71 RIVET ...

Page 1036: ...stalled position and install screws washers and if neces sary spacer washers Torque screws 2 Install baggage door switch E Baggage Door Switch CURRENT CONFIG Removal Ref Figure 405 1 Remove screws 17 and disconnect wire harness 2 Remove nuts 18 lock washers 19 washers 11 and screws 12 Remove switches 20 and switch actuator 21 F Baggage Door Switch CURRENT CONFIG Installation Ref Figure 405 1 Put s...

Page 1037: ...L 9 2 PL EARLY CONFIG CURRENT CONFIG 12 2 PL 18 2 PL 22 NOTE IF NECESSARY TO GET THE CORRECT ADJUSTMENT ADD WASHERS BETWEEN BRACKET AND HELICOPTER STRUCTURE 10 3 PL 17 6 PL 1 BRACKET 2 WASHER 3 SCREW 4 SPACER WASHER 5 WASHER 6 SCREW 7 SWITCH 8 LOCK WASHER 9 NUT 10 SCREW 11 WASHER 12 SCREW 13 SCREW 14 WASHER 15 SPACER WASHER 16 NUT 17 SCREW 18 NUT 19 LOCK WASHER 20 SWITCH 21 SWITCH ACTUATOR 22 BRAC...

Page 1038: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 438 Revision 32 52 00 00 This page intentionally left blank ...

Page 1039: ...e Ref Section 52 00 00 8 Inspect door latching mechanisms for functional operation excessive wear cracks and or corrosion at contact locations No damage allowed If any damage is evident replace components Ref Section 52 00 00 a Cabin Door Inspect vertical movement of door latch pin with door handle in closed SAFE LOCK position Refer to rigging verification procedure for movement limitations and ad...

Page 1040: ...l positions 2 Close and latch doors from inside and inspect entire contacting surface areas for even alignment 3 Verify that latching mating surfaces align properly and strike extends 0 325 010 inches into striker plate when closed and 0 450 010 inches when locked 4 Observe that door is forced inward for seal compression at each latch position a Unequal striking or latching may indicate latch asse...

Page 1041: ...r using a force of 30 lb 13 61 kg Mechanism shall prevent door from closing 15 CURRENT CONFIG Open door to 52 in 132 cm position Ensure forward edge of door is aft of aft door pillar C Baggage Door Operational Test 1 Verify door handle at all positions for functional operation 2 Close and latch door from outside and observe closure and positive locking as handle is turned to SAFELOCK position 3 Ve...

Page 1042: ...cover plate 1 15 in 3 25 cm c Push down on upper pin Pin shall move less than 0 05 in 1 27 mm 3 CURRENT CONFIG On bottom latch pin verify pin protrudes past cover plate 1 36 in 3 45 cm a Push up on bottom pin Pin shall move less than 0 05 in 1 27 mm b On upper latch pin verify pin protrudes past cover plate 1 28 in 3 25 cm c Push down on upper pin Pin shall move less than 0 05 in 1 27 mm 4 Rotate ...

Page 1043: ... ÏÏÏÏ SAFE LOCK FLIGHT POSITION KEYLOCK OPEN SLAM MAINTAIN A STRAIGHT ALIGNMENT OF THESE TWO ITEMS AT THE LOADING POSITION WHEN THE BOLT IS CLAMPED DOWN DETENT ADJUSTMENT SETSCREW 4 3 2 1 ORIGINAL CONFIGURATION 1 LINK 2 CLEVIS 3 SCREW 4 CABLE SUPPORT PLATE Figure 602 Cockpit Door Latch Mechanism Rigging Verification ...

Page 1044: ...RRENT CONFIG SHOWN COVER PLATE 1 28 IN 3 25 CM NOTE 1 COVER PLATE 80 o TYP TO CLOSE LATCHING POSITION OPENED POSITION SAFE LOCK FLIGHT POSITION KEY LOCK 80 o TYP TO OPEN CURRENT CONFIGURATION OPENED POSITION SAFE LOCK FLIGHT POSITION KEY LOCK EARLY CONFIGURATION 160 o 80 o 10 30 o SLAM Figure 603 Cabin and Baggage Door Latch Mechanism Rigging Verification Sheet 1 of 2 ...

Page 1045: ...M 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 607 Revision 22 52 00 00 BOLT ROD ASSEMBLY BOLT ROD ASSEMBLY 9G52 016 Figure 603 Cabin and Baggage Door Latch Mechanism Rigging Verification Sheet 2 of 2 ...

Page 1046: ...stays off when door is in SAFELOCK Power Off 4 Make sure all electrical power is disconnected from helicopter Ref CSP RMM 3 Section 96 00 00 B Baggage Door Switch Adjustment CURRENT CONFIG Ref Figure 405 1 Apply external electrical power to helicopter Ref CSP RMM 3 Section 96 00 00 2 Loosen nuts 18 and adjust switches 20 until BAGGAGE DOOR caution light on IIDS stays on when door is not in SAFELOC...

Page 1047: ...Doors Windows A Cabin Door Window Water Leak Repair Consumable Materials Ref CSP SPM Item Nomenclature C221 Silicone Compound C419 Alcohol Isopropyl Alcohol Isopropyl C419 1 Clean area to be sealed with isopropyl alcohol C419 and dry Silicone Compound C221 2 Apply silicone compound C221 locally as required to stop water leakage ...

Page 1048: ......

Page 1049: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual FUSELAGE Chapter ...

Page 1050: ......

Page 1051: ... Wipers Option 1 C Chin Windscreens 1 D Windscreen Washer Option 1 Figure 1 Windscreens and Nose Area 2 3 Cockpit Installation 2 A Cockpit Assembly 2 Figure 2 Cockpit Installation and Cockpit Assembly 4 B Cockpit Roof Skin 4 C Tub Forward Skins 5 D Lower Nose Panel 5 E Lower Fillets 5 F Landing Light Window 5 G Attachment Angles Cleats and Reinforcing Strap 5 H Cockpit Upper Door Seals 5 Fault Iso...

Page 1052: ... Panel Removal 206 P Relay Panel Installation 206 Q Windscreen Wiper Inspection 206 Figure 203 Windscreen Wiper Installation Sheet 1 of 2 207 Figure 204 Windscreen Wiper Relay Panel 210 R Windscreen Wipers Rigging Operational Check EARLY CONFIG 211 S Windscreen Wipers Rigging Operational Check CURRENT CONFIG 211 T Wiper Arm Tension Adjustment 211 Figure 205 Windscreen Wiper Rigging Operational Che...

Page 1053: ...hment Fittings 9 G FS 155 50 Frame Assembly 9 Figure 5 FS 155 50 Tub Bulkhead and Frame Assemblies Forward Skid Attachment Fittings 10 H FS 230 50 Tub Bulkhead Assembly 11 I FS 230 50 Lower Frame Assemblies 11 J Aft Skid Attachment Assembly 11 K Cabin Door Frames Assemblies 12 L Boat Tail Assembly 12 Figure 6 Aft Skid Attachment Assembly 13 M Step Ribs 13 N Tie Down Fittings 13 3 Side Skin Install...

Page 1054: ... E Fuselage Cabin Area Inspection 202 Figure 201 Cockpit Cabin and Baggage Compartment Floor Panels 202 F Aft Fuselage Area and Baggage Compartment Inspection 203 2 Cockpit Outboard Left Floor Panel AL129 203 A Cockpit Outboard Left Floor Panel Removal 203 B Cockpit Outboard Left Floor Panel Installation 203 3 Cockpit Outboard Right Floor Panel AR129 204 A Cockpit Outboard Right Floor Panel Remova...

Page 1055: ... Center Panel Installation 211 11 Baggage Floor Outboard Panels AL250 and AR250 211 A Baggage Floor Outboard Panels Removal 211 B Baggage Floor Outboard Panels Installation 211 Figure 204 Baggage Compartment Floor Panels 212 12 Cabin Step Optional 212 A Cabin Step Removal 212 B Cabin Step Installation 212 13 Cabin Step Plug 213 A Cabin Step Plug Removal 213 B Cabin Step Plug Installation 213 Figur...

Page 1056: ...e 8 Forward Duct Aft Duct Anti Torque Diffuser Stator and Diverter Plate Installation 19 D Anti Torque Fan Support Structure 20 E Tailboom Attachment Ring Assembly 20 Figure 9 Anti Torque Fan Support Structure Aft Duct Assembly and Tailboom Attachment Ring Assembly 21 Figure 10 Rear Fuselage Shell Assemblies 22 F Rear Fuselage Shell Assemblies 22 Figure 11 Baggage Door Frame Installation 23 6 Bagg...

Page 1057: ...igure 403 Access Door Strikers EARLY CONFIG 406 4 Forward Fairing Support Assembly 407 A Forward Fairing Support Assembly Removal 407 B Forward Fairing Support Assembly Installation 407 Figure 404 Forward Fairing Support Assembly 408 5 Fixed Panel Assembly 408 A Fixed Panel Assembly Removal 408 B Fixed Panel Assembly Installation 408 Figure 405 Fixed Panel Assembly 409 6 Fixed Panel Bracket Assemb...

Page 1058: ... Assembly Removal 417 B Inlet Screen Assembly Installation 417 14 Upper Inlet Duct Assembly T240 417 A Inlet Assembly Removal 417 B Inlet Assembly Installation 417 15 Middle Inlet Duct Assembly F4 417 A Middle Inlet Duct Assembly Removal 417 B Middle Inlet Duct Assembly Installation 418 Figure 410 Upper and Middle Inlet Duct Assemblies 419 16 Forward Duct Assembly Anti Torque Fan F1 F2 and F3 420 ...

Page 1059: ...ssembly 801 A Cowling Latch Replacement EARLY CONFIG 801 Figure 801 Cowling Latch Replacement EARLY CONFIG 802 B Forward Access Door Seal Replacement 802 C Transmission Access Door Seal Replacement 803 Figure 802 Transmission Access Door and Forward Access Door Seals 804 2 Support Assembly 804 A Support Assembly Duct Frame Seal Replacement 804 Figure 803 Support Assembly Duct Frame Seal 805 3 Swas...

Page 1060: ...03 Tailboom Thruster and Extension Fairings 208 3 Lower Tailboom Thruster Fairing Assembly S2 209 A Lower Tailboom Thruster Fairing Assembly Removal 209 B Lower Tailboom Thruster Fairing Assembly Installation 209 4 Upper Tailboom Thruster Fairing Assembly SL1 SR1 209 A Upper Tailboom Thruster Fairing Assembly Removal 209 B Upper Tailboom Thruster Fairing Assembly Installation 209 5 Thruster Extens...

Page 1061: ...ver Installation 219 C Tailboom Aft Coaxial Cover Removal 220 D Tailboom Aft Coaxial Cover Installation 220 E Tailboom Aft Wiring Cover Removal 220 F Tailboom Aft Wiring Cover Installation 221 53 55 00 Empennage A Description and Operation 1 1 Empennage General 1 2 Horizontal Stabilizer 1 A Horizontal Stabilizer Bonded Assembly 1 B Lower Structural Skin Panel 1 C Inboard and Outboard Rib 1 D Empen...

Page 1062: ...plates Vertical Stabilizer 405 B Endplate Installation 405 Inspection Test 601 1 Empennage 601 A Empennage Inspection Area 7 601 B Endplate Inspection Area 7 601 C Endplate Spar Tube Inspection Area 7 601 D Elastomeric Damper Condition Test 601 Figure 601 Endplate Spar Tube Bearing Journal Measurement 602 Figure 602 Elastomeric Damper Condition Test 602 Repairs 801 1 Replacement of a Journal Beari...

Page 1063: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 53 00 00 Fuselage ...

Page 1064: ......

Page 1065: ...s nuts rivets and screws i Misalignment of control and drive components j Mismatch of panels k Warps 2 For the NOTAR fan assembly do the Anti Torque Fan Sudden Stoppage Conditional Inspection ref Section 05 50 00 Table 204 3 Do the Helicopter Leveling ref Section 08 20 00 Maintenance Practices NOTE For each floor do an inclinometer meas urement longitudinally and laterally a Put an inclinometer T2...

Page 1066: ...Maintenance Manual Page 602 Revision 35 53 00 00 A DIM RHB DIM LHB 9G53 13 5 DIM FRS DIM FLS OPPOSITE DIM ARS DIM ALS OPPOSITE DIM RFD DIM LFD OPPOSITE DIM RAD DIM LAD OPPOSITE RIGHT SIDE SHOWN LEFT SIDE OPPOSITE Figure 601 Symmetry Measurements ...

Page 1067: ...n FRS 0 1 inch 2 5 mm d Measure the distance from the aft top of the left passenger door step to the ground 1 Record the measurement as Dimension ALS 2 Dimension ALS must equal Di mension ARS 0 1 inch 2 5 mm e Measure the distance from the forward screw in the top of the right passenger cabin door frame to the cabin floor 1 Record the measurement as Dimension RFD 2 Dimension RFD must be 49 4 to 49...

Page 1068: ... Seat Restraint System Inspection ref Section 25 20 00 Inspection Test b Do the Seat Restraint System Operational Test ref Section 25 20 00 Inspection Test c Do the Seat Operational Test ref Section 25 20 00 Inspection Test d Do the Seat Energy Absorption System EAS Inspection ref Section 25 20 00 Inspection Test 9 Examine the landing gear a Examine the crosstubes forward spacer fittings skid tube...

Page 1069: ... Test g Do the Fuselage Aft Area Inspection ref Section 53 30 00 Inspection Test 12 Examine the tailboom a Do the Tailboom Inspection ref Section 53 40 00 Maintenance Practices b Do the Tailboom Bumper Inspection ref Section 53 40 00 Maintenance Practices 13 Examine the empennage a Do the Empennage Inspection ref Section 53 55 00 Inspection Test b Do the Endplate Inspection ref Section 53 55 00 In...

Page 1070: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 606 Revision 35 53 00 00 This page intentionally left blank ...

Page 1071: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 53 10 00 Windscreens and Nose Area ...

Page 1072: ......

Page 1073: ...screens are stretched acrylic transparencies located in front of each crew station The windscreens are mounted to the framework of the cockpit assembly by machine screws packings washers and self locking nuts B Windscreen Wipers Option The windscreen wiper option installs wind screen wipers onto the pilots and copilots windscreens Hardcoat Windscreens are required for wiper installation and operat...

Page 1074: ...wer nose panel lower fillet components aircraft battery compartment and the chin bow sill Additional components include attachment angles and cleats a reinforcing strap and various seals A Cockpit Assembly The cockpit assembly includes the cockpit and chin windscreens landing light window and nose access door assembly The major compo nents of the cockpit assembly are the cockpit roof structure cen...

Page 1075: ...hanically fastened to the left and right door pillar assemblies The lower portion of the assembly is mechanically fastened to the cockpit subfloor support structure and to the tub shell of the general tub assembly Fastening is by rivets The chin bow assembly is made up of an outer skin panel and left and right inner skin panels that are secondarily bonded together The outer skin panel is fabricate...

Page 1076: ...bow assembly This provides an environmental seal for the battery compartment The access door is fabricated of multiple plies of graphite epoxy and barrier plies of fiber glass epoxy cocured with a syntactic epoxy foam core Around the periphery of the door the panel transitions to a monolithic laminate The mounting bracket and shim are fabricated from aluminum alloy sheet The hinges and turnlock fa...

Page 1077: ...t window The lower nose panel is fabricated of multiple plies of graphite epoxy and barrier plies of fiberglass epoxy cocured with a syntactic epoxy foam core Around the periphery the panel transitions to a monolithic laminate A ply of Astrostrik is cocured to the exterior surface of the panel E Lower Fillets The left and right lower fillets are secondary structural components that complete the jo...

Page 1078: ......

Page 1079: ...lty relay CURRENT CONFIG Replace relay 20 60 00 Left or right wiper does not operate in any switch position Faulty wiring Test and repair wiring 20 60 00 Faulty circuit breaker Replace circuit breaker 20 60 00 Faulty wiper switch Replace wiper switch 20 60 00 Faulty relay CURRENT CONFIG Replace relay 20 60 00 Faulty wiper motor Replace wiper motor 53 10 00 Left or right wiper does not provide a cl...

Page 1080: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 102 Revision 24 53 10 00 This page intentionally left blank ...

Page 1081: ...dscreen 1 2 Carefully cut and remove sealant from around windscreen 3 Remove screws 2 packing washers 3 flat washers 4 and nuts 5 which secure windscreen to airframe 4 Lift windscreen from airframe using care to prevent damage to seal bond surfaces B Windscreen Installation Ref Figure 201 Consumable Materials Ref CSP SPM Item Nomenclature C207 Sealing Compound Fuel Resistant NOTE Installation of e...

Page 1082: ...c Rotorcraft Maintenance Manual Page 202 Original 53 10 00 1 2 3 4 5 9G53 088 1 RIGHT CHIN WINDSCREEN 2 RIGHT COCKPIT WINDSCREEN 3 COCKPIT INSTALLATION 4 LEFT COCKPIT WINDSCREEN 5 LEFT CHIN WINDSCREEN Figure 201 Cockpit Windscreens ...

Page 1083: ...12 7 mm C Windscreen Inspection Ref Figure 202 and Table 201 NOTE Minor defects or imperfections that do not block pilot visibility or that are not obvi ous signs of imminent structural failure can be thought of as negligible ref Table 201 for approved repair limits 1 Inspect all windscreens for cracks scratches and obstructions to visibility 2 Inspect windscreen edge sealant for cuts tears cracks...

Page 1084: ...ut maximum of 60 in lb 6 78 Nm 5 Install nut and washer attaching arm to wper blade onto wiper blade Torque nut Ref CSP SPM 6 Torque hub bolt Ref CSP SPM 7 Perform rigging check Ref R EARLY CONFIG or S CURRENT CONFIG Windscreen Wipers Rigging Operational Check E Wiper Link Removal EARLY CONFIG Ref Figure 203 and Figure 205 1 Remove nut 7 and washer 8 Figure 205 and remove wiper link from wiper bla...

Page 1085: ... 3 Remove bolts 23 and washers 21 and remove motor L Wiper Motor Installation Ref Figure 203 Consumable Materials Ref CSP SPM Item Nomenclature C205 Sealing Compound 1 Position wiper motor and install bolts and washers Torque bolts Ref CSP SPM Verify proper P535 P536 con nection 2 Prepare surface for electrical bond Ref CSP SPM 3 Attach bonding jumper and electrical connection 4 Perform electrical...

Page 1086: ...l 3 Remove relay panel P Relay Panel Installation Power Off 1 Verify all power is removed from helicopter Ref Section 96 00 00 2 Place relay panel 3 in position and install screws 1 and washers 2 Torque screws 3 Attach connector P539 to connector J1 4 Install access panels PL120 and PR120 Ref Section 06 00 00 5 Restore power to helicopter Ref Section 96 00 00 Q Windscreen Wiper Inspection Ref Figu...

Page 1087: ...6 1 1 2 3 2 PL 4 5 6 2 PL 7 2X 2 PL 8 2X 2 PL 9 2 PL 10 2 PL 11 2 PL 13 2 PL 12 20 2 PL 21 2X 2 PL 22 2 PL 15 25 4 PL 27 25 2 PL 23 4 PL 24 4 PL 9 REF ROTATED 180 LH SHOWN RH OPP 31 32 29 8 PL 30 16 PL 33 2 PL 34 2 PL 35 2 PL 36 2 PL 37 38 39 14 2 PL 40 4PL 41 4PL 42 4PL 43 4PL Figure 203 Windscreen Wiper Installation Sheet 1 of 2 ...

Page 1088: ...tenance Manual Page 208 Revision 20 53 10 00 9G53 126 2 28 CURRENT CONFIGURATION OPTIONAL LOCATIONS WIPERS HI LO OFF CURRENT CONFIGURATION WINDSCREEN WIPER CONTROL EARLY CONFIGURATION 44 46 46 46 Figure 203 Windscreen Wiper Installation Sheet 2 of 2 ...

Page 1089: ...SCREW PAN HEAD 17 WASHER FLAT 18 WASHER FLAT 19 NUT HEX SELF LOCKING 20 BOLT HEX HEAD EARLY CONFIG 21 WASHER FLAT EARLY CONFIG 22 NUT HEX SELF LOCKING EARLY CONFIG 23 SCREW PAN HEAD 24 WASHER FLAT 25 FAY MATERIAL 26 SPACER SLEEVE 27 JUMPER BONDING 28 SWITCH INSTALLATION EARLY CONFIG 29 NUTPLATE SELF LOCKING 30 RIVET FLUSH 31 WIPER BLADE RH 32 WIPER BLADE LH 33 NUT WIPER ARM ATTACH 34 WASHER HUB 35...

Page 1090: ...MM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 210 Revision 20 53 10 00 9g53 130 3 1 2 3 PLCS LOOKING INBOARD 1 SCREW 2 WASHER 3 PANEL WINDSCREEN WIPER RELAY Figure 204 Windscreen Wiper Relay Panel ...

Page 1091: ...nal Check CURRENT CONFIG Ref Figure 205 Do Not operate wipers on a dry windscreen 1 Apply electrical power to the helicopter and verify that the motor is in the PARK position Ref Section 96 00 00 2 Remove power from aircraft Ref Section 96 00 00 3 Verify that wiper blade attach end of wiper arms are 2 0 4 5 in 5 1 11 4 cm from aircraft BL 0 00 4 If adjustment is required loosen hub bolt 37 and nut...

Page 1092: ...N 2 9 2 PL 10 4 PL 11 2 PL 14 6 EARLY CONFIGURATION 7 2 PL 8 2 PL 1 WIPER BLADE LH 2 WIPER BLADE RH 3 LINK ASSEMBLY LH 4 LINK ASSEMBLY RH 5 ARM WIPER 6 ARM WIPER 7 NUT SELF LOCKING EARLY CONFIG 8 WASHER PLASTIC EARLY CONFIG 9 BOLT CURRENT CONFIG 10 WASHER FLAT CURRENT CONFIG 11 NUT SELF LOCKING CURRENT CONFIG 12 WASHER CURRENT CONFIG 13 SPACER CURRENT CONFIG 14 LINK UPPER CURRENT CONFIG Figure 205...

Page 1093: ...t Window Panel Installation Ref Figure 206 1 Position landing light window panel in frame and align screw holes 2 Secure window to airframe with screws packing washers and flat washers 4 Nose Access Door N80 A Nose Access Door Inspection 1 Inspect door for general condition and security No damage allowed 2 Inspect door lock if applicable and quarter turn fasteners for security and verify proper op...

Page 1094: ...from hinge attach points at top of inside surface of door 4 Remove screws washers and nuts which secure door and bonding leads to hinges C Nose Access Door Installation Ref Figure 206 Consumable Materials Ref CSP SPM Item Nomenclature C203 Sealing Compound 1 Prepare surface for electrical bond Ref CSP SPM 2 Secure door and bonding leads to hinges with screws washers and nuts Torque nuts Sealing Co...

Page 1095: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 53 20 00 Lower and Center Fuselage ...

Page 1096: ......

Page 1097: ... console installation the general tub assembly the side skin installation the cockpit cabin and baggage floor installations the door track installation and the upper and lower work platform installations GENERAL TUB ASSEMBLY SIDE SKIN INSTALLATION DOOR TRACKS INSTALLATION CONSOLE INSTALLATION COCKPIT FLOOR INSTALLATION CABIN FLOOR INSTALLATION BAGGAGE FLOOR INSTALLATION LOWER WORK PLATFORM INSTALL...

Page 1098: ...fuel drain access panel assembly and the aft crosstube cover All panels are secondary structural components Avionics Access Panel Assemblies The left and right avionics access panel assemblies include an access panel a mounting frame access panel seal and miscellaneous mounting brackets and hardware Aircraft Serial Numbers 900 00010 through 900 00017 The access panel is fabricated as a composite s...

Page 1099: ...reas in which secondary attachment of the support rib channels occurs the honeycomb core is tapered and additional reinforcement plies of epoxy resin impregnated carbon fiber fabric are inlaid Support Rib Channels The support rib channels are secondary structural components that capture the upper edge of each respective fuel cell rib when the fuel cell liner assemblies are installed Each support r...

Page 1100: ...SEMBLY CENTER ACCESS PANEL ASSEMBLY COCKPIT SUBFLOOR SUPPORT STRUCTURE ASSEMBLY AFT CROSSTUBE COVER LH FS 166 50 DOOR FRAME ASSEMBLY RH OPPOSITE TUB SHELL ASSEMBLY BOAT TAIL ASSEMBLY LH FS 218 50 DOOR FRAME ASSEMBLY RH FS 218 50 DOOR FRAME ASSEMBLY LH FS 230 50 LOWER FRAME ASSEMBLY RH FS 230 50 LOWER FRAME ASSEMBLY NOTE FWD SKID ATTACHMENT FITTING AND AFT SKID ATTACHMENT ASSEMBLY ARE NOT SHOWN FS ...

Page 1101: ...erglass epoxy and a ply of Astrostrik is cocured to the panel Fuel Cell Support Ribs The fuel cell support ribs are the primary structural components that support the loads in the vertical direction produced by the fuel in the fuel cell Six fuel cell support ribs are positioned laterally between the keel beams and are located at FS 166 50 FS 176 60 FS 190 25 FS 199 20 FS 209 90 and FS 220 20 The r...

Page 1102: ... 00 Early Configuration keel beams are second arily bonded to the interior skin of the tub shell and riveted to the boat tail tub Current Configuration keel beams are riveted to the tub shell and the boat tail tub The keel beams are composite sandwich panels The panels utilizes multiple ply graphite epoxy and aramid epoxy skins cocured with Nomex honeycomb cores In areas in which secondary attachm...

Page 1103: ...pport cockpit loads in the longitudinal and vertical direc tions Each assembly combines a vertical web with an integral upper flange a lower flange cap and several vertical stiffening channels and angles All components within each assembly with the exception of the secondary attach ment angle along the aft edge and hardware are fabricated from aluminum alloy sheet The secondary attachment angles a...

Page 1104: ...tings provide the structural interface between the crew seat assemblies and the cockpit subfloor support structure assembly There are six crew seat attachment fittings three inboard and three outboard that support each crew seat These fittings are machined from aluminum alloy stock Attachment of the inboard crew seat fittings is by means of secondary channels attached to the web of each respective...

Page 1105: ...e left and right forward skid attachment fittings are machined from aluminum alloy stock Each fitting is joined to adjacent structure by pins and collars G FS 155 50 Frame Assembly Ref Figure 5 The FS 155 50 frame assembly is a primary structure This frame assembly provides support for loads in the vertical and lateral directions This frame assembly attaches the upper end of the cockpit assembly c...

Page 1106: ...age 10 Revision 25 53 20 00 RH FWD SKID ATTACHMENT FITTING FS 155 50 TUB BULKHEAD ASSEMBLY TUB ASSEMBLY REFERENCE FS 155 50 FRAME ASSEMBLY LH FWD SKID ATTACHMENT FITTING 9G53 031A Figure 5 FS 155 50 Tub Bulkhead and Frame Assemblies Forward Skid Attachment Fittings ...

Page 1107: ...tical and lateral directions Each assembly incorporates a vertical web web doubler plate an inboard reinforcing channel horizontal stiffening angles second ary attachment angles a splice plate and a butt joint strap All components within each assembly are with the exception of the secondary keel beam attachment angles and the hardware fabricated from aluminum alloy sheet The secondary keel beam at...

Page 1108: ... left and right rear fuselage shell assemblies The components included in this assembly are the boat tail tub the boat tail sills attachment cleats spoiler attachment inserts and bonded nutplates Boat Tail Tub The boat tail tub is a primary structural component and is the load bearing skin in the aft lower section of the fuselage The boat tail tub is a composite sandwich panel that utilizes multip...

Page 1109: ... installed between the tub shell and the adjacent keel beam on each side of the general tub assembly The step ribs are fabricated from aluminum alloy sheet Fastening of these components to adjacent components is by means of rivets N Tie Down Fittings The tie down fittings are secondary structural components that are the provisions for attachment of the passenger seat tracks and cargo tie down ring...

Page 1110: ... the step tread plate and grip are secondarily bonded to the precured skin panel Side Skin Panel The left and right side skin panels are composite sandwich panels that utilizes skins and reinforcement plies of graphite epoxy and fiberglass epoxy cocured with a syntactic epoxy foam core 0 020 inch 0 51 mm Around the periphery of each panel and in the areas of secondary attach ment of additional com...

Page 1111: ...each panel the core is tapered and the panel transitions to form integral monolithic laminate attachment flanges B Metallic Floor Panels Ref Figure 7 The floor panels that are metallic are the center floor panel the left and right outboard floor panels the fixed floor panel and the access panel beneath the right crew seat C Kick Strips The left and right kick strips cover the interface between the...

Page 1112: ...attachment of the fuel vent valve access covers B Metallic Panels and Covers Ref Figure 8 The panels that are metallic are the left and right outboard floor assemblies the left and right forward fuel vent valve access covers and the left and right aft fuel vent valve access covers These panels are fabricated from aluminum alloy sheet C Seat Tracks Ref Figure 8 The seat tracks are installed for att...

Page 1113: ...FORWARD ACCESS COVER ASSEMBLY AR155 SEAL SEAT TRACK 4 PL FORWARD FLOOR PANEL ASSEMBLY AR160 SEAL 3 PL SEAL 3 PL AFT FLOOR PANEL ASSEMBLY A217 SEAT TRACK 4 PL SEAL 4 PL CENTER FLOOR PANEL ASSEMBLY A170 LH FORWARD ACCESS COVER ASSEMBLY AL155 LH OUTBOARD FLOOR ASSEMBLY AL165 SEAL LH AFT ACCESS COVER ASSEMBLY AL230 LH CABIN KICK STRIP SEAT TRACK 6 PL RH AFT ACCESS COVER ASSEMBLY AR230 9G53 035 Figure ...

Page 1114: ...attachment flanges A Outboard Baggage Floor Panels Ref Figure 9 The left and right outboard baggage floor panels are fabricated from aluminum alloy sheet B Center Tie Down Fitting Ref Figure 9 The center tie down fitting is installed at the forward edge of center floor panel This fitting is machined from aluminum alloy stock C Aft Tie Down Plate Ref Figure 9 The aft tie down plate is installed cen...

Page 1115: ... base for the instrument panel the console also provides the provisions for installation of the engine fuel control panel the electrical light ing control panel the essential bus circuit breaker panel the utility panel the four channel DC dimmer and optional avionic equipment For information relating to the instrument panel refer to Section 95 00 00 For informa tion relating to the respective elec...

Page 1116: ...latform Assemblies Ref Figure 1 and Figure 10 The platform assemblies are attached by riveted hinges and cable assemblies All components within this installation are secondary structural components Upper and Lower Platform The upper and lower platform are composite sandwich panel assemblies that utilizes multiple ply skins and reinforcement plies of graphite epoxy and fiberglass epoxy cocured with...

Page 1117: ...LE ASSEMBLY 2 PL HINGE 2 PL PLATFORM SUPPORT BRACKET 2 PL QUARTER TURN FASTENER 2 PL UPPER PLATFORM NOTE LH UPPER AND LOWER INSTALLATION SHOWN RH OPPOSITE LOWER PLATFORM QUARTER TURN FASTENER 2 PL PLATFORM SUP PORT BRACKET 2 PL HINGE 2 PL CABLE ASSEMBLY 2 PL QUARTER TURN FASTENER RECEPTACLE 2 PL 9G53 042 Figure 10 Work Platforms ...

Page 1118: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 22 Original 53 20 00 This page intentionally left blank ...

Page 1119: ...e through the open floor panels No defects permitted 9 Remove the tailboom Ref Section 53 40 00 10 Use a 10X power glass to inspect the faying surfaces of the tailboom attach ring assembly and tailboom forward end fitting for cracks No cracks permitted 11 Inspect the roof structure from the tailboom attach frame forward for 18 in 45 7 cm a Look for rivets that are loose or have indications of move...

Page 1120: ...se None permitted E Fuselage Cabin Area Inspection 1 Inspect FS 155 50 frame assembly in cabin area for cracks mechanic dam age and mechanical fasteners that are loose None permitted 2 Inspect the A frame assembly for cracks mechanical damage and mechanical fasteners that are loose None permitted 3 Inspect the outboard side of keel beams for cracks delamination and impact damage None permitted 4 I...

Page 1121: ...eft Floor Panel Removal Ref Figure 202 Screw lengths vary at different locations around each floor panel Failure to install the correct length screws may damage nutplates in the floor substructure or cause loss of screws and possible FOD contamination During panel removal keep track of screw locations by pressing screws into a sheet of cardboard in a pat tern following the original hardware instal...

Page 1122: ... Removal Ref Figure 202 Screw lengths vary at different locations around each floor panel Failure to install the correct length screws may damage nutplates in the floor substructure or cause loss of screws and possible FOD contamination During panel removal keep track of screw locations by pressing screws into a sheet of cardboard in a pat tern following the original hardware installation Use of p...

Page 1123: ...nce Manual Page 205 Original 53 20 00 3 1 2 4 9G53 102 1 COCKPIT OUTBOARD LEFT FLOOR PANEL AL129 2 COCKPIT OUTBOARD RIGHT FLOOR PANEL AR129 3 COCKPIT FLOOR LEFT ACCESS PANEL AL138 4 COCKPIT FLOOR RIGHT ACCESS PANEL AR138 Figure 202 Cockpit Floor Panels ...

Page 1124: ...e access cover to the floor panel Torque all screws 5 If necessary install the cabin carpet and seats Ref Section 25 20 00 6 Cabin Floor Outboard Panels AL165 and AR165 A Cabin Floor Outboard Panel Removal Ref Figure 203 Defuel the helicopter before you remove both floor panels AL165 and AR165 Damage to the structure can occur if you remove both of these panels with fuel in the helicopter Screw le...

Page 1125: ...ack of screw locations by pressing screws into a sheet of cardboard in a pat tern following the original hardware installation Use of power tools during removal or installation of panels and attaching hard ware may damage nutplates or deform holes in composite panels and covers 1 Defuel the helicopter Ref Section 12 00 00 2 If necessary remove the cabin seats and carpet Ref Section 25 20 00 3 Remo...

Page 1126: ...the cabin floor center panel assembly A170 8 6 Thread fuel cell rod T801 with jam nuts and backing plates into four holes in panel 8 Engage threads into the fuel cell access covers 7 Thread the jam nuts down against backing plates 8 Remove the screws that attach the fuel cell to the floor panel 9 Loosen the jam nuts until there is no torque pressure from fuel cell rod T801 Remove rods with jam nut...

Page 1127: ...plates or deform holes in composite panels and covers 1 Defuel the helicopter Ref Section 12 00 00 2 If necessary remove the cabin seats and carpet Ref Section 25 20 00 3 Remove the screws and washers along trailing edge of cabin floor center panel assembly A170 8 4 Remove the left and right cabin floor aft access covers AL230 and AR230 Ref Section 53 20 00 5 Remove the baggage floor center panel ...

Page 1128: ...ent locations around each floor panel Failure to install the correct length screws may damage nutplates in the floor substructure or cause loss of screws and possible FOD contamination During panel removal keep track of screw locations by pressing screws into a sheet of cardboard in a pat tern following the original hardware installation Use of power tools during removal or installation of panels ...

Page 1129: ...damage nutplates or deform holes in composite panels and covers Defuel the helicopter before you remove floor panel A235 Damage to the struc ture can occur if you remove this panel with fuel in the helicopter NOTE This task is typical for the removal of the left and right baggage compartment floor panels AL250 and AR250 1 Defuel helicopter Ref Section 12 00 00 2 If necessary remove the baggage com...

Page 1130: ...t from the step to airframe interface 4 Install the cabin step plugs 5 if the cabin step is permanently removed 5 Install the outboard floor panel AL165 or AR165 Ref Section 53 20 00 B Cabin Step Installation Ref Figure 205 Consumable Materials Ref CSP SPM Item Nomenclature C237 Sealant NOTE This task is typical for installation of the left and right cabin steps 1 Remove the cabin step plugs 5 if ...

Page 1131: ...moval of the forward aft left side and right side cabin step plugs 1 Remove sealant from the plug to airframe interface 2 Remove the cabin step plug 5 B Cabin Step Plug Installation Ref Figure 205 Consumable Materials Ref CSP SPM Item Nomenclature C237 Sealant Sealant C237 NOTE This task is typical for installation of the forward aft left side and right side cab in step plugs 1 Apply sealant C237 ...

Page 1132: ...licopters Inc Rotorcraft Maintenance Manual Page 214 Original 53 20 00 9G53 118 4 6 6 3 2 2 1 1 2 2 3 5 2PL 7 7 1 NUT 2 WASHER 3 BOLT 4 CABIN STEP 5 CABIN STEP PLUG 6 BOOT 7 SUPPORT SADDLE Figure 205 Cabin Step Optional ...

Page 1133: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 53 30 00 Fuselage Upper Deck and Aft Area ...

Page 1134: ......

Page 1135: ...ly Ref Figure 2 The components that are included in the roof assembly are the roof structure assembly intermediate and aft cowling attachment angles aft fillet fairing and ribs rear fuselage shell assemblies the anti torque fan support structure and aft duct and the tailboom attachment ring assembly Additional components include various hardware such as an anchor plate receptacles and standard har...

Page 1136: ...MBLY AFT COWLING INSTALLATION FIREWALL BUILD UP ASSEMBLY 900 CONFIG FORWARD DUCT INSTALLATION AND NOTAR DIVERTER STATOR AND DIVERTER PLATE INSTALLATION NOT VISIBLE IN THIS VIEW NOTAR INLET SCREEN ASSEMBLY ENGINE DECK THERMAL INSULATION INSTALLATION NOT VISIBLE IN THIS VIEW 9G53 038A NACA CONFIG Figure 1 Fuselage Upper Deck and Aft Area ...

Page 1137: ... ATTACHMENT ANGLE RH SHOWN LH OPPOSITE RH AFT COWL ATTACHMENT ANGLE RH SHOWN LH OPPOSITE ROOF STRUCTURE ASSEMBLY LH REAR FUSELAGE SHELL ASSEMBLY LH SHOWN RH OPPOSITE LH AFT FILLET FAIRING LH SHOWN RH OPPOSITE ANTI TORQUE FAN SUPPORT STRUCTURE ANTI TORQUE FAN AFT DUCT ASSEMBLY 9G53 045 Figure 2 Roof Assembly ...

Page 1138: ...on shear and secondary attachment clips and cleats reinforcement gussets and standard hard ware B Engine Deck Aft Deck and Aft Outer Deck Skins Ref Figure 3 The engine deck aft deck and aft outer deck skins complete the deck skin aft of the forward roof deck skin for the roof assembly These components are primary structural compo nents and function as the shear panels for the roof assembly The lef...

Page 1139: ...OOF BEAM INSTALLATION RH OPPOSITE LH TITANIUM DECK SKIN LH ENGINE DECK SKIN LH AFT DECK SKIN RH AFT DECK SKIN LH AFT OUTER SKIN RH AFT OUTER SKIN LH AFT OUTER SKIN COMPONENT OF LH ROOF BEAM INSTALLATION RH OPPOSITE FWD DECK SKIN COMPONENT OF MID ROOF INSTALLATION RH TITANIUM DECK SKIN RH ENGINE DECK SKIN 9G53 044 Figure 3 Roof Structure Assembly ...

Page 1140: ...left and right vertical legs are machined from aluminum alloy stock Mast Fitting Assemblies The left and right forward mast fitting assemblies are primary structural components that are the provisions for attachment of the forward support trusses of the static mast assembly Each mast fitting assembly is installed with pins and collars Each mast fitting assembly consists of a machined fitting and f...

Page 1141: ...e local area reinforcement for secondary attachment of additional deck mounted hydraulic components The longeron doublers deck skin stiffeners reinforcing strap and doubler and attachment cleats and clips are fabricated from aluminum alloy sheet Forward Roof Intercostal The forward roof intercostal is a primary structural component that supports the hydraulic system compo nents mounted on the uppe...

Page 1142: ...nd functions as the shear panel for the roof structure The forward roof skin is fabricated from 020 inches thick aluminum alloy sheet Roof Longerons Five roof longerons are utilized within this assembly to join the FS 230 50 upper aft frame assembly the A frame assembly and the forward deck skin These longerons are primary structural components that support upper deck loads in the vertical and lon...

Page 1143: ...on Deck Doublers The left and right FS 220 50 deck skin doublers and the left and right inboard longeron deck doublers are secondary structural components that are installed near the aft edge of the forward roof deck skin The deck skin doublers and inboard longeron deck skin doublers are fabricated from aluminum alloy sheet Deck Skin Stiffeners and Lower Flange Channels The deck skin stiffeners an...

Page 1144: ...bricated from aluminum alloy sheet Aft Deck Engine Attachment Assemblies The left and right aft engine attachment assemblies are primary structural components that provide the provisions for attachment of the two aft legs of the bipod engine mounts Each aft engine attachment assembly consists of a fitting and a flanged bushing The aft engine attachment fittings are machined from titanium alloy sto...

Page 1145: ...e The aft deck angle is a primary structural component that functions as the attachment angle between the respec tive engine deck aft outer and aft deck skins and the rear fuselage shell assembly The aft deck angle is fabricated from aluminum alloy sheet Track Pockets The track pockets are secondary structural components that form evironmental closeouts at the cutouts in the forward outer skin for...

Page 1146: ... INSTALLATION RH ROOF BEAM INSTALLATION LH ROOF BEAM INSTALLATION A FRAME ASSEMBLY FS 230 50 UPPER FRAME ASSEMBLY RH FIREWALL SUPPORT CHANNEL AFT DECK STRUCTURE ASSEMBLY FWD ROOF STRUCTURE INSTALLATION LH FIREWALL SUPPORT CHANNEL NOTE UPPER DECK AND ROOF BEAM SKINS NOT SHOWN FOR CLARITY 9G53 043 Figure 5 Roof Structure Beam and Frame Assembly ...

Page 1147: ...mast fitting assemblies are attached to the FS 230 50 frame web at LBL and RBL 18 50 and roof longerons by pins and collars The fittings are attached to the deck skin by rivets Each mast fitting assembly consists of a fitting and a flanged bushing The mast fittings are machined from aluminum alloy stock The flanged bushings are machined from corrosion resistant steel The bushings are press fit ins...

Page 1148: ... Build Up Assembly Inlet Panels The inlet panels for the left and right engines form the forward and aft vertical walls of the air inlet plenum The inlet panels the associated attachment and stiffening angles and the components that are utilized to form the forward and aft seal land assemblies are formed and fabricated from either tita nium alloy or corrosion resistant steel Fastening is by monel ...

Page 1149: ...by monel rivets 4 Engine Deck Thermal Insulation Installation Ref Figure 7 The engine deck thermal insulation installa tion installs the fireproof and heat insulating blankets onto the left and right engine deck skins Each installation includes a forward aft and inboard thermal insulation compo nent All components are retain by sections of corrosion resistant steel material that incorpo rates a ho...

Page 1150: ...INLET SCREEN ASSEMBLY NOTAR INLET DUCT ASSEMBLY ROOF ASSEMBLY REFERENCE INBOARD FIREWALL ASSEMBLY UPPER PORTION INLET ASSEMBLY MIDDLE NOTAR INLET DUCT ASSEMBLY LH ENGINE DECK THERMAL INSULATION LH SHOWN RH OPPOSITE AFT INLET PANEL FORWARD INLET PANEL 9G53 050 Figure 7 Firewall Build Up Assembly ...

Page 1151: ...ontains the mounting provisions for the upper half of the fan stator vane assembly center diffuser and the anti torque fan aft diffuser The upper duct is a composite component that is fabricated with multiple plies of graphite epoxy In areas in which attachment of metallic components will occur barrier plies of fiberglass epoxy are cocured to the faying surfaces The secondary attachment angles and...

Page 1152: ...upper and lower components of the center diffuser are aligned by pins that are retained in the lower Both the upper and lower components of the center diffuser are are fabricated as monolithic laminates Each composite laminate utilizes multiple plies of graphite epoxy Upper and Lower Aft Diffuser The combined components of the aft diffuser function to diffuse the air flow exiting the anti torque f...

Page 1153: ...LY STATOR VANES ASSEMBLY UPPER CENTER DIFFUSER ASSEMBLY LOWER CENTER DIFFUSER ASSEMBLY LOWER FORWARD NOTAR INLET DUCT NOTAR DRIVE SHAFT COVER LOWER AFT NOTAR INLET DUCT LH NOTAR FAN FAIRING CENTER BODY RH NOTAR FAN FAIRING CENTER BODY FAN SUPPORT STRUCTURE REFERENCE 9G53 107 Figure 8 Forward Duct Aft Duct Anti Torque Diffuser Stator and Diverter Plate Installation ...

Page 1154: ... aluminum alloy sheet Aft Frame The aft frame is a primary structural component that provides the aft structural interface and support for the fan installation The aft frame also attaches the forward end of the fan aft duct assembly The aft frame assembly is fabricated from alumi num alloy sheet Duct Inner Skins The left and right duct inner skins are primary structural components that provide the...

Page 1155: ...INNER SKIN DUCT LOWER SKIN WEB AFT FRAME ANTI TORQUE FAN SUPPORT STRUCTURE TAILBOOM ATTACHMENT RING ASSEMBLY UPPER INTERCOSTAL LOWER INTERCOSTAL WL 159 00 INTERCOSTALS UPPER DUCT ASSEMBLY LOWER ACCESS PANEL ASSEMBLY LOWER DUCT ASSEMBLY 9G53 033 Figure 9 Anti Torque Fan Support Structure Aft Duct Assembly and Tailboom Attachment Ring Assembly ...

Page 1156: ...FS 230 50 frame roof structure assemblies and the tailboom attach ring assembly The rear fuselage shell assemblies incorporate a secondarily bonded foot step assembly located aft and below the cutouts for the installation of the work platforms The foot step step plate foot step support angle and the work platforms provide for access to the upper deck The rear fuselage shell assemblies are fabricat...

Page 1157: ...door frame compo nents These frames are secondary structural components and reinforce the baggage door opening formed by the left and right rear fuselage shells and aft edge of the boat tail assembly All components within this installa tion are installed using rivets B Splice Plate The splice plate is a secondary structural component and is used to secure the butt joint between the left and right ...

Page 1158: ...s and the sandwich panel transitions to form monolithic laminate flanges that incorporate additional reinforce ment plies of graphite epoxy B Forward Fairing Support Assemblies The left and right forward fairing support assemblies attach to and support the forward and aft swashplate fairing assemblies Door latching strikers receptacles are attached at forward and transmission access door interface...

Page 1159: ...d the periphery of each door assembly are closed cell silicone material with a self adhering backing EARLY CONFIG Each access door assem bly is hinge mounted to the outboard edges of the aft swashplate fairing assembly and is retained in the closed position by means of latches and or quarter turn fasteners The transmission access door assemblies are fabricated of graphite epoxy skins cocured with ...

Page 1160: ... NOTE FORWARD SWASHPLATE FAIRING ASSEMBLY OIL DIPSTICK HANDHOLD TRANSMISSION ACCESS DOOR ASSEMBLY FIXED PANEL ASSEMBLY OIL COOLER AIR INLET SCREEN FORWARD ACCESS DOOR ASSEMBLY 900 CONFIG LH SHOWN RH OPPOSITE 9G53 104A NACA CONFIG NOTE 902 CONFIG FMU VAPOR SHROUD VENT IS INCORPORATED INBOARD OF OIL COOLER EXHAUST Figure 12 Forward Fairings and Doors ...

Page 1161: ...istant steel wire The screen frames are fabricated from titanium alloy sheet The screens and screen frames are retained by rivets The insulation blanket provides fire and heat protection for the composite panel The insulation blanket is a molded assembly that is fabricated with special fire proof fabric inner and outer skins separated by heat insulating filler material Installation of the blanket ...

Page 1162: ...nce Manual Page 28 Original 53 30 00 9G53 105 TAILBOOM UPPER FAIRING ASSEMBLY EXHAUST EJECTOR COWL ASSEMBLY LH SHOWN RH OPPOSITE ENGINE COWL ASSEMBLY LH SHOWN RH OPPOSITE FIREWALL BUILD UP ASSEMBLY AND INSTALLATION REFERENCE Figure 13 Aft Engine Cowling ...

Page 1163: ...ccess door assembly 1 or 2 to gain access to door strut Ref Section 06 00 00 2 Disconnect strut attachment to access door bracket Ref Section 53 30 00 3 Disengage locking ends of hinge pins 3 and remove pins and access door 1 or 2 from fairing 4 or 5 B Access Door Assembly Installation Ref Figure 401 NOTE Installation of forward access doors L155 and R155 and transmission access doors L210 and R21...

Page 1164: ...n access to door strut 2 Ref Section 53 30 00 2 Disconnect upper attachment to bracket 3 on access door and lower attachment to bracket on swashplate fairing assembly a Slide case 9 of quick disconnect ball joint end fitting along axis of strut b Pull end fitting socket away from ball end of ball screw 8 on bracket 3 Remove access door strut B Access Door Strut Installation Ref Figure 402 NOTE Ins...

Page 1165: ...NOTE Removal of access door strut brackets is typical 1 Gain access to door strut 2 and strut bracket 3 2 Disconnect door strut attachment to strut bracket Ref Section 53 30 00 3 Remove screws 4 and washers 5 and remove strut bracket 4 Remove nut 7 washers 6 and ball screw 8 from bracket D Access Door Strut Bracket Installation Ref Figure 402 NOTE Installation of access door strut brack ets is typ...

Page 1166: ...nal 53 30 00 8 6 VIEW ROTATED 7 6 3 LOOKING INBOARD LEFT SIDE 9 VIEW ROTATED 9G53 087A 1 2 2 9 2 4 2 PL 5 2 PL 10 1 DOOR PANEL 2 DOOR STRUT 3 STRUT BRACKET 4 SCREW 5 WASHER 6 WASHER 7 NUT 8 BALL SCREW 9 CASE 10 LOCK RELEASE COLLAR Figure 402 Access Door Strut and Strut Bracket ...

Page 1167: ...e b Retain striker plate striker adjust ment plate and mounting hardware in sets marked with the installed location B Access Door Striker Installation Ref Figure 403 NOTE Installation of latch strikers for forward access doors L155 and R155 and transmis sion access doors L210 and R210 assem blies are typical 1 Position striker plate 2 6 or 10 onto striker adjustment plate 3 7 or 11 using position ...

Page 1168: ... LOOKING FWD 11 10 6 3 4 2 PL 5 2 PL 7 8 2 PL 9 2 PL 1 12 2 PL 13 2 PL 2 9G53 064 1 FORWARD ACCESS DOOR L155 R155 2 STRIKER PLATE 3 STRIKER ADJUSTMENT PLATE 4 BOLT 5 WASHER 6 STRIKER PLATE 7 STRIKER ADJUSTMENT PLATE 8 BOLT 9 WASHER 10 STRIKER PLATE 11 STRIKER ADJUSTMENT PLATE 12 BOLT 13 WASHER Figure 403 Access Door Strikers EARLY CONFIG ...

Page 1169: ...ct frame of support assembly is clear of oil cooler air inlet duct and remove B Forward Fairing Support Assembly Installation Ref Figure 404 NOTE Installation of the left and right for ward fairing support assemblies is typical 1 Position forward fairing support assembly 1 on upper deck outboard of oil cooler blower air inlet duct 2 Slide support assembly inboard ensur ing oil cooler blower air in...

Page 1170: ...5 deck angle 6 and engine air inlet assembly 7 Ensure upper aft corner of panel assembly frame 8 clears flange of inlet assembly as panel assembly is removed B Fixed Panel Assembly Installation Ref Figure 405 NOTE Installation left and right fixed panel assemblies is typical 1 Position fixed panel assembly 4 at the corner of the engine air inlet 7 and upper deck angle 6 a Ensure the flange of the ...

Page 1171: ...e striker 1 for aft latch of transmission access door Ref Section 53 30 00 4 Remove screw 2 and washer 3 from lower forward corner or fixed panel assembly 4 5 Remove bolts 9 and washers 10 securing fixed panel bracket 5 to upper deck B Fixed Panel Bracket Assembly Installation Ref Figure 405 NOTE Installation of left and right fixed panel bracket assemblies is typical 1 Position the fixed panel br...

Page 1172: ... C211 C212 C213 or C214 or primer C309 and torque screws 8 Swashplate Forward Fairing Assembly T155 A Swashplate Forward Fairing Assembly Removal Ref Figure 406 1 Remove forward access doors L155 and R155 and transmission access doors L210 and R210 assemblies Ref Section 53 30 00 2 Disconnect vent system inlet to separa tor flexible duct 8 by removing band clamp at bottom of duct Ref Section 21 20...

Page 1173: ...ing Compound C211 Primer C309 3 Install screws and washers to secure support assemblies to flanges of fairing assembly Install screws with wet sealing compound C211 C212 C213 or C214 or primer C309 and torque screws 4 Install torq set bolts 4 washers 5 and nuts 6 to secure flanges of fairing assembly to splice angle 7 Install bolts with wet sealing compound C211 C212 C213 or C214 or primer C309 an...

Page 1174: ...orward access doors L155 and R155 and transmission access doors L210 and R210 assemblies Ref Section 53 30 00 2 Remove screws and washer from left and right oil cooler air outlet screens 1 3 Remove screws and washers securing aft edge of swashplate aft fairing assembly 3 to firewall and engine air inlet assemblies 4 Remove screws washers and nuts at joint to swashplate forward fairing assembly 5 R...

Page 1175: ... outboard flanges of fairing assembly to splice angle 7 Install bolts with wet sealing compound C211 C212 C213 or C214 or primer C309 Torque nuts 5 Install screws washers and nuts at joint to forward swashplate fairing assembly Install screws with wet sealing compound C211 C212 C213 or C214 or primer C309 Torque screws 6 Install screws and washers on aft edge of assembly Install screws with wet se...

Page 1176: ...airframe 2 Remove screws 4 and washers 5 which secure lower forward and upper edges of exhaust ejector cowl assembly 6 and remove assembly Ensure assembly is clear of ejector outlet prior to complete removal B Exhaust Ejector Cowl Assembly Installation Ref Figure 408 NOTE Installation of exhaust ejector cowl L270 and R270 assemblies is typical 1 Position exhaust ejector cowl assembly 6 over ejecto...

Page 1177: ...tor Ref Section 71 60 00 5 Remove engine wash system Ref Section 71 60 00 6 Remove engine firewall to plenum seals Ref Section 71 00 00 7 Remove bolts 1 and washers 2 which secure upper inlet assembly 3 to firewall assembly 4 Remove inlet assembly B Engine Upper Inlet Assembly Installation Ref Figure 409 NOTE Installation of left and right engine up per inlet assemblies is typical 1 Secure upper i...

Page 1178: ... 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 416 Original 53 30 00 9G53 116 1 15 PL 2 15 PL 4 3 1 BOLT 2 WASHER 3 ENGINE UPPER INLET ASSEMBLY 4 FIREWALL ASSEMBLY Figure 409 Engine Upper Inlet Assembly ...

Page 1179: ...duct assembly 3 to upper deck 5 Lift and remove inlet duct assembly 3 from middle inlet duct 8 and firewall B Inlet Assembly Installation Ref Figure 410 FOD 1 Position and align mounting holes of inlet assembly 3 to upper deck and install bolts 4 and washers 5 Torque screws 2 Install swashplate aft fairing assembly Ref Section 53 30 00 3 Install left and right engine cowl assemblies Ref Section 53...

Page 1180: ...t a Wipe contact surfaces with a clean lint free cloth dampened in isopropyl alcohol C419 b Wipe surfaces before alcohol dries c Allow to air dry for a minimum of ten minutes Release Agent C417 d Apply release agent C417 to contact surfaces of duct upper deck and fan support structure Allow releasing agent to dry before applying sealant Sealing Compound C209 NOTE Do not apply sealant in nutplate r...

Page 1181: ...5 ENGINE AND FIREWALL NOT SHOWN 10 8 3 2 1 5 4 PL 4 4 PL 9 6 5 PL 7 5 PL 1 CAPTIVE SCREW 2 INLET SCREEN ASSEMBLY 3 UPPER INLET DUCT ASSEMBLY T240 4 BOLT 5 WASHER 6 BOLT 7 WASHER 8 MIDDLE INLET DUCT ASSEMBLY F4 9 FAN SUPPORT STRUCTURE 10 UPPER DECK Figure 410 Upper and Middle Inlet Duct Assemblies ...

Page 1182: ...ve screws 12 which fasten left half 9 of fairing to right half 10 c Remove bolts 13 nuts 14 and washers 6 securing forward end of fairing half 9 to inside contour of duct assembly 7 d Remove bolts 15 securing fairing half 9 to left hand and bottom struts of fan support structure 4 5 Remove Wire Harness W130 a Remove bolts 13 nuts 14 and washers 16 securing clamps 17 and harness 18 to inside of rig...

Page 1183: ...tallation Sealing Compound C209 NOTE Do not apply sealant in nutplate re gions of duct assembly or drive shaft cover 3 Attach drive shaft cover 19 to the underside of upper deck a Apply a coat of sealing compound C209 to contact surface of drive shaft cover 19 b Align cover with nutplates in upper deck c Secure cover to deck with bolts 5 and washers 6 Torque bolts 4 Attach forward section of duct ...

Page 1184: ...ts of fan support frame with one bolt 15 each b Attach forward end of fairing half to inside contour of forward duct 7 with bolts 13 washers 6 and nuts 14 c Fasten centerbody fairing halves together with screws 12 d Secure centerbody fairing assembly to upper inlet duct cover 11 with screw 8 and washer 6 10 Torque all hardware installed in the preceding steps Sealing Compound C209 NOTE Do not appl...

Page 1185: ... PL 11 4 5 6 9G53 023A 1 BOLT REF IPL 53 30 30 FIG 3 2 WASHER 3 AFT SECTION OF FORWARD DUCT F2 4 FAN SUPPORT STRUCTURE 5 BOLT 6 WASHER 7 FORWARD SECTION OF DUCT F2 8 SCREW 9 LEFT HALF OF FAIRING CENTERBODY F3 10 RIGHT HALF OF FAIRING CENTERBODY F3 11 UPPER INLET DUCT COVER 12 SCREW 13 BOLT 14 NUT 15 BOLT 16 WASHER 17 CLAMP 18 WIRE HARNESS 19 DRIVE SHAFT COVER F1 Figure 411 Forward Duct and Fairing...

Page 1186: ... ers 9 maximum to get the correct grip length b Do not torque the screws 3 Install washers 11 and screws 12 a Do not torque the screws Do not torque stator vane screws too much Damage to the stator vanes can occur 4 Install screws 14 and washers 13 a Torque screws 14 3 to 6 in lb 0 34 to 0 68 Nm plus drag torque 5 Torque screws 6 12 D Installation of Access Panels F7 and F8 Ref Figure 412 Consumab...

Page 1187: ...ructions 7 Remove the 0 20 inch 5 1 mm shims 8 Install the baggage compartment roof insulation panel ref Section 25 50 00 9G53 024C 13 6 PL 1 4 5 4 PL 6 11 7 PL 10 4 PL 8 4 PL 14 6 PL LOOKING AFT 8 REF 9 REF 10 REF 13 REF 14 REF 13 REF 14 REF 12 7 PL 2 5 REF 3 7 11 REF 12 REF 9 AS NECESSARY 7 REF 1 ACCESS PANEL F5 IPL 53 30 04 FIG 1 2 ADJUSTABLE TENSION LATCH 3 ACCESS PANEL F7 IPL 53 30 00 FIG 4 4...

Page 1188: ...hment ring 16 10 Remove screws 19 washers 20 Access Panel F9 5 diverter plate 18 and upper and lower aft diffusers 21 22 from Access Panel F5 15 11 Remove nylon fasteners 17 from outboard edges of diverter plate 18 B Installation Ref Figure 413 Consumable Materials Ref CSP SPM Item Nomenclature C205 Sealing Compound C417 Release Agent C419 Alcohol Isopropyl C802 Cloth Non Lint 1 Install the anti t...

Page 1189: ...7 in the outboard edges of diverter plate 18 12 2 PL 13 2 PL 5 20 6 PL 19 6 PL 4 23 4 PL 22 18 21 1 2 PL 6 7 8 9 11 10 3 12 PL 2 12 PL 14 16 17 15 9G53 108 1 SCREW REF IPL 53 30 00 FIG 4 2 SCREW 3 WASHER 4 ELECTRICAL ACCESS COVER 5 ACCESS PANEL F9 6 SCREW NO IPL REF 7 WASHER 8 CLAMP 9 CLAMP 10 WIRE HARNESS 11 COAX CABLE 12 SCREW REF IPL 53 30 04 FIG 1 13 WASHER 14 BRACKET 15 ACCESS PANEL F5 16 TAI...

Page 1190: ...arness 10 and coax cable 11 to the airframe with clamps 8 9 screw 6 and washer 7 b Torque screw 6 c Attach the electrical connectors 7 Install electrical access cover 4 with washers 3 and screws 1 2 Sealing Compound C205 8 Apply a fillet bead of sealing compound C205 along the mating surfaces of the aft duct electrical access cover 4 and diverter plate 18 9 Connect the force limiting control rod t...

Page 1191: ...No damage allowed 4 Visually inspect interior and exterior of rear fuselage shell assemblies for cracks mechanical damage and security of mechanical fasteners No damage allowed 2 Latch and Striker Adjustment EARLY CONFIG A Cowling Latch Adjustment Ref Figure 601 NOTE Adjustment of cowling latches for access doors L155 L210 R155 and R210 is typ ical Adjustment of the cowling latch affects alignment...

Page 1192: ... shear pin with the striker plate Adjustment of the striker plate will affect alignment in the direction shown in Figure 602 1 Determine amount and direction of adjustment required 2 Loosen bolts 1 securing striker plate 2 sufficiently to allow movement of striker plate over serrations of striker adjustment plate 3 3 Adjust position of striker plate to striker adjustment plate Serrations allow mov...

Page 1193: ...nual Page 603 Revision 32 53 30 00 1 2 PL LEFT SIDE LOOKING INBOARD 4 LOOKING FWD 3 1 2 PL 2 LOOKING AFT 2 3 1 2 PL LOOKING AFT 3 2 9G53 075 1 BOLT 2 STRIKER PLATE 3 STRIKER ADJUSTMENT PLATE 4 ACCESS DOOR Figure 602 Access Door Striker Adjustment EARLY CONFIG ...

Page 1194: ...iceable Limits Maximum Repairable Limits Repair Procedure Stator vane around threaded insert for radial cracks Cracks that are not repaired are not permitted Maximum permitted crack length 0 375 in 9 53 mm Lightly clean crack use scouring pad C817 and isopropyl alcohol C419 Seal crack use cyanoacrylate adhesive C442 If necessary after adhesive is cured make damage smooth Use 400 grit abrasive clot...

Page 1195: ...R155 or R210 to gain access to cowling latch mounting hardware Ref Section 06 00 00 2 Remove screws 4 washers 5 and nuts 6 3 Remove cowling latch 2 and latch shim s 3 Retain latch shim s and mounting hardware in sets marked with installed location 4 Position replacement cowling latch 2 and shim s 3 on interior surface of access door panel 1 5 Install screws 4 washers 5 and nuts 6 and torque nuts 6...

Page 1196: ...l Replacement Ref Figure 802 Consumable Materials Ref CSP SPM Item Nomenclature C425 Solvent Cleaning NOTE Seal replacement for forward access doors L155 and R155 is typical During seal replacement place door as sembly on appropriate pads to avoid dam age to composite door skin During seal removal use appropriate non metallic scraper if required to avoid damage to composite seal lands 1 Remove acc...

Page 1197: ...ment place door as sembly on appropriate pads to avoid dam age to composite door skin During seal removal use appropriate non metallic scraper if required to avoid damage to composite seal lands 1 Remove access door assembly Ref Section 53 30 00 2 Remove seals 2 and 3 from access door panel 1 3 Clean and remove residue from seal lands Ref CSP SPM Section 20 50 00 4 Prior to removal of protective f...

Page 1198: ...c scraper if required to avoid damage to composite duct frame 1 Remove support assembly 1 Ref Section 53 30 00 2 Remove seal 2 from entire periphery on inner surface of duct frame on support assembly 1 3 Clean and remove residue from seal surface Ref CSP SPM Section 20 50 00 4 Prior to removal of protective film from surface with adhesive position seal material on inner surface of duct frame on su...

Page 1199: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 805 Original 53 30 00 9G53 114A 1 2 900 CONFIG NACA CONFIG 1 SUPPORT ASSEMBLY 2 SEAL Figure 803 Support Assembly Duct Frame Seal ...

Page 1200: ...handhold and transfer existing rivet hole pattern in hinge to flange of handhold 5 Transfer existing turnlock receptacle locations on fairing assembly to outboard flange of handhold 6 Remove handhold and drill transferred hole patterns Drill rivet and turnlock fastener holes 7 Position seal 6 prior to removal of protective film on surface with adhe sive around perimeter of handhold adjacent to edg...

Page 1201: ...MM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 807 Original 53 30 00 9G53 084 3 2 PL 6 1 5 2 5 PL 4 2 PL 1 HANDHOLD 2 RIVET 3 STUD 4 RETAINING WASHER 5 HINGE 6 SEAL Figure 804 Oil Dipstick Handhold ...

Page 1202: ...h of the two composite stiffening ribs and around the perimeter of both air inlet screens 3 Remove bonding material residue and clean surfaces Ref Section 20 20 00 4 Temporarily position replacement cowl insulation 1 on interior surface of engine cowl panel 2 Transfer loca tions of cowl attachment fasteners and mark required edge trim if required 5 Remove insulation and cut 0 38 in 9 65 mm diamete...

Page 1203: ...opters Inc Rotorcraft Maintenance Manual Page 809 810 blank Original 53 30 00 LOOKING OUTBOARD LEFT SIDE 9G53 082 TOP VIEW LOOKING UP 2 1 1 ENGINE INSULATION 2 ENGINE COWL PANEL Figure 805 Engine Cowl Insulation Replacement ...

Page 1204: ......

Page 1205: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 53 40 00 Tailboom ...

Page 1206: ......

Page 1207: ... with the thruster extension the tailboom thruster left and right upper fairing assemblies cover and fair the empennage to tailboom and the upper half of the tailboom to thruster extension attach points The tail boom thruster lower fairing assembly covers and fairs the lower portion of the empennage attachment frames and the lower half of the tailboom to thruster extension attach point Attachment ...

Page 1208: ...age 2 Revision 27 53 40 00 TAILBOOM ASSEMBLY TAILBOOM BUMPER LOWER TAILBOOM THRUSTER FAIRING ASSEMBLY RH TAILBOOM THRUSTER UPPER FAIRING ASSEMBLY LH TAILBOOM THRUSTER UPPER FAIRING ASSEMBLY THRUSTER EXTENSION FAIRING TAILBOOM VORTEX GENERATOR Figure 1 Tailboom Area ...

Page 1209: ...e open area on the right side of the assembly the core is tapered and the panel transitions to form monolithic laminate flanges At the aft end of the assembly in the area at and aft of the attach ment of the empennage forward attachment frame the panel transitions into a combina tion of a monolithic laminate and cored panel incorporating a core of syntactic foam Along the lower surface the panel i...

Page 1210: ...ailing edge of the slat assembly the lower airfoil and the forward coaxial cover Each inlet ramp is secondarily bonded and faired to the interior surfaces of the tailboom mating surfaces of the airfoils and slat assembly The upper and lower inlet ramps are both nonme tallic components fabricated from polycarbo nate plastic sheet H Forward Coaxial Cover Aft Coaxial Cover and Aft Wiring Cover The co...

Page 1211: ...er fairing lower tailboom thrust er extension fairing and right thruster extension fairing FORWARD EMPENNAGE ATTACH FRAME TAILBOOM ASSEMBLY SLOT VANE TAILBOOM LOWER AIRFOIL DIVERTER PLATE LH DIVERTER ATTACH FLANGE FUSELAGE ATTACH FRAME LOWER INLET RAMP UPPER INLET RAMP RH DIVERTER ATTACH FLANGE TAILBOOM UPPER AIRFOIL SLOT VANE RH INTERCOSTAL AFT EMPENNAGE ATTACH FRAME LH INTERCOSTAL 9G53 111A VORT...

Page 1212: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 6 Revision 27 53 40 00 This page intentionally left blank ...

Page 1213: ...me and attach holes for cracks and corrosion No defects permitted f If installed examine thruster exten sion barrel for cracks voids dents holes scratches delaminations and correct installation No defects permitted g If installed examine thruster exten sion fairing support for cracks voids dents holes scratches delamina tions and correct installation No defects permitted h Examine tailboom thruste...

Page 1214: ...MD Helicopters Inc Rotorcraft Maintenance Manual Page 202 Revision 35 53 40 00 1 9G53 110B 5 6 2 4 3 7 10 9 8 11 14 12 15 13 17 16 18 19 20 16 PL 20 16 PL DIM A BOTTOM OF THRUSTER 6 REF Figure 201 Tailboom Assembly ...

Page 1215: ...n access panels and rotating cone B Tailboom Bumper Inspection Ref Figure 201 1 Examine bumper for correct installa tion a No defects permitted 2 Examine bumper 5 or 6 for deforma tion a Bumper 5 Measure outer dimension of tube in the bend radius at upper end of bumper 5 in two positions 90 degrees from each other 1 If the difference of the two measure ments is more than 5 percent the bumper must ...

Page 1216: ...on 34 53 40 00 26 27 28 29 31 48 30 25 35 36 33 36 34 37 32 38 39 40 43 45 46 47 47 45 44 42 41 9G53 048A 2 4 6 8 10 12 14 16 18 20 22 24 1 3 5 7 9 11 13 15 17 19 21 23 LOOKING FORWARD TAILBOOM END FITTING TORQUE SEQUENCE 49 24 PL 50 50 Figure 202 Tailboom Assembly Installation ...

Page 1217: ... 28 and 29 which secure wire harness 30 and coax cable 31 to airframe 5 Disconnect wire harness 30 and coax 31 6 Disconnect control cable rod end 32 from directional bellcrank 33 a Remove and discard cotter pin 34 b Remove bolt 35 washers 36 and nut 37 7 Remove rod end 32 tab washer 38 jam nut 39 and sleeve 40 from cable 41 8 Disconnect swivel 42 from control bracket 43 a Remove nuts 44 washers 45...

Page 1218: ...ith bolt holes in tailboom end fitting c Route control cable through access hole and install jam nut and swivel on cable before routing cable through control bracket d Install tailboom onto captive bolts while routing control cable wire harness and coax cable through their respective holes e Install washers and nuts on captive bolts f Install bolts and washers through tailboom end fitting and torq...

Page 1219: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 207 Revision 34 53 40 00 17 Install baggage compartment roof insulation interior panel ref Section 25 50 00 ...

Page 1220: ...RUSTER EXTENSION 7 9 32 PL 10 32 PL 11 NOTE EMPENNAGE NOT SHOWN FOR CLARITY 8 4 5 12 11 1 SCREW 2 SCREW 3 WASHER 4 LOWER TAILBOOM THRUSTER FAIRING ASSEMBLY 5 UPPER TAILBOOM THRUSTER FAIRING ASSEMBLY 6 TAILBOOM FRAME 7 LH THRUSTER EXTENSION FAIRING 8 RH THRUSTER EXTENSION FAIRING 9 SCREW 10 WASHER 11 THRUSTER FRAME 12 THRUSTER EXTENSION FAIRING SUPPORT 13 THRUSTER EXTENSION Figure 203 Tailboom Thru...

Page 1221: ...re 203 1 Remove lower thruster tailboom fairing 2 Remove screws 1 2 and washers 3 Remove fairing 5 B Upper Tailboom Thruster Fairing Assembly Installation Ref Figure 203 1 Align upper tailboom thruster fairing SL1 and SR1 with FWD and AFT tailboom frames and thruster extension fairing support 2 Install screws and washers Torque screws 3 Install lower thruster tailboom fairing 4 If tailboom extensi...

Page 1222: ...ual Page 210 Revision 35 53 40 00 9G53 085C 5 2 1 1 3 4 VIEW LOOKING FWD 1 COTTER PIN REF IPL 53 40 00 FIG 2 2 TAILBUMPER PIN 3 TAILBOOM BUMPER 4 TAILBOOM BUMPER ASSEMBLY 5 FWD AND AFT TAILBOOM THRUSTER FRAMES REF IPL 53 40 10 FIG 2 Figure 204 Tailboom Bumper ...

Page 1223: ... 4 Remove tailboom bumper 3 or 4 5 Remove sealing compound from mating surfaces of bumper 3 or 4 and frames 5 B Tailboom Bumper Installation Ref Figure 204 Consumable Materials Ref CSP SPM Item Nomenclature C205 Sealing Compound Sealing Compound C205 1 Apply sealing compound C205 to the mating surfaces of tailboom bumper 3 or 4 and forward and aft tailboom frames 5 to prevent the movement of the b...

Page 1224: ...ACE 19X 2 75 IN 6 99 cm 16X 6 00 IN 15 24 cm 2X 1 00 IN 2 54 cm 19X 3 40 IN 8 64 cm VIEW LOOKING INBOARD RIGHT SIDE 1 2 3 4 9G53 131A 12 15 13 15 IN 30 86 33 40 cm 11 50 12 50 IN 29 21 31 75 cm 5 VIEW LOOKING FORWARD REF 4 REF 5 REF 5 1 TAILBOOM 2 RIGHT SIDE UPPER TAILBOOM THRUSTER FAIRING 3 LOWER TAILBOOM THRUSTER FAIRING 4 RIGHT SIDE THRUSTER EXTENSION FAIRING 5 VORTEX GENERATOR Figure 205 Vorte...

Page 1225: ...ce where the vortex generator will be installed Apply tape with 0 020 inch 0 51 mm clearance around the vortex generator Do not sand into or expose composite fi bers Do not use aluminum oxide abrasives on graphite epoxy materials 2 Remove surface gloss with scouring pad C817 or 180 grit or finer sandpaper Solvent Cleaner C429 3 Clean residue from sanded area with solvent cleaner C429 4 Remove surf...

Page 1226: ...es since application of activator fill void with more adhesive ref manufacturer s instructions b If it is more than fifteen minutes since application of activator apply activator and then fill void with more adhesive ref manufacturer s instruc tions 10 Remove masking tape Alcohol Isopropyl C419 11 Remove unwanted adhesive with isopropyl alcohol C419 12 Let adhesive C440 cure ref manufac turer s in...

Page 1227: ...hers 2 6 Remove thruster extension 3 from tailboom B Thruster Extension Installation Ref Figure 206 1 Prepare mating surfaces of tailboom and thruster extension at the 1 o clock and 11 o clock positions 0 62 inch 15 8 mm diameter for Class L electrical bond ref CSP SPM 2 Install bolts and washers attaching thruster extension to tailboom Torque bolts 3 Test thruster extension for Class L electrical...

Page 1228: ...53 133 UPPER VANE SHOWN LOWER VANE TYPICAL 1 REF 1 2 16 PL 3 4 5 6 2 16 PL REF 2 8 9 10 11 7 1 TAILBOOM 2 SLOT VANE 3 UPPER AIRFOIL 4 SLAT ASSEMBLY 5 LOWER AIRFOIL 6 SEALING COMPOUND 7 AFT COAXIAL COVER 8 FORWARD COAXIAL COVER 9 LOWER INLET RAMP 10 UPPER INLET RAMP 11 AFT WIRING COVER Figure 207 Tailboom Secondary Details ...

Page 1229: ... B Tailboom Slot Vane Installation Ref Figure 207 Consumable Materials Ref CSP SPM Item Nomenclature C419 Alcohol Isopropyl C234 Sealing Compound C442 Adhesive Cyanoacrylate NOTE This task is typical for upper and lower slot vane installation Alcohol Isopropyl C419 1 Clean surface of slot vane and attach surfaces with isopropyl alcohol C419 Do not use cotton or wool cloth with cyanoacrylate adhesi...

Page 1230: ...207 Consumable Materials Ref CSP SPM Item Nomenclature C419 Alcohol Isopropyl C426 Adhesive C405 Adhesive Epoxy NOTE This task is typical for upper and lower inlet ramp installation Alcohol Isopropyl C419 1 Wipe inlet ramp and tailboom with isopropyl alcohol C419 NOTE Align inlet ramp to match contour of tailboom surface Maximum incorrect align ment 0 10 inch 2 5 mm Adhesive C426 2 Mix adhesive C4...

Page 1231: ...Consumable Materials Ref CSP SPM Item Nomenclature C419 Alcohol Isopropyl C426 Adhesive C405 Adhesive Epoxy 1 Trim forward flange of forward coaxial cover to fit flush within 0 030 inch 0 76 mm of forward edge of tailboom Alcohol Isopropyl C419 2 Wipe froward coaxial cover and tail boom with isopropyl alcohol C419 Adhesive C426 3 Mix adhesive C426 refer to manufac turer s instructions NOTE The thi...

Page 1232: ...ign aft coaxial cover forward end to match contour of mating airfoils Alcohol Isopropyl C419 1 Wipe aft coaxial cover and tailboom with isopropyl alcohol C419 Adhesive C426 2 Mix adhesive C426 refer to manufac turer s instructions NOTE The thickness of the adhesive must be 0 002 to 0 040 inch 0 05 to 1 02 mm 3 Bond aft coaxial cover to inner surface of tailboom with adhesive C426 4 Allow adhesive ...

Page 1233: ...y NOTE Align aft wiring cover forward end to match contour of mating airfoils Alcohol Isopropyl C419 1 Wipe aft wiring cover and tailboom with isopropyl alcohol C419 Adhesive C426 2 Mix adhesive C426 refer to manufac turer s instructions NOTE The thickness of the adhesive must be 0 002 to 0 040 inch 0 05 to 1 02 mm 3 Bond aft wiring cover to inner surface of tailboom with adhesive C426 4 Allow adh...

Page 1234: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 222 Revision 34 53 40 00 This page intentionally left blank ...

Page 1235: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 53 55 00 Empennage ...

Page 1236: ......

Page 1237: ...l is installed on the bottom of the horizontal stabilizer spar between the empennage attach frames The panel gives access to the inner side of the spar during the installation of the inboard ribs and empennage attach fittings The empennage wire harnesses come out through this panel The panel is made from aluminum alloy sheet The panel is installed with blind titanium fasteners C Inboard and Outboa...

Page 1238: ...tach plates are machined from aluminum alloy stock The pins are heat treated corrosion resistant steel 4 Endplate Ref Figure 1 The upper and lower endplates are movable control surfaces that help control yaw of the helicopter in forward flight Each side upper and lower endplates are installed on a spar tube that is controlled by the Vertical Stabiliz er Control System VSCS for more data about the ...

Page 1239: ...onded onto the trailing edge of the endplate bodies with an epoxy adhesive 5 Fairing The forward and aft fairings close the out board ends of the horizontal stabilizer and fair the endplates to the horizontal stabilizer The position lights are also installed on the fairings refer to Section 96 40 00 for more data about the position lights The fairings are installed with screws and nutplates on the...

Page 1240: ... SIDE UPPER ENDPLATE RIGHT SIDE LOWER ENDPLATE ELASTOMERIC DAMPER LH FORWARD FAIRING LH AFT FAIRING HORIZONTAL STABILIZER 9G53 040 1 ACCESS COVER 2 PL HORIZONTAL TRAILING EDGE TAB UPPER AND LOWER LEFT AND RIGHT ACCESS COVER 2 PL BONDED ASSEMBLY LEADING EDGE ACCESS COVER LOWER SKIN PANEL LEFT SIDE ATTACH FITTING LH INBOARD RIB RH OPPOSITE RIGHT SIDE ATTACH FITTING FORWARD ATTACH INTERCOSTAL AFT NOT...

Page 1241: ...BEARING HOUSING RH OPPOSITE LH OUTBOARD RIB RH OPPOSITE LH LOWER JOURNAL BEARING HOUSING RH OPPOSITE JOURNAL BEARING 4 PL 9G53 040 2 ENDPLATE BODY CLOSEOUT TIP CAP AFT CLOSEOUT ENDPLATE BLOCK 2 PL FORWARD CLOSEOUT TRAILING EDGE TAB IF INSTALLED LEFT UPPER ENDPLATE SHOWN TYPICAL Figure 1 Empennage Sheet 2 of2 ...

Page 1242: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 6 Revision 33 53 55 00 This page intentionally left blank ...

Page 1243: ...Fuel Resistant 1 Put empennage above attach frames and put a support below it 2 Connect electrical connectors P310 P317 and antenna coaxial connector if installed 3 Align empennage left mount with damper safety pins and right mount trunnions with bushings in right side of attach frames 4 Install bolts shims washers and plastic washers Use shims to get a clearance of 0 00 0 002 in 0 00 0 051 mm bet...

Page 1244: ...ic Damper A Elastomeric Damper Removal Ref Figure 401 1 Remove empennage 2 Remove lockwire from bolts 14 and discard 3 Remove bolts 14 washers 8 and damper 7 B Elastomeric Damper Installation Ref Figure 401 1 Install damper bolts and washers Torque bolts and safety with lockwire C702 2 Install empennage ...

Page 1245: ...1 12 11 13 13 12 11 9 2 PL FWD MOUNT SHOWN AFT MOUNT OPPOSITE 15 16 LOOKING AFT 7 REF 18 4 PL 17 1 BOND JUMPER 2 FORWARD ATTACH FRAME 3 NUT 4 WASHER 5 BOLT 6 EMPENNAGE 7 ELASTOMERIC DAMPER 8 WASHER 9 JAM NUT 10 BOLT 11 WASHER 12 SHIM 13 PLASTIC WASHER 14 BOLT 15 ELECTRICAL CONNECTOR P310 16 ELECTRICAL CONNECTOR P317 17 AFT ATTACH FRAME 18 WASHER Figure 401 Empennage ...

Page 1246: ...p 8 and bond jumper 4 B Stabilizer Outboard Fairing SR3 SL3 Installation Ref Figure 402 NOTE Installation of left and right outboard fairings is typical 1 Install aft fairing screws and washers Torque screws 2 Install bond jumper clamp screw washers and nut Torque nut 3 Connect wires to position light 4 Install forward fairing screws and washers Torque screws 9G53 006 9 3 1 2 4 5 6 2 PL 8 7 10 11 ...

Page 1247: ...t holes of the end plates are out of round B Endplate Installation Ref Figure 403 NOTE This task is typical for the left and right upper and lower endplate installa tion Consumable Materials Ref CSP SPM Item Nomenclature C216 Sealant Fuel Resistant C228 Sealant Primer C226 Sealing and Locking Compound C429 Solvent Cleaner 1 Prepare surface of endplate 1 062 inch 26 98 mm dimension around attach ho...

Page 1248: ...hen you install lower right endplate make sure tab on trailing edge of end plate is pointed inboard Lower left endplate does not have a trail ing edge tab Bolts 1 that attach endplates have a lock device 5 Make sure lock devices in endplate attach bolts 1 are serviceable ref CSP SPM Section 20 10 00 6 Put endplates 3 4 in their installed positions with washers 2 and bolts 1 a Torque bolts 9 to 17 ...

Page 1249: ... If attach bolt is loose or environmental seal is loose or missing do the proce dure that follows a Remove remaining sealant b Remove bolt make sure lock device is serviceable ref CSP SPM Section 20 10 00 c Install bolt and environmentally seal ref Endplate Installation C Endplate Spar Tube Inspection Area 7 Ref Section 67 20 00 D Elastomeric Damper Condition Test Ref Figure 602 NOTE Do test at 55...

Page 1250: ...M END OF JOURNAL BEARING PERPENDICULAR TO THE TORQUE TUBE MEASURE TOTAL PLAY AFT TO FORWARD OR LEFT TO RIGHT MAXIMUM PERMITTED PLAY 0 013 IN 0 33 mm 9G53 128A MEASURE RADIAL PLAY WITH A DIAL INDICATOR MAKE MEASUREMENT NO MORE THAN 0 125 IN 3 275 mm FROM END OF JOURNAL BEARING PERPENDICULAR TO THE TORQUE TUBE MEASURE TOTAL PLAY AFT TO FORWARD OR LEFT TO RIGHT MAXIMUM PERMITTED PLAY 0 013 IN 0 33 mm...

Page 1251: ...earing on inner aft side to make it easier to collapse the journal bearing When you cut a journal bearing stop and measure the depth of the cut frequently 5 Carefully cut a groove the full circum ference of journal bearing 1 to an approximate depth of 0 20 inch 5 1 mm with a hacksaw blade 6 Collapse journal bearing 1 7 Push journal bearing 1 in to remove it from the journal housing Acetone C436 8 ...

Page 1252: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 802 Revision 36 53 55 00 9G53 13 7 Figure 801 Removal and Installation of the Journal Bearings and Housings ...

Page 1253: ... of a journal housing 1 Remove the horizontal spar endplate tube ref CSP 900RMM 2 Section 67 20 00 Removal Installation Procedure 78 A Do not remove the upper and lower journal housings opposite one another at the same time The opposite journal housing must be installed to get the correct alignment of both journal housings and to prevent binding of the horizontal spar endplate tube 2 Remove the jo...

Page 1254: ... shim thickness c Hold the gap of Dimension D to 2 160 to 2 165 inch 54 86 to 54 99 mm d Add or remove shim material as necessary to get Dimension D Primer C310 7 Apply primer C310 to fasteners 6 7 Remove only one Cleco fastener at a time to install one fastener 6 7 This will help to keep the alignment of the journal housings and bearings 8 Wet install fasteners 6 7 and new journal housing 2 3 4 o...

Page 1255: ...h tape Release Agent C417 6 Apply release agent C417 to inner and outer side of access door and on spacers 7 Dry release agent C417 in air for 15 minutes minimum 8 Apply another layer of release agent C417 to inner and outer side of access door and on spacers 9 Dry release agent C417 in air for 30 minutes minimum Sealing Compound C234 10 Apply a thin layer of sealing compound C234 adhesion promote...

Page 1256: ...he hole with a 10X magnific ation glass for cracks and damage a No cracks or damage is permitted 4 Measure the diameter of the hole a The diameter must be 0 4995 to 0 5005 inch 12 687 to 12 713 mm Chemical Coating C233 5 Apply chemical coating C233 on the mating surfaces of the hole for corrosion protection ref CSP SPM 20 40 00 B Installation Acetone C436 1 Clean the bushing hole in fitting 3 with...

Page 1257: ...rcraft Maintenance Manual Page 807 Revision 36 53 55 00 9G53 136 3 1 2 2 1 4 1 BUSHING REF IPL 53 55 00 FIG 3 ITEM 32 2 BUSHING ITEM 33 3 FITTING ITEM 31 4 HORIZONTAL STABILIZER ASSEMBLY Figure 802 Removal and Installation of the Bushings ...

Page 1258: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 808 Revision 36 53 55 00 This page intentionally left blank ...

Page 1259: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Chapter MAIN ROTOR ...

Page 1260: ......

Page 1261: ... Assembly 1 4 Main Rotor Hub Assembly 2 A Upper and Lower Hub Halves 2 B Flexbeam 2 C Hub Plate 2 D Fretting Buffer 2 E Tapered Roller Bearing Set 2 F Hub Liner 2 G Drive Ring 2 H Grounding Brushes and Straps 2 I Droop Stop 2 5 Data Plates 3 A Data Plate Marking 3 B Identification Data Plates 3 C Overhaul Data Plates 3 Figure 1 Main Rotor System 4 6 Upper Flight Controls Subsystem 5 A Mixer Assemb...

Page 1262: ...nspection 601 B Main Rotor Blade Abrasion Strip Inspection 601 Figure 601 Main Rotor Blade Inspection Sheet 1 of 2 602 C Main Rotor Blade Trim Tab Inspection 604 D Inspection of Protective Tape 605 Figure 602 Torque Check for the 101 Blade Retention Bolts 606 2 Blade Retention Bolts 607 A Visual Inspection of the Blade Retention Bolts 607 B Torque Check of the Blade Retention Bolts PN 900R3100001 ...

Page 1263: ...oval Installation 401 1 Main Rotor Hub Assembly 401 A Removal 401 B Installation 401 Figure 401 Main Rotor Hub Assembly and Helicopter Sling 402 2 Main Rotor Dampers 405 A Removal 405 B Installation 406 Figure 402 Main Rotor Hub Damper Feathering Bearing and Pitchcase Installation 406 Table 401 Main Rotor Damper Shim Quantity 407 3 Pitchcase Assemblies 408 A Removal 408 B Installation 408 4 Main R...

Page 1264: ...e Main Rotor 414 12 Lower Hub Main Rotor 414 13 Flexbeam Bumper Assemblies 414 A Removal 414 B Installation 414 Figure 406 Main Rotor Hub Flexbeam Installation 415 14 Lead Lag Leg Wear Shims 416 A Removal 417 B Installation 417 15 Main Rotor Upper Hub Assembly 417 A Upper Hub Buildup 417 16 Upper Seal Upper Hub Assembly 418 A Removal 418 B Installation 418 17 Upper Bearing Upper Hub Assembly 418 A...

Page 1265: ...Hub Identification 425 27 Hub Pitchcase Balance Weight 426 A Removal 426 B Installation 426 28 Pitch Horn 426 A Removal 426 B Installation 426 Figure 409 Pitch Horn Replacement 427 Inspection Test 601 1 Main Rotor Hub Assembly 601 A Main Rotor Hub Assembly Inspection Area 4 601 Figure 601 Main Rotor Hub Assembly 602 B Identification Data Plate Inspection 604 C Flexbeam Inspection Area 4 604 Figure...

Page 1266: ...r Surface Corrosion 801 Figure 801 Main Rotor Hub Repair 802 Figure 802 Flexbeam Pockets Hub Mating Surfaces and Hub Plate 802 C Flexbeam Pockets and Hub Mating Surfaces Corrosion 803 D Hub Plate Corrosion 803 Figure 803 Flexbeam Bumper Replacement 804 2 Repairs for the Flexbeam Bumper Assemblies 805 A Flexbeam Bumper Repair 805 Figure 804 Flexbeam Fissure Fill and Nick Repair 806 B Flexbeam Fissu...

Page 1267: ...d Ref Paragraphs 2 C and D 405 Figure 404 Lateral and Longitudinal Link Assemblies 406 4 Lateral Anti Torque Drive Link Assembly 406 A Removal 406 B Installation 406 5 Longitudinal Drive Link Assembly 407 A Removal 407 B Installation 407 Figure 405 Non Adjustable and Adjustable Collective Links 408 6 Non Adjustable Collective Drive Link Assembly 408 A Removal 408 B Installation 409 7 Adjustable Co...

Page 1268: ...te Bearing Preload Measurement One Piece Retainer Rings Installation 417 B EARLY CONFIG Retainer Rings and Seals Installation One Piece Retainer Ring 418 C CURRENT CONFIG Retainer Rings and Seals Installation Two Piece Retainer Ring 419 Figure 410 CURRENT CONFIG Swashplate Retainer Rings Installation Two Piece Retainers 419 15 Non Rotating Swashplate Assembly 420 A Removal 420 B Installation 420 F...

Page 1269: ...gure 802 Bearing Staking 803 C Staking 803 Figure 803 Proof Load Check 804 D Proof Load Check 804 Figure 804 Scissors Drive Link Repair 805 2 Scissors Assembly Drive Link Repair 107 805 A Upper Drive Link Repair 805 B Lower Drive Link Repair 806 Figure 805 Upper Drive Link Flanged Bearing 808 C Upper Drive Link Flanged Bearing Removal 809 D Upper Drive Link Flanged Bearing Installation 809 Figure ...

Page 1270: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Page x Revision 36 62 Contents TABLE OF CONTENTS Cont Para Figure Table Title Page This page intentionally left blank ...

Page 1271: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 62 00 00 Main Rotor System ...

Page 1272: ......

Page 1273: ...de protection against erosion Inboard abrasion strips are titanium Outboard abrasion strips are nickel Behind the lower edge of each abrasion strip is a fiberglass pad that resists low angle of incidence abrasion C Trim Tabs Trim tabs are located on the trailing edge of each rotor blade The trim tabs are bent up or down to track the rotor blades D Electrical Grounding An embedded metallic mesh Ast...

Page 1274: ...r The tapered roller bearing sets are located between the upper hub half and the non rotating components of the main rotor installation F Hub Liner The hub liner is a stainless steel tube in the center of the upper hub half that fits snugly over the stationary support mast During main rotor hub installation a hub retaining nut is threaded to the top of the stationary support mast The retaining nut...

Page 1275: ...ent data transferred to a new plate Data shall not be stamped directly on any part assembly or item of equipment B Identification Data Plates The rotor hub data identification plate provides the operator with manufacturer s data The data plates provide part number and serial number identification for the main rotor hub assembly as a complete unit and the upper hub assembly specifically Exceptions ...

Page 1276: ...D ABRASION STRIP TRIM TAB ASSEMBLY PITCHCASE FLEXBEAM ROTOR BLADE INBOARD ABRASION STRIP 9G62 001A ROTOR BLADE RETENTION BOLTS CENTERING BEARING PITCH CHANGE HORN DRIVE PLATE DAMPER UPPER HUB DRIVE RING SCISSORS LOWER HUB FLEXBEAM BUMPER GROUNDING STRAPS UPPER DAMPER CAP Figure 1 Main Rotor System ...

Page 1277: ...hplate is constructed of forged 7050 aluminum alloy The stationary swashplate receives collective and cyclic control inputs and coordinates longitudinal and lateral flight control The stationary swashplate also transmits the control inputs to the rotating swashplate through the swashplate bearing C Rotating Swashplate The rotating swashplate is located directly above and assembled to the stationar...

Page 1278: ...SCISSORS DRIVE LINK ASSEMBLY LATERAL AND ANTI ROTATION LINK ASSEMBLY PITCH LINK ASSEMBLY LONGITUDINAL LINK ASSEMBLY ADJUSTABLE COLLECTIVE LINK ASSEMBLY MIXER PIVOT SUPPORT ASSEMBLY HYDRAULIC ACTUATOR MOUNTING BRACKET SUPPORT ROD ATTACHMENT NON ADJUSTABLE COLLECTIVE LINK ASSEMBLY LONGITUDINAL MIXER ARM LATERAL MIXER ARM STATIONARY SWASHPLATE ASSEMBLY Figure 2 Upper Flight Controls Subsystem ...

Page 1279: ...ct main rotor blades 62 10 00 Main rotor blades out of track Track main rotor blades 18 00 00 Vertical or lateral vibration Main rotor components reinstalled in other than original position Install main rotor components in original position or do the track and balance of main rotor 62 00 00 18 00 00 Main rotor hub or hub components damaged Inspect main rotor hub assembly 62 20 00 Main rotor blades...

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Page 1281: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 62 10 00 Main Rotor Blade ...

Page 1282: ......

Page 1283: ... 10 109 ref Figure 402 NOTE Record the locations because the main rotor blades and blade retention bolts are installed in their original locations during installation 2 Release the collective friction to remove the preload of the flexbeams ref Section 67 10 00 Rotor Flight Con trols Removal Installation a Apply electrical power with ground power unit T2002 ref CSP 900RMM 3 Section 96 00 00 Electri...

Page 1284: ...h NOTE If necessary lightly tighten hex nut 4 to release tension on internal locking mech anism This lets the plunger move more easi ly in the bolt 3 Loosen hex nut 4 until approxi mately two threads show 16 20 1 17 18 3 NOTE 5 5 4 4 9G62 002F 101 CONFIGURATION 103 105 CONFIGURATION 6 15 8 19 10 4 FEET 1 22M BLADE TIP BLADE ATTACH POINT LEVEL 22 21 12 15 10 19 109 CONFIGURATION 11 13 14 2 9 Figure...

Page 1285: ...sary use a socket to hold and loosen nut 8 a Disengage spring clip 7 Leave cam handles 9 and spring clips 7 on removed blade retention bolts 6 in the OPEN posi tion Bushings can become damaged when the bolt is not installed and cam handle is closed b Open cam handles 9 Do not tap the bottom or top of the blade retention bolts Dam age to the blade retention bolts can occur NOTE Remove the bolt afte...

Page 1286: ...e Special Tools Ref CSP SPM Item Nomenclature T920 Guide Pin Tool Rotor Blade T2001 Hydraulic Mule T2002 Ground Power Unit NA Push Pull Spring Scale 50 to 150 lbf 22 68 to 68 04 kgf Carefully install the main rotor blades Damage can easily occur to the thin plies in the forward area of the root fitting ref Figure 401 Do not move the rotor blade tip up more than 4 00 feet 1 22 m when the rotor is n...

Page 1287: ...m in its correct position parallel to the pitch case so as to let guide pin tool T920 fully pass thru the lag hole b Install cotter pin 22 in guide pin tool T920 21 Support the main rotor blade during installation Have one person on a maintenance stand 6 Position main rotor blade 1 in pitch case 16 with flexbeam 20 between the top and bottom blade root bushings 7 Push main rotor blade 1 in until i...

Page 1288: ... INCH 0 127 MM 3 5 6 9G62 096A 2 4 3 8 4 A A 1 5 PL 9 5 PL 7 5 PL SECTION A A TYPICAL 10 11 1 BLADE RETENTION BOLT REF IPL 62 10 00 FIG 1 2 PLUNGER 3 THRUST WASHER 4 HEX NUT 5 LOCK RING 6 PAWL 7 PITCHCASE 8 FLEXBEAM 9 MAIN ROTOR BLADE 10 GUIDE PIN TOOL 11 COTTER PIN Figure 403 Installation of 101 Blade Retention Bolts ...

Page 1289: ...on bolts Make sure the bolts freely go into the blades The bolts can be installed by hand with minimum force f Install blade retention bolt 1 at the top of pitchcase 7 as you remove guide pin tool T920 10 g Install bolt 1 until thrust washer 3 is 0 010 to 0 040 inch 0 25 to 1 02 mm from the top surface of pitch case 7 h Make sure lock ring 5 is fully outside of the bottom surface of pitchcase 7 i ...

Page 1290: ...FORCE F 3 4 5 10 6 8 2 BOTTOM SURFACE 9G62 097A SECTION A A TYPICAL 12 13 1 BLADE RETENTION BOLT REF IPL 62 10 00 FIG 1 2 THRUST WASHER 3 CAM HANDLE 4 SPRING CLIP 5 ADJUSTMENT NUT 6 LOCK RING 7 O RING 8 RETAINER 9 PITCHCASE 10 FLEXBEAM 11 MAIN ROTOR BLADE 12 GUIDE PIN TOOL 13 COTTER PIN Figure 404 Installation of 103 Blade Retention Bolts ...

Page 1291: ...r blade removed This prevents damage to the flexbeam and pitchcase Do not install 101 bolts with 103 or 105 bolts If 103 and 105 bolts are installed on the same rotor head equally space the bolts around the ro tor head to prevent a rotor imbalance Ref Figure 404 14 BLADE RETENTION BOLT PN 900R3100001 103 Install blade retention bolt 1 a If necessary move main rotor blade 11 to let guide pin tool T...

Page 1292: ...llation of the spring clip If the blade is not held level the bushings of the blade re tention bolt will not expand equally Keep the bolt holes of retainer 8 pitchcase 9 flexbeam 10 and main rotor blade 11 in alignment as you apply force A misalignment during installation can damage a blade retention bolt NOTE Force F is when spring clip 4 has pushed across the bolt end just before full engagement...

Page 1293: ...e lock ring 6 is expand ed outside the bottom surface of pitchcase 9 8 Make sure the hex hole of spring clip 4 engages and is centered over adjustment nut 5 9 Make sure the gap between thrust washer 2 and retainer 8 is not more than 0 100 inch 2 54 mm k Do steps i thru j again for the lag hole installation l Record the final installation force of each blade retention bolt 1 in Rotorcraft Log Book ...

Page 1294: ...L SLOT SECTION A A BOTTOM SURFACE 6 7 5 4 3 2 8 9 11 13 14 TYPICAL 1 BLADE RETENTION BOLT REF IPL 62 10 00 FIG 1 2 TORQUE NUT 3 CAM HANDLE 4 THRUST WASHER 5 SPRING CLIP 6 ADJUSTMENT NUT 7 LOCK RING 8 O RING 9 RETAINER 10 PITCHCASE 11 FLEXBEAM 12 MAIN ROTOR BLADE 13 GUIDE PIN TOOL 14 COTTER PIN Figure 405 Installation of 105 Blade Retention Bolt ...

Page 1295: ...or head to prevent a rotor imbalance Ref Figure 405 15 BLADE RETENTION BOLT PN 900R3100001 105 Install blade retention bolt 1 a If necessary move main rotor blade 12 to let guide pin tool T920 13 move freely in the lead hole b Remove cotter pin 14 from guide pin tool T920 13 in the lead hole c Install O ring 8 under thrust washer 4 d Put retainer 9 on top of pitchcase 10 Do not align the slots of ...

Page 1296: ...e to the torque nut of the other blade retention bolt NOTE Torque is when spring clip 5 has pushed across the bolt end just before full engagement with adjustment nut 6 j Torque torque nut 2 350 to 450 in lb 39 54 to 50 84 Nm as you keep the bolt holes aligned until cam handle 3 closes NOTE A high torque value in the specified limit is recommended 1 Lightly tap both sides of the cam head with a ru...

Page 1297: ...Record the final installation torque of each blade retention bolt 1 in the Rotorcraft Log Book for future special inspections ref Section 05 20 10 Table 203 Special Inspection After Component Installation Main Rotor Blade Retention Bolt Torque Check and torque checks ref Section 62 10 00 Inspection Check Torque Check of the 105 Blade Retention Bolts ...

Page 1298: ...EF 5 REF 11 3 4 TYPICAL 10 9g62 1000 406 1 A A 6 REF 2 REF 2 REF 6 REF DIM D 13 REF 10 REF 9 REF DIM C 1 BLADE RETENTION BOLT REF IPL 62 10 00 FIG 1 2 MAIN ROTOR BLADE 3 GUIDE PIN TOOL 4 COTTER PIN 5 RETAINER 6 PITCHCASE 7 O RING 8 BOLT HEAD 9 SPRING CLIP 10 ADJUSTMENT NUT 11 FLEXBEAM 12 CAM HANDLE 13 LOCK RING 14 THRUST WASHER Figure 406 Installation of 109 Blade Retention Bolt ...

Page 1299: ...e bolts around the rotor head to prevent a rotor im balance Ref Figure 406 16 BLADE RETENTION BOLT PN 900R3100001 109 Install blade retention bolt 1 a If necessary move main rotor blade 2 to let guide pin tool T920 3 move freely in the lead hole b Remove cotter pin 4 from guide pin tool T920 3 in the lead hole c Put retainer 5 on top of pitchcase 8 d Install O ring 7 under bolt head 8 Do not align...

Page 1300: ...t nut b If spring clip 9 cannot be closed continue to torque adjust ment nut 10 in increments until the spring clip can close NOTE A high torque value below the specified limit is recommended c The maximum torque cannot be more than 975 in lb 110 16 Nm 3 Align the 12 points of adjustment nut 10 with the 12 point hole of spring clip 9 4 If necessary turn adjustment nut 10 in the tightening directio...

Page 1301: ...f CSP SPM Section 20 50 00 Electrical Bonding b Attach bonding jumpers 18 to main rotor blade 1 with bolts 17 1 Torque bolts 17 15 to 20 in lb 1 69 to 2 26 Nm c Test bonding jumper 18 attach ments of main rotor blade 1 and pitchcase 16 for electrical bond Class H ref CSP SPM Section 20 50 00 Electrical Bonding d Safety bolts 17 with lockwire C702 Sealant Fuel Resistant C216 e Seal the heads of bol...

Page 1302: ...re corners to reduce the chance of peeling 3 Apply a minimum of adhesive promoter C725 inside the mask 4 Install protective tape C724 on rotor blade a Overlap the inboard abrasion strip and root end fairing Be careful as you cut the tape Do not scratch or chip the paint on the rotor blade b Split or cut protective tape C724 to fit the blade root fairing NOTE Use a new razor blade or equivalent to ...

Page 1303: ...sion 36 62 10 00 9G62 103 ROOT END FAIRING PROTECTIVE TAPE 1 INCH 25 MM MIN INBOARD ABRASION STRIP ROTOR BLADE TYP PROTECTIVE TAPE ROOT END FAIRING INBOARD ABRASION STRIP BOTTOM VIEW TOP VIEW 2 INCH 51 MM MIN 1 INCH 25 MM Figure 407 Removal and Installation of Protective Tape ...

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Page 1305: ...nce the surface of the blade is contaminated that area cannot be bonded 1 Examine abrasion strips 2 3 for erosion a if there is erosion do a blend repair of those areas ref CSP SPM Section 20 40 00 Mechanical Defects NOTE For areas that cannot be blended out tell the MDHI Field Service Department to get more information 2 Examine abrasion strips 2 3 for corrosion a If there is corrosion remove it ...

Page 1306: ...ge of the inboard abrasion strip 2 is not permitted 3 A crack that does not follow the leading edge or goes in a chord wise direction is not permitted 7 Examine outboard abrasion strip 3 where it overlaps the edge of inboard abrasion 2 strip for voids open to edge Sealant Fuel Resistant C216 a If there are voids seal the voids in this area with sealant C216 ref CSP SPM Section 20 50 00 Environment...

Page 1307: ...DS NOTE 3 NO ANOMALIES WITHIN THIS AREA FOR LENGTH OF BOTH STRIPS NOTE 4 NO ANOMALIES WITHIN 1 00 INCH 25 4 MM OF INBOARD AND OUTBOARD EDGES 9G62 015F LE 1 00 INCH 25 4 MM NOTE 4 OUTBD 0 15 INCH 3 8 MM NOTE 3 TE 0 50 INCH 12 7 MM LE 0 15 INCH 3 8 MM NOTE 3 TE 1 00 INCH 25 4 MM NOTE 4 INBD 0 50 INCH 12 7 MM 0 15 INCH 3 8 MM NOTE 3 1 MAIN ROTOR BLADE 2 INBOARD ABRASION STRIP 3 OUTBOARD ABRASION STRI...

Page 1308: ...uel Resistant Do not do a fluorescent pene trant inspection FPI Once the surface of the blade is contaminated that area cannot be bonded 1 Examine the trim tabs 5 for cracks a If there are cracks tell the MDHI Field Service Department to get more information and instruction NOTE Some indications can appear on the sur face parallel to the chord wise direction These are usually the bondlines between...

Page 1309: ...6 a If there is a void in this area seal voids with sealant C216 ref CSP SPM Section 20 50 00 Environmental Sealing Methods D Inspection of Protective Tape 1 Examine protective tape C724 for large bubbles and pleats a Replace or repair protective tape C724 if there are large bubbles or pleats 2 Examine protective tape C724 for damage and if the edge of the tape is loose a Replace or repair protect...

Page 1310: ...LT MAKE SURE YOU FOLLOW THE PROCEDURE 2 0 005 INCH 0 127 MM 0 005 INCH 0 127 MM 3 5 6 9G62 093 7 9 1 NOTE 4 8 1 BLADE RETENTION BOLT REF IPL 62 10 00 FIG 1 2 PLUNGER 3 THRUST WASHER 4 HEX NUT 5 LOCK RING 6 PAWL 7 PITCHCASE REF IPL 62 20 00 FIG 1 8 FLEX BEAM 9 MAIN ROTOR BLADE REF IPL 62 10 00 FIG 1 Figure 602 Torque Check for the 101 Blade Retention Bolts ...

Page 1311: ...not loosen blade retention bolts 1 1 Release the collective friction to remove the preload of flexbeams ref 67 10 00 Rotor Flight Controls Removal Installation a Apply electrical power with ground power unit T2002 ref CSP 900RMM 3 Electrical Power Maintenance Practices Helicopter Electrical Power b Push the collective friction release switch forward to release the collective friction c Raise the p...

Page 1312: ...6 LOCK RING 7 O RING 8 RETAINER 9 PITCHCASE REF IPL 62 20 00 FIG 1 10 FLEX BEAM 11 MAIN ROTOR BLADE REF IPL 62 10 00 FIG 1 Figure 603 Torque Check for the 103 Blade Retention Bolts 6 After plunger 2 is in the up position make sure lock ring 5 has expanded outside the bottom surface of pitchcase 7 7 Make sure there is a 0 005 inch 0 13 mm minimum gap between lock ring 5 and the bottom surface of pi...

Page 1313: ...f bolt 1 Release the collective friction to remove the preload of the flexbeams ref Section 67 10 00 Rotor Flight Controls Removal Installation a Apply electrical power with ground power unit T2002 ref CSP 900RMM 3 Section 96 00 00 Electrical Power Maintenance Practices b Push the collective friction release switch forward to release the collective friction c Raise the pilot collective stick suffi...

Page 1314: ...ich ever is greater retorque blade retention bolt ref Section 62 10 00 Main Rotor Blade Removal Installation d If necessary turn hex nut 5 in the tightening direction only to align and center the hex nut 5 with the hex shaped hole of spring clip 4 without a recheck of Force F 6 Move and center spring clip 4 over hex nut 5 NOTE Listen for a click or snap when the spring clip moves over the hex nut ...

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Page 1316: ...LLOW THE PROCEDURE 9G62 095 10 12 1 NOTE 2 3 4 5 6 7 8 9 BOTTOM SURFACE 11 1 BLADE RETENTION BOLT REF IPL 62 10 00 FIG 1 2 TORQUE NUT 3 CAM HANDLE 4 THRUST WASHER 5 SPRING CLIP 6 ADJUSTMENT NUT 7 LOCK RING 8 O RING 9 RETAINER 10 PITCHCASE REF IPL 62 20 00 FIG 1 11 FLEX BEAM 12 MAIN ROTOR BLADE REF IPL 62 10 00 FIG 1 Figure 604 Torque Check for the 105 Blade Retention Bolts ...

Page 1317: ...to the blade retention bolts can occur NOTE It can take 10 to 15 taps before the bushings and collets release 4 Lightly tap both sides of the cam head of blade retention bolt 1 with a rubber mallet or equivalent to loosen its bushings and collets NOTE If necessary make small movements of the main rotor blade to help loosen the bushings 5 Do a torque check on torque nut 2 a The torque must be 350 t...

Page 1318: ...14 Revision 36 62 10 00 10 Make sure the gap between thrust washer 4 and retainer 9 is 0 100 inch 2 54 mm 11 Record the locations of blade retention bolts 1 that lost torque in the Rotor craft Log Book 12 Repeat this procedure for the remaining 9 blade retention bolts 1 ...

Page 1319: ...iring surface with a clean cloth dampened with solvent cleaner C429 or equivalent a Wipe with a clean dry cloth b Air dry for 15 minutes minimum at ambient temperature NOTE If filler is not applied within 2 hours do the solvent wipe cleaning Step 2 again Adhesive Epoxy C438 Do not machine mix epoxy as it will cause air to be included in the epoxy which will reduce its strength 3 Thoroughly mix epo...

Page 1320: ...o 0 75 inch 12 7 to 19 1 mm Resin Epoxy C504 Do not machine mix epoxy as it will cause air to be included in the epoxy which will reduce its strength 3 Thoroughly mix epoxy resin C504 by weight in accordance with manufactur er s instructions Fiber Cloth E Glass C501 4 Cut two plies of fiber cloth C501 to fabricate the required doublers with an additional 1 00 inch 25 4 mm outside dimension on each...

Page 1321: ... hours at ambient temperat ure or 12 hours at ambient temperat ure followed by 1 5 to 2 5 hours at 170 to 1905F 76 7 to 87 85C Protective Equipment 13 Fair by sanding with wet or dry abrasive paper C814 or finer 14 Touch up main rotor blade paint ref CSP SPM ÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌ VACUUM SOURCE BREATHER RELEASE FILM R...

Page 1322: ...M A DAMAGE AREA BOTTOM VIEW 1ST PLY COVER PLY 1ST PLY BOTTOM VIEW TRAILING EDGE DAMAGE AREA 2ND PLY COVER PLY TOP VIEW TRAILING EDGE BLADE TRAILING EDGE NOTCH BLADE TRAILING EDGE 2ND PLY 2ND PLY DIM H DIM D DIM C DIM B DIM G DIM F DIM H DIM G DIM F DIM E DIM D DIM C DIM B BLADE TRAILING EDGE RAD N RAD P RAD R DIM E DIM M DIM K DIM L DIM H DIM G DIM F RAD N RAD P RAD R DIM J DIM K DIM L DIM G DIM F...

Page 1323: ...1 00 inch 25 4 mm minimum must be between repairs Consumable Materials Ref CSP SPM Item Nomenclature C410 Adhesive Epoxy Paste C501 Fiber Cloth E Glass C807 Sandpaper C429 Solvent Cleaner C438 Adhesive Epoxy The main rotor blade trailing edge must be straight after the repair is completed Protective Equipment 1 Remove damaged fibers maximum after removal 0 50 inch 12 7 mm radius from trailing edge...

Page 1324: ... Make sure there are no air bubbles under the plies Air bubbles under the plies are not permitted 11 Place the first smaller ply on the repair NOTE Fiberglass orientation is optional 12 Place the second ply on the first ply 13 Cover repair with nonporous release film and work out all trapped air or wrinkles 14 Vacuum bag top and bottom repair area together and apply vacuum pressure 20 to 29 inHg 5...

Page 1325: ...Sealing Compound Corrosion Inhibitive C234 Sealing Compound 1 Apply masking tape to blade on two sides of area to be sealed Sealing Compound C212 Sealing Compound C213 Sealing Compound C234 2 Seal all of top and bottom abrasion strip edges with sealing compound C212 sealing compound C213 or sealing compound C234 NOTE Use sealing compound C234 in colder temperatures a Use a plastic spatula or flat ...

Page 1326: ...pair may be repeated only once if the crack is still within the 1 75 inch 44 5 mm of the inboard abrasion strip overlay 1 Measure the visible crack length from the overlap edge of the inboard abra sion strip to the end of the crack a If the entire crack is within 1 75 inch 44 5 mm repair the crack 2 Lightly abrade the surface of the cracked area with a scouring pad C817 3 Clean surface with solven...

Page 1327: ...emoval area of tape adhes ive with isopropyl alcohol C419 and non lint cloth C802 4 Let the repair area dry B Make an Overlap Patch Option 1 1 Cut protective tape C724 1 00 to 1 50 inch 25 4 to 38 1 mm more than the area to be repaired NOTE If possible cut the patch with rounded corners to reduce the chance of peeling 2 Apply a minimum of adhesive promoter C725 to the repair and overlap areas 3 Ca...

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Page 1329: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 62 20 00 Main Rotor Hub Assembly ...

Page 1330: ......

Page 1331: ... rotor drive plate ref Section 63 10 00 NOTE Deleted 5 Deleted 6 Remove lockwire from bolts 1 7 Remove bolts 1 in order of 12 thru 1 as shown on safety ring 2 a Remove safety ring 2 8 Remove retention nut 3 a Install two bolts 1 in retention nut 3 NOTE Do not fully tighten bolts 1 Retention nut 3 has left han ded threads b Turn retention nut 3 clockwise with two bolts 1 c Remove retention nut 3 9 ...

Page 1332: ... 2 REF 10 8 5 PL 7 5 PL 6 8 9 3 4 1 2 5 10 11 6 7 12 1 BOLT REF IPL 62 00 00 FIG 2 2 SAFETY RING 3 RETENTION NUT 4 NUT RETAINER 5 HELICOPTER SLING 6 MAIN ROTOR HUB 7 CLEVIS FITTING 8 BUSHED HOLE IN ROTOR HUB WEB 9 CLEVIS BOLT OR PIN 10 STATIC MAST 11 UPPER SEAL REF IPL 62 20 00 FIG 1 12 SEAL SPRING Figure 401 Main Rotor Hub Assembly and Helicopter Sling ...

Page 1333: ...lts or pins 9 b Remove clevis fittings 7 8 Install retention nut 3 a Install nut retainer 4 with the open side up b Make sure the threads of retention nut 3 and bolts 1 have no oil or grease contamination The retention nut has left han ded threads c Install retention nut 3 counterclock wise on static mast 10 d Make sure the threads of bolts 1 have no oil or grease contamination Compound Anti Seize...

Page 1334: ... the top of the static mast and not slip off when the bolts are fully torqued p Install safety ring 2 over retention nut 3 1 Make sure the bolt holes of the retention nut and the safety ring are aligned 2 Align the tabs of safety ring 2 with the notches in the top of static mast 10 Compound Anti Seize C220 q Apply anti seize compound C220 to bolts 1 Do not loosen the bolts between each torque sequ...

Page 1335: ...occur NOTE This task is for the removal of one damp er set at a time with the main rotor hub installed on the helicopter and is typical 1 Lift the main rotor blade approximately level and put a support below it or remove it ref Section 62 10 00 2 Release the collective friction unit and move the collective up until the outboard end of the pitchcase is approximately 90 to the static mast ref Sectio...

Page 1336: ... follows a Temporarily install upper and lower damper cap on pitchcase using bolts and washers Torque bolts b Measure the dimension from outside center of upper damper cap to outside center of lower damper cap 1 Record the dimension c Remove damper caps from pitchcase 9G62 0064A 8 9 2 PL 3 4 6 5 12 13 10 16 15 14 13 12 5 1 4 6 PL 3 6 PL 7 11 17 18 19 20 4 PL 2 PL DRAIN HOLE 2 1 LOWER DAMPER CAP RE...

Page 1337: ...rapped in the center k Install bonding jumpers bolts 7 and washers 8 l Connect bonding jumpers together where they are across each other 1 Put tie wraps 2 inch 51 mm apart m Torque all upper damper cap bolts n Measure the dimension from the outside center of upper damper cap to the outside center of lower damper cap 1 Record the dimension o Subtract the dimension recorded in Step b 1 from the dime...

Page 1338: ...ain rotor hub droop angle test 7 Do the Main Rotor Track and Balance procedure ref Section 18 00 00 3 Pitchcase Assemblies Ref Figure 402 A Removal NOTE If more than one pitchcase is removed identify all removed components to make sure they are installed in their initial posi tion Do not move the rotor blade tip up more than 4 0 ft 1 22 m when the rotor is not in operation And do not move the flex...

Page 1339: ...g bearing installation Lubricant Solid Film C101 1 Spray threads of snubber bolt 20 with solid film lubricant C101 Hold snubber bolt 20 with a wrench as you tighten nut 18 to prevent movement of the snubber bush ing 2 Install centering bearing 11 washer 19 and nut 18 a Torque nut 18 300 to 360 in lb 33 90 to 40 67 Nm b Install new cotter pin 17 3 Install main rotor hub dampers 5 Main Rotor Droop S...

Page 1340: ...Adjustment Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C234 Sealing Compound C302 Finish Enamel White Do not remove the snubber bushing NOTE Only adjust a snubber bushing that moved during removal or installation 1 Slowly turn snubber bushing with a wrench to the correct position Angle A 95 29 30 to 95 30 30 Sealing Compound C234 2 Fillet seal both ends of snubber bushing wit...

Page 1341: ...op angle test 7 Droop Stop Supports Ref Figure 405 Consumable Materials Ref CSP SPM Item Nomenclature C211 Sealing Compound Corrosion Inhibitive A Removal NOTE This task is typical for main rotor droop stop support removal Do not move the rotor blade tip up more than 4 0 ft 1 22 m when the rotor is not in operation And do not move the flexbeam up more than 1 0 in 2 54 cm at the blade attach point ...

Page 1342: ... 2 PL 1 2 PL 1 COTTER PIN REF IPL 62 20 00 FIG 1 2 NUT 3 WASHER 4 BOLT 5 STRIKER PLATE 6 SHIM 7 DROOP STOP SUPPORT 8 NUT 9 WASHER 10 WASHER 11 BOLT 12 COTTER PIN 13 NUT 14 WASHER 15 BOLT 16 BONDING JUMPER 17 COTTER PIN 18 NUT 19 WASHER 20 BOLT 21 GROUNDING ASSEMBLY 22 SETSCREW 23 GROUNDING BRUSH 24 NUT 25 WASHER 26 COUNTERSUNK WASHER 27 BOLT 28 DRIVE RING ASSEMBLY Figure 405 Main Rotor Hub Droop S...

Page 1343: ...ng assembly brush 1 Disconnect scissors link from main rotor drive ring assembly Ref Section 62 30 00 2 Remove setscrew 22 3 Remove grounding brush 23 B Installation NOTE This task is typical for installation of each grounding assembly brush 1 Install grounding brush and setscrew 2 Tighten set screw until it stops do not tighten more than 45 in lb 5 08 Nm 3 Connect scissors link to main rotor driv...

Page 1344: ...nk washers 3 and bolts 4 5 Remove cotter pins 5 a Discard cotter pins 5 NOTE Aid of 1 or 2 persons is recommended When you remove bolts 9 and separate the hub halves the flexbeams will not be kept in hub The flexbeams can fall and damage to flexbeam can occur Do not use force to remove flexbeam bolt 9 Damage to lead lag shims 14 15 can occur 6 Remove nuts 6 washers 7 counter sunk washers 8 and fle...

Page 1345: ...6 2 629 cm 14 15 ADHESIVE 7 1 E 13 6 10 12 8 14 3 5 11 7 9 2 4 15 B D A C TORQUE SEQUENCE TOP VIEW 16 1 NUT REF IPL 62 20 00 FIG 1 2 WASHER 3 COUNTERSUNK WASHER 4 BOLT 5 COTTER PIN 6 NUT 7 WASHER 8 COUNTERSUNK WASHER 9 FLEXBEAM BOLT 10 LOWER HUB 11 UPPER HUB 12 HUB PLATE 13 FLEXBEAM 14 LEAD LEG SHIM UPPER 15 LAG LEG SHIM LOWER 16 IDENTIFICATION PLATE Figure 406 Main Rotor Hub Flexbeam Installation...

Page 1346: ...torque for bolts 4 2 Torque nuts 1 to the run on torque for bolts 4 NOTE Bolts 4 must be snug but not tight a Stop when the torque of nuts 1 begins to be more than the run on torque of bolt 4 9 Do these steps for flexbeams installed on 900R1101000 117 and subsequent hub assemblies a Torque nuts 6 in sequence A B C D and E 800 to 850 in lb 90 39 to 96 04 Nm plus locking torque b Torque nuts 6 again...

Page 1347: ...r shim installation tool T908 Adhesive C426 5 In less than 2 hours after adhesive promoter is dry apply a thin layer approximate thickness 0 005 to 0 015 inch 0 13 to 0 38 mm of adhesive C426 to shim mating surface 6 Install shim in hub and align hole in shim with bolt hole in hub NOTE Do not let edges of shim be on fillet radii in pocket of hub 7 Install flexbeam wear shim installation tool T908 ...

Page 1348: ...nd the hub retention nut ref Procedure 1 B 17 Upper Bearing Upper Hub Assembly Ref Figure 407 Consumable Materials Ref CSP SPM Item Nomenclature C104 Grease Special Tools Ref CSP SPM Item Nomenclature T907 Upper Bearing Removal Tool A Removal NOTE Bearing cones rollers and cups must be replaced as a set It can be necessary to install a different bearing spacer shim when you replace upper bearing I...

Page 1349: ...ÏÏÏ ÏÏÏÏ ÏÏÏÏ 6 7 8 9 10 12 11 13 5 14 GREASE GREASE GREASE 8 6 15 1 UPPER BEARING REF IPL 62 20 00 FIG 1 2 BEARING CONE 3 BEARING ROLLER 4 BEARING CAGE 5 BEARING CUP OUTER RACE 6 UPPER SEAL 7 SEAL SPRING 8 SEAL STOP 9 LOWER SEAL 10 LOWER BEARING 11 HUB LINER 12 CENTER SEAL 13 HUB SHIM 14 UPPER HUB 15 UPPER BEARING REMOVAL TOOL T907 Figure 407 Bearing and Seal Removal Installation ...

Page 1350: ...uch bearing cup 5 4 Make sure the space above upper bearing 1 is full to the top edge of bearing cone 2 with grease C104 5 Install seal stop 8 6 Install new upper seal 6 ref Proce dure 16 B 18 Main Rotor Hub Shim Ref Lower Bearing Removal and Installation 19 Main Rotor Lower Seal Ref Figure 407 Consumable Materials Ref CSP SPM Item Nomenclature C104 Grease C310 Primer Special Tools Ref CSP SPM Ite...

Page 1351: ...tool T919 2 Remove lower seal 9 from hub liner 11 3 Remove lower bearing 10 from hub liner 11 with hub lower bearing liner tool T910 B Installation Bearing cones rollers and cups must be replaced as a set Always wear rubber or clean fabric gloves when you touch the bearing to prevent contamination of the bearing with oil from your skin NOTE It is not necessary to replace grease C104 on bearing and...

Page 1352: ...o install a different bearing spacer shim when you replace upper bearing If you replace bearing record serial num ber of new bearing in rotorcraft log book Always wear rubber or clean fabric gloves when you touch bearing to prevent con tamination of bearing with oil from your skin 1 Measure and record outer diameter of bearing cup use 6 7 in outside micrometer T2020 2 Measure and record inner diam...

Page 1353: ...Always wear rubber or clean fabric gloves when you touch bearing to prevent con tamination of bearing with oil from your skin 1 Remove lower bearing 2 Put race removal tool T917 below bottom of lower bearing cup 5 and tighten 3 Push bearing cup out of hub with hydraulic press T2018 B Installation NOTE Bearing cones rollers and cups must be replaced as a set If you replace bearing record serial num...

Page 1354: ...ame shim thickness as the shim removed from the hub assembly or the middle thickness shim Always wear rubber or clean fabric gloves when you touch the bearing to prevent contamination of the bearing with oil from your skin 1 Clean bearings 1 10 ref CSP SPM Grease C104 2 Apply a thin film of grease C104 to bearings 1 10 3 Assemble upper hub 14 center seal 12 lower bearing 10 hub liner 11 assembly m...

Page 1355: ...the hub with 2000 lb 907 02 kg force on bearing as measured in Step 10 and must be between 3 5 and 5 0 lb 1 59 and 2 27 kg 2 If the force to turn the hub with 6000 lb 2721 08 kg of force on bearing is more than with 2000 lb 907 02 kg of force on bearing or is not between 3 5 and 5 0 lb 1 59 and 2 27 kg install a different shim and repeat steps 4 thru 11 12 Remove upper and lower bearings hub liner...

Page 1356: ...pitch link from the pitchcase ref Section 62 30 00 2 Remove the sealing compound from nuts 1 3 Remove the lockwire from nuts 1 a Discard the lockwire 4 Remove the sealing compound from pitch horn 3 5 Remove nuts 1 washers 2 and pitch horn 3 6 If necessary remove bolts 4 Do not use chemicals to remove the sealant 7 Remove sealing compound from the mating surface of pitchcase 5 and pitch horn 3 B In...

Page 1357: ...inish Enamel White C302 5 If necessary touch up paint with white finish enamel C302 ref CSP SPM 6 Connect the pitch link to pitchcase 5 ref Section 62 30 00 9G62 081C 3 4 4 PL 5 2 4 PL 1 4 PL 1 NUT REF IPL 62 20 00 FIG 3 2 WASHER 3 PITCH HORN 4 BOLT 5 PITCHCASE Figure 409 Pitch Horn Replacement ...

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Page 1359: ...ting surfaces of upper hub 3 Figure 802 and lower hub 4 Figure 802 for corrosion cracks and damage 1 Replace a lower hub or upper hub with cracks or damage 2 If there is corrosion repair the lower hub or upper hub ref Repair Flexbeam Pockets and Hub Mating Surfaces Corrosion c Examine top surface of upper hub Figure 801 for corrosion 1 If there is corrosion repair upper hub ref Repair Upper Hub Up...

Page 1360: ...TO FLEXBEAM INSTALLATION FOR TORQUE PROCEDURE 3 EXAMINE ELASTROMERIC MATERIAL FOR DETERIORATION 1 MAIN ROTOR HUB 2 FLEXBEAM NUT 3 UPPER DAMPER CAP 4 LOWER DAMPER CAP 5 DAMPER 6 CENTERING BEARING 7 PITCHCASE 8 ROTOR BLADE 9 FLEXBEAM 10 FLEXBEAM BUMPER 11 STRIKER PLATE DROOP STOP 12 DROOP STOP SUPPORT 13 DROOP STOP ROLLER 14 DRIVE RING 15 GROUNDING JUMPER 16 GROUNDING JUMPER 17 GROUNDING BRUSH HOLDE...

Page 1361: ...ine droop stop striker plate 11 for cracks and correct installation a No cracks are permitted b Torque or replace loose or missing hardware 15 Examine droop stop striker plate for a maximum wear of 0 100 inch 2 54 mm where the roller touches the plate 16 Examine droop stop supports 12 a Examine supports 12 for condition b Examine supports 12 for cracks in the upper bend area c Replace supports 12 ...

Page 1362: ...son on a mainte nance stand Cleaner C432 1 Use cleaner C432 to clean the flex beam before inspection 2 Inspect the areas of the flexbeam that you can access for delamination fiber fuzz separation breakage 3 EARLY CONFIG Inspect the top and bottom of the flexbeam where lead and lag legs join Maximum crack length 2 0 inch 5 08 cm NOTE Ref Service Bulletin SB900 001 most current revision for ferry fl...

Page 1363: ... ON EDGE OF FLEXBEAM OF 0 20 IN 0 508 mm MAXIMUM DEPTH WITH NO FIBER DAMAGE ARE PERMITTED BREAK SHARP EDGES AND FILL WITH A RESIN WASH 10 A LOOSE OR BROKEN WRAP THAT CAN BE LIFTED UP ALONG AN EDGE IS CAUSE FOR REJECTION 11 MANUFACTURING FOLDS OR WRINKLES IN THE WRAP CAN APPEAR TO BE FIBER SEPARATION OR BREAK CLOSE EXAMINATION IS NECESSARY TO DETERMINE WHETHER THE INDICATION IS A FIBER SEPARATION O...

Page 1364: ...WASH 4 A SEPARATION SPLIT EXTENDING OUTBOARD FROM THE APEX IS NOT PERMITTED IF IT IS VISIBLE BEYOND THE FLEXBEAM BRIDGE 5 IGNORE SHEAR WEB SEPARATION IN THIS AREA DISBONDED INBOARD SHOES CAN BE REPAIRED WITH SEALANT ADHESIVE 6 DARK LINES INDICATING GAPS BETWEEN THE EDGE OF ONE WRAP AND THE EDGE OF THE NEXT WRAP ARE NORMAL AND PERMITTED 7 NO BUMPER ASSEMBLY DETERIORATION SUCH AS PERMANENT COMPRESSI...

Page 1365: ...ring Removal Solvent Cleaning C421 2 Remove grease from bearing use cleaning solvent C421 3 Remove grease from bearing cup 5 4 Examine bearing rollers 3 bearing cage 4 bearing cup 13 and bearing cone 20 for cracks scores and heat damage None permitted 5 Examine bearing rollers and bearing cup for scratches a Small surface scratches on non wear surfaces with no metal movement are permitted b Maximu...

Page 1366: ...ection Area 4 Ref Figure 603 Consumable Materials Ref CSP SPM Item Nomenclature C104 Grease C421 Solvent Cleaning Always wear rubber gloves when you hold the bearing This prevents contamination of the bearing with the oil in your skin NOTE The non wear surfaces are top and bot tom surfaces of bearing cone and top and bottom surface of bearing cup You must remove the lower bearing to do the inspect...

Page 1367: ... if it can not be felt and no bearing noise can be heard True brinelling is caused by heavy impact loads from rollers to cup An indication of true brinelling is metal deformation 12 Examine bearing rollers and bearing cup for true brinelling Maximum permitted 0 015 in 0 381 mm in width and 0 030 in 0 762 mm in length H Center Seal Inspection Area 4 Ref Figure 603 NOTE You must remove hub liner to ...

Page 1368: ...EARING 2 UPPER BEARING CONE 3 UPPER BEARING ROLLER 4 UPPER BEARING CAGE 5 UPPER BEARING CUP 6 UPPER BEARING SEAL 7 UPPER BEARING SEAL SPRING 8 UPPER BEARING SEAL STOP 9 CENTER SEAL 10 LOWER BEARING SEAL 11 UPPER HUB HALF 12 LOWER BEARING 13 LOWER BEARING CUP 14 HUB CENTER PLATE 15 FLEXBEAM POCKET 16 LOWER HUB HALF 17 HUB LINER 18 LEAD SHIM UPPER 19 LAG SHIM LOWER 20 LOWER BEARING CONE 21 LOWER BEA...

Page 1369: ... 10 00 2 Examine upper surface of main rotor upper hub surface for corrosion None permitted Make sure paint stripper and solvent does not go into upper bearing and grease seal area 3 If necessary remove paint from bolt holes 3 and bolt hole upper chamfer Use paint removal chemical procedure ref CSP SPM 4 Examine bolt holes 3 for cracks use a light and 10X or more magnification glass No cracks perm...

Page 1370: ...4 62 20 00 REF 4 1 5 PL 2 5 PL 3 8 6 5 9G62 026G REF 7 9 10 PL 7 4 1 RIB 2 FILLET 3 PITCHCASE 4 DAMPER 5 FLEXBEAM 6 PITCH HORN 7 CENTERING BEARING 8 MAIN ROTOR UPPER HUB 9 BOLT HOLE AREA 10 NUT 11 PIN 12 NUT Figure 605 100 Hour Main Rotor Hub and 50 Hour Centering Bearing Inspection ...

Page 1371: ... drive flange use a light and 10X or more magnification glass No cracks permitted 5 If you are not sure of the results of a visual inspection do the Main Rotor Hub Eddy Current Inspection 6 Examine main rotor upper hub between the ribs in the fillet area 2 for cracks with a light and 10X or more magnifica tion glass No cracks permitted 7 If you are not sure of the results of a visual inspection do...

Page 1372: ...ing separation a Replace center bearings 7 with a separation between the elastomeric material and housing 3 Examine center bearings 7 for separation between the elastomeric material and center bushing NOTE Black powder is an indication of a light deterioration of the elastomeric material and is permitted Rubber particles are indication of separa tion If the housing is not aligned with the cen ter ...

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Page 1374: ...OR EQUIVALENT AS FOLLOWS POSITION HORIZONTAL 128 POSITION VERTICAL 128 FREQUENCY 90KHz GAIN HORIZONTAL 52 GAIN VERTICAL 73 PHASE 274 FILTERS HI 2 LOW 100 EACH SQUARE 1 mil NOTE 1 5 PL 5 PL NOTE 2 5 PL 5 PL CRACK INDICATIONS NOISE 2 INCREMENT 10 PL NOTES 1 NUT WASHER AND BOLT REMOVED TO CLEARLY SHOW AREA OF INSPECTION 2 EXAMINE THE TWO SIDES OF RIB Figure 606 Main Rotor Upper Hub Eddy Current Inspe...

Page 1375: ...event wear on the probe 3 Calibrate inspection unit and probe ref manufacturer instructions to detect a 0 010 inch 0 25 mm mini mum crack NOTE Unit and probe must be calibrated be fore inspection each half hour during in spection at the end of inspection and if a cable or probe is changed NOTE The upper hub material is forged alumi num alloy 7149 T7352 4 Set inspection unit for inspection ref manu...

Page 1376: ...ch rotor blade a Put inclinometer T203 on a flat and level surface of upper hub 1 parallel to pitchcase 2 1 Record the angle measurement b Put inclinometer T203 on the top surface of upper damper cap 2 parallel to pitchcase 4 1 Record the angle measurement 3 The droop angle must be 7 0 to 7 5 degrees at each position NOTE The droop angle is the difference be tween the angle measurement of upper hu...

Page 1377: ...dy current inspection of repair area ref CSP SPM 5 Apply alodine C241 to repair area ref CSP SPM 6 Apply primer C308 and white finish enamel C302 ref CSP SPM B Upper Hub Upper Surface Corrosion Ref Figure 801 Consumable Materials Ref CSP SPM Item Nomenclature C804 Abrasive Cloth 1 Remove paint from area to be repaired ref CSP SPM Remove corrosion to a maximum depth of 0 006 inch 0 15 mm You can on...

Page 1378: ...ES AND OUTER SURFACE OF WEB 9G62 046B REMOVE CORROSION FROM UPPER SURFACE OF UPPER HUB Figure 801 Main Rotor Hub Repair 9G62 061A VIEW LOOKING DOWN VIEW LOOKING UP WEAR SHIM WEAR SHIM REMOVED 3 1 50 INCH 38 1 MM 1 MATING SURFACE TYPICAL SHADED 4 2 2 1 HUB PLATE 2 FLEXBEAM POCKET 3 UPPER HUB 4 LOWER HUB Figure 802 Flexbeam Pockets Hub Mating Surfaces and Hub Plate ...

Page 1379: ...identification to prevent damage 2 Remove ion vapor deposited IVD coating from both upper and lower surfaces of hub plate 1 a Use glass bead ref CSP SPM or aluminum oxide grit blasting Remove corrosion to a maxi mum depth of 0 006 inch 0 15 mm 3 Remove corrosion ref CSP SPM 4 Surface finish of hub plate after repair a Areas larger than 0 25 inch 6 4 mm and less than 0 50 inch 12 7 mm from edge of ...

Page 1380: ...aft Maintenance Manual Page 804 Revision 34 62 20 00 3 50 INCH 88 9 MM 2 50 INCH 63 5 MM 15 2 INCH 38 61 CM 14 8 INCH 37 59 CM 1 2 1 2 SIDE VIEW 1 4 PLACES 9G62 076B 2 00 INCH 50 8 MM 1 00 INCH 25 4 MM Figure 803 Flexbeam Bumper Replacement ...

Page 1381: ...er 1 and flexbeam 2 with a non lint cloth C802 moist with cleaning solvent C425 5 Do Step 4 until cloth stays clean Sealing Compound C201 6 Mix sealing compound C201 refer to manufacturers instructions NOTE You must mix sealant in a clean non waxed container Apply sealant before expiration of its pot life 7 Apply a 0 010 to 0 020 inch 2 54 to 5 08 mm thick layer of sealing com pound C201 to the tw...

Page 1382: ...FILLED 3 AREA WHERE NICKS CAN BE REPAIRED Figure 804 Flexbeam Fissure Fill and Nick Repair B Flexbeam Fissure Fill Ref Figure 804 Consumable Materials Ref CSP SPM Item Nomenclature C216 Sealant Fuel Resistant C425 Solvent Cleaning C504 Resin Epoxy C802 Cloth Non Lint NOTE A fissure is an opening in surface of epoxy resin or sealant on flexbeam Fissures that are in resin between flex beam apex and ...

Page 1383: ...poxy resin C504 or sealant C216 to seal fissure 1 2 4 Cure epoxy resin C504 or sealant C216 ref manufacturers instruc tions C Flexbeam Nick Repair Ref Figure 804 Consumable Materials Ref CSP SPM Item Nomenclature C425 Solvent Cleaning C504 Resin Epoxy C802 Cloth Non Lint C807 Sandpaper 1 Break sharp edges of nick with sandpa per C807 Solvent Cleaning C425 2 Clean surface of flexbeam in area of nic...

Page 1384: ...ir Ref Figure 805 Consumable Materials Ref CSP SPM Item Nomenclature C216 Sealant Fuel Resistant C425 Solvent Cleaning C802 Cloth Non Lint NOTE The flexbeam assembly must be re moved to do this repair Solvent Cleaning C425 1 Clean the surface of repair area with a non lint cloth C802 moist with cleaning solvent C425 Sealant Fuel Resistant C216 2 Mix sealant C216 ref manufacturer instructions 3 Put...

Page 1385: ... more current configura tion All early configuration hub assemblies can be changed to the 900R5101117 confi guration This change is not mandatory 1 Remove main rotor hub assembly ref Main Rotor Hub Assembly 2 Remove and disassemble upper hub 1 lower hub 2 and hub plate 3 ref Main Rotor Hub Assembly 3 Discard all parts and hardware that are unserviceable 4 Assemble hub with components shown in Tabl...

Page 1386: ...x 900R2101018 105 serialized part 4 5 Flexbeam Bolt 900R2100011 101 900R2100011 103 5 5 Lead Leg Wear Shim 900R2101003 101 900R2101003 103 6 5 Lag Leg Wear Shim 900R2101015 101 if installed 900R2101015 103 7 10 Slide Bushing 900R2101128 101 new part 8 15 Nut Hex HS4447 624C HS5489 6C 9 15 Bolt Head Tension HS5482 6 42 46 or Alternate HS5482 6 50 10 1 Identification ID Plate old ID plate HS4726 3 1...

Page 1387: ... mm apply oxide film C244 to the flange surface ref manufacturers instruc tions B Inner Diameter of the Male Bushings Ref Figure 807 Consumable Materials Ref CSP SPM Item Nomenclature C244 Oxide Film Corrosion Resistant C425 Solvent Cleaning C802 Cloth Non Lint NOTE The pitchcase assembly must be re moved to do this repair Do not disassemble the pitchcase assembly Solvent Cleaning C425 1 Clean the...

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Page 1389: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 62 30 00 Swashplate and Mixer ...

Page 1390: ......

Page 1391: ...3 washer 12 bushing 11 washer 8 and bolt 6 a Discard cotter pin 14 5 Remove cotter pin 14 nut 13 washer 12 bushing 11 washer 8 and bolt 7 a Discard cotter pin 14 6 Remove pitch link assembly 1 with elastomer ring 2 from swashplate assembly 4 and pitch horn 15 B Installation 1 For a new pitch link assembly 1 make sure the nominal length is 16 60 inch 42 16 cm 2 Make sure pitch link assemblies 1 are...

Page 1392: ...rack and Balance procedure ref Section 18 00 00 7 8 11 12 14 13 1 16 18 17 3 13 14 11 4 8 5 12 14 13 9 11 10 10 9 6 TYPICAL TWO PLACES TYPICAL THREE PLACES 9G62 070B 15 2 1 PITCH LINK ASSEMBLY REF IPL 62 00 00 FIG 2 2 ELASTOMER RING 3 BEARING REF IPL 63 30 00 FIG 4 4 SWASHPLATE ASSEMBLY REF IPL 62 00 00 FIG 2 5 BOLT 6 BOLT 7 BOLT 8 WASHER 9 WASHER 10 COUNTERWEIGHT 11 BUSHING 12 WASHER 13 NUT 14 CO...

Page 1393: ...to 0 15 mm of play between the drive link assembly and drive ring before you torque nuts 7 2 Typical two places Install the shims 9 sleeves 10 washers 8 bolts 11 and nuts 7 through link assembly 4 and drive ring 12 a Torque nuts 7 b Install new cotter pins 6 3 Install washer 3 and nut 2 on link assembly 4 a Torque nut 2 b Install new cotter pin 1 4 Do the Swashplate Drive Link Inspec tion ref Insp...

Page 1394: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 404 Revision 36 62 30 00 Figure 403 Disassembly and Assembly of the Scissors Drive Link Assembly ...

Page 1395: ...scissors drive link assembly NOTE Bolt 4 head must be installed in the direction of rotation of the main rotor system 1 OLD CONFIG Assemble lower link 4 to upper link 5 with pivot sleeve 6 and laminated washers 7 CURRENT CONFIG Assemble lower link 4 to upper link 5 with pivot sleeves 6 and laminated washers 7 NOTE Laminated washers 7 to be equal within 0 002 inch 0 050 mm of each other after adjus...

Page 1396: ...26 BOLT 27 COTTER PIN 28 NUT 29 WASHER 30 BUSHING 31 WASHER 32 BOLT 33 LONGITUDINAL DRIVE LINK 34 LONGITUDINAL MIXER BELLCRANK ASSEMBLY 35 LATERAL MIXER BELLCRANK ASSEMBLY Figure 404 Lateral and Longitudinal Link Assemblies 4 Lateral Anti Torque Drive Link Assembly Ref Figure 404 A Removal 1 Remove cotter pin 2 a Discard cotter pin 2 2 Remove nut 3 washer 4 bushing 5 washer 6 and upper bolt 7 3 Re...

Page 1397: ... Link Assembly Ref Figure 404 A Removal 1 Remove cotter pin 21 a Discard cotter pin 21 2 Remove nut 22 washer 23 bushing 24 washer 25 and upper bolt 26 3 Remove cotter pin 27 a Discard cotter pin 27 4 Remove nut 28 washer 29 bushing 30 washer 31 and lower bolt 32 5 Remove drive link 33 B Installation 1 Install drive link 33 with washers 23 25 29 bushings 24 30 bolts 26 32 and nuts 22 28 a Torque n...

Page 1398: ... NUT 25 COTTER PIN 26 WASHER 27 COTTER PIN 28 NUT Figure 405 Non Adjustable and Adjustable Collective Links 6 Non Adjustable Collective Drive Link Assembly Ref Figure 405 A Removal 1 Remove forward access door assemblies L155 and R155 ref Section 53 30 00 2 Remove forward swashplate fairing assembly T155 ref Section 53 30 00 3 Release collective friction Ref Section 67 10 00 and raise collective s...

Page 1399: ...eral and longitudinal drive links to enable movement of swashplate 5 Remove and discard cotter pin 15 6 Remove nut 16 washer 14 shims 13 washer 12 and upper bolt 11 7 Remove and discard cotter pin 27 8 Remove nut 28 washer 26 bushing 19 washer 18 and lower bolt 17 9 Raise swashplate to allow removal of drive link 2 B Installation NOTE If installing new adjustable collective drive link ensure there...

Page 1400: ...LT REF IPL 62 00 00 FIG 2 6 WASHER 7 BUSHING 8 WASHER 9 NUT 10 COTTER PIN 11 BOLT 12 WASHER 13 BUSHING 14 BUSHING 15 WASHER 16 NUT 17 BOLT REF IPL 62 30 20 FIG 1 18 LATERAL PIVOT SUPPORT 19 RETAINING RING 20 LATERAL PIVOT THRUST WASHER 21 LATERAL PIVOT CAP 22 WASHER 23 NUT 24 COTTER PIN 25 BOLT 26 LONGITUDINAL PIVOT SUPPORT 27 RETAINING RING 28 LONGITUDINAL PIVOT THRUST WASHER 29 LONGITUDINAL PIVO...

Page 1401: ...dinal drive link 5 Install lateral anti torque drive link 6 Connect upper end of lateral longitudi nal and collective hydraulic actuators ref Section 67 10 00 9 Lateral Mixer Bellcrank Ref Figure 406 A Removal 1 Disconnect upper end of lateral hydrau lic actuator ref Section 67 10 00 2 Disconnect lower end of lateral anti torque drive link 3 Remove cotter pin 24 a Discard cotter pin 24 4 Remove nu...

Page 1402: ...omenclature C308 Primer C317 Primer Epoxy C436 Acetone 1 Install longitudinal mixer bellcrank 3 2 Install longitudinal pivot thrust washer 28 longitudinal pivot support 26 and retaining ring 27 Primer C308 Primer Epoxy C317 Acetone C436 Add acetone C436 to make epoxy primer C317 more li quid Do not use water as a thinner for in stallation procedures with epoxy primer C317 Corrosion can occur 3 App...

Page 1403: ... mixer bellcrank 2 B Installation 1 Install collective mixer bellcrank left bolt washer bushing washer and nut a Torque nut 9 b Install new cotter pin 10 2 Install right bolt washers bushings and nut a Torque nut 16 b Install new cotter pin 10 3 Connect lower ends of non adjustable and adjustable collective drive links 4 Install longitudinal mixer bellcrank 3 5 Install lateral mixer bellcrank 4 6 ...

Page 1404: ...ONNECTOR P430 REF WIRING HARNESS W129 Figure 407 Removal and Installation of the Azimuth Sensor Motional Transducer 12 Azimuth Sensor Motional Transducer Ref Figure 407 Consumable Materials Ref CSP SPM Item Nomenclature C701 Lockwire C702 Lockwire A Removal of the Azimuth Sensor 1 Disconnect Electrical Connector P430 10 2 Remove lockwire C702 from locknuts 4 5 a Discard lockwire C702 3 Remove sens...

Page 1405: ...ansducer NOTE If this is the first installation of an MHS5284 motional transducer you must change the electrical connector to PN MS3456W10SL 4S the backshell to PN MHS5842WR1002L and get two NAS1423C10 nuts Discard the MS25082C10 nut that comes with the transducer 1 Turn setscrew 1 until it is flush with the surface of rotating swashplate 2 2 Align setscrew 1 with the opening for transducer 9 3 Me...

Page 1406: ...inal drive link assem bly 5 Connect lateral anti torque drive link assembly 6 Install the main rotor hub ref Section 62 20 00 7 Install scissors drive link assembly 8 Install pitch link assemblies 14 Swashplate Bearing Retainer Rings and Labyrinth Seals A Removal Ref Figure 408 1 Remove and discard lockwire from bolts 1 2 Remove bolts 1 and washers 3 from top of swashplate 2 NOTE If one piece reta...

Page 1407: ...SION MEASURING POINT 10 PL BEARING HEIGHT DIMENSION BEARING OUTER RACE ROTATING SWASHPLATE NON ROTATING SWASHPLATE SPHERICAL SLIDER BEARING OUTER RACE BOLT WITH LARGE AREA WASHER 3PL MEASURING POINT 10 PL BEARING INNER RACE Figure 409 EARLY CONFIG Swashplate Bearing Preload Measurement One Piece Retainer Rings Installation ...

Page 1408: ...te at ten locations adjacent to bolt holes a Record the average dimension 2 Repeat step 1 between outer bearing race and top of rotating swashplate 3 If both average dimensions inner and outer are 0 0055 inch 0 140 mm or greater proceed to step 5 4 If either average dimension is less than 0 0055 inch 0 140 mm do these steps a Mask the angular and spherical swashplate bearings and plug bolt holes N...

Page 1409: ...nner and outer retainer rings onto swashplate recessed surface pointed down with gap between ring halves approximately equal Sealing Compound C203 4 Apply sealing compound C203 to fill gap between retainer ring halves 5 Install inner and outer labyrinth seal rings with bolts and washers a Torque bolts 70 to 90 in lb 7 91 to 10 17 Nm b Safety bolts with lockwire C702 9G62 044A BEARING ANNULAR CONTA...

Page 1410: ...swashplate 8 6 Place swashplate press plate T505 5 on bolt heads a Make sure swashplate assembly and tooling are centered beneath piston of press b Press non rotating swashplate assembly from rotating swashplate B Installation 1 Place non rotating swashplate support tool T507 6 on base of press 2 Support non rotating swashplate on support tool Compound Anti Seize C220 3 Apply a thin coat of anti s...

Page 1411: ... 9G62 069 1 ANGULAR CONTACT BALL BEARING SUPPORT TOOL T506 2 SWASHPLATE ASSEMBLY REF IPL 62 30 10 FIG 1 3 NAS6604 60 BOLT 4 NON ROTATING SWASHPLATE ASSEMBLY 5 SWASHPLATE PRESS PLATE T505 6 NON ROTATING SWASHPLATE SUPPORT TOOL T507 7 ANGULAR CONTACT BALL BEARING 8 ROTATING SWASHPLATE ASSEMBLY Figure 411 Removal and Installation of the Non Rotating Swashplate Assembly ...

Page 1412: ...ches at bottom of non rotating swashplate and contact outer race of spherical bearing 3 6 Place swashplate press plate T505 7 on bolt heads a Make sure swashplate assembly 2 and tooling are centered beneath piston of press b Press swashplate assembly 2 from spherical slider bearing B Installation 1 Place non rotating swashplate support tool T507 1 on base of bearing press 2 Support swashplate asse...

Page 1413: ...EMOVAL BEARING INSTALLATION 1 NON ROTATING SWASHPLATE SUPPORT TOOL T507 2 SWASHPLATE ASSEMBLY REF IPL 62 30 10 FIG 1 3 SPHERICAL SLIDER BEARING 4 NON ROTATING SWASHPLATE 5 SPHERICAL SLIDER BEARING SUPPORT TOOL T504 6 NAS6604 60 BOLT 7 SWASHPLATE PRESS PLATE T505 8 BRACKET 9 BRACKET 10 BOLT 11 WASHER 12 NUT Figure 412 Removal and Installation of the Swashplate Spherical Slider Bearing ...

Page 1414: ...shplate 1 3 Place a wooden board on base of press 4 Place swashplate upside down on wooden board 5 Place angular contact ball bearing support tool T506 3 on top of bearing 4 and press bearing from swashplate B Installation 1 Heat rotating swashplate 1 to approx imately 1505F 65 65C 2 Place a wooden board on base of press Compound Anti Seize C220 3 Apply a coat of anti seize compound C220 to inside...

Page 1415: ...G INSTALLATION BEARING REMOVAL 9G62 067 A 5 4 1 3 1 4 2 3 PL 1 ROTATING SWASHPLATE REF IPL 62 30 10 FIG 1 2 NAS6604 60 BOLT 3 ANGULAR CONTACT BALL BEARING SUPPORT TOOL T506 4 ANGULAR CONTACT BALL BEARING 5 SWASHPLATE PRESS PLATE T505 Figure 413 Removal and Installation of the Swashplate Ball Bearing ...

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Page 1417: ... lateral and longitudinal links attach 12 13 and 14 to non rotating swashplate 1 Check for a maximum play of 0 008 inch 0 203 mm radial and 0 040 inch 1 016 mm axial 7 With pitch links and swashplate drive link disconnected inspect for smooth ness of rotation No ratcheting noise or binding permitted 8 Inspect bearing lower grease seal for leakage Minor grease leakage allowed if bearing operates sm...

Page 1418: ...ATING SWASHPLATE ASSEMBLY 3 SELF ALIGNING SPHERICAL SLIDER BEARING 4 BEARING RETAINER RING OUTER 5 BEARING RETAINER RING INNER 6 LABYRINTH SEAL RING ROTATING 7 LABYRINTH SEAL RING NON ROTATING 8 BOLT 9 WASHER 10 ANGULAR CONTACT BALL BEARING 11 SPHERICAL BEARING DRIVE LINK ATTACH 12 SPHERICAL BEARING COLLECTIVE LINK ATTACH 13 SPHERICAL BEARING LATERAL ATTACH 14 SPHERICAL BEARING LONGITUDINAL ATTACH...

Page 1419: ...ial indicator so the plunger is compressed against the head of one of the lower pitch link attach bolts d Prevent the rotor from turning use rotor brake if installed e Manually rotate swashplate forward and backward without moving the main rotor Maximum allowable play of 0 140 inch 3 556 mm f If allowable play is exceeded repair or replace drive scissors assembly ref Scissors Drive Link Assembly R...

Page 1420: ...cracks permitted 2 Inspect bearings for a maximum play of 0 008 inch 0 203 mm radial and 0 040 inch 1 016 mm axial 3 Inspect links for gouges and scratches No damage permitted 4 Inspect for corrosion None permitted 5 Inspect bellcranks for gouges dents and scratches No damage permitted ÎÎÎ ÎÎÎ ÎÎÎ VIEW ROTATED 9g62 079 INSPECTION AREA FOR CRACKS 1 2 1 LATERAL MIXER BELLCRANK 2 LATERAL ANTI TORQUE ...

Page 1421: ...Y CONFIG Examine bearing for a maximum play of 0 008 in 0 203 mm radial and 0 040 in 1 016 mm axial 3 LATER CONFIG Examine bearing for a maximum play of 0 005 in 0 127 mm radial and 0 025 in 0 635 mm axial 4 Examine bearing for corrosion contam ination or binding None permitted 5 Examine for wear with swashplate clevis None permitted CERAMIC MATERIAL LATER CONFIG 9g62 078A EARLY CONFIG Figure 604 ...

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Page 1423: ...m MAXIMUM PERMITTED DIMENSION 9G62 058B Figure 801 Pitch Link Bearing Removal and Bore Inspection 1 Pitch Link Bearing A Removal Ref Figure 801 Consumable Materials Ref CSP SPM Item Nomenclature C429 Solvent Cleaner NOTE This task is typical for the two pitch link bearings When bearings have been replaced more than one time you must do a careful in spection of housing bore Carefully remove the bea...

Page 1424: ... not use primer that contains chlorinated solvents Add acetone C436 to make epoxy primer C317 more li quid Do not use water as a thinner for in stallation procedures with epoxy primer C317 Corrosion can occur Primer must not go into the bearing 2 Apply epoxy primer C317 to the mating surfaces of the bearing Do not apply a force of more than 450 lb 204 kg 3 Wet install the bearing with the correct ...

Page 1425: ...MUM ABOVE OR BELOW SURFACE OF HOUSING NECESSARY DIMENSIONS BEFORE STAKING ROLLER SWAGE STAKING ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÍÍÍ ÍÍÍ ÎÎÎ ÉÉÉÉ ÉÉÉÉ ÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÇÇÇÇÇÇ ÇÇÇÇÇÇ ÇÇÇÇÇÇ ÈÈÈ ÈÈÈ ÈÈÈ ÈÈÈ ÈÈÈ ÈÈÈ ÎÎ Ï Ï ÇÇ ÇÇ ÇÇ ÏÏ ÏÏ 9G62 056C Figure 802 Bearing Staking C Staking Ref Figure 802 Special Tools Ref CSP SPM Item Nomenclature T2024 ...

Page 1426: ...TO BEARING OUTER RACE PLATEN HOUSING Figure 803 Proof Load Check D Proof Load Check Ref Figure 803 Consumable Materials Ref CSP SPM Item Nomenclature C319 Lacquer Acrylic Gloss Red Use correct dimension tools 1 Do a proof load check of the bearing installation with a force of 500 to 510 lb 226 8 to 231 3 kg a The outer race cannot move more than 0 002 inch 0 05 mm in each direction from its initia...

Page 1427: ... C308 Primer C317 Primer Epoxy Be careful when you remove link assembly lower link can contact upper link and damage can occur 1 Remove scissors drive link assembly 1 2 Remove lower scissors drive link 3 NOTE Flanged bearings have a dark brown or black material bonded to the bearing hole and flange 3 Examine flanges of bearings 4 for wear in bonded material metal of bearing shows through bonded ma...

Page 1428: ...u remove link assembly lower link can contact upper link and damage can occur 1 Remove scissors drive link assembly 1 2 Remove upper scissors drive link 2 3 Examine hole of flanged bearings 6 Maximum inner dimension 0 3760 inch 9 55 mm Replace bearings as a set 4 Examine lower scissors drive link 3 for condition and damage a The maximum depth of damage cannot be more than 0 005 inch 0 13 mm Chemic...

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Page 1430: ...FLANGED BEARING WITH BOTTOM TAP 3 INSTALL FLANGED BEARING REMOVAL TOOL AND REMOVE BEARINGS 4 THESE FLANGED BEARINGS ARE LONGER THAN THE THICKNESS OF THE DRIVE LINK SUPPORT FOR DRIVE LINK MUST HAVE A HOLE LARGER THAN OUTER DIMENSION OF BEARING SO BEARING CAN GO FULLY THROUGH DRIVE LINK 1 UPPER DRIVE LINK REF IPL 63 30 00 FIG 3 2 OUTBOARD FLANGED BEARING 3 INBOARD FLANGED BEARING 4 PUNCH 5 PLATE 6 L...

Page 1431: ...anged bearing removal a Remove inboard bearings 3 with arbor press and support T508 6 b Remove lower end bearings 6 with arbor press and support T508 6 3 Examine holes in upper scissor a Maximum inner dimension 0 5001 to 0 5006 inch 12 703 to 12 715 mm b Maximum scratch depth permitted 0 0005 inch 0 013 mm Chemical Coating C233 c Make damaged area smooth and apply chemical coating C233 D Upper Dri...

Page 1432: ...OTES 2 AND 4 NOTES 3 AND 4 T508 6 T508 6 NOTE 4 9G62 083A 4 NOTES 1 REMOVE SHOULDER FROM ONE FLANGED BEARING 2 REMOVE BEARING USE A 0 482 IN 12 123 mm PUNCH 3 REMOVE OTHER BEARING USE A 0 495 IN 12 573 mm PUNCH 4 USE T508 6 BEARING SUPPORT UNDER LOWER DRIVE LINK 1 LOWER DRIVE LINK 2 FLANGED BEARING 3 LAMINATED WASHER 4 LUG 5 PUNCH Figure 806 Lower Drive Link Flanged Bearing ...

Page 1433: ...moval tool T508 6 and remove bearing with inner shoulder and laminated washer 3 4 Put lower drive link on flanged bearing removal tool T508 6 point stop lug 4 down Remove bearing with re moved shoulder 5 Examine the hole in the drive link a Inner dimension must be 0 5000 to 0 5005 inch 12 700 to 12 713 mm b The maximum scratch depth is 0 0005 inch 0 013 mm Chemical Coating C233 6 Make damaged area...

Page 1434: ...Link Attach Bearing Replacement Ref Figure 807 Special Tools Ref CSP SPM Item Nomenclature T918 Bearing Flange Cutting Tool A Removal 1 Remove swashplate 2 Bearing swaged flange must be cut off be fore bearing removal The dimension of the bearing cutter can not be more than 0 900 inch 22 86 mm 2 Install bearing flange cutting tool T918 on swashplate 2 with clamp 5 a Put the pilot of cutter 3 throu...

Page 1435: ... Procedure 1 C 3 Do a proof load check of bearing 1 ref Pitch Link Bearing Proof Load Check Procedure 1 D 4 Install swashplate 2 ÏÏ Ï Ï 1 2 3 4 2 REF 9G62 075A 5 1 BEARING REF IPL 62 30 10 FIG 1 2 SWASHPLATE 3 CUTTER BEARING FLANGE CUTTING TOOL T918 4 BACK UP BLOCK BEARING FLANGE CUTTING TOOL T918 5 CLAMP Figure 807 Drive Link Attach Bearing Flange Removal ...

Page 1436: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 814 Revision 35 62 30 00 30 3 4 5 2 1 DIM A ANGLE B 1 2 5 4 3 9g62_105 Figure 808 Rotor Control Pitch Link Assembly ...

Page 1437: ... rod end assembly 1 2 Remove LH thread rod end assembly 3 a Remove lockwire C702 from LH thread nut 4 and barrel 5 b Loosen LH thread nut 4 c Remove LH thread rod end assembly 3 from barrel 5 d Remove LH thread nut 4 from LH thread rod end assembly 3 3 Install RH thread rod end assembly 1 a Install RH thread nut 2 on RH thread rod end assembly 1 1 Do not tighten the nut b Install RH thread rod end...

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Page 1439: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Chapter TRANSMISSION AND DRIVE SYSTEM ...

Page 1440: ......

Page 1441: ...Level Indicator 5 D Pressure Transducer 5 E Pressure Switch 5 F Temperature Probe Switch 6 G Magnetic Chip Detector 6 H Vent Breather 6 I Cooling Blowers 6 J Oil Coolers 6 K Blower Ducts 6 Figure 2 Lubrication Schematic 7 4 Rotor Brake Subsystem 7 A Disk 8 B Brake Head Assembly 8 C Hydraulic Control Valve 8 D Control Linkage 8 E Hydraulic Tubing 8 F Proximity Switches 8 Figure 3 Rotor Brake System...

Page 1442: ...on 404 Figure 402 Main Rotor Drive Shaft Upper Seal 404 Figure 403 Main Rotor Drive Shaft Lower Seal 406 4 Main Rotor Drive Shaft Lower Seal 406 A Main Rotor Drive Shaft Lower Seal Removal 406 B Main Rotor Drive Shaft Lower Seal Installation 406 Figure 404 Removal and Installation of the Input Drive Shaft Assemblies 408 5 Input Drive Shaft Assemblies 408 A Drive Shaft Removal 408 B Drive Shaft Ins...

Page 1443: ...nce 610 5 Main Rotor Drive Plate Nut Torque Check 611 A Procedure 611 Repairs 801 1 Diaphragm Input Shaft Assembly Repairs 801 A Blend Repair 801 2 Diaphragm NOTAR Drive Assembly Repairs 801 A Blend Repair 801 3 Main Rotor Drive Shaft Repairs 802 A Blend Repair 802 Figure 801 Drive Plate Pitting Repair 802 4 Main Rotor Drive Plate Repairs 803 A Pitting Repair 803 63 20 00 Gearboxes A Removal Insta...

Page 1444: ...5 6 Blower Drive Assembly 415 A Removal 415 B Installation 415 7 Pressure Transducer 416 A Removal 416 B Installation 416 8 Transmission Speed Pickup 417 A Removal 417 B Installation 417 Figure 408 Transmission Pressure Transducer Speed Pickup Chip Detector Temperature Probe and Switch and Pressure Switch 418 9 Temperature Probe and Switch 419 A Removal 419 B Installation 419 10 Low Pressure Switc...

Page 1445: ...B Fan Drive Assembly Seal and Wear Sleeve Replacement 806 Figure 803 Fan Drive Assembly 807 Figure 804 Fan Drive Assembly Lockwasher and Flange Assembly Removal 808 Figure 805 Fan Drive Assembly Wear Sleeve Replacement 810 Figure 806 Fan Drive Assembly Oil Seal Replacement 810 C Blower Drive Pinion Assembly Seal Replacement On Transmission 811 D Blower Drive Pinion Assembly Seal and Wear Sleeve Re...

Page 1446: ...ee and Seventy Five Micron Filters 406 A Removal 406 B Installation 407 Figure 404 Cooling System 408 6 Blower Impeller 409 A Removal 409 B Installation 410 Figure 405 Impeller Tip Clearance 410 7 Heat Exchanger Assembly 411 A Removal 411 B Installation 411 8 Thermal Bypass Valve 412 A Removal 412 B Installation 413 Figure 406 Blower Housing Assembly 414 9 Blower Housing Assembly 414 A Removal 414...

Page 1447: ...or Brake Head Assembly 401 A Rotor Brake Head Assembly Removal 401 B Rotor Brake Head Assembly Installation 401 2 Rotor Brake Lining 402 A Rotor Brake Lining Removal 402 B Rotor Brake Lining Installation 402 3 Rotor Brake Proximity Switch 402 A Rotor Brake Proximity Switch Removal 402 B Rotor Brake Proximity Switch Installation 402 Figure 401 Rotor Brake Head and Rotor Brake Disk 403 4 Rotor Brake...

Page 1448: ... 63 30 00 Main Rotor Static Mast A Removal Installation 401 1 Main Rotor Static Mast Assembly 401 A Removal 401 Figure 401 Static Mast Lifting 401 B Installation 401 Figure 402 Main Rotor Static Mast 402 2 Truss Strut Assembly 403 A Left Hand Forward Truss Strut Removal 403 B Left Hand Forward Truss Strut Installation 403 C Left Hand Middle Forward Truss Strut Removal 404 D Left Hand Middle Forwar...

Page 1449: ...lation 408 G Right Hand Aft Truss Fitting Deck Removal 409 H Right Hand Aft Truss Fitting Deck Installation 409 4 Mixer Pivot Support Assembly 409 A Removal 409 B Installation 410 5 Actuator Support Tie Strap Assembly 410 A Removal 410 B Installation 410 6 Actuator Support Assembly 410 A Removal 410 B Installation 410 Inspection 601 1 Main Rotor Static Mast 601 A Main Rotor Static Mast Inspection ...

Page 1450: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Page x Revision 36 63 Contents TABLE OF CONTENTS Cont Para Figure Table Title Page This page intentionally left blank ...

Page 1451: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 63 00 00 Rotor Drive System ...

Page 1452: ......

Page 1453: ...nsmission case housing and is used to stop the main rotor after landing and to prevent windmilling of the rotor in high wind conditions A Main Transmission The main transmission is a self contained wet sump design Externally it consists of a forged aluminum alloy Top Case Assembly that attaches the transmission assembly to the Static Mast Base Assembly and cast alumi num alloy Main Case assembly t...

Page 1454: ...damage to the surrounding area or components in the unlikely event of a failure of the diaphragm C Main Rotor Drive Shaft The main rotor drive shaft transmits power between the planetary carrier and the main rotor drive plate It has a crowned spline at each end that allows angular misalignment between the carrier spline and the drive plate spline This allows for manufacturing toler ances and fligh...

Page 1455: ... BLOWER HOUSING ASSEMBLY TRANSMISSION ASSEMBLY STRUT ASSEMBLY STATIC MAST SUPPORT ASSEMBLY DECK FITTING ASSEMBLY HYDRAULIC PUMP DRIVE LUBRICATION PUMP PRESSURE TRANSDUCER TEMPERATURE PROBE AND SWITCH INPUT DRIVE SHAFTS MAIN ROTOR DRIVE SHAFT NOTAR FAN DRIVE SHAFT Figure 1 Drive System Sheet 1 of 2 ...

Page 1456: ...al 63 00 00 9G63 022 2 EXHAUST DUCT INTERCONNECT DUCT OIL COOLER INLET DUCT AIRFRAME DECK PRESSURE SWITCH LOW MAGNETIC CHIP DETECTOR OIL LEVEL INDICATOR VIEW ROTATED STATIC MAST SUPPORT ASSEMBLY AND MAIN ROTOR DRIVE SHAFT REMOVED FOR CLARITY Figure 1 Drive System Sheet 2 of 2 ...

Page 1457: ...olers and transmission oil passages and jets B Filter Unit A dual stage replaceable filter contained within a cast aluminum alloy located inside the lubrication pump is used to eliminate particles contained in the lubricant The replaceable first stage filter is a 75 micron nominal element and the replaceable second stage is a 3 micron nominal element The unit contains a bypass system to allow cont...

Page 1458: ...cator The vent breather provides an ambient vent for gear case heat and oil vapors The vent breather also serves as a filler cap to service the lubrication system with oil I Cooling Blowers Two cooling blowers are mounted on the main transmission housing The blowers are driven by the blower drive quills to provide additional cooling air to the main transmission oil coolers J Oil Coolers Two oil co...

Page 1459: ...pplied after engine shutdown when main rotor rpm reaches 70 or less The rotor brake subsys tem consists of the following components Disk braking surface that is attached to the Anti Torque fan drive quill Brake Head Assembly houses the calipers pistons steel carriers and linings that are hydraulically actuated to engage the disk Hydraulic Control Valve provides pressurized hydraulic fluid to actua...

Page 1460: ...e lining Bleeder assemblies are located on the brake head housing The bleeder assemblies provide a means to bleed air from the hydraulic lines and brake head housing internal ports C Hydraulic Control Valve The hydraulic control valve is located on the main transmission deck The control valve is a reservoir for hydraulic fluid C112 used to operate the rotor brake subsystem A remov able filler cap ...

Page 1461: ...nc Rotorcraft Maintenance Manual Page 9 10 blank Original 63 00 00 VIEW ROTATED PROXIMITY SWITCH DISK BRAKE HEAD ASSEMBLY PROXIMITY SWITCH HYDRAULIC CONTROL VALVE HYDRAULIC TUBE CONTROL LINKAGE 9G63 024 Figure 3 Rotor Brake System ...

Page 1462: ......

Page 1463: ...e Cause Corrective Action Ref Section Overspeed Perform appropriate Main Rotor Overspeed inspection 05 50 00 Overtorque Perform appropriate Overtorque inspection 05 50 00 Excessive oil leak from input pinion assembly Damaged seal Replace pinion Assy or perform Input Pinion Assembly Seal Replacement 63 20 00 Poor fit between seal and shaft Replace pinion Assy or perform Input Pinion Assembly Seal R...

Page 1464: ... blower drive assembly 63 21 00 Faulty thermal bypass valve Replace thermal bypass valve 63 21 00 XMSN HI OIL TEMP WARNING illuminated but XMSN HI OIL TEMP WARNING not displayed on IIDS A N display Open wire between P412 D and P104 M P412 E and ground Test and repair wiring 98 00 00 Faulty temp probe switch transducer Replace temp probe switch transducer 63 20 00 Loss of XMSN OIL TEMP reading Faul...

Page 1465: ...R CAUTION and or WARNING illuminated Faulty pressure transducer Replace pressure transducer 63 20 00 Open or loose wiring Test and repair wiring 98 00 00 Transmission serviced above FULL mark Drain oil until level is 1 4 below but 3 4 above the Fill mark If problem persists proceed with following steps 12 00 00 Drain transmission while oil is still warm 12 00 00 Remove chip detector and screen val...

Page 1466: ...98 00 00 Faulty chip detector Replace chip detector 63 20 00 Faulty IIDS Replace IIDS 95 30 00 ACFTFALT 7 After five successful chip clear events the transmis sion chip burn count over limit ACFTFALT 7 is set and a CHECK FAULT LOG message displays Inspect chip detector for metal particles Clear Fault Log 63 20 00 Table 601 CSP 900RMM 2 S1 S2 S3 TQ SPLIT EXCEED displayed on IIDS A N display resulti...

Page 1467: ...4 5 10 9G63 030A 1 PRESSURE TRANSDUCER REF IPL 63 20 00 FIG 1 2 SPEED PICKUP 3 TEMPERATURE PROBE 4 LOW PRESSURE SWITCH 5 CHIP DETECTOR 6 CONNECTOR P411 REF IPL 98 00 00 FIG 6 AND RMM 98 30 00 FIG 10 7 CONNECTOR P417 8 CONNECTOR P412 9 CONNECTOR P413 10 CONNECTOR P415 Figure 101 Transmission Sensors Location ...

Page 1468: ...D BELOW 24 PSI AND 75 PSI NOTE 2 AND 3 LOW PRESSURE WARNING NR 51 85 16 PSI AND 50 PSI NOTE 3 AND 4 NOTES HIGH PRESSURE ENUNCIATIONS ARE ILLUMINATED ON INCREASING PRESSURE LOW PRESSURE ENUNCIATIONS ARE ILLUMINATED ON DECREASING PRESSURE 1 WARNING DISPLAY AFTER FIVE 5 SECOND DELAY 2 WHEN IN DISPLAY BY EXCEPTION MODE THE PSI DIGITAL DISPLAY ACTIVATES WHEN PSI IS WITHIN 2 OF HIGH OR LOW CAUTION 3 SIG...

Page 1469: ... AND 5 NOTES HIGH PRESSURE ENUNCIATIONS ARE ILLUMINATED ON INCREASING PRESSURE LOW PRESSURE ENUNCIATIONS ARE ILLUMINATED ON DECREASING PRESSURE 1 WARNING DISPLAY AFTER FIVE 5 SECOND DELAY 2 WHEN IN DISPLAY BY EXCEPTION MODE THE PSI DIGITAL DISPLAY ACTIVATES WHEN PSI IS WITHIN 2 OF HIGH OR LOW CAUTION 3 SIGNAL SOURCE IS OIL PRESSURE TRANSDUCER TRANSDUCER IS 0 200 PSIG WITH 0 75 mv OUTPUT 75 mv 200 ...

Page 1470: ...I LO HI LO 37 36 P NR HI NR LO T 31 30 29 LO 2 LO 1 HI L K XMSN OIL PRESS LO M XMSN OIL TEMP HI W123 W122 23 22 P P T 71 70 69 T 21 22 P P W123 T T 26 27 25 Q Q 2 3 4 1 W129 Q B C D A 5 6 P P T T 12 13 11 A B P T B A C W122 21 24 28 29 W123 14 D E 15 16 C SPARE B A A SPARE C B OIL PRESSURE NR SPEED SENSOR OIL TEMP SENSOR A403 MAIN TRANSMISSION A2 IIDS XMSN OIL PRESS EXCIT XMSN OIL PRESS XMSN OIL T...

Page 1471: ...ance Manual Page 109 Revision 25 63 00 00 9G63 023 OIL COOLER PRESSURE TRANSDUCER PRESSURE SWITCH FILTER LUBE PUMP TEMPERATURE TRANSDUCER TEMPERATURE SWITCH OIL IN OIL COOLER PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE Figure 104 Lubrication Schematic ...

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Page 1473: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 63 10 00 Drive Shafts Clutches Couplings ...

Page 1474: ......

Page 1475: ... and discard o ring 9 6 Remove wear sleeve 17 and spacer 18 B Main Rotor Drive Shaft Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C110 Grease Synthetic C101 Lubricant Solid Film C211 Sealing Compound Corrosion Inhibitive C106 Oil Lubricating or C122 Oil Lubricating Make sure the correct lubricat ing oil specification for trans mission before starting work Do not m...

Page 1476: ... 2 START NUMBERS AT ONE OF THE 10 HOLES VIEW LOOKING DOWN AT TOP OF HUB TO SHOW TORQUE SEQUENCE EXAMPLE 1 2 8 7 3 4 10 9 5 6 NOTES 19 1 MAIN ROTOR DRIVE SHAFT COVER REF IPL 62 00 00 FIG 2 2 BOLT 3 COUNTERSUNK WASHER 4 WASHER 5 NUT 6 O RING 7 DAMPER 8 RETAINING RING 9 O RING 10 MAIN ROTOR DRIVE SHAFT 11 STATIC MAST 12 MAIN ROTOR DRIVE PLATE 13 BOLT 14 WASHER 15 NUT 16 O RING POST SL900 066 17 WEAR ...

Page 1477: ...ain Rotor Drive Plate Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C101 Lubricant Solid Film C122 Oil Lubricating C211 Sealing Compound Corrosion Inhibitive 1 Number torque sequence on drive plate 12 with a permanent marker NOTE Do not install fretting buffer 20 Fret ting buffer is not necessary and its removal will make it easier to apply the environmen tal seal ...

Page 1478: ...f CSP SPM 10 Install the main rotor drive shaft 11 Refer to Section 05 20 10 Table 203 Special Inspection After Component Installation Main Rotor Drive Plate Nut Torque Verification for more maintenance 3 Main Rotor Drive Shaft Upper Seal A Main Rotor Drive Shaft Upper Seal Removal Ref Figure 402 1 Remove main rotor drive plate ref Section 63 10 00 2 Remove spiral retaining ring 3 from drive plate...

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Page 1480: ...nsmission seal 1 4 Remove transmission seal 1 from static mast base 2 5 Remove O ring 5 a Discard O ring 5 If serviceable the transmission seal can be reused Use care during removal of the lower seal to prevent damage to the transmission seal 6 Remove lower seal 6 from transmis sion seal 1 a Discard lower seal 6 B Main Rotor Drive Shaft Lower Seal Installation Ref Figure 403 Consumable Materials R...

Page 1481: ...mpound C205 5 Apply sealing compound C205 to bolts 3 6 With sealing compound C205 still wet install transmission seal 1 with bolts 3 and washers 4 a Torque bolts 3 36 to 46 in lb 4 07 to 5 20 Nm Sealing Compound C211 7 Seal bolts 3 with sealing compound C211 ref CSP SPM 20 50 00 Mechanical Fastener Sealing 8 Install main transmission ref Section 63 20 00 ...

Page 1482: ...ove bolts 2 from engine flange 4 4 Carefully remove drive shaft 1 from transmission flange 3 and engine flange 4 B Drive Shaft Installation Ref Figure 404 The drive shaft has a very thin wall thick ness Try to not touch other parts during installation of the drive shaft Damage can cause an unbalanced drive shaft Axial displacement can cause too much oil leakage from the input pinion assembly If yo...

Page 1483: ... between transmission flange 3 and engine flange 4 NOTE Correct alignment provides zero to posi tive clearance between the flanges to install the drive shaft in tension 4 Install bolts 2 in transmission flange 3 5 Install bolts 2 in engine flange 4 6 Torque bolts 2 70 to 90 in lb 7 91 to 10 17 Nm more than the locking torque ...

Page 1484: ... 96 00 00 4 Remove the anti torque fan forward duct assembly F1 F2 and F3 ref Section 53 30 00 5 Remove the upper inlet duct cover from the forward duct assembly ref Section 53 30 00 The fan drive shaft has very thin wall thickness Avoid contact with other parts during removal of the fan drive shaft Damage can cause an unbalanced fan drive shaft Do not remove couplings from fan drive shaft Removal...

Page 1485: ...e anti torque fan support installation ref Section 64 30 00 3 Make sure the minimum running torque of the nutplates is 3 5 in lb 0 40 Nm before bolt installation Epoxy Primer C231 2 Wet install bolts 2 with epoxy primer C231 a Make sure there is no epoxy primer C231 on the threads of bolts 2 before installation b Torque bolts 2 70 to 90 in lb 7 91 to 10 17 Nm more than the locking torque 3 Install...

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Page 1487: ...the center tube for dents nicks or scratches 2 Measure the depth and diameter of all dents nicks and scratches a A dent nick or scratch that is more than 0 005 inch 0 13 mm deep and 1 00 inch 25 4 mm long is not permitted b Dents that blend smoothly into adjacent surface area with no sharp change in contour and are not more than 0 015 inch 0 38 mm deep and 1 00 inch 25 4 mm long are permitted c Ni...

Page 1488: ...N 0 005 INCH 0 13 MM DEEP AND 1 00 INCH 25 4 MM LONG PERMITTED NO NICKS DENTS CORROSION OR SCRATCHES INTO BASE METAL PERMITTED IN THIS AREA OF DIAPHRAGM NO CORROSION ON FLANGE FACES AT A DEPTH MORE THAN 0 006 INCH 0 15 MM PERMITTED Figure 601 Input Drive Shaft Inspection 9g63 042 1A NO NICKS DENTS CORROSION OR SCRATCHES PERMITTED IN BASE METAL IN THIS AREA PROFILE AREA NICKS CORROSION AND SCRATCHE...

Page 1489: ... are permitted b If there are dents in the profile area replace the input drive shaft 3 Externally inspect diaphragm profile paint for crazed lines a If there are crazed lines reject and replace the input drive shaft NOTE This is an indication that the input drive shaft has seen an over angle or over torque condition 4 Externally inspect the outer rim for nicks or scratches ref Figure 601 a Nicks ...

Page 1490: ...cks and scratches 1 If there is a dent nick or scratch that is deeper than 0 005 inch 0 13 mm and longer than 1 000 inch 25 40 mm in length replace the shaft assembly 2 Dents that blend smoothly into surrounding surface area with no sharp change in contour and are not more than 0 010 inch 0 254 mm deep and 1 000 inch 25 40 mm long are permitted 3 Nicks and scratches less than 0 005 inch 0 13 mm de...

Page 1491: ...atches on the outer rim up to 0 010 inch 0 25 mm in depth and 1 000 inch 25 40 mm in length which can be polished out are permitted b Nicks and scratches on the outer rim deeper than 0 0100 inch 0 25 mm and longer than 1 000 inch 25 40 mm in length are not permitted Replace input drive shaft 5 Inspect diaphragm surface for corro sion Shafts with traces of corrosion on this area must be discarded C...

Page 1492: ...00 TYPICAL MEASUREMENT 4 PLACES BOTH ENDS 45 DEGREES APART NOT ALLOWED MEASURE AT APEX OF SPLINE DIM A UPPER DIM B LOWER PIN SPLINE PIN DRIVE SHAFT SPALLING IS IRREGULAR SHAPED CRATERS MADE WHEN MATERIAL HAS FLAKED OFF 9g63_066 Figure 604 Excessive Wear Measurements for Drive Shaft Splines ...

Page 1493: ...re the temperature of the drive shaft is between 72 to 82F 22 to 28C b Carefully put 2 0 1420 inch 3 607 mm diameter pins at the face width midpoint of each spline 180 degrees apart ref Figure 604 c Make sure the pins are parallel to one another and to the drive shaft d Measure the distance over the pins Dimension A for the upper spline and Dimension B for the lower spline at 4 places minimum 45 d...

Page 1494: ...palling or heavy grooved wear marks over more than 50 percent of the wear area is not permitted Measurements are to be taken between the two pins at a four places minimum approximately 45 degrees apart and av eraged Resulting value must be less than or equal to the maximum value specified 4 Examine the splines for excessive wear by measuring distance across two 0 1420 inch 3 607 mm diameter pins p...

Page 1495: ...ore than or equal to 2 109 inch 53 66 mm do these steps 1 Subtract Dimension 2 from Dimension 1 and record the result as Dimension 4 2 If Dimension 4 is more than or equal to 2 108 inch 53 54 mm subtract Dimension 2 from Dimension 3 and record the result as Dimension 5 3 If Dimension 5 is more than or equal to 0 191 inch 4 85 mm do the Drive Plate Pitting Repair 3 After completion of a Drive Plate...

Page 1496: ...IN ROTOR UPPER HUB WITH DRIVE PLATE REMOVED 1 2 8 7 3 4 10 9 5 6 NOTE 1 MAIN ROTOR DRIVE PLATE ATTACHMENT HARDWARE TORQUE SEQUENCE 2 TORQUE NUTS TO 230 250 IN LB 25 98 28 25 Nm PLUS LOCKING TORQUE MAIN ROTOR DRIVE PLATE ATTACH BOLTS AND NUTS 10 PL 9G63 036 NOTE 1 NOTE 2 Figure 606 Main Rotor Drive Plate Nut Torque Sequence ...

Page 1497: ...ts and nuts if applicable 3 Make sure the main rotor drive plate nuts are above the minimum torque a Torque check nuts to 230 in lb 25 98 Nm b Record the position of all nuts that moved in the Rotorcraft Log Book 4 Torque nuts in sequence 1 thru 10 to 230 to 250 in lb 25 98 to 28 25 Nm plus the locking run on torque ref CSP SPM Section 20 10 00 Torque Wrenches Sealing Compound C211 5 Once no loss ...

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Page 1499: ...resite C311 3 Apply heresite primer C311 to abraded area of shaft a Let heresite primer C311 dry for 1 hour minimum at 203 F 95 C Primer Heresite C312 4 Apply heresite primer C312 to primed area of shaft a Let heresite primer C312 dry for 1 hour minimum at 203 F 95 C 2 Diaphragm NOTARr Drive Assembly Repairs A Blend Repair Consumable Materials Ref CSP SPM Item Nomenclature C311 Primer Heresite C31...

Page 1500: ... A Blend Repair Consumable Materials Ref CSP SPM Item Nomenclature C423 Solvent Cleaning C309 Primer C804 Abrasive Cloth 1 Blend damaged area no deeper than 0 004 inch 0 10 mm with abrasive cloth C804 to completely remove damage a Total blended area cannot be more than 25 percent on the circumference at any point Solvent Cleaning C423 2 Clean shaft with cleaning solvent C423 Primer C309 3 Apply tw...

Page 1501: ...assembly to satisfy the following requirements a Machine the surface 0 001 inch 0 03 mm past depth required to remove all corrosion and fretting pits b The surface finish must be 32 RMS c The fillet radius must be 0 005 to 0 015 inch 0 13 to 0 38 mm d The mating surface must be perpen dicular to the centerline of Base A within 0 005 inch 0 13 mm 2 Do a magnetic particle inspection ref CSP SPM Sect...

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Page 1503: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 63 20 00 Gearboxes ...

Page 1504: ......

Page 1505: ...igure 402 g Detach lateral vibration sensor connector P431 21 NOTE Residual oil could remain in oil lines and heat exchanger assemblies When re moving oil lines or components take precau tions to catch oil with rags or a suitable con tainer System Contamination 8 Remove lockwire from left and right hand oil out hoses 1 Remove left and right hand oil out hoses 1 Drain residual oil 9 Remove lockwire...

Page 1506: ...all caster jackscrews 4 Ref Figure 401 until clearance is obtained between transmission and mast base 24 Remove right hand mid forward truss and mid aft truss mast base support strut assemblies Ref Section 63 30 00 25 Rotate transmission as necessary to clear blockages and slide transmission to end of tray NOTE If replacing main transmission with like new item perform the following steps 26 Remove...

Page 1507: ...heads of screws 14 2 Install velocimeter bracket 8 Lubricant Solid Film C101 a Spray threads of bolts 7 with solid film lubricant C101 b Remove sealing compound from upper two existing bolts in left hand input pinion assembly c Remove upper two existing bolts in order to replace with longer bolts 7 to install velocimeter bracket 8 d Install velocimeter bracket 8 with bolts 7 Torque bolts 7 Sealing...

Page 1508: ...ntenance Manual Page 404 Revision 19 63 20 00 17 16 15 14 13 12 11 TYP 3 2 1 2 PL 6 5 4 2 PL 8 7 2 PL 9 18 19 20 10 21 25 30 in lb 2 8 3 8 N m 22 150 161 in lb 16 94 18 18 N m 8 PL 4 PL 23 2 PL 2 PL 9G63 018B 24 25 Figure 402 Transmission Assembly ...

Page 1509: ...tall unions Torque unions 2 10 Lubricate new O rings 6 with the correct lubrication oil and install on unions 5 Install unions 5 Torque unions 5 11 Ensure spring 22 and lockwasher 24 are installed 12 Install transmission on dolly assembly T301 1 1 ref Figure 401 13 Slide transmission on tray assembly T301 2 3 under mast base assembly and orient correctly 14 Lower ball caster jackscrews 4 at each c...

Page 1510: ...02 32 Connect oil in hoses 4 Torque hoses 4 33 Safety oil in hoses 4 with lockwire C702 34 Attach connectors a Attach pressure transducer connector P411 3 ref Figure 408 b Attach temperature probe and switch connector P412 11 c Attach pressure switch connector P413 14 d Attach chip detector connector P415 17 e Attach speed pickup connector P417 6 f Attach vertical vibration sensor connector P432 1...

Page 1511: ...mission assembly 2 and discard O ring 5 B Installation Ref Figure 403 Consumable Materials Ref CSP SPM Item Nomenclature C106 Oil Lubricating or C122 Oil Lubricating C205 Sealing Compound C702 Lockwire Special Tools Ref CSP SPM Item Nomenclature T304 Guide Pins T2004 Heat Gun NOTE This task is typical for left or right input pinion installation Oil Lubricating C122 Oil Lubricating C106 Make sure t...

Page 1512: ...cal fastener sealing method ref CSP SPM apply sealing compound C205 to heads of bolts 3 10 Using fillet surface sealing method ref CSP SPM apply sealing compound C205 to parting line of input pinion assembly 1 and main transmission assembly 2 11 Install input drive shaft assembly ref Section 63 10 00 12 Service transmission ref Section 12 00 00 13 Verify no leaks are present in flammable fluid sys...

Page 1513: ...Page 409 Revision 35 63 20 00 4 8 PL 9G63 006A 6 7 REMOVAL 1 2 5 62 82 in lb 7 9 2 N m 3 8 PL 1 INPUT PINION ASSEMBLY REF IPL 63 20 00 FIG 1 2 MAIN TRANSMISSION ASSEMBLY 3 BOLT 4 WASHER 5 O RING 6 GUIDE PINS T304 7 JACKSCREWS T306 Figure 403 Input Pinion Assembly ...

Page 1514: ...ssembly and discard O ring 5 B Installation Consumable Materials Ref CSP SPM Item Nomenclature C106 Oil Lubricating or C122 Oil Lubricating C205 Sealing Compound C702 Lockwire Oil Lubricating C122 Oil Lubricating C106 Make sure the correct lubrica tion oil is used for the transmis sion before you start work Do not mix dif ferent specification lubrication oils damage will result ref Section 12 00 0...

Page 1515: ...ump Drive Assembly Ref Figure 405 NOTE Deleted A Removal Special Tools Ref CSP SPM Item Nomenclature T306 Jackscrews 1 Remove lubrication pump ref Section 63 21 00 NOTE Residual oil could remain in oil lines When removing oil lines or components take precautions to catch oil with rags or a suitable container 2 Remove sealing compound from surfaces of lubrication pump drive assembly 1 and main tran...

Page 1516: ... drive assembly with main transmission 2 and evenly push into place by hand Sealing Compound C205 3 Using fillet surface sealing method ref CSP SPM apply sealing compound C205 to parting line of lubrication pump drive assembly 1 and main transmission 2 4 Install lubrication pump ref Section 63 21 00 ...

Page 1517: ...mp accessory drive assembly re moval 1 Remove hydraulic pump assembly ref Section 29 00 00 2 Cut and discard lockwire from flexible drain tubing 3 Disconnect tubing from drive assembly 3 Remove sealing compound from bolts 4 Remove bolts 4 and washers 5 4 Remove sealing compound from surfaces of hydraulic pump accessory drive assembly 1 and main transmis sion 2 5 Remove accessory seal housing assem...

Page 1518: ...ing assem bly 7 with accessory bearing retainer assembly 9 and evenly push into place by hand 2 Lubricate new O ring 6 with the correct lubrication oil and install on accessory bearing retainer assembly 9 3 Align hydraulic pump accessory drive assembly 1 with main transmission 2 and evenly push into place by hand 4 Install bolts 4 and washers 5 Torque bolts 4 5 Connect flexible drain tubing 3 to h...

Page 1519: ...e Materials Ref CSP SPM Item Nomenclature C106 Oil Lubricating or C122 Oil Lubricating C702 Lockwire C205 Sealing Compound NOTE This task is typical for left or right blow er drive assembly installation Oil Lubricating C122 Oil Lubricating C106 Make sure the correct lubrica tion oil is used for the transmis sion before you start work Do not mix dif ferent specification lubrication oils damage will...

Page 1520: ...il Lubricating or C122 Oil Lubricating C205 Sealing Compound C712 Lockwire Oil Lubricating C122 Oil Lubricating C106 Make sure the correct lubrica tion oil is used for the transmis sion before you start work Do not mix dif ferent specification lubrication oils damage will result ref Section 12 00 00 Table 1 1 Lubricate new O ring 4 and pressure transducer 1 threads with the correct lubrication oil...

Page 1521: ...g C122 Oil Lubricating C106 Make sure the correct lubrica tion oil is used for the transmis sion before you start work Do not mix dif ferent specification lubrication oils damage will result ref Section 12 00 00 Table 1 2 Lubricate new O ring 9 with the correct lubrication oil and install on transmission speed pickup 5 3 Install speed pickup with bolts 7 and washers 8 Torque bolts 7 Sealing Compou...

Page 1522: ...9 6 N m 1 PRESSURE TRANSDUCER REF IPL 63 20 00 FIG 1 2 MAIN TRANSMISSION 3 CONNECTOR P411 4 O RING 5 TRANSMISSION SPEED PICKUP 6 CONNECTOR P417 7 BOLT 8 WASHER 9 O RING 10 TEMPERATURE PROBE SWITCH 11 CONNECTOR P412 12 O RING 13 PRESSURE SWITCH LOW 14 CONNECTOR P413 15 O RING 16 CHIP DETECTOR 17 CONNECTOR P415 18 O RING 19 CHIP DETECTOR SCREEN VALVE ASSEMBLY 20 O RING Figure 408 Transmission Pressu...

Page 1523: ...und Oil Lubricating C122 Oil Lubricating C106 Make sure the correct lubrica tion oil is used for the transmis sion before you start work Do not mix dif ferent specification lubrication oils damage will result ref Section 12 00 00 Table 1 1 Lubricate new O ring 12 and temper ature probe and switch 10 threads with the correct lubrication oil Install O ring on temperature probe and switch 2 Install a...

Page 1524: ...ica tion oil is used for the transmis sion before you start work Do not mix dif ferent specification lubrication oils damage will result ref Section 12 00 00 Table 1 1 Lubricate new O ring 15 and pres sure switch 13 threads with the correct lubrication oil Install O ring on pressure switch 2 Install and torque pressure switch 13 Safety pressure switch with lockwire C712 Sealing Compound C205 3 Usi...

Page 1525: ...g or C122 Oil Lubricating Oil Lubricating C122 Oil Lubricating C106 Make sure the correct lubrica tion oil is used for the transmis sion before you start work Do not mix dif ferent specification lubrication oils damage will result ref Section 12 00 00 Table 1 1 Lubricate new O ring 18 with the correct lubrication oil and install on chip detector 16 2 Push chip detector 16 into valve assembly 19 an...

Page 1526: ...l Lubricating or C122 Oil Lubricating C205 Sealing Compound C712 Lockwire Oil Lubricating C122 Oil Lubricating C106 Make sure the correct lubrica tion oil is used for the transmis sion before you start work Do not mix dif ferent specification lubrication oils damage will result ref Section 12 00 00 Table 1 1 Lubricate new O ring 20 and chip detector screen and valve assembly 19 threads with the co...

Page 1527: ...than 2cc in one hour or one drop in one minute 3 Examine input pinions for indication of leakage Leakage rate at input pinions must be less than 2cc in one hour or one drop in one minute 4 Examine external surface of transmis sion for damage and corrosion None permitted 5 Examine transmission for loose or missing environmental seal at all mating lines and on all bolts and nuts 6 Examine all electr...

Page 1528: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 602 Revision 29 63 20 00 9g63 065 1 MATING LINE ENVIRONMENTAL SEAL Figure 601 Transmission Mating Line Environmental Seal Sheet 1 of 3 ...

Page 1529: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 603 Revision 29 63 20 00 9g63_065_2 Figure 601 Transmission Mating Line Environmental Seal Sheet 2 of 3 ...

Page 1530: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 604 Revision 29 63 20 00 9g63_065_3 Figure 601 Transmission Mating Line Environmental Seal Sheet 3 of 3 ...

Page 1531: ...sary to overhaul transmission Other metals in transmission are 4340 clutches and 4130 lock nuts Metal particles can be found on chip detector when transmission CHIPS caution message is shown on Integrated Instrument Display System IIDS or during usual maintenance If there are metal particles it is not necessarily an indication transmission is unserviceable But the type and quantity of metal partic...

Page 1532: ...perature f Transmission low yellow oil C caution segment is not illuminated g Transmission high yellow oil C caution segment is not illuminated h Transmission high red oil C warning segment is not illuminated i Transmission CHIPS is not illumi nated j Transmission FIRE is not illumi nated k Check ROTOR BRAKE is not illuminated in caution warning cluster 3 Start and operate engine left or right at ...

Page 1533: ...ansmission input and anti torque fan drive shafts Ref Section 63 10 00 2 Remove main rotor drive shaft Ref Section 63 10 01 3 Manually rotate one transmission input pinion in the drive direction and observe a Rotation is smooth and requires constant input torque b Ensure pinion is rotated a minimum of 6 complete revolutions 4 Subsequent to the rotational test in the drive direction manually rotate...

Page 1534: ...ger than 0 14 inch 3 56 mm in any direction replace transmission 8 If the amount of metal particle deposits have decreased and only small amounts are found continue transmission in service 9 After 5 hours of normal operation perform chip detector inspection 10 If the amount of metal particle deposits have decreased and only small amounts are found continue transmission in service E Transmission Fl...

Page 1535: ... bypass pop up indicator has not popped 12 Install chip detector and screen valve housing assembly 13 Replenish transmission with oil Ref Section 12 00 00 F Main Transmission Lubrication Pump Filter Assembly Cleaning Consumable Materials Ref CSP SPM Item Nomenclature C106 Oil Lubricating Oil Lubricating C106 1 The 3 micron filter is not cleanable however it can be flushed by hand in lubricating oi...

Page 1536: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 610 Revision 29 63 20 00 This page intentionally left blank ...

Page 1537: ...from input pinion assembly using puller assembly T313 Ref Figure 802 View B 8 Remove the spacer 12 between input pinion assembly 1 and clutch outer race 7 NOTE Current Configuration clutch outer race 7 Figure 801 has plasma coating at seal land area and replaces Early Configuration clutch outer race 7 and wear sleeve 14 9 Inspect seal lip contact area on clutch outer race 7 a Current Configuration...

Page 1538: ...t pinion assembly 1 19 Assemble clutch assembly if disas sembled for inspection a Install clutch 13 into clutch outer race 7 using guide T312 Ref Figure 802 View E NOTE In the next step clutch outer race must be rotated counter clockwise while inserting onto input pinion assembly to allow clutch sprags to disengage from the inner race 20 Install clutch outer race onto input pinion assembly 21 Usin...

Page 1539: ...A 1 1 1 10 9 7 2 3 4 5 6 8 1 10 9 6 5 4 2 3 7 8 1 1 EARLY CONFIGURATION 12 12 13 13 14 1 INPUT PINION ASSEMBLY 2 RETAINER RING 3 SLEEVE 4 O RING 5 LOCKWASHER 6 LOCKNUT 7 CLUTCH OUTER RACE 8 BEARING 9 SEAL HOUSING 10 O RING 11 OIL SEAL 12 SPACER 13 CLUTCH 14 WEAR SLEEVE Figure 801 Input Pinion Assembly ...

Page 1540: ...INPUT PINION ASSEMBLY LOCKWASHER PULLER T315 T309 VIEW A INPUT PINION LOCKWASHER REMOVAL BEARING CLUTCH OUTER RACE INPUT PINION ASSEMBLY CLUTCH SPACER PULLER ASSEMBLY T313 ROTATE VIEW B REMOVAL OF THE CLUTCH OUTER RACE 9G63 058 Figure 802 Input Pinion Assembly Seal Replacement Special Tools Sheet 1 of 2 ...

Page 1541: ... HOUSING 9G63 059 OIL SEAL INSTALLATION OIL SEAL REMOVAL VIEW C VIEW D VIEW E VIEW F E E GUIDE CLUTCH CLUTCH OUTER RACE MARKING IS VISIBLE AS VIEWED FROM ABOVE VIEW E E CLUTCH INSTALLATION PUSHER T310 BEARING CLUTCH INPUT PINION PUSH ASSEMBLY OUTER RACE BALL BEARING INSTALLATION PUSH INPUT PINION Figure 802 Input Pinion Assembly Seal Replacement Special Tools Sheet 2 of 2 ...

Page 1542: ...visible depth in the seal lip contact area nor any visible damage to wear surface or flange Any damage requires replacement of wear sleeve 6 9 Replace damaged wear sleeve 6 Refer to Figure 805 for tool set up NOTE Wear sleeve flange may have to be cut prior to attaching remover assembly T324 a If installed mark location of wear sleeve inner end on flange assembly b If installed remove wear sleeve ...

Page 1543: ...n 25 63 20 00 11 Discard O rings 5 and 11 1 10 9 6 8 4 3 2 1 1 5 7 P63 047A 2 3 1 4 7 8 6 11 10 5 9 1 FAN DRIVE ASSEMBLY 2 LOCKWASHER 3 LOCKNUT 4 FLANGE ASSEMBLY 5 O RING 6 WEAR SLEEVE 7 RETAINER RING 8 DUST SEAL 9 OIL SEAL 10 SEAL HOUSING 11 O RING Figure 803 Fan Drive Assembly ...

Page 1544: ...age 808 Revision 25 63 20 00 ROTATE PULLER T320 FLANGE ASSEMBLY FAN DRIVE ASSEMBLY MOUNT T318 9G63 060 PULLER T322 FAN DRIVE LOCKWASHER MOUNT T318 LOCKWASHER REMOVAL FLANGE ASSEMBLY REMOVAL ROTATE Figure 804 Fan Drive Assembly Lockwasher and Flange Assembly Removal ...

Page 1545: ...ion 12 00 00 Table 1 13 Apply proper oil to new O ring 11 and install on seal housing 10 14 Apply proper oil to new O ring 5 and install on fan drive assembly 1 15 Install seal housing 10 into fan drive assembly 1 Lubricating Grease C119 16 Liberally apply lubricating grease C119 to spline teeth of fan drive assembly 1 17 Install flange assembly 4 into fan drive assembly 18 Apply proper lubricatin...

Page 1546: ...ON WEAR SLEEVE REMOVAL DUST SEAL RETAINING RING RETAINING RING DUST SEAL REMOVAL OF FLANGE IF IT EXISTS WEAR SLEEVE FLANGE MAY HAVE TO BE CUT PRIOR TO ATTACHING PULLER ASSEMBLY Figure 805 Fan Drive Assembly Wear Sleeve Replacement PUSH OIL SEAL SEAL HOUSING PUSHER T334 9G63 051 PUSH PUSHER T321 SEAL HOUSING OIL SEAL OIL SEAL INSTALLATION OIL SEAL REMOVAL Figure 806 Fan Drive Assembly Oil Seal Repl...

Page 1547: ...sible damage to wear surface or flange Any damage to wear sleeve requires removal and replace ment per Blower Drive Pinion Assem bly Seal and Wear Sleeve Replacement 5 Replace oil seal 6 in seal housing 4 Refer to Figure 809 for tool set up a Remove oil seal from seal housing using pusher assembly T337 Lubricating Grease C119 b Apply lubricating grease C119 to inner surface of seal housing c Inser...

Page 1548: ...ar sleeve 5 for damage no visible depth in the seal lip contact area nor any visible damage to wear surface or flange Any damage requires replacement of wear sleeve 5 6 Replace damaged wear sleeve 5 Refer to Figure 808 for tool setup Use care not to cut or damage gearshaft or housing bore when removing wear sleeve Damaged gearshaft or housing requires replacement of Blower Drive Pinion Assembly a ...

Page 1549: ...oper lubricating oil to O ring 7 and install on seal housing 9 Install seal housing 4 into blower drive pinion assembly 1 10 Install laminated shim 3 If new shim installed measure and adjust thickness of laminated shim 3 as indicated a Install seal housing and retaining ring into drive pinion assembly b Measure clearance between seal housing 4 and retaining ring 2 with thickness gage Dial gage may...

Page 1550: ...814 Revision 25 63 20 00 10 9 8 6 3 4 5 2 7 1 10 1 9 8 5 6 7 4 3 2 9G63 052 1 BLOWER DRIVE PINION ASSEMBLY 2 RETAINING RING 3 LAMINATED SHIM 4 SEAL HOUSING 5 WEAR SLEEVE 6 OIL SEAL 7 O RING 8 LOCKWASHER 9 LOCKNUT 10 BLOWER PINION Figure 807 Blower Drive Pinion Assembly ...

Page 1551: ... Manual Page 815 Revision 25 63 20 00 WEAR SLEEVE MOUNT ASSEMBLY T341 9G63 055A WEAR SLEEVE REMOVAL PUSHER T330 PUSH WEAR SLEEVE BLOWER PINION WEAR SLEEVE INSTALLATION A FLANGE OF WEAR SLEEVE Figure 808 Blower Drive Pinion Assembly Wear Sleeve Replacement ...

Page 1552: ...orcraft Maintenance Manual Page 816 Revision 25 63 20 00 PUSHER T337 SEAL HOUSING OIL SEAL 9G63 053A PUSH PUSHER T329 OIL SEAL SEAL HOUSING PUSH SEAL REMOVAL SEAL INSTALLATION Figure 809 Blower Drive Pinion Assembly Oil Seal Replacement ...

Page 1553: ...pth in the seal lip contact area nor any visible damage to wear surface or flange Any damage requires replacement of wear sleeve 2 4 Replace damaged wear sleeve 2 Refer to Figure 811 for tool setup Use care not to cut or damage gearshaft or housing bore when removing wear sleeve Damaged gearshaft or housing requires replacement of Hydrau lic Pump Accessory Drive Assembly a Mark location of wear sl...

Page 1554: ... C119 b Apply lubricating grease C119 to inner surface of seal housing c Insert new oil seal into seal housing using pusher T326 and mount T336 d Liberally apply lubricating grease C119 between two lips of new oil seal 9 Figure 810 Wipe off excess grease 6 Apply proper lubricating oil to O ring 10 and install on seal housing 7 Install seal housing 11 into accessory drive assembly 8 Install accesso...

Page 1555: ...aintenance Manual Page 819 Revision 25 63 20 00 1 2 3 4 5 6 7 8 9 10 11 9G63 061 1 PINION 2 WEAR SLEEVE 3 RETAINER 4 BEARING 5 WASHER 6 BOLT 7 LOCKNUT 8 LOCKWASHER 9 OIL SEAL 10 O RING 11 HOUSING Figure 810 Hydraulic Pump Accessory Drive Assembly ...

Page 1556: ...R SLEEVE ACCESSORY DRIVE ASSEMBLY DETAIL A A P63 063 A WEAR SLEEVE ACCESSORY DRIVE ASSEMBLY Figure 811 Hydraulic Pump Accessory Drive Assembly Wear Sleeve Replacement P63 062 PUSH PUSHER PUSHER MOUNT PUSH OIL SEAL OIL SEAL SEAL HOUSING SEAL HOUSING MOUNT Figure 812 Hydraulic Pump Accessory Drive Assembly Oil Seal Replacement ...

Page 1557: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 63 21 00 Transmission Lubrication and Cooling System ...

Page 1558: ......

Page 1559: ...P 7 BOLT 8 WASHER 9 O RING Figure 401 Oil Filler Assembly B Installation Consumable Materials Ref CSP SPM Item Nomenclature C101 Lubricant Solid Film C106 Oil Lubricating or C122 Oil Lubricating C211 Sealing Compound Corrosion Inhibitive C702 Lockwire Oil Lubricating C122 Oil Lubricating C106 Make sure the correct lubrica tion oil is used for the transmis sion before you start work Do not mix dif ...

Page 1560: ... in lb 7 0 9 2 N m 9G63 014A 8 4 PL 12 11 REMOVAL 13 1 LUBRICATION PUMP REF IPL 63 20 00 FIG 1 2 TRANSMISSION 3 OIL HOSE REF IPL 63 21 00 FIG 1 4 FITTING REF IPL 62 00 00 FIG 2 5 O RING 6 BOLT REF IPL 63 20 00 FIG 1 7 CHIP DETECTOR 8 WASHER 9 O RING 10 O RING 11 O RING 12 TRANSFER TUBE 13 REMOVAL SCREWS Figure 402 Lubrication Pump Assembly ...

Page 1561: ...ad and alternately tighten to provide an even pull to remove pump 1 from transmission 2 and discard O rings 9 10 and 11 NOTE Make sure oil transfer tube 12 stays in position in transmission 2 B Installation Consumable Materials Ref CSP SPM Item Nomenclature C106 Oil Lubricating or C122 Oil Lubricating C205 Sealing Compound C702 Lockwire Oil Lubricating C122 Oil Lubricating C106 Make sure the corre...

Page 1562: ...access panels L155 and R155 ref Section 06 00 00 280 305 in lb 31 6 34 4 N m 20 25 in lb 2 2 2 8 N m 1 2 3 11 10 4 PL 9G63 005A 4 5 6 7 8 9 13 12 14 16 15 220 240 in lb 24 8 27 1 N m 1 PRESSURE RELIEF VALVE REF IPL 63 20 00 FIG 1 2 LUBRICATION PUMP 3 O RING 4 FILTER 3 MICRON 5 FILTER 75 MICRON 6 O RING 7 O RING 8 TRANSFER TUBE 9 O RING 10 BOLT 11 WASHER 12 LUBRICATION PUMP HOUSING COVER PLATE 13 O...

Page 1563: ...result ref Section 12 00 00 Table 1 1 Lubricate new O ring 3 and threads of relief valve with the correct lubrica tion oil and install O ring on relief valve 2 Install pressure relief valve 1 in lubrication pump 2 and torque relief valve 1 3 Safety relief valve with lockwire C702 4 Service transmission ref Section 12 00 00 5 Install Access Panel L155 ref Section 53 30 00 6 Verify no leaks are pres...

Page 1564: ...Materials Ref CSP SPM Item Nomenclature C106 Oil Lubricating or C122 Oil Lubricating 1 Remove Access Panel L155 ref Section 53 30 00 NOTE Oil can stay in oil lines When you re move oil lines or components catch the re maining oil in an oil resistant container 2 Remove bolts 10 and washers 11 3 Remove lubrication pump housing cover plate 12 a If necessary install bolts 10 in jacking holes and alter...

Page 1565: ...cted for general condition before installation Op eration hours must be transferred to the new Transmission Log and limited to the original replacement time requirements ref Section 05 20 10 3 Install filters 4 5 with O rings 6 7 in lubrication pump 2 4 Lubricate new O ring 9 with the correct lubricating oil 5 Install O ring 9 on transfer tube 8 6 Lubricate new O ring 13 with correct lubricating o...

Page 1566: ... 2 PL 33 35 34 36 40 38 39 37 28 26 30 14 PL 29 14 PL NOTE 1 25 2 PL 32 6 PL 24 2 PL NOTE 1 25 2 PL 21 22 9G63 007B 23 2 PL NOTE 1 31 6 PL NOTE 1 27 5 14 PL NOTE 1 41 NOTE 3 43 NOTES 1 TORQUE 36 46 in lb 4 0 5 1 N m 2 TORQUE 160 180 in lb 18 0 20 3 N m 3 TORQUE 50 60 ft lb 67 8 81 3 N m 4 TORQUE 129 179 in lb 14 6 20 2 N m 43 42 NOTE 3 44 NOTE 4 45 NOTE 4 Figure 404 Cooling System ...

Page 1567: ...ture T302 Lockwasher Puller T303 Transmission Blower Shaft Socket NOTE This task is typical for left or right blow er impeller removal 1 Remove access panels L155 and R155 ref Section 53 30 00 2 Remove access panels L210 and R210 ref Section 53 30 00 3 Remove Access Panel T220 ref Section 53 30 00 NOTE Residual oil may remain in oil lines When removing oil lines or components take precautions to c...

Page 1568: ...o decrease tip clear ance Add peel shim to increase tip clearance 6 Make sure the tip clearance between impeller 9 and shroud 13 is 0 020 to 0 024 inch 0 51 to 0 61 mm ref Figure 405 0 020 0 024 INCH 0 51 0 61 MM 9 13 9G63 009A Figure 405 Impeller Tip Clearance a If required remove shroud 13 ref Figure 404 and adjust shim 14 thickness to get the correct clearance b If clearance is acceptable insta...

Page 1569: ... ing Condenser ref Section 21 50 00 13 Remove cooling interconnect duct 4 by removing bolts 5 7 and washers 6 8 14 Remove sealing compound from heat exchanger mount bolts 23 24 15 Remove mount bolts 23 and 24 and countersunk washers 25 16 Remove heat exchanger cooling inlet duct 26 and heat exchanger mounts 27 28 as a unit 17 Remove bolts 29 31 and washers 30 32 NOTE If replacing heat exchanger wi...

Page 1570: ...xchanger 3 Torque hose nut 13 Safety oil in hose 1 and oil out hose 2 with lockwire C702 14 Install oil in hose 21 and oil out hose 22 to heat exchanger 3 Torque hose nut 15 Safety oil in hose 21 and oil out hose 22 with lockwire C702 16 Install forward fairing support assem bly ref Section 53 30 00 17 Service transmission ref Section 12 00 00 18 Service engines ref Section 12 00 00 19 Verify no l...

Page 1571: ...ve installation If thermal bypass valve is reinstalled valve gasket must be replaced with new one 1 Apply a thin coat of the correct lubrica tion oil to new valve gasket 43 2 Install new valve gasket 43 onto thermal bypass valve 41 or 42 3 Install thermal bypass valve 41 or 42 into heat exchanger 3 and torque bypass valve 41 or 42 4 Safety thermal bypass valve 41 or 42 with lockwire C702 5 Install...

Page 1572: ...ve blower impeller ref Section 63 21 00 2 Remove bolts 2 washers 3 and cooling exhaust duct 1 3 Remove adhesive and lockwire from bolts 5 4 Remove bolts 5 washers 6 and blower housing assembly 4 B Installation Consumable Materials Ref CSP SPM Item Nomenclature C101 Lubricant Solid Film C211 Sealing Compound Corrosion Inhibitive C702 Lockwire NOTE This task is typical for left or right blower housi...

Page 1573: ...shers 6 a Torque bolts 5 3 Safety bolts 5 with lockwire C702 Sealing Compound C211 4 Seal bolts 5 with sealing compound C211 with mechanical fastener sealing method ref CSP SPM 5 Install cooling exhaust duct 1 Lubricant Solid Film C101 6 Lubricate the threads of bolts 2 with solid film lubricant C101 7 Install bolts 2 and washers 3 a Torque bolts 2 36 to 46 in lb 4 07 to 5 20 Nm 8 Install blower i...

Page 1574: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 416 Revision 25 63 21 00 This page intentionally left blank ...

Page 1575: ...04 1 Open transmission access door assem bly L210 and R210 Ref Section 06 00 00 2 Remove cooling interconnect duct 3 Inspect impeller blades for cracks nicks or damage No damage allowed 4 Inspect for rubbing on blower shroud None allowed 5 Inspect for security of bearing retaining lockwasher Replace if loose 6 Inspect housing for cracks nicks and debris No damage allowed 7 Install cooling intercon...

Page 1576: ...acks permitted Reference Figure 601 9 Inspect the flange area that surrounds the third nutplate from the bottom on the forward side of the heat exchanger Use a 3X power magnifying glass No cracks permitted Reference Figure 601 CONDENSER NOT SHOWN FOR CLARITY NOTE 1 NOTE 2 NOTES 1 INSPECT NUTPLATE AREA FOR CRACKS 2 INSPECT AFT MOUNT OUTBOARD WEB FOR CRACKS LEFT SIDE SHOWN 9G63 040 Figure 601 Heat E...

Page 1577: ...eakened water emulsion cleaner and flush with water Alodine C241 5 Brush on alodine C241 so that all repaired surfaces are fully coated Allow 1 hour of drying time and apply a second coat of chemical film B Nicks and Scratches Removal Consumable Materials Ref CSP SPM Item Nomenclature C432 Cleaner C814 Abrasive Paper C813 Nylon Abrasive Mat C241 Alodine 1 Using a Swiss file followed by abrasive pa...

Page 1578: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 802 Revision 27 63 21 00 This page intentionally left blank ...

Page 1579: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 63 22 00 Rotor Brake ...

Page 1580: ......

Page 1581: ...ly Ref Related Manufacturers Publications 01 00 00 Lining worn excessively Replace lining Ref Related Manufacturers Publications 01 00 00 binding of caliper head hardware Lightly lubricate guide bolts springs and slide bore of lining using spray lubricant C120 63 22 00 loose or worn bolts or bushings that attach caliper head assembly Replace bolts springs and bushings as a set 63 22 00 Rotor Brake...

Page 1582: ... head assembly Ref Related Manufacturers Publications 01 00 00 Faulty IIDS Replace IIDS 95 30 00 P103 P105 A2 IIDS P104 J3 J5 J4 41 ROTOR BRAKE INSTALLED ROTOR BRAKE 2 ENGAGED BRAKE ON GND ROTOR BRAKE 1 ENGAGED BRAKE ON OPEN D N P523 P522 P155 J155 J1 J1 E GS105 C E GS107 C OUTPUT COMMON 16 32VDC 16 32VDC COMMON OUTPUT M L K A B C G H J A B C W123 W129 P171 J1 GS102 K A612 FWD INTERCONNECT PANEL J...

Page 1583: ...1 J1 E GS105 C E GS107 C OUTPUT COMMON 16 32VDC 16 32VDC COMMON OUTPUT M L A B C G H J K A B C W123 W129 P171 J1 GS102 K A612 FWD INTERCONNECT PANEL J3 P170 E TB2 1 A D C N R S J M 92 94 52 1 1 W122 A601 CIRCUIT BREAKER PANEL P128 J2 7 BAT BUS 7 5A CB7 900 CONFIG CB13 902 CONFIG IIDS 9G63 028 2 ROTOR BRAKE 1 SENSOR ROTOR BRAKE 2 SENSOR EFFECTIVITY 00035 SUBS 114 115 E F A TB2 7 G J9 P174 W124 Figu...

Page 1584: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 104 Revision 19 63 22 00 This page intentionally left blank ...

Page 1585: ...table clean container Hydraulic Fluid C112 4 Fill container with enough hydraulic fluid C112 to submerge free end of drain line T2017 to prevent backflow of air 5 Release rotor brake handle by raising up 0 5 inch 12 7 mm and rotating handle 15 degrees clockwise then lower handle down 6 Open bleeder valve 2 7 Close bleeder valve 2 finger tight release rotor brake handle 8 Repeat steps 5 6 and 7 thr...

Page 1586: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 302 Original 63 22 00 9G63 034 2 1 1 SCREW 2 BLEEDER VALVE Figure 301 Rotor Brake Bleeding ...

Page 1587: ...on Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire NOTE Ensure there is adequate clearance be tween brake linings to fit over rotor brake disc Running clearance to be 0 060 in 1 524 mm between disk and linings 1 Install rotor brake head assembly 1 on main transmission 2 Install bolts 9 and washers 10 Torque bolts 9 2 Safety bolts 9 with lockwire C702 Hydraulic Fluid...

Page 1588: ...ard disk NOTE If bolts 19 are being replaced with new hardware replace bolts 19 bushings 23 and springs 20 as a set Compound Anti Seize C220 2 Install bushings 23 springs 20 and bolts 19 Apply anti seize compound C220 to bolts 19 threads Lubricant Spray C120 3 Apply light coat of spray lubricant C120 to bolts 19 springs 20 and slide bore of lining 21 Activate stroke brake mechanism to run in lubri...

Page 1589: ...b 4 2 4 7 N m 150 160 in lb 16 9 18 1 N m 22 12 15 in lb 1 3 1 6 N m 1 ROTOR BRAKE HEAD 2 MAIN TRANSMISSION 3 CONNECTOR P522 4 CONNECTOR P523 5 HYDRAULIC TUBE 6 CLAMP 7 SCREW 8 WASHER 9 BOLT 10 WASHER 11 ROTOR BRAKE DISK 12 FLANGE 13 NUT 14 BOLT 15 WASHER 16 WASHER 17 SCREW 18 BLEEDER VALVE 19 BOLT 20 SPRING 21 LINING 22 PROXIMITY SWITCH 23 BUSHING Figure 401 Rotor Brake Head and Rotor Brake Disk ...

Page 1590: ...ead assembly Ref Section 63 22 00 3 Install anti torque drive shaft Ref Section 63 10 00 5 Rotor Brake Control Linkage A Rotor Brake Control Linkage Removal Ref Figure 402 1 Release rotor brake handle by raising up 0 5 inch 12 7 mm and rotating handle 15 degrees clockwise then lower handle down 2 Remove and discard cotter pin 4 3 Remove washer 5 and pin 6 4 Remove bolts 7 and 8 and washers 9 B Rot...

Page 1591: ... into stow bracket 2 3 Check rotor brake rigging Ref Section 63 22 00 7 Rotor Brake Hydraulic Control Valve A Rotor Brake Hydraulic Control Valve Removal Ref Figure 402 1 Open forward access door assembly R155 Ref Section 06 00 00 2 Remove and discard cotter pin 4 3 Remove washer 5 and pin 6 4 Remove hose clamp assembly 18 5 Remove screws 19 washers 20 and closeout assembly 21 6 Remove tiedown str...

Page 1592: ... Maintenance Manual Page 406 Original 63 22 00 9G63 031 4 5 6 5 8 9 9 9 7 8 1 10 11 12 REF 1 12 3 PLACES 3 13 14 15 REF 15 24 25 26 27 31 30 28 29 32 32 33 33 34 REF 15 16 17 2 18 19 4 PL 20 4 PL 21 23 22 Figure 402 Rotor Brake Control Linkage ...

Page 1593: ...ssembly 22 on rotor brake control valve 3 Install bolts 16 and washers 17 Torque bolts 16 3 Install closeout assembly 21 screws 19 and washers 20 Torque screws 19 4 Install hose clamp assembly 18 5 Install pin 6 and washer 5 Install new cotter pin 4 Hydraulic Fluid C112 6 Remove cap and plug and connect hydraulic line 15 on rotor brake control valve 3 and torque tube nut Ref CSP SPM 7 Install flex...

Page 1594: ... Figure 402 Hydraulic Fluid C112 1 Install hydraulic line 15 clamp block 34 bolts 32 and washers 33 2 Remove cap and plug and connect hydraulic line 15 on rotor brake control valve 3 3 Remove cap and plug and connect hydraulic line 5 Ref Figure 401 on rotor brake head assembly 1 4 Install screw 7 and washer 8 in clamp 6 Torque screw 7 5 Install clamps 27 Ref Figure 402 screws 25 washers 26 and nut...

Page 1595: ...ess than 0 060 inch 1 52 mm 8 Inspect rotor brake connectors for security Tighten connectors B Rotor Brake Rigging Ref Figure 601 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire 1 Release rotor brake handle 1 from stowed position by raising the lever arm up 0 5 inch 12 7 mm Rotate handle approximately 15 degrees clockwise then lower handle down approximately 5 to 10 degrees 2 Remo...

Page 1596: ...raft Maintenance Manual Page 602 Original 63 22 00 1 3 4 5 2 NOTE NOTE SPECIAL TORQUE 165 195 in lb 18 64 22 03 N m 9G63 032 2 NOTE 1 ROTOR BRAKE HANDLE 2 NUT 3 LOWER LINK 4 ROTOR BRAKE HANDLE LINKAGE 5 PISTON Figure 601 Rotor Brake Rigging ...

Page 1597: ...2 00 ROTOR BRAKE REPAIRS 1 Rotor Brake Assembly A Rotor Brake Head Repairs For repairs to rotor brake head refer to Related Manufacturers Publications Ref Section 01 00 00 B Rotor Brake Disk Repairs For repairs to rotor brake disk refer to Related Manufacturers Publications Ref Section 01 00 00 ...

Page 1598: ......

Page 1599: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 63 30 00 Main Rotor Static Mast ...

Page 1600: ......

Page 1601: ...r pins 10 7 Remove nuts 11 washer 12 counter sunk washer 13 and bolts 14 8 Remove base assembly 1 NOTE If the base assembly is to be replaced with a like new item do steps 9 10 and 11 9 Remove the mixer pivot support assemblies ref Procedure 4 A 10 Remove the actuator support assem blies ref Procedure 6 A 11 Remove the main rotor drive shaft lower seal ref Section 63 10 00 B Installation Ref Figur...

Page 1602: ...ision 36 63 30 00 8 9 7 37 6 5 4 36 3 35 2 38 23 28 27 26 24 25 9G63 026A 10 11 12 13 14 49 47 46 41 22 40 20 44 19 18 43 45 21 42 39 48 34 33 32 17 2 PL 15 2 PL 1 2 PL 2 PL 16 2 PL 4 PLACES RIGHT FORWARD STRUT ONLY 4 PLACES 29 30 30 51 31 50 Figure 402 Main Rotor Static Mast ...

Page 1603: ...UATOR SUPPORT 49 RIGHT HAND ACTUATOR SUPPORT 50 THIN NUT REF IPL 62 00 00 FIG 1 51 SCREW a Torque nuts 11 1400 to 1700 in lb 158 18 to 192 07 Nm 5 Install new cotter pins 10 6 Torque nuts 15 550 to 650 in lb 62 14 to 73 44 Nm 7 Remove mast lifting tool T905 NOTE If the static mast is to be replaced with a like new item do steps 8 9 and 10 8 Install the mixer pivot support assem blies ref Procedure...

Page 1604: ...p of 0 05 inch 1 27 mm un der washer at bolt head and a minimum gap of 0 05 inch 1 27 mm at nut side 5 Install new cotter pin 10 6 Install clamps 7 Install swashplate forward fairing assembly T155 and L210 fairing Ref Section 53 30 00 E Left Hand Middle Aft Truss Strut Removal Ref Figure 402 1 Remove swashplate forward fairing assembly T155 L210 and T220 fairings ref Section 53 30 00 2 Remove clam...

Page 1605: ...5 and R210 fairing ref Section 53 30 00 2 Remove clamps 3 Remove sealing compound nut 29 washer 30 and bonding jumper 31 4 Remove cotter pin 10 a Discard cotter pin 10 5 Remove nut 11 washer 12 counter sunk washer 13 and bolt 14 6 Remove nuts 15 washers 16 and bolts 17 7 Remove strut 9 J Right Hand Forward Truss Strut Installation Ref Figure 402 Consumable Materials Ref CSP SPM Item Nomenclature C...

Page 1606: ...e Aft Truss Strut Removal Ref Figure 402 1 Remove swashplate forward fairing assembly T155 R210 and T220 fairings Ref Section 53 30 00 2 Remove half clamp from oil filler 3 Remove cotter pin 10 a Discard cotter pin 10 4 Remove nut 11 washer 12 counter sunk washer 13 and bolt 14 5 Remove nuts 15 washers 16 and bolts 17 6 Remove strut 7 N Right Hand Middle Aft Truss Strut Installation Ref Figure 402...

Page 1607: ... nut 32 bolt 34 and PLI washer 33 a Discard PLI washer 33 5 Remove truss fitting 35 B Left Hand Forward Truss Deck Fitting Installation Ref Figure 402 Consumable Materials Ref CSP SPM Item Nomenclature C211 Sealing Compound Corrosion Inhibitive 1 Install truss fitting 35 bolt 34 new PLI washer 33 and nut 32 2 Torque bolt 34 in the following method a Hold bolt 34 insert scribe or equivalent into ho...

Page 1608: ...ompound C211 3 Using sealing compound C211 seal bolt 34 using mechanical fastener sealing method ref CSP SPM 4 Using sealing compound C211 seal around truss fitting 36 using fillet surface sealing method ref CSP SPM 5 Install aft roof insulation panel ref Section 25 20 00 6 Install left hand middle aft truss and left hand aft truss ref Section 63 30 00 E Right Hand Forward Truss Deck Fitting Remov...

Page 1609: ...r 33 a Discard PLI washer 33 5 Remove truss fitting 37 H Right Hand Aft Truss Fitting Deck Installation Ref Figure 402 Consumable Materials Ref CSP SPM Item Nomenclature C211 Sealing Compound Corrosion Inhibitive 1 Install truss fitting 37 bolt 34 new PLI washer 33 and nut 32 2 Torque bolt 34 in the following method a Hold bolt 34 insert scribe or equivalent into hole of new PLI washer 33 NOTE Tor...

Page 1610: ...otter pin 18 4 Remove nut 19 washer 20 counter sunk washer 21 bolt 22 and actuator support tie strap 23 B Installation Ref Figure 402 NOTE This task is typical for left or right hand actuator support tie strap installation 1 Install actuator support tie strap 23 bolt 22 countersunk washer 21 washer 20 and nut 19 2 Install bolt 28 countersunk washer 27 washer 26 and nut 25 3 Torque nut 19 70 to 90 ...

Page 1611: ...r 6 Check for corrosion that penetrates to the base material red or dark brown in color in the areas that follow a Check for corrosion in the open area less than 0 125 inch 3 175 mm below the lower bearing boss and away from from the boss radius None allowed No repair allowed b Maximum repairable depth is 0 005 inch 0 127 mm in the remain ing inspection areas Reference 63 30 00 Main Rotor Static M...

Page 1612: ......

Page 1613: ...Clean repair area with solvent cleaner C429 and a non lint cloth C802 Do not use a mechanical grinder to re move corrosion It can cause too much heat in repair areas Corrosion removal must not go into the area 0 125 in 3 175 mm immediately below lower bearing boss 2 Remove corrosion use scouring pad C817 NOTE Cadmium plating must be done as speci fied in QQ P 416 Type II Class 2 mini mum thickness...

Page 1614: ...boss is a critical area No repair is permitted on the lower bear ing boss The area 0 125 in 3 175 mm immedi ately below lower bearing boss is a critical area No repair is permitted in this area Repair is permitted on lower angled area between mast base and nickel plated sur face Repair is permitted in open area that is more than 0 125 in 3 175 mm below lower bearing boss and above nickel plated su...

Page 1615: ...ea and on data plate 7 Dry main rotor static mast in air for a minimum of 15 minutes before you apply primer Primer C308 8 Apply primer C308 to repair area of static mast Dry film thickness of 0 0006 0 0010 in 0 015 0 025 mm Ref CSP SPM Section 20 30 00 9 Dry in air for a minimum of one hour before you apply finish enamel Finish Enamel White C302 10 Apply white finish enamel C302 to primed areas o...

Page 1616: ...es the dimension of the depth dimension a Remove pitting use sandpaper C807 or finer Move sandpaper parallel to mast center line and not radially b Solvent wipe with cleaner C432 and a non lint cloth C802 c Visually examine repair area to make sure pit s are removed use a bright light and minimum of10x magnifica tion d Inner dimension of static mast can not be than 3 769 in 95 733 mm If inner dime...

Page 1617: ...n 62 20 00 13 Install main rotor drive shaft 14 Do the Main Rotor Drive Plate Nut Torque Verification Ref Special Inspection After Component Installa tion Section 05 20 10 and Section 63 10 00 9G63 044 MAXIMUM ALLOWABLE ID AFTER REPAIR 3 769 INCH 95 7326 MM ID REPAIR AREA Figure 802 Main Rotor Support Static Mast Pitting Repair ...

Page 1618: ...xamine main rotor support static mast for corrosion Ref Main rotor Static Mast Inspection Primer C308 4 Apply primer C308 to mast base Dry film thickness of 0 0006 0 0010 in 0 015 0 025 mm Ref CSP SPM Section 20 30 00 5 Dry in air for a minimum of one hour before you apply finish enamel Finish Enamel White C302 6 Apply white finish enamel C302 to primed areas of mast mast Dry film thickness of 0 0...

Page 1619: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual ANTI TORQUE ASSEMBLY Chapter ...

Page 1620: ......

Page 1621: ... 404 D Deleted Ref Section 64 30 01 404 E Deleted Ref Section 64 30 01 404 F Deleted Ref Section 64 30 01 404 Figure 403 Deleted Ref Section 64 30 03 405 2 Deleted Ref Section 64 30 03 405 A Deleted Ref Section 64 30 03 405 B Deleted Ref Section 64 30 03 405 Figure 404 Removal and Installation of the Fan Support 406 3 NOTAR Fan Support Assembly 407 A Removal 407 B Deleted Ref Section 64 30 02 407 ...

Page 1622: ... A Deleted Ref Section 64 30 01 801 64 30 01 NOTAR Fan Assembly A Removal Installation 401 1 Disassembly 401 A Fan Blade Removal 401 B Removal of Counterweights 401 C Removal of the Interrupter 401 Figure 401 Assembly and Disassembly of the Fan Assembly Sheet 1 of 2 402 2 Assembly 404 A Installation of the Interrupter 404 B Installation of the Balance Studs 404 C Installation of Fan Blade Bushings...

Page 1623: ...Tension Torsion Strap Assemblies 609 A Visual Inspection 609 B X Ray Inspection 609 Repair And Modification 801 1 Repair 801 A Replacement of Balance Weight Rivet Studs 801 Figure 801 Rivet Stud Replacement Typical 801 B Replacement of Center Spline Bushings 802 Figure 802 Bushing Replacement Typical 802 Figure 803 Fan Hub 803 C Drill the Interrupter Hole 803 2 Modification 804 A Upgrades for Fan ...

Page 1624: ...ring Retainer 203 64 30 03 NOTAR Fan Pitch Assembly A Maintenance Practices 201 1 Description and Operation 201 A Description 201 B Operation 201 Figure 201 Disassembly and Assembly of the Pitch Assembly 202 2 Disassembly and Assembly 203 A Disassembly 203 B Assembly 203 3 Inspection 204 A Inspection of the Pitch Plate Bearing 204 B Inspection of the Rod End Bearing 204 C Inspection of the Outside...

Page 1625: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 64 30 00 NOTAR Anti Torque Fan System ...

Page 1626: ......

Page 1627: ...ar filament wound around a Corrosion Resistance Steel Alloy CRES spool type bushing at each end Fan Blades Each blade is comprised of an aluminum alloy forged spar and polypropylene injection molded blade The pitch horns are aluminum alloy and hard anodized to mini mize wear and corrosion Attaching washers to the counterweight arms on the spar of the blade and positioning of index marked counter w...

Page 1628: ... MD Helicopters Inc Rotorcraft Maintenance Manual Page 2 Original 64 30 00 BLADE ASSY FAN HUB FAN LINER FAN PITCH CONTROL ASSY VIEW LOOKING FORWARD 9G64 001 TENSION TORSION STRAPS Figure 1 Anti Torque Fan Assembly ...

Page 1629: ... blades and the felt seal a The clearance must be 0 030 to 0 065 inch 0 76 to 1 65 mm 10 Measure and record clearance between each fan blade and the hub a If clearance of a blade is more than the average clearance of other blades by more than 0 10 inch 2 5 mm remove and inspect the torsion ten sion strap for that blade ref Section 64 30 01 Inspection Test 11 Remove upper center diffuser assembly F...

Page 1630: ...D END BEARING 13 REF 1 FAN ASSEMBLY REF IPL 64 30 00 FIG 1 2 FAN SUPPORT SHAFT 3 LOCKNUT 4 LOCKWASHER 5 PITCH ASSEMBLY 6 WASHER 7 BOLT 8 FAN CONTROL SHAFT ASSEMBLY REF IPL 67 20 00 FIG 5 9 WASHER 10 BOLT 11 NUT 12 COTTER PIN 13 FAN FRAME ASSEMBLY NO IPL REF 14 FELT SEAL REF IPL 64 30 00 FIG 2 Figure 401 Removal and Installation of the NOTAR Fan Assembly ...

Page 1631: ... on fan support shaft 2 4 Push lockwasher 4 forward over locknut 5 Make sure two tabs of lockwasher 4 go through notches of locknut 3 and engage forward side of locknut 3 6 If necessary disengage the rotor brake 7 Make sure the clearance between the tips of the fan blades and the fan liner is 0 030 to 0 065 inch 0 76 to 1 65 mm 8 Install upper center diffuser F6 ref Section 53 30 00 9 Put pitch as...

Page 1632: ...rom the cockpit that the flight controls are discon nected 18 Do the Anti Torque Directional Controls Travel Rigging Verification procedure ref Section 67 20 00 19 Install access panels F7 and F8 ref Section 53 30 00 20 Do the Fan Balance Procedure ref Section 18 00 00 21 Install baggage compartment soft insulation roof panels ref Section 25 50 00 Deleted Figure 402 Deleted Ref Section 64 30 01 C ...

Page 1633: ... Helicopters Inc Rotorcraft Maintenance Manual Page 405 Revision 35 64 30 00 Deleted Figure 403 Deleted Ref Section 64 30 03 2 Deleted Ref Section 64 30 03 A Deleted Ref Section 64 30 03 B Deleted Ref Section 64 30 03 ...

Page 1634: ...10 9 8 4 13 1 FAN SUPPORT REF IPL 64 30 00 FIG 1 2 AZIMUTH SENSOR BRACKET 3 VIBRATION SENSOR VELOCIMETER BRACKET 4 WASHER 5 BOLT 6 BOLT 7 BOLT 8 NUT 9 COTTER PIN 10 FAN SHAFT COUPLING 11 NUT 12 LOCKWASHER 13 HUB SHIM 14 VELOCIMETER 15 AZIMUTH SENSOR 16 NUT 17 WASHER 1 MINIMUM 3 MAXIMUM 18 WASHER 19 NUT 20 FAN FRAME ASSEMBLY Figure 404 Removal and Installation of the Fan Support ...

Page 1635: ...an fall out of sup port frame when you remove bolts Hold fan support when you remove last bolt 14 Remove cotter pin 9 nut 8 washers 4 and bolt 5 from the 12 o clock position 15 Remove fan support 1 B Deleted Ref Section 64 30 02 C Deleted Ref Section 64 30 02 D Installation 1 Install fan support 1 in the support frame and align the bolt holes NOTE Do not torque nuts 8 until all nuts are installed ...

Page 1636: ...mm 16 Remove layers from hub shim 13 to get the necessary thickness NOTE Shim laminates are 0 003 inch 0 08 mm thick 17 Remove the two bolts from the anti torque drive shaft and fan shaft coupling 10 18 Remove anti torque drive shaft ref Section 63 10 00 19 Remove nut 11 with anti torque shaft socket T603 20 Remove fan shaft coupling 10 21 Install hub shim 13 fan shaft coup ling 10 and nut 11 with...

Page 1637: ... C702 6 Install right half of anti torque fan center body ref Section 53 30 00 5 Velocimeter Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire A Removal 1 Remove left half of anti torque fan center body ref Section 53 30 00 2 Remove and discard lockwire from Electrical Connector P434 velocimeter 14 and bracket 3 3 Disconnect Electrical Connector P434 4 Remove velocime...

Page 1638: ...900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 410 Revision 35 64 30 00 9G64 023 1 2 3 1 FELT SEAL REF IPL 64 30 00 FIG 2 2 RIVET 3 RIVET Figure 405 Removal and Installation of the Felt Seal ...

Page 1639: ... SPM Item Nomenclature T601 Inner Tube Sealing Compound C234 1 Apply sealing compound C234 to the mating surfaces of felt seal 1 and structure 2 Install felt seal 1 with larger counter bore rivet hole forward nearest to fan support strut 3 While sealing compound C234 is still wet install rivets 2 3 4 Put inner tube T601 on felt seal 1 and inflate sufficiently to hold the felt seal against the stru...

Page 1640: ... TIP SEAL TOOL PART 2 13 CAP SCREW 14 WASHER 15 POSITION LOCK KNOB 16 ADJUSTMENT KNOB 17 SPEED HANDLE 18 AIR PRESSURE VALVE 19 BOLT 20 WASHER 21 NUT 22 BALL LOCK PIN 23 SPACER Figure 406 Felt Seal Machining C Felt Seal Machining Ref Figure 406 Special Tools Ref CSP SPM Item Nomenclature T602 Fan Tip Seal Tool NOTE Do this procedure only after a new felt seal is installed 1 Remove anti torque fan d...

Page 1641: ... on tool 1 and install ball lock pin 22 21 Install cap screws 13 washers 14 and spacers 23 Torque cap screws 22 Make sure there is no radial or axial movement in tool 1 23 Lubricate tool motor with pneumatic tool oil Eye protection a respirator gloves and protective cloth ing must be worn during felt seal ma chining 24 Loosen position lock knob 15 and turn adjustment knob 16 to position cutter 3 f...

Page 1642: ... 00 39 Remove nuts washers and bolts 40 Remove pin 41 Clean baggage compartment fan duct and diffuser areas 42 Remove masking tape and plastic sheet 43 Install support assembly 44 Install diaphragm NOTAR shaft assembly ref Section 63 10 00 45 Install fan assembly 46 Install pitch assembly ...

Page 1643: ...or a EARLY CONFIG The clearance must be 0 020 to 0 040 inch 0 51 to 1 02 mm b CURRENT CONFIG The clear ance must be 0 040 to 0 060 inch 1 02 to 1 52 mm c If necessary adjust azimuth sensor transducer 7 Install access panels F7 and F8 ref Section 53 30 00 8 Install the insulation panel on the baggage compartment roof ref Section 25 50 00 B Deleted Ref Section 64 30 01 C Deleted Ref Section 64 30 03...

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Page 1645: ... Rotorcraft Maintenance Manual Page 801 Revision 35 64 30 00 NOTAR ANTI TORQUE FAN SYSTEM REPAIR MODIFICATION 1 Deleted Ref Section 64 30 01 A Deleted Ref Section 64 30 01 2 Deleted Ref Section 64 30 01 A Deleted Ref Section 64 30 01 ...

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Page 1647: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 64 30 01 NOTAR Fan Assembly ...

Page 1648: ......

Page 1649: ...d washers are not defective or damaged do not remove the balance studs or washers 10 If a fan blade is replaced and more than one washer is installed on its related balance stud 4 do the procedure that follows a Remove nut 7 and washer 6 b If installed remove the balance washer s NOTE There is one installation washer 6 on each balance stud 4 All other washers are to balance the fan assembly c Inst...

Page 1650: ... 13 PL 14 13 PL BLADE SPAR 11 13 PL 17 18 13 PL 23 13 PL 22 13 PL 21 13 PL 19 13 PL 20 4 5 6 7 3 2 22 13 PL 10 13 PL 12 13 PL 9 9 TYPICAL 13 PL 11 REF COUNTERWEIGHT ARM INDEX MARK TYP TYPICAL 13 PL COUNTER WEIGHT ARM TYP 8 13 PL 1 1 REF PITCH HORN 10 13 PL Figure 401 Assembly and Disassembly of the Fan Assembly Sheet 1 of 2 ...

Page 1651: ...OF INK MARK DATE LORD SHELTON CT USA 11 04 CURE DATE R DIA A DIA B 1 FAN HUB REF IPL 64 30 01 FIG 1 2 PIN 3 COLLAR 4 BALANCE STUD 5 LOCKING COLLAR 6 WASHER 7 NUT 8 FAN BLADE BUSHING 9 COUNTERWEIGHT 10 SET SCREW 11 FAN BLADE 12 SLEEVE 13 TENSION TORSION STRAP 14 PIN 15 WASHER 16 COTTER PIN 17 PITCH PLATE 18 PITCH PLATE BUSHING 19 CENTER SPLINE BUSHING 20 CENTER SPLINE 21 BOLT 22 WASHER 23 NUT Figur...

Page 1652: ...f pin 2 with a nonmetallic hammer until the pin is fully installed 6 Install collar 3 B Installation of the Balance Studs NOTE If the fan hub is not replaced or the bal ance studs are not defective go to the next procedure 1 If removed install balance stud s 4 ref Repair and Modification Replace ment of Balance Weight Rivet Studs 2 Do the procedures for Anti Torque Fan Assembly Balance ref Section...

Page 1653: ...on straps 13 a If a tension torsion strap 13 is new do these steps 1 Remove tension torsion strap 13 from package NOTE Ref Storage procedures for unused ten sion torsion straps that have been removed from the package but not used 2 Write the words EXPIRATION DATE on the strap face and date month year five years after the package is opened with permanent ink ref Detail D 3 Make an item component re...

Page 1654: ...8 to the threads of bolts 21 a Let sealant primer C228 fully dry 12 Install washers 22 on bolts 21 Be careful when you install bolts 21 Do not push center spline bushings 19 out of center spline 20 13 Install bolts 21 through fan hub 1 center spline 20 and tension torsion straps 13 Sealing and Locking Compound C226 14 Apply sealing and locking compound C226 to the threads of bolts 21 15 Install wa...

Page 1655: ...he words EXPIRATION DATE on the strap face and date five years after the package is opened with permanent ink ref Figure 401 Sheet 2 b Put new desiccant C827 in the package c Put the tension torsion strap in the package d Seal the package openings with tape NOTE If you cannot seal the package put the tension torsion strap package and desic cant C827 in a new plastic bag e Put the package in a box ...

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Page 1657: ...ment for more instructions 1 Examine tension torsion straps for nicks or cuts where Kevlar fibers show a None permitted 2 Examine bushings for cracks and wear a None permitted C Blade Retention Pins 1 Examine the pins for wear and corro sion a Polish to remove scratches and corrosion b The pin diameter must be 0 311 inch 7 90 mm minimum D NOTAR Fan Blade Bushings 1 Examine the bushings in the inne...

Page 1658: ...4 RIVET Figure 601 NOTAR Pitch Plate Assembly Table 601 Damage Limits for the Pitch Plate Ref Figure 601 Examine Maximum Serviceable Limits Maximum Repairable Limits Repair Procedure Pitch plate for scratches nicks and missing material Maximum damage permitted 0 020 inch 0 51 mm in depth or 0 020 inch2 12 9 mm2 in area Minimum distance between damage 0 250 inch 6 35 mm No more than three locations...

Page 1659: ...llation 3 Examine the pitch horn for too much wear not round a None permitted ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ 9G64 009D 0 5 IN 12 7 mm B C A 0 125 IN 3 18 mm 0 30 IN 7 62 mm 0 06 IN 1 52 mm 3 0 IN 7 62 cm 0 06 IN 1 52 mm 0 30 IN 7 62 mm D E F VIEW LOOKING UP G VIEW LOOKING DOWN 0 050 1 27mm MINIMUM REPAIR SURFACE 45 ANGLE H J 2 5 IN 6 35 cm NOTE IGNORE TOOL ...

Page 1660: ...e for damage and missing material Damage permitted within specified limits in location shown Maximum material removal 0 020 inch 0 51 mm Make damage smooth with 240 grit abrasive cloth C810 or finer Remove damaged material or sharp edges Area D Fan blade cuff for nicks and missing material Maximum damage permitted on flange 0 020 inch 0 51 mm in depth or 0 004 inch2 2 58 mm2 in area Minimum distan...

Page 1661: ...h and 0 004 inch2 2 58 mm2 in area Maximum material removal 0 020 inch 0 51 mm Make damage smooth with 240 grit abrasive cloth C810 or finer Remove surface defects or sharp edges Touch up surface finish with alodine C241 and primer C308 Area H Fan blade outer tip surface for scratches nicks missing material and damage Damage permitted within specified limits in location shown Material can not be r...

Page 1662: ...ub Ref Figure 603 and Table 603 1 Examine the fan hub for cracks a None permitted 2 Examine the balance studs for loose ness or damage a None permitted 3 Examine the interrupter for looseness or damage a None permitted 4 Examine the hub sleeves for missing segments a None permitted b If sleeve is replaced examine its hole in the fan hub for wear 1 No wear permitted ...

Page 1663: ... of damage permitted in each square inch Maximum material removal 0 010 inch 0 25 mm Make damage smooth with 240 grit abrasive cloth C810 or finer Remove surface defects or sharp edges Touch up surface finish with alodine C241 and primer C308 Area C Fan hub flange for scratches nicks and missing material Maximum damage permitted 0 050 inch 1 27 mm in depth No more than three locations of damage pe...

Page 1664: ... TIME 25 SECONDS FFD 48 INCHES FILM D2 OR EQUIVALENT SCREENS NONE DENSITY IN VERY IMPORTANT AREAS 1 80 to 2 25 H D SHOTS 0 AND 90 DE GREES S N XXX XXX XXXXXXXXXX XX XX CURE DATE PART NUMBER SERIAL NUMBER 0 DEGREES 90 DEGREES RADIATION SOURCE RADIATION SOURCE VERY IMPORTANT AREA VERY IMPORTANT AREA X RAY VERY IMPORTANT AREAS BUSHING BUSHING Figure 604 X Ray Inspection of the Tension Torsion Straps ...

Page 1665: ... bushings for cracks and wear a None permitted B X Ray Inspection NOTE The X ray inspection must be done and interpreted at an X ray laboratory by a Level II or higher X ray technician 1 Do an X ray inspection of all straps NOTE If a defect is found during the X ray in spection turn the strap and do the inspec tion again to make sure the indication is cor rect 2 Examine all areas of strap on X ray...

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Page 1667: ... hub 5 with hex wrench and locking pliers 3 Prepare hub for balance rivet stud installation a Remove all chips burrs and foreign material from rivet holes of hub 4 Install pin rivet stud 3 Adhesive Epoxy C402 a Lightly coat holes with epoxy adhe sive C402 NOTE Install pin rivet stud 3 while epoxy adhesive C402 is still wet b Insert rivet stud 3 in prepared hole c Gently tap head of pin rivet stud ...

Page 1668: ... of Center Spline Bushings Ref Figure 802 Special Tools Ref CSP SPM Item Nomenclature T2018 Press Hydraulic Consumable Materials Ref CSP SPM Item Nomenclature C310 Primer 9G64 020 2 TYP 1 1 CENTER SPLINE REF IPL 64 30 01 FIG 1 2 BUSHING Figure 802 Bushing Replacement Typical 1 Remove bushing 2 from center spline 1 with hydraulic press T2018 2 Make sure the diameter of the bushing hole is 0 3751 to...

Page 1669: ...he Interrupter Hole Ref Figure 803 1 Point the inner rim of fan hub 1 down NOTE The pin hole is 4 125 inch 104 78 mm from the center of the fan hub 2 Drill a 0 1605 to 0 1625 inch 4 077 to 4 128 mm hole 3 Remove all burrs and clean the pin hole 4 Apply corrosion protection to the surfaces adjacent to the pin hole ref CSP SPM Section 20 40 00 NOTE Do not apply primer in the pin hole ...

Page 1670: ...441005 105 by replacement of 900R2441013 105 fan hub with a 900R2441013 109 fan hub and addi tion of 900R2441017 101 sleeves Table 801 Conversions for Fan Assembly Configurations Configuration From To Modification Required Ref Item No Table 802 900R1441002 113 900R1441002 109 1 900R1441002 109 900R1441005 101 2 900R1441005 101 900R1441005 103 3 900R1441005 103 900R1441005 105 4 NOTE Configuration ...

Page 1671: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 64 30 02 NOTAR Fan Support Assembly ...

Page 1672: ......

Page 1673: ...t assembly has these components Two NOTAR bearing labyrinth seals 1 NOTAR fan support bearing 6 NOTAR fan support shaft 5 NOTAR fan bearing removal ring 4 NOTAR fan support housing assembly 3 NOTAR fan bearing retainer 2 B Operation The NOTAR fan assembly ref Section 64 30 01 is centered on the support bearing 6 which reacts to changes to thrust in the forward and aft directions The center spline ...

Page 1674: ...re A Disassembly 1 Remove bearing retainer 2 and labyrinth seal 1 2 Remove support shaft 5 with support bearing 6 and bearing removal ring 4 from support housing 3 and labyrinth seal 1 3 Remove support bearing 6 and bearing removal ring 4 4 Remove labyrinth seals 1 B Assembly 1 Push labyrinth seals 1 in bevelled sides of bearing retainer 2 and support housing 3 Different types of grease can be nec...

Page 1675: ...on Ref Figure 201 NOTE If you think a part is unserviceable speak to MDHI Field Service Department for more instructions A Inspection of the Labyrinth Seals 1 Examine labyrinth seals 1 for tears and deterioration a None permitted B Inspection of the Support Bearing 1 Examine support bearing 6 for spalls and pits on ball bearings heat damage blue color and corrosion on ball bearings and races a Non...

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Page 1677: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 64 30 03 NOTAR Fan Pitch Assembly ...

Page 1678: ......

Page 1679: ...bolt a nut and a cotter pin The pitch assembly has these components NOTAR pitch plate bearing 1 Precision rod end double row ball bearing 2 NOTAR pitch bearing outside retainer 5 NOTAR pitch bearing inside retainer 6 NOTAR pitch slider 7 NOTAR fan pitch bearing housing assem bly 8 which has a housing and three threaded inserts The pitch assembly is an integral component of the pitch control for th...

Page 1680: ... 7 6 1 5 4 3 2 9 3 PL 10 3 PL B B LOCKWIRE SECTION B B 8 9 10 4 2 3 7 DIM A 6 1 7 1 PITCH PLATE BEARING REF IPL 64 20 03 FIG 1 2 ROD END BEARING 3 NUT 4 LOCKWASHER 5 OUTSIDE RETAINER 6 INSIDE RETAINER 7 SLIDER 8 HOUSING ASSEMBLY 9 WASHER 10 BOLT Figure 201 Disassembly and Assembly of the Pitch Assembly ...

Page 1681: ...ferent types of grease are necessary for different bearing part numbers 1 Lubricate pitch plate bearing 1 as necessary ref Section 12 00 00 2 Assemble rod end bearing 2 nut 3 lockwasher 4 duplex bearing 1 outside retainer 5 and inside retainer 6 a Use Dimension A to adjust rod end bearing 2 from face of outside retainer 5 to center of rod end bearing 2 b Torque nut 3 c Safety nut 3 to lockwasher 4...

Page 1682: ...removal 0 005 inch 0 13 mm deep and 0 010 inch2 6 45 mm2 in area e No limit on quantity of separate areas of damage D Inspection of the Inside Retainer 1 Examine inside retainer 6 for cracks nicks scratches and corrosion a None permitted E Inspection of the Slider 1 Examine slider 7 for cracks nicks scratches and corrosion a No cracks permitted b TFE bearing surface can be worn to a minimum outer ...

Page 1683: ...leaning C802 Cloth Non Lint Alcohol Isopropyl C419 1 Clean pitch assembly components with a solution of clean water and mild soap or isopropyl alcohol C419 and a soft bristle brush 2 Dry thoroughly with a clean non lint cloth C802 3 Remove old sealant with a plastic scraper Paint Stripper C313 Solvent Cleaning C420 4 Remove old primer with paint stripper C313 and cleaning solvent C420 or equivalen...

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Page 1685: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual FLIGHT CONTROLS Chapter ...

Page 1686: ......

Page 1687: ...heet 1 of 2 6 3 Collective Controls Subsystem 8 A Collective Stick Assembly 8 B Copilot Quick Release Collective Stick 8 C Collective Friction Unit 8 D Collective Friction Release Switch 8 E Collective Linkages 9 F Collective Controls Balance Spring 9 G Collective Servoactuator 9 Figure 3 Anti Torque Directional Controls Subsystem Sheet 1 of 3 10 4 Anti Torque Directional Controls Subsystem 13 A A...

Page 1688: ...B Collective Control Module Installation 401 3 Pilot Collective Control Stick Assembly 401 A Pilot Collective Control Stick Assembly Removal 401 B Pilot Collective Control Stick Assembly Installation 402 4 Collective Friction Unit Link Assembly 403 A Collective Friction Unit Link Assembly Removal 403 B Collective Friction Unit Link Assembly Installation 403 5 Collective Friction Unit Arm Assembly ...

Page 1689: ...ective Position Sensor Assembly Installation 410 14 Collective Lower Closet Bellcrank Assembly 411 A Collective Lower Closet Bellcrank Assembly Removal 411 B Collective Lower Closet Bellcrank Assembly Installation 411 15 Collective Lower Closet Bellcrank Bracket Assembly 411 A Collective Lower Closet Bellcrank Bracket Assembly Removal 411 B Collective Lower Closet Bellcrank Bracket Assembly Instal...

Page 1690: ...lective Controls Cockpit Sheet 1 of 2 418 25 FS 157 730 Collective Bellcrank Assembly 420 A Collective Bellcrank Assembly Removal 420 B Collective Bellcrank Assembly Installation 420 26 Collective Cabin Control Rod Assembly 420 A Collective Cabin Control Rod Assembly Removal 420 B Collective Cabin Control Rod Assembly Installation 420 27 Collective Upper Deck Bellcrank Assembly 420 A Collective Up...

Page 1691: ...nterconnect Control Rod Assembly Installation 428 36 Pilot Cyclic Base Assembly 428 A Pilot Cyclic Base Assembly Removal 428 B Cyclic Base Disassemble 429 C Cyclic Base Reassemble 429 D Pilot Cyclic Base Assembly Installation 429 Figure 406 Cyclic Base Assembly 430 37 Lateral Bellcrank Assembly 431 A Lateral Bellcrank Assembly Removal 431 B Lateral Bellcrank Assembly Installation 431 38 Lateral Br...

Page 1692: ...ation 436 47 FS 165 588 Lateral Bellcrank Assembly 437 A Lateral Bellcrank Assembly Removal 437 B Lateral Bellcrank Assembly Installation 437 48 FS 165 588 Lateral Bracket Assembly 437 A Lateral Bracket Assembly Removal 437 B Lateral Bracket Assembly Installation 437 Figure 408 Upper Deck Lateral Cyclic Controls 438 49 Lateral Control Link Assembly 438 A Lateral Control Link Assembly Removal 438 B...

Page 1693: ...dinal Bracket Assembly Installation 443 59 FS 144 775 Longitudinal Bracket Assembly 444 A Longitudinal Bracket Assembly Removal 444 B Longitudinal Bracket Assembly Installation 444 60 FS 132 900 Longitudinal Control Rod Assembly 444 A Longitudinal Control Rod Assembly Removal 444 B Longitudinal Control Rod Assembly Installation 444 61 Longitudinal Aft Cockpit Control Rod Assembly 445 A Longitudina...

Page 1694: ...70 FS 171 090 Longitudinal Bellcrank Assembly 451 A Longitudinal Bellcrank Assembly Removal 451 B Longitudinal Bellcrank Assembly Installation 451 71 FS 171 090 Longitudinal Bracket Assembly 451 A Longitudinal Bracket Assembly Removal 451 B Longitudinal Bracket Assembly Installation 451 72 Longitudinal To Actuator Control Rod Assembly 452 A Longitudinal To Actuator Control Rod Assembly Removal 452...

Page 1695: ...rocedure 601 1 Rotor Flight Control System 601 A Rotor Flight Control System Inspection Area 1 601 B Rotor Flight Control System Inspection Area 2 602 C Rotor Flight Control System Inspection Area 3 603 D Rotor Flight Control System Operational Test 603 E Cyclic Stick In Center Position Procedure 605 Figure 601 Cyclic Stick In Center Position Procedure 605 F Deleted 606 Figure 602 Deleted 607 G Ro...

Page 1696: ...ive Control Module 401 A Collective Control Module Removal 401 B Collective Control Module Disassemble 401 C Collective Control Module Reassemble 401 D Collective Control Module Installation 401 Figure 401 Collective Control Module Installation 402 Figure 402 Collective Control Module Assembly 402 2 Cyclic Grip 403 A Cyclic Grip Removal 403 B Cyclic Grip Disassemble 403 C Cyclic Grip Reassemble 40...

Page 1697: ...stallation 402 C Copilot Pedal Shaft Disengagement 402 7 Crank Assembly Right Pedal Pilot 403 A Crank Assembly Right Pedal Removal 403 B Crank Assembly Right Pedal Installation 403 8 Crank Assembly Left Pedal Pilot 403 A Crank Assembly Left Pedal Removal 403 B Crank Assembly Left Pedal Installation 403 9 Pedal Pivot Support 404 A Pedal Pivot Support Removal 404 B Pedal Pivot Support Installation 4...

Page 1698: ...tallation 406 20 Directional Crank Assembly FS 109 000 407 A Directional Crank Assembly Removal 407 B Directional Crank Assembly Installation 407 21 Pedal Directional Control Clevis Assembly 407 A Pedal Directional Control Clevis Assembly Removal 407 B Pedal Directional Control Clevis Assembly Installation 407 22 Forward Cockpit Directional Control Rod Assembly 408 A Forward Cockpit Directional Co...

Page 1699: ...ctuator Input Control Rod Assembly Removal 415 B Directional Actuator Input Control Rod Assembly Installation 415 31 Directional Actuator Output Control Rod Assembly 416 A Directional Actuator Output Control Rod Assembly Removal 416 B Directional Actuator Output Control Rod Assembly Installation 416 32 Hydraulic Anti Torque Directional Actuator 416 A Anti Torque Directional Actuator Removal 416 B ...

Page 1700: ...Assembly Installation 421 43 FS 277 723 Directional Bellcrank Assembly 422 A Directional Bellcrank Assembly Removal 422 B Directional Bellcrank Assembly Installation 422 44 FS 277 723 Directional Bracket Assembly 422 A Directional Bracket Assembly Removal 422 B Directional Bracket Assembly Installation 422 45 Directional Fwd Cable Bracket 422 A Directional Fwd Cable Bracket Removal 422 B Direction...

Page 1701: ...Support Bracket Installation 430 54 Sector Guard Clip 431 A Sector Guard Clip Removal 431 B Sector Guard Clip Installation 431 55 Sector 431 A Sector Removal 431 B Sector Installation 431 56 Sector Rigging Plate 432 A Sector Rigging Plate Removal 432 B Sector Rigging Plate Installation 432 57 Sector Support Shaft 432 A Sector Support Shaft Removal 432 B Sector Support Shaft Installation 432 58 Sec...

Page 1702: ...rt Bearing Installation 436 66 Lightning Strike Shield 436 A Lightning Strike Shield Removal 436 B Lightning Strike Shield Installation 436 67 Lightning Strike Ground Jumper 437 A Removal 437 B Installation 437 Figure 404 Thruster and Controls Installation 438 68 Rotating Cone Control Rod 439 A Rotating Cone Control Rod Removal 439 B Rotating Cone Control Rod Installation 439 69 Thruster 440 A Thr...

Page 1703: ...tor 447 A Actuator Removal Typical 447 B Actuator Installation Typical 447 75 VSCS Control Rod 448 A Control Rod Removal Typical 448 B Control Rod Installation Typical 448 76 Tube Adapter 448 A Tube Adapter Removal 448 B Tube Adapter Installation 449 77 Spar Tube Bellcrank 449 A Bellcrank Removal Typical 449 B Bellcrank Installation Typical 449 78 Horizontal Endplate Spar Tube 450 A Spar Tube Remo...

Page 1704: ...ional Test 614 Figure 604 VSCS System 615 Figure 605 VSCS Diagnostics Test Box Right Installation Typical 616 E VSCS Fault Isolation Procedure 616 Figure 606 Special Inspection of FS 401 73 Cable Attachment Bracket Assembly 620 3 Special Inspections 621 A Special Inspection of the FS 401 73 Cable Attachment Bracket Assembly 621 Repair 801 1 Actuator Anti Torque Directional Repair 801 2 Nicks Scrat...

Page 1705: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 67 00 00 Flight Controls ...

Page 1706: ......

Page 1707: ...roll attitude Cyclic Stick Centering Device Assists the pilot in centering the cyclic stick assembly both longitudinally and laterally during engine start up and shut down Cyclic Stick Base Separates longitudinal and lateral inputs and contains the second ary cyclic control stops Longitudinal Trim Actuator Allows the pilot to alleviate longitudinal cyclic stick flight loads for trim flight conditi...

Page 1708: ...LOSET CONTROL ROD LONGITUDINAL CLOSET CONTROL ROD LATERAL GRADIENT SPRING LONGITUDINAL CONTROL ROD LATERAL TRIM ACTUATOR CRANK LONGITUDINAL TRIM ACTUATOR LATERAL TRIM ACTUATOR LATERAL BRACKET LONGITUDINAL TRIM ACTUATOR LONGITUDINAL GRADIENT SPRING EXPANDABLE DIAMETER BOLT REF UPPER DECK CONTROLS DUAL CONTROLS LATERAL ROD END BEARING LATERAL CONTROL TUBE DUAL CONTROLS LONGITUDINAL CONTROL ROD LONGI...

Page 1709: ...LLCRANK LATERAL BRACKET LONGITUDINAL BRACKET LATERAL CONTROL LINK LATERAL BRACKET LATERAL CONTROL ROD LONGITUDINAL ACTUATOR CONTROL ROD LONGITUDINAL CONTROL ROD LATERAL ACTUATOR CONTROL ROD LATERAL BELLCRANK UPPER DECK LATERAL ACTUATOR ATTACH CLEVIS LONGITUDINAL ACTUATOR ATTACH CLEVIS 9G67 002 2B UPPER DECK CONTROL BRACKET UPPER CONTROLS LATERAL MIXER ARM UPPER CONTROLS LONGITUDINAL MIXER ARM Figu...

Page 1710: ...pensate for control loads from the main rotor system during flight The actuators act through spring cartridges to provide gradient force from the centered position the pilot selects The cyclic trim switch located on top of the cyclic stick grip has five positions OFF at the center FORWARD AFT LEFT RIGHT When the trim button is moved from the spring loaded OFF position to one of the four trim direc...

Page 1711: ...ated on the upper deck directly in front of the transmission The servoactuators use hydraulic power to assist positioning of the upper flight controls The longitudinal and lateral control primary control stops are internal to the servoactua tors Primary control stops are not adjustable for total control travel Total control travel is moved by proportionately adjusting the servoactuator input and o...

Page 1712: ...TUDINAL COLLECTIVE FOD COVER COLLECTIVE SERVOACTUATOR CONTROL ROD COLLECTIVE HYDRAULIC SERVOACTUATOR COLLECTIVE FRICTION RELEASE SWITCH COLLECTIVE INTERCONNECT CONTROL ROD ENGINE MANUAL CONTROL INTERCONNECT CABLE COLLECTIVE BELLCRANK COPILOT COLLECTIVE STICK POSITION SENSOR LINK SENSOR CLAMP POSITION TRANSDUCER 9G67 011 1b POSITION SENSOR BRACKET POSITION SENSOR CRANK COLLECTIVE POSITION SENSOR IN...

Page 1713: ...K DOWN STOP R P M EEC RESET OFF LDG HVR UP DOWN R GA R L EXT RET LIGHTS HIGH NORM OFF GATE YAW 900 C0NFIG COMMUNICATIONS SWITCH GO AROUND SWITCH SEARCH LIGHT CONTROL SWITCH OPTION N2 BEEP EEC RESET TO AUTO LANDING HOVER LIGHT SWITCH OFF GATE RELEASE SWITCH EARLY CONFIG YAW SYNC CURRENT CONFIG AUTO PILOT YAW OPTION YAW SYNC CURRENT CONFIG TAKE OFF TIMER EARLY CONFIG EEC RESET TO AUTO LANDING HOVER ...

Page 1714: ...cated on the collective stick assembly The grips provide the pilot with manual engine control in the event of an EEC failure The grips are positioned in the NORMAL detent position for engine operation in the AUTO or electronically controlled mode Attached to the end of the collective stick assembly is a control module The control head has electrical controls for hover landing lights collective fri...

Page 1715: ... Spring The collective controls balance spring balances collective control loads caused be control component weight The balance spring attaches to a bracket which is attached to cockpit sub structure and to a clip attached to the bottom connecting bolt of the collective closet control rod An electrical tie down strap is installed loosely through the balance spring to retain the spring in position ...

Page 1716: ...LLCRANK AFT DIRECTIONAL CONTROL ROD DIRECTIONAL CRANK PEDAL CRANK CONTROL ROD HEEL REST UPPER DECK DIRECTIONAL BELLCRANK AFT DIRECTIONAL CONTROL ROD PEDAL ADJUSTMENT KNOB PEDAL CRANK DIRECTIONAL PEDAL LINK PEDAL FRICTION ASSEMBLY 9G67 012 1A COCKPIT FLOOR PILOT RIGHT PEDAL CRANK PEDAL ADJUSTMENT STOP HOOK AND LOOP FASTENER FOR STOWING PEDALS PEDAL CRANK CONTROL ROD ATTACH BOLT 902 CONFIG PEDAL ANT...

Page 1717: ...ECTIONAL BRACKET FOD COVER UPPER DECK CONTROL BRACKET DIRECTIONAL BELLCRANK ANTI TORQUE DIRECTIONAL SERVOACTUATOR ACTUATOR SUPPORT BRACKET UPPER DECK DIRECTIONAL CONTROL ROD DIRECTIONAL CONTROL ROD OUTER BELLCRANK 9G67 012 2A DIRECTIONAL BRACKET DIRECTIONAL BELLCRANK TO THRUSTER DIRECTIONAL CONTROL ROD DIRECTIONAL CONTROL CABLE DIRECTIONAL PUSH PULL CABLE HOUSING ATTACH BRACKET DIRECTIONAL BELLCRA...

Page 1718: ...ER CONTROL CABLE DRUM THRUSTER CABLE DRUM BRACKET THRUSTER CONTROL ROD THRUSTER BUILDUP ASSEMBLY ROTATING CONE ASSEMBLY TAILBOOM ASSEMBLY DIRECTIONAL CONTROL PUSH PULL CABLE THRUSTER CONTROL ROD 9G67 012 3C THRUSTER CONTROL CABLE SECTOR LIGHTNING STRIKE SHIELD CONTROL BEARING THRUSTER STATIONARY CONE ASSEMBLY THRUSTER EXTENSION ASSEMBLY Figure 3 Anti Torque Directional Controls Subsystem Sheet 3 o...

Page 1719: ...ing anti torque fan pitch change This allows the EECs to anticipate a change in power demand caused by fan pitch The pedal anticipator also provides the IIDS with pedal position A ground adjustable pedal friction device allows the amount of effort required to push the pedals to be set The friction is set to a predetermined value and is not to be used for a pilot s friction preference The copilot p...

Page 1720: ...The linkages transmit inputs from the splitter assembly to the direct jet thruster The linkages are installed across the aft side of Fuselage Station 230 5 frame assembly and aft to the tailboom A push pull cable is installed through the tailboom to the thruster control rod assembly to the stationary thrust er The control rod connects to the thruster control cable sector assembly on the upper side...

Page 1721: ...lateral acceleration signal is 3 75 Vdc g C VSCS Yaw Rate Gyros The yaw rate gyros are located in the left and right avionics bay one on each side The gyros output a yaw rate signal to the VSCS control units that is 80 mV degree second They have a maximum rate output of 60 degrees second D VSCS Control Units The VSCS control units are located in the right and left avionics bays The control units a...

Page 1722: ...dplates The horizontal endplates are mounted on the endplate spar tube The spar tube rotates in the horizontal stabilizer in upper and lower journal bearings The VSCS linear actuators control the horizontal endplates through control rods and cranks H VSCS Position Indicators The VSCS position indicators indicate the position of the horizontal endplates and can be used to evaluate the operation of ...

Page 1723: ...late damage remove and replace actuator if necessary 67 10 00 Upper deck swashplate mix er linkage restriction Isolate damage or restriction and remove repair or replace 67 10 00 Binding in controls linkage Isolate damage or obstruction and remove repair or replace 67 10 00 Cyclic control pressure cannot be reduced by operating trim switch Faulty wiring Test and repair wiring 98 00 00 Faulty conne...

Page 1724: ...llective stick pressure does not release when collective friction unit CFU release button is depressed Faulty connection Troubleshoot CFU connection 67 10 00 Faulty wiring Test and repair wiring 98 00 00 Release switch inoperative Troubleshoot switch on collective control module collective grip to CFU connection and operation 67 10 20 Collective Friction Unit inoperative Replace CFU 67 10 00 Bindi...

Page 1725: ...ailure CFU Replace Collective Friction Unit 67 10 00 NCFAL1 5 on IIDS alphanumeric display Faulty wiring Test and repair wiring 98 00 00 CLP sine failure CFU Replace Collective Friction Unit 67 10 00 NCFAL1 7 on IIDS alphanumeric display Faulty wiring Test and repair wiring 98 00 00 CLP cosine failure CFU Replace Collective Friction Unit 67 10 00 NCFAL2 2 on IIDS alphanumeric display Faulty wiring...

Page 1726: ...ng jet thruster Isolate restriction or damage and remove repair or replace 67 20 00 Binding in controls linkage Isolate damage or obstruction and remove repair or replace 67 20 00 Binding restriction or malfunction of directional servoactuator Verify hydraulic supply to actuator 29 00 00 Inspect actuator connections and operation isolate damage and remove repair or replace 67 20 00 Replace actuato...

Page 1727: ...d replace bearings as required 67 20 00 Degraded operation of vertical stabilizer endplates when collective stick is moved through its range of travel Faulty wiring Test and repair wiring 98 00 00 Collective position transducers improperly adjusted Adjust collective position transducers 67 20 00 Incorrect VSCS rigging Correct rigging 67 20 00 Malfunction of VSCS component Perform VSCS Test Box and...

Page 1728: ...splay of IIDS Faulty wiring Test and repair wiring 98 00 00 Faulty VSCS component Perform VSCS Test Box and System Diagnostics Procedures Replace faulty component 67 20 00 No deflection in lightning strike contact no measurable gap between contact and cone surface Liquid shim in this area too thick Sand liquid shim minimum required while maintaining an even surface for mating part See Notes 67 20 ...

Page 1729: ...UR 2 15 on IIDS alphanumeric display Faulty wiring Test and repair wiring 98 00 00 Pedal Potentiometer Replace potentiometer 67 20 00 EEC Ref P WC Fault Isolation Charts Ref Related Manufacturers Publications 01 00 00 NOTES 1 Maximum thickness of shim material C409 not to exceed 015 in above surface of cone Area to be 2 75 3 25X2 75 3 25 in square Use sandpaper C807 Dry Method and epoxy paste adhe...

Page 1730: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 108 Revision 19 67 00 00 This page intentionally left blank ...

Page 1731: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 67 10 00 Rotor Flight Controls ...

Page 1732: ......

Page 1733: ...ne controls twist grip 4 as necessary and install screw 5 a Torque screw 5 3 Connect electrical connector P1 3 4 Do the mechanical engine controls operational check ref Section 76 00 00 3 Pilot Collective Control Stick Assembly Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C216 Sealant Fuel Resistant C220 Compound Anti Seize C702 Lockwire Special Tools Ref CSP SPM Item Nomencla...

Page 1734: ...e stick bracket and install bolts 24 washers 25 and 26 bonding jumper right side only and nuts 22 a Torque nuts 22 and install new cotter pins 23 3 Do a test on collective stick for Class L electrical bond ref CSP SPM Sealant Fuel Resistant C216 4 Environmentally seal bonding jumper with sealant C216 ref CSP SPM 5 Connect collective link 16 and install bolt 11 washers 13 14 and 15 and nut 19 a Tor...

Page 1735: ... link 21 B Collective Friction Unit Link Assembly Installation 1 Install collective friction unit link 21 bolt 29 washers 31 and nut 30 a Torque nut 30 and install new cotter pin 28 2 Install bolt 18 washers 20 and nut 19 a Torque nut 19 and install new cotter pin 17 3 Install access panel B142 ref Section 06 00 00 4 Install collective stick boot 1 5 Do steps 10 through 14 of collective controls s...

Page 1736: ...15 to 30 percent shown on IIDS to unload the collective controls 4 Remove external electrical power ref CSP 900RMM 3 5 Disconnect Electrical Connector P153 37 6 Remove cotter pin 28 from bolt 29 7 Remove nut 30 washers 31 and bolt 29 8 Remove environmental seal from around collective friction unit 19 9 Remove bolts 21 washers 22 and collective friction unit 19 B Installation 1 Prepare collective f...

Page 1737: ...ENT MODULE 14 12 10 15 15 24 13 11 26 22 23 25 16 27 26 24 25 23 22 8 NOTE 18 20 20 19 21 17 29 31 28 32 30 31 35 33 34 40 36 41 4 PLS 38 39 TO COPILOT S COLLECTIVE DUAL CONTROLS 9 7 3 5 6 4 2 1 37 MECHANICAL ENGINE CONTROL CABLE COUPLING TYPICAL 9G67 053 C Figure 401 Collective Stick and Collective Friction Installation ...

Page 1738: ... CONTROL CABLE ASSEMBLIES 9 MECHANICAL ENGINE CONTROLS INTERCONNECT ASSEMBLIES 10 COTTER PIN 11 BOLT 12 NUT 13 WASHER 14 WASHER 15 WASHER 16 COLLECTIVE LINK ASSEMBLY 17 COTTER PIN 18 BOLT 19 NUT 20 WASHER 21 COLLECTIVE FRICTION LINK ASSEMBLY 22 NUT 23 COTTER PIN 24 BOLT 25 WASHER 26 WASHER 27 COLLECTIVE STICK BRACKET ASSEMBLY 28 COTTER PIN 29 BOLT 30 NUT 31 WASHER 32 NUT 33 WASHER 34 BOLT 35 COLLE...

Page 1739: ...nd install new cotter pin 3 Install access panel AR145 and B142 Ref Section 06 00 00 4 Install collective stick boot 5 Install pilot crew seat Ref Section 25 10 00 8 Collective Cockpit Control Tube Assembly Ref Figure 402 A Collective Cockpit Control Tube Assembly Removal 1 Remove pilot crew seat Ref Section 25 10 00 2 Remove floor access panel AR138 and B142 Ref Section 06 00 00 3 DUAL CONTROLS R...

Page 1740: ...t seal from around collec tive stick bracket 14 5 Remove nuts 27 washers 8 and bolts 28 Remove collective stick bracket 14 B Collective Stick Bracket Assembly Installation 1 Prepare mating surfaces of collective stick bracket and structure for electri cal bond Ref CSP SPM 2 Install collective stick bracket bolts washers and nuts Torque nuts 3 Do a test on collective stick bracket for Class L elect...

Page 1741: ...3 Moving Flight Controls 4 Pull collective friction release switch and lift pilot collective stick 2 to approximately 15 to 30 percent shown on IIDS to unload collective controls 5 Remove external electrical power Ref CSP 900RMM 3 NOTE Make a mark adjacent to the hole bal ance spring is installed in on lower collective balance spring bracket 39 6 Remove cotter pin 6 from bolt 46 7 Remove nut 7 was...

Page 1742: ...pin 6 from bolt 45 7 Remove nut 7 four washers 8 bushing 22 and bolt 45 8 Remove wires from module block 34 Ref CSP SPM 9 Remove bolts 33 washers 11 and collective position sensor assembly 35 B Collective Position Sensor Assembly Disassemble 1 Remove cotter pin 6 from bolt 24 2 Remove nut 7 washers 20 and bolt 24 Remove sensor link 25 3 Remove cotter pin 6 from bolt 41 4 Remove nut 7 washers 8 and...

Page 1743: ...osen screw on clamp on transducer and turn forward half of transducer to get the correct indication Tighten screw on clamp sufficiently to prevent move ment of forward half of transducer NOTE Horizontal endplate movement occurs during a collective stick movement of approximately 25 to 65 collective stick position as shown on the IIDS 13 Move collective stick full up and then full down and visually...

Page 1744: ... Bellcrank Bracket Assembly Ref Figure 402 Consumable Materials Ref CSP SPM Item Nomenclature C216 Sealant Fuel Resistant A Collective Lower Closet Bellcrank Bracket Assembly Removal 1 Remove collective lower closet bell crank 2 Remove collective position sensor assembly 3 Remove environmental seal from around collective bellcrank bracket 48 4 Remove bolts 4 washers 8 and collective bracket 48 B C...

Page 1745: ...7 8 14 17 26 46 8 8 7 6 11 6 7 31 43 11 2 PL 33 2 PL 11 2 PL 32 2 PL 8 30 27 8 29 2 PL 43 4 PL VIEW ROTATED REF 43 REF 17 REF 26 REF 43 6 6 6 6 REF 17 REF 31 7 8 8 3 4 5 10 15 7 20 20 24 REF 33 REF 11 25 47 34 35 36 37 38 39 40 8 8 REF 25 42 7 8 7 8 8 44 REF 44 45 41 23 8 8 22 48 8 TO COPILOT COLLECTIVE 11 6 7 49 2 PL 50 5 51 Figure 402 Pilot Collective Controls Cockpit ...

Page 1746: ...WASHER 16 900 CONFIG Copilot Quick Release Collective Control Stick Ref Figure 403 A Removal 1 Remove collective stick boot 1 2 Remove Access Panel AL129 ref Section 06 00 00 3 Disconnect Electrical Connector P2 3 4 Remove dust cap 26 from dust cap receptacle 35 and install on Electrical Connector J141 4 5 Remove threaded collar 22 from spring loaded collar 23 and move up collective control stick ...

Page 1747: ...l Stick Assembly Installation 1 Prepare inner surface of inboard collective stick bracket to collective stick attach point and bonding jumper for electrical bond Ref CSP SPM 2 Install collective control stick bolts washers bonding jumper inboard and nuts Torque nuts and install new cotter pins Sealant Fuel Resistant C216 3 Environmentally seal bonding jumper use sealant C216 Ref CSP SPM 4 Install ...

Page 1748: ...ess panels AL129 AL138 and B142 Ref Section 06 00 00 Be careful when you disconnect mechanical engine control cable assemblies If you are not careful damage can occur NOTE Mark left and right mechanical engine control interconnect cable assemblies 17 If necessary rotate collective stick grips to disengage interconnect cables 4 Remove and discard lockwire Loosen nuts at both ends of mechanical engi...

Page 1749: ...16 Remove collective link assembly B Copilot Collective Link Assembly Installation 1 Install bolt washers and nut attaching lower end of collective link assembly to bellcrank assembly Torque nut and install new cotter pin 2 Install copilot collective control stick assembly 23 Collective Bellcrank Assembly Copilot Ref Figure 403 A Copilot Collective Bellcrank Assembly Removal 1 Remove copilot colle...

Page 1750: ... that attach bracket assembly 14 to airframe 4 Remove fillet seal from around bracket assembly Remove bracket B Copilot Collective Stick Bracket Assembly Installation 1 Prepare mating surfaces of collective stick bracket and structure for electri cal bond Ref CSP SPM 2 Install bolts and washers attaching copilot collective bracket assembly to airframe mounting structure Torque bolts Sealant Fuel R...

Page 1751: ... 1 15 3 PL 7 6 11 11 11 8 17 19 11 11 6 7 11 3 PL 9 11 11 7 6 20 5 2 PL 11 2 PL 10 11 13 11 11 7 6 11 7 6 18 11 11 6 7 16 14 12 21 16 25 24 1 23 22 20 1 3 4 26 2 14 17 EARLY 900 CONFIG MECHANICAL ENGINE CONTROL CABLE COUPLING TYPICAL 24 31 30 Figure 403 Copilot Collective Controls Cockpit Sheet 1 of 2 ...

Page 1752: ... BRACKET 15 BOLT 16 COLLECTIVE STICK BELLCRANK 17 MECHANICAL ENGINE CONTROLS INTERCONNECT CABLES 18 BOLT 19 BOLT 20 INTERCONNECT CONTROL ROD 21 DUAL ROD END BEARING 22 THREADED COLLAR 23 SPRING LOADED COLLAR 24 MECHANICAL ENGINE CONTROL CABLE NUT 25 MICRO ADJUST ADAPTER 26 DUST CAP 27 ELECTRICAL CONNECTOR P2 28 ELECTRICAL RECEPTACLE J532 29 QUICK RELEASE PIN 30 COLLECTIVE STICK BASE 31 COPILOT QUI...

Page 1753: ...tall roof panels Ref Section 25 20 00 7 Install access panels L155 R155 and T155 Ref Section 06 00 00 26 Collective Cabin Control Rod Assembly Ref Figure 404 A Collective Cabin Control Rod Assembly Removal 1 Remove cabin interior roof panels Ref Section 25 20 00 2 Remove and discard cotter pins 2 Remove nuts 3 washers 4 and bolts 5 attaching both ends of collective cabin control rod assembly 7 to ...

Page 1754: ...7 collective bracket assembly 16 to mounting deck surface Remove bracket B Collective Bracket Assembly Installation 1 Install bolts and washers attaching FS 170 877 collective bracket assembly to upper deck surface Torque bolts 2 Install collective upper deck bellcrank assembly 29 Collective To Actuator Control Rod Assembly Ref Figure 404 A Collective To Actuator Control Rod Assembly Removal 1 Rem...

Page 1755: ...CONTROL DECK BRACKET ASSEMBLY 10 BOLT 11 COLLECTIVE UPPER DECK BELLCRANK ASSEMBLY 12 FOD COVER COLLECTIVE LONGITUDINAL 13 COLLECTIVE TO ACTUATOR CONTROL ROD ASSEMBLY 14 WASHER 15 BOLT 16 COLLECTIVE BRACKET ASSEMBLY FS 170 877 17 BOLT 18 COLLECTIVE SERVOACTUATOR UNIT 19 BOLT 20 WASHER Figure 404 Collective Controls Upper Deck 30 Cyclic Stick Boot Ref Figure 405 A Cyclic Stick Boot Removal 1 Remove ...

Page 1756: ...sher Torque screw Sealant Fuel Resistant C216 6 Environmentally seal bonding jumper using sealant C216 Ref CSP SPM NOTE If converting to dual cyclic controls re move dust cap from receptacle J143 and install onto dummy receptacle 7 Attach electrical connector P1 to receptacle J142 pilot or J143 copilot 8 Test bonding jumper assembly for class L electrical bond Ref CSP SPM 9 Install cyclic control ...

Page 1757: ... autopilot is not installed remove protective cover from J143 and install it on adjacent dummy recep tacle 5 If necessary install screw 12 and washer 11 attaching bonding jumper 10 to airframe 6 Connect two piece electrical bond jumper 10 7 Install cyclic stick boot over cyclic stick assembly 8 Press hook and loop fasteners together to secure against floor and close around cyclic stick 9 If necess...

Page 1758: ...s Inc Rotorcraft Maintenance Manual Page 426 Revision 36 67 10 00 9G67 054 1 2 3 4 5 6 7 22 24 IN LB 2 4 2 7 Nm 12 11 10 6 9 8 9 REF 1 13 REF 13 17 16 16 19 15 18 VIEW ROTATED 14 20 Figure 405 Cyclic Stick Assembly Sheet 1 of 2 ...

Page 1759: ...Helicopters Inc Rotorcraft Maintenance Manual Page 427 Revision 36 67 10 00 9G67 061 1 5 7 10 20 OPEN CLOSED 21 2 COPILOT QUICK RELEASE CYCLIC STICK ASSEMBLY 11 12 22 24 23 Figure 405 Cyclic Stick Assembly Sheet 2 of 2 ...

Page 1760: ...IC STICK BOOT ASSEMBLY 3 SCREW 4 WASHER 5 CONNECTOR P1 6 BOLT 7 CYCLIC BASE LONGITUDINAL CRANK ASSEMBLY 8 NUT 9 WASHER 10 ELECTRICAL BOND JUMPER 11 WASHER 12 SCREW 13 PILOT CYCLIC STICK CENTERING STRAP ASSEMBLY 14 NUT 15 WASHER 16 RADIUS BLOCK 17 HOOK TAPE FASTENER HALF 18 WASHER 19 BOLT 20 CYCLIC BASE ASSEMBLY 21 EXPANDABLE BOLTS SPRING CLIPS ...

Page 1761: ...tall new cotter pins 6 Install FS 144 774 longitudinal bracket assembly 35 Lateral Dual Control Interconnect Control Rod Assembly Ref Figure 406 A Lateral Interconnect Control Rod Assembly Removal 1 Remove FS 144 775 longitudinal bracket assembly 2 Remove copilot crew seat Ref Section 25 10 00 3 remove access panels AL138 and B142 Ref Section 06 00 00 4 Remove and discard cotter pins 9 Remove nuts...

Page 1762: ...ly into cyclic base assembly Lubricant Solid Film C101 3 Apply solid film lubricant C101 to threads of lateral crank assembly 4 Install washer and nut attaching aft end of crank assembly to base assem bly Torque nut and install lockwire C702 5 Install bolt washers and nut attaching forward end of lateral crank assembly to base assembly Torque nut and install new cotter pin 6 Install screws and was...

Page 1763: ...ASSEMBLY 3 NUT 4 WASHER 5 BOLT 6 CYCLIC BASE LONGITUDINAL CRANK ASSEMBLY 7 DUAL ROD END BEARING 8 DUAL CONTROL INTERCONNECT CONTROL ROD ASSEMBLY 9 COTTER PIN 10 NUT 11 WASHER 12 BOLT 13 CYCLIC BASE LATERAL CONTROL TUBE ASSEMBLY 14 LATERAL BELLCRANK ASSEMBLY 15 BOLT 16 BOLT 17 COPILOT CYCLIC BASE LATERAL CRANK ASSEMBLY 18 CYCLIC STICK LONGITUDINAL CONTROL ROD ASSEMBLY 19 WASHER 20 NUT 21 WASHER 22 ...

Page 1764: ...attaching bracket assembly 5 B Lateral Bracket Assembly Installation 1 Prepare bellcrank bracket and fuselage structure mounting surfaces for electrical bond CSP SPM 2 Install bolts and washers attaching lateral bracket assembly Torque bolts 3 Test lateral bracket assembly for class R electrical bond CSP SPM 4 Install lateral bellcrank assembly 39 Lateral Gradient Spring Assembly Ref Figure 407 A ...

Page 1765: ...ator and mounting surface 2 Install bolts and washers attaching lateral trim actuator assembly to mounting surface Torque bolts 3 Attach electrical connector P146 to the actuator assembly 4 Install lateral trim actuator crank assembly 5 Verify cyclic trim actuator operation Ref Rotor Flight Control System Operational Test 42 Lateral Lower Closet Bellcrank Assembly Ref Figure 407 A Lateral Lower Cl...

Page 1766: ...to mounting surface Torque bolt 4 Install lateral lower closet bellcrank assembly 44 Lateral Closet Control Rod Assembly Ref Figure 407 A Lateral Control Rod Removal 1 Remove pilot crew seat Ref Section 25 10 00 2 Remove access panel AR138 Ref Section 06 00 00 3 Remove insulation and controls closet panels behind right crew seat Ref Section 25 10 00 4 Remove and discard cotter pin 12 Remove nut 13...

Page 1767: ...n 36 67 10 00 9G67 003 1B 16 14 REF 3 15 14 14 13 12 REF 2 12 13 14 14 17 14 13 12 REF 10 19 4 PL 18 4 PL REF 5 11 REF 6 12 13 14 REF 4 14 20 21 14 22 23 28 2 PL 26 2 PL 27 2 PL 26 2 PL REF 25 24 4 PL 1 2 3 4 5 6 7 8 9 10 25 Figure 407 Cockpit Lateral Cyclic Controls Sheet 1 of 2 ...

Page 1768: ...ELLCRANK BRACKET ASSEMBLY 6 LATERAL FORCE GRADIENT SPRING ASSEMBLY 7 LATERAL CLOSET BELLCRANK BRACKET ASSEMBLY 8 LATERAL CLOSET LOWER BELLCRANK ASSEMBLY 9 LATERAL CLOSET CONTROL TUBE ASSEMBLY 10 LATERAL FORE AND AFT CONTROL TUBE ASSEMBLY 11 LATERAL DUAL BEARING ROD END 12 COTTER PIN 13 NUT 14 WASHER 15 BOLT 16 BOLT 17 BOLT 18 WASHER 19 BOLT 20 BOLT 21 NUT SELF LOCKING 22 BOLT 23 LATERAL TRIM ACTUA...

Page 1769: ... attaching lateral deck control rod assembly to bellcrank 3 Install bolt washers and nut attaching lateral control rod assembly to bell crank 4 Torque all nuts and install new cotter pins 5 Install FOD cover FS 155 500 6 Install roof panels Ref Section 25 20 00 7 Install controls closet and insulation panels behind right crew seat Ref Section 25 10 00 8 Close access panels R155 and R210 Ref Sectio...

Page 1770: ...sembly 12 B Lateral Bellcrank Assembly Installation 1 Install bolt washers and nut attaching FS 165 588 bellcrank assembly to lateral bracket assembly 2 Install bolt washers and nut attaching lateral deck control rod assembly to bellcrank 3 Install bolt washers and nut attaching lateral controls link assembly to bellcrank 4 Verify lateral cyclic control system rigging 5 Torque nuts and install new...

Page 1771: ... 49 Lateral Control Link Assembly Ref Figure 409 A Lateral Control Link Assembly Removal 1 Remove roof panels Ref Section 25 20 00 2 Remove and discard cotter pin 2 Remove nut 3 washers 4 and bolt 14 that attach lateral control link assembly 15 to FS 165 588 lateral bellcrank assembly 16 3 Remove and discard cotter pin 2 Remove nut 3 washers 4 and bolt 12 that attach link 15 to FS 170 536 lateral ...

Page 1772: ...ins 6 Install lateral FOD cover 7 Install roof panels Ref Section 25 20 00 8 Close access panels L155 and L210 Ref Section 06 00 00 51 Lateral Actuator Control Rod Assembly Ref Figure 409 A Lateral Actuator Control Rod Assembly Removal 1 Open access panels L155 and L210 Ref Section 06 00 00 2 Remove roof panels Ref Section 25 20 00 3 Loosen hose clamp on lateral upper deck control rod boot 4 Remov...

Page 1773: ...s and washers attaching FS 170 536 lateral bracket assembly to mounting surface Torque bolts 2 Install lateral bellcrank assembly 3 Install roof panels Ref Section 25 20 00 4 Close access panels L155 and L210 Ref Section 06 00 00 3 4 4 14 15 6 7 4 8 11 4 12 13 4 2 3 4 4 3 2 10 9 2 3 4 5 2 3 4 4 9G67 056 1 2 16 1 LATERAL SERVOACTUATOR INPUT 2 COTTER PIN 3 NUT 4 WASHER 5 BOLT 6 LATERAL ACTUATOR CONT...

Page 1774: ...tem Operational Test 5 Install bolt washers and nut attaching longitudinal gradient spring assembly to longitudinal trim actuator crank assembly 6 Verify longitudinal cyclic control system rigging 7 Torque nut and install new cotter pin 8 Install access panel AR138 and close access panel R128 Ref Section 06 00 00 9 Install pilot crew seat Ref Section 25 10 00 54 Longitudinal Trim Actuator Crank As...

Page 1775: ...nstall access panel AR138 and close access panel R128 Ref Section 06 00 00 6 Install pilot crew seat Ref Section 25 10 00 56 FS 144 775 Longitudinal Bellcrank Assembly Ref Figure 410 A Longitudinal Bellcrank Assembly Removal 1 Remove pilot crew seat Ref Section 25 10 00 2 Remove access panel AR138 Ref Section 06 00 00 3 Remove and discard cotter pins 1 Remove nuts 2 washers 3 and bolts 25 that att...

Page 1776: ...gitudinal bellcrank assembly to FS 150 064 longitudinal bracket assembly 2 Install bolt spacer grommet washers and nut attaching lower end of longitu dinal closet control rod assembly to bellcrank assembly 3 Install bolt spacer washers balance spring clip and nut attaching balance spring cable assembly to bellcrank assembly 4 Install bolts washers and nuts attaching longitudinal gradient spring an...

Page 1777: ... attach FS 144 775 longitudinal bellcrank assembly 29 to FS 144 775 longitudinal bracket assembly 24 9 Remove bolt 4 washers 3 and nuts 6 that attach bracket assembly 24 to mounting surface B Longitudinal Bracket Assembly Installation 1 Prepare surface for electrical bond Ref CSP SPM 2 Install bolt washers and nut attaching FS 144 775 longitudinal bracket assembly 3 Install bolt washers and nut at...

Page 1778: ...s closet and insulation panels behind right crew seat Ref Section 25 10 00 5 Install access panel AR138 Ref Section 06 00 00 6 Install pilot crew seat Ref Section 25 10 00 62 Longitudinal Closet Control Rod Assembly Ref Figure 410 A Longitudinal Closet Control Rod Assembly Removal 1 Remove pilot crew seat Ref Section 25 10 00 2 Remove access panel AR138 Ref Section 06 00 00 3 Remove insulation and...

Page 1779: ... Install access panel AR138 Ref Section 06 00 00 6 Install pilot crew seats Ref Section 25 10 00 64 Balance Spring Clip Ref Figure 410 A Balance Spring Clip Removal 1 Remove pilot crew seat Ref Section 25 10 00 2 Remove access panel AR138 Ref Section 06 00 00 3 Remove insulation and controls closet panels behind right crew seat Ref Section 25 10 00 4 Remove and discard cotter pin 1 Remove nut 17 w...

Page 1780: ... Ref Section 25 10 00 2 Remove access panel AL138 Ref Section 06 00 00 3 Remove and discard cotter pins 1 Remove nuts 2 washers 3 and bolts 49 that attach interconnect control rod assembly 53 and copilots FS 132 900 longitudinal control rod assembly 31 to FS 143 785 longitudi nal bellcrank assembly 54 4 Remove and discard cotter pin 1 Remove nut 2 washers 3 and bolt 50 that attach bellcrank assemb...

Page 1781: ...4 3 6 VIEW ROTATED 19 18 1 17 20 21 REF 10 42 1 38 39 40 41 43 44 45 REF 35 REF 46 22 1 27 14 14 28 26 NOTE 2 REF 29 REF 24 1 2 3 3 25 4 6 3 REF 31 1 2 30 3 27 30 1 2 3 3 25 15 1 2 3 3 36 37 REF 35 3 14 48 TO DUAL CONTROLS NOTES 1 TORQUE 50 70 in lb 5 64 7 90 N m 2 TORQUE 70 90 in lb 7 90 10 16 N m 25 3 2 PL 2 1 56 4 PL VIEW ROTATED 23 3 3 6 16 24 1 2 14 14 9 REF 10 3 47 Figure 410 Cockpit Longitu...

Page 1782: ...LT 22 BALANCE SPRING CABLE ASSEMBLY 23 BOLT 24 FS 144 775 LONGITUDINAL BRACKET ASSEMBLY 25 BOLT 26 NUT 27 BOLT 28 WASHER 29 FS 144 775 LONGITUDINAL BELLCRANK ASSEMBLY 30 CYCLIC STICK LONGITUDINAL SECONDARY STOP 31 FS 132 900 LONGITUDINAL CONTROL ROD ASSEMBLY 32 BOLT 33 GROMMET 34 SPACER 35 LONGITUDINAL CLOSET CONTROL ROD ASSEMBLY 36 BOLT 37 FS 157 387 LONGITUDINAL BELLCRANK ASSEMBLY 38 NUT 39 WASH...

Page 1783: ...o bellcrank assembly 8 3 Verify longitudinal cyclic control system rigging Ref Section 67 10 00 4 Torque nuts and install new cotter pins 5 Install FS 155 50 FOD cover 1 Ref Section 67 10 00 6 Install roof panels Ref Section 25 20 00 7 Install controls closet panels behind right crew seat Ref Section 25 10 00 8 Install insulation panels behind right crew seat Ref Section 25 10 00 9 Close access pa...

Page 1784: ...tudinal control rod assembly 7 and longitudi nal to actuator control rod assembly 15 to bellcrank assembly 13 3 Verify longitudinal cyclic control system rigging Ref Section 67 10 00 4 Torque nuts and install new cotter pins 5 Install collective longitudinal FOD cover 14 Ref Section 67 10 00 6 Install roof panels Ref Section 25 20 00 7 Close access panels R155 and R210 Ref Section 06 00 00 71 FS 1...

Page 1785: ...gitudinal bell crank assembly 13 5 Remove control rod assembly 15 B Longitudinal To Actuator Control Rod Assembly Installation NOTE Adjustment of control rod might be re quired for installation 1 Install bolt washers and nut attaching longitudinal to actuator control rod assembly to FS 171 090 longitudinal bellcrank assembly 13 2 Install collective longitudinal FOD cover Ref Section 67 10 00 Care ...

Page 1786: ...N 3 NUT 4 WASHER 5 BOLT 6 LONGITUDINAL CLOSET CONTROL ROD ASSEMBLY 7 FS 157 387 LONGITUDINAL CONTROL ROD ASSEMBLY 8 FS 157 387 LONGITUDINAL BELLCRANK ASSEMBLY 9 BOLT 10 FS 155 50 CONTROL DECK BRACKET ASSEMBLY 11 BOLT 12 BOLT 13 FS 171 090 LONGITUDINAL BELLCRANK ASSEMBLY 14 COLLECTIVE LONGITUDINAL FOD COVER 15 LONGITUDINAL TO ACTUATOR CONTROL ROD ASSEMBLY 16 FS 171 090 LONGITUDINAL BRACKET ASSEMBLY...

Page 1787: ... 10 00 4 Install FS 157 387 longitudinal bell crank assembly Ref Section 67 10 00 5 Install FS 157 590 directional bellcrank assembly Ref Section 67 20 00 6 Install FS 155 500 FOD cover 1 Ref Section 67 10 00 74 FS 155 500 FOD Cover Ref Figure 412 Consumable Materials Ref CSP SPM Item Nomenclature C235 Release Agent Fluorocarbon C205 Sealing Compound A FOD Cover Removal 1 Open access panel R155 Re...

Page 1788: ...hers 8 that attach collective longitudinal FOD cover 9 to the mounting deck surface 5 Remove screws 35 and washers 36 that attach drip pan drains 33 to drip pan 31 NOTE Sealing compound used between FOD cover and mounting surface is actually a self forming gasket Care should be taken not to damage this gasket when removing FOD cover 6 Using a putty knife if necessary carefully break seal between f...

Page 1789: ...al FOD cover 11 to mounting deck surface 5 Remove screws 35 and washers 36 that attach drip pan drain 33 to drip pan 32 NOTE Sealing compound used between FOD cover and mounting surface is actually a self forming gasket Care should be taken not to damage this gasket when removing FOD cover 6 Using a putty knife or equivalent if necessary carefully break seal between faying surfaces 7 Remove FOD co...

Page 1790: ...s 24 25 and 26 Ref Section 67 10 00 3 Remove screws 35 and washers 36 that attach drip pan drains 33 to drip pans 31 and 32 4 Remove collective longitudinal FOD cover 9 and lateral FOD cover 11 Ref Section 67 10 00 with drip pans 31 and 32 5 Remove upper deck control rod boots 10 or 14 Ref Section 67 10 00 6 Separate bond between FOD covers 9 and 11 and drip pans 31 and 32 and remove B Drip Pan As...

Page 1791: ...rol rod boots 10 or 14 faying surface only NOTE Proceed with the following steps only if forming a new FOD cover seal Sealing Compound C205 2 Apply sealing compound C205 to faying surface of boot 10 or 14 3 Press boot 10 or 14 down on faying FOD cover surface with enough pressure to cause squeeze out of compound NOTE Screws are only to keep holes from clog ging 4 Install screws 5 but do not tighte...

Page 1792: ...ctuator longitudinal to actuator and collective to actuator control rods Ref Section 67 10 00 6 Remove and discard cotter pins 30 Remove nuts 29 washers 28 and bolts 27 that attach both ends of dual hydraulic actuator units 24 25 and 26 to mixer assembly 19 and boosted system bracket assembly 20 7 Remove actuator unit 24 25 and 26 B Dual Hydraulic Actuator Unit Installation NOTE This task is typic...

Page 1793: ...th drip pans 31 and 32 Ref Section 67 10 00 4 Remove bolts 21 and 22 and washers 17 that attach bracket assembly 20 to mounting deck surface 5 Remove bracket assembly 20 B Boosted System Bracket Assembly Installation 1 Install bolts 21and 22 and washers 17 attaching boosted system bracket assembly 20 to mounting deck surface Torque bolts 2 Install collective longitudinal fod cover 9 and lateral fo...

Page 1794: ...OTE 2 12 5 NOTE 1 6 7 8 REF 9 5 NOTE 2 12 REF 23 REF 10 REF 14 REF 23 2 PL 8 PL 21 17 5 PL 22 17 2 PL 16 15 18 17 17 3 PLACES REF 19 27 28 28 29 30 6 PLACES 31 34 33 36 35 32 REF 20 9G67 008B NOTES 1 TORQUE 20 25 in lb 2 25 2 82 N m 2 TORQUE 12 15 in lb 1 35 1 69 N m 12 13 OLD CONFIGURATION 37 35 4 PL 36 4 PL Figure 412 Upper Deck FOD Covers Boots and Actuators ...

Page 1795: ...CK CONTROL ROD BOOT 11 LATERAL FOD COVER 12 WASHER 13 NUT 14 LATERAL UPPER DECK CONTROL ROD BOOT 15 COTTER PIN 16 BOLT 17 WASHER 18 NUT 19 MIXER ASSEMBLY 20 BOOSTED SYSTEM BRACKET ASSEMBLY 21 BOLT 22 BOLT 23 HOSE CLAMP 24 LONGITUDINAL HYDRAULIC ACTUATOR 25 COLLECTIVE HYDRAULIC ACTUATOR 26 LATERAL HYDRAULIC ACTUATOR 27 BOLT 28 WASHER 29 NUT 30 COTTER PIN 31 DRIP PAN RH 32 DRIP PAN LH 33 DRIP PAN DR...

Page 1796: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 464 Revision 36 67 10 00 This page intentionally left blank ...

Page 1797: ...rmitted Moving Flight Controls Do not move rotor flight controls through their full range unless hydraulic power is supplied to the helicopter Cyclic stick must be centered before you move collective control through its full range of travel Collective control must be set at approxi mately 80 before you move cyclic control through its full range of travel 5 Apply 1000 psig 6894 8 kPa hydrau lic pre...

Page 1798: ...maximum scratch limit for the FS 153 5 collective closet control rod is 2 000 inch 50 80 mm long by 0 005 inch 0 13 mm deep in the constant diameter part of the rod b Scratches within these limits must be polished out c Apply chemical coating and primer after polish ref CSP SPM d No damage or too much play per mitted 14 Examine the bellcranks and brackets for correct installation and damage 15 Exa...

Page 1799: ...ic System Number 1 with hydraulic mule T2001 ref Section 29 00 00 2 Apply external electrical power with ground power unit T2002 ref CSP 900RMM 3 3 Examine main rotor flight controls for too much play a Too much play is not permitted 4 Make sure all nuts bolts and safety devices are correctly installed a If safety device is missing torque nut or bolt and install new safety device 5 Examine all con...

Page 1800: ...he cyclic stick must move freely through the full range of travel 5 Trim the cyclic stick full forward 6 Pull the cyclic stick full aft a Release the cyclic stick b Make sure the cyclic stick goes back to full forward when released 7 Trim the cyclic stick aft until the trim motor stops 8 Push the cyclic stick full forward a Release the cyclic stick b Make sure the cyclic stick goes back to full af...

Page 1801: ...of the test is complete ref Procedure 1 E Cyclic Stick in Center Position Procedure 25 Pull pilot collective friction release switch 5 lb 2 27 kg and move the collective stick from full down to full up and back to full down a Measure the force at the base of the grip near the attachment screw b The force necessary to move the stick must be equal to the force to move the stick down within 1 lb 0 45...

Page 1802: ...hile sitting in the pi lot crew seat 3 Detach the bottom of cyclic stick center position strap 1 4 Extend cyclic stick center position strap 1 forward until it touches instrument panel 3 cyclic stick center position placard 2 5 Strap 1 must be fully extended in line with placard 2 and touch placard 2 a If necessary move cyclic stick 4 6 Attach the bottom of cyclic stick center position strap 1 7 R...

Page 1803: ...P 900RMM 3 4 Put cyclic stick 31 in center position 5 Pull collective friction release switch 12 a Lower collective stick 8 to down stop b Release switch 6 Make sure collective servoactuator input lever 4 is overtraveled in the retracted direction 7 Pull collective friction release switch 12 a Raise collective stick 8 to the full up position b Release switch 8 Make sure collective servoactuator in...

Page 1804: ...l pitch links and turn pitch links up 6 Temporarily attach pitch links to rotor head ref Section 62 30 00 7 Apply 1000 psig 6894 8 kPa hydrau lic pressure to hydraulic system number 1 with hydraulic mule T2001 ref Section 29 00 00 8 Apply external electrical power with ground power unit T2002 ref CSP 900RMM 3 9 Pull collective friction release switch 12 and lower collective stick 8 to down stop 13...

Page 1805: ...ion 33 Put cyclic stick 31 in center position 34 Remove hydraulic pressure ref Section 29 00 00 35 Remove external electrical power ref CSP 900RMM 3 36 Connect bottom end of all pitch links to swashplate ref Section 62 30 00 37 Install roof panels ref Section 25 20 00 38 Install FS155 50 collective longitudi nal and lateral FOD covers 39 Install swashplate forward fairing T155 ref Section 06 00 00...

Page 1806: ...ng rig pin T501 2 40 can be put through bracket 39 and bellcrank 42 with collective stick 8 against down stop 13 16 Apply 1000 psig 6894 8 kPa hydrau lic pressure to Hydraulic System Number 1 with the hydraulic mule T2001 ref Section 29 00 00 NOTE Overtravel is shown when servoactua tor input lever bushing has moved from its center position with servoactuator against its travel stop Make sure to a...

Page 1807: ...terference between the rod ends and bellcrank clevis 30 Connect lower end of pitch links ref Section 62 30 00 31 Make sure all nuts are tight 32 Make sure all safety devices cotter pins lock tabs and lockwire are installed 33 Install the collective longitudinal FOD cover 34 Install swashplate forward fairing T155 ref Section 06 00 00 35 Install the roof panels ref Section 25 20 00 36 Install acces...

Page 1808: ...nks as necessary to get this clearance Be careful when you connect control rod to servoactua tor Align servoactuator bearing with clevis of control rod damage to bearing seal can occur 20 Connect longitudinal control rod 47 21 Connect lateral control rod 37 22 Make sure the rod ends are not adjust ed out past witness holes 23 Make sure all jam nuts are tight to prevent interference between rod end...

Page 1809: ...21 Use trim switch 32 to move the cyclic stick 31 to the full forward position NOTE Overtravel is shown when the servoac tuator input lever bushing has moved from its center position with servoactuator against its travel stop Be careful when you connect control rod to servoactuator Align servoactuator bearing with clevis of control rod damage to bearing seal can oc cur 22 Adjust longitudinal contr...

Page 1810: ...e installed remove access cover L109 and R128 ref Section 06 00 00 Moving Flight Controls 9 Apply 1000 psig 6894 8 kPa hydrau lic pressure to Hydraulic System Number 1 with hydraulic mule T2001 ref Section 29 00 00 10 Apply external electrical power with ground power unit T2002 ref CSP 900RMM 3 11 Pull collective friction release switch 12 a Lower collective stick 8 to down stop 13 b Release the s...

Page 1811: ...a minimum of 0 062 inch 1 57 mm between controls and adjacent structure a Adjust the control rods adjacent to the bellcranks get necessary clear ance 27 Make sure the rod ends are not adjust ed out past witness holes 28 Make sure all jam nuts are tight to prevent interference between rod ends and the bellcrank clevis 29 Make sure all nuts are tight 30 Make sure all safety devices cotter pins lock ...

Page 1812: ...N EXTENDED DIRECTION UP 5 SERVOACTUATOR TYPICAL 3 1 2 PILOT COLLECTIVE COPILOT TYPICAL NOTES 1 ONLY PILOT COLLECTIVE HAS A COLLECTIVE FRICTION UNIT 2 ONLY PILOT CYCLIC HAS TRIM ACTUATORS AND GRADIENT SPRINGS REF 9 14 29 25 NOTE 2 23 NOTE 2 20 NOTE 2 27 31 32 PILOT CYCLIC COPILOT TYPICAL 21 NOTE 2 22 16 NOTE 2 26 NOTE 2 15 30 26 18 17 19 24 Figure 602 Rotor Flight Controls Lower Sheet 1 of 2 ...

Page 1813: ...OR ARM 22 RIG PIN SPECIAL TOOL 23 LATERAL TRIM ACTUATOR 24 LATERAL INTERCONNECT CONTROL ROD 25 LONGITUDINAL TRIM ACTUATOR 26 LONGITUDINAL TRIM ACTUATOR ARM 27 RIG PIN SPECIAL TOOL 28 LONGITUDINAL CRANK 29 RIG PIN SPECIAL TOOL 30 BRACKET 31 CYCLIC STICK 32 CYCLIC STICK TRIM SWITCH REF IPL 67 10 20 FIG 1 33 RIG PIN SPECIAL TOOL 34 LATERAL BELLCRANK REF IPL 67 10 00 FIG 7 35 LATERAL CONTROL ROD 36 LA...

Page 1814: ...static mast 1 at position 6 a Make a record of the angle 11 Put inclinometer T203 on top of collective mixer bellcrank 4 at position 5 Make a record of the angle 12 Make sure the angle between static mast 1 and top of collective mixer bellcrank 4 is between 101 2 to 101 4 degrees All servoactuator piston rod end adjust ments must be made with the piston away from its internal travel stops Servoact...

Page 1815: ...raise the collective stick 17 to the full up position a Release the switch Collective servoactuator must overtravel in its full extended and full retracted positions 17 Make sure servoactuator input lever 7 is overtraveled in the extended direc tion 18 Make sure angle between static mast 1 and top of collective mixer bellcrank 4 is 90 3 to 92 1 degrees 19 Make sure there is no interference between...

Page 1816: ...TION DOWN 10 9 7 OVERTRAVEL IN EXTENDED DIRECTION UP 8 2 181 IN 55 397 mm MAXIMUM NOTE 2 13 12 11 1 4 6 5 NOTE 1 14 1 STATIC MAST 2 COLLECTIVE SERVOACTUATOR CONTROL ROD 3 COLLECTIVE SERVOACTUATOR 4 COLLECTIVE MIXER BELLCRANK 5 COLLECTIVE INCLINOMETER POSITION 6 STATIC MAST INCLINOMETER POSITION 7 INPUT LEVER 8 INPUT BEARING 9 STOP BUSHING 10 FEEDBACK LINK 11 LOCK RING 12 NUT 13 ROD END 14 SERVOACT...

Page 1817: ...22 to the full down position b Release the switch 9 Install 2 5 in long rig pin T501 2 21 through bellcrank 19 and bracket 20 10 Use the trim switch 25 to move the cyclic stick 24 to the full forward position 11 Disconnect control rod 5 12 Push down on servoactuator input lever 11 until servoactuator piston 15 is fully retracted 13 Put inclinometer T203 against static mast 1 at position 10 a Make ...

Page 1818: ...t lever 11 overtraveled in the retracted direction 18 Use the trim switch 25 to move the cyclic stick 24 to the full aft position Longitudinal servoactuator must overtravel in its full ex tended and full retracted positions 19 Make sure servoactuator input lever 11 is overtraveled in the extended direction 20 Make sure angle between static mast 1 and top of longitudinal mixer bellcrank 8 is 99 97 ...

Page 1819: ...2 to full down position b Release the switch 9 Install 2 5 in long rig pin T501 2 21 through bellcrank 19 and bracket 20 10 Use trim switch 25 to move the cyclic stick 24 to the full left position 11 Disconnect control rod 4 12 Lift servoactuator input lever 11 until servoactuator piston 15 is fully in the extended direction 13 Put inclinometer T203 against static mast 1 at position 10 a Make a re...

Page 1820: ...r 11 overtraveled in the extended direction 18 Use trim switch 25 to move the cyclic stick 24 to the full right position Longitudinal servoactuator must overtravel in its full ex tended and full retracted positions 19 Make sure servoactuator input lever 11 is overtraveled in the retracted direction 20 Make sure angle between static mast 1 and the top of lateral mixer bell crank 2 is 101 6 to 102 0...

Page 1821: ...AN 2 181 IN 55 397 mm ABOVE TOP OF SERVOACTUATOR PISTON 3 8 SERVOACTUATOR TYPICAL 1 STATIC MAST 2 LATERAL MIXER BELLCRANK 3 LATERAL SERVOACTUATOR 4 LATERAL SERVOACTUATOR CONTROL ROD 5 LONGITUDINAL SERVOACTUATOR CONTROL ROD 6 LONGITUDINAL SERVOACTUATOR 7 LONGITUDINAL INCLINOMETER POSITION 8 LONGITUDINAL MIXER BELLCRANK 9 LATERAL INCLINOMETER POSITION 10 STATIC MAST INCLINOMETER POSITION 11 INPUT LE...

Page 1822: ...longitudinal trim resistor wires 1 b Push in the TRIM circuit breaker on the essential bus circuit breaker panel Moving Flight Controls c Use the trim switch to move the cyclic stick forward d Make sure the trim actuator moves the cyclic stick forward e Use the trim switch to move the cyclic stick aft f Make sure the trim actuator moves the cyclic stick aft g Go to Step k if the trim actuator move...

Page 1823: ...hru f if the trim actuator does not move in one of the two directions i Do a test for an open circuit condition and a short circuit condition if the trim actuator does not move after the lowest resistance resistor is installed ref CSP 900RMM 3 Section 98 40 00 and CSP SPM Section 20 60 00 j Replace the trim actuator and go to step a if there are no short or open circuit conditions k Make sure the ...

Page 1824: ...ire C1C22 no less than 3 inch 76 mm from terminal block TB3 10K on A612 forward intercon nect panel b Install splice C820 on the wire connected to TB3 10K ref CSP SPM Section 20 60 00 c Connect digital multimeter T1003 between the two parts of wire C1C22 2 Install a splice on rotorcraft with autopilot system as follows NOTE Ref Honeywell Rotorcraft Maintenance Manual 006 00757 0000 Drawing 159 081...

Page 1825: ...tronic stop d Examine the amperage on digital multimeter T1003 while you use the trim switch to move the cyclic stick to its longitudinal forward and aft electronic stop e Examine the amperage on digital multimeter T1003 while you use the trim switch to move the cyclic stick to its lateral left and right stops 1 Replace the trim actuator if amper age does not go to zero when trim actuator is at it...

Page 1826: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 630 Revision 36 67 10 00 This page intentionally left blank ...

Page 1827: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 67 10 20 Collective Control Module Cyclic Grip ...

Page 1828: ......

Page 1829: ...tion 98 40 00 Table 101 Collective Control Module Cyclic Grip Troubleshooting Fault Probable Cause Corrective Action Ref Section Specific action does not occur when switch is activated Faulty wiring Isolate damage to component wiring Ref Figure 101 Figure 102 67 10 20 Repair wiring 98 00 00 Troubleshoot system wiring 98 00 00 Faulty switch Replace specific switch 67 10 20 Auto Pilot feature on cyc...

Page 1830: ...IM L H D T S V U Z A D E F S1 S2 S3 S4 S5 A218 167578 00 S5 S1 XMIT ICS H L D A X B J Y W 900C3010064 103 STANDARD GRIP 900C3010064 105 ALTERNATE GRIP WIRING REQUIRED FOR FLOAT AND AUTO PILOT INSTALLED OPTIONS NC NO NO NC S1 XMIT ICS A X B J Y W NO NO NC A218 167576 02 A218 101117 02 LT RT UP DN PITCH ROLL TRIM Z A D E F S2 A218 067679 00 S4 AUTO PILOT DISC A218 067573 02 S3 CARGO HOOK REL T S V U...

Page 1831: ...0 S8 S9 S2 S3 COLLECTIVE FRICTION RELEASE SWITCH S1 EEC RESET S2 OFF GATE RELEASE S9 GO AROUND S7 S4 FOR FUTURE USE RADIO TUNING S8 S10 AUTOPILOT YAW S6 SEARCH LIGHT LIGHTS S5 RPM SWITCH S3 HIGH NORM 1 2 3 4 6 5 9G67 027 1 S1 EARLY CONFIG Figure 102 Collective Control Module Switch Wiring Sheet 1 of 3 ...

Page 1832: ...00RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 104 Original 67 10 20 9G67 027 3 S3 S2 S5 S6 S7 S8 S9 900 CONFIG OFF GATE REMOVED Figure 102 Collective Control Module Switch Wiring Sheet 2 of 3 ...

Page 1833: ...ers Inc Rotorcraft Maintenance Manual Page 105 106 blank Original 67 10 20 9G67 027 2 902 CONFIG 115 902 CONFIG 117 S3 S8 S10 S7 S6 S5 S9 S2 S3 S2 S5 S6 S7 S8 S9 Figure 102 Collective Control Module Switch Wiring Sheet 3 of 3 ...

Page 1834: ......

Page 1835: ...e cover 1 4 Unsolder applicable wires if removing any switches 5 Remove any set screws that may secure specific switches to switchplate 6 Unscrew any nuts 3 or other attach ing hardware that secures switches to cover 1 or control module assembly 4 7 Remove specific switch for replacement C Collective Control Module Reassemble Ref Figure 402 Consumable Materials Ref CSP SPM Item Nomenclature C221 S...

Page 1836: ...electrical connector P1 1 on bottom of control module 2 Tighten connector P1 1 collar 6 Test electrical bond between points A and B 7 Restore power to aircraft Ref Section 96 00 00 9G67 030 1 2 3 4 5 POINT A POINT B 1 CONNECTOR P1 2 COLLECTIVE CONTROL MODULE 3 TWIST GRIP 4 SCREW 5 COLLECTIVE CONTROL STICK ASSEMBLY Figure 401 Collective Control Module Installation 9G67 045 3 4 1 2 4 PL 1 SWITCHPLAT...

Page 1837: ...ve set screws 5 that secure specific switches 6 Remove switch for replacement C Cyclic Grip Reassemble Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C221 Silicone Compound 1 Install switch for replacement 2 Install set screws 5 that secure specific switches in place 3 Solder wires to new switch 4 Install screws 2 and or 6 attaching switchplate cover 3 and or handle cover 4 Sili...

Page 1838: ... to remove B Wire Harness W135 Cyclic Controls Installation Ref Figure 403 Power Off 1 Verify all power is removed from aircraft ref Section 96 00 00 2 Route W135 wire harness 9 through cyclic stick assembly 3 from upper end to lower end 3 Prepare the surface for electrical bond ref CSP SPM NOTE Electrical bond preparation should be made for outside surface of insert 10 to cy clic stick assembly 3...

Page 1839: ... 031A 2 3 1 8 9 11 7 4 5 REF 1 10 7 6 REF 13 12 REF 3 13 1 COLLAR 2 CYCLIC GRIP ASSEMBLY 3 CYCLIC STICK ASSEMBLY 4 NUT 5 WASHER 6 BOLT 7 RADIUS BLOCK 8 LOWER CONNECTOR 9 W135 WIRE HARNESS 10 INSERT 11 JUMPER ASSEMBLY 12 WASHER 13 CYCLIC STICK CENTERING STRAP Figure 403 Cyclic Grip Installation ...

Page 1840: ...licopters Inc Rotorcraft Maintenance Manual Page 406 Original 67 10 20 5 4 2 4 PL 3 9G67 044 1 6 5 PL 1 CYCLIC GRIP ASSEMBLY 2 SCREW 3 SWITCHPLATE COVER 4 HANDLE COVER 5 SET SCREW 6 SCREW Figure 404 Cyclic Grip Assembly ...

Page 1841: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 67 20 00 Anti Torque Directio nal Flight Controls ...

Page 1842: ......

Page 1843: ...l shaft assembly 13 or 17 B Directional Control Pedals Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C216 Sealant Fuel Resistant Sealant Fuel Resistant C216 1 Apply sealant C216 to mating sur faces of directional control pedal 12 and pedal shaft assembly 13 or 17 2 Install bolt 11 washer 10 and nut 8 attaching control pedal 12 to shaft assembly 13 or 17 3 Torque nu...

Page 1844: ...attach upper ends of pedal return springs 27 to directional pedal shaft assemblies 13 and 17 3 Remove hardware that attaches bonding jumper 4 Remove pedal pivot support 28 and remove pedal shaft assemblies 13 and 17 B Pedal Shaft Assemblies Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C216 Sealant Fuel Resistant NOTE Prepare area for electrical bond on shaft assem...

Page 1845: ...sembly Left Pedal Pilot A Crank Assembly Left Pedal Removal Ref Figure 401 NOTE Position shaft assembly 13 in crank assembly 39 to minimize tension on pedal return spring 27 1 Remove and discard cotter pin 19 Remove nut 23 washers 24 bushing 25 and bolt 26 that attach upper end of pedal return spring 27 to direction al pedal shaft assembly 13 2 Remove and discard cotter pin 19 Remove nut 20 washer...

Page 1846: ...rt Removal Ref Figure 401 1 Remove rivets 14 from adjustment handle 15 and remove handle 2 Remove adjustment pin 16 pedal spring 40 and spring support 41 B Pedal Spring Support Installation Ref Figure 401 1 Install pedal spring 40 spring support 41 and adjustment pin 16 2 Install adjustment handle 15 with rivets 14 12 Spring Return Arbor A Spring Return Arbor Removal Ref Figure 401 1 Remove nuts 4...

Page 1847: ... return springs 27 to pedal shaft assemblies 13 or 17 5 Torque nuts and install new cotter pins 14 FS 104 459 Lower Directional Crank Assembly A Lower Directional Crank Assembly Removal Ref Figure 401 1 Remove and discard cotter pins 19 Remove nuts 20 washers 29 and bolts 30 that attach both left and right side link assemblies 31 to lower directional crank assembly 48 2 Remove and discard cotter p...

Page 1848: ...3 Remove friction links 38 B Friction Link Installation Ref Figure 401 1 Install bolt 30 bushing 51 washers 49 and 50 and nut 20 attaching friction links 38 to pedals bracket assembly 5 2 Install bolt 37 friction disks 36 friction retainer 34 compression spring 35 washers 29 and 33 and nut 32 attaching lower end of friction links 38 19 Directional Interconnect Control Rod Assembly A Directional In...

Page 1849: ...nal control rod assembly 57 to crank assembly 58 3 Install bolt 53 washers 50 and 52 and nut 20 attaching Fwd cockpit directional control rod assembly 59 to crank assembly 58 4 Verify directional control system rigging Ref Section 67 20 00 5 Torque nuts and install new cotter pins 6 Close access panel R128 Ref Section 06 00 00 21 Pedal Directional Control Clevis Assembly A Pedal Directional Contro...

Page 1850: ...otter pins 5 Install floor access panel AR138 Ref Section 53 20 00 6 Install pilot crew seat Ref Section 25 10 00 23 Aft Cockpit Directional Control Rod Assembly A Aft Cockpit Directional Control Rod Assembly Removal Ref Figure 401 1 Remove pilot crew seat Ref Section 25 10 00 2 Remove floor panel AR138 Ref Section 53 20 00 3 Remove and discard cotter pin 19 Remove nut 20 washers 50 and 52 and bol...

Page 1851: ... of control rods might be re quired for installation 2 Install bolt 55 washers 50 and 52 and nut 20 attaching Aft cockpit directional control rod assembly 57 to lower closet bellcrank assembly 61 3 Install bolt 56 washers 50 and 52 and nut 20 attaching closet control rod assembly 63 to lower closet bellcrank assembly 61 4 Verify directional control system rigging Ref Section 67 20 00 5 Torque nuts...

Page 1852: ...ef Section 67 20 00 3 Remove friction device components friction retainer 34 compression spring 35 friction disks 36 friction links 38 Ref Section 67 20 00 4 Remove pedal pivot support 28 pedal shaft assemblies 13 and 17 and pedal crank assemblies 18 and 39 Ref Section 67 20 00 5 Remove attaching hardware that secures directional pedal bracket assembly 5 to airframe structure 6 Remove bracket asse...

Page 1853: ... Potentiometer Installation Ref Figure 401 NOTE Make sure you push potentiometer fully against bracket before you tighten nut 1 Align hole in arm with hole in bracket and install potentiometer Tighten nut sufficiently to prevent movement 2 Connect electrical wires to potentiome ter Ref CSP SPM 3 Do the pedal anticipator rigging 28 Bracket Potentiometer Pedal Anticipator 902 CONFIG A Potentiometer ...

Page 1854: ... 21 20 19 15 16 40 41 14 23 19 24 18 24 42 24 30 29 31 26 24 24 19 23 25 27 43 44 19 20 29 17 19 29 20 29 30 48 30 29 19 20 29 19 29 47 29 39 30 50 51 38 49 49 38 50 20 19 33 32 29 35 34 5 36 36 31 29 30 37 19 20 29 55 50 20 19 29 65 20 19 29 48 64 55 50 28 22 39 45 46 48 Figure 401 Anti Torque Directional Pedal Assembly Sheet 1 of 2 ...

Page 1855: ... 82 78 71 71 71 80 79 80 77 80 83 72 72 74 76 70 72 72 73 69 VIEW ROTATED LOOKING FORWARD REF 18 55 50 52 20 19 9 9 6 4 6 7 8 7 8 19 20 29 29 62 19 20 52 50 53 58 57 63 19 20 52 4 54 50 29 20 19 56 50 19 61 20 19 52 20 52 50 55 56 50 2x 20 19 3 1 2 66 50 59 60 902 CONFIG 48 Figure 401 Anti Torque Directional Pedal Assembly Sheet 2 of 2 ...

Page 1856: ...R 35 COMPRESSION SPRING 36 FRICTION DISK 37 BOLT 38 FRICTION LINK 39 PEDAL CRANK ASSEMBLY LEFT 40 PEDAL SPRING 41 SPRING SUPPORT 42 NUT 43 WASHER 44 SCREW 45 BOLT 46 SPRING RETURN ARBOR 47 BOLT 48 LOWER DIRECTIONAL CRANK ASSEMBLY 49 WASHER 50 WASHER 51 BUSHING 52 WASHER 53 BOLT 54 BOLT 55 BOLT 56 BOLT 57 AFT COCKPIT DIRECTIONAL CONTROL ROD 58 FS 109 000 DIRECTIONAL CRANK ASSEMBLY 59 FORWARD COCKPI...

Page 1857: ...rod assembly 63 Ref Figure 401 to bellcrank assembly 7 3 Verify directional control system rigging Ref Section 67 20 00 4 Torque nuts and install new cotter pins 5 Install FS 155 500 FOD cover 1 Ref Section 67 10 00 6 Install roof panels Ref Section 25 20 00 7 Close access panels T155 and R155 Ref Section 53 30 00 30 Directional Actuator Input Control Rod Assembly A Directional Actuator Input Cont...

Page 1858: ...ty with lockwire C702 for step 1 5 Torque nut and install new cotter pin for step 2 6 Install roof panels Ref Section 25 20 00 32 Hydraulic Anti Torque Directional Actuator A Anti Torque Directional Actuator Removal Ref Figure 402 1 Remove roof panels Ref Section 25 20 00 2 Remove pressure from hydraulic system Ref Section 29 00 00 3 Disconnect hydraulic lines from directional actuator 11 Ref Sect...

Page 1859: ...n actuator bracket 20 and actuator attach bracket assembly 18 to mounting surface 3 Remove bracket 20 B Anti Rotation Actuator Bracket Installation Ref Figure 402 1 Install bolts 19 and washers 10 attaching anti rotation actuator bracket 20 and actuator attach bracket assembly 18 to mounting surface Torque bolts 2 Install roof panels Ref Section 25 20 00 34 Actuator Attach Bracket Assembly A Actua...

Page 1860: ...urface 6 Remove splitter assembly 14 B Splitter Assembly Installation Ref Figure 402 1 Install bolts 27 and washers 4 attaching splitter assembly 14 to roof mounting surface and bolts 19 and washers 4 23 and 29 to vertical mounting surface Torque bolts 2 Connect force limiting control rod assembly 26 Ref Section 67 20 00 to splitter cam 28 3 Connect FS 231 500 directional control rod assembly 25 R...

Page 1861: ...que nuts and install new cotter pins 4 Secure baggage compartment soft insulation roof panels Ref Section 25 50 00 38 Lateral Control Rod Assembly A Lateral Control Rod Assembly Removal Ref Figure 402 1 Gain access to splitter assembly 14 Ref Section 67 20 00 2 Remove and discard cotter pin 2 Remove nut 3 washers 4 and bolt 37 that attach lateral control rod assembly 33 to splitter assembly 14 3 R...

Page 1862: ...ew assembly re move new rod end 60 Do not discard 2 Install bolt 38 washers 4 and nut 3 to secure control rod 26 to outer bellcrank assembly 39 3 Verify directional control system rigging Ref Section 67 20 00 4 Torque nuts 3 and 61 5 Install new cotter pin 2 and safety lock washer 62 using lockwire C702 6 Apply torque stripe Ref CSP SPM Section 20 10 00 Identification Stripe 40 FS 234 000 Directio...

Page 1863: ...rframe mounting surface Torque bolts 2 Install FS 234 000 bellcrank assembly 40 Ref Section 67 20 00 3 Secure baggage compartment soft insulation roof panels Ref Section 25 50 00 42 FS 234 000 Directional Control Rod Assembly A Directional Control Rod Assembly Removal Ref Figure 402 1 Gain access to directional control rod assembly 41 through baggage compartment soft insulation roof panels Ref Sec...

Page 1864: ... to bellcrank assembly 48 4 Torque nuts and install new cotter pins 5 Secure baggage compartment soft insulation roof panels Ref Section 25 50 00 44 FS 277 723 Directional Bracket Assembly A Directional Bracket Assembly Removal Ref Figure 402 1 Gain access to directional bracket assembly 49 through baggage compartment soft insulation roof panels Ref Section 25 50 00 2 Remove FS 277 723 directional...

Page 1865: ...ard cotter pin 55 Remove nut 56 washers 57 and bolt 58 that attach bellcrank assembly 39 to diverter plate assembly Ref Section 53 30 00 5 Remove outer bellcrank assembly 39 B Fan Control Outer Bellcrank Assembly Installation Ref Figure 402 1 Install bolt 58 washers 57 and nut 56 attaching outer bellcrank assembly 39 to diverter assembly Ref Section 53 30 00 2 Install bolt 59 washers 29 and nut 3 ...

Page 1866: ...control shaft assembly 54 to fan control inner bellcrank assembly 45 3 Torque nuts and install new cotter pins 49 NOTAR Fan Control Shaft Assembly A Fan Control Shaft Assembly Removal Ref Figure 402 1 Gain access to diverter plate area Ref Section 53 30 00 2 Remove and discard cotter pin 2 Remove nut 3 washers 4 and bolt 13 that attach forward end of fan control shaft assembly 54 to NOTAR fan asse...

Page 1867: ...9G67_063 1 REF 1 REF 6 REF 12 REF 6 DIVERTER PLATE ASSEMBLY 6 12 25 41 4 2 3 7 9 4 8 4 3 2 REF 6 4 5 4 5 4 3 2 10 21 10 19 20 15 16 4 3 2 24 10 19 23 22 4 17 18 2 3 10 REF CLOSET CONTROL ROD 200 250 in lb 22 59 28 24 N m 11 26 Figure 402 Anti Torque Directional Control Upper Deck Sheet 1 of 2 ...

Page 1868: ... 14 3 4 REF 12 4 13 13 4 4 3 2 4 3 2 28 19 29 29 23 4 31 2 PL 30 2 PL 42 3 2 4 4 13 40 4 3 2 2 3 4 4 13 43 4 44 4 52 2 PL 23 2 PL 4 2 PL 4 50 23 51 13 4 4 58 57 53 4 45 4 3 2 56 55 57 54 3 29 2 59 29 3 2 48 2 19 4 3 4 47 4 49 59 58 57 38 4 26 4 3 2 55 56 57 2 3 29 46 REF 41 2 3 4 13 29 39 60 62 61 95 110 in lb 10 73 12 43 N m REF 63 32 64 2 PL Figure 402 Anti Torque Directional Control Upper Deck ...

Page 1869: ...Y 25 FS 231 500 DIRECTIONAL CONTROL ROD ASSEMBLY 26 FORCE LIMITING CONTROL ROD ASSEMBLY 27 BOLT 28 SPLITTER CAM 29 WASHER 30 BOLT 31 WASHER 32 WASHER 33 LATERAL CONTROL ROD ASSEMBLY 34 WASHER 35 TRACK ROLLER 36 BOLT 37 BOLT 38 BOLT 39 OUTER BELLCRANK ASSEMBLY 40 FS 234 000 DIRECTIONAL BELLCRANK ASSEMBLY 41 FS 234 000 DIRECTIONAL CONTROL ROD ASSEMBLY 42 BOLT 43 FS 234 000 DIRECTIONAL BRACKET ASSEMB...

Page 1870: ... Remove excess sealant 5 Cure sealant for 7 days at room temperature or 4 hours at room temperature followed by 2 hours at 190 210 5F 87 7 98 9 5C 6 Torque cover attach screws 7 Test cover for class R electrical bond Ref CSP SPM Section 20 50 00 51 Rotating Cone Assembly Ref Figure 403 Consumable Materials Ref CSP SPM Item Nomenclature C310 Primer C702 Lockwire A Rotating Cone Assembly Removal 1 R...

Page 1871: ...e 28 69 to 28 71 in 72 87 to 72 92 cm 3 Remove race and trim cone if dimension is not met Solvent Cleaner C429 4 Clean mating surfaces of cone and race with solvent cleaner C429 or equiva lent and air dry for fifteen minutes Adhesive Promoter Epoxy C412 5 Apply adhesive promoter C412 to bearing race Adhesive Epoxy C402 6 Apply epoxy adhesive C402 1 25 to 1 50 in 3 175 to 3 81 cm wide around inner ...

Page 1872: ...ort Bracket Ref Figure 404 Special Tools Ref CSP SPM Item Nomenclature T2015 Tensiometer A Removal 1 Remove rotating cone 2 Remove locking clips from one rotating cone control cable turnbuckle 5 and remove tension from forward rotating cone control cables 6 3 Remove and discard cotter pin 25 Remove nut 24 and washer 16 4 Remove screws 33 and washers 16 Remove support bracket 30 B Installation 1 In...

Page 1873: ...t sector guard clip and glass fiber laminate C502 in their installed position Install rivets wet with primer C310 3 Install sector support bracket 55 Sector Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire Special Tools Ref CSP SPM Item Nomenclature T2015 Tensiometer A Sector Removal 1 Remove sector support bracket 2 Remove remaining locking clips from rotating cone ...

Page 1874: ...s 22 and 37 3 Remove sector rigging plate 4 Remove bolts 43 washers 16 and sector support shaft 41 B Sector Support Shaft Installation Sealing Compound C205 1 Apply sealing compound C205 to mating surfaces of sector rigging plate sector support shaft and sector brack et 2 Install sector support shaft sector rigging plate bolts and washers Torque bolts 3 Install washers 4 Install sector 58 Sector S...

Page 1875: ...702 2 Connect forward and aft control cables to turnbuckles 3 Adjust tension of rotating cone control cable to 36 44 lbs 16 33 19 96 kg use tensiometer T2015 Install turnbuckle locking clips 4 Install rotating cone 5 Do the Anti Torque Directional Controls Travel Rigging Verification 60 Rotating Cone Aft Control Cable Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C225 Sealing a...

Page 1876: ...ami nated washers is not be necessary if pulley bracket or thruster is not a replace ment Primer C310 1 Install pulley bracket laminated washers bolts and washers Install bolts wet with primer C310 Torque bolts 2 Install rotating cone aft control cables C Control Cable Pulley Removal NOTE This task is typical for left or right control cable pulley It is not necessary to remove cable from control c...

Page 1877: ...und jumper terminal lug ground jumper terminal lug washer and collar use sealing compound C205 Ref CSP SPM 5 Install washers on drum bracket shaft 6 Install drum 7 Do the Anti Torque Directional Controls Travel Rigging Verification 64 Wire Braid Ground Jumper Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C205 Sealing Compound C310 Primer A Wire Braid Ground Jumper Removal 1 Rem...

Page 1878: ...upport Bearing Removal 1 Remove rotating cone 2 Remove bolt 9 washers 10 and 13 and support bearing 11 B Rotating Cone Support Bearing Installation 1 Install support bearing washers and bolt Torque bolt Before you install rotating cone make sure all support bearings turn freely 2 Install rotating cone 66 Lightning Strike Shield Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C205...

Page 1879: ...in rivet 29 washer 16 and the ends of ground jumper 14 and wire braid ground jumper 55 B Installation 1 Prepare mating surfaces of drum bracket 8 ground jumper 14 lightning strike shield 15 washers 16 and wire braid ground jumper 55 for electrical bond ref CSP SPM Section 20 50 00 Primer C308 Primer Epoxy C317 Acetone C436 Add acetone C436 to make epoxy primer C317 more li quid Do not use water as...

Page 1880: ... 6 PL 16 6 PL 31 2 PL REF 6 40 16 2 PL 43 2 PL 42 39 44 6 PL 41 38 2 PL 16 2 PL 16 2 PL 35 2 PL REF 4 REF 3 36 30 16 22 37 14 51 2 PL 50 2 PL 49 2 PL 16 2 PL 47 2 PL 16 2 PL 48 2 PL 46 54 2 PL 52 2 PL 45 2 PL 52 2 PL 16 27 29 27 28 3 PLACES 15 16 6 PL 17 6 PL 18 16 55 REF 14 NOTE 48 2 PL 47 2 PL 49 2 PL 8 13 10 11 10 9 54 16 53 5 PL 16 5 PL 53 16 55 LOOKING INBOARD LOWER LEFT SIDE Figure 404 Thrus...

Page 1881: ...IN CONTROL CABLE PULLEY 50 COTTER PIN 51 NUT 52 WASHER 53 RIVET 54 BOLT 55 WIRE BRAID GROUND JUMPER Sealing Compound C205 7 Environmentally seal ground jumper 14 with sealing compound C205 ref CSP SPM Section 20 50 00 8 Install the rotating cone 68 Rotating Cone Control Rod Ref Figure 405 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire A Removal 1 Remove rotating cone 17 2 Remove ...

Page 1882: ...ntrol System Travel Rigging Check ref Section 67 20 00 Inspection Test Rigging 69 Thruster Ref Figure 405 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire A Removal 1 Remove rotating cone 17 2 Remove lockwire bolt 21 and washer 3 a Discard the lockwire Hold the thruster while you re move the last bolt 3 Remove bolts 19 washers 3 and thruster 18 B Installation 1 Prepare the mating s...

Page 1883: ...24 REF 16 2 PL 3 2 PL 25 26 3 7 3 23 24 14 2 PL NOTE 2 2 2 PL 16 2 PL 3 2 PL 23 REF 28 3 2 PL 29 2 PL 31 2 PL 30 27 16 2 PL 3 2 PL 22 3 19 10 PL 3 3 PL 3 3 PL 5 6 9 10 11 13 3 PL 18 14 2 PL 22 REF 22 REF REF 23 WITNESS HOLE 32 20 REF 21 3 VIEW ROTATED 90 CW 33 35 35 REF 36 12 PL 3 2 PL 37 2 PL 17 38 Figure 405 Thruster and Forward Directional Control Cable Sheet 2 of 2 ...

Page 1884: ...ckwire C702 5 Install rotating cone 6 Do the Anti Torque Directional Control System Travel Rigging Check ref Section 67 20 00 Inspection Test Rigging 70 Forward Directional Control Cable Ref Figure 405 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire A Removal 1 Remove baggage compartment ceiling panels ref Section 25 50 00 2 Remove cotter pin 5 nut 4 washers 3 and bolt 1 a Discard...

Page 1885: ...fitting down on flat surface d Carefully bend the two ends of control in opposite directions until it is in the shape of an 8 e If necessary to fit into a shipping container pull the two ends to make the 8 smaller NOTE Continue to carefully bend the two ends in opposite directions until the cable is in the shape of two 8 one on top of the other Do not tighten wire too much f Carefully put a wire a...

Page 1886: ...ire C702 NOTE Telescopic part also functions as a jam nut for cable rod end bearing 10 Install forward telescopic part on forward directional control cable tighten with your hand 11 Install serrated tab washer and rod end bearing tighten with your hand 12 Connect rod end bearing to bellcrank with bolt washers and nut a Torque nut b Install new cotter pin Control Rod Thread Engage ment 13 Pre SB900...

Page 1887: ...nk with bolt washers and nut a Torque nut b Install new cotter pin Control Rod Thread Engage ment 6 Torque telescopic part 60 to 80 in lb 6 78 to 9 04 Nm a Safety with lockwire C702 7 Do the Anti Torque Directional Control System Travel Rigging Check ref Section 67 20 00 Inspection Test Rigging 8 Install baggage compartment ceiling panels ref Section 25 50 00 72 Forward Directional Control Cable F...

Page 1888: ...9 3 1 3 PL 2 3 PL 7 4 PL 8 4 PL 10 12 3 PL 11 3 PL 3 1 3 PL 2 3 PL 4 4 PL 5 4 PL 6 RH AVIONICS BAY LH AVIONICS BAY 1 SCREW REF IPL 67 20 00 FIG 11 2 WASHER 3 CONTROL UNIT 4 SCREW 5 WASHER 6 YAW RATE GYRO 7 SCREW 8 WASHER 9 ACCELEROMETER 10 BRACKET 11 SCREW 12 WASHER Figure 406 Removal and Installation of the VSCS Equipment ...

Page 1889: ...igging 7 Install Access Panel L109 or R128 ref Section 06 00 00 75 Yaw Rate Gyros Ref Figure 406 A Removal Typical 1 Remove Access Panel L109 or R128 ref Section 06 00 00 Make sure gyro has stopped be fore you remove it Damage to gyro can occur Power Off 2 Make sure all electrical power is removed from the rotorcraft ref CSP 900RMM 3 Section 96 00 00 3 Disconnect Electrical Connector P175 or P176 ...

Page 1890: ...ter so that the arrow points inboard 4 If the arrow is missing from accelerom eter 9 do this procedure a Apply electrical power to the rotor craft with ground power unit T2002 ref Section 96 00 00 b Tilt accelerometer 9 approximately 455 right c Do a check for movement of the right horizontal endplate trailing edge to the right 1 If the horizontal endplate moves the trailing edge left the accel er...

Page 1891: ...CSP SPM Item Nomenclature C702 Lockwire C205 Sealing Compound 1 Install actuator 5 spring washer 14 and alignment cup 15 with bolt 12 and washers 13 11 a Safety with lockwire C702 2 Install bolt 10 washers 8 9 and nut 7 that connect VSCS control rod 16 to crank a Install new cotter pin 6 3 Prepare bond jumper 3 and actuator 5 for a Class L electrical bond ref CSP SPM Section 20 50 00 4 Connect bon...

Page 1892: ...IGHT SIDE OPPOSITE 9G67 046B 10 9 8 7 6 29 28 4 PL 26 4 PL 27 4 PL 25 4 PL 24 4 PL 16 5 4 23 22 2 PL 21 2 PL 19 2 PL 18 2 PL 30 31 ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ REF 37 32 33 2 PL 34 35 36 46 2 PL 12 13 11 15 14 17 30 2 PL 1 2 3 Figure 407 Assembly of the Vertical Stabilization Control System ...

Page 1893: ...Typical Consumable Materials Ref CSP SPM Item Nomenclature C220 Compound Anti Seize C702 Lockwire Compound Anti Seize C220 1 Apply anti seize compound C220 to the threads in control rod 2 Clean anti seize compound C220 from the end of control rod 16 3 Install control rod 16 a Adjust the control rod to dimension recorded in Step 78 A 2 a b Torque nut 17 c Safety with lockwire C702 4 If there is no ...

Page 1894: ...val 1 Remove control rod 16 2 Remove cotter pins 18 nuts 19 washers 20 21 and bolts 22 a Discard cotter pins 18 3 Remove tube adapter 23 4 Remove nut 17 B Installation Consumable Materials Ref CSP SPM Item Nomenclature C220 Compound Anti Seize C702 Lockwire 1 Install nut 17 on tube adapter 23 Compound Anti Seize C220 2 Apply a thin layer of anti seize com pound C220 to the part of tube adapter 23 ...

Page 1895: ...p are installed do not permit the sealing compound to touch the spar tube bearings 3 Turn spar tube 30 as necessary to install bellcrank 31 and bellcrank strap 29 with bolts 28 washers 26 27 and nuts 25 a Torque nuts 25 b Install new cotter pins 24 4 Install bolt 10 washers 8 9 and nut 7 that connect VSCS control rod to crank a Torque nut 7 b Install new cotter pin 6 5 Do the VSCS Rigging Procedur...

Page 1896: ...PM Section 20 50 00 Make sure the clamp does not scratch or nick the spar tube 5 Install clamp 34 screw 36 bond jumper 35 washers 33 and nut 32 a Torque nut 32 6 Test the spar tube for a Class L electrical bond ref CSP SPM Section 20 50 00 Sealing Compound C205 7 Environmentally seal clamp 34 and bond jumper 35 with sealing com pound C205 ref CSP SPM Section 20 50 00 8 Install the upper and lower ...

Page 1897: ...amine control tubes and rod or clevis ends for condition and correct installa tion No damage or incorrect installa tion permitted 3 Examine bearings and or bushings for rough operation corrosion and play None permitted 4 Examine all linkages for condition and correct installation No damage or incorrect installation permitted 5 Examine bellcranks and brackets for condition and correct installation ...

Page 1898: ...nc Rotorcraft Maintenance Manual Page 602 Revision 35 67 20 00 5 4 20 1 6 3 TO ANTI TORQUE FAN TO THRUSTER CONTROL BELLCRANK 7 11 2 21 22 TO THRUSTER CONTROL 8 9 9G67 050 1B Figure 601 Anti Torque Directional Controls Sheet 1 of 2 ...

Page 1899: ...LY 17 AFT CABLE ASSEMBLY 18 CONTROL CABLE DRUM ASSEMBLY 19 CABLE DRUM BRACKET ASSEMBLY 20 PEDAL INTERCONNECT CONTROL ROD ASSEMBLY 21 PEDAL FRICTION DEVICE 22 PEDAL STOPS 23 THRUSTER CONTROL BEARINGS 24 SUPPORT BRACKET 25 TURNBUCKLE LOCKING CLIPS Figure 601 Anti Torque Directional Controls Sheet 2 of 2 D Anti Torque Directional Controls System Inspection Area 6 Ref Figure 601 1 Examine directional ...

Page 1900: ...rrect installation No damage or incorrect installation permitted 5 Examine bellcranks and brackets for condition and correct installation No damage or incorrect installation permitted 6 Examine all hardware for condition correct installation and locking devices Torque fasteners and replace locking devices as necessary 7 Deleted 8 Examine VSCS system for condition and operation ref VSCS Operational...

Page 1901: ... 00 00 2 Move right directional pedal full forward until it touches stop Move left directional pedal full forward until it touches stop and then back to neutral position Directional pedals must move freely through full range of travel Do not manually turn rotating cone more than one half left or right open 3 Make sure rotating cone moves freely thru its full range of travel 4 Make sure anti torque...

Page 1902: ...2 1 6 3 TO ANTI TORQUE FAN 7 12 2 23 24 TO THRUSTER CONTROL 8 9 9G67 018 1G 34 REF 4 REF 24 30 40 50 607080 90 20 10 VIEW ROTATED 33 31 30 40 50 607080 90 20 10 30 40 50 607080 90 20 10 335 355 FAN RIG 795 815 RIGHT 865 875 LEFT Figure 602 Anti Torque Directional Control System Rigging Sheet 1 of 2 ...

Page 1903: ...DAL RIG 9G67 018 2F VIEW LOOKING UP 7 VIEW ROTATED 14 18 18 17 17 19 19 21 20 15 11 REF 12 35 36 37 25 26 27 28 29 26 902 CONFIG REF 14 30 ÎÎ ÎÎ LOOKING OUTBOARD RIGHT SIDE 1 950 2 010 in 4 953 5 105 cm REF 2 REF 1 13 38 REF 15 16 32 Figure 602 Anti Torque Directional Control System Rigging Sheet 2 of 2 ...

Page 1904: ...onal Control System Travel Rigging Check Ref Figure 602 Special Tools Ref CSP SPM Item Nomenclature T2001 Hydraulic Mule Moving Flight Controls 1 Apply 500 psig 3447 5 kPa hydraulic pressure to aircraft System 2 Hy draulics with hydraulic mule T2001 ref Section 29 00 00 2 Put pilot s left pedal full forward against stop and make sure anti torque fan angle is 86 to 87 Do not manually turn thruster ...

Page 1905: ...rod end does not twist Damage to the rod end bearing can occur Control Rod Thread Engage ment 3 Adjust directional control rod 3 so distance from actuator attach bracket 2 to body of actuator 1 is 1 950 to 2 010 inch 4 953 to 5 105 cm a Torque control rod 3 b Safety control rod 3 4 Remove hydraulic pressure from the system ref Section 29 00 00 Control Rod Thread Engage ment 5 Do not move actuator ...

Page 1906: ... forward end of cable 8 cable forward attach point 31 aft attach point 30 or control rod 14 if necessary Torque and safety all hardware 23 Make sure rod ends and bellcranks do not touch 24 Make sure all hardware is tight and safetied 25 Install the rotating cone 13 26 Put pilots left pedal full forward 27 Without thruster extension Find index rivet 35 and left side index hole 36 NOTE A dot can be ...

Page 1907: ...edal Forces Adjustment ref Procedure 1 K 39 Disconnect hydraulic mule T2001 from rotorcraft ref Section 29 00 00 J Pedal Anticipator Transducer Rigging 902 CONFIG Ref Figure 602 Special Tools Ref CSP SPM Item Nomenclature T1001 Analog Multimeter Portable T501 4 Rig Pin 3 75 In Long Moving Flight Controls 1 Apply 500 psig 3447 5 kPa hydraulic pressure to System 2 Hydraulics with hydraulic mule T200...

Page 1908: ...2 Put the pilot s directional control pedals in their mid travel position 3 Attach digital pull gage T2023 or equivalent to pilot s left or right pedal and measure breakaway force 4 While holding bolt 2 adjust nut 3 as necessary to get 5 to 10 pounds 2 27 to 4 54 kg breakaway force 5 Disconnect hydraulic mule T2001 from rotorcraft ref Section 29 00 00 1 2 3 PILOTS PEDAL ASSEMBLY 9G67 052A 1 PILOT ...

Page 1909: ...els have a sealing compound gasket formed at installation Do not re move sealing compound from access panels 10 Install access panels SL7 and SR7 ref Section 06 00 00 B VSCS Spar Tube Inspection Area 7 1 Remove VSCS spar tube 2 Inspect spar tube body a No discrepancies permitted 3 Inspect spar tube sleeves for gouges scratches and corrosion a Maximum depth 0 020 inch 0 51 mm b Minimum diameter 2 3...

Page 1910: ...ROTATED LH LOOKING FORWARD 2 6 2 REF 5 5 9G67 019G 8 9 14 10 11 12 13 1 LEFT VSCS ACTUATOR 2 VERTICAL ENDPLATE RIG PIN 3 DELETED 4 LEFT CONTROL ROD 5 LEFT HORIZONTAL ENDPLATE 6 RIGHT HORIZONTAL ENDPLATE 7 HORIZONTAL STABILIZER 8 SPAR TUBE SLEEVE 9 SPAR TUBE 10 BELLCRANK 11 BOLT 12 RIVETS QUANTITY 3 OR 5 13 VSCS ACTUATOR ATTACH BRACKET 14 BELLCRANK STRAP Figure 604 VSCS System ...

Page 1911: ...power unit T2002 ref CSP 900RMM 3 Section 96 00 00 Do not look at the VSCS test box switch placard when you do the steps that follow Look at the right horizontal endplate and make sure its trailing edge is fully left Damage to VSCS control system can oc cur 13 Fully retract right VSCS actuator with stabilizer test box T1009 Control Rod Thread Engage ment 14 Put vertical endplate rig pin T502 1 2 a...

Page 1912: ...g 6894 8 kPa hydrau lic pressure to Hydraulic System Number 1 with hydraulic mule T2001 ref Section 29 00 00 3 Move VSCS ON OFF TEST switch on cockpit utility panel from ON position to TEST position and back to ON position a A VSCS fault indication must show on the IIDS display b If system tests good the fault lights will go off after approximately 5 to 8 seconds Moving Flight Controls 4 Raise the...

Page 1913: ...Test Box Right Installation Typical E VSCS Fault Isolation Procedure Ref Figure 605 Special Tools Ref CSP SPM Item Nomenclature T1009 Stabilizer Test Box T1001 Analog Multimeter Portable T2002 Ground Power Unit T2001 Hydraulic Mule NOTE This failure isolation procedure will test left or right system to find defective system components or damaged wires Do the steps that follow until a defect or dam...

Page 1914: ... accelerometer 1805 if the horizontal endplate moves trailing edge left because the accelerometer polarity is incorrect 12 Put analog multimeter T1001 leads into collective position jacks of stabiliz er test box T1009 Moving Flight Controls 13 Apply 1000 psig 6894 8 kPa hydrau lic pressure to Hydraulic System Number 1 with hydraulic mule T2001 ref Section 29 00 00 14 Lower collective stick to its ...

Page 1915: ...ght Controls 30 Apply 1000 psig 6894 8 kPa hydrau lic pressure to Hydraulic System Number 1 with hydraulic mule T2001 ref Section 29 00 00 31 Lower collective stick to full down position 32 Make sure there is 7 4 0 2 volts shown on analog multimeter T1001 a Adjust the potentiometer if the voltage indication is incorrect ref Section 67 10 00 NOTE Horizontal endplate movement occurs over a collectiv...

Page 1916: ...PL 3 1 REF 6 4 PL 7 4 PL 5 6 4 PL 9 2 PL 8 2 PL 10 2 PL 8 2 PL 1 REF NOTE EMPENNAGE AND FRAMES NOT SHOWN 1 TAILBOOM ASSEMBLY REF IPL 53 40 10 FIG 1 2 BRACKET ASSEMBLY 3 LOCKPLATE 4 DOUBLER 5 FORWARD CABLE ASSEMBLY 6 WASHER 7 SCREW 8 WASHER 9 BOLT 10 NUT Figure 606 Special Inspection of FS 401 73 Cable Attachment Bracket Assembly ...

Page 1917: ...tion a No cracks damage or deformation permitted 8 If installed examine lockplates 3 for cracks damage deformation and loose nutplates a No cracks damage deformation or loose nutplates permitted 9 Examine forward cable assembly 5 for damage and deformation a No damage or deformation permitted 10 Examine bracket assembly 2 for cracks damage deformation and loose nutplates a No cracks damage deforma...

Page 1918: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 622 Revision 35 67 20 00 This page intentionally left blank ...

Page 1919: ...urfaces Ref CSP SPM NOTE Repaired ferrous metal surfaces non corrosive resistant steels require treatment equivalent to original anodized surface treatment 3 Adapter Fitting Replacement Consumable Materials Ref CSP SPM Item Nomenclature C112 Hydraulic Fluid C212 Sealing Compound Corrosion Inhibitive Special Tools Ref CSP SPM Item Nomenclature T606 1 Removal Tool Supply Adapter T606 2 Combination W...

Page 1920: ...e 804 NOTE Scratches dings and rough spots are not allowed in the O ring contact area on the adapter or in the port Hydraulic Fluid C112 1 Lubricate internal surfaces of port and entire adapter 2 using hydraulic fluid C112 NOTE To avoid possible damage to O ring adapter should not be rotated in a counter clockwise direction 2 By hand using a clockwise rotation insert smaller thread of adapter 2 in...

Page 1921: ...g counter clockwise Retract lockring by following Lockring Re traction steps Tighten fitting clockwise as described in steps 3 and following until serrations are aligned Again attempt to install lockring 7 With socket or open end wrench over wrench drive tool turn in clockwise direction until tool bottoms on port surface Ref Figure 804 Visually observe that the tool has bottomed 8 Run a bead of se...

Page 1922: ... PULLER HALVES 1 SLEEVE RETRACTED PULLER HALVES READY TO BE LOCATED IN LOCKRING GROOVE SLEEVE OVER PULLER HALVES READY FOR LOCKRING RETRACTION 9g67 048 2 3 2 4 ÇÇ ÇÇ ÈÈ ÈÈ ÈÈ ÈÈ ÈÈ ÈÈ ÈÈ ÈÈ ÈÈ ÈÈ È ÉÉÉ ÉÉÉ ÉÉÉ Í Í Í Í Í Í Í Í Í Í Í Í 1 LOCKRING 2 ADAPTER FITTING 3 REMOVAL TOOL 4 NYLON PAD Figure 802 Lockring Retraction 2 O RING AFTER ASSEMBLY 3 O RING BEFORE ASSEMBLY 9g67 048 1 1 1 O RING 2 ADAPTE...

Page 1923: ...ls Ref CSP SPM Item Nomenclature C802 Cloth Non Lint Do not hold actuator housing when you loosen the nut Dam age to splined housing can occur 1 Remove lockwire from lockwasher 3 and nut 2 2 Hold hex on end of output shaft 4 and loosen nut 2 3 Remove rod end 1 nut 2 and lockwasher 3 4 Mark notch in output shaft 4 on electrical connector side of actuator with a pencil 5 Measure end play of actuator...

Page 1924: ...little force to remove the shaft 12 Turn output shaft 4 counterclockwise and remove it from motor housing 9 with LVDT core 11 and attached hardware Do not loosen the nylon screw or LVDT core NOTE If necessary hold the splined housing with a rubber tipped tool Use care when you remove the splined housing There are loose parts installed between the splined housing and motor housing 13 Remove splined...

Page 1925: ...o not let too much grease be removed from acme nut threads by belleville spring 4 Install output shaft until inboard end of spline is approximately flush with end of motor housing and notch with pencil mark aligned with electrical connector 5 Fully fill grooves in splined housing with grease 6 Install splined housing Align inspec tion seal or tape 7 Apply a film of grease to seal housing where sea...

Page 1926: ...1 12 13 14 A B 9g67 065A 16 10 11 NOTE ALIGN THESE TWO EDGES 1 ROD END 2 NUT 3 LOCKWASHER 4 OUTPUT SHAFT 5 SEAL HOUSING 6 SPLINED HOUSING 7 OUTER CAVITY 8 ACME NUT THREADS 9 MOTOR HOUSING 10 INNER CAVITY 11 LVDT CORE 12 SHIM 13 SHIM 14 SHIM 15 SPACER 16 BELLEVILLE SPRING 17 BELLEVILLE SPRING 18 SPACER 19 SHIM 20 SHIM 21 SHIM 22 SCREW Figure 805 VSCS Actuator ...

Page 1927: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual POWERPLANT Chapter ...

Page 1928: ......

Page 1929: ...2 Engine Sensor Wiring Diagram Sheet 1 of 2 111 2 Starter System Troubleshooting 113 Table 103 Starter System Troubleshooting 113 3 Ignition System Troubleshooting 114 Table 104 Ignition System Troubleshooting 114 Figure 103 Start Sequence Wiring Diagram Sheet 1 of 3 115 Removal Installation 401 1 Powerplant 401 A Engine Removal 401 Figure 401 Engine Bonding Jumper and Wire Harness Clamps 402 Figu...

Page 1930: ...auge Engine Alignment 604 6 Engine Ignition Functional Test 605 A Helicopter Serial Number 900 000008 thru 900 000124 605 B Helicopter Serial Number 900 000125 and Subsequent 606 71 20 00 Engine Mounts A Description and Operation 1 1 Mounts 1 Figure 1 Engine Mounts 1 Removal Installation 401 1 Tripod Mount Assembly 401 A Tripod Mount Assembly Removal 401 B Tripod Mount Assembly Installation 401 2 ...

Page 1931: ... Wash System 4 3 Generator Cooling Modification Optional 5 Figure 4 Generator Cooling Modification 5 Fault Isolation 101 1 Inlet Particle Separator NACA Inlet System Troubleshooting 101 Table 101 Inlet Particle Separator System Troubleshooting 101 Figure 101 Inlet Particle Separator Wiring Diagram Sheet 1 of 2 102 Removal Installation 401 1 Inlet Panel Assembly 401 A Inlet Panel Assembly Removal 4...

Page 1932: ...tallation 406 9 Naca Inlet Door Actuator Assembly 406 A Inlet Door Actuator Assembly Removal 406 B Inlet Door Actuator Assembly Installation 406 10 Inlet Flapper Door Assembly 407 A Flapper Door Assembly Removal 407 B Flapper Door Assembly Installation 407 11 Flapper Door Shaft 407 A Door Shaft Removal 407 12 Door Shaft Installation 408 Figure 403 Naca Inlet Assembly Sheet 1 of 2 408 13 Engine Was...

Page 1933: ...ription and Operation 1 1 Engine Drain System 1 A Combustor Drain Tube Assembly 1 B Forward Drain Tube Assembly 1 C Fuel Catch Can Assembly Optional 1 Figure 1 Engine Drain Lines and Optional Fuel Catch Can 2 Removal Installation 401 1 Engine Drain Lines 401 A Engine Drain Line Removal 401 B Engine Drain Line Installation 401 Figure 401 Engine Drain Lines 402 2 Fuel Catch Can Assembly Optional 403...

Page 1934: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Page vi Revision 34 71 Contents TABLE OF CONTENTS Cont Para Figure Table Title Page This page intentionally left blank ...

Page 1935: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 71 00 00 Powerplant ...

Page 1936: ......

Page 1937: ... for each engine Oil Pressure lubrication oil scavenge and filtration for each engine Powerplant Controls Controls inputs for each engine EEC system operation or backup mechanical throttle control for each engine Engine Indicating Supplies cockpit indications of each engines operational performance Starting Start system for each engine Drains Drain system for each engine s oil and fuel Bleed Air P...

Page 1938: ...izes fuel from the fuel storage subsystem The PW206E PW207E have a suction feed system as a back up feed mode Pressure Oil Pump Drive Pad Internal drive that drives the integral oil pump Accessory Drive Pad External drive pad for optional gearbox driven accessories Turbomachinery Module The turbomachinery module operates the reduction gearbox The system uses the EEC to give engine operational para...

Page 1939: ...206A ignition system supplies each engine with light ups over a wide temperature range The system energizes from the battery bus through the auto ignition relay The system generates from 9 to 30 Vdc Ignition Exciters Ignitor Box There is one engine ignitor box for each engine The ignitor box attaches to the airframe The ignition exciters supply a pulsed high voltage output 3000 volts When the igni...

Page 1940: ...n the PW206E PW207E engine encloses the FMU fuel pump and filter This is a requirement for Category A opera tion The purpose of a shroud is to contain vapors or fuel that may emanate from the system 9G71 001A TURBOSHAFT ENGINE STARTER GENERATOR IGNITOR CABLES IGNITOR BOX FORWARD FIRESEAL AFT FIRESEAL 902 CONFIG FMU SHROUD 900 CONFIG Figure 1 Powerplant ...

Page 1941: ... Corrective Action Ref Section No NG DD on IIDS Faulty EEC Ref P WC Fault Isolation Charts Ref Directives and Related Manufacturers Publications 01 00 00 Incorrect starting procedure Perform dry motoring run and repeat starting procedure Ref appropriate Rotorcraft Flight Manual in Directives and Related Manufacturers Publications RFM Faulty engine wiring harness Test and repair engine wiring harne...

Page 1942: ...ppropriate Rotorcraft Flight Manual in Directives and Related Manufacturers Publications RFM Low battery voltage Ref battery fault isolation guide 96 10 00 Replace battery Faulty IIDS Replace IIDS 95 30 00 Faulty engine Rectify engine problem Ref Directives and Related Manufacturers Publications 01 00 00 Faulty starter Ref starter fault isolation guide Ref Directives and Related Manufacturers Publ...

Page 1943: ...ider Ref Directives and Related Manufacturers Publications 01 00 00 Restricted fuel filter Replace fuel filter Ref Directives and Related Manufacturers Publications 01 00 00 Contaminated fuel system Perform the Contaminated Fuel Cell Procedure 28 00 00 Blocked fuel nozzles Clean fuel nozzles Ref Directives and Related Manufacturers Publications 01 00 00 Replace fuel nozzles Hot start Faulty EEC Re...

Page 1944: ...ed Manufacturers Publications RFM Obstructed or covered engine inlet or exhaust duct Clear inlet or exhaust duct Ref appropriate Rotorcraft Flight Manual in Directives and Related Manufacturers Publications RFM Faulty PLA rigging Test PLA rigging 76 00 00 Faulty exhaust gas temperature indication system Test MGT indication system Ref Directives and Related Manufacturers Publications 01 00 00 Fault...

Page 1945: ...ight Manual in Directives and Related Manufacturers Publications RFM Faulty detent module Replace detent module 67 10 00 Faulty fuel flow divider Replace fuel flow divider Ref Directives and Related Manufacturers Publications 01 00 00 Restricted fuel filter Replace fuel filter Ref Directives and Related Manufacturers Publications 01 00 00 Contaminated fuel system Perform the Contaminated Fuel Cell...

Page 1946: ...zles Faulty FMU Replace FMU Ref Directives and Related Manufacturers Publications 01 00 00 Slow to accelerate Faulty EEC Ref P WC Fault Isolation Charts Ref Directives and Related Manufacturers Publications 01 00 00 Faulty PLA rigging Test PLA rigging 76 00 00 Faulty fuel flow divider Replace fuel flow divider Ref Directives and Related Manufacturers Publications 01 00 00 Restricted fuel filter Re...

Page 1947: ...r pump on no fuel filter impending bypass indication and adequate fuel on board Faulty PLA rigging Test PLA rigging 76 00 00 Faulty fuel flow divider Replace fuel flow divider Ref Directives and Related Manufacturers Publications 01 00 00 Faulty fuel pump Replace fuel pump Ref Directives and Related Manufacturers Publications 01 00 00 Faulty FMU Replace FMU Ref Directives and Related Manufacturers...

Page 1948: ... fuel flow divider Ref Directives and Related Manufacturers Publications 01 00 00 Faulty Ng or Npt speed probe Replace speed probe Ref Directives and Related Manufacturers Publications 01 00 00 Faulty IIDS Replace IIDS 95 30 00 Faulty FMU Replace FMU Ref Directives and Related Manufacturers Publications 01 00 00 System Inspection 05 50 00 Engine overtorque System Inspection 05 50 00 Engine vibrati...

Page 1949: ... 00 00 Faulty IIDS Replace IIDS 95 30 00 Failure to pass power assurance check Obstructed or covered engine inlet Perform inlet particle separator or inlet plenum inspection Clear inlet 71 60 00 Engine impeller dirty Perform performance recovery engine wash Ref appropriate Rotorcraft Flight Manual in Directives and Related Manufacturers Publications RFM Bleed air leak Inspect bleed air fitting and...

Page 1950: ...anual Page 110 Revision 1 71 00 00 9G71 008A 1 2 3 4 5 6 4 VIEW LOOKING AFT SOME DETAILS REMOVED FOR CLARITY 900 CONFIG ENGINE SHOWN 1 T1 T6 JUNCTION 2 T6 THERMOCOUPLE 3 T1 SENSOR 4 NG SPEED SENSOR 5 NPT SPEED SENSOR 6 TORQUE SENSOR Figure 101 Engine Sensors ...

Page 1951: ... 4 3 2 1 9 8 7 12 11 10 1 2 54 53 51 52 52 51 2 1 54 53 J3 P103 IID S A2 NG RIGHT HI NG RIGHT LO EGT RIGHT LO EGT RIGHT HI NP RIGHT HI NP RIGHT LO NP LEFT LO NP LEFT HI EGT LEFT HI EGT LEFT LO NG LEFT LO NG LEFT HI D P P P P P P P P P P P P P P P P P P P P P F W142 W143 W143 W142 W122 W142 W123 P A B C 9G71 009 1 E Figure 102 Engine Sensor Wiring Diagram Sheet 1 of 2 ...

Page 1952: ... PHASE C STEPPER MOTOR PHASE A STEPPER MOTOR PHASE B STEPPER MOTOR EXCIT OVERSPEED SOLENOID RTN OVERSPEED SOLENOID PWR NG A RTN NG A SIGNAL NG B RTN NG B SIGNAL NPT QB RTN NPT QB SIGNAL MGT TRIM RTN MGT TRIM 429 IN LO 429 IN HI 429 OUT LO 429 OUT HI TTI RTN TTI LO TTI HI EGT LO EGT HI PMA PHASE A PMA PHASE B PMA PHASE C TQ RTN TQ LO TQ HI NPT QA RTN NPT QA SIGNAL WF E1 WF COMMON WF E2 WF EXCIT LO ...

Page 1953: ...stem Troubleshooting Fault Probable Cause Corrective Action Ref Section Starter does not operate Faulty airframe wiring Test and repair wiring 98 00 00 Faulty key switch Replace key switch 96 00 00 Faulty engine control switch Replace engine control switch 96 00 00 Faulty start relay Replace start relay 96 00 00 Faulty start enable relay Replace start enable relay 96 00 00 Faulty start enable EEC ...

Page 1954: ...al Ref Figure 103 Table 104 Ignition System Troubleshooting Fault Probable Cause Corrective Action Ref Section Ignitors do not operate Faulty airframe wiring Test and repair wiring 98 00 00 Faulty ignitor box Replace ignitor box 71 00 00 Faulty ignitor Replace ignitor Ref Directives and Related Manufacturers Publications 01 00 00 Faulty ignitor cable Replace ignitor cable Ref Directives and Relate...

Page 1955: ...1 LH IGNITOR BOX W123 E H P377 P376 H P171 P170 J3 J1 6 1 P150 J1 J1 P150 A650 DETENT MODULE S R A612 FWD INTERCONNECT PANEL W123 W122 LEFT ENGINE THROTTLE SHOWN IN NORMAL OR AUTO POSITION WHERE EEC IS IN CONTROL LEFT ENGINE SHOWN ONLY NOTE W122 SH 2 C SH 2 A SH 2 B 9G71 022 1C Figure 103 Start Sequence Wiring Diagram Sheet 1 of 3 ...

Page 1956: ...76 J4 H M L J K P375 J1 D 14 R P N X2 X1 A3 A1 A2 K J L M TB1 5 1 2 A2 A1 A3 X1 X2 B2 B1 B3 11 12 13 X2 X1 A2 A1 23 22 E1 16 21 TB1 8 H G E F FROM BATTERY OR EXTERNAL POWER NOTE LEFT ENGINE SHOWN RIGHT ENGINE IS TYPICAL RELAYS SHOWN IN START MODE FROM SELECTION OF IDLE OR FLY ON ENGINE CONTROL PANEL E S1 MANUAL START SWITCH START RELAY K1 LH START ENABLE RELAY K8 6 E SH 3 E SH 3 F SH 3 G SH 3 H SH...

Page 1957: ...A201 LEFT EEC START INHIBIT ZS D P341 J1 J1 P341 J A Y X STARTER GENERATOR SPEED SENSE START RELAY CONTROL START INPUT A409 LH GCU P411 J1 B A P P A407 LH STARTER GENERATOR P131 J1 11 BAT BUS 5A CB1 L GCU A601 CIRCUIT BREAKER PANEL P377 C P375 D 1 2 16 E SWITCHES SHOWN IN START POSITION FOR LEFT ENGINE RIGHT ENGINE IS TYPICAL TB1 B E GS403 NOTE E W124 E SH 2 D SH 2 F SH 2 H SH 2 J SH 2 K SH 2 G SH...

Page 1958: ......

Page 1959: ...f Section 12 00 00 NOTE Residual oil could remain in oil lines When removing oil lines or components take precautions to catch oil with rags or a suitable container 3 Verify helicopter electrical power is off Ref Section 96 00 00 4 Remove transmission access door assembly L210 and R210 Ref Section 53 30 00 5 Remove engine cowling assembly L260 and R260 Ref Section 53 30 00 6 Remove aft swashplate ...

Page 1960: ...y Ref Section 21 50 00 19 Remove main transmission input drive shaft Ref Section 63 10 00 20 Disconnect mechanical engine control box assembly Ref Section 76 00 00 21 Remove lockwire and disconnect engine oil in hose 1 22 Remove nuts 5 and washers 4 and disconnect engine oil out hose 2 Discard O ring 3 23 Disconnect engine accessory gearbox oil drain hose 6 from deck fitting 24 Disconnect engine o...

Page 1961: ...ntenance Manual Page 403 Revision 14 71 00 00 23 24 22 21 18 19 20 REF 1 9G71 012 1C 8 10 in lb 0 90 1 12 N m 8 10 in lb 0 90 1 12 N m 39 43 41 42 44 40 1 10 9 6 2 PW206E PW207E 900 CONFIG PW206A Figure 402 Engine Removal Installation Sheet 1 of 2 ...

Page 1962: ...EMBLY 8 COMBUSTOR DRAIN TUBE ASSEMBLY 9 ENGINE FUEL FEED HOSE 10 IGNITOR BOX 11 IGNITOR CABLE 12 SCREW 13 NUT 14 WASHER 15 BUSHING 16 COUNTERSUNK WASHER 17 BOLT 18 NUT 19 WASHER 20 BUSHING 21 COUNTERSUNK WASHER 22 BOLT 23 ENGINE FIRESEAL CLAMP FORWARD 24 ENGINE FIRESEAL CLAMP AFT 25 CLAMP SUPPORT 26 CLAMP SUPPORT 27 SCREW 28 WASHER 29 NUT 30 CLAMP 31 CLAMP 32 SCREW 33 WASHER 34 CLAMP 35 CLAMP 36 S...

Page 1963: ...02 CONFIG Remove and discard lockwire 43 from fuel line shroud 41 c 902 CONFIG Disconnect fitting 40 from deck to detach fuel feed hose 42 30 Attach engine sling T402 to suitable hoist 31 Position engine sling 3 Ref Figure 403 over engine and attach cables to engine lifting brackets 1 with quick release pins 2 32 Put slight tension on sling cables with hoist NOTE Do not remove engine mount assem b...

Page 1964: ...900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 406 Original 71 00 00 9G71 010 1 2 ADJUSTABLE FULCRUM POINT 3 2 1 1 LIFTING BRACKET 2 QUICK RELEASE PIN 3 ENGINE SLING Figure 403 Engine Sling ...

Page 1965: ...or connector 13 P407 left hand or P406 right hand d Detach fuel filter bypass indicator connector 14 P409 left hand or P408 right hand e Remove existing engine bolt 38 and engine wire harness clamp 16 remove engine indication wire harness 15 from engine wire harness bundle and reinstall clamp 16 with bolt 38 Torque bolt 38 f Remove existing engine bolts 38 clamps 17 and engine indication wire harn...

Page 1966: ...TE 4 14 2 1 NOTE 1 4 PL NOTES 1 TORQUE 133 150 in lb 15 02 16 94 N m 2 TORQUE 32 35 in lb 3 61 3 95 N m 3 TORQUE 95 105 in lb 10 73 11 86 N m 4 TORQUE 36 40 in lb 4 06 4 51 N m 5 TORQUE 20 25 in lb 2 25 2 82 N m 6 TORQUE 145 155 in lb 16 37 17 50 N m 7 TORQUE 50 in lb 5 64 N m 4 PL 36 NOTE 2 4 40 39 NOTE 7 37 PW206E PW207E 9G71 013 1C 41 42 43 44 47 LEFT ENGINE SHOWN 19 32 33 PW206A PW206E PW207E ...

Page 1967: ...8 WIRE HARNESS SUPPORT BRACKET 19 ENGINE FUEL FEED HOSE 20 ELBOW 21 NUT 22 O RING 23 COMBUSTOR DRAIN TUBE ASSEMBLY LEFT ENGINE TEE TO DECK 24 COMBUSTOR DRAIN TUBE ASSEMBLY LEFT ENGINE DRY FORWARD 25 COMBUSTOR DRAIN TUBE ASSEMBLY LEFT ENGINE DRY AFT 26 COMBUSTOR DRAIN TUBE ASSEMBLY LEFT ENGINE WET 27 COMBUSTOR DRAIN TUBE ASSEMBLY RIGHT ENGINE TEE TO DECK 28 COMBUSTOR DRAIN TUBE ASSEMBLY RIGHT ENGIN...

Page 1968: ... torque nut and safety with lockwire C702 8 PW206E PW207E Install engine fuel feed hose a Install engine fuel feed hose 46 assembly on fuel pump b Position as in Figure 404 Torque fitting 45 9 Remove existing engine nuts 36 from inboard engine lifting bracket 37 and install wire harness support bracket 18 Reinstall and torque nuts 36 10 PW206E PW207E Install shroud box cover 43 a Engage latches 44...

Page 1969: ... 3 with bolts 1 and countersunk washers 2 a Torque bolts 1 133 to 150 in lb 15 03 to 16 95 Nm b Safety bolts 1 with lockwire C702 D Engine Installation Ref Figure 402 NOTE This task is typical for both LH or RH engine installation unless otherwise noted Consumable Materials Ref CSP SPM Item Nomenclature C102 Lubricant Solid Film C106 Oil Lubricating C205 Sealing Compound C215 Sealing Compound Fire...

Page 1970: ... 29 e PW206A PW206E Install clamps 25 and 26 on combustor drain tubes 7 and 8 with screws 27 nuts 29 and washers 28 Torque nuts 29 Sealing Compound C215 f Apply sealing compound C215 to ignitor cable flanges and screws using fillet surface sealing and mechanical fastener sealing methods ref CSP SPM g Apply sealing compound C215 to ignitor cable sheath at top and bottom h Connect ignitor cables to ...

Page 1971: ... hand at firewall Verify that red color band on connector is covered to ensure that connector is fully coupled If necessary use mini strap wrench T2016 21 Connect bleed air check valve cabin heat hose Ref Section 21 00 00 and inlet particle separator tube Ref Section 76 00 00 to bleed air fitting if applicable Torque hose nuts 22 Install primary exhaust nozzle Ref Section 78 00 00 23 Install fixed...

Page 1972: ... Removal 6 Remove lockwire V band clamp 39 and starter generator 40 7 Discard O ring from starter generator shaft B Installation Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C106 Oil Lubricating C702 Lockwire NOTE This task is typical for left or right hand starter generator and for starter gen erator with the cooling modification ref Section 71 60 00 Oil Lubricating C106 1 Lu...

Page 1973: ...N GND REF GEN GND S G SPEED SENSE E E BLK WHT S G SPEED SENSE BLK WHT Figure 406 Starter Generator Wire Terminal Connection Diagram 3 Ignitor Box A Ignitor Box Removal Ref Figure 407 NOTE This task is typical for left or right hand ignitor box 1 Verify helicopter electrical power is off Ref Section 96 00 00 2 Open baggage compartment door L262 Ref 06 00 00 3 Remove baggage compartment ceiling soft...

Page 1974: ... P342 right hand to ignitor box Adhesive Sealant C415 5 To prevent passage of moisture through deck seal around ignitor cable and shielding using adhesive sealant C415 6 Install baggage compartment ceiling soft insulation panel Ref Section 25 50 00 7 Close baggage compartment door L262 Ref Section 06 00 00 8 Restore helicopter electrical power Ref Section 96 00 00 9 Perform powerplant operational ...

Page 1975: ...ant 1 Install engine firewall to plenum seal 32 or 33 over forward or aft section of engine 2 Install bolts 34 and washers 35 Torque bolts Adhesive Sealant C415 3 Seal any gaps between engine fire ring and engine firewall to plenum seal with adhesive sealant C415 4 Remove engine from engine mainte nance stand T404 Ref Directives and Related Manufacturers Publications Section 01 00 00 5 Install eng...

Page 1976: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 418 Revision 21 71 00 00 This page intentionally left blank ...

Page 1977: ...aust areas of engine for evidence of fluid leaks Identify and correct fluid leaks as required c Inspect intake and exhaust areas of engine for obstruction or foreign object damage None allowed 6 Visually inspect engine for evidence of dissimilar metal corrosion at engine mount pad attach points None allowed 7 Refer to Directives and Related Manufacturers Publications Ref Section 01 00 00 for detai...

Page 1978: ...gine Motoring Run ref applic able Rotorcraft Flight Manual Section VIII 4 Powerplant Operational Test 1 Apply external power ref Section 96 00 00 2 Do the IIDS panel operational test ref Section 95 30 00 3 On IIDS secondary panel observe the following conditions a Left and right engine oil PSI digital display indicates 0 PSI 1 PSI b Left and right engine oil PSI low yellow caution segment is illum...

Page 1979: ... and right engine oil C low yellow caution segment is not illumi nated h Left and right engine oil C high yellow caution segment is not illumi nated i Left and right engine oil C high red warning segment is not illuminated j Left and right engine CHIPS seg ment is not illuminated k Left and right engine FIRE segment is not illuminated 5 Shut down left and right engines ref applicable Rotorcraft Fl...

Page 1980: ...er the engine inspection shaft b If inspection slider will not fit over the engine inspection shaft adjust tripod and bipod engine mount aft support rods and rear mount support rod as necessary to achieve fit c Retract inspection slider from engine inspection shaft 5 Perform engine to transmission axial distance inspection Ensure transmission input flange is fully AFT a Pull transmission input fla...

Page 1981: ...left engine and listen for ignitor when you do the steps that follows 7 Do the Engine Ignition Operational Check of one ignitor on left engine Ref Part number 3038324 Pratt Whitney Maintenance Manual Section 74 11 00 Use POWER switch on ELECTRICAL MASTER panel as an alternative to ignition breaker given in referred to operational check Power On 8 On ELECTRICAL MASTER panel set POWER switch to ON M...

Page 1982: ...RICAL MASTER panel set POWER switch to ON Make sure other person hears first right engine ignitor 22 On ELECTRICAL MASTER panel set POWER switch to OFF Power Off 23 Make sure all electrical power is disconnected from helicopter Ref CSP 900RMM 3 Section 96 00 00 24 Do the Engine Ignition Operational Check on other ignitor of right engine Ref Part number 3038324 Pratt Whitney Maintenance Manual Sect...

Page 1983: ...NTR switch Power Off 8 Make sure all electrical power is disconnected from helicopter Ref CSP 900RMM 3 Section 96 00 00 9 Do the Engine Ignition Operational Check on other ignitor of left and right engine Ref Part number 3038324 Pratt Whitney Maintenance Manual Section 74 11 00 Use POWER switch on ELECTRICAL MASTER panel and IGNTR switch on A620 electrical load center as an alternative to ignition...

Page 1984: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 608 Revision 32 71 00 00 This page intentionally left blank ...

Page 1985: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 71 20 00 Engine Mounts ...

Page 1986: ......

Page 1987: ...ge stations 230 5 and 229 5 Each forward inboard mount consists of three adjustable links constructed of Ti 6Al 4v titanium Each forward outboard mount consists of two adjustable links constructed of Ti 6Al 4v titanium The aft engine mount for each engine attaches to the gas generator case and the fuselage attachment fitting The fuselage attachment fitting is located on the engine deck at fuselage...

Page 1988: ......

Page 1989: ...move bolts 15 countersunk washers 16 nuts 19 washers 18 bushings 17 and tripod mount assembly B Tripod Mount Assembly Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire NOTE If replacing engine mount with like new item use removed mount as a guide for initial support rod settings or adjust sup port rods to nominal settings Ref Figure 401 Maintain equal eng...

Page 1990: ...ountersunk washers 16 nuts 19 washers 18 bushings 17 and bipod mount assem bly B Bipod Mount Assembly Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire NOTE If replacing engine mount with like new item use removed mount as a guide for initial support rod settings or adjust sup port rods to nominal settings Ref Figure 401 Maintain equal engagement of threa...

Page 1991: ...ear Stay Mount Assembly Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire NOTE If replacing engine mount with like new item use removed mount as a guide for initial support rod settings or adjust sup port rods to nominal settings Ref Figure 401 Maintain equal engagement of threads in upper and lower end of support rods This task is typical for left or rig...

Page 1992: ...9 5 14 10 11 13 6 9 16 15 17 18 19 9G71 024 32 36 33 35 34 REF 26 37 38 39 40 41 27 26 28 31 30 29 7 70 TRUE NOMINAL 7 40 TRUE NOMINAL 5 93 TRUE NOMINAL REF 5 VIEW ROTATED VIEW ROTATED 2 PL 2 PL 11 7 15 16 17 18 19 REF 4 9 03 TRUE NOMINAL 7 15 TRUE NOMINAL 6 40 TRUE NOMINAL VIEW ROTATED REF 3 VIEW ROTATED VIEW ROTATED NOTE ALL DIMENSIONS ARE IN INCHES 8 Figure 401 Engine Mount Assemblies ...

Page 1993: ...BEARING 8 FORK TRIPOD 9 JAM NUT 10 JAM NUT 11 POSITIVE INDEX LOCKING DEVICE 12 ADAPTER ASSEMBLY BIPOD 13 SUPPORT ROD BIPOD FORWARD 14 FORK BIPOD 15 BOLT 16 COUNTERSUNK WASHER 17 BUSHING 18 WASHER 19 NUT 20 BOLT 21 BUSHING 22 BOLT 23 BUSHING 24 BOLT 25 BOLT 26 SUPPORT ROD REAR MOUNT 27 FORK REAR SUPPORT 28 ROD END BEARING 29 JAM NUT 30 JAM NUT 31 POSITIVE INDEX LOCKING DEVICE 32 BOLT 33 COUNTERSUNK...

Page 1994: ......

Page 1995: ...ngine mount pad attach points None allowed 3 Inspect tripod and bipod mount pad assemblies for cracks corrosion or mechanical damage None allowed 4 Inspect tripod and bipod mount adapter and fork assemblies and rear support fork assembly for cracks None allowed 5 Inspect tripod and bipod mount adapter and fork assemblies and rear support fork assembly for corrosion or mechani cal damage Ref Table ...

Page 1996: ...ge or corrosion allowed on any threads Minimum distance between adjacent dents and scratches is 0 125 in 3 175 mm Depth limit 0 010 in 0 254 mm Length limit 0 063 in 1 60 mm of repairable damages Blend damage to break sharp edges with fine abrasive cloth to remove sharp edges and irregularities Impact damage corners of hexagonal support rods Depth limit 0 050 in 1 27 mm Blend to break sharp edges ...

Page 1997: ...with a 10X magnification glass a No cracks permitted 4 Examine bore for scratches with a 10X magnification glass a No scratches permitted 5 Measure Diameter A of the mount pad bore a Diameter A must be 0 7500 to 0 7505 inch 19 050 to 19 063 mm b Diameter A must have a circularity of 0 00025 B Bearing Installation Ref Figure 801 Consumable Materials Ref CSP SPM Item Nomenclature C310 Primer Do not ...

Page 1998: ...ÍÍÍÍ ÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÍÍÍÍÍ ÍÍÍÍÍ ÍÍÍÍÍ ÍÍÍÍÍ ÍÍÍÍÍ ÍÍÍÍÍ FLANGE ÍÍÍÍÍ ÍÍÍÍÍ ÍÍÍÍÍ ÍÍÍÍÍ ÍÍÍÍÍ ÍÍÍÍÍ ÍÍÍÍÍÍ ÍÍÍÍÍÍ ÍÍÍÍÍÍ ÍÍÍÍÍÍ ÍÍÍÍÍÍ ÍÍÍÍÍÍ ÍÍÍÍÍÍ ÍÍÍÍÍÍ ÍÍÍÍÍÍ ÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇ FLANGE SUPPORT PRESS TOOL STAKED FLANGE ÇÇÇ ÇÇÇ ÇÇÇ ÇÇÇ ÇÇÇ BEARING REMOVAL DIA A 9G62 058B Figure 801 Bearing Removal B...

Page 1999: ... BELOW SURFACE OF MOUNT PAD FLANGE NECESSARY DIMENSIONS BEFORE STAKING ROLLER SWEGE STAKING ÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ ÍÍÍ ÍÍÍ ÎÎÎ ÉÉÉÉ ÉÉÉÉ ÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇ ÈÈÈ ÈÈÈ ÈÈÈ ÈÈÈ ÈÈÈ ÈÈÈ ÎÎ Ï Ï ÇÇ ÇÇ ÇÇ ÏÏ ÏÏ 9G62 056B Figure 802 Bearing Staking C Bearing Staking Ref Figure 802 Special Tools Ref CSP SPM Item Nomenclature T20...

Page 2000: ...f Load Check Ref Figure 803 Consumable Materials Ref CSP SPM Item Nomenclature C319 Lacquer Acrylic Gloss Red When you do a proof load on the bearing use the correct tools Damage to the mount pad bore or bearing can occur 1 Apply 490 to 510 lbf 2179 to 2269 N on the bearing installation a Outer race must not move more than 0 002 inch 0 05 mm in each of the two directions from its initial posi tion...

Page 2001: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 71 60 00 Air Intake ...

Page 2002: ......

Page 2003: ... before it enters the engine The particle separator is located on the upper intake cowling Ambient air enters the particle separator and the air velocity is increased as the air passes over swirl guides The swirl guides create a vortex that separates heavy particles from the air The particles drop to the bottom of the particle separator panel A solenoid valve and bleed air lines route engine compr...

Page 2004: ... 71 60 00 SOLENOID SHUTOFF VALVE PARTICLE SEPARATOR EJECTOR EJECTOR TUBE ASSEMBLY BLEED AIR TUBE ASSEMBLY PARTICLE SEPARATOR PANEL BYPASS DOOR SOLENOID LATCH INLET PANEL BYPASS DOOR LEFT SIDE SHOWN RIGHT SIDE IS TYPICAL 9G71 003 Figure 1 Inlet Screen Inlet Particle Separator IPS ...

Page 2005: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 3 Original 71 60 00 9G71 028 IPS NACA INLET NACA INLET SCREENED INLET Figure 2 Naca Inlet ...

Page 2006: ...o the engine wash panel fittings permits the water or solution to clean the engine while motoring Each engine wash system consists of a wash nozzle located over the engine inlet The system uses tubing rigid or Teflon to connect the wash nozzles to the engine wash panel which is located in the right side transmission access door 9G71 004 LEFT ENGINE WASH TUBE ASSEMBLY RIGHT ENGINE WASH TUBE ASSEMBL...

Page 2007: ...ers equipped with PW207E engines Outside air is forced through scoops on the forward swashplate fairing and then routed through ducts connected to the starter genera tors The new starter generators come with a modified cooling inlet that allows attachment of the cooling ducts Ref 71 00 00 This option becomes standard after Unit 117 9G71 031 STARTER GENERATOR COOLING DUCTS COOLING DUCTS SCOOP SCOOP...

Page 2008: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 6 Revision 21 71 60 00 This page intentionally left blank ...

Page 2009: ...bris from panel or replace panel 71 60 00 Faulty left or right engine air filter pressure switch Replace engine air filter pressure switch 71 60 00 Faulty wiring Test and repair wiring 98 00 00 Faulty IIDS Replace IIDS 95 30 00 No compressor bleed air emits from inlet particle separator ejector tube Faulty solenoid shutoff valve Replace solenoid shutoff valve 71 60 00 Faulty wiring Test and repair...

Page 2010: ...46 WHT RED RED WHT ZB ZC Z ZA D C 99 98 80 81 U V A B ZH 28VDC IPS 7 5A E TB1 1 C B A D X2 X1 A1 A3 A2 B1 B3 B2 C1 C2 C3 35 36 J D K7 1 2 K G H J TB1 1 TB1 4 C B A E E W312 W312 W123 W124 W124 W124 W122 W124 W123 A612 ELECTRICAL LOAD CENTER A612 FWD INTERCONNECT PANEL E3 E3 W124 W123 W123 A SH2 B SH2 C SH2 D SH2 IPS BYPASS RELAY 9G71 006 1A RH DIFFERENTIAL PRESSURE SWITCH LH DIFFERENTIAL PRESSURE ...

Page 2011: ...HT A B B A WHT BLUE M K L H G J F D A B C TB302 1 E W X V U 4 6 1 3 5 2 82 98 107 83 R ENG BLEED AIR L ENG BLEED AIR IPS BYPASS ZI ZK A W124 W123 W123 W123 W122 W124 W124 W311 W311 A2 IIDS A612 FWD INTERCONNECT PANEL A606 UTILITY CONTROL PANEL A SH1 D SH1 C SH1 B SH1 IPS SWITCH LH SOLENOID SHUTOFF VALVE IPS BLEED AIR RH SOLENOID SHUTOFF VALVE IPS BLEED AIR Figure 101 Inlet Particle Separator Wirin...

Page 2012: ......

Page 2013: ...ef Figure 402 NOTE This task is typical for left or right hand particle separator panel 1 Open engine cowling assembly L260 or R260 Ref Section 06 00 00 2 Open transmission access door assem bly L210 or R210 Ref Section 06 00 00 Engine FOD 3 Remove screws 4 and washers 5 and disconnect particle separator ejector 3 4 Remove screws 2 washers 5 and particle separator panel 1 B Particle Separator Pane...

Page 2014: ...rews 4 2 Attach particle separator panel to ejector support bracket with screw 10 washer 5 and nut 9 Torque nut 9 3 Connect ejector tube 6 to particle separator ejector Torque tube nut 4 Close engine cowling assembly L260 or R260 Ref Section 06 00 00 4 Bypass Door Subassembly A Bypass Door Subassembly Removal Ref Figure 402 NOTE This task is typical for left or right hand bypass door subassembly E...

Page 2015: ...ef Section 71 60 00 4 Perform inlet particle separator functional test Ref Section 71 60 00 6 Engine Air Filter Pressure Switch A Engine Air Filter Pressure Switch Removal Ref Figure 402 NOTE This task is typical for left or right hand engine air filter pressure switch 1 Open transmission access door assem bly L210 or R210 Ref Section 06 00 00 Engine FOD 2 Remove bypass door subassembly Ref Sectio...

Page 2016: ... J520 3 Disconnect bleed air tube 7 from solenoid shutoff valve 16 4 Disconnect ejector tube 6 from shutoff valve 5 Remove jam nut 17 and washer 18 from shutoff valve Remove shutoff valve from valve support bracket B Solenoid Shutoff Valve Installation Ref Figure 402 NOTE This task is typical for left or right hand solenoid shutoff valve 1 Install solenoid shutoff valve 16 in valve support bracket...

Page 2017: ... OUTBOARD 85 105 in lb 9 60 11 86 N m 65 80 in lb 7 34 9 03 N m 5 5 2 1 PARTICLE SEPARATOR PANEL 2 SCREW 3 PARTICLE SEPARATOR EJECTOR 4 SCREW 5 WASHER 6 EJECTOR TUBE ASSEMBLY 7 BLEED AIR TUBE ASSEMBLY 8 EJECTOR TO FIREWALL GASKET 9 NUT 10 SCREW 11 BYPASS DOOR SUBASSEMBLY 12 BYPASS DOOR SOLENOID LATCH 13 ENGINE AIR FILTER PRESSURE SWITCH ASSEMBLY 14 NUT 15 WASHER 16 SOLENOID SHUTOFF VALVE 17 NUT 18...

Page 2018: ...cific to the IPS NACA As sembly 1 Locate inlet assembly 1 in position 2 Install bolts 6 and washers 4 attaching aft end of inlet 1 to upper and lower support brackets 27 and 28 3 Install bolts 6 and washers 4 attaching forward end of inlet 1 to support assembly 7 4 Attach inlet 1 scoop with screws 8 and washers 4 5 Attach inlet door actuator 2 electrical connector with IPS installation 6 Install s...

Page 2019: ... and washers 25 that hold shaft 20 in center bearing housing assembly 23 7 Slide shaft 20 out from door 26 8 Remove flapper door 26 B Flapper Door Assembly Installation Ref Figure 403 1 Locate flapper door assembly 26 in position and insert flapper door shaft 20 2 Install screws 22 and washers 19 that hold flapper door assembly 26 to door shaft 20 3 Install screws 24 and washers 25 that hold shaft...

Page 2020: ...in center bearing housing assembly 23 4 Attach input crank assembly 14 to door shaft 20 5 Install screw 17 washers 19 and nut 18 that attaches retainer cap 21 to flapper door shaft 20 6 Connect forward rod end 15 of actuator 2 to input crank 14 7 Install upper and lower transmission access door assemblies R210 or L210 Ref Section 53 30 00 9G71 026 1 FS 196 510 VIEW LOOKING INBOARD LEFT SIDE 3 4 5 ...

Page 2021: ...aft Maintenance Manual Page 409 Original 71 60 00 9G71 026 2 16 11 4 12 13 17 18 19 2 REF 10 4 12 13 14 15 22 12 PL 19 12 PL 20 24 25 2 PL VIEW ROTATED 23 26 1 REF 26 REF 21 4 2 PL NOTE 6 2 PL NOTE Figure 403 Naca Inlet Assembly Sheet 2 of 2 ...

Page 2022: ...nd engine wash tube assembly 2 3 or 4 as necessary B Engine Wash Installation Ref Figure 404 NOTE Tube assemblies 2 3 or 4 may be re placed with Teflon tubing 16 and 17 1 Engine wash tubing 900 CONFIG Original aircraft configuration Eff 10 thru 51 used the rigid engine wash tube assemblies 2 3 and 4 902 CONFIG or aircraft that have had the NACA inlet modification use a replacement Teflon tubing in...

Page 2023: ...60 11 86 N m CURRENT CONFIGURATION 20 16 NOTE 2 17 NOTE 2 19 8 18 20 19 19 8 1 SPRAY NOZZLE 2 ENGINE WASH TUBE ASSEMBLY LEFT PANEL TO UNION 3 ENGINE WASH TUBE ASSEMBLY LEFT UNION TO NOZZLE 4 ENGINE WASH TUBE ASSEMBLY RIGHT 5 SCREW 6 WASHER 7 NUT 8 LOOP CLAMP 9 UNION 10 ELBOW 90 DEGREE 11 ELBOW 45 DEGREE 12 WASHER 13 NUT 14 WASHER 15 CAP AND LANYARD ASSEMBLY 16 TEFLON TUBING 17 TEFLON TUBING 18 ANG...

Page 2024: ...Consumable Materials Ref CSP SPM Item Nomenclature C216 Sealant Fuel Resistant 1 Carefully insert cooling duct 1 through transmission access door taking care to avoid sharp edges 2 Route duct 1 to clear rotating swash plate travel and insure drain hole is low point of duct a Cycle flight controls while rotating swashplate assembly to ensure there is no contact with duct s Ref Section 67 10 00 Roto...

Page 2025: ... Maintenance Manual Page 413 Revision 21 71 60 00 9G71 032 LEFT SIDE LOOKING INBOARD VIEW ROTATED FWD SWASHPLATE FAIRING REF 1 3 4 6 PL 5 6 PL 2 STARTER GEN REF 6 9 8 7 Figure 405 Generator Cooling Modification LH Shown RH Typical Sheet 1 of 2 ...

Page 2026: ...Maintenance Manual Page 414 Revision 21 71 60 00 4 RIGHT SIDE LOOKING INBOARD 9 9 9G71 033 Figure 405 Generator Cooling Modification RH Clamp Positions Sheet 2 of 2 1 COOLING DUCT 2 SCOOP 3 SCREEN 4 SCREW 5 WASHER 6 CLAMP 7 WASHER 8 NUT 9 CLAMP ...

Page 2027: ...ty Torque or replace loose or missing hardware c Inspect inlet plenum for foreign object damage None allowed d Inspect engine firewall to plenum seals for holes cracks tears and security of installation No damage allowed Torque or replace loose or missing hardware 3 Remove flexible tubing from engine air filter pressure switch fitting 4 Close inlet particle separator bypass door 2 Inlet Panel Insp...

Page 2028: ... compressed air to pressure test kit regulator External Power 3 Apply external power Ref Section 96 00 00 4 Perform IIDS panel operational test Ref Section 95 30 00 5 On UTILITY panel set IPS switch to ON 6 On IIDS primary panel observe that IPS BYPASS is not illuminated on the alphanumeric display 7 Gradually increase pressure on the differential pressure switch by turning the regulator valve in ...

Page 2029: ...witch located on center control panel is in the NORMAL position External Power 3 Apply external power Ref Section 96 00 00 or turn on aircraft s electri cal system 4 Verify NACA DOOR lights or IIDS alphanumeric display illumination a 900 CONFIG aircraft with NACA modification Verify NACA lights show CLOSED NACA DOOR lights should always be illuminated in either the CLOSED or OPEN indication b 902 ...

Page 2030: ...b Verify that the inlet doors remain closed NOTE 900 CONFIG aircraft with NACA modi fication Verify that the NACA lights re main on CLOSED 902 CONFIG Verify that the message NACA DOOR is displayed on the IIDS after approximately 15 5 seconds after the indicated airspeed passes through 47 KIAS 9 With the indicated airspeed still at 100 KIAS move the override switch to the NORMAL position 10 Verify ...

Page 2031: ... Cooling Duct and Screen Inspection NOTE This task is typical for left or right hand cooling ducts and screens 1 Visually inspect cooling duct a Remove any FOD internal to the duct b Inspect duct for punctures or kinks that would reduce airflow to starter generator None allowed NOTE Cooling ducts contain a drain hole for excess water This hole is allowed 2 Visually inspect screens a Remove any FOD...

Page 2032: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 606 Revision 21 71 60 00 This page intentionally left blank ...

Page 2033: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 71 70 00 Engine Drains ...

Page 2034: ......

Page 2035: ...h engine has stainless steel combustor drain tubes that vent residual fuel from the combustor The flow divider dump valve drains through a stainless steel tube that attaches to the deck fitting and combustor drain tube assembly The combustor drain tube connects to hot oil and fuel resistant rubber tubing that is routed along the aircraft skin and keel beam B Forward Drain Tube Assembly The forward...

Page 2036: ...ECK COMBUSTOR DRAIN TUBE ASSEMBLY FORWARD DRY COMBUSTOR DRAIN TUBE ASSEMBLY WET COMBUSTOR DRAIN TUBE ASSEMBLY VIEW LOOKING AFT 9G71 005B FORWARD DRAIN TUBE ASSEMBLY COMBUSTOR DRAIN TUBE ASSEMBLY AFT DRAIN TUBE ASSEMBLY FUEL CATCH CAN ASSEMBLY OPTIONAL PW206A and PW206E ONLY Figure 1 Engine Drain Lines and Optional Fuel Catch Can ...

Page 2037: ... Engine Drain Line Installation Ref Figure 401 Consumable Materials Ref CSP SPM Item Nomenclature C702 Lockwire C606 Rubber Tubing NOTE This task is typical for left or right hand engine drain line installation as necessary 1 Install fuel drain line a Connect combustor drain tube 2 to bulkhead union 3 Torque tube nut b Install clamp 6 on combustor drain tube 2 with screws 4 washers 5 bracket 15 an...

Page 2038: ...D 7 5 5 12 8 6 REF 1 REF 2 12 REF 1 REF 1 AIRCRAFT SKIN REF 1 14 5 8 13 7 5 8 5 4 AIR CRAFT SKIN VIEW ROTATED 1 RUBBER TUBING C606 2 COMBUSTOR DRAIN TUBE ASSEMBLY 3 BULKHEAD UNION 4 SCREW 5 WASHER 6 CUSHIONED CLAMP 7 NUT 8 PLASTIC LOOP CLAMP 9 THREADED STANDOFF COMPOSITE BASE 10 TUBE TO HOSE ELBOW 11 TEE 12 SCREW 13 SPACER 14 SCREW 15 BRACKET Figure 401 Engine Drain Lines ...

Page 2039: ...re 402 Consumable Materials Ref CSP SPM Item Nomenclature C109 Grease C702 Lockwire C606 Rubber Tubing Grease C109 NOTE This task is typical for left or right hand fuel catch can assembly If replacing fuel catch can with like new item install drain valve 1 Lubricate O ring 9 with grease C109 and install on fuel catch can drain valve 10 2 Install fuel catch can drain valve in fuel catch can 1 Torqu...

Page 2040: ...71 70 00 9G71 021B LEFT SIDE SHOWN RIGHT SIDE IS TYPICAL 1 2 3 4 6 5 7 9 10 11 6 6 8 7 REF 1 1 FUEL CATCH CAN ASSEMBLY 2 RUBBER TUBING 3 SCREW 4 WASHER 5 BONDING JUMPER 6 WASHER 7 NUT 8 STUD ADHESIVE BONDED 9 O RING 10 DRAIN VALVE 11 TEE Figure 402 Fuel Catch Can Assembly Optional ...

Page 2041: ...loose or missing clamps and hardware 2 Fuel Catch Can Optional A Fuel Catch Can Inspection 1 Visually inspect fuel catch can a Inspect fuel catch cans for dents cracks or corrosion None allowed b Inspect drain valves for dents or obstruction leaking O ring and freedom of operation Replace dam aged O ring or drain valve 2 Visually inspect flexible rubber tubing a Inspect for chafed cut or nicked fl...

Page 2042: ......

Page 2043: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual ENGINE BLEED AIR Chapter ...

Page 2044: ......

Page 2045: ... Fitting Bleed Air Port Closure Plate 2 Maintenance Practices 201 1 Bleed Air Engine Interface Inspection 201 A Bleed Air Fitting Closure Plate End Cap Inspection 201 2 Bleed Air Port Closure Plate 201 A Bleed Air Port Closure Plate Removal 201 B Bleed Air Port Closure Plate Installation 201 3 Bleed Air Fitting 201 A Bleed Air Fitting Removal 201 B Bleed Air Fitting Installation 201 4 Bleed Air En...

Page 2046: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page ii Revision 25 75 Contents TABLE OF CONTENTS Cont Para Figure Table Title Page This page intentionally left blank ...

Page 2047: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 75 00 00 Engine Bleed Air ...

Page 2048: ......

Page 2049: ...ment for the bleed air lines and bleed air check valve B Engine Bleed Air Check Valve The engine bleed air check valve is an in line check valve that prevents reverse flow of bleed air into the engine compressor Reverse flow would occur through the heat defog lines if one engine was producing less power The bleed air check valve attaches to the bleed air fitting and heat defog lines C Engine Bleed...

Page 2050: ...icopters Inc Rotorcraft Maintenance Manual Page 2 Original 75 00 00 9G75 001 BLEED AIR FITTING ASSEMBLY BLEED AIR GASKET BLEED AIR PORT CLOSURE PLATE FITTING REMOVED Figure 1 Bleed Air Fitting Bleed Air Port Closure Plate ...

Page 2051: ...s task is typical for left or right hand bleed air port closure plate 1 Install bleed air port closure plate 5 with gasket 4 nuts 2 and washers 3 Torque nuts 2 2 Close engine cowling assembly L260 or R260 Ref Section 06 00 00 3 Perform engine operational test Ref Section 71 00 00 3 Bleed Air Fitting A Bleed Air Fitting Removal Ref Figure 201 NOTE This task is typical for left or right hand bleed a...

Page 2052: ...ing assembly L260 or R260 Ref Section 06 00 00 2 Remove inlet particle separator end cap 6 if applicable 3 Remove heat defog end cap 7 if applicable B Bleed Air End Cap Installation Ref Figure 201 NOTE This task is typical for left or right hand bleed air end cap 1 Install heat defog end cap 7 if applicable Torque end cap 2 Install inlet particle separator end cap 6 if applicable Torque end cap 3 ...

Page 2053: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual ENGINE CONTROLS Chapter ...

Page 2054: ......

Page 2055: ...ent Module Assembly 8 11 Throttle Control Relay 8 12 Engine Cables 8 13 Mechanical Engine Control Box 8 14 Interconnect Cable 8 Fault Isolation 101 1 Engine Control Troubleshooting 101 Table 101 Engine Control System Troubleshooting 101 2 EEC Fault Log Code Troubleshooting 103 Table 102 Fault Log Failed Bit Indications 103 Figure 101 Electronic Engine Control 111 3 Engine Operation Troubleshooting...

Page 2056: ...embly 404 3 Detent Module Assembly 405 A Detent Module Removal 405 B Detent Module Installation 405 Figure 403 Detent Module Assembly 406 4 Electronic Engine Control EEC 407 A Electronic Engine Control Removal 407 B Electronic Engine Control Installation 407 Figure 404 Electronic Engine Control 408 Inspection Test 601 1 Engine Controls 601 A Engine Controls Inspection 601 B Engine Controls Operati...

Page 2057: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 76 00 00 Engine Controls ...

Page 2058: ......

Page 2059: ... EECs 3 provide Ambient condition sensing Signal conditioning Analog to digital conversion Serial data transmission The EEC controls the fuel flow rate of the fuel metering unit FMU During normal opera tion the EEC has full authority In the manual mode the EEC deactivates the FMU stepper motor and auto ignition relay The EEC computes specified gains during engine transient power demands which resu...

Page 2060: ...FIG 900 CONFIG 3 A201 5 J2 4 J1 7 P361 9 P363 8 PARTIAL 6 PARTIAL 3 A200 5 J2 1 13 P362 12 PARTIAL 10 PARTIAL 11 P360 11 P360 10 PARTIAL 13 P362 12 P362 3 A200 1 4 J1 5 J2 3 A201 5 J2 4 J1 9 P363 8 PARTIAL 6 PARTIAL 7 P361 4 J1 2 2 Figure 1 Engine Fuel Control Panel and Electronic Engine Controls Sheet 1 of 2 ...

Page 2061: ...rcraft Maintenance Manual Page 3 Revision 35 76 00 00 9G76 016 2 900 CONFIG 902 CONFIG 15 14 A604 16 J2 P124 17 15 14 A604 16 J2 P124 17 16 J1 P130 16 J1 P130 Figure 1 Engine Fuel Control Panel and Electronic Engine Controls Sheet 2 of 2 ...

Page 2062: ... Left and Right Engine Power Management Select Switches Ref Figure 1 Each engine has a power management select switch 16 located on engine control panel 15 of the main console in the crew compartment The switches are a rotary lift to turn type that provides selection of OFF IDLE FLY or TRAIN modes for engine operation When the IDLE or FLY position is selected the start enable and start inhibit rel...

Page 2063: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 5 Revision 35 76 00 00 This page intentionally left blank ...

Page 2064: ... FOR CLARITY ENGINE CABLES DETENT MODULE ASSEMBLY CONTROL CABLES COLLECTIVE STICK ASSEMBLY COLLECTIVE FRICTION UNIT INTERCONNECT CABLE ASSEMBLY REF COPILOT COLLECTIVE STICK THROTTLE TWIST GRIPS FUEL METERING UNIT FMU OFF GATE RELEASE FUEL METERING UNIT FMU MECHANICAL ENGINE CONTROL BOX ASSEMBLY EARLY 900 CONFIG REF SECTION 67 10 20 FOR MORE CURRENT MODULE CONFIGURATIONS Figure 2 Engine Controls ...

Page 2065: ...detent position The mechanical override provides the pilot with full range control of each engine throttle to maintain engine torque requirements or to manually shutdown the engines 7 Collective Lever Position Transducers The collective control stick position transduc ers are located in collective friction unit CFU The left transducer sends an electrical signal to the left engine EEC The right tra...

Page 2066: ...dule assembly is activated the auto ignition relay is energized 11 Throttle Control Relay The throttle control relay is energized when the two tandem twist grips are not in the OFF position The throttle control relay powers the detent module assembly 12 Engine Cables Ref Figure 2 The left and right engine cables connect the detent module assembly to each FMU The cables transfer control inputs from...

Page 2067: ...ctive Action Ref Section EEC FAIL on IIDS Faulty engine wiring harness Test and repair engine wiring harness Ref Directives and Related Manufacturers Publications 01 00 00 Faulty EEC Ref P WC Fault Isolation Charts Ref Directives and Related Manufacturers Publications 01 00 00 Faulty airframe wiring Test and repair wiring 98 00 00 Collective twist grips will not rotate from NORMAL to OFF position ...

Page 2068: ...embly 76 00 00 Faulty engine control cable Replace engine control cable 76 00 00 Faulty mechanical engine control box Replace mechanical engine control box 76 00 00 Improper engine control rigging Perform engine control rigging 76 00 00 Faulty FMU Replace FMU Ref Directives and Related Manufacturers Publications 01 00 00 Slow acceleration decelera tion rate in manual mode Faulty FMU Perform Manual...

Page 2069: ...00 Faulty airframe wiring Test and repair wiring 98 00 00 CFAIL 2 on IIDS alphanumeric display CFUR 1 2 NG speed sensor Faulty engine wiring harness EEC Ref P WC Fault Isolation Charts Ref Related Manufacturers Publications 01 00 00 Faulty airframe wiring Test and repair wiring 98 00 00 CFAIL 3 on IIDS alphanumeric display CFUR 1 3 EEC Ref P WC Fault Isolation Charts Ref Related Manufacturers Publ...

Page 2070: ...ications 01 00 00 IIDS Replace integrated instrument display system IIDS 95 30 00 Faulty airframe wiring Test and repair wiring 98 00 00 CFUR1 10 on IIDS alphanumeric display EEC Ref P WC Fault Isolation Charts Ref Related Manufacturers Publications 01 00 00 Faulty airframe wiring Test and repair wiring 98 00 00 CFUR1 11 on IIDS alphanumeric display Faulty engine wiring harness EEC DCU 206E only R...

Page 2071: ...facturers Publications 01 00 00 CLP resolver CFU Replace Collective Friction Unit 67 10 00 Faulty airframe wiring Test and repair wiring 98 00 00 NCFAL1 4 on IIDS alphanumeric display NCFUR 1 4 Faulty engine wiring harness Temperature MGT trim box EEC DCU 206E only Ref P WC Fault Isolation Charts Ref Related Manufacturers Publications 01 00 00 Faulty airframe wiring Test and repair wiring 98 00 00...

Page 2072: ... on IIDS alphanumeric display Faulty engine wiring harness EEC Q MGT Matching Selection Switch 207E only Ref P WC Fault Isolation Charts Ref Related Manufacturers Publications 01 00 00 Faulty airframe wiring Test and repair wiring 98 00 00 NCFAL1 10 on IIDS alphanumeric display NCFUR 1 10 EEC Ref P WC Fault Isolation Charts Ref Related Manufacturers Publications 01 00 00 Static pressure port on EE...

Page 2073: ...NCFUR 1 16 Faulty engine wiring harness T1 sensor EEC Ref P WC Fault Isolation Charts Ref Related Manufacturers Publications 01 00 00 Faulty airframe wiring Test and repair wiring 98 00 00 NCFAL2 1 on IIDS alphanumeric display NCFUR 2 1 EEC Ref P WC Fault Isolation Charts Ref Related Manufacturers Publications 01 00 00 IIDS Replace integrated instrument display system IIDS 95 30 00 Faulty airframe...

Page 2074: ...FAL2 7 on IIDS alphanumeric display Faulty engine wiring harness NG speed sensor EEC Ref P WC Fault Isolation Charts Ref Related Manufacturers Publications 01 00 00 Faulty airframe wiring Test and repair wiring 98 00 00 NCFUR2 7 on IIDS alphanumeric display Faulty engine wiring harness T1 T6 terminal box T6 harness T1 probe DCU NG speed sensor EEC Ref P WC Fault Isolation Charts Ref Related Manufa...

Page 2075: ...umeric display EEC Replace EEC 76 00 00 NCFAL2 14 on IIDS alphanumeric display NCFUR 2 14 Faulty engine wiring harness EEC Ref P WC Fault Isolation Charts Ref Related Manufacturers Publications 01 00 00 Faulty airframe wiring Test and repair wiring 98 00 00 NCFUR2 15 on IIDS alphanumeric display Pedal Potentiometer Replace potentiometer 67 20 00 EEC Ref P WC Fault Isolation Charts Ref Related Manu...

Page 2076: ...on Charts Ref Related Manufacturers Publications 01 00 00 Static pressure port on EEC obstructed Clear static port NCFUR3 5 on IIDS alphanumeric display Faulty engine wiring harness T1 sensor EEC Ref P WC Fault Isolation Charts Ref Related Manufacturers Publications 01 00 00 Faulty airframe wiring Test and repair wiring 98 00 00 NCFUR3 6 on IIDS alphanumeric display EEC Ref P WC Fault Isolation Ch...

Page 2077: ...ions and available data from the EEC s The wiring diagram Ref Figure 103 shows the wiring connection for these data ports at UART connector J139 The three data sources available from this connector are the left EEC right EEC and IIDS These data ports are a universal asynchronous receiver transmitter UART driven point to point communica tions link with an electrical interface that is defined by Ele...

Page 2078: ... K UART OUT HI A620 ELECTRICAL LOAD CENTER W123 W122 P363 J2 UART OUT HI UART OUT LO K L A201 LEFT EEC P P363 J2 P104 J4 ZM ZK ZB ZA P A201 LEFT EEC A2 IIDS RS422 LO RS422 HI P W123 J5 P105 ZB ZA ZM ZK RS 422 HI RS 422 LO P P W122 J1 P361 P305 J305 6 5 4 3 2 1 ZD J K ZE 429 IN LO 429 IN HI 429 OUT LO 429 OUT HI P P P P P P J1 P360 J ZD ZE K 429 OUT LO 429 OUT HI 429 IN LO 429 IN HI P P A200 RIGHT ...

Page 2079: ... SIGNAL WF E1 WF COMMON WF E2 WF EXCIT LO WF EXCIT HI PHASE D PHASE C PHASE A PHASE B EXCIT OVERSPEED SOLENOID RTN OVERSPEED SOLENOID PWR NG A RTN NG A SIGNAL NG B RTN NG B SIGNAL NPT Q B RTN NPT Q B SIGNAL MGT TRIM RTN MGT TRIM Q GAIN TRIM Q TRIM RTN Q BIAS TRIM W143 T T T T T T T T T T P P P P P P P P P P P P P P P P P P P 5T LEFT P W ENG HARNESS FIREWALL BREAK P103 J2 J303 P303 4 5 6 7 8 9 1 2 ...

Page 2080: ... A STEPPER MOTOR PHASE B STEPPER MOTOR EXCIT OVERSPEED SOLENOID RTN OVERSPEED SOLENOID PWR NG A RTN NG A SIGNAL NG B RTN NG B SIGNAL NPT Q B RTN NPT Q B SIGNAL MGT TRIM RTN MGT TRIM Q GAIN TRIM Q TRIM RTN Q BIAS TRIM NP LEFT LO NP LEFT HI EGT LEFT HI EGT LEFT LO NG LEFT LO NG LEFT HI TORQUE TRIM BOX P8 P10 P6 P7 P3 P5 A C B P4 A C A B E F NPT SENSOR E F B A C D NG SENSOR F B A G K L M N P T S H A ...

Page 2081: ...CIT LO T T P P W122 P153 SP2 P153 J1 P363 J2 P171 J1 J3 P170 29 30 31 55 33 34 56 54 53 52 51 50 49 48 DD CC E ZR X 3 5 4 6 2 1 A201 LEFT EEC A612 FWD INTERCONNECT PANEL A651 CFU COS HI SIN HI COS LO SIN LO CLP EXCIT HI CLP EXCIT LO CLP EXCIT LO CLP EXCIT HI CLP COMM CLP SIN CLP COS T T T T P P P P W123 W122 T T P P LEFT EEC COLLECTIVE RESOLVER INTERFACE RIGHT EEC COLLECTIVE RESOLVER INTERFACE A65...

Page 2082: ...T RIGHT ENGINE RELAY X2 PIN B TB1 2 S2 D1 S4 C1 B3 S5 RIGHT ENGINE IGNITOR OFF SWITCH GROUND A B C D E F G H K J L M N P R S T U 28V 28V NC C LEFT ENGINE IGNITOR OFF SWITCH LEFT ENGINE NORMAL DETENT SWITCH LEFT ENGINE NORMAL DETENT LATCH SOLENOID 28 V PIN M S8 B1 S7 C1 S6 D3 X2 PIN B X1 D2 C2 B2 ELECTRICAL SCHEMATIC SHOWN IN NORMAL POSITION WITH SOLENOIDS DE ENERGIZED CURRENT VOLTAGE REGULATOR LEF...

Page 2083: ...Y K1 1 2 X1 TO GND VIA EEC RESET RELAY AND SWITCH LEFT DETENT MODULE WIRING SHOWN IN NORMAL AUTO DETENT AUTO MODE IIDS DISPLAY NOTHING 28V 28V R M B H F E GND CB12 L IGNTR CB15 L DENTENT TO EEC J2 PIN AA COMMON GND VIA LEFT RESET RELAY G L S TO AUTO RELAY K7 7 X2 TO EEC J2 PIN B AUTO MAN SELECT TO LEFT IGNITER AND K7 7 X1 VIA DIODE TO LEFT RESET RELAY K1 1 2 X1 TO GND VIA EEC RESET RELAY AND SWITC...

Page 2084: ...ENGINE CONTROL SWITCH W123 TB2 6 J K J3 P170 88 45 ZB AUTO MANUAL P171 J1 P363 J2 A201 LEFT EEC A650 DETENT MODULE P173 P170 J3 J2 7 54 D3 D2 D1 B3 B2 B1 X2 X1 A1 A2 A3 C1 C2 C3 LEFT THROTTLE RELAY K1 1 2 A612 FWD INTERCONNECT PANEL A612 LEFT ENGINE SHOWN 9G76 009B S9 OVSP TEST SWITCH A201 LEFT EEC A612 FWD INTERCONNECT PANEL 28V 28V R M B H F E GND G L S P150 P150 LEFT DETENT MODULE WIRING SHOWN ...

Page 2085: ... RELAY CONTROL START INPUT 11 13 X2 X1 L ENGINE START A2 23 22 BAT BUS A409 LH GCU J1 P341 E J3 P170 J3 P377 P375 D 14 R P N L START ENABLE EEC X2 X1 A3 A1 A2 K J L TB1 5 2 A2 A1 A3 X1 X2 TB1 8 H G E F B2 B1 B3 E S1 MANUAL START SWITCH L START ENABLE PMS 7 R P N K J L X2 X1 H ON M G LEFT PLA IN AUTO DETENT M P105 J5 LEFT PLA IN NORMAL DETENT ZB X2 X1 A2 A3 A1 K7 7 RELAY TB1 6 X2 X1 A1 A3 A2 R P N ...

Page 2086: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 120 Revision 19 76 00 00 This page intentionally left blank ...

Page 2087: ...er lever on engine with washer 4 and nut 5 Torque nut 5 3 Install bolts 3 attaching control box 6 to adapter plate 7 but do not tighten 4 Record force at maximum throttle position to move power lever through its range of motion 5 Tighten bolt A 3 until snug Test power lever movement to determine if force requirements have increased Use hand force to pivot control box about bolt A to find position ...

Page 2088: ...mbly Removal Ref Figure 402 NOTE This task is typical for left or right en gine control cable 1 Remove crew seat Ref Section 25 10 00 2 Remove crew compartment interior soft panels behind crew seat Ref Section 25 10 00 3 Open R155 Ref Section 06 00 00 4 Open L210 and R210 Ref Section 06 00 00 5 Remove and discard lockwire Discon nect mechanical engine control cable coupling nut 16 at detent module...

Page 2089: ...ads 3 Connect inner cable connection at detent module 4 Connect coupling nut to detent module 5 Apply anti seize compound C220 to engine control box threads 6 Connect inner cable connection at engine control box 7 Connect coupling nut to engine control box NOTE Turn collective throttle twist grips though their range of travel make sure power lever 8 Figure 401 moves in both directions 8 Torque cou...

Page 2090: ...CHANICAL ENGINE CONTROL INNER CABLE COUPLING TYPICAL 17 16 2 PL 18 19 1 LEFT MECHANICAL ENGINE CONTROL CABLE 2 RIGHT MECHANICAL ENGINE CONTROL CABLE 3 SCREW 4 WASHER 5 NUT 6 WASHER 7 RETAINING STRAP 8 SCREW 9 SPACER 10 SCREW 11 CLAMP 12 SCREW 13 CLAMP 14 SCREW 15 CLAMP 16 ENGINE CONTROL CABLE COUPLING NUTS 17 INNER CABLE CONNECTION 18 DETENT MODULE 19 ENGINE CONTROL BOX Figure 402 Mechanical Engin...

Page 2091: ... Prepare surfaces for electrical bond Ref CSP SPM Section 20 50 00 2 Install brackets bolts washers and nuts Do not torque at this time 3 Install detent module bolts and washers Torque bolts 4 Torque nuts 7 securing brackets 6 to detent module 1 5 Test detent module for class L electrical bond Ref CSP SPM Section 20 50 00 6 Apply a polyurethane resin to electri cally bonded areas Ref CSP SPM Secti...

Page 2092: ...ters Inc Rotorcraft Maintenance Manual Page 406 Revision 28 76 00 00 1 2 2 3 3 4 5 4 5 4 5 6 6 6 7 8 8 9 7 8 8 9 9 8 7 8 10 9G76 015A MECHANICAL ENGINE CONTROL INNER CABLE COUPLING TYPICAL 11 Figure 403 Detent Module Assembly ...

Page 2093: ... cotter pins b Remove nuts 7 washers 8 bolts 9 bonding jumper and remove EEC from hinged avionics shelf c Remove washers 10 from hinged avionics shelf and remove adhesive residue from bonded washer location B Electronic Engine Control Installation Ref Figure 404 Consumable Materials Ref CSP SPM Item Nomenclature C435 Adhesive Electrically Conductive NOTE This task is typical for left or right hand...

Page 2094: ...tric power Ref Section 96 00 00 8 Perform EEC operational test Ref Section 76 00 00 9G76 008B 900 CONFIG LEFT SIDE SHOWN VIEW ROTATED 6 4 PL 8 4PL 2 3 4 5 1 8 4 PL 9 4PL 25 28 in lb 2 82 3 16 N m 10 12 in lb 1 12 1 35 N m 7 4 PL 10 4 PL ELECTRICAL BOND PREPARED AREA 902 CONFIG INSTALLATION IS TYPICAL 1 ELECTRONIC ENGINE CONTROL 2 SCREW 3 LOCKWASHER 4 WASHER 5 BONDING JUMPER 6 COTTER PIN 7 NUT 8 WA...

Page 2095: ...witch on the ENGINE CON TROL panel from the OFF position as this could initiate an engine start Flight Control Movement 4 On IIDS primary panel observe that there are no EEC faults illuminated on the alphanumeric display that would indicate that the EEC is off line and not in command of its engine control functions To avoid damage to collective stick it is necessary to first press the CFU release ...

Page 2096: ...t module inoperative NOTE When rigging pilot and copilot collective stick twist grips ensure that rig pin in en gine control box is removed or engine control cables between detent module and engine control boxes are disconnected 3 Loosen jam nuts 2 and cable end fittings 4 on bottom side of the detent module 1 To avoid damage to collective stick it is necessary to first press the CFU release butto...

Page 2097: ...rials Ref CSP SPM Item Nomenclature C702 Lockwire Special Tools Ref CSP SPM Item Nomenclature T405 Engine Control Rig Pin 1 Apply external power Ref Section 96 00 00 2 Apply hydraulic pressure Ref External Hydraulic Pressure Application GSE Cart Section 29 00 00 Avoid applying side loads on detent module control rod ends when connecting or disconnecting control cables from detent module Bending of...

Page 2098: ...or by applying a reversing side load to the power lever 12 of the FMU 13 8 Adjust the connectors 3 on the top side of the detent module 1 so that freeplay at the control box 6 as indicated by relative motion between the FMU power lever 12 and the slot in the engine rig plate 15 is equidis tant about the rig setting on the FMU 13 9 Torque jam nuts on top side of detent module Verify distance betwee...

Page 2099: ...MU 7 It shall be possible to move the grip from the OFF position through the off gate toward NORMAL counterclock wise when viewed from the collective stick base without having to push the OFF GATE REL 900 CONFIG button To avoid damage to collective stick it is necessary to first press the CFU release button on the collec tive control module before attempting to move collective stick 8 With the twi...

Page 2100: ...engaged and the pinion gear of the engine control box restrained lost motion of the system measured at the twist grips shall not exceed 4 degrees at any twist grip position 0 044 inch 1 118 mm measured on the circumference of the collective stick outer tube Ref Figure 601 14 From the NORMAL position rotate the twist grips for both engines through the off gate 900 CONFIG by depress ing the OFF GATE...

Page 2101: ...tenance Manual Page 607 Revision 19 76 00 00 9G76 003 1C 7 8 9 2 6 PL 3 6 PL 4 6 PL 1 R CIRCUMFERENTIAL BACKLASH MEASUREMENT LEFT AND RIGHT ENGINE R REF 9 11 5 REF 8 0 84 INCH 21 33 mm MAX 4 PL L R Figure 601 Mechanical Engine Controls Sheet 1 of 2 ...

Page 2102: ...NTROL BOX REMOVED FOR CLARITY 13 RIG PIN INSTALLED 15 0 78 INCH 19 81 mm MAX 2 PL 1 DETENT MODULE 2 JAM NUTS 3 ADJUSTMENT CONNECTORS 4 CABLE END FITTINGS 5 COLLECTIVE TWIST GRIPS 6 MECHANICAL ENGINE CONTROL BOX 7 MECHANICAL ENGINE CONTROL CABLE 8 COLLECTIVE STICK 9 COLLECTIVE CONTROL MODULE 10 IIDS PANEL 11 EEC RESET BUTTON 12 POWER LEVER 13 FUEL METERING UNIT FMU 14 PINION GEAR 15 RIG PLATE 16 AD...

Page 2103: ...ule will disengage the EEC to the manual controls Observe that EEC MAN is illuminated on IIDS panel for indica tion that the EEC is disengaged 6 Depress EEC RESET until EEC MAN blinks on IIDS panel Rotate the collective twist grip back to NORMAL position and verify that detent engages and EEC MAN is off 7 Shut down engine per current Rotor craft Flight Manual Ref Section 01 00 00 Table 201 8 Remov...

Page 2104: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 610 Revision 22 76 00 00 This page intentionally left blank ...

Page 2105: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual ENGINE EXHAUST Chapter ...

Page 2106: ......

Page 2107: ...Support Installation 402 4 Secondary Ejector Insulation 402 A Secondary Ejector Insulation Removal 402 B Secondary Ejector Insulation Installation 402 Figure 402 Secondary Ejector 403 Inspection Test 601 1 Primary Exhaust Nozzle Assembly 601 A Primary Exhaust Nozzle Assembly Inconel Inspection 601 B Primary Exhaust Nozzle Assembly Stainless Steel Special Inspection 601 C Primary Exhaust Nozzle Ass...

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Page 2109: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 78 00 00 Engine Exhaust ...

Page 2110: ......

Page 2111: ...t routes hot exhaust gases to the secondary ejector Earlier exhaust nozzles were made of stainless steel The exhaust nozzle attaches to the hot section of the engine with a V band clamp B Secondary Exhaust Ejector The secondary exhaust ejector is a duct constructed of stainless steel that encases the primary exhaust nozzle to direct engine exhaust gases away from the helicopter Earlier exhaust eje...

Page 2112: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 2 Original 78 00 00 PRIMARY EXHAUST NOZZLE ASSEMBLY SECONDARY EJECTOR INSULATION BLANKET 9G78 001 Figure 1 Exhaust System ...

Page 2113: ...ent pin to slot in engine flange 2 Install V band clamp 1 around engine and exhaust nozzle flanges 3 Torque nut on V band clamp and safety clamp with lockwire C702 4 Close engine cowling assembly L260 or R260 Ref Section 06 00 00 9G78 002 1 2 ENGINE FLANGE SLOT ALIGNMENT PIN V BAND CLAMP OMITTED FOR CLARITY 75 80 in lb 8 47 9 03 N m 1 EXHAUST V BAND CLAMP 2 PRIMARY EXHAUST NOZZLE Figure 401 Primar...

Page 2114: ...pport Installation Ref Figure 402 NOTE This task is typical for left or right hand bearing assembly support 1 Install bearing assembly support 6 on secondary exhaust support brace assembly 10 with screws 11 and washers 12 Torque screws 11 2 Install secondary ejector weldment assembly Ref Section 78 00 00 3 Install exhaust ejector cowl assembly L270 or R270 Ref Section 53 30 00 4 Secondary Ejector ...

Page 2115: ... LEFT SIDE IS TYPICAL RIGHT SIDE SHOWN LEFT SIDE IS TYPICAL 20 25 in lb 2 25 2 82 N m 20 25 in lb 2 25 2 82 N m 1 COTTER PIN 2 NUT 3 WASHER 4 SECONDARY EXHAUST BUSHING 5 BOLT 6 BEARING ASSEMBLY SUPPORT 7 SECONDARY EJECTOR TOP HALF INSULATION 8 SECONDARY EJECTOR BOTTOM HALF INSULATION 9 SECONDARY EJECTOR WELDMENT ASSEMBLY 10 SECONDARY EXHAUST SUPPORT BRACE ASSEMBLY 11 SCREW 12 WASHER Figure 402 Sec...

Page 2116: ......

Page 2117: ...ge allowed B Primary Exhaust Nozzle Assembly Stainless Steel Special Inspection NOTE If you think a part is unserviceable speak to MDHI Field Service Department for more instructions 1 Remove primary exhaust nozzle Ref Section 78 00 00 2 Visually inspect primary exhaust nozzle for cracks a Cracks that are less than 3 0 inches 76 2 mm in length may be re paired Ref Section 78 00 00 Replace primary ...

Page 2118: ...l play None allowed 5 Visually inspect secondary ejector insulation a Inspect secondary ejector insulation blankets for cuts or tears None allowed b Inspect secondary ejector insulation blankets for security of installation Tighten or replace loose or broken lockwire securing insulation blan kets B Secondary Ejector Weldment Assembly Titanium Inspection NOTE If you think a part is unserviceable sp...

Page 2119: ...B Primary Exhaust Nozzle Assembly Inconel Repair 1 Cracks that meet inspection criteria Ref Section 78 00 00 may be repaired as follows a Stop drill each end of crack with 0 040 inch diameter drill b Use stainless steel brush to clean at least one inch 25 4 on all sides of crack Cleaning should remove all carbon from both inner and outer surfaces and from crack itself c Weld crack using inert arc ...

Page 2120: ......

Page 2121: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual ENGINE OIL Chapter ...

Page 2122: ......

Page 2123: ...ne Oil Out Hose Removal 401 B Engine Out Oil Hose Installation 402 3 Engine Oil Pressure Sensor 402 A Engine Oil Pressure Sensor Removal 402 B Engine Oil Pressure Sensor Installation 402 4 Engine Oil Temperature Sensor 403 A Engine Oil Temperature Sensor Removal 403 B Engine Oil Temperature Sensor Installation 403 5 Engine Oil Drain Lines 403 A Engine Oil Drain Line Removal 403 B Engine Oil Drain ...

Page 2124: ...CSP 900RMM 2 MD Helicopters Inc ROTORCRAFT MAINTENANCE MANUAL Page ii Revision 32 79 Contents TABLE OF CONTENTS Cont Para Figure Table Title Page This page intentionally left blank ...

Page 2125: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Section 79 00 00 Engine Oil ...

Page 2126: ......

Page 2127: ... windmill situation Oil Cooler each engine s pressure oil from the oil pump is routed to one of the combina tion engine and transmission oil coolers The oil cooler has separate core tubes to provide a heat exchange for the engine or transmission oil Cooled engine oil from the oil cooler returns to the engine reduction gearbox through the oil filter assembly Oil Filter Assembly the oil filter assem...

Page 2128: ...ated Shutoff Valve the P3 shutoff valve is located above the accessory drive pad The shutoff valve is activated by P3 air to reduce the flow restriction created by the scavenge pump during shutdown When the shutoff valve is open the second scavenge pump No 5 bearing scavenge is assisted by P3 air entering the bearing cavity and returns scavenge oil from No 5 bearing to the reduction gearbox sump T...

Page 2129: ...ce Manual Page 3 Original 79 00 00 9G79 001 1 OIL IN HOSE VIEW ROTATED ENGINE OIL PRESSURE SENSOR ENGINE OIL TEMPERATURE SENSOR OIL PRESSURE SENSOR TUBE ASSEMBLY OIL CHIP DETECTOR OIL FILLER OIL OUT HOSE 900 CONFIG Figure 1 Engine Oil System Sheet 1 of 2 ...

Page 2130: ...DETAIL OMITTED FOR CLARITY ENGINE OIL OVERFLOW DRAIN TUBE ASSEMBLY STARTER GENERATOR PAD DRAIN TUBE ASSEMBLY FUEL PUMP PAD DRAIN TUBE ASSEMBLY OIL DRAIN TUBE ASSEMBLY ENGINE SEAL DRAIN HOSE ENGINE OIL FILTER CASE OIL BREATHER SYSTEM VIEW FROM TOP REF FIREWALL SIGHT GLASS Figure 1 Engine Oil System Sheet 2 of 2 ...

Page 2131: ...ne Full wire diagrams are available Ref CSP 900RMM 3 Section 98 40 00 Table 101 Engine Lubrication System Fault Isolation Fault Cause Correction Procedure Ref Section CHIPS caution shows on IIDS Magnetic chips on chip detector Examine chip detector refer to P WC Fault Isolation Charts Ref Related Manufacturers Publications 01 00 00 Defective chip detector Replace chip detector Ref Related Manufact...

Page 2132: ...facturers Publications 01 00 00 Defective oil shutoff valve Replace oil shutoff valve Ref Related Manufacturers Publications 01 00 00 Defective oil pressure sensor Replace oil pressure sensor 79 00 00 Defective helicopter wires Test and repair wires CSP 900RMM 3 Section 98 00 00 and CSP SPM Unserviceable IIDS Replace IIDS CSP 900RMM 3 Section 95 30 00 Unserviceable engine Rectify engine problem Re...

Page 2133: ...S Replace IIDS CSP 900RMM 3 Section 95 30 00 Unserviceable engine Repair or replace engine Ref Related Manufacturers Publications 01 00 00 Oil leak from com pressor shroud bleed port Oil leak near engine inlet Repair oil leak Ref Related Manufacturers Publications 01 00 00 Unserviceable engine Repair or replace engine Ref Related Manufacturers Publications 01 00 00 Too much oil comes out of breath...

Page 2134: ...ut shaft leaks Repair oil leak Ref Related Manufacturers Publications 01 00 00 Heat exchanger leaks Repair oil leak or replace heat exchanger 63 21 00 Pressure adjustment valve cover leaks Repair oil leak Ref Related Manufacturers Publications 01 00 00 Unserviceable engine Repair or replace engine Ref Related Manufacturers Publications 01 00 00 Oil filter impending bypass indication Oil filter has...

Page 2135: ...urers Publications 01 00 00 Defective pressure adjustment valve Replace pressure adjustment valve Ref Related Manufacturers Publications 01 00 00 Defective shutoff valve Replace shutoff valve Ref Related Manufacturers Publications 01 00 00 Defective oil pressure sensor Replace oil pressure sensor 79 00 00 Defective helicopter wires Test and repair wires CSP 900RMM 3 Section 98 00 00 and CSP SPM Un...

Page 2136: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 106 Revision 32 79 00 00 This page intentionally left blank ...

Page 2137: ... and torque hose fittings Safety hose with lockwire C702 2 Connect oil in hose to oil cooler and torque hose fittings Safety hose with lockwire C702 Oil Lubricating C106 3 Service engine with lubricating oil C106 Ref Section 12 00 00 4 Close transmission access door assem bly L210 or R210 Ref Section 06 00 00 5 Verify no leaks are present in flammable fluid systems where maintenance or replacement...

Page 2138: ...or right hand engine oil pressure sensor 1 Open transmission access door assem bly L210 or R210 Ref Section 06 00 00 NOTE Residual oil could remain in oil lines When removing oil lines or components take precautions to catch oil with rags or a suitable container 2 Detach electrical connector P403 from engine oil pressure sensor 6 3 Disconnect oil pressure sensor tube 7 from oil pressure sensor 4 R...

Page 2139: ...re sensor threads with lubricating oil C106 Install and torque sensor 3 Safety oil temperature sensor with lockwire C702 4 Attach electrical connector P405 to oil temperature sensor Tighten connector hand tight 5 Close transmission access door assem bly L210 or R210 Ref Section 06 00 00 6 Perform powerplant operational test Ref Section 71 00 00 7 Verify no leaks are present in flammable fluid syst...

Page 2140: ...EF 19 8 10 21 22 10 9 13 14 1 ENGINE OIL IN HOSE 2 ENGINE OIL OUT HOSE 3 NUT 4 WASHER 5 O RING 6 ENGINE OIL PRESSURE SENSOR 7 OIL PRESSURE SENSOR TUBE 8 SCREW 9 NUT 10 WASHER 11 BRACKET 12 CLAMP 13 ENGINE OIL TEMPERATURE SENSOR 14 O RING 15 OIL OVERFLOW DRAIN TUBE ASSEMBLY 16 STARTER GENERATOR PAD DRAIN TUBE ASSEMBLY 17 FUEL PUMP PAD DRAIN TUBE ASSEMBLY 18 OIL DRAIN TUBE ASSEMBLY 19 ENGINE SEAL DR...

Page 2141: ...n 53 30 00 4 Remove exhaust ejector cowl assembly L270 or R270 Ref Section 53 30 00 5 Remove upper inlet duct assembly T240 Ref Section 53 30 00 6 Loosen hose clamps 5 disconnect engine oil breather hose 6 or 7 from engine oil breather adapter 1 and engine oil breather tube 8 or 9 and remove hose 7 Loosen hose clamps 5 disconnect engine oil breather hose 10 from engine oil breather tube 8 or 9 and...

Page 2142: ...ARD 12 13 14 REF 8 REF 9 12 11 5 NOTE 5 NOTE 5 NOTE 5 NOTE NOTE TORQUE 18 in lb 2 03 N m 1 ENGINE OIL BREATHER ADAPTER 2 ENGINE OIL BREATHER GASKET 3 NUT 4 WASHER 5 HOSE CLAMP 6 ENGINE OIL BREATHER HOSE LEFT HAND 7 ENGINE OIL BREATHER HOSE RIGHT HAND 8 ENGINE OIL BREATHER TUBE LEFT HAND 9 ENGINE OIL BREATHER TUBE RIGHT HAND 10 ENGINE OIL BREATHER HOSE AFT 11 SCREW 12 WASHER 13 NUT 14 CLAMP 15 BRAC...

Page 2143: ...ent on only one engine at a time a Operate engine at IDLE for 5 min monitor all engine parameters Record oil temperature oil pressure exhaust gas temperature and outside air temperature b Visually check all external oil lines for leaks Correct leaks as required c Switch engine to FLY let engine stabilize at 100 Np for 2 min d Rotate twist grip on collective to obtain 77 78 Ng speed on engine Verif...

Page 2144: ...CSP 900RMM 2 MD Helicopters Inc Rotorcraft Maintenance Manual Page 602 Revision 21 79 00 00 This page intentionally left blank ...

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